New Holland CR9040 CR9060 CR9070 Repair Manual Combine - PDF DOWNLOAD by www.heydownloads.com

CR9040, CR9060, CR9070 REPAIR MANUAL COMPLETE CONTENTS SECTION 00 - GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SECTION 10 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SECTION 14 - LIVE PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SECTION 21 - TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SECTION 25 - FRONT MECHANICAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SECTION 29 - HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SECTION 33 - BRAKES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SECTION 35 - HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SECTION 41 - STEERING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 SECTION 50 - CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SECTION 55 - ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SECTION 60 - PRODUCT FEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 SECTION 66 - THRESHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 SECTION 72 - DISCHARGE BEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 SECTION 74 - CLEANING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 SECTION 80 - GRAIN STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 SECTION 88 - ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 SECTION 90 - PLATFORM, CAB, BODYWORK, DECALS . . . . . . . . . . . . . . . 87

The following pages are the collation of the contents pages from each section and chapter of the CR9040, CR9060, and CR9070 Repair manual. Complete Repair part # 87682452. The sections used through out all New Holland product Repair manuals may not be used for each product. Each Repair manual will be made up of one or several books. Each book will be labeled as to which sections are in the overall Repair manual and which sections are in each book. The sections listed above are the sections utilized for the CR9040, CR9060, and CR9070 Combines. ©

2007 CNH America LLC Printed In U.S.A.

87682467 1st Printing

6/07

SECTION 00 - GENERAL INFORMATION BOOK 1 - 87682453

Chapter 1 - General Information CONTENTS Section

Description

Page

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 About Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Part and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Machine Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Personal Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Equipment Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operational Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Health and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Acids and Alkalis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Adhesives and Sealers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Battery Acids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Brake and Clutch Linings and Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Chemical Materials - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Clutch Linings and Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Corrosion Protection Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Dewaxing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Do’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Don’ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Dusts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Exhaust Fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fiber Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 00 - GENERAL INFORMATION BOOK 1 - 87682453

Chapter 1 - General Information (Continued) CONTENTS Section

Description

Page

First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Foams- Polyurethane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Gas Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Gas Shielding Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Gas Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 General Workshop Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Glues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 High-pressure Air, Lubrication and Oil Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 12 Legal Aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Lubricants and Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Noise Insulation Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Paints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Paint Thinners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Pressurized Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Resistance Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Sealers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Solder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Service Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Straw Chopper (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Powered Rear Axle Wheel Motors (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Minimum Hardware Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Recommended Lubricants and Coolants (North America Only) . . . . . . . . . . . . . . . . . . . . . 20

SECTION 10 - ENGINE BOOK 1 - 87682453

Chapter 1 - 9.0L Engine Removal and Replace CONTENTS Section

Description

Page

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SECTION 10 - ENGINE BOOK 1 - 87682453

Chapter 2 - 10.3L Complete Engine, Removal and Replace CONTENTS Section

Description

Page

SECTION 10 - ENGINE BOOK 1 - 87682453

Chapter 3 - Common Engine Compartment Components CONTENTS Section

Description

Page

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cooling Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Radiator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Rotary Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Rotary Screen Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Rotary Screen Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Rotary Screen Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Rotary Screen Brush Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

SECTION 14 - LIVE PTO BOOK 1 - 87682453

Chapter 1 - Engine Gearbox, Clutch Pack Removal/Installation CONTENTS Section

Description

Page

Special Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Labor Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Clutch Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 14 - LIVE PTO BOOK 1 - 87682453

Chapter 2 - Engine Gearbox, Clutch Pack Rebuild CONTENTS Section

Description

Page

Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Main Clutch Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Main Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Unload Clutch Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Unload Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SECTION 14 - LIVE PTO BOOK 1 - 87682453

Chapter 3 - Engine Gearbox Removal/Installation CONTENTS Section

Description

Page

Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Flexplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SECTION 14 - LIVE PTO BOOK 1 - 87682453

Chapter 4 - Engine Gearbox Rebuild CONTENTS Section

Description

Page

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Component Repair -- Bearing and Race Removal/Installation . . . . . . . . . . . . . . . . . . 9 Component Repair -- Clutch Cylinder Bushing Removal/Installation . . . . . . . . . . . . . 9 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Unloader Clutch Shimming Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Main Clutch Shimming Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Clutch Temperature Sender Shim Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SECTION 21 - TRANSMISSION BOOK 1 - 87682453

Chapter 1 - Transmission CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sectional/Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Transmission Cover (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Gearbox Shafts (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Shifting Diagram (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Shifting Disc/Drive Gear (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Shifting Disc/Drive Gear (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Differential (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Differential (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Differential Shafts (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Drive Shaft/Cover (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Drive Shaft (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Drive Shaft (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Input Shaft And Bearing Caps (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Input Shaft (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Input Shaft (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

SECTION 25 - FRONT MECHANICAL DRIVE BOOK 2 - 87682454

Chapter 1 - Planetary Final Drive CONTENTS Section

Description

Page

General Specification -- Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Final Drive -- Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Final Drive -- Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Final Drive -- Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Final Drive -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Final Drive Input Shaft -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Final Drive Input Shaft -- Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Final Drive Reducer, Satellite and Planetary -- Exploded View . . . . . . . . . . . . . . . . . . . . . 7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Distance Ring Combinations Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Final Drive Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Final Drive Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Final Drive Reducer, Satellite and Planetary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Final Drive Wheel Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Half-Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

SECTION 25 - FRONT MECHANICAL DRIVE BOOK 2 - 87682454

Chapter 2 - 11/111 Final Drives CONTENTS Section

Description

Page

25 000

SECTION 29 -- HYDROSTATIC SYSTEM BOOK 2 - 87682454

Chapter 1 -- Hydrostatic Drive System Introduction CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydrostatic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydrostatic Pump (CR9040 and 9060 Machines w/HD 11/111 Final Drives) . . . . . . . . . 3 Hydrostatic Pump (CR9040 and 9060 Machines w/Planetary Final Drives) . . . . . . . . . . 3 Hydrostatic Pump (CR9070 Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydrostatic Drive Motor (CR9040 and 9060 Machines w/HD 11/111 Final Drives) . . . . 4 Hydrostatic Drive Motor (CR9040 and 9060 Machines w/Planetary Final Drives; CR9070 Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Oil Cooler Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydrostatic Brake (Integrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydrostatic Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Powered Rear Axle (PRA) (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hydrostatic Drive Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydrostatic Block Operation (Integrated Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Gear Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Multi Function Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Charge Check Valve 8a -- 9a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Pressure Limiter 8b -- 9b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 High Pressure Relief Valve 8c -- 9c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Bypass Valve 8d -- 9d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SECTION 29 -- HYDROSTATIC SYSTEM BOOK 2 - 87682454

Chapter 1 -- Hydrostatic Drive System Introduction (Continued) CONTENTS Section

Description

Page

Servo Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 System in Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Servo Solenoid Valve 10a Energized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Hydrostatic Drive Motor Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Shuttle Spool Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Flushing Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Pressure Release Valve Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Oil Cooler bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Hydrostatic Pump and Drive Motor Identification Numbers . . . . . . . . . . . . . . . . . . . . . . 24 Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Pump Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Hydrostatic Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Drive Motor Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SECTION 29 - HYDROSTATIC SYSTEM BOOK 2 - 87682454

Chapter 2 - Filling the Hydrostatic System/Start-up Procedure CONTENTS Section

Description

Page

29 000

Filling the Hydrostatic System and Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 29 -- HYDROSTATIC SYSTEM BOOK 2 - 87682454

Chapter 3 -- Powered Rear Axle CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Flow Regulator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2WD--4WD Hydraulic System -- Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2WD-4WD Hydraulic System -- Detailed View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Selector Valve -- Dynamic Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Flow Regulator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Hydraulic Line -- Plumbing Schema PRA Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2WD-4WD Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Selector Valve -- Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Two-Speed Valve -- Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Two-Speed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

SECTION 29 - HYDROSTATIC SYSTEM BOOK 2 - 87682454

Chapter 4 - Pressure Testing and Troubleshooting CONTENTS Section

Description

Page

29 000

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Main Hydrostatic System, Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Servo Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 29 - HYDROSTATIC SYSTEM BOOK 2 - 87682454

Chapter 5 - Hydrostatic Pump and Motor Repair CONTENTS Section

Description

Page

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 29 212

Main Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

29 218

Shaft Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

29 218

Shaft Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

29 218

Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

29 218

Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

29 212

Charge Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

29 212

Charge Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Major Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Electric Displacement Control (EDC) Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SECTION 29 - HYDROSTATIC SYSTEM BOOK 2 - 87682454

Chapter 5 - Hydrostatic Pump and Motor Repair (Continued) CONTENTS Section 29 218

Description

Page

Multi-Function Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

29 218

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

29 218

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Pump Charge Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

29 212

Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Major Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

29 218

Motor Charge Relief Valve -- Style 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

29 218

Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Shuttle Spool Valve -- 100 cc/rev Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Motor Pressure Relief Valve -- 130 cc/rev Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Shuttle Spool Valve -- 130 cc/rev Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Pressure Release Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Pressure Release Valve Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

SECTION 33 -- BRAKES AND CONTROLS BOOK 2 - 87682454

Chapter 1 -- Brakes and Controls CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Brake Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Bleeding the Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Brake Caliper and Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Parking Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Parking Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Parking Brake Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Manual Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Parking Brake Piston Travel and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Parking Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Bleeding the Hydraulic Parking Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Parking Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Parking Brake Caliper -- Cross Section View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

SECTION 35 -- HYDRAULIC SYSTEMS BOOK 3 - 87682455

Chapter 1 -- Introduction CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 High Pressure System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Low Pressure System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Low Pressure Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 High Pressure Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 High Pressure Circuit Diagram, Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 High Pressure Circuit Diagram, Main (with Autoguidance Steering Valve) . . . . . . . 11 Main Frame Stack Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Main Frame Stack Valve (with Autoguidance Steering Valve) . . . . . . . . . . . . . . . . 15 Feeder Stack Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Low Pressure System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Low Pressure System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Low Pressure System with Positive Straw Discharge . . . . . . . . . . . . . . . . . . . . . . . 32 Low Pressure System with Chopper Infeed Roll Motor with Valve -Model Year 2005 and Later . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

SECTION 35 -- HYDRAULIC SYSTEMS BOOK 3 - 87682455

Chapter 2 -- Description of Operation CONTENTS Section

Description

Page

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Closed Center Load Sensing (CCLS) Variable Displacement Pump . . . . . . . . . . . . . . . . 2 Principal of Pump Operation -- Fixed Vs. Variable Displacement . . . . . . . . . . . . . . . . 3 Flow and Pressure Compensating Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Low Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 High Pressure Circuit High Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 High Pressure Circuit Low Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Controlling Maximum System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Main Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Feeder Valve Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Stack Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Header Height Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Accumulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Function Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Rotor Variator/Feeder Variator/Reel Raise--lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Unloading Auger Swing/Feeder Reverser Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Lateral Float Valve/Reel Fore--Aft Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Reel Drive Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Stone Trap Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Hydraulic Cleaning Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Low Pressure System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Chaff Spreader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Chaff Spreader/PSD Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Chopper Infeed Roll Motor Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Low Pressure Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

SECTION 35 - HYDRAULIC SYSTEMS BOOK 3 - 87682455

Chapter 3 - Pressure Testing and Fault Finding The High and Low Pressure Hydraulic Systems CONTENTS Section

Description

Page

Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Specifications - Closed Center Systems

..........................................4

Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Low Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CCLS Pump Pressure and Flow Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CCLS Pump Low Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CCLS Pump High Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 CCLS Pump Load Sensing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 CCLS Pump Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Steering Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Steering Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Steering Relief Valve Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Hydraulic Cleaning Fan Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Low Pressure System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Low Pressure System – Chaff Spreader Pressure Test . . . . . . . . . . . . . . . . . . . . . . 18 Chaff Spreader/PSD Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Low Pressure System – Regulated Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Low Pressure System – Individual Circuit Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Low Pressure System – Pump Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SECTION 35 - HYDRAULIC SYSTEMS BOOK 3 - 87682455

Chapter 4 - Stack Valves Overhaul CONTENTS Section

Description

Page

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Main Stack Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Feeder Stack Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Low Pressure Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SECTION 41 - STEERING AXLE BOOK 3 - 87682455

Chapter 1 - Axle, General CONTENTS Section

Description

Page

Introduction and General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Axle Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Axle Center Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Heavy Duty Adjustable Steering Axle (HDASA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Powered Rear Axle (PRA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Center Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Toe In Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION 41 -- STEERING AXLE BOOK 3 - 87682455

Chapter 2 -- Wheel Bearings (HDASA) CONTENTS Section

Description

Page

Introduction and General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Repacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SECTION 41 -- STEERING AXLE BOOK 3 - 87682455

Chapter 3 -- Steering Pivot (HDASA) CONTENTS Section

Description

Page

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hub and Kingpin Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hub and Kingpin -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 41 - STEERING AXLE BOOK 3 - 87682455

Chapter 4 - Hydrostatic Motor CONTENTS Section

Description

Page

SECTION 41 - STEERING AXLE BOOK 3 - 87682455

Chapter 4 - Hydrostatic Motor (Continued) CONTENTS Section

Description

Page

Radial Clip Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Setting Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Tool Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Hydrostatic Motor - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Bleeding the Rear Axle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Hydrostatic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

SECTION 50 -- CLIMATE CONTROL BOOK 3 - 87682455

Chapter 1 - Heating, Ventilation and Air-Conditioning CONTENTS Section

Description

Page

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 A/C Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Air Conditioning Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Climate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Automatic Temperature Control (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SECTION 50 -- CLIMATE CONTROL BOOK 3 - 87682455

Chapter 1 - Heating, Ventilation and Air-Conditioning (Continued) CONTENTS Section

Description

Page

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Problem Solving Pressure Test Results and Temperature/Pressure Chart . . . . . . 10 Air-conditioning Temperature/Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Ventilation System Separator Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Ventilation System Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Electrical Control Temperature Control Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Electrical Control Blower Speed Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electrical Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Electronic HVAC Control -- Display Data Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Electronic HVAC Control -- ATC Control Switch and Mode Control Switch . . . . . . . . . 24 Electronic HVAC Control -- ATC Controller Power Supply . . . . . . . . . . . . . . . . . . . . . . . 25 Sensing System High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Sensing System Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Sensing System Outlet Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Sensing System Cab Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Sensing System Evaporator Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Evacuating the Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

SECTION 50 - CLIMATE CONTROL BOOK 3 - 87682455

Chapter 2 - Air Filters CONTENTS Section

Description

Page

SECTION 50 - CLIMATE CONTROL BOOK 3 - 87682455

Chapter 3 - Blower Fans CONTENTS Section

Description

Page

SECTION 50 – CLIMATE CONTROL BOOK 3 - 87682455

Chapter 4 – Compressor CONTENTS Section

Description

Page

SECTION 50 - CLIMATE CONTROL BOOK 3 - 87682455

Chapter 5 - Condenser CONTENTS Section

Description

Page

SECTION 50 - CLIMATE CONTROL BOOK 3 - 87682455

Chapter 6 - Cool Box CONTENTS Section

Description

Page

SECTION 50 - CLIMATE CONTROL BOOK 3 - 87682455

Chapter 7 - Evaporator CONTENTS Section

Description

Page

SECTION 50 - CLIMATE CONTROL BOOK 3 - 87682455

Chapter 8 - Heater Core CONTENTS Section

Description

Page

SECTION 50 -- CLIMATE CONTROL BOOK 3 - 87682455

Chapter 9 -- High/Low Pressure Cutout Switch CONTENTS Section

Description

Page

SECTION 50 - CLIMATE CONTROL BOOK 3 - 87682455

Chapter 10 - Receiver/Dryer CONTENTS Section

Description

Page

SECTION 50 - CLIMATE CONTROL BOOK 3 - 87682455

Chapter 11 - Thermal Expansion Valve CONTENTS Section

Description

Page

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 4 - 87682456

Chapter 1 -- General Information CONTENTS Section

Description

Page

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction to Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fault Codes and Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 The Digital Multi-Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Measuring Voltage (Volts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Measuring Current (Amps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Measuring Resistance (Ohms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Continuity (Buzzer) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Electrical Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Electrical Test Procedure 1: Continuity Test -- Short to Ground . . . . . . . . . . . . . . . . . . . 12 Electrical Test Procedure 2: Voltage Measurement or Short to Positive Supply Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Electrical Test Procedure 3: Resistance Test for Electrical Parts . . . . . . . . . . . . . . . . . 13 Electrical Test Procedure 4: Continuity Test -- Check for Open Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Circuit Components - Basic Description and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Flashers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Resistance Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Fluid Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Potentiometer Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Electromagnetic Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Pwm Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Speed and Position Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 4 - 87682456

Chapter 1 -- General Information (Continued) CONTENTS Section

Description

Page

Electronic Modules (CCM’s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 CCM Power and Ground Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 CCM1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 CCM2 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 CCM3 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Combine Control Module (CCM) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 28 CCM Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Instructional Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Removal of CCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 CCM Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Instructional Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Wiring Harness Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Temporary Wiring Harness Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Harness Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Cab Electrical Connectors X002 and X003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Removal of Rear Speaker Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Installation of Rear Speaker Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 4 - 87682456

Chapter 2 -- IntelliViewt (II or Plus II) Monitor Diagnostic Functions CONTENTS Section

Description

Page

55 000

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fault Archive Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Active Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Active Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Error History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Service Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Display Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 CAN Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Settings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 4 - 87682456

Chapter 3 -- Electrical Schematics CONTENTS Section 55 000

Description

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Schematic Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Machine Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wire Harness Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Component Index, 2007 Production -- SN HAJ110001 and Above . . . . . . . . . . . . . . . . 19 2007 Production -- SN HAJ110001 and Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 4 - 87682456

Chapter 4 -- CAN Data Bus Network CONTENTS Section

Description

Page

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CAN Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Checking Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Troubleshooting a Module Offline Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Troubleshooting Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Troubleshooting “A2000 Communication Lost” Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Troubleshooting Leg 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 IntelliView Monitor Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 CAN Data Bus Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 CAN Data Bus Cab Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Harvest Guidance System (HGS) Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . 18 DGPS Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 RHM Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Diagnostic Jack Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Troubleshooting Leg 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ECU Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 HHC Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ASP Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Front Frame Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 CCM3 Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 CCM2 Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Cab Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Cab Roof Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 CCM1 Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 4 - 87682456

Chapter 4 -- CAN Data Bus Network (Continued) CONTENTS Section

Description

Page

Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Cab Roof Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 CCM2 Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ECU Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 IVECO 10L Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Cummins 9.0L Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 CAN 2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 DGPS (CAN Bus 2) Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 4 - 87682456

Chapter 5 -- Engine Systems CONTENTS Section

Description

Page

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 4 - 87682456

Chapter 5 -- Engine Systems (Continued) CONTENTS Section

Description

Page

Starting System -- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A -- Key Switch Power Supply Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 B -- Key Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 C – Neutral Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 D – Neutral Start Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 E – 24 V Start Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F – 24V Starter Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 G -- Starting Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Alternator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Charging System -- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A -- Charging System Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Grid Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grid Heater Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grid Heater Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 4 - 87682456

Chapter 5 -- Engine Systems (Continued) CONTENTS Section

Description

Page

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 CCM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Engine Control Unit (ECU) -- IVECO 10.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Right Hand Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ECU Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Engine-Related Error Codes -- Automatic Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 ECU Related Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 IVECO 10.3 l sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Engine Oil Temperature/Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 CNH 9.0L Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Engine Camshaft RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Engine Flywheel RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Boost Pressure/Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Fuel Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 All Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Rotary Screen Brush Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Air Filter Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Fuel Pump Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

SECTION 55 - ELECTRICAL SYSTEMS BOOK 5 - 87682457

Chapter 6 - Power Distribution and Lighting CONTENTS Section

Description

Page

Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuse/Relay Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Fuse/Circuit Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Power Distribution: Unswitched and Switched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Power Distribution Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Power Distribution Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Lighting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Circuit/Fuse Lighting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 CR NA Lighting - Steering Column Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 CR Australian Lighting - Steering Column Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 CR NA Lighting - Rocker Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 CR Australian Lighting - Rocker Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Lighting Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Hazard Light Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Marker Light Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Road Lights - Low Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Road Lights - High Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Brake Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Beacon Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Front Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Rear Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Side Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Stubble Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Grain Tank Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Unload Tube Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Header Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Center Work Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

SECTION 55 - ELECTRICAL SYSTEMS BOOK 5 - 87682457

Chapter 6 - Power Distribution and Lighting (Continued) CONTENTS Section

Description

Page

Service Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Backlighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 CCM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 RHM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Exterior Lighting System Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Fuse/Circuit Lighting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Exterior Lighting System Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Exterior Lighting System Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

SECTION 55 - ELECTRICAL SYSTEMS BOOK 5 - 87682457

Chapter 7 - Cab Systems CONTENTS Section

Description

Page

SECTION 55 - ELECTRICAL SYSTEMS BOOK 5 - 87682457

Chapter 7 - Cab Systems (Continued) CONTENTS Section

Description

Page

Wiper System Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Wiper System Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Wiper System Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Windscreen Washer System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Power Mirror System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Cab Roof Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Power Mirror Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Power Mirror Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Heated Mirror Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Power Mirror Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Mirror Fuse -- Power and Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Mirror Adjust Switch S-27 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Mirror Select Switch S-57 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Left Hand Mirror Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Right Hand Mirror Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Additional Mirror Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Mirror Heat Switch S-19 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Mirror Heat Circuits Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Horn System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Horn System Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Horn System Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Horn System Circuit Diagnostic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Audio System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Audio System Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Audio System Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Audio System Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 5 - 87682457

Chapter 8 -- Hydraulic Systems CONTENTS Section

Description

Page

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 55 000

Gearbox Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydraulic Reservoir Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Reservoir Level Low Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Gearbox Filter Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Return Filter Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Control Pressure Low Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 5 - 87682457

Chapter 9 -- Driveline Systems CONTENTS Section

Description

Page

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 5 - 87682457

Chapter 9 -- Driveline Systems (Continued) CONTENTS Section

Description

Page

Park Brake Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Park Brake Electrical Component Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Park Brake Switch S09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Service Brake Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Service Brake Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Gearshifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Special Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Gearshift Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Gearshift Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Gear Select Switch S24 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Ground Speed RPM Sensor B17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Ground Speed RPM Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Rear Wheel Assist (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Special Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Rear Wheel Assist Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Rear Wheel Assist Switch S10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 5 - 87682457

Chapter 10 -- Header Systems CONTENTS Section

Description

Page

Reel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Configuration Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Reel Speed Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Reel Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Configuration Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Reel Positioning Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Header Height Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Header Height Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Configuration Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Head Accumulator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Header Operating Modes – Dynamic Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . 21 Header Operating Modes -- Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Header Operating Modes – Stubble Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Header Operating Modes -- Autofloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Header Operating Modes – Pressure Compensation . . . . . . . . . . . . . . . . . . . . . . . 24 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Header Height Control Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 5 - 87682457

Chapter 11 -- Feeder Systems CONTENTS Section

Description

Page

Description of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Feeder Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Feeder Engagement Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Conditions that Prevent Feeder Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Feeder Engage – Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Feeder Engage – Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Feeder Engage Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Feeder Engage – Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Feeder Speed (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Feeder Speed Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Feeder Speed Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Feeder Speed -- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Feeder Reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Feeder Reverser – Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Feeder Reverser – Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Feeder Reverser -- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Advanced Stone Protection (ASP) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Stone Ejection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ASP System – Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 ASP System – Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 ASP System – Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 6 - 87682458

Chapter 12 -- Threshing Systems CONTENTS Section

Description

Page

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 55 000

Thresher System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Thresher Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Thresher Disengage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Thresher Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Thresher Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Troubleshooting Thresher System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Rotor Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Rotor Speed Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Rotor Speed Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Rotor Speed Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Rotor Speed Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Concave Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Concave Clearance Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Concave Clearance Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Concave Clearance Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Concave Clearance Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 6 - 87682458

Chapter 13 -- Cleaning Systems CONTENTS Section

Description

Page

Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Self-Leveling Cleaning Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cleaning Fan Motor (Hydraulic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fault Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cleaning System Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Lateral Inclination Sensor B02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fan Speed Switch S15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cleaning Fan RPM Sensor B16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Left Returns RPM Sensor B06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Clean Grain Elevator RPM Sensor B08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Right Returns RPM Sensor B39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Loss Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Remote Sieve Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Cleaning Fan Motor M05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Loss Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Left Rotor Loss Sensor B-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Right Rotor Loss Sensor B-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Sieves Loss Sensor B-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Remote Sieve Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Upper Remote Sieve Adjust Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Lower Remote Sieve Adjust Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Upper Sieve Rear Adjust Switch S-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Lower Sieve Rear Adjust Switch S-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 6 - 87682458

Chapter 14 -- Clean Grain Systems CONTENTS Section

Description

Page

Unload Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Unload Engage – Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Unload Engage – Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Unload Engage – Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Grain Bin Sensors S-28 and S-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Grain Bin Sensors – Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Grain Bin Sensors – Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Grain Bin Sensors – Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Unload Tube Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Unload Tube Swing -- Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Unload Tube Swing -- Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Unload Tube Swing -- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Grain Bin Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Grain Bin Covers -- Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Grain Bin Covers -- Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Grain Bin Covers -- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 6 - 87682458

Chapter 15 -- Crop Residue CONTENTS Section

Description

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Straw Chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Chopper RPM Sensor B10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Alarm Code Chopper RPM Sensor B10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fault Codes for Chopper RPM Sensor B10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Chaff Spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Chaff Spreader Valve Solenoid L28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fault Code for Chaff Spreader Valve Solenoid L28 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Positive Straw Discharge (PSD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Straw Chopper Spreader Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Spreader Plate Switch S23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fault Codes for Spreader Plate Switch S23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Spreader Plate Motor M11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fault Codes for Spreader Plate Motor M11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Spreader Plate Switch S23 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Spreader Plate Motor M11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 6 - 87682458

Chapter 16 -- Precision Farming CONTENTS Section

Description

Page

Precision Farming Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Moisture Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Grain Yield Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Grain Yield Sensor Offset Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Autoguidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Edge Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 GPS Autoguidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 GPS Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Differential GPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Real Time Kinematic (RTK) DGPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Standard GPS Autoguidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Differential GPS Autoguidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 The GPS-Equipped CR Combine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Precision Farming Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Precision Farming Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Precision Farming Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

SECTION 55 - ELECTRICAL SYSTEMS BOOK 6 - 87682458

Chapter 17 - Electrical Connectors CONTENTS Section

Description

Page

Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 X001

Cab Main/Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

X002

Cab Main/Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

X003

Cab Main/Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

X004

Main Frame/Cab Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

X005

Main Frame/Cab Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

X006

Cab Main/HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

X007

Front Frame/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

X008

Main Frame/Front Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

X009

Main Frame/Grain Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

X010

Main Frame/Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

X011

Main Frame/Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

X012

CCM-3 J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

X013

CCM-3 J2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

X014

CCM-3 J3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

X015

CCM-2 J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

X016

CCM-2 J2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

X017

CCM-2 J3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

X018

CCM-1 J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

X019

CCM-1 J2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

X020

CCM-1 J3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

X021

Front Frame/Feeder Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

X023

Front Frame/Lower Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

X024

Main Frame/Straw Walker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

X025

Straw Walker/Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

X026

RHM J6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

X027

RHM J7A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

X028

RHM J7B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

X029

RHM J8A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

X030

RHM J8B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

X031

Front Frame/Cab Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

X032

Header/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

SECTION 55 - ELECTRICAL SYSTEMS BOOK 6 - 87682458

Chapter 17 - Electrical Connectors (Continued) CONTENTS Section

Description

Page

X033

Cab Main/Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

X034

Expansion/Main Frame A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

X035

Gearbox Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

X036

Cab Roof/Outer Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

X037

Spreader Plate S23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

X038

Alternate Settings S21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

X039

Feeder Reverser S07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

X040

Reel Speed Mode S08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

X041

Neutral Lock S22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

X042

Lower Sieves S14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

X043

Upper Sieves S13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

X044

Concave Clearance S16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

X045

Fan Speed S15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

X046

Rotor Speed S17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

X047

Feeder Speed S18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

X048

Gear Select S24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

X049

On the Road S12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

X050

Dual Range S11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

X051

Rear Wheel Assist 210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

X052

Park Brake S09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

X053

Splice Block A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

X054

Splice Block B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

X055

Thresher Engage S30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

X056

Feeder Engage S31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

X057

Ground Speed R04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

X058

Audio Alarm H01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

X059

Neutral Switch S22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

X059

Neutral Switch S22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

X059

Neutral Switch S22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

X060

Throttle S36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

X061

Header Height S04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

X062

Header Width Adjust S06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

SECTION 55 - ELECTRICAL SYSTEMS BOOK 6 - 87682458

Chapter 17 - Electrical Connectors (Continued) CONTENTS Section

Description

Page

X063

Vertical Knives S51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

X065

Diagnostics and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

X067

Acc. Socket J06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

X068

Key Switch S02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

X069

Lighter R08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

X070

Lighter Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

X071

Straw Hood/Straw Walker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

X072

Lower Frame Rear/Straw Walker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

X073

Seat Switch S05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

X074

Seat Pump M26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

X075

Accessory Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

X076

Accessory Outlet J08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

X077

Ground, 3, CM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

X079

Reverser Disengage B09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

X080

Feeder Reverser M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

X081

Lat Float Pot R02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

X082

ASP Amplifier KN2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

X083

ASP Door Position B-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

X084

LH Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

X085

RH Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

X086

ASP Amplifier KN2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

X087

Ground Speed RPM B17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

X088

Shoe Motor M03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

X089

Cleaning Fan RPM B16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

X090

Cleaning Fan Motor M05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

X091

Hydrostat Motor Temp B46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

X092

Foot and Inch L05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

X093

Trans Shift Position B37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

X094

Transmission Shift Motor M02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

X095

Ground, 2, FF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

X097

Gearbox Temperature B32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

SECTION 55 - ELECTRICAL SYSTEMS BOOK 6 - 87682458

Chapter 17 - Electrical Connectors (Continued) CONTENTS Section

Description

Page

X098

Control Pressure B35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

X099

Clutch Temperature B45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

X100

Ground Speed Hydrostat L23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

X101

Charge Pressure S37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

X102

Ground, 1, GB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

X103

Reservoir Temperature B18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

X104

Reservoir Level S33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

X105

Unload Tube Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

X106

Left Rear Work Light E27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

X107

3/4 Full Bin Sensor S28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

X108

Grain Tank Light E30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

X109

Full Bin Sensor S29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

X110

Right Rear Work Light E28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

X111

Left Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

X112

Left Outer Work Light E15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

X113

Left Beacon Light E31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

X114

Left Middle Work Light E19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

X115

Left Inner Work Light E17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

X116

Wiper Motor M25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

X117

Right Inner Work Light E18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

X118

Right Middle Work Light E20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

X119

Right Beacon Light 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

X120

Right Outer Work Light E16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

X121

Right Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

X122

Right Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

X123

Left Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

X126

Mirror Adjust Switch S27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

X127

Mirror Heat Switch S19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

X128

HVAC Control Panel A09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

X129

Dome Light E34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

X130

Beacon Light Switch S41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

SECTION 55 - ELECTRICAL SYSTEMS BOOK 6 - 87682458

Chapter 17 - Electrical Connectors (Continued) CONTENTS Section

Description

Page

X131

Rear Work Light Switch S44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

X132

Front Work Lights Switch S43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

X133

Splice Block C, Backlighting, CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

X134

Washer Switch S38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

X135

Wiper Switch S20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

X136

Front Left Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

X137

Door Switch S40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

X138

Right Console Light E35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

X139

Front Right Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

X141

Transceiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

X142

G.P.S. Unit A11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

X143

Separator Blower M18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

X144

Separator Blower M18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

X145

Ground, 3, AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

X147

Cold Box Door M15 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

X148

Outlet Temp Sensor B27 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

X149

Cab Temperature Sensor B26 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . 80

X150

Evaporator Probe B28 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

X151

Water Valve M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

X152

Blower Speed Control A-14 (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

X160

Left Front Hazard Light E03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

X161

Left Front Service Socket J02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

X162

Left Header Light E21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

X163

Left Lower Work Light E23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

X164

Left Road Light E13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

X165

Right Front Hazard Light E04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

X167

Right Header Light E22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

X168

Right Lower Work Light E24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

X169

Right Road Light E14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

X170

Lateral Inclination Sensor B02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

X171

Wiper Washer Motor M24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

SECTION 55 - ELECTRICAL SYSTEMS BOOK 6 - 87682458

Chapter 17 - Electrical Connectors (Continued) CONTENTS Section

Description

Page

X172

Horn H02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

X172

Horn H02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

X173

Brake Pressure S39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

X173

Brake Pressure S39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

X174

Feeder Angle R03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

X175

Ground, 2, MF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

X177

Rotor RPM B01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

X178

Mirror Select Switch S-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

X180

Spice Block E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

X181

Left Returns RPM B06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

X182

Clean Grain RPM B08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

X183

Fuel Pump M23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

X184

Fuel Level R01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

X186

Right Returns RPM B39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

X188

RH Rotor Loss B20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

X189

Concave Position R06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

X190

Concave Motor M04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

X193

ECU Connector B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

X194

Service Socket J05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

X195

Covers Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

X198

Splice Block F, Backlighting, RC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

X202

Air Filter S61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

X206

Rotary Screen Brush M27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

X211

Grid Heater Relay K37/K39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

X215

A/C Clutch L07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

X216

A/C High Pressure S47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

X217

A/C Low Pressure S48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

X218

Flip-Up Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

X219

Expansion B/Main Frame B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

X221

Moisture Sensor B12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

X222

Sample Motor M28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

SECTION 55 - ELECTRICAL SYSTEMS BOOK 6 - 87682458

Chapter 17 - Electrical Connectors (Continued) CONTENTS Section

Description

Page

X223

Yield Sensor R05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

X224

Spreader Plate Motor M11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

X225

Upper Sieve Adjust S35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

X226

Lower Sieve Adjust S46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

X227

Upper Sieve Motor M06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

X228

Lower Sieve Motor M07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

X232

Sieves Loss B21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

X233

RWA Solenoid L26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

X234

Sieve Light E37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

X235

Chaff Spreader Solenoid L28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

X237

Sieve Light Switch S54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

X238

Gearbox Filter Bypass S34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

X239

Returns Filter Bypass S32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

X243

Left Tail Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

X244

Unload Cradle B38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

X246

Right Tail Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

X247

Rear Beacon Light E-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

X248

Back Up Alarm H-08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

X248

Back Up Alarm H-08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

X251

Rear Ladder B22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

X252

Right Service Socket J03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

X253

Chopper RPM B10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

X255

Flasher Module A05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

X256

Road Lights Switch S26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

X257

Turn Indicator E09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

X258

High Beam/Trailer E10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

X259

Hazard Switch S25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

X261

ASP Bottom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

X262

LH Bottom ASP Sensor B49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

X263

RH Bottom ASP Sensor B48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

X266

Feeder Reverse L21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

SECTION 55 - ELECTRICAL SYSTEMS BOOK 6 - 87682458

Chapter 17 - Electrical Connectors (Continued) CONTENTS Section

Description

Page

X267

Lateral Float CW L18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

X268

Reel AFT L15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

X269

Reel Down L13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

X270

Feeder Forward L20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

X271

Lateral Float CCW L19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

X272

Reel Fore L16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

X273

Reel Up L14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

X274

Reel Drive L17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

X275

Rotor Increase L29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

X276

Unload Tube In L03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

X277

Unload Tube Out L04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

X278

Rotor Decrease L30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

X279

HDR Height Pressure B29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

X280

Accumulator L06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

X281

HHC Module A07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

X282

Feeder Decrease L12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

X283

Feeder Increase L11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

X284

Feeder RPM B14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

X285

Trailer Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

X287

German Third Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

X288

Covers Position B-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

X289

Covers Actuator M-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

X292

Stone Door Open L31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

X293

Dual Range Solenoid L27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

X294

LH Brake Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

X295

RH Brake Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

X296

Dome Light Power E-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

X314

FM Radio “B” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

X315

FM Radio “C” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

X316

Center Work LT E38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

X321

DGPS Module Antenna A-11 (252 Receiver) . . . . . . . . . . . . . . . . . . . . . . 115

SECTION 55 - ELECTRICAL SYSTEMS BOOK 6 - 87682458

Chapter 17 - Electrical Connectors (Continued) CONTENTS Section

Description

Page

X322

Unload Tube Work LT E29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

X323

Unload Tube Marker LT E39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

X326

HID Distance LT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

X327

Brake Fluid Level S49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

X329

Brake Limiting Valve L-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

X330

Air Filter Resistor R15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

X339

Left Light Switch S-63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

X340

Engine Light Switch S-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

X341

Right Light Switch S-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

X342

LH Shield LTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

X343

RH Shield LTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

X344

Right Shield Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

X345

Left Front Light E-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

X346

Left Rear LIght E-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

X347

Right Front Light E-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

X348

Right Rear Light E-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

X349

Engine Light E-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

X350

RH Position Light E-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

X351

LH Position Light E-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

X352

RH Flashing Light E-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

X353

LH Flashing Light E-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

X354

RH Front Austria Light E-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

X355

LH Front Austria Light E-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

X356

RH Front Turn/Position Light E-04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

X357

LH Front Turn/Position Light E-03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

X358

RH Marker Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

X359

LH Marker Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

X360

RH Rear Marker Light E-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

X361

LH Rear Marker Light E-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

X368

Park Brake Pressure B53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

X371

IVECO Harness to Boost Temperature/Pressure Sensor B-23 . . . . . . . 124

SECTION 55 - ELECTRICAL SYSTEMS BOOK 6 - 87682458

Chapter 17 - Electrical Connectors (Continued) CONTENTS Section

Description

Page

X372

IVECO Harness to Fuel Temperature B-36 . . . . . . . . . . . . . . . . . . . . . . . . 125

X373

IVECO Harness to Coolant Temperature B-44 . . . . . . . . . . . . . . . . . . . . . 126

X376

IVECO Harness to Fuel Actuator 1, L-34 (Cyl 1) . . . . . . . . . . . . . . . . . . . 127

X377

IVECO Harness to Fuel Actuator 1, L-34 (Cyl 4) . . . . . . . . . . . . . . . . . . . 128

X378

IVECO Harness to Fuel Actuator 3, L-36 (Cyl 2) . . . . . . . . . . . . . . . . . . . 129

X379

IVECO Harness to Fuel Actuator 4, L-37 (Cyl 6) . . . . . . . . . . . . . . . . . . . 129

X380

IVECO Harness to Fuel Actuator 5, L-38 (Cyl 3) . . . . . . . . . . . . . . . . . . . 130

X381

IVECO Harness to Fuel Actuator 6, L-39 (Cyl 5) . . . . . . . . . . . . . . . . . . . 130

X382

Chopper RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

X389

Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

X396

Blower Speed Control A-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

X397

ATC Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

X414

ECU Connector B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

X415

ECU -- Power (Cummins ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

X419

WIF Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

X422

Terminator at ECU (Cummins Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

X424

Water in Fuel Sensor B-59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

X439

Coolant Level S-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

X444

Fan Drive Solenoid L-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

X446

CAN 1 Terminator R-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

X462

Rear Axle Angle B-70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

X464

Steering Sensor B-69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

X469

Straw Walker/Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

X471

IVECO Harness to Injector Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

X472

Washer Motor M-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

X474

Grid Heater Relay K-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

X476

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

X483

Alternator G-01 +12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

X484

Auto Guidance Switch S-78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

X485

RCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

X487

Expansion C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

SECTION 55 - ELECTRICAL SYSTEMS BOOK 6 - 87682458

Chapter 17 - Electrical Connectors (Continued) CONTENTS Section

Description

Page

X498

DGPS Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

X500

CAN 2 Terminator R-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

X502

Display A-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

X503

Rotary Encoder S-79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

X504

Display Home Switch S-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

X505

Display Escape Switch S-81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

X506

Display Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

X509

USB Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

X513

PSD RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

X515

IVECO Harness; ECU to Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

X516

IVECO Harness; ECU to Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

X517

IVECO Harness to Engine Oil Temperature/Pressure Sensor B-75 . . . 147

X518

IVECO Harness to Engine Camshaft RPM B-07 . . . . . . . . . . . . . . . . . . . 148

X519

IVECO Harness to Engine Flywheel RPM B-05 . . . . . . . . . . . . . . . . . . . . 149

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 7 - 87682459

Chapter 18 -- CCM1 Error Codes CONTENTS Section

Description

Page

E0000 Stone Trap Closed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 E0001 Bin Covers Open Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 E0003 Unload Tube Cradled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 E0004 Fdr Reverser Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 E0006 Return Filter Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 E0007 Gearbox Filter Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 E0008 Left Turn Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 E0009 Front Work Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 E0010 Rear Work Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 E0011 Road Lights Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 E0012 Right Turn Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 E0013 Cleaning Fan RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 E0014 Feeder RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 E0015 Left Returns RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 E0016 Clean Grain Elevator RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 E0018 Right Returns RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 E0023 Hydrostat Motor Temp

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

E0024 Hydraulic Reservoir Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 E0025 Gearbox Temp Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 E0026 Rear Ladder Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 E0029 Lateral Float Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 E0032 Shoe Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 E0033 Lateral Inclination Sens

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

E0034 Concave Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 E0037 CCM1 5V Ref Voltage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 E0038 CCM1 8V Ref Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 E0039 CCM1 5V Ref Voltage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 E0040 CCM1 Key Switch Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 E0042 Current Sense Reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 E0043 Current Sense Lev Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 7 - 87682459

Chapter 18 -- CCM1 Error Codes (Continued) CONTENTS Section

Description

Page

E0044 Current Sense Concave CL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 E0045 Current Sense Bin Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 E0046 CCM1 Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 E0047 V Supply Feeder Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 E0050 Isense Feeder Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 E0052 Feeder Clutch Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 E0053 Chaff Spreader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 E0054 Fan Drive Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 E0059 Dual Range Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 E0061 Feeder Jog Forward Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 E0062 Fan / Reverser Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 E0065 Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 E0066 Rear Wheel Assist Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 E0067 Feeder Jog Reverse Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 E0068 Unload Tube Light Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 E0069 Covers / Concave Cl Sel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 E0070 Front Work Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 E0071 Rear Work Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251 E0072 Side Work Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 E0073 Field Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 E0075 Leveling Shoe Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 E0077 Reverser Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 E0078 Concave Clearance Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 E0079 Grain Bin Covers Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 E0080 HHC Module Bad Intelligent Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 E0082 Feeder Speed Incr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 E0083 Feeder Speed Decr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 E0084 Voting Conflicts Found . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 E0085 Voting Differences Found . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 8 - 87682460

Chapter 19 -- CCM2 Error Codes CONTENTS Section

Description

Page

E0128

Trans Shift Gear N Sens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

E0129

Trans Shift Gear 3 Sens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

E0130

Trans Shift Gear 2 Sens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

E0131

Trans Shift Gear 1 Sens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

E0132

Trans Shift Gear 4 Sens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

E0133

Hydraulic Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

E0134

Brake Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

E0135

Charge Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

E0136

Beacon Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

E0137

Open Covers Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

E0138

Hazards Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

E0140

Operator Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

E0141

Header Reel RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

E0142

Groundspeed RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

E0143

Chopper RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

E0146

Thresher RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

E0148

Header Type Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

E0151

Thresher Clutch Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

E0152

Air Filter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

E0154

Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

E0159

Grain Bin Full Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

E0162

Control Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

E0164

V Supply Ground Spd Hydro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

E0165

CCM2 5V Ref Voltage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

E0166

CCM2 8V Ref Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

E0167

CCM2 5V Ref Voltage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

E0168

CCM2 Keyswitch Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

E0169

Current Sense Reel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

E0171

Curr Sense Transm Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

E0172

Curr Sense Rot Scr Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 8 - 87682460

Chapter 19 -- CCM2 Error Codes (Continued) CONTENTS Section

Description

Page

E0174

CCM2 Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

E0175

V Supply Thresher Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

E0177

Isense Unload Cross Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

E0178

Isense Thresher Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

E0179

LoP Isense Grnd Spd Hydro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

E0180

Thresher Clutch Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

E0181

Parking Brake Disengage Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

E0183

Brake Limiting Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

E0184

Unload Cross Auger Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

E0185

Header Reel Fore Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

E0186

Header Reel Drive Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

E0187

Header Reel Up Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

E0188

Header Reel Down Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

E0189

Header Reel Back Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

E0191

Thresher Speed Increase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

E0192

Thresher Speed Decrease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

E0193

Unload Tube In Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

E0194

Unload Tube Out Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

E0195

Foot-an-Inch Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

E0198

Backlighting Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

E0199

Brake Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

E0200

Beacon Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

E0201

Flasher System Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

E0202

Ground Speed Hydrostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

E0203

Transmission Shift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

E0204

Header Reel Speed Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

E0206

Rotary Screen Brush Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

E0208

ECU Module Data Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 9 - 87682461

Chapter 20 -- CCM3 Error Codes CONTENTS Section

Description

Page

E0261 Lower Sieve Decrease -- Rear Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 E0262 Upper Sieve Decrease -- Rear Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 E0263 Lower Sieve Increase -- Rear Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 E0282 Upper Sieve Increase -- Rear Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 E0283 Moisture Temp Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 E0284 Moisture Sensor -- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 E0285 Moisture Sensor + . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 E0287 Upper Sieve Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 E0288 Grain Yield Sensor

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

E0289 Spreader Plate Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 E0290 Lower Sieve Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 E0293 CCM3 5V Ref Voltage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 E0294 CCM3 8V Ref Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 E0295 CCM3 5V Ref Voltage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 E0296 CCM3 Keyswitch Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 E0297 Current Sense Spreader Pl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 E0300 Current Sense Lower Sieve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 E0301 Current Sense Upper Sieve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 E0302 CCM3 Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 E0310 Bypass Unit Engage Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 E0325 Upper/Lower Sieve Sel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 E0332 Spreader Plates Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 E0334 Lower Sieve Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 E0335 Upper Sieve Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 9 - 87682461

Chapter 21 -- HHC Diagnostic Codes CONTENTS Section

Description

Page

E0512 Feeder Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 E0513 Header Lift Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 E0514 R Stubble Height / Flex R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 E0515 L Stubble Height / Flex L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 E0516 Lateral Float CCW Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 E0517 Lateral Float CW Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 E0518 Header Up Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 E0519 Header Down Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 E0520 HHC 12V Supply Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 E0523 HHC Diagnostic LED Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 E0524 10V Reference Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 E0525 HHC Accumulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 10 - 87682462

Chapter 22 -- ASP Fault Codes CONTENTS Section

Description

Page

E1281 ASP Bottom Sensor (One) Line Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 E1283 ASP Bottom Sensor (Both) Shorted to High Source . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 E1284 ASP Stonedoor Output Unidentified Failure Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 E1286 ASP Sensitivity OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 E1287 ASP Sensitivity ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 10 - 87682462

Chapter 23 -- RHM Fault Codes CONTENTS Section

Description

Page

E0641

RHM 5V Reference Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

E0643

MFH Position Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

E0645

Gear Select Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

E0646

RHM Feeder Reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

E0648

RHM Spreader Plate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

E0649

RHM Header Height Mode (HHC Auto Height) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

E0652

RHM Engine Throttle Increase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

E0653

RHM Header Height Mode (HHC Compensation) . . . . . . . . . . . . . . . . . . . . . . . . . 26

E0654

RHM On the Road Switch (Road Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

E0655

RHM Spreader Plate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

E0656

RHM Engine Throttle Decrease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

E0657

RHM Reel Speed Mode (Set/Automatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

E0661

RHM Reel Speed Mode (Set/Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

E0662

RHM Fan Speed (Increase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

E0663

RHM Fan Speed (Decrease) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

E0664

RHM Rotor Speed (Increase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

E0665

RHM Rotor Speed (Decrease) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

E0666

RHM Feeder Speed (Increase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

E0667

RHM Feeder Speed (Decrease) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

E0668

RHM Park Brake (On) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

E0669

RHM Park Brake (Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

E0670

RHM Concave Clearance (Decrease) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

E0671

RHM Concave Clearance (Increase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

E0672

RHM Upper Sieve (Decrease) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

E0673

RHM Upper Sieve (Increase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

E0674

RHM Lower Sieve (Decrease) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

E0675

RHM Lower Sieve (Increase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

E0676

RHM Work Width (Increase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

E0677

RHM HHC Fine Adjust (Decrease) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 10 - 87682462

Chapter 23 -- RHM Fault Codes (Continued) CONTENTS Section

Description

Page

E0678

Current Protection Line 0 Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

E0679

Current Protection Line 1 Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

E0680

Current Protection Line 2 Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

E0681

HSW Unload Tube Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

E0682

HSW Unload Tube Out Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

E0683

HSW Unload Auger – Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

E0684

HSW Unload Tube In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

E0685

HSW Unload Tube In Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

E0686

HSW ILM (Handle) Unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

E0688

HSW Reel Fore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

E0689

HSW Reel Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

E0690

HSW Reel Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

E0691

HSW Reel Speed Decr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

E0692

HSW Reel Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

E0693

HSW Reel Speed Incr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

E0694

HSW Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

E0695

HSW Lateral Tilt CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

E0696

HSW Header Down Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

E0697

HSW Header Up Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

E0698

HSW Header Up Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

E0699

HSW HHC Resume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

E0700

HSW Lateral Tilt CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

E0701

HSW Header Down Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

SECTION 55 -- ELECTRICAL SYSTEMS BOOK 11 - 87682463

Chapter 24 -- Cursor 10.3L Engine Error Codes CONTENTS Section

Description

Page

IVECO 10.3L Engine Fault Code Cross Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 E1559 -- Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 E1560 -- Coolant Temperature Sensor Dynamic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 E1561 -- Boost Temp Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 E1562 -- Boost Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 E1563 -- Fuel Temp Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 E1564 -- Oil Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 E1565 -- Oil Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 E1566 -- Oil Temp Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 E1567 -- Oil Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 E1569 -- Coolant Temperature Sensor Absolute Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 E1570 -- Crankshaft Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 E1571 -- Running With Camshaft Sensor Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 E1572 -- Camshaft Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 E1573 -- Offset Between Camshaft and Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

SECTION 55 - ELECTRICAL SYSTEMS BOOK 11 - 87682463

Chapter 25 - CNH 9.0L Engine Fault Codes CONTENTS Section

Description

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CNH 9.0L Engine Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SECTION 60 - PRODUCT FEEDING BOOK 12 - 87682464

Chapter 1 - Feeder House CONTENTS Section

Description Page Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special Bolt Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Feeder House . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Feeder Drive Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Feeder Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Front Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Polyethylene Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Lateral Float Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Cradle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Face Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Feeder Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Front Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Rear Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Hydraulic Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

SECTION 60 - PRODUCT FEEDING BOOK 12 - 87682464

Chapter 2 - Feeder Drives CONTENTS Section

Description

Page

Special Bolt Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Primary Feeder Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Replacement (Fixed Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Replacement (Variable Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Variable Sheave Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Variable Drive Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Variable Drive Sheave Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Torque Sensing Drive Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Cross Shaft and Bearing Replacement (Fixed Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Cross Shaft and Bearing Replacement (Variable Drive) . . . . . . . . . . . . . . . . . . . . . . . . . 38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

SECTION 60 - PRODUCT FEEDING BOOK 12 - 87682464

Chapter 2 - Feeder Drives (Continued) CONTENTS Section

Description

Page

Feeder/Header Drive Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Feeder/Header Drive Clutch -- Cross Section View . . . . . . . . . . . . . . . . . . . . . . . . . 44 Feeder/Header Drive Clutch -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Secondary Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Feeder Reverser Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Feeder Reverser Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Feeder Chain Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Slip Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

SECTION 60 - PRODUCT FEEDING BOOK 12 - 87682464

Chapter 2 - Feeder Drives (Continued) CONTENTS Section

Description

Page

Pivot Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

SECTION 60 - PRODUCT FEEDING BOOK 12 - 87682464

Chapter 3 - Stone Ejection System CONTENTS Section

Description

Page

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Bottom Sensor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjustment and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Top Sensor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Stone Ejection System Actuating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Stone Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Removal and Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Skid Plate (Inner Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SECTION 66 - THRESHING BOOK 12 - 87682464

Chapter 1 - Rotor Chamber CONTENTS Section

Description

Page

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Front Infeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Concave Wear Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Rotor Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Concave Adjusting Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Concave Adjustment Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Concave Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Separator Grates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

SECTION 66 - THRESHING BOOK 12 - 87682464

Chapter 2 - Rotors CONTENTS Section

Description

Page

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rasp Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SECTION 66 -- THRESHING BOOK 12 - 87682464

Chapter 3 -- Main Threshing Drives CONTENTS Section

Description

Page

SECTION 66 -- THRESHING BOOK 12 - 87682464

Chapter 3 -- Main Threshing Drives (Continued) CONTENTS Section

Description

Page

Rotor Variable Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Rotor Variable Drive Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Rotor Variable Drive Sheave Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Torque Sensing Drive Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Rotor Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Right Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Left Rotor Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

SECTION 72 -- DISCHARGE BEATER BOOK 13 - 87682465

Chapter 1 -- Discharge Beater CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Discharge Beater Grate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Discharge Beater Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Discharge Beater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Beater Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Beater Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 74 - CLEANING SYSTEMS BOOK 13 - 87682465

Chapter 1 - Cleaning Shoe Frame CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Upper Cleaning Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Grain Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Lower Cleaning Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Cleaning Shoe Support Arm Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Connecting Arm Pivot Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Drive and Upper Connecting Arm Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Lower Connecting Arm Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Cleaning Shoe Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

SECTION 74 - CLEANING SYSTEMS BOOK 13 - 87682465

Chapter 1 - Cleaning Shoe Frame (Continued) CONTENTS Section

Description

Page

Leveling Frame - Pivot Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Leveling Frame - Rear Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Leveling Frame - Rear Pivot Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

SECTION 74 - CLEANING SYSTEMS BOOK 13 - 87682465

Chapter 2 - Cleaning Shoe Drive CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Upper Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Lower Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Eccentric Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

SECTION 74 - CLEANING SYSTEMS BOOK 13 - 87682465

Chapter 3 - Cleaning Fan and Drives CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pump -- Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pump -- Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Motor -- Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Motor -- Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Valve Block -- Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Valve Block -- Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cleaning Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Canvas Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Deflector Plate Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Cleaning Fan Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SECTION 74 - CLEANING SYSTEMS BOOK 13 - 87682465

Chapter 4 - Returns System CONTENTS Section

Description

Page

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Left Returns Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Right Returns Auger (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Disassembly -- Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Inspection -- Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Assembly -- Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Disassembly -- Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Inspection -- Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Assembly -- Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Returns Auger Safety Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Verify Clutch Slip Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Returns Auger Safety Clutch Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Returns Auger Safety Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Returns Auger Safety Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Returns Auger Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Right Auger Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Left Auger Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Right Auger Paddle Replacement (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Left Auger Paddle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Returns Auger Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

SECTION 80 -- GRAIN STORAGE BOOK 14 - 87682466

Chapter 1 -- Clean Grain Transport CONTENTS Section

Description

Page

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Clean Grain Cross Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Clean Grain Cross Auger -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Grain Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Grain Elevator Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Grain Elevator Upper Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Grain Elevator Upper Shaft -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Grain Flow Sensor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Moisture Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Sensitivity Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Bubble-up Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Bubble-up Gearbox -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

SECTION 80 -- GRAIN STORAGE BOOK 14 - 87682466

Chapter 2 -- Unloading System CONTENTS Section

Description

Page

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Unloading Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Unloading Intermediate Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Unloading Intermediate Shaft -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sprocket Shearbolt -- Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Drive System Unloading Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Drive System Unloading Gearbox -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . 10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Drive System Unloading Tube Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Drive System Unloading Tube Gearbox -- Exploded View . . . . . . . . . . . . . . . . . . . . 23 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Unloading Auger -- Vertical Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Unloading Auger -- Cross Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Cross Auger -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Unloading Tube Auger -- Unloading Tube and Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Unloading Tube Auger -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Support Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

SECTION 88 -- ACCESSORIES BOOK 14 - 87682466

Chapter 1 -- Straw Chopper CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Secondary Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Primary Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Chopper Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Counter Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Spreader Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Divider Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Divider Plate Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Chopper Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Chopper Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

SECTION 88 -- ACCESSORIES BOOK 14 - 87682466

Chapter 1 -- Straw Chopper (Continued) CONTENTS Section

Description

Page

Chop/Drop Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SECTION 88 -- ACCESSORIES BOOK 14 - 87682466

Chapter 2 -- Chaff/Corn Spreader CONTENTS Section

Description

Page

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydraulic Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Spreader Disc/Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Chaff/Corn Spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SECTION 88 -- ACCESSORIES BOOK 14 - 87682466

Chapter 3 -- Positive Straw Discharge (PSD) CONTENTS Section

Description

Page

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 PSD (Positive Straw Discharge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 PSD Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 PSD Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

SECTION 90 - PLATFORM, CAB, BODYWORK, DECALS BOOK 14 - 87682466

Chapter 1 - Cab CONTENTS Section

Description

Page

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cab Suspension System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Air Ride Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Seat Compressor/Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Seat Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Seat Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Steering Column Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Right Hand Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Outside Cab Roof Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

SECTION 90 - PLATFORM, CAB, BODYWORK, DECALS BOOK 14 - 87682466

Chapter 2 - Shielding and Ladders CONTENTS Section

Description

Page

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Side Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Gas Strut Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rear Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Rear Ladder Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Strut Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Front Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Platform Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

SECTION 90 - PLATFORM, CAB, BODYWORK, DECALS BOOK 14 - 87682466

Chapter 3 - Blow Off System CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 WABCO Compressor (412 352 008 0) Flange Mount (CR9070) . . . . . . . . . . . . . . . . . . . 3 WABCO Compressor (911-153-010-0) Flange -- Mount (CR9040, CR9060) . . . . . . . . . 4 WABCO Unloader Valve (975 303 072 0) For Flange Mount Compressor (CR9040 -- CR9060 -- CR9070) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Specific Arrangement -- CR9040, CR9060 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Specific Arrangement -- CR9070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Air Compressor -- CR9070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Air Compressor – CR9040, CR9060 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Performance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

SECTION 00 - GENERAL INFORMATION Chapter 1 - General Information CONTENTS Section

Description

Page

00-1

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 Section

Description

Page

00-2

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 FOREWORD correct at the time of issue, but New Holland policy is one of continuous improvement, and, the right to change specifications, equipment, or design at any time, without notice, is reserved.

Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all equipment, as well as the personal safety of the individual performing the repair. This Repair Manual provides troubleshooting, overhaul, and pressure-testing instructions using recommended procedures and equipment. Following these instructions will ensure the safe, efficient, and timely completion of the service or repair.

ABOUT IMPROVEMENTS New Holland is continually striving to improve its products. We must, therefore, reserve the right to make improvements or changes when it becomes practical and possible to do so, without incurring any obligation to make changes or additions to the equipment sold previously.

There are numerous variations in procedures, techniques, tools, and parts for servicing machines, as well as in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this manual must first establish that their personal safety, the safety of others, and the integrity of the machine will not be compromised by the choice of methods, tools or parts.

ALL SPECIFICATIONS ARE CHANGE WITHOUT NOTICE.

SUBJECT

PART AND ACCESSORIES Genuine NEW HOLLAND parts and accessories have been specifically designed for NEW HOLLAND MACHINES.

The manual is divided into sections which are subdivided into chapters: Each chapter contains information on general operating principles, detailed inspection, overhaul and, where applicable, specific troubleshooting, special tools, and specifications.

We would like to point out that “NON GENUINE” parts and accessories have not been examined and released by NEW HOLLAND. The installation and or use of such products could have a negative effect upon the design characteristics of your machine and thereby affect its safety. NEW HOLLAND is not liable for any damage caused by the use of “NON GENUINE” NEW HOLLAND parts and accessories.

Any reference in this manual to right, left, rear, front, top, or bottom is as viewed from the operator’s seat, looking toward the normal direction of travel. All data and illustrations in this manual are subject to variations in build specification. This information was

00-3

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

PRECAUTIONARY STATEMENTS PERSONAL SAFETY

SAFETY PRECAUTIONS

Throughout this manual and on machine decals, you will find precautionary statements (“DANGER”, “WARNING”, and “CAUTION”) followed by specific instructions. These precautions are intended for the personal safety of you and those working with you. Please take the time to read them.

Practically all service work involves the need to drive the combine. The operator’s manual, supplied with each combine, contains detailed safety precautions relating to driving, operating, and servicing the combine. These precautions are as applicable to the service technician as they are to the operator and should be read, understood and practiced by all personnel.

DANGER This word “DANGER” indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury. The color associated with Danger is RED.

Prior to undertaking any maintenance, repair, overhaul, dismantling or reassembly operations, whether within a workshop facility or in the field, consideration should be given to factors that may have an effect upon safety, not only upon the mechanic carrying out the work, but also upon bystanders.

WARNING This word “WARNING” indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE.

PERSONAL CONSIDERATIONS The wrong clothes or carelessness in dress can cause accidents. Be sure to wear suitable clothing when servicing equipment.

CAUTION

Some jobs require special protective equipment; be sure to use protective equipment when required.

This word “CAUTION” indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also used to alert against unsafe practices. The color associated with Caution is YELLOW.

Skin Protection Used motor oil may cause skin cancer. Follow work practices that minimize the amount of skin exposed and length of time used oil stays on your skin.

FAILURE TO FOLLOW THE “DANGER”, “WARNING”, AND “CAUTION” INSTRUCTIONS MAY RESULT IN SERIOUS BODILY INJURY OR DEATH.

Eye Protection The smallest eye injury may cause loss of vision. Injury can be avoided by wearing eye protection when engaged in chiselling, grinding, discing, welding, and painting.

MACHINE SAFETY The additional precautionary statement (“IMPORTANT”) is followed by specific instructions. This statement is intended for machine safety.

Breathing Protection Fumes, dust, and paint spray are unpleasant and harmful. These can be avoided by wearing respiratory protection.

IMPORTANT: The word “IMPORTANT”is used to inform the reader of something he needs to know to prevent minor machine damage if a certain procedure is not followed.

Hearing Protection Loud noise may damage your hearing, and the greater the exposure the worse the damage. If the noise is excessive, wear ear protection.

INFORMATION NOTE: Instructions used to identify and present supplementary information.

Lifting Protection Avoid injury by correctly handling components. Make sure you are capable of lifting the object. If in doubt get help.

00-4

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 Compressed Air The pressure from a compressed-air line often exceeds 100 PSI (690 kPa). It is perfectly safe if used correctly. Any misuse may cause injury.

Hand Protection It is advisable to use a protective cream before work to prevent irritation and skin contamination. After work clean your hands with soap and water. Solvents such as mineral spirit and kerosene may harm the skin.

Never use compressed air to blow dust, filing, and dirt away from your work area unless the correct type of nozzle is fitted.

Foot Protection Substantial or protective foot wear with reinforced toe caps will protect your feet from falling objects. Additionally, oil-resistant soles will help to avoid slipping.

Compressed air is not a cleaning agent; it will only move dust from one place to another. Look around before using an air hose as bystanders may get grit into their eyes, ears, or skin.

Special Clothing For certain work it may be necessary to wear flame or acid-resistant clothing.

Hand Tools Many cuts, abrasions and injuries are caused by defective tools. Never use the wrong tool for the job, as this generally leads either to an injury, a poor job, or damaged equipment.

EQUIPMENT CONSIDERATIONS Machine Guards Before using any machine, check to ensure that the machine guards are in position and serviceable. These guards not only prevent parts of the body or clothing coming in contact with the moving parts of the machine, but also ward off objects that might fly off the machine and cause injury.

When removing or replacing hardened pins, use a copper or brass drift rather than a hammer.

Lifting Devices Always ensure that lifting equipment, such as chains, slings, lifting brackets, hooks and eyes, are thoroughly checked and in good condition before use. If in doubt of weight capacity, select stronger equipment than is necessary.

Electricity Electricity has become so familiar in day to day usage, that its potentially dangerous properties are often overlooked. Misuse of electrical equipment can endanger life.

For dismantling, overhaul, and assembly of major and sub-components, always use the Special Service Tools recommended. These will reduce the work effort, labor time, and the repair cost.

Before using any electrical equipment particularly portable appliances - make a visual check to make sure that the wiring is not worn or frayed and that the plugs and sockets are intact. Make sure you know where the nearest isolating switch for your equipment is located.

Never stand under a suspended load or raised implement.

00-5

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 GENERAL CONSIDERATIONS

OPERATIONAL CONSIDERATIONS

Solvents Use cleaning fluids and solvents that are known to be safe. Certain types of fluids can cause damage to components such as seals and can cause skin irritation. Solvents should be checked that they are suitable not only for the cleaning of components and individual parts, but also that they do not affect the personal safety of the user.

Stop the engine, if at all possible, before performing any service. Place a warning sign on the combine which, due to service or overhaul, would be dangerous to start. Disconnect the battery leads if leaving such a unit unattended. Do not attempt to start the engine while standing beside the combine or attempt to bypass the safety start switch.

Housekeeping Many injuries result from tripping over or slipping on objects or material left lying around by a careless worker. Prevent these accidents from occurring. If you notice a hazard, remove the hazard.

Avoid prolonged running of the engine in a closed building or in an area with inadequate ventilation as exhaust fumes are highly toxic. Always turn the radiator cap to the first stop to allow pressure in the system to dissipate when the coolant is hot.

A clean, hazard-free place of work improves the surroundings and daily environment for everybody.

Never work beneath a combine which is on soft ground. Always take the unit to an area which has a hard working surface, preferably concrete.

Fire Fire has no respect for persons or property. The destruction that a fire can cause is not always fully realized. Everyone must be constantly on guard.

If it is found necessary to raise the combine for ease of servicing or repair, make sure that safe and stable supports are installed beneath axle housings, casings, etc., before starting work.

Extinguish matches, cigars, and cigarettes before throwing them away. Work cleanly, disposing of waste material into proper containers.

Use ladders or working platforms when servicing those areas of a combine that are not within easy reach.

Locate the fire extinguishers and find out how to operate them.

WARNING Do not use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Stop the engine and relieve pressure before connecting or disconnecting lines. Tighten all connections before starting the engine or pressurizing lines. If any fluid is injected into the skin, obtain medical attention immediately or gangrene may result. Failure to comply could result in serious injury or death.

Do not panic - warn those near and raise the alarm. Do not allow or use an open flame near the combine fuel tank, battery, or component parts. First Aid In the type of work that mechanics are engaged in, dirt, grease, and fine dusts settle upon the skin and clothing. If a cut, abrasion or burn is disregarded it may become infected within a short time. Seek medical aid immediately. Cleanliness Cleanliness of the combine hydraulic system is essential for optimum performance. When carrying out service and repairs, plug all hose ends and component connections to prevent dirt entry.

WARNING Escaping hydraulic/diesel fluid under pressure can penetrate the skin causing serious injury. Failure to comply could result in serious injury or death.

Clean the exterior of all components before carrying out any form of repair. Dirt and abrasive dust can reduce the efficiency and working life of a component and lead to costly replacement. Use of a high-pressure washer or steam cleaner is recommended.

Before loosening any hoses or tubes connecting implements to remote control valves, etc., switch off the engine, remove all pressure in the lines by operating levers several times. This will remove the danger of personal injury by oil pressure.

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SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 ACIDS AND ALKALIS (SEE BATTERY ACIDS, I.E., CAUSTIC SODA, SULFURIC ACID)

Prior to pressure testing, make sure all hoses and connectors of the combine and the test equipment are in good condition and tightly sealed. Pressure readings must be taken with the gauges specified. The correct procedure should be rigidly observed to prevent damage to the system or the equipment, and to eliminate the possibility of personal injury.

Used in batteries and cleaning materials. Irritating and corrosive to the skin, eyes, nose and throat. Causes burns.

Always lower equipment to the ground when leaving the combine.

Avoid splashes to the skin, eyes, and clothing. Wear suitable protective gloves and goggles. Can destroy ordinary protective clothing. Do not breathe mists.

Beware of overhead power, electric or telephone cables when travelling.

Ensure access to water and soap is readily available for splashing accidents.

Do not park or attempt to service a combine on an incline. If unavoidable, take extra care and block all wheels.

ADHESIVES AND SEALERS (SEE FIRE)

CAUTION Highly flammable, combustible.

Observe recommended precautions as indicated in this Repair Manual when dismantling the air conditioning system as escaping refrigerant can cause frostbite.

Generally should be stored in “NO SMOKING” areas; cleanliness and tidiness while in use should be observed, i. e., from applications where possible, disposable paper should be dispensed to cover benches. Containers, including secondary containers, should be labelled.

Prior to removing wheels and tires from the combine, check to determine whether additional ballast (liquid or weights) has been added. Seek assistance and use suitable equipment to support the weight of the wheel assembly.

Solvent-Based Adhesives/Sealers (See Solvents) Follow manufacturer’s Instructions

When inflating tires, beware of over inflation constantly check the pressure. Over inflation can cause tires to burst and result in personal injury.

Water-Based Adhesives/Sealers Those based on polymer emulsions and rubber lattices may contain small amounts of volatile toxic and harmful chemicals.

HEALTH AND SAFETY PRECAUTIONS Many of the procedures associated with vehicle maintenance and repair involve physical hazards or other risks to health. This section lists, alphabetically, some of these hazardous operations, materials and equipment associated with them. The precautions necessary to avoid these hazards are identified.

Skin and eye contact should be avoided, and adequate ventilation provided during use. Follow manufacturer’s Instructions Resin-Based Adhesive/Sealers (i.e., Epoxide and Formaldehyde Resin Based) Mixing should only be carried out in well-ventilated areas as harmful or toxic volatile chemicals may be released.

The list is not inclusive; all operations, procedures, and handling of materials should be carried out with health and safety in mind.

Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and absorption of toxic, or harmful chemicals through the skin. Splashes can damage the eyes. Provide adequate ventilation; avoid skin and eye contact. Follow manufacturer’s instructions.

00-7

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 Anaerobic Cyanoacrylate and other Acrylic Adhesives Many are irritating, sensitizing, or harmful to the skin. Some are eye irritants.

(North America Only)

CALIFORNIA Proposition 65 Warning Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

Skin and eye contact should be avoided and the manufacturer’s instructions followed. Cyanoacrylate adhesives (super-glues) must not contact the skin or eyes. If skin or eye tissue is bonded, cover with a clean moist pad and get medical attention. Do not attempt to pull tissue apart. Use in well-ventilated areas as vapors can cause irritation of the nose and eyes.

BRAKE AND CLUTCH LININGS AND PADS (SEE LEGAL ASPECTS)

For two-part systems: See Resin-Based Adhesive/ Sealers

These items create dust and residue which, if inhaled, may cause lung damage and, in some cases, cancer.

Isocyanate (Polyurethane) Adhesive/Sealers (See Resin-Based Adhesives) Individuals suffering from asthma or respiratory allergies should not work with, or near, these materials as sensitivity reactions can occur.

The normal handling and fitting of these items should not cause any hazard, but any drilling, grinding, or filling of friction materials may produce dust and should only be carried out under strictly controlled conditions.

Any spraying should preferably be carried out in exhaust ventilated booths removing vapors and spray droplets from the breathing zone. Individuals working with spray applications should wear supplied air respirators.

Care should be taken to avoid inhalation of dust from clutch and brake systems during servicing of brakes and clutches. The use of drum cleaning units, vacuum cleaning, or damp wiping is preferred to the use of air jets for “blowing-out.”

ANTIFREEZE (SEE FIRE, SOLVENTS, I.E., ISOPROPANOL, ETHYLENE GLYCOL, METHANOL)

The dust should be collected in a sealed plastic bag and disposed appropriately, according to local laws and regulations.

CAUTION

BRAZING (SEE WELDING)

Highly flammable, combustible.

CHEMICAL MATERIALS - GENERAL (SEE LEGAL ASPECTS)

Used in vehicle coolant systems, brake air pressure systems, and windshield washing solutions.

Chemical materials such as solvents, sealers, adhesives, paints, resin foams, battery acids, antifreeze, oils, and grease should always be used with caution, stored and handled with care. They may be toxic, harmful, corrosive, irritating, or highly flammable, causing hazardous fumes and dusts.

Vapors given off from coolant antifreeze (Glycol) arise only when heated. Antifreeze may be absorbed through the skin in toxic or harmful quantities. Swallowed antifreeze is fatal if not treated; medical attention must be sought immediately.

The effects of excessive exposure to chemicals may be immediate or delayed, briefly experienced or permanent, cumulative, superficial, life threatening, or may reduce life expectancy.

BATTERY ACIDS (SEE ACIDS AND ALKALIS) Gases released during charging are explosive. Never use an open flame or allow sparks near charging or recently charged batteries.

00-8

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 CLUTCH LININGS AND PADS (SEE BRAKE AND CLUTCH LININGS AND PADS)

Do not apply heat or flame to chemical materials, except under the manufacturer’s instructions. Some are highly flammable, and some may release toxic or harmful fumes.

CORROSION PROTECTION MATERIALS (SEE SOLVENTS, FIRE)

Do not leave containers open. Escaping fumes can build up to toxic, harmful, or explosive concentrations. Some fumes are heavier than air and will accumulate in confined areas, pits, etc.

CAUTION Highly flammable, combustible. These materials are varied; the manufacturer’s instructions should be followed. They may contain solvents, resins, and petroleum products. Skin and eye contact should be avoided. They should only be sprayed in conditions of adequate ventilation, and not in confined spaces.

Do not transfer chemical materials to unlabeled containers. Do not clean hands or clothing with chemical materials. Chemicals, particularly solvents and fuels, will dry the skin, and may cause irritation with dermatitis. Some can be absorbed through the skin in toxic or harmful quantities.

CUTTING (SEE WELDING) DEWAXING (SEE SOLVENTS AND FUELS KEROSENE)

Do not use emptied. containers for other materials, except when they have been cleaned under supervised conditions.

DO’S Do remove chemical materials from the skin and clothing as soon as practicable. Change heavily soiled clothing and have it cleaned.

Do not sniff or smell chemical materials. Brief exposure to high concentrations of fumes can be harmful or toxic.

Do carefully read and observe hazard and precaution warnings given on material containers (labels) and in any accompanying leaflets, poster or other instructions. Material health and safety data sheets can be obtained from manufacturers.

DUSTS Powder or dusts may be an irritant, harmful or toxic. Avoid breathing dusts from powdery chemical materials, or those arising from dry abrasion operations. Wear respiratory protection if ventilation is inadequate.

Do organize work practices by wearing protective clothing and safety devices to avoid contact with chemical materials; breathing vapors, aerosols, dusts, and fumes; inadequate container labelling; or fire and explosion hazards.

ELECTRIC SHOCK Electric shocks can result from the use of faulty electrical equipment or from the misuse of equipment even in good condition.

Do wash before job breaks, before eating, smoking, drinking, or using toilet facilities when handling chemical materials.

Ensure electrical equipment is maintained in good condition and frequently tested.

Do keep work areas clean, uncluttered, and free of spills.

Ensure flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked, or otherwise damaged.

Do store according to national and local regulations.

Ensure electric equipment is protected by the correct rated fuse.

Do keep chemical materials out of reach of children.

Never use electrical equipment or any other equipment which is in any way faulty. The results could be fatal.

DON’TS Do not mix chemical materials except under the manufacturer’s instructions; some chemicals can form other toxic or harmful chemicals, releasing toxic or harmful fumes, or be explosive when mixed together.

Use reduced voltage equipment for inspection and working lights, where possible. Ensure the cables of mobile electrical equipment cannot get trapped and damaged, such as in a vehicle hoist.

Do not spray chemical materials, particularly those based on solvents, in confined spaces, i.e., when people are inside a vehicle.

00-9

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 In Cases of Electrocution: • •

• •

Switch off electricity before approaching victim. If this is not possible, push or drag the victim from the source of electricity using dry non-conductive material. Commence resuscitation if trained to do so. CALL FOR MEDICAL ASSISTANCE IMMEDIATELY.

EXHAUST FUMES These contain asphyxiating, harmful and toxic chemicals, and particles such as carbon oxides, nitrogen oxides, aldehydes, lead, and aromatic hydrocarbons. Engines should only run under conditions of adequate extraction, or general ventilation, not in confined spaces. (North America Only)

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm. Diesel Engine Soot, discomfort, and irritation usually give adequate warning signs of hazardous fume concentration.

FIBER INSULATION (SEE DUSTS) Used in noise and sound insulation. The fibrous nature of surfaces and cut edge can cause skin irritation. This is usually a physical, not a chemical effect. Precautions should be taken to avoid excessive skin contact through careful organization of work practices and the use of gloves.

FIRE (SEE WELDING, FOAMS, LEGAL ASPECTS) Many of the materials found on, or associated with, the repair of vehicles are highly flammable. Some release toxic or harmful fumes if burned. Observe strict fire safety when storing and handling flammable materials or solvents, particularly near electrical equipment or welding processes. Before using electrical or welding equipment, be sure there is no fire hazard present.

Have a suitable fire extinguisher available when using welding or heating equipment.

FIRST AID Apart from meeting any legal requirements, it is desirable for someone in the workshop to be trained in first aid procedures. Splashes in the eye should be flushed with clean water for at least ten minutes. Soiled skin should be washed with soap and water. Inhalation affected individuals should be removed to fresh air immediately. If chemicals are swallowed, consult a doctor immediately with (label) information on material used. Do not induce vomiting, unless indicated by manufacturer.

FOAMS- POLYURETHANE (SEE FIRE) Used in sound and noise insulation. Cured foams are used in seat and trim cushioning. Follow manufacturer’s instructions. Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves and goggles. Individuals with chronic respiratory diseases, asthma, bronchial medical problems, or histories of allergic diseases should not work with or near uncured materials. The component’s vapors and spray mists can cause direct irritation and/or sensitivity reactions and may be toxic or harmful. Vapors and spray mists must not be breathed. These materials must be applied with adequate ventilation and respiratory protection. Do not remove respirator immediately after spraying, wait until vapor/mists have cleared. Burning of the uncured components and the cured foams can generate toxic and harmful fumes. Smoking, open flames, or the use of electrical equipment should not be allowed during foaming operations until vapors/mists have completely cleared. Any heat cutting of cured foams or partially cured foams should be conducted with extraction ventilation (see Legal Aspects).

00-10

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 FUELS (SEE FIRE, LEGAL ASPECTS, CHEMICALS - GENERAL, SOLVENTS)

Diesel Fuel (Gas-Oil) (See Fuels-Kerosene)

CAUTION

Used as fuels and cleaning agents.

Combustible.

Gasoline (Petrol)

Gross or prolonged skin contact with high boiling gas oils may cause serious skin disorders, including skin cancer.

CAUTION Highly flammable, combustible.

GAS CYLINDERS (SEE FIRE)

Swallowing can result in mouth and throat irritation; absorption from the stomach can result in drowsiness and unconsciousness. Small amounts can be fatal to children. Aspiration of liquid into the lungs, i.e., through vomiting, is a very serious hazard.

Gases such as oxygen, acetylene, carbon dioxide, argon, and propane are normally stored in cylinders at pressures of up to 2000 PSI (137.8 bar). Great care should be taken in handling these cylinders to avoid mechanical damage to them or the valve gear attached. The contents of each cylinder should be clearly identified by appropriate markings.

Prolonged or repeated contact with gasoline dries the skin and causes irritation and/or dermatitis. Liquid in the eye causes severe pain.

Cylinders should be stored in well-ventilated enclosures and protected from ice, snow, or direct sunlight. Fuel gases, i.e., acetylene and propane, should not be stored in close proximity to oxygen cylinders.

Motor gasoline may contain high quantities of benzene which is toxic upon inhalation; the concentrations of gasoline vapors must be kept very low. High concentrations will cause eye, nose and throat irritation, nausea, headache, depression and symptoms of drunkenness. Very high concentrations will result in rapid loss of consciousness.

Care should be exercised to prevent leaks from gas cylinders and lines and to avoid sources of ignition. Only trained personnel should undertake work involving gas cylinders.

Ensure there is adequate ventilation when handling and using gasoline. Great care must be taken to avoid the serious consequences of inhalation in the event of vapor build-up arising from spillages in confined spaces.

GASES (SEE GAS CYLINDER) GAS SHIELDING WELDING (SEE WELDING) GAS WELDING (SEE WELDING)

Special precautions apply to cleaning and maintenance operations on gasoline storage tanks.

GENERAL WORKSHOP TOOLS AND EQUIPMENT

Gasoline should not be used as a cleaning agent. It must not be siphoned by mouth.

It is essential that all tools and equipment are maintained in good condition and the correct safety equipment used where required.

Kerosene (Paraffin) Used also as heating fuel, solvent, and cleaning agent.

Never use tools or equipment for any purpose other than for which they were designed. Never overload equipment such as hoists, jacks, axle and chassis stands, or lifting slings. Damage caused by overloading is not always immediately apparent and may result in a fatal failure the next time the equipment is used.

CAUTION Flammable. Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if liquid aspiration into the lungs occurs. Liquid contact dries the skin and can cause irritation and/or dermatitis. Splashes in the eye may be slightly irritating.

Do not use damaged, defective tools or equipment, particularly high-speed equipment such as grinding wheels. A damaged grinding wheel can disintegrate without warning causing serious injury.

In normal circumstances, the low volatility does not give rise to harmful vapors. Exposure to mists and vapors from kerosene at elevated temperatures should be avoided (mists may arise in dewaxing). Avoid skin and eye contact; be sure there is adequate ventilation.

Wear suitable eye protection when using grinding, chiselling, or sandblasting equipment. Wear a suitable breathing mask when using sandblasting equipment or using spraying equipment.

00-11

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 CAUTION

GLUES (SEE ADHESIVE AND SEALERS) HIGH-PRESSURE AIR, LUBRICATION AND OIL TEST EQUIPMENT (SEE LUBRICANTS AND GREASES) Always keep high-pressure equipment in good condition and regularly maintained, particularly joint and unions. Never direct a high-pressure nozzle at the skin, as the fluid may penetrate to the underlying tissue and can cause serious injury.

LEGAL ASPECTS

Highly flammable. Paints can contain harmful or toxic pigments, driers, and other components, as well as solvents. Spraying should only be carried out with adequate ventilation. Two-part or catalyzed paints can also contain harmful and toxic unreacted resins and resinhardening agents. The manufacturer’s instructions should be followed and the section on resin-based adhesives, isocyanate containing adhesive and foams should be consulted.

Workshops should be familiar, in detail, with these laws and regulations.

Spraying should preferably be carried out in exhausted ventilated booths, removing vapor and spray mists from the breathing zone. Individuals working in booths should wear respiratory protection. Those doing small-scale repair work in the open shop should wear supplied air respirators.

LUBRICANTS AND GREASES

PAINT THINNERS (SEE SOLVENTS)

Many laws and regulations make requirements relating to health and safety in the use of materials and equipment in workshops.

Avoid all prolonged and repeated contact with mineral oils, especially used oils. Gross and prolonged skin contact with used oils contaminated during service, i.e., routine service change sump oils, are more irritating and more likely to cause serious effects, including skin cancer. Wash skin thoroughly after work involving oil. Proprietary hand cleaners may be of value provided they can be removed from the skin with water. Do not use petrol, paraffin, or other solvents to remove oil from the skin. Lubricants and greases may be slightly irritating to the eyes. Repeated or prolonged skin contact should be avoided by wearing protective clothing, if necessary. Particular care should be taken with used oils and greases containing lead. Do not allow work clothing to be contaminated with oil. Dry clean or launder such clothing at regular intervals. Discard oil-soaked shoes. Do not use previously used engine oils as lubricants or for any application where major skin contact is likely to occur. Used oils may only be disposed of in accordance with local regulations.

PRESSURIZED EQUIPMENT (SEE HIGHPRESSURE AIR, LUBRICATION AND OIL TEST EQUIPMENT) RESISTANCE WELDING (SEE WELDING) SEALERS (SEE ADHESIVES AND SEALERS) SOLDER (SEE WELDING) Solders are mixtures of metals in which the melting point of the mixture is below that of constituent metals (normally lead and tin). Solder application does not normally give rise to toxic lead fumes, provided a gas/air flame is used. Oxyacetylene flames should not be used, as they are much hotter and will cause lead fumes to be released. Some fumes may be produced by the application of any flame to surfaces coated with grease, etc., and inhalation of these should be avoided.

WELDING When welding on the unit always:

Refer to the “Recommended Lubricants and Coolants Charts”, for the recommended lubricants.

• •

NOISE INSULATION MATERIAL (SEE FOAMS, FIBER INSULATION)

•

PAINTS (SEE SOLVENTS AND CHEMICAL MATERIALS- GENERAL)

• • •

00-12

Disconnect the negative ground battery cable. Attach the welder ground cable close to the area being welded. Eliminate any fire hazards. Remove crop residue from the area around the welding. Ensure a fire extinguisher is immediately available. Protect hydraulic hoses from weld splatter. Protect tires when welding near a mounted tire.

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 SERVICE TECHNIQUES GENERAL Clean the exterior of all components before starting any type of repair. Dirt and abrasive dust can reduce the efficient working life of a component and lead to costly replacement. Time spent on the preparation and cleanliness of working surfaces will pay dividends in making the job easier and safer and will result in overhauled components being more reliable and efficient in operation. Use cleaning fluids which are known to be safe. Certain types of fluid can cause damage to O-rings and cause skin irritation. Solvents should be checked that they are suitable for the cleaning of components and also that they do not risk the personal safety of the user. Replace O-rings, seals or gaskets whenever they are disturbed. Never mix new and old seals or O-rings, regardless of condition. Always lubricate new seals and O-rings with hydraulic oil before installation. When replacing component parts, use the correct tool for the job.

HOSES AND TUBES Always replace hoses and tubes if the cone end or the end connections on the hose are damaged. When installing a new hose, loosely connect each end and make sure the hose takes up the designed position before tightening the connection. Clamps

should be tightened sufficiently to hold the hose without crushing and to prevent chafing. After hose replacement to a moving component, check that the hose does not foul by moving the component through the complete range of travel. Be sure any hose which has been installed is not kinked or twisted. Hose connections which are damaged, dented, crushed or leaking, restrict oil flow and the productivity of the components being served. Connectors which show signs of movement from the original swagged position have failed and will ultimately separate completely. A hose with a chafed outer cover will allow water entry. Concealed corrosion of the wire reinforcement will subsequently occur along the hose length with resultant hose failure. Ballooning of the hose indicates an internal leakage due to structural failure. This condition rapidly deteriorates and total hose failure soon occurs. Kinked, crushed, stretched or deformed hoses generally suffer internal structural damage which can result in oil restriction, a reduction in the speed of operation and ultimate hose failure. Free-moving, unsupported hoses must never be allowed to touch each other or related working surfaces. This causes chafing which reduces hose life.

00-13

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 PRODUCT IDENTIFICATION The serial number of the combine, the engine and the attachments can be found on the following locations:

BASE UNIT On a plate, 1, positioned on the right-hand side of the operator’s platform.

86060928

ENGINE 9.0L Engine On a plate at the top, left-hand side of engine.

86063482

2 10.3L Engine On a plate positioned on top of the rocker cover.

86063484

00-14

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 It is also on a plate on the cylinder block.

86063483

STRAW CHOPPER (IF EQUIPPED) The identification plate, 1, for the straw chopper, if equipped, is located at the right rear of the chopper.

50021347

POWERED REAR AXLE WHEEL MOTORS (IF EQUIPPED) The identification plate, 1, for each of the PRA wheel motors are located on the wheel motor carrier.

1 50021348

00-15

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON-METERS (FOOT POUNDS) FOR NORMAL ASSEMBLY APPLICATIONS

METRIC NON-FLANGED HARDWARE AND LOCKNUTS CLASS 5.8

CLASS 8.8

CLASS 10.9

PLATED W/ZnCr

UNPLATED

PLATED W/ZnCr

LOCKNUT CL.8 W/CL8.8 BOLT

2.6 (23)*

3.4 (30)*

3.7 (33)*

4.8 (42)*

2.3 (20)*

7.6 (67)*

8.9 (79)*

12 (102)*

13 (115)*

17 (150)*

7.8 (69)*

14 (124)*

18 (159)*

22 (195)*

28 (248)*

31 (274)*

40 (354)*

19 (169)*

M10

28 (21)

36 (27)

43 (32)

56 (41)

61 (45)

79 (58)

38 (28)

M12

49 (36)

63 (46)

75 (55)

97 (72)

107 (79)

138 (102)

66 (49)

M16

121 (89)

158 (117)

186 (137)

240 (177)

266 (196)

344 (254)

164 (121)

M20

237 (175)

307 (226)

375 (277)

485 (358)

519 (383)

671 (495)

330 (243)

M24

411 (303)

531 (392)

648 (478)

839 (619)

897 (662)

1160 (855)

572 (422)

NOMINAL SIZE

UNPLATED

PLATED W/ZnCr

1.7 (15)*

2.2 (19)*

5.8 (51)*

UNPLATED

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION HEX CAP SCREW AND CARRIAGE BOLTS CLASSES 5.6 AND UP MANUFACTURER’S IDENTIFICATION

PROPERTY CLASS

HEX NUTS AND LOCKNUTS CLASSES 05 AND UP MANUFACTURER’S IDENTIFICATION

86529681 REV F 5.1

PROPERTY CLASS

00-16

CLOCK MARKING

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON-METERS (FOOT POUNDS) FOR NORMAL ASSEMBLY APPLICATIONS

INCH NON-FLANGED HARDWARE AND LOCKNUTS SAE GRADE 2 NOMINAL UNPLATED SIZE or PLATED SILVER 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

6.2 (55)* 13 (115)* 23 (17) 37 (27) 57 (42) 81 (60) 112 (83) 198 (146) 193 (142) 289 (213)

SAE GRADE 5

PLATED W/ZnCr

SAE GRADE 8

PLATED W/ZnCr

GOLD

UNPLATED or PLATED SILVER

8.1 (72)* 17 (149)* 30 (22) 47 (35) 73 (54) 104 (77) 145 (107) 256 (189) 248 (183) 373 (275)

9.7 (86)* 20 (178)* 35 (26) 57 (42) 87 (64) 125 (92) 174 (128) 306 (226) 495 (365) 742 (547)

13 (112)* 26 (229)* 46 (34) 73 (54) 113 (83) 163 (120) 224 (165) 397 (293) 641 (473) 960 (708)

GOLD

UNPLATED or PLATED SILVER

LOCKNUTS

PLATED W/ZnCr GOLD

GR.B w/GR5 BOLT

14 (121)* 18 (157)* 8.5 (75)* 28 (250)* 37 (324)* 17.5 (155)* 50 (37) 65 (48) 31 (23) 80 (59) 104 (77) 50 (37) 123 (91) 159 (117) 76 (56) 176 (130) 229 (169) 111 (82) 244 (180) 316 (233) 153 (113) 432 (319) 560 (413) 271 (200) 698 (515) 904 (667) 437 (323) 1048 (773) 1356 (1000) 654 (483)

GR.C w/GR8 BOLT

NOMINAL SIZE

12.2 (109)* 25 (220)* 44 (33) 71 (53) 108 (80) 156 (115) 215 (159) 383 (282) 617 (455) 924 (681)

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION CAP SCREWS AND CARRIAGE BOLTS

SAE GRADE 2

SAE GRADE 5

SAE GRADE 8 REGULAR NUTS

SAE GRADE 5 HEX NUTS

SAE GRADE 8 HEX NUTS

LOCKNUTS

GRADE IDENTIFICATION

GRADE A NO NOTCHES

GRADE A NO MARKS

GRADE B ONE CIRCUMFERENTIAL NOTCH

GRADE B THREE MARKS

GRADE C TWO CIRCUMFERENTIAL NOTCHES

GRADE C SIX MARKS MARKS NEED NOT BE LOCATED AT CORNERS

86529681 REV F 5.2

GRADE A NO MARK GRADE B LETTER B GRADE C LETTER C GRADE IDENTIFICATION

00-17

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 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.

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 O-RING BOSS PLUGS ADJUSTABLE FITTING LOCKNUTS, SWIVEL JIC - 37° SEATS

TUBE NUTS FOR 37° FLARED FITTINGS

1/4

6.4

7/16-20

TORQUE FOOT NEWTON POUNDS METERS Min. Max. Min. Max. 9 12 12 16

5 6

5/16 3/8

7.9 9.5

1/2-20 9/16-18

12 21

15 24

16 29

20 33

10 15

15 20

14 20

20 27

8 10

1/2 5/8

12.7 15.9

3/4-18 7/8-14

35 53

40 53

47 72

54 79

25 35

30 40

34 47

41 54

12 14

3/4 7/8

19.1 22.2

1-1/16-12 1-3/16-12

77 90

82 100

104 122

111 136

60 70

70 80

81 95

95 109

25.4

1-5/16-12

110

120

149

163

108

122

20 24

1-1/4 1-1/2

31.8 38.1

1-5/8-12 1-7/8-12

140 160

150 175

190 217

204 237

95 120

115 140

129 163

158 190

50.8

2-1/2-12

225

240

305

325

250

300

339

407

SIZE

TUBING OD In. mm

THREAD SIZE

These torques are not recommended for tubes of 1/2″ (12.7 mm) OD and larger with wall thickness of 0.035″ (0.889 mm) or less. The torque is specified for 0.035″ (0.889 mm) wall tubes on each application individually.

TORQUE FOOT NEWTON POUNDS METERS Min. Max. Min. Max. 6 10 8 14

solvent or Loctite cleaner and apply hydraulic sealant Loctite no. 569 to the 37° flare and the threads. Install fitting and torque to specified torque, loosen fitting and retorque to specifications.

Before installing and torquing 37° flared fittings, clean the face of the flare and threads with a clean

00-18

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 PIPE THREAD FITTING TORQUE

Thread Size

Before installing and tightening pipe fittings, clean the threads with a clean solvent or Loctite cleaner and apply sealant Loctite no. 567 for all fittings including stainless steel or no. 565 for most metal fittings. For high filtration/zero contamination systems use no. 545.

1/8″ - 27

13 N⋅m (10 ft-lb)

1/4″ - 18

16 N⋅m (12 ft-lb)

3/8″ - 14

22 N⋅m (16 ft-lb)

1/2″ - 14

41 N⋅m (30 ft-lb)

3/4″ - 14

54 N⋅m (40 ft-lb)

Torque (Maximum)

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. IMPORTANT: 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.

50011183

IMPORTANT: Always use genuine New Holland replacement oils and filters to ensure proper lubrication and filtration of engine and hydraulic system oils.

1 8

The use of proper oils, grease, and keeping the hydraulic system clean will extend machine and component life.

00-19

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 RECOMMENDED LUBRICANTS AND COOLANTS (NORTH AMERICA ONLY)

CAUTION

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.

Some illustrations in this manual show shields opened or removed to show areas being serviced. Replace all shields before operating this machine. Failure to comply may result in minor or moderate injury.

IMPORTANT: Always use genuine New Holland replacement parts, oils and filters to ensure proper operation, filtration of engine and hydraulic systems. See your New Holland dealer for additional oil quantities.

Always clean the area around dipsticks, fill caps, and check plugs when checking fluid levels. Failure to clean these areas may allow contamination to enter the system. Drain, flush and refill the system anytime you suspect it is contaminated.

GENERAL INFORMATION

Grease Fittings Wipe dirt from fittings before greasing.

Regular lubrication is the best insurance against delays and repairs. Proper lubrication will extend machine life. Refer to the following charts for lubricants and service intervals.

Pump fresh grease into fitting to adequately lubricate the component and force out any contamination from the grease passage.

IMPORTANT: Failure to complete the required maintenance at the recommended intervals can cause unnecessary downtime.

Wipe off excess grease. Use a grease gun containing clean high grade of multipurpose grease.

The intervals listed in the Lubrication Chart are guidelines to be used when operating in normal conditions. Adjust the intervals for operating in adverse environmental and working conditions. The intervals should be shortened for sandy, dusty and extremely hot operating conditions.

Chains Stop all drives before lubricating chains.

DANGER Observe these safety precautions before performing lubrication and maintenance. 1. Shut off engine. 2. Disengage all drives. 3. Lower all attachments to the ground or raise and engage all locks 4. Close all shields opened and reinstall any shields removed for lubrication and maintenance proposes. Failure to comply will result in serious injury or death.

00-20

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 North America (Only) Lubricant

Type and Description

Part Number

Container Size

Engine Oil

AMBRA SUPER GOLD SSL ENGINE OIL SAE 10W-40

86994335

2.5G / 9.46L

AMBRA SUPER GOLD HSP ENGINE OIL SAE 10W

86641050

5G / 18.93L

AMBRA SUPER GOLD HSP ENGINE OIL SAE 10W-30

9613313

1QT / .946L

86641052

1G / 3.785L

9613314

2.5G / 9.46L

9673508DS

5G / 18.93L

9613286

1QT / .946L

86641043

1G / 3.785L

9613289

2.5G / 9.46L

86641044

5G / 18.93L

AMBRA SUPER GOLD HSP ENGINE OIL SAE 40

9624812DS

55G / 208.2L

AMBRA SUPER GOLD HSP ENGINE OIL SAE 15W-40

86641081

1QT / .946L

86641082

1G / 3.785L

86641084

2.5G / 9.46L

86641083

5G / 18.93L

AMBRA SUPER GOLD HSP ENGINE OIL SAE 20W-50

86994337

5G / 18.93L

AMBRA AUTO SUPREME SAE 5W-30

9673589DS

1QT / .946L

AMBRA AUTO SUPREME SAE 10W-30

86641101

1QT / .946L

AMBRA MULTI TRAN

86639558

1G / 3.785L

86639559

2.5G / 9.46L

86639560

5G / 18.93L

AMBRA MULTI TRAN SSL

86994339

2.5G / 9.46L

AMBRA MULTI BIO S

86994341

2.5G / 9.46L

AMBRA MULTI G 134

9624655DS

1QT / .946L

9624656DS

1G / 3.785L

9624450

2.5G / 9.46L

9624451

5G / 18.93L

AMBRA HYDROSYSTEM 46 HYD FLUID

86109085

5G / 18.93L

AMBRA HYDROSYSTEM 68 HYD FLUID

86994331

5G / 18.93L

AMBRA HYDROSYSTEM 100 HYD FLUID

86994343

5G / 18.93L

AMBRA HYDRODEX 3 ATF

9613304

1QT / .946L

9613312

2.5G / 9.46L

9613295

1QT / .946L

9613294

2.5G / 9.46L

86994348

16G / 60.6L

87027134*

1QT / .946L

87027135

2.5G / 9.46L

86994351

16G / 60.6L

AMBRA TRANSAXLE FLUID

86994352

5G / 18.93L

AMBRA HYPOIDE SSL GEAR LUBE

86994354

1QT / .946L

AMBRA GR-9 MULTI-PURPOSE GREASE

9613310

TUBE - 14 OZ.

AMBRA HI-TEMP GREASE

9861804DS

TUBE - 14 OZ.

AMBRA CORN HEAD GREASE

94107DS

TUBE - 14 OZ.

AMBRA GR 75 MD GREASE

87400001

TUBE - 14 OZ.

AMBRA GR 1000 SYNTHETIC GREASE

86994355

TUBE - 14 OZ.

LIMITED SLIP ADDITIVE

B96606

Brake Fluid

BRAKE LHM FLUID ( Mineral Based Oil)

86541699DS

1QT / .946L

Coolant

ESE-M97B18-D, Ethylene Glycol Coolant Concentrate

FGCC2701DS

1G / 3.785L

Propylene Glycol Concentrate

FGCC2711DS

1G / 3.785L

AMBRA SUPER GOLD HSP ENGINE OIL SAE 30

Transmission Oil

Hydraulic Oil

ATF Oil Gear Oil

AMBRA HYPOIDE 90 GEAR LUBE

AMBRA HYPOIDE 140 GEAR LUBE

Grease

00-21

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 All Markets Except North America Lubricant

Type and Description

Engine Oil

AMBRA SUPER GOLD SSL ENGINE OIL SAE 10W-40 AMBRA SUPER GOLD HSP ENGINE OIL SAE 10W AMBRA SUPER GOLD HSP ENGINE OIL SAE 10W-30

AMBRA SUPER GOLD HSP ENGINE OIL SAE 30

AMBRA SUPER GOLD HSP ENGINE OIL SAE 40 AMBRA SUPER GOLD HSP ENGINE OIL SAE 15W-40

AMBRA SUPER GOLD HSP ENGINE OIL SAE 20W-50 AMBRA AUTO SUPREME SAE 5W-30 AMBRA AUTO SUPREME SAE 10W-30 Transmission Oil

AMBRA MULTI TRAN

AMBRA MULTI TRAN SSL AMBRA MULTI BIO S Hydraulic Oil

AMBRA MULTI G 134

AMBRA HYDROSYSTEM 46 HYD FLUID AMBRA HYDROSYSTEM 68 HYD FLUID AMBRA HYDROSYSTEM 100 HYD FLUID ATF Oil

AMBRA HYDRODEX 3 ATF

Gear Oil

AMBRA HYPOIDE 90 GEAR LUBE

AMBRA HYPOIDE 140 GEAR LUBE

AMBRA TRANSAXLE FLUID AMBRA HYPOIDE SSL GEAR LUBE Grease

AMBRA GR-9 MULTI-PURPOSE GREASE AMBRA HI-TEMP GREASE AMBRA CORN HEAD GREASE AMBRA GR 75 MD GREASE AMBRA GR 1000 SYNTHETIC GREASE LIMITED SLIP ADDITIVE

Brake Fluid

BRAKE LHM FLUID ( Mineral Based Oil)

Coolant

ESE-M97B18-D, Ethylene Glycol Coolant Concentrate Propylene Glycol Concentrate

00-22

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 RECOMMENDED SEALANTS (NORTH AMERICA ONLY) Description

Part Number

Typical Applications

Strength

Color

Thread Lock

L22200 (222)

Small screws/hardware

Low

Purple

L24231 (242)

Small screws/hardware

Medium

Blue

L29000 (290)

Wicking Type

Medium

Green

L26231 (262)

Nuts & Bolts

High

Red

L54531 (545)

Hydraulic/Pneumatic

Non-fouling

L56531 (565)

Pipe Sealant

Controlled strength

L56747 (567)

Pipe Sealant

High temperature

L81724 (3.5 oz tube)

Ultra Blue RTV Gasket

Non-corrosive

Blue

L58775 (10.2 oz cartridge)

Ultra Blue RTV Gasket

Non-corrosive

Blue

L82180 (3.35 oz tube)

Ultra Blue RTV Gasket

Non-corrosive

Black

L59875 (10.2 oz cartridge)

Ultra Blue RTV Gasket

Non-corrosive

Black

L51831DS

Mating Machined Surfaces

Flexible

Red

Thread Sealant

Silicones

518 Gasket Eliminator

RECOMMENDED SEALANTS (ALL MARKETS EXCEPT NORTH AMERICA) Description

Part Number

Typical Applications

Strength

Color

Thread Lock

82995773 (2995773)-242

Small screw/hardware

Medium

Blue

82995772 (2995772)-262

Nuts & Bolts

High

Red

Thread Sealant

82995768 (2995768)-565

Pipe Sealant

Controlled strength

Silicones

82995775 (2995775)-595 50ml

Superflex RTV Gasket

82995776 (2995776)-300 ml Gasket Dressing

82995774 (2995774)-60 ml

Non-hardening sealant-enhances sealing of all types of precut gaskets

Super Flue Gel

82995778 (2995778)-20 ml

General purpose non-drip gel adhesive ideal for repair of cab trim, bonds to most materials including wood, rubber, metals, most plastics

00-23

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

00-24

SECTION 10 - ENGINE - CHAPTER 1

SECTION 10 - ENGINE Chapter 1 - 9.0L Engine Removal and Replace CONTENTS Section

Description

Page

10-1

SECTION 10 - ENGINE - CHAPTER 1

REMOVAL

ENGINE

NOTE: The engine and cooling system used in the CR Combine is designed to be removed as a modular unit. The following engine removal procedure demonstrates the removal of the engine only from the module. This procedure takes into consideration the possible unavailability of proper, or sufficient lifting equipment for complete module removal. When possible, remove the engine and cooling system module as designed. 1. Remove the gearbox and hydraulic pumps from the engine. (Refer to “Section 14 --Gearbox Removal”) 2. Place a suitable container, 1, below the coolant drain hose, 2. NOTE: The cooling system has a coolant capacity of 31.5 liters (8.3 gal.). Be sure to use clean containers with adequate capacity when draining the cooling system.

1 10013105

1 3. Turn the drain petcock, 1, on the radiator, 2, counter clockwise to open the coolant drain. Drain all of the coolant into the containers.

2 1

10013106

10-2

SECTION 10 - ENGINE - CHAPTER 1 4. Open the valve, 1, to the oil pan.

86063115

3 5. Remove the plug, 1. Drain all of the engine oil into suitable containers. NOTE: The New Holland engine has an oil capacity of 22.7 liters (6.0 gal.). Be sure to use clean containers with adequate capacity when draining the engine oil.

1 86063117

4 6. Disconnect the negative cables from the batteries, 1.

1 86063134

10-3

SECTION 10 - ENGINE - CHAPTER 1 7. Loosen and remove the nut, 1. (behind boot) Disconnect the main starter cable, 2, from the starter solenoid, 3. Remove the starter shield hardware (not shown) from under shield, 4. Remove starter shield. Unbolt the starter motor, 3, and remove from the engine.

3 2 1

86062996

6 8. Disconnect the shock absorber, 1, from the engine lid, 2.

2 1

86063833

7 9. Remove the two retaining rings, 1, washers, 2, and hinge pins, 3, from the engine lid. Remove the engine lid from the combine.

1 2

66063844

10-4

SECTION 10 - ENGINE - CHAPTER 1 10. Loosen all hose clamps on the hoses, 1, going to the coolant tank, 2. Remove all hoses.

11. Unplug coolant level sensor, 3.

12. Loosen and remove the hardware, 4, to the mounting brackets, 5. Remove coolant tank.

4 2

66063820

9 13. Remove the hardware, 1, from the top and sides of the engine cover frame. Remove the engine covers, 2.

66063831

10 14. Remove engine cover hardware, 1, from step support (see insert) and remove engine cover, 2.

1 66063812

10-5

SECTION 10 - ENGINE - CHAPTER 1 15. Remove hardware, 1, from bottom step support bracket, 2.

86063816

12 16. Remove the step support mounting bolts, 1, (see insert) and remove the step support, 2, from engine compartment.

17. Remove the engine lid support bracket mounting bolts, 3, and remove the engine lid support bracket, 4, from the grain tank wall.

66063811

13 18. Remove muffler support bracket hardware, 1, from muffle support bracket, 2.

1 86063815

2 14

10-6

SECTION 10 - ENGINE - CHAPTER 1 19. Loosen clamp, 1, to the exhaust pipe, 2.

20. Loosen clamp, 3, to the exhaust aspiration pipe, 4.

21. Remove the muffler, 5, from the engine compartment.

3 4 2

86063832

15 22. Loosen and remove hardware, 1, securing exhaust pipe, 2, to the exhaust pipe support bracket, 3.

23. Loosen exhaust clamp, 4, to the turbocharger and remove exhaust pipe, 2, from engine.

86063833

16 24. Loosen and remove hardware, 1, securing the exhaust aspiration pipe to the platform, 2.

2 86063816

10-7

SECTION 10 - ENGINE - CHAPTER 1 25. Loosen clamp, 1, connecting the exhaust aspiration pipe to the filter housing, 2. Connection is behind the filter housing near bottom. Remove the aspiration pipe.

86063817

18 26. Loosen pipe clamp, 1, to air intake pipe 2.

27. Loosen and remove hardware, 3, from support clamp, 4. 28. Loosen pipe clamp, 5, at filter housing connection, 6. 29. Remove air intake pipe, 2, from engine.

86063819

19 30. Loosen clamp, 3, at the turbocharger for the outlet pipe to intercooler.

1 86063818

2 20

10-8

SECTION 10 - ENGINE - CHAPTER 1 31. Loosen pipe clamp, 1, from intercooler pipe, 2. Remove intercooler pipe from engine. 32. Loosen pipe clamp, 3, to top coolant pipe, 4 from the radiator neck.

2 1 4

86063828

21 33. Loosen pipe clamp, 1, to upper coolant pipe, 2, and remove coolant pipe from engine.

66063822

22 34. Loosen pipe clamp, 1, to lower coolant pipe, 2.

1 86063823

10-9

SECTION 10 - ENGINE - CHAPTER 1 35. Loosen pipe clamp, 1, to lower coolant pipe, 2. Remove the coolant pipe from the lower radiator neck.

1 66063824

2 24

36. Loosen pipe clamp, 1, to the air intake, 2.

2 86063825

25 37. Loosen pipe clamp, 1, to intake cooler pipe, 2. Remove the intake cooler pipe from the engine. 38. Remove the A/C compressor from the engine as described in Section 50 of this manual. It should not be necessary to open the A/C system; place the A/C compressor out of the way on the engine platform.

2 86063826

10-10

SECTION 10 - ENGINE - CHAPTER 1 39. Loosen the adjusting nut, 1, to release the tension on the idler pulley, 2. Remove the two fan belts, 3.

1 66063845

27 40. Loosen and remove the radiator support mounting hardware, 1, and remove the radiator support, 2.

10013116

28 41. Remove the main drive belt, 1, from the engine.

1 66063626

10-11

SECTION 10 - ENGINE - CHAPTER 1 42. From inside the grain tank, loosen the mounting nuts on the carriage bolts, 1, and turn the rotary screen drive pulley adjusting bolt, 2, counter clockwise, to release the tension on the drive belt.

1 3

2 10013118

30 43. Bleed the pressure from the fuel system. Remove the fuel line, 1, coming from the fuel pump and remove the return fuel line, 2, going to the fuel tank. Secure the fuel lines out of the way and above the fuel tank.

2 86063843

31 44. Disconnect the main engine electrical harness connector, 1.

86063847

10-12

SECTION 10 - ENGINE - CHAPTER 1 45. Open the rotary screen door and disconnect the rotary screen brush electrical connector, 1, if installed.

10013132

33 46. Feed the connector and wire loom, 1, and grommet, 2, through the hole in the radiator frame. Secure the wire loom and connector, (if installed), to the engine to prevent damage during removal. NOTE: Removal of the rubber grommet in the radiator frame hole may be necessary to remove the radiator screen brush electrical connector.

1 2

10013133

34 47. Loosen the nut, 1, and remove the oil hose, 2, from the hose guide, 3.

2 10013125

10-13

SECTION 10 - ENGINE - CHAPTER 1 48. Cut the wire ties, 1, and separate the engine wire harness, 2, from the gearbox wire harness, 3. Secure each harness to prevent damage during engine removal.

1 10013126

36 49. Loosen the hose clamp, 1, (not shown) and disconnect the rear heater hose, 2, from the engine. Disconnect hose clamp, 3, securing hose to engine block.

1 2

3 86062996

37 50. Loosen the hose clamp, 1, and disconnect the front heater hose, 2, from the engine.

86063823

10-14

SECTION 10 - ENGINE - CHAPTER 1 51. Remove the nut and bolt, 1, from the front fan support bracket, 2.

1 10013129

39 52. Remove the clamp, 1, from the engine oil pan, 2. Disconnect the oil hoses, 3, and plug the hole in the oil pan, 2.

86063115

40 53. Attach a suitable chain to the front lift eye, 1, at the front of the engine.

86062998

10-15

SECTION 10 - ENGINE - CHAPTER 1 54. Attach a suitable chain to the back lift eye, 1, at the rear of the engine.

86062999

42 55. Connect the lift chain to a suitable lifting device. Raise the lifting device enough to support the engine during removal of the engine mounting bolts.

10013136

43 56. Loosen the two front, engine mounting bolts, 1, in the center of the of the engine under the damper. Do not remove the mounting bolts at this time.

86063000

10-16

SECTION 10 - ENGINE - CHAPTER 1 57. Loosen the six left rear and four right rear, engine mounting bolts, 1. Do not remove the mounting bolts at this time. 58. With the engine securely supported by the lifting device, remove all of the engine mounting bolts loosened in the previous steps. 59. Carefully lift the engine from the frame and remove from the combine.

1 10013138

INSTALLATION 1. Attach a suitable chain to the front lift eye, 1, at the front of the engine.

86062998

46 2. Attach a suitable chain to the back lift eye, 1, at the rear of the engine.

86062999

10-17

SECTION 10 - ENGINE - CHAPTER 1 3. Connect the lift chain to a suitable lifting device. 4. Carefully lift the engine above the combine and lower into position in the frame.

10013136

48 5. Position the engine in the frame, aligning the two front mounting holes. Install the mounting bolts, 1. Install the washers, 2, and nuts, 3, on the bolt.

86063000

49 6. Align the rear mounting holes and install the mounting bolt, 1, and washer, 2. 7. Tighten and torque the front engine mounting nuts to 217 N⋅m (160 ft-lb). 8. Tighten and torque the rear engine mounting bolts to 240 N⋅m (177 ft-lb).

1 10013138

10-18

SECTION 10 - ENGINE - CHAPTER 1 9. Install starter. Connect the main starter cable, 1, to the starter solenoid, 2, and secure with the nut, 3. Install the hardware for the shield, 4 and tighten.

2 1 3

86062996

51 10. Remove the plug from the oil pan, 1, and connect the oil hose, 2, to the oil pan. Secure with the clamp, 3.

1 3 2 86063115

52 11. Secure the front fan support bracket, 1, with the bolt and nut, 2. Tighten securely.

2 10013129

10-19

SECTION 10 - ENGINE - CHAPTER 1 12. Connect the front heater hose, 1, to the engine and tighten the hose clamp, 2, securely.

86063823

54 13. Connect the rear heater hose, 1, to the engine and tighten the hose clamp, 2, (not shown) securely. Secure hose clamp, 3 to engine block.

2 3

1 86062996

55 14. Secure the gearbox wire harness, 1, to the engine wire harness, 2, with wire ties, 3.

3 10013126

10-20

SECTION 10 - ENGINE - CHAPTER 1 15. Secure the oil hose, 2, to the hose guide, 3, and tighten the nut, 1.

2 10013125

57 16. Feed the rotary screen brush electrical connector (if installed) and wire loom, 1, and grommet, 2, up through the hole in the radiator frame.

10013133

58 17. Connect the rotary screen brush electrical connector, 1, (if installed) and secure the wire loom with wire ties, 2.

2 1

10013132

10-21

SECTION 10 - ENGINE - CHAPTER 1 18. Connect the main engine electrical harness connector, 1.

86063847

60 19. Connect the fuel line, 1, coming from the fuel pump and connect the return fuel line, 2, going to the fuel tank.

2 86063843

61 20. Install the rotary screen brush drive belt, 1, onto the pulley, 2, and engine crankshaft pulley. Turn the pulley adjusting bolt, 3, clockwise to adjust the belt tension until the belt is tight. Tighten the lock nuts on the carriage bolts, 4, when the belt is properly adjusted. Adjustment is correct when the belt deflection is 3 mm (1/8 in) in the center of the belt, with a force of 23 N (5.2 lbf) applied to the belt.

3 10013118

2 62

10-22

SECTION 10 - ENGINE - CHAPTER 1 21. Install the main drive belt, 1, onto the engine. Install the A/C compressor on the engine as described in Section 50 of this manual.

1 66063626

63 22. Install the radiator support, 1, assembly onto the radiator frame, 3, and fan support frame, 4.

23. Install and tighten the mounting hardware, 5.

5 4 86060925

64 24. Install the two fan belts, 1, onto the fan pulley and engine crankshaft pulley. Tighten the adjuster nut, 2, until the washer, 3, is even with the end of the gauge, 4. Tighten the nut on the idler, 5, when adjustment is correct.

3 2

1 66063845

10-23

SECTION 10 - ENGINE - CHAPTER 1 25. Install two clamps, 1, onto cooler pipe, 2, and connect intake cooler pipe to upper cooler neck. Tighten clamp.

2 86063826

66 26. Install other end of pipe into air intake, 2. Adjust position of clamp, 1, to seal. Tighten clamp.

2 86063825

67 27. Install pipe clamp, 1, to lower coolant pipe, 2. Install the coolant pipe to the lower radiator neck. Adjust position of clamp, 1, to seal. Tighten clamp.

66063824

2 68

10-24

SECTION 10 - ENGINE - CHAPTER 1 28. Install pipe clamp, 1, to the other end of lower coolant pipe, 2. Install coolant pipe into the water pump outlet. Adjust position of clamp, 1, to seal. Tighten clamp.

1 86063823

69 29. Install two pipe clamps, 1, to upper coolant pipe, 2, and install coolant pipe to water pump inlet and upper radiator neck. Adjust position of clamps, 1, to seal. Tighten clamps.

1 86060925

70 30. Install pipe clamps, 1, to intake air pipe, 2. Adjust position of clamps, 1, to seal. Tighten clamps.

31. Install and tighten hardware, 3, to support clamp, 4.

86063819

4 2 1 71

10-25

SECTION 10 - ENGINE - CHAPTER 1 32. Install pipe clamp, 1, to cooler pipe, 2. Install cooler pipe to intercooler.

2 1

86063828

72 33. Install clamp, 1, to the cooler pipe flange, 2. Install the cooler pipe assembly to the turbocharger, making sure the connection is seated properly. Tighten clamp.

86063818

73 34. Install clamp, 1, connecting the exhaust aspiration pipe to the filter housing, 2. Connection is behind the filter housing near bottom. Install the aspiration pipe. Adjust position of clamp, 1, to seal. Tighten clamp.

NOTE: Let the aspiration pipe lay in this position until ready to install the other end into muffler.

86063817

10-26

SECTION 10 - ENGINE - CHAPTER 1 35. Install the exhaust pipe clamp, 1, and install the exhaust pipe, 2, to the turbocharger. 36. Install hardware, 4, securing exhaust pipe, 2, to the exhaust pipe support bracket, 3. Tighten hardware, 4.

2 1 4

86063833

75 37. Install the muffler, 1, to the exhaust pipe, 2. 38. Tighten clamp, 3, to the exhaust pipe, 2.

39. Install clamp, 4, to the exhaust aspiration pipe, 5. Install aspiration pipe to muffler, 1. Adjust position of clamp, 1, to seal. Tighten clamp.

4 5 86063832

76 40. Install hardware, 1, securing the exhaust aspiration pipe to the platform, 2. Tighten hardware.

86063816

10-27

SECTION 10 - ENGINE - CHAPTER 1 41. Install muffler support bracket hardware, 1, to muffle support bracket, 2. Tighten hardware.

1 2

86063815

78 42. Install the engine lid support bracket, 1, to the grain tank wall using mounting hardware, 2, and tighten.

43. Install the step support, 3, to engine lid support bracket. Install the step support mounting bolts, 4, (see insert) and tighten.

66063811

79 44. Install mounting hardware, 1, to bottom step support bracket, 2, and tighten.

86063816

10-28

SECTION 10 - ENGINE - CHAPTER 1 45. Install the engine covers, 1.Install the hardware, 2, to the top and sides of the engine cover frame and tighten.

66063831

81 46. Install engine cover, 1. Install engine cover hardware, 2, from step support (see insert) and tighten.

2 66063812

82 47. Install coolant tank.

48. Install all hose clamps onto the hoses, 1, going to the coolant tank, 2. Install all hoses.

49. Connect the coolant level sensor, 3. 50. Install and tighten the hardware, 4, to the mounting brackets, 5.

4 2

66063820

10-29

SECTION 10 - ENGINE - CHAPTER 1 51. Install the engine lid to the combine. Install the two retaining rings, 1, washers, 2, and hinge pins, 3, to the engine lid.

1 2

66063844

84 52. Connect the shock absorber, 1, to the engine lid, 2.

2 1

86063833

85 53. Replace the plug, 1. 54. Fill the engine with the proper amount and type of oil. See Specifications.

1 86063117

10-30

SECTION 10 - ENGINE - CHAPTER 1 55. Turn the drain petcock, 1, on the radiator, 2, clockwise to close the coolant drain. Fill the cooling system with the proper amount and type of coolant. See Specifications.

56. Install the gearbox and hydraulic pumps onto the engine. (Refer to “Section 14 -- Gearbox Installation”).

10013106

87 57. Connect the battery cables to the batteries, 1.

1 86063134

88 58. Disconnect the fuel pump wire connector, 1, to disable the fuel pump, 2. Leave valve, 3, in the closed position.

59. Check the engine oil level and top off if necessary. 60. Crank the engine over for three ten second intervals. This will distribute lubricating oil to the engine operating systems and will allow oil pressure to be built before starting the engine. Recheck the engine oil level, and top off as required.

50020119

3 89

10-31

SECTION 10 - ENGINE - CHAPTER 1 61. Open valve, 1. Connect the fuel pump wire connector, 2, and bleed the air from fuel injection system, by turning the key switch to the “ON” position for 35 seconds to allow the fuel pump to run, then turn the key switch “OFF” for several seconds. Repeat this ON--OFF cycle two more times to thoroughly prime the fuel system. 62. Start the engine and check all hoses, fittings and clamps for leaks.

CAUTION Monitor the vehicle display at all times during initial engine start up to ensure the engine has proper oil pressure. Shut down the engine immediately if oil pressure is not adequate. 63. Be certain that all electrical components are working properly.

10-32

50020119

1 90

SECTION 10 - ENGINE - CHAPTER 2

SECTION 10 - ENGINE Chapter 2 - 10.3L Complete Engine, Removal and Replace CONTENTS Section

Description

Page

10-1

SECTION 10 - ENGINE - CHAPTER 2 ENGINE REMOVAL NOTE: The engine and cooling system used in the CR Combine is designed to be removed as a modular unit. The following engine removal procedure demonstrates the removal of the engine only from the module. This procedure takes into consideration the possible unavailability of proper, or sufficient lifting equipment for complete module removal. When possible, remove the engine and cooling system module as designed. 1. Remove the gearbox and hydraulic pumps from the engine. (Refer to “Section 14 -- Gearbox Removal”) 2. Place a suitable container, 1, below the coolant drain hose, 2. NOTE: The cooling system has a coolant capacity of 42 liters (11.1 gal.). Be sure to use clean containers with adequate capacity when draining the cooling system.

1 10013105

1 3. Turn the drain petcock, 1, on the radiator, 2, counter clockwise to open the coolant drain. Drain all of the coolant into the containers.

2 1

10013106

10-2

SECTION 10 - ENGINE - CHAPTER 2 4. Open the valve, 1, to the oil pan.

86063115

1 86063117

4 6. Disconnect the shock absorber, 1, from the engine lid, 2.

2 1

86063836

10-3

SECTION 10 - ENGINE - CHAPTER 2 7. Remove the two retaining rings, 1, washers, 2, and hinge pins, 3, from the engine lid. Remove the engine lid from the combine.

1 2

66063844

6 8. Remove the hardware, 1, from the top and sides of the engine cover frame. Remove the engine covers.

1 1

1 66070220

1 7

9. Remove the coolant hose, 1, support clamp from shield, 2.

10. Remove shield, 2, from cover assembly and step support, 3.

11. Remove U-bolt, 4, from the step support, 3. 12. Remove the two M8x25 Hex Head Cap screws, nuts and washers, 5. Remove the step support.

86070221

2 8

10-4

SECTION 10 - ENGINE - CHAPTER 2 13. Remove hardware, 1, from bottom step support bracket, 2.

86063816

9 14. Remove the step support mounting bolts, 1, (see insert) and remove the step support, 2, from engine compartment.

15. Remove the engine lid support bracket mounting bolts, 3, and remove the engine lid support bracket, 4, from the grain tank wall.

66063809

10 16. Loosen all hose clamps (not shown) on the hoses, 1, going to the coolant tank, 2. Remove all hoses.

2 5

17. Remove coolant level sensor, 3. 18. Loosen and remove the hardware, 4, to the mounting brackets, 5.

19. Remove coolant tank.

86063835

10-5

SECTION 10 - ENGINE - CHAPTER 2 20. Remove muffle support bracket hardware, 1, from muffle support bracket, 2.

21. Loosen clamp, 3, to the exhaust aspiration pipe, 4.

4 2 1 86063836

12 22. Loosen clamp, 1, to the exhaust pipe, 2.

23. Loosen and remove hardware, 3, securing exhaust pipe, 2, to the exhaust pipe support bracket, 4.

24. Remove the muffler, 5, from the engine compartment.

1 2

4 86063840

13 25. Loosen clamp, 1, to the exhaust pipe, 2. 26. Remove the exhaust pipe from the engine.

86063838

10-6

SECTION 10 - ENGINE - CHAPTER 2 27. Loosen and remove hardware, 1, securing the exhaust aspiration pipe to the platform, 2.

1 2

86063816

15 28. Loosen clamp, 1, connecting the exhaust aspiration pipe to the blower, 2. Connection is behind the blower near bottom. Remove the aspiration pipe.

86063817

16 29. Loosen clamp, 1, to the intercooler pipe, 2, (hot).

2 86063841

10-7

SECTION 10 - ENGINE - CHAPTER 2 30. Loosen clamp, 1, to the intercooler pipe, 2, (hot) that connects to the intercooler.

1 2

86070224

18 31. Loosen pipe clamp, 1, to crankcase ventilation tube, 2.

32. Loosen pipe clamp, 3, to blower intake pipe. 4.

2 86070222

19 33. Loosen clamp, 1, to air compressor hose, 2, and remove if that option is used.

86070225

10-8

SECTION 10 - ENGINE - CHAPTER 2 34. Loosen pipe clamp, 1, to blower intake pipe 2. 35. Remove the blower intake pipe, 2, from the engine.

1 86073842

21 36. Remove the U--bolt, 1, and hardware from the support bracket, 2.

37. Remove the hardware, 3, from the support bracket, 2, and remove the bracket from the engine. 38. Loosen clamp, 4, to the intercooler pipe (cold).

4 1 86070223

22 39. Loosen clamp, 1, to the intercooler pipe (cold), 2. Remove the intercooler pipe (cold), from the engine.

40. Loosen pipe clamp, 3, to top coolant pipe, 4 from the radiator neck.

1 4

86063828

10-9

SECTION 10 - ENGINE - CHAPTER 2 41. Loosen pipe clamp, 1, to upper coolant pipe, 2, that goes to the inlet of the water pump (not shown).

42. Loosen pipe support, 3, and remove from coolant pipe.

43. Remove the upper coolant pipe, 2, from engine.

86070228

24 44. Loosen pipe clamp, 1, to lower coolant pipe, 2, that goes to the outlet of the water pump, 3.

45. Loosen pipe clamp, 4, to the front heater hose, 5, and remove the hose.

1 5

86070226

4 25

46. Loosen pipe clamp, 1, to lower coolant pipe, 2. Remove the coolant pipe from the lower radiator neck.

86070227

10-10

SECTION 10 - ENGINE - CHAPTER 2 WARNING Do not disconnect any air conditioning lines or hoses during compressor removal, as serious injury could result.

47. Disconnect the electrical connectors, 1, and remove the four mounting bolts, 2, from the air conditioning compressor, 3. Remove the compressor from the engine and tie the assembly out of the way.

40015211

27 48. Loosen the adjusting nut, 1, to release the tension on the idler pulley, 2. Remove the two fan belts, 3.

1 66063845

28 49. Loosen and remove the radiator support mounting hardware, 1, and remove the radiator support, 2.

1 2

86070229

10-11

SECTION 10 - ENGINE - CHAPTER 2 50. From inside the grain tank, loosen the mounting nuts on the carriage bolts, 1, and turn the rotary screen drive pulley adjusting bolt, 2, counter clockwise, to release the tension on the drive belt, 3. Remove drive belt.

1 3

2 10013118

30 51. Bleed the pressure from the fuel system. (See section 4-27 in the operator’s manual). 52. Loosen the fitting, 1, and remove the fuel line, 2, at the electronic fuel control block, 3.

3 40015957

31 53. Loosen the hose clamp, 1, on the fuel return line, 2, and disconnect the fuel return line from the fuel pump, 3.

1 2

40015958

10-12

SECTION 10 - ENGINE - CHAPTER 2 54. Disconnect the main engine electrical harness connector, 1.

1 10004682

33 55. Open the rotary screen door and disconnect the rotary screen brush electrical connector, 1, if installed.

10013132

34 56. Feed the connector and wire loom, 1, and grommet, 2, through the hole in the radiator frame. Secure the wire loom and connector, if installed, to the engine to prevent damage during removal. NOTE: Removal of the rubber grommet in the radiator frame hole may be necessary to remove the radiator screen brush electrical connector.

1 2

10013133

10-13

SECTION 10 - ENGINE - CHAPTER 2 57. Cut the wire ties and separate the engine wire harness, 1, from the gearbox wire harness, 2. Secure each harness to prevent damage during engine removal.

40015960

36 58. Disconnect the negative cables from the batteries, 1.

1 86063134

37 59. Loosen and remove the nut, 1. (behind boot) Disconnect the main starter cable, 2, from the starter solenoid, 3. Remove the starter ground wire, 4. Remove starter.

4 2 86070231

10-14

SECTION 10 - ENGINE - CHAPTER 2 60. Attach a suitable chain to the front lift eye, 1, at the front of the engine.

86070232

39 61. Attach a suitable chain to the back lift eye, 1, at the rear of the engine.

86070233

40 62. Connect the lift chain to a suitable lifting device. 63. Raise the lifting device enough to support the engine during removal of the engine mounting bolts.

10013136

10-15

SECTION 10 - ENGINE - CHAPTER 2 64. From inside the grain tank, loosen the two front, engine mounting bolts, 1. Do not remove the mounting bolts at this time.

86070234

42 65. From the platform side, loosen the two front, engine mounting bolts, 1. Do not remove the mounting bolts at this time.

86070230

43 66. From inside the grain tank, loosen the four right rear engine mounting bolts, 1. Do not remove the mounting bolts at this time. Do the same to the left rear engine mount. 67. With the engine securely supported by the lifting device, remove all of the engine mounting bolts loosened in the previous steps. 68. Carefully lift the engine from the frame and remove from the combine.

1 10013138

10-16

SECTION 10 - ENGINE - CHAPTER 2 INSTALLATION 1. Attach a suitable chain to the front lift eye, 1, at the front of the engine.

86070232

45 2. Attach a suitable chain to the back lift eye, 1, at the rear of the engine.

86070233

46 3. Connect the lift chain to a suitable lifting device. 4. Carefully lift the engine above the combine and lower into position in the frame.

10013136

10-17

SECTION 10 - ENGINE - CHAPTER 2 5. Position the engine in the frame, aligning the two front mounting holes. Install the mounting bolts, 1. Install the washers, 2, and nuts, 3, on the bolt.

86070230

48 6. Align the rear mounting holes and install the mounting bolt, 1, and washer, 2. 7. Tighten and torque the front engine mounting nuts to 217 N⋅m (160 ft-lb) 8. Tighten and torque the rear engine mounting bolts to 240 N⋅m (177 ft-lb)

1 10013138

49 9. Install starter. Connect the main starter cable, 1, to the starter solenoid, 2, and secure with the nut, 3. Connect the ground wire, 4, to the starter solenoid.

4 2

3 1 86070231

10-18

SECTION 10 - ENGINE - CHAPTER 2 10. Secure the front fan support bracket, 1, with the bolts and nuts, 2. Tighten securely.

2 1

86070229

51 11. Connect the front heater hose, 1, to the engine and tighten the hose clamp, 2.

86070226

2 52

12. Connect the rear heater hose, 1, to the engine and tighten the hose clamp, 2, securely.

2 86070237

10-19

SECTION 10 - ENGINE - CHAPTER 2 13. Secure the gearbox wire harness, 1, to the engine wire harness, 2, with wire ties, 3.

3 10013126

54 14. Secure the oil hose, 2, to the hose guide, 3, and tighten the nut, 1.

2 10013125

55 15. Feed the rotary screen brush electrical connector (if installed) and wire loom, 1, and grommet, 2, up through the hole in the radiator frame.

1 2

10013133

10-20

SECTION 10 - ENGINE - CHAPTER 2 16. Connect the rotary screen brush electrical connector, 1, (if installed) and secure the wire loom with wire ties, 2.

10013132

57 17. Connect the main engine electrical harness connector, 1.

1 10004682

58 18. Connect the fuel return line, 1, to the fuel pump, 2. Tighten the hose clamp, 3, on the fuel return line.

3 2 40015958

1 59

10-21

SECTION 10 - ENGINE - CHAPTER 2 19. Connect the fuel line, 2, to the fitting, 1, at the electronic fuel control block, 3.

3 40015957

60 20. Install the rotary screen brush drive belt, 1, onto the pulley, 2, and engine crankshaft pulley. Turn the pulley adjusting bolt, 3, clockwise to adjust the belt tension until the belt is tight. Tighten the lock nuts on the carriage bolts, 4, when the belt is properly adjusted. Adjustment is correct when the belt deflection is 3 mm (1/8 in) in the center of the belt, with a force of 23 N (5.2 lbf) applied to the belt.

4 1

10013118

WARNING Do not disconnect any air conditioning lines or hoses during compressor removal, as serious injury could result.

21. Install the compressor to the engine and install the four mounting bolts, 2, to bracket. Connect the electrical connectors, 1, to the air conditioning compressor, 3.

40015211

10-22

SECTION 10 - ENGINE - CHAPTER 2 22. Install the two fan belts, 1, onto the fan pulley and engine crankshaft pulley. Tighten the adjuster nut, 2, until the washer, 3, is even with the end of the gauge, 4. Tighten the nut on the idler, 5, when adjustment is correct.

1 66063845

63 23. Install hose clamp, 1, onto lower coolant pipe, 2, and connect lower coolant pipe to lower radiator neck. Tighten clamp.

86070227

64 24. Install other end of pipe, 1, into water pump outlet, 2. Adjust position of clamp, 3, to seal. Tighten clamp.

25. Install front heater hose, 4, to water pump and tighten clamp, 5.

1 86070226

3 4

5 65

10-23

SECTION 10 - ENGINE - CHAPTER 2 26. Install upper coolant pipe, 1, that goes to the inlet of the water pump (not shown). 27. Adjust position of clamp, 2, to seal. Tighten clamp.

28. Install pipe support bracket, 3, and tighten.

3 1

86070228

66 29. Install the other end of the upper coolant pipe, 1, to the upper radiator neck, 2. Adjust position of clamp, 3, to seal. Tighten clamp.

2 86063828

67 30. Install inter cooler pipe, 1, to air intake, 2.

31. Adjust position of clamp, 3, to seal. Tighten clamp. 32. Install the support bracket, 4, and the hardware, 5, onto the intake housing, 2, and secure. 33. Install U-bolt, 6, over pipe into bracket and secure with hardware, 7.

7 3 86070223

6 68

10-24

SECTION 10 - ENGINE - CHAPTER 2 34. Install pipe clamp, 1, to the other end of cooler pipe, 2. Install cooler pipe to intercooler neck.

86063828

69 35. Install blower intake pipe, 1, to blower intake. Adjust position of clamp, 2, to seal. Tighten clamp.

1 2 86073842

70 36. Install air compressor hose, 1, and install clamp, 2, and tighten. (If this option is used).

86070225

10-25

SECTION 10 - ENGINE - CHAPTER 2 37. Install the other end of blower intake pipe, 1, to turbocharger, 2. Adjust position of clamp, 3, to seal. Tighten clamp.

38. Install crankcase ventilation tube, 4, to blower intake pipe. Tighten clamp, 5.

4 86070222

72 39. Install the intercooler (hot) pipe, 1, to turbocharger, 2. Adjust position of clamp, 3, to seal. Tighten clamp.

2 3

1 86063841

73 40. Install the other end of intercooler (hot) pipe, 1, to the intercooler neck and adjust position of clamp, 2, to seal. Tighten clamp.

2 1

86070224

10-26

SECTION 10 - ENGINE - CHAPTER 2 41. Install clamp, 1, connecting the exhaust aspiration pipe to the blower, 2. Connection is behind the blower near bottom. Install the aspiration pipe. Adjust position of clamp, 1, to seal. Tighten clamp.

NOTE: Let the aspiration pipe lay in this position until ready to install the other end into muffler.

86063817

75 42. Install the exhaust pipe clamp, 1, and install the exhaust pipe, 2, to the turbocharger.

86063838

76 43. Install hardware, 1, securing exhaust pipe, 2, to the exhaust pipe support bracket, 3. Tighten hardware.

4 1

44. Install the muffler, 4, to the exhaust pipe, 2. 45. Install pipe clamp, 5, to the exhaust pipe and tighten.

5 2

3 86063840

10-27

SECTION 10 - ENGINE - CHAPTER 2 46. Install muffler support bracket hardware, 1, to muffle support bracket, 2, and tighten.

47. Install the aspiration pipe, 3, to the muffler. Adjust position of clamp, 4, to seal. Tighten clamp.

3 2 1 86063836

78 48. Install hardware, 1, securing the exhaust aspiration pipe to the platform, 2. Tighten hardware

1 2

86063816

79 49. Install the engine lid support bracket, 1, to the grain tank wall using mounting hardware, 2, and tighten.

50. Install the step support, 3, to engine lid support bracket. Install the step support mounting bolts, 4, (see insert) and tighten.

66063809

10-28

SECTION 10 - ENGINE - CHAPTER 2 51. Install mounting hardware, 1, to bottom step support bracket, 2, and tighten.

86063816

81 52. Install coolant tank.

53. Install all hose clamps onto the hoses, 1, going to the coolant tank, 2. Install all hoses.

54. Install coolant level sensor, 3. 55. Install and tighten the hardware, 4, to the mounting brackets, 5.

4 2

66063820

82 56. Install the engine covers. Install the hardware, 2, to the top, sides of the engine cover frame and tighten.

1 1

1 66070220

1 83

10-29

SECTION 10 - ENGINE - CHAPTER 2 57. Install the engine lid to the combine. Install the two retaining rings, 1, washers, 2, and hinge pins, 3, to the engine lid.

66063844

84 58. Connect the shock absorber, 1, to the engine lid, 2.

2 1

86063836

85 59. Remove the plug from the oil pan, 1, and connect the oil hose, 2, to the oil pan. Secure with the clamp, 3.

1 3 2 86063115

10-30

SECTION 10 - ENGINE - CHAPTER 2 60. Replace the plug, 1. 61. Fill the engine with the proper amount and type of oil. See Specifications.

1 86063117

87 62. Turn the drain petcock, 1, on the radiator, 2, clockwise to close the coolant drain. Fill the cooling system with the proper amount and type of coolant. See Specifications.

63. Install the gearbox and hydraulic pumps onto the engine. (Refer to “Section 14 -- Gearbox Installation”).

10013106

88 64. Connect the battery cables to the batteries, 1.

1 86063134

10-31

SECTION 10 - ENGINE - CHAPTER 2 65. Disconnect the fuel pump wire connector, 1, to disable the fuel pump, 2.

66. Check the engine oil level and top off if necessary. 67. Crank the engine over for three ten second intervals. This will distribute lubricating oil to the engine operating systems and will allow oil pressure to be built before starting the engine.

50020119

90 68. Connect the fuel pump wire connector, 1, and bleed the air from fuel injection system, as described in the Operators manual.

69. Start the engine and check all hoses, fittings and clamps for leaks.

CAUTION Monitor the instrument warning light bar at all times during initial engine start up to ensure the engine has proper oil pressure. Shut down the engine immediately if oil pressure is not adequate. 70. Be certain that all electrical components are working properly.

10-32

50020119

SECTION 10 -- ENGINE -- CHAPTER 3

SECTION 10 - ENGINE Chapter 3 - Common Engine Compartment Components CONTENTS Section

Description

Page

10-1

SECTION 10 -- ENGINE -- CHAPTER 3 OVERHAUL NOTE: Illustrations may vary from the Pegasus 9.0 L engine and the Iveco Cursor 10.3 L engine. All have the same common reference unless otherwise noted.

COOLING FAN DRIVE Removal

1. Loosen and remove the mounting hardware from the protection cover, 1. Remove the cover from the engine compartment.

66070220

1 2. Unbolt hardware, 1, from the support frame, 2. Remove the frame from the combine.

86070229

2 3. Loosen and remove the six cap screws, nuts, and washers, 1, from the fan shaft hub.

4. Remove the fan, 2, from the combine.

20016205

10-2

SECTION 10 -- ENGINE -- CHAPTER 3 5. Remove fan drive belts, 1. 6. Loosen and remove fan drive pulley cap screw, 2.

2 20016206

4 7. Loosen and remove the fan drive belt tensioning spring, 1. 8. Apply blows with a mallet to the fan drive pulley, to remove the pulley from the tapered end of the shaft. Capture the shaft key when the pulley comes off.

86063829

5 9. Remove the snap ring, 1, from the inside of the shaft bearing housing, 2.

10. Apply blows with a mallet to the shaft hub, 3, to remove the assembly from the housing.

20016209

10-3

SECTION 10 -- ENGINE -- CHAPTER 3 Disassembly 1. Set the shaft assembly, 1, in a press with the tapered end up. Push the shaft from the bearing, 2.

1 2

20016210

7 2. Remove the snap ring, 1, from the shaft assembly. 3. Set the shaft assembly in a press with the tapered end up. Push the shaft from the bearing, 2.

1 2

20016211

8 Inspection Inspect the shaft for cracks and wear. Inspect the bearings for grease leakage. Replace the bearings if they roll rough, or there are indications that grease has been leaking past the seals. Inspect the inside of the bearing housing. Replace the housing and frame if there are indications that the outer bearing races have been turning inside the housing. Inspect the snap rings for cracks. Inspect the fan for cracks.

20016212

10-4

SECTION 10 -- ENGINE -- CHAPTER 3 Assembly 1. Place the large snap ring, 1, onto the shaft hub.

20016213

10 2. Set the shaft in a press and push on the larger bearing, 1.

20016214

11 3. Secure the large bearing in place using the small snap ring, 1.

20016211

10-5

SECTION 10 -- ENGINE -- CHAPTER 3 4. Set the shaft in a press and push on the smaller bearing, 1.

20016215

13 Installation 1. Set the shaft assembly into the bearing housing, 1, with the hub end of the shaft, 2, toward the radiator. Apply blows with a mallet on the hub to drive the shaft assembly into the housing if required.

1 3

2. Install the snap ring, 3, into the housing to secure the shaft in place.

20016209

14 NOTE: The pulley can only be installed one way. 3. Set the shaft key, 1, into place. Apply a light film of anti-seize compound to the shaft and key.

4. Set the fan drive belts into place on the pulley. Line up the keyway in the pulley with the keyed shaft and slide the pulley onto the shaft as far as possible. Apply light blows with a mallet if required.

20016217

10-6

SECTION 10 -- ENGINE -- CHAPTER 3 5. Install and tighten the fan drive pulley cap screw, 1. 6. Ensure that the drive belts are properly positioned in the grooves of the idler, crankshaft and fan drive pulleys.

1 20016206

16 7. Install the fan drive belt tensioning spring, 1. Tighten the adjusting nut, 2, until the bottom of the spring holder, 3, is even with the spring gauge, 73 mm (3″), 4.

8. Check the torque of the fan drive pulley cap screw and tighten if required.

3 2 1 20016208

17 9. Set support frame, 1, into place. Install the hardware at 2, but do not tighten until instructed.

86070229

10-7

SECTION 10 -- ENGINE -- CHAPTER 3 10. Install the protection covers, 1, and secure with the mounting hardware previously removed.

66070220

RADIATOR UNIT Removal NOTE: The radiator assembly can be removed as individual components. Not all steps must be performed to remove some components. •

• •

To remove the intercooler, neither the engine cooling system or the oil system need to be drained. To remove the engine radiator, only the cooling system needs to be drained. To remove the oil cooler, all steps will need to be performed.

66070220

1. Loosen and remove the mounting hardware from the protection covers, 1. Remove the covers from the engine compartment. NOTE: Drain the cooling system only if the engine radiator is to be removed.

2. Place a suitable container, 1, below the coolant drain hose, 2. NOTE: The cooling system has a capacity of approximately 31.5 L (8.3 gals). Be sure to use clean containers with adequate capacity when draining the cooling system.

10013105

10-8

SECTION 10 -- ENGINE -- CHAPTER 3 3. Turn the drain petcock, 1, on the radiator, 2, counter-clockwise to open the coolant drain. Drain all of the coolant into the containers.

10013106

22 4. Drain the remaining engine coolant into suitable containers by breaking the joint at, 1, on the cab side of the engine.

40016220

23 NOTE: Drain the engine gearbox and hydraulic reservoir only if the corresponding cooler is to be removed. NOTE: Verify the origin of each drain hose before draining any oil. NOTE: The engine gearbox holds approximately 11 L (11.6 qts) of oil. 5. Remove the plug from the engine gearbox drain line. Empty the contents of the gearbox into a suitable, clean storage container.

86063117

NOTE: The hydraulic reservoir holds approximately 60 L (16 gals) of oil. 6. Remove the plug from the hydraulic reservoir drain line. Empty the contents of the reservoir into a suitable, clean storage container.

10-9

SECTION 10 -- ENGINE -- CHAPTER 3 7. Drain the remaining oil in the hydraulic system by loosening the hydraulic oil filter outlet line, 1.

40016219

25 8. Disconnect the intercooler inlet and outlet lines, 1.

9. Remove all hardware along the top and down each side securing the fan shroud, 2, to the radiator assembly. 10. Turn out the two cap screws at the bottom of the shroud to detach it from the rotary screen cleaner channel.

66063822

26 11. Turn off the nuts securing the top vibration dampers, 1, to the rotary cleaning screen frame, 2.

2 1

NOTE: It is not necessary to remove the dampers from the intercooler.

40016224

10-10

SECTION 10 -- ENGINE -- CHAPTER 3 NOTE: Do not attempt to completely remove the shroud from the engine compartment.

12. Pull the top of the shroud, 1, back, away from the radiator assembly.

13. Turn out sixteen cap screws, 2, from both attaching plates, 3.

40016223

28 NOTE: Foam rubber strips are installed between each component to prevent damage from rubbing. To remove each component, gently pry the unit being removed from the one below it.

14. Lift the intercooler, 1, from the radiator assembly.

40016225

29 NOTE: If the engine coolant radiator is to be removed, ensure the coolant has been drained as described earlier in this procedure.

15. Disconnect the radiator inlet, 1, and drain, 2, on the back side of the unit. 16. Disconnect the radiator outlet and overflow lines on the cab side of the unit.

40016226

10-11

SECTION 10 -- ENGINE -- CHAPTER 3 NOTE: Foam rubber strips are installed between each component to prevent damage from rubbing. To remove each component, gently pry the unit being removed from the one below it.

17. Lift the coolant radiator, 1, from the oil cooler, 2.

2 40016227

31 NOTE: If the oil coolers are to be removed, ensure the gearbox and hydraulic oil has been drained as described earlier in this procedure. 18. Turn off the four nuts, 1, securing the oil cooler to the engine module support frame.

1 40016229

32 NOTE: Some residual oil will be present in the coolers. When disconnecting the lines, drain the residual oil into a suitable container.

19. Disconnect the gearbox, 1, and hydraulic, 2, cooler lines from the unit on both sides. Plug the oil lines and cap the cooler ports to prevent foreign material from entering the system. 20. Remove the oil cooler assembly from the engine module frame.

2 40016228

10-12

SECTION 10 -- ENGINE -- CHAPTER 3 Disassembly Intercooler

2 1

1. Turn out the four cap screws, 1, and two cap screws, 2, to remove the frame from the cooler.

2 40016230

34 Oil Coolers 1. Turn out the four cap screws, 1, to remove the side frames from the oil coolers.

2. Remove six caps screws, 2, along the bottom of the cooler. Detach the lower frame from the cooler.

2 40016232

35 3. Remove the engine gearbox cooler fittings, 1. 4. Turn out the hydraulic system cooler fittings, 2.

Inspection Inspect the cooling fins of all units for dirt and other debris. Clean the fins as required.

2 40016232

10-13

SECTION 10 -- ENGINE -- CHAPTER 3 Inspect the accessible areas inside the coolant radiator for corrosion or debris. Clean the inside of the radiator as necessary. If excessive corrosion is observed, replace the engine coolant radiator. Fill the engine coolant radiator with water and perform a leak check to a pressure of 1 bar (14.5 psi). No leakage from the body of the unit is allowed. Seepage from capped and test connections is acceptable. Repair or replace the radiator as required. 40016231

37 Inspect the accessible areas inside the intercooler for debris. Clean the inside of the intercooler as necessary. Inspect the entire outside surface of the intercooler for cracks. Repair or replace as required.

40016230

38 Inspect the accessible areas inside the oil cooler assembly for debris. Clean the inside of the assembly as necessary. Inspect the entire outside surface of the cooler assembly for cracks. Repair or replace as required.

40016232

10-14

SECTION 10 -- ENGINE -- CHAPTER 3 Assembly Intercooler

2 1

1. Attach the side frames to the intercooler using four cap screws at 1, and two cap screws at 2. Torque all cap screws to 24 Nám (17 ft-lbs).

2. Apply black RTV sealant along the edges of the frames at 3. 3. Attach a 1/2″ wide foam rubber strip along the inside bottom edge of the cooler. 4. Install vibration dampers into the outside face of the cooler.

40016230

Oil Coolers 1. Attach the side frames to the oil cooler using four cap screws at 1. Torque the cap screws to 24 Nám (17 ft-lbs).

2. Attach the lower frame to the oil cooler using six cap screws at 2. Torque the cap screws to 24 Nám (17 ft-lbs).

1 3

3. Apply black RTV sealant along the edges of the frames at 3. 4. Attach 1/2″ wide foam rubber strip along the inside top edge of the cooler.

40016232

2 41

5. Install the engine gearbox cooler fittings, 1. Torque the fittings to 70 Nám (51 ft-lbs).

6. Turn in the hydraulic system cooler fittings, 2. Torque the fittings to 186 Nám (137 ft-lbs). 7. Install vibration dampers, 3, into the lower cooler frame.

2 3 40016232

10-15

SECTION 10 -- ENGINE -- CHAPTER 3 Coolant Radiator

1. Attach a 1/2″ wide foam rubber strip along the outside top and bottom edges of the radiator, 1.

40016231

43 Installation NOTE: This step only needs to be performed if the oil cooler had been removed.

1. Set the oil cooler, 1, into place. Turn on nuts, 2, until snug.

2 40016229

44 NOTE: These two steps only need to be performed if the engine coolant radiator had been removed.

2. Set the engine coolant radiator, 1, in place on top of the oil cooler, 2. Orient the radiator with the overflow line closest to the cab.

3. Adjust the position of the engine coolant radiator so that the outside face and sides are even with the oil cooler. 4. Apply a 1/2″ wide foam rubber strip along the front and back edges of the radiator tanks, 3.

2 40016233

10-16

SECTION 10 -- ENGINE -- CHAPTER 3 5. Set the intercooler, 1, in place on top of the coolant radiator, 2. 6. Adjust the position of the intercooler so that the outside face and sides are even with the radiator and oil cooler.

7. Insert the formed rubber pads, 3, on the top and bottom, front and back corners of the radiator.

3 2 40016235

46 8. Install the front and back attaching frames, 1. Tighten the front and back attaching frame cap screws. Torque the cap screws to 24 Nám (17 ft-lbs).

40016234

47 NOTE: This step only needs to be performed if the oil cooler had been removed. 9. Push and hold the bottom of the radiator assembly against the rotary screen cleaner frame. Tighten the four bottom vibration damper nuts, 1, to secure the unit in place.

1 40016229

10-17

SECTION 10 -- ENGINE -- CHAPTER 3 10. Secure the intercooler vibration dampers, 1, to the rotary screen cleaner frame.

40016236

49 NOTE: This step only needs to be performed if the oil cooler had been removed.

11. Connect engine gearbox oil lines, 1, using new O-rings. Connect hydraulic system oil lines, 2, using new O-rings.

NOTE: This step only needs to be performed if the engine coolant radiator had been removed. 12. Attach the engine coolant radiator inlet, 3, and outlet hoses. Connect the drain line to the petcock, 4, and verify that the petcock is shut. Attach the overflow line to the radiator.

1 2 40016226

13. Set the bottom edge of the fan shroud, 1, into the two clips located across the lower radiator frame.

14. Secure the shroud to the radiator assembly using the nine previously removed cap screws. 15. Connect the intercooler inlet and outlet hoses, 2.

66063822

10-18

SECTION 10 -- ENGINE -- CHAPTER 3 16. Verify coolant return connections, 1, are tight.

1 40016220

52 17. Set support frame, 1, into place. Install the hardware at 2, and tighten.

NOTE: This step only needs to be performed if the engine coolant radiator had been removed. 18. Fill the engine coolant system through the reservoir with the previously removed fluid.

NOTE: These two steps only need to be performed if the oil cooler had been removed. 19. Fill the engine gearbox with the previously removed oil.

86070229

20. Fill the hydraulic system with the previously removed oil. NOTE: The following retest procedure only needs to be performed if the oil cooler or engine coolant radiator had been removed.

21. Verify static pressure leak tightness by checking all coolant and oil joints broken. 22. Start the combine engine. 23. Verify operating pressure leak tightness of all gearbox and hydraulic system joints broken. 24. Run the engine until the coolant reaches normal operating temperature. Verify operating pressure leak tightness by checking all coolant joints broken.

66070220

25. Secure the combine engine. 26. Install the protective covers, 1, and secure with the mounting hardware previously removed.

10-19

SECTION 10 -- ENGINE -- CHAPTER 3 ROTARY SCREEN

Removal 1. Pull the tensioner, 1, down and remove the drive belt, 2.

2. Turn out the two cap screws, 3, along the bottom of the plastic channel. Turn off the nut, 4, and remove the channel.

3. If equipped, unplug the brush positioning motor.

10020102

55 4. Loosen and remove the two bolts, 1, on the air conditioning condenser and pivot condenser away from rotary screen.

50020199

56 5. Remove the idler spring, 1. NOTE: The jam nuts and cap screws, 2, are located inside the rotary screen cavity and can be accessed from underneath the air conditioning condenser.

6. Loosen the two jam nuts, 2, and turn out the cap screws holding the rotary screen shaft.

CAUTION The rotary screen is awkward and moderately heavy. Two individuals should be used to remove the screen from the combine. 7. Carefully remove the screen from the combine by pulling it away from the engine.

10-20

10020103

SECTION 10 -- ENGINE -- CHAPTER 3 Disassembly 1. If equipped, unplug the brush positioning motor at connector, 1.

2. Remove cap screw, nut and washer at 2.

1 10020104

58 3. Turn out the three cap screws, 1, from the bearing holder. Capture the plate on the other side of the screen. 4. Remove the bearing assembly by turning out cap screw, 2.

10020105

59 5. Disengage the bearing lock collar, 1. 6. Remove the three carriage bolts, washers and nuts, 2, holding the bearing to the frame.

10020106

10-21

SECTION 10 -- ENGINE -- CHAPTER 3 7. Remove the shaft assembly from the rotary screen.

10020107

61 8. Slide the bearing, 1, flangettes, 2, and lock collar, 3, from the shaft.

10020108

62 Inspection 9. Inspect the outside bearing, 1, for damage and smooth rotation.

10020109

10-22

SECTION 10 -- ENGINE -- CHAPTER 3 10. Inspect the inside bearing, 1, for damage and smooth rotation.

11. Inspect the shaft, 2, for damage or wear. 12. Inspect the wire for worn insulation and broken connectors.

10020108

64 Assembly

1. If equipped, route the brush positioning wire through the shaft so that the male connector, 1, will be positioned as shown. Assemble the connector with the blue wire in the “B” socket.

2. Slide the bearing lock collar, 2, onto the shaft.

3. Assemble the bearing, 3, onto the shaft with a flangette, 4, on either side.

1 10020108

65 4. Work the shaft assembly, 1, into position in the rotary screen.

10020107

10-23

SECTION 10 -- ENGINE -- CHAPTER 3 5. Attach the inside bearing using three carriage bolts, washers and nuts, 1.

10020106

67 6. Insert the plate, 1, into place between the shaft and screen. 7. Turn the cap screw and bearing into the shaft from the front of the screen. Secure the bearing assembly to the screen with three cap screws and washers.

8. Engage the inside bearing locking collar by turning it in the direction of rotation.

10020110

68 9. Orient the shaft so that the wire runs into the top. This will line up the dimple on the underside of the shaft with the inside set screw.

10. Attach the brush frame to the shaft using cap screw, washer and nut, 1. 11. If equipped, plug in the brush positioning motor at 2.

2 10020104

10-24

SECTION 10 -- ENGINE -- CHAPTER 3 Installation

CAUTION

The rotary screen is awkward and moderately heavy. Two individuals should be used to install the screen onto the combine. 1. Carefully install the screen by pushing it toward the engine. 2. Rotate the shaft until cap screw, 1, is vertical. 10020104

70 3. Turn in the set screw closest to the engine at 1 until finger tight. Rock the shaft back and forth to verify that the cap screw is seated inside the dimple.

4. Turn in the second cap screw at 1. Tighten both cap screws and lock in place with the jam nuts. 5. Install the idler spring, 2.

10020103

71 6. Route the drive belt, 1, around the rotary screen, drive pulley, 2, and tensioning idler.

7. Set the plastic channel into place and turn on nut at 3.

8. Install cap screws, 4. Tighten all hardware.

10020102

1 72

10-25

SECTION 10 -- ENGINE -- CHAPTER 3 9. Close the air conditioning condenser and install the two bolts, 1.

1 50020199

ROTARY SCREEN DRIVE SHAFT Removal 1. Pull the tensioner, 1, down and remove the drive belt, 2.

2 1

10020102

74 2. Loosen and remove cap screw, 1.

3. Remove drive shaft pulley, 2.

4. Loosen and remove two carriage bolts, washers and nuts, 3, from the bearing housing.

10020178

10-26

SECTION 10 -- ENGINE -- CHAPTER 3 5. Remove access cover, 1, in grain tank.

10020181

76 6. Loosen and remove belt tension bolt, 1, completely. 7. Remove the drive belt, 2.

2 10020182

77 8. Loosen and remove two carriage bolts, washers and nuts, 1, from the bearing housing. 9. Remove drive shaft from combine.

1 10020183

10-27

SECTION 10 -- ENGINE -- CHAPTER 3 Installation

1. Install drive shaft, and replace drive belt, 1. 2. Install and tighten two carriage bolts, washers and nuts, 2, to bearing housing.

2 10020183

79 3. Install and tighten two carriage bolts, washers and nuts, 1, to bearing housing.

3 2

4. Install drive shaft pulley, 2. 5. Install and tighten cap screw, 3.

10020178

80 6. Pull down on tensioner, 1 and install drive belt, 2.

2 1

10020102

10-28

SECTION 10 -- ENGINE -- CHAPTER 3 7. Install belt tension bolt, 1 and check belt for proper tension. Tension is correct when the belt deflection is 3 mm (1/8″) in the center of the belt, with a force of 23 Nám (5.2 ft-lbs) applied to the belt.

10020182

82 8. Replace access cover, 1.

10020181

10-29

SECTION 10 -- ENGINE -- CHAPTER 3 ROTARY SCREEN SEAL Replacement

1. Remove the rotary screen, 1, from the combine in accordance with the removal procedure.

10020102

84 2. The rotary screen seal, 1, is installed in three sections. Drill out or chisel off the pop rivets from each section to remove the seal. 3. Secure the three sections of the new seal into place with pop rivets.

4. Install the rotary screen onto the combine in accordance with the installation instructions.

10020112

10-30

SECTION 10 -- ENGINE -- CHAPTER 3 ROTARY SCREEN BRUSH Removal NOTE: Removal of the rotary screen is not required for brush replacement.

1. Remove the clip, 1, from the brush positioning motor ball joint. 2. Pry the ball joint apart.

10020111

86 3. Remove the carriage bolts, washers and nuts, 1. Lift the brush assembly, 2, from the rotary screen.

1 2 10020113

87 4. Remove the snap ring, 1, from both ends of the brush holder.

5. Slide the brushes from the shaft.

10020114

10-31

SECTION 10 -- ENGINE -- CHAPTER 3 6. Press the bearing, 1, from each brush wheel.

10020115

89 7. The inside brush wheel bearings, 1, may not come off with the brushes. Remove the inside bearings. 8. Using emery cloth or a light sandpaper, clean all rust and debris from the brush shafts.

1 10020116

90 Installation 1. Press the new inner brush wheel bearings, 1, onto the wheel shafts.

1 10020116

10-32

SECTION 10 -- ENGINE -- CHAPTER 3 2. Press a new bearing, 1, into each brush wheel.

10020115

92 3. Install the rotary screen brush wheels onto the shafts. Secure the brushes in place with snap rings, 1.

10020114

93 4. Set the brush assembly, 1, into place and secure to the rotary screen using carriage bolt, washers and nuts at 2.

2 1 10020113

10-33

SECTION 10 -- ENGINE -- CHAPTER 3 5. Assemble the actuating motor ball joint and secure using clip, 1.

10020111

ROTARY SCREEN BRUSH ACTUATOR Removal NOTE: Removal of the rotary screen is not required for actuator replacement.

1. Remove the clip, 1, from the brush positioning motor ball joint. 2. Pry the ball joint apart.

10020111

96 3. Unplug connector, 1. 4. Turn off nut, 2. Lift the actuator from the cleaning brush frame.

1 10020104

10-34

SECTION 10 -- ENGINE -- CHAPTER 3 Installation 1. Attach the actuator to the cleaning brush frame with washer and nut at 1.

2. Orient the actuator so the motor side, 2, is furthest from the screen. 3. Plug the actuator into the brush control wiring harness at 3.

2 3 10020104

98 4. Assemble the actuating motor ball joint and secure using clip, 1.

10020111

10-35

SECTION 10 -- ENGINE -- CHAPTER 3

10-36

SECTION 14 -- LIVE PTO -- CHAPTER 1

SECTION 14 - LIVE PTO Chapter 1 - Engine Gearbox, Clutch Pack Removal/Installation CONTENTS Section

Description

Page

14-1

SECTION 14 -- LIVE PTO -- CHAPTER 1 SPECIAL TORQUE Item

Torque

Thresher shaft rolling torque

1250 -- 1500 N⋅mm (11 -- 13 in-lb)

Thresher shaft spur gear cap screws

110 -- 120 N⋅m (81 -- 88 ft-lb)

Hydraulic pump drive housing

190 -- 210 N⋅m (140 -- 155 ft-lb)

Hydraulic pump drive rolling torque

300 -- 400 N⋅mm (2 -- 3 in-lb)

Engine flange cap screws

80 -- 90 N⋅m (59 -- 66 ft-lb)

Input shaft rolling torque

1400 -- 1500 N⋅mm (12 -- 14 in-lb)

Clutch housing cover cap screws

45 -- 50 N⋅m (33 -- 37 ft-lb)

Main clutch cylinder cap screws

35 N⋅m (26 ft-lb)

Unload clutch piston cap screws

35 N⋅m (26 ft-lb)

Clutch housing spur gear cap screws

45 -- 50 N⋅m (33 -- 37 ft-lb)

LABOR GUIDE Gearbox Removal - 8 hours

Main Clutch Assembly - 2 hours

Gearbox Disassembly - 4 hours

Unload Clutch Disassembly - 2 hours

Gearbox Assembly - 6 hours

Unload Clutch Assembly - 2 hours

Gearbox Replacement - 8 hours

Clutch Cylinder Bushing Removal - 5 minutes

Main Clutch Disassembly - 2 hours

Clutch Cylinder Bushing Installation - 5 minutes

14-2

SECTION 14 -- LIVE PTO -- CHAPTER 1 OVERHAUL CLUTCH PACK The engine gearbox clutch packs can be serviced without removing the gearbox from the combine. Although it is physically possible to remove the clutch packs, great care must be exercised when working at the gearbox level. The main clutch pack weighs approximately 31.7 kg (70 lb), the unload clutch pack will be slightly less. Any operation or repair to the clutch packs that would change the stack height of the unit, such as bearing replacement, will require the entire gearbox be removed from the machine. Improperly shimmed clutch packs may cause early bearing failure. Removal NOTE: The engine gearbox holds approximately 11 L (11.6 lq qt) of oil. 1. Attach a hose to the engine gearbox drain line, 1, and direct the open end to a suitable storage container. Drain the oil from the gearbox.

NOTE: The hydraulic reservoir holds approximately 60 L (16 gal) of oil.

2. Attach a hose to the hydraulic reservoir drain line, 2, and direct the open end to a suitable storage container. Drain the oil from the reservoir.

86063117

3. Loosen the unloading auger belt tensioning spring, 1. Lift the belt from the gearbox sheave and store it out of the way.

86063004

14-3

SECTION 14 -- LIVE PTO -- CHAPTER 1 4. Turn out cap screws, 1, and remove the belt tensioner from the combine. Cap screw, 2, may have to be loosened to gain access to the lower mounting cap screws. Store the tensioner in a suitable location.

2 86063004

3 5. Loosen the main thresher drive belt tensioning spring, 1.

86063005

4 6. Loosen the straw chopper drive belt tensioning spring, 1. Lift the straw chopper and main drive belts from the combine and store in a suitable location.

1 86063006

14-4

SECTION 14 -- LIVE PTO -- CHAPTER 1 NOTE: When disconnecting hydraulic lines, have a suitable container readily available to capture any residual hydraulic oil. 7. Disconnect and cap the two low pressure hydraulic pump lines, 1.

1 86063007

6 8. Disconnect and cap the four high pressure hydraulic pump lines, 1.

86063008

7 9. Loosen but do not remove the pump mounting nuts, 1. NOTE: Remove left-hand side shield before the removal of the high/low pressure hydraulic pump. (Refer to the Repair manual, Section 90, “Platform and Cab”.)

10012185

14-5

SECTION 14 -- LIVE PTO -- CHAPTER 1 NOTE: The high/low pressure hydraulic pump weighs approximately 29 kg (63 lbs). 10. Securely attach the high pressure pump to a tow motor. Remove the mounting nuts and lift the pump from the combine. Store the pump in a suitable location.

10012186

9 NOTE: The gearbox is shown removed from the combine.

11. Using a wrench on the flats of the unloading sheave, 1, turn out the cap screw, 2.

10013330

10 NOTE: The unloading shaft is tapered. Heat may need to be applied to remove the sheave. 12. Remove the bolt from the shaft and install a longer bolt in its place. Use a shallow socket on bolt head and attach a puller onto the unloading sheave to remove the sheave from the shaft. NOTE: The longer bolt and socket will keep the pulley from flying off the shaft.

10013331

14-6

SECTION 14 -- LIVE PTO -- CHAPTER 1 13. Using a wrench on the flats of the main output sheave, 1, turn out the cap screw, 2. If there are no flats, use a strap wrench on the sheave.

10013332

12 NOTE: The main output shaft is tapered. Heat may need to be applied to remove the sheave. 14. Remove the bolt from the shaft and install a longer bolt in its place. Use a shallow socket on bolt head and attach a puller onto the main output sheave, and remove the sheave from the shaft. NOTE: The longer bolt and socket will keep the pulley from flying off the shaft.

10013333

13 15. Remove the threaded sensor, 1, from the gearbox.

IMPORTANT: DO NOT lose the shim washers. The washers will be required upon reassembly to maintain minimum acceptable clearance.

10004283

14-7

SECTION 14 -- LIVE PTO -- CHAPTER 1 16. Remove the unload shaft key, 1. 17. Remove the housing cover cap screws, 2.

10004281

2 15

18. Install jacking bolts, 1. Tighten the bolts until the housing cover, 2, has broken loose from the gearbox. Remove the housing cover.

NOTE: When taking off the housing cover, protect the radial seal, 3, against damage from the key way of the unload clutch shaft.

3 10004282

2 16

NOTE: The unload clutch shaft is heavy. Exercise care when removing the unit from the gearbox.

19. Pull the unload clutch, 1, straight out until the rings have disengaged from the cylinder on the inside end of the shaft.

10013341

14-8

SECTION 14 -- LIVE PTO -- CHAPTER 1 20. Angle the outside end of the shaft toward the front of the combine until the gear will clear the main clutch pack. Carefully pull the shaft from the gearbox and store in a suitable location.

10013342

18 NOTE: The main clutch shaft is heavy. Exercise care when removing the unit from the gearbox.

21. Insert a tool or rod, 1, such as a 1/2″ drive breaker bar, into the female spline of the main clutch pack, 2. Work the clutch pack back and forth while pulling on it to ease the rings from the cylinder on the inside end of the shaft. Continue to pull the main clutch out until the rings have disengaged from the cylinder.

10013343

19 22. Angle the outside end of the shaft, 1, toward the front of the combine. Carefully pull the shaft from the gearbox and store in a suitable location.

Refer to the appropriate chapter in this section to repair the desired component. IMPORTANT: If any clutch pack bearings are damaged and require replacement, the gearbox must be removed from the combine. Shimming of the clutch packs cannot be performed while the gearbox is installed. Machine damage may result from improperly shimmed bearings.

10013344

14-9

SECTION 14 -- LIVE PTO -- CHAPTER 1 Installation

1. Set the main clutch shaft, 1, in the gearbox.

10013344

21 2. Raise the inside end of the shaft to the cylinder. Work the main clutch shaft, 1, back and forth using a tool, 2, inserted into the female spline of the shaft. Carefully push the shaft into the cylinder and line the gear up with the thresher shaft gear.

10013343

22 3. Set the unload clutch shaft in the gearbox.

10013342

14-10

SECTION 14 -- LIVE PTO -- CHAPTER 1 4. Raise the inside end of the shaft to the cylinder. Work the unload clutch shaft, 1, back and forth to push the inside end into the cylinder while lining up the gear with the inside main clutch shaft gear.

10013341

24 NOTE: The gearbox is shown removed from the combine. 5. Remove all grease, oil, or dirt from the sealing surfaces of the housing. Apply a thin coat of Loctite™ 518 to the gearbox casing sealing surface. IMPORTANT: Use of any other gasket compound could effect the pre-load of the bearings. 6. Place the housing cover on the gearbox and secure using mounting cap screws, 2. Torque to 54 - 60 N⋅m (39 - 44 ft-lb).

10004281

2 25

7. Set the unload shaft key, 1, into place. 8. Install the clutch temperature sender, 1, into the gearbox.

10004283

14-11

SECTION 14 -- LIVE PTO -- CHAPTER 1 NOTE: The high/low pressure hydraulic pump weighs approximately 29 kg (63 lb). 9. Using the appropriate lifting gear, set the hydraulic pump into place and secure using two mounting nuts and washers, 1.

10012185

27 10. Attach the four high pressure hydraulic pump lines, 1, to the pump.

86063008

28 11. Connect the two low pressure hydraulic pump lines, 1, to the pump.

1 86063007

14-12

SECTION 14 -- LIVE PTO -- CHAPTER 1 12. Install the unloading auger belt tensioner to the gearbox using the cap screws, 1.

86063004

30 13. Set the main output sheave, 1, onto the shaft, and turn in cap screw, 2. Torque to 35 N⋅m (26 ft-lb).

10013332

31 14. Set the unloading sheave, 1, onto the shaft, and turn in cap screw, 2. Torque to 35 N⋅m (26 ft-lb).

1 10013330

14-13

SECTION 14 -- LIVE PTO -- CHAPTER 1 15. Route the main thresher drive belt and tighten the adjuster to the spring gauge, 1, 122 mm (4.8125 in).

86063005

33 16. Route the straw chopper drive belt and tighten the adjuster to the spring gauge, 1, 100 mm (4.0 in).

1 86063006

34 17. Route the unloading auger drive belt and tighten the adjuster to the spring gauge, 1, 130 mm (5.125 in).

86063004

14-14

SECTION 14 -- LIVE PTO -- CHAPTER 1 18. Shut or verify shut the engine gearbox and hydraulic reservoir drain line connections. 19. Fill the engine gearbox with 11 L (11.6 lq qt) of hydraulic oil. 20. Fill the hydraulic reservoir with 60 L (16 gal) of hydraulic oil. 21. Start the engine and allow the oil level in the gearbox to stabilize. Fill the gearbox as necessary with hydraulic oil to maintain the level in the sight glass, but below the red full mark. 86063117

14-15

SECTION 14 -- LIVE PTO -- CHAPTER 1

14-16

SECTION 14 -- LIVE PTO -- CHAPTER 2

SECTION 14 - LIVE PTO Chapter 2 - Engine Gearbox, Clutch Pack Rebuild CONTENTS Section

Description

Page

14-1

SECTION 14 -- LIVE PTO -- CHAPTER 2 SPECIAL TOOL Tool #380000660 - Modified chisel The modified chisel shown should be used to disengage the locknuts installed on various components in the gearbox. An unmodified tool will not have the capability to pull the indentation from the shaft slot, and will make removal more difficult. If a tool similar to the one shown is not available, carefully cut the locknut free of the shaft. Any damage to the shaft threads caused by this operation must be repaired prior to installation of the new locknut.

6.5 - 7.5 mm 1/4 in

12 - 13 mm 1/2 in

10006348

GENERAL Do not pack the tapered bearings with grease. The bearings used in this gearbox are oil lubricated. Races and bearings must not be mixed up. For easier assembly, all bearings may be pre-heated to a maximum temperature of 100 °C (212 °F). When checking the pre-load and roll torque of the shafts, bearings must be cooled to normal temperature. Radial seals are to be mounted in the housing free from oil and grease. Apply an oil film to ease assembly of all fitting surfaces, bearing seats, sealing rings, spacer washers and piston rings. Cap screws must be free of oil and/or grease prior to installation. Securing the slotted nut: Swage the retaining edge of the adjusted slotted nut into the longitudinal groove of the shaft by means of a rounded mandrel. The retaining edge must be deformed evenly into the longitudinal groove until it is in contact with the mid-section of the groove bottom. The retaining edge must not tear. If necessary, it should therefore not be swaged entirely to the bottom of the groove. (Groove width - mandrel dia; Approx. 2 mm)

14-2

SECTION 14 -- LIVE PTO -- CHAPTER 2 OVERHAUL MAIN CLUTCH DISASSEMBLY 1. Remove the shaft seal rings, 1, from the main clutch shaft. Slightly expand the shaft seal ring to take it off.

NOTE: Remove the shaft seal rings without using any tools. Do not apply excessive force.

56062995

2 2. Undo the deformed retention of the threaded bushing using special tool #380000660. If necessary, break open the threaded bushing by means of a modified chisel, 1.

3. Remove the threaded bushing from the main clutch shaft.

10006344

3 4. Using a bearing puller, remove the tapered bearing, 1, from the pump side of the main clutch assembly.

NOTE: All bearings and races removed should be labeled, if not being replaced, to ensure they are installed into their original locations. If a bearing is to be replaced, the outer race must also be replaced.

10004292

14-3

SECTION 14 -- LIVE PTO -- CHAPTER 2 5. Attach a gear puller to the pump side gear of the main clutch assembly.

10004293

5 6. Pull the pump side gear, 1, and tapered bearing, 2, off together.

1 2

10004294

6 7. Position the main clutch assembly, 1, with the spur gear facing up, onto a press. Place a slotted press sleeve, 2, over the shaft, making sure the diameter sleeve clears the snap ring, 3. Press the spur gear down until enough pressure is relieved from snap ring. Remove snap ring.

2 1

3 56070238

14-4

SECTION 14 -- LIVE PTO -- CHAPTER 2 8. With the snap ring off, the gear; 1, can be pulled from the shaft using a gear puller or pressed off the shaft by using a press.

1 86063787

8 9. Remove the piston, 1, from the shaft and clutch plates, 2.

2 86063789

9 10. Carefully separate the piston, 1, from the cylinder, 2.

11. Remove the seals, 3, from the piston. One inner seal O-ring and one outer seal O-ring. Check seals if worn or damaged.

3 10004300

14-5

SECTION 14 -- LIVE PTO -- CHAPTER 2 12. Lift the twelve double spring assemblies, 1, from the inner clutch body. Check for worn or broken springs and replace as needed. 13. Lift the clutch plates, 2, from the inner clutch body.

1 2

86063793

11 14. Check the pressure plate, 1, if it is worn or cracked. If it needs replaced, remove it from the inner clutch body.

86063799

MAIN CLUTCH ASSEMBLY

1. Set the clutch disks, 1, onto the inner body. Place a metal disk on the pressure plate followed by a friction disk. Continue placing the disks in an alternating fashion until ten metal and nine friction disks have been stacked onto the clutch assembly. If the double spring, 2, assemblies were removed, replace them in the inner clutch body.

2 86063790

14-6

SECTION 14 -- LIVE PTO -- CHAPTER 2 2. Install the inner seal O-ring, 1, into the groove of the piston.

10004305

14 3. Compress the slide ring to give it a kidney shape without producing any sharp kinks, 1.

4. Insert the slide ring into the lower part of the groove and press it into the groove in an outward direction, 2.

5. Install the outer O-ring into the groove of the piston.

10004302

15 6. Heat the outer slide ring to about 80°C (170°F) in an oil or water bath.

CAUTION The slide ring is very hot. Failure to use insulating gloves could cause serious personal injury. 7. Expand the outer slide ring by pushing it over the guide chamfer on the piston and let it snap into the groove. As the expanded slide ring cools down to room temperature, it resumes its original shape.

10004305

14-7

SECTION 14 -- LIVE PTO -- CHAPTER 2 8. Lubricate the inner piston O-ring with clean hydraulic fluid. Insert the piston onto the inner clutch body.

86063789

17 9. Position the main clutch shaft and spur gear assembly, 1, in a press. Set the clutch pack, 2, onto the spline of the shaft and press them together until the pack is seated against the spur gear.

10012223

18 10. Press the tapered roller bearing, 1, on in the same manner. Set a spacer ring, 2, on top of the roller bearing.

10012224

14-8

SECTION 14 -- LIVE PTO -- CHAPTER 2 11. Lower the outer basket and spur gear, 1, onto the assembly.

10012225

20 12. Press the tapered roller bearing, 1, onto the assembly until it is seated against the outer bearing race in the spur gear.

10012226

21 13. Press the tapered roller bearing, 1, on in the same manner with the taper oriented toward the end of the shaft as shown.

10012227

14-9

SECTION 14 -- LIVE PTO -- CHAPTER 2 14. Turn the nut, 1, onto the end of the main clutch shaft. Tighten the nut to 250 - 265 N⋅m (185 - 196 ft-lbs) and secure the nut by deforming the front collar into the shaft groove, 2. NOTE: Swage the retaining edge of the nut into the groove of the shaft by means of a rounded mandrel. The retaining edge must be deformed evenly into the longitudinal groove until it is in contact with the mid-section of the groove bottom. The retaining edge must not tear. If necessary, it should therefore not be swaged entirely to the bottom of the groove. (Groove width - mandrel dia.; Approx. 2 mm.)

10012228

23 15. Mount the shaft seal rings, 1, without using any tool. Make sure that they are free to turn smoothly in the shaft groove.

56062995

UNLOAD CLUTCH DISASSEMBLY 1. Remove the outside tapered bearing, 1, using a bearing puller.

10004292

14-10

SECTION 14 -- LIVE PTO -- CHAPTER 2 2. Place the unload clutch assembly, 1, on a press, with it resting on the spur gear, 2.

WARNING Do not, under any circumstances, remove snap ring in front of the multi-disk clutch, until pressure is removed from the pressure plate. The pressure plate is under very high spring pressure. Improper disassembly of the multidisk clutch will cause severe personal injury. 3. Place a slotted press sleeve, 3, over shaft and press piston enough to relieve pressure from snap ring, 4.

1 4

56063805

4. Remove the snap ring. 5. Retract the press and remove clutch assembly from the press. 6. Remove the piston, 1, and the cylinder, 2, together from the unload shaft.

7. Remove the seals, 3, from the piston. One inner seal O-ring and one outer seal O-ring. Remove the seal from the cylinder, 4. Check seals if worn or damaged.

3 66063806

2 27

8. Take out the twelve double spring assemblies, 1, from the inner clutch body and check them for worn or broken springs. Replace as needed. If springs are in good condition, reinstall at this time.

NOTE: Illustration is for reference only. It is not the actual clutch assembly mentioned in this section.

86063793

14-11

SECTION 14 -- LIVE PTO -- CHAPTER 2 9. Lift the friction plates, 1, and the separator plates, 2, from the inner clutch body. Clean out any clutch debris and check all bearings for foreign matter, clean accordingly.

2 66063807

UNLOAD CLUTCH ASSEMBLY

1. Lubricate the inner clutch body with oil. 2. Set the clutch disks onto the inner body. Place a metal disk, 1, on the cylinder followed by a friction disk, 2. Continue placing the disks in an alternating fashion until seven metal and six friction disks have been stacked onto the clutch assembly.

2 66063807

30 3. Install the inner O-ring, 1, into the groove of the piston, 2.

2 66063806

14-12

SECTION 14 -- LIVE PTO -- CHAPTER 2 4. Compress the slide ring to give it a kidney shape without producing any sharp kinks, 1.

5. Insert the slide ring seal into the lower part of the groove and press it into the groove in an outward direction, 2.

10004302

32 6. Install the outer O-ring, 1, into the groove of the cylinder, 2.

7. Heat the outer slide ring to about 80°C (170°F) in an oil or water bath.

CAUTION The slide ring is very hot. Failure to use insulating gloves could cause serious personal injury. 8. Expand the outer slide ring by pushing it over the guide chamfer on the cylinder and let it snap into the groove. As the expanded slide ring cools down to room temperature, it resumes its original shape.

66063806

9. Lubricate the piston seal, 3, and cylinder seal, 1, with oil. 10. Place the piston onto the unload shaft, followed by the cylinder as far as they will go on. Lubricate the shaft seal O-ring with oil and insert the O-ring onto the shaft, followed by the snap ring as far as they will go also. 11. Place the unload clutch assembly, 1, on a press with it resting on the spur gear, 2.

12. Place a slotted press sleeve, 3, over shaft and press piston enough to go below the second groove on the shaft.

13. Slide the O-ring down to that second groove. 14. Insert the snap ring into the first groove. 15. Retract the press and remove clutch assembly from the press. 56063805

2 34

14-13

SECTION 14 -- LIVE PTO -- CHAPTER 2

14-14

SECTION 14 -- LIVE PTO -- CHAPTER 3

SECTION 14 - LIVE PTO Chapter 3 - Engine Gearbox Removal/Installation CONTENTS Section

Description

Page

14-1

SECTION 14 -- LIVE PTO -- CHAPTER 3 GEARBOX Removal 1. Remove left-hand side shield as described in Section 90.

2. Remove rear hinge support, 1, and rear fixed shield, 2.

2 86063003

1 3. If hydraulic pressure is available to operate the unloading auger, rotate the auger away from the combine and securely block it in place.

4. If hydraulic pressure is not available to operate the unloading auger, loosen the hydraulic lines, 1, to the unloading auger cylinder. Detach the rod end of the cylinder, 2, from the auger. 5. Rotate the unloading auger away from the combine, tie and block it securely in place.

CAUTION 40020127

As the auger is rotated further away from the combine, the force on the auger to return to its standby position increases. Only move the auger far enough to allow sufficient room to remove the gearbox with a tow motor. Failure to comply could cause serious injury.

NOTE: The engine gearbox holds approximately 11 liters (11.6 qts) of oil. 6. Drain the engine gearbox oil through hose, 1, and catch the oil in a clean suitable container. NOTE: The hydraulic reservoir holds approximately 60 liters (16 gals) of oil.

1 2

7. Drain the hydraulic reservoir through hose, 2, and catch the oil in a clean suitable container. 86063117

14-2

SECTION 14 -- LIVE PTO -- CHAPTER 3 8. Loosen the unloading auger belt tensioning spring, 1. Lift the belt from the gearbox sheave and store it out of the way.

10012180

4 9. Turn out cap screws, 1, and remove the belt tensioner to the unloading auger from the combine. Cap screw, 2, may have to be loosened to gain access to the lower mounting cap screws. Store the tensioner in a suitable location.

2 86063004

5 10. Loosen the main drive belt tensioning spring, 1. Remove roll pin, 2, and clevis pin, 3, and remove from combine. Store the tensioner in a suitable location.

2 1 86063005

3 6

14-3

SECTION 14 -- LIVE PTO -- CHAPTER 3 11. Loosen chopper drive tensioner, 1. 12. Remove chopper drive and main drive belts.

13. Remove the three mounting bolts, 2, and remove the tensioner assembly from the combine. Store the tensioner in a suitable location.

86063006

7 NOTE: When disconnecting hydraulic lines, have a suitable container readily available to capture any residual hydraulic oil. 14. Disconnect and cap the two low pressure hydraulic pump lines, 1.

1 86063007

8 15. Disconnect and cap the four high pressure hydraulic pump lines, 1.

16. Loosen but do not remove the pump mounting nuts, 2.

2 1

86063008

14-4

SECTION 14 -- LIVE PTO -- CHAPTER 3 NOTE: The high/low pressure hydraulic pump weighs approximately 29 kg (63 lbs). 17. Securely attach the high pressure pump to a tow motor. Remove the mounting nuts and lift the pump from the combine. Store the pump in a suitable location.

10012186

10 18. Remove the two hoses, 1, to the cleaning fan drive pump, 2, and cap.

2 86063009

11 NOTE: When disconnecting hydraulic lines, have a suitable container readily available to capture any residual hydraulic oil.

3 2

19. Disconnect hydraulic lines, 1, from the main hydrostatic pump (forward and reverse high pressure lines). If the combine has the powered rear axle option, remove lines, 2. Turn four cap screws out from each fitting, 2, to disconnect the hydraulic lines from the pump. Cover the lines just removed in a bag and wire tie to the hoses to keep dirt out. Tie the hoses out of the way. Disconnect and cap case drain ground drive motor hydraulic line, 3, from the main hydrostatic pump.

56063010

4 12

20. Disconnect and suction line, 4, from the reservoir to the main hydrostatic pump.

14-5

SECTION 14 -- LIVE PTO -- CHAPTER 3 21. Disconnect and cap hydraulic line, 1, from the main hydrostatic pump. Detach the connector, 2, from the oil pressure switch. Unplug the connector, 3, from the Electronic Displacement Control (EDC) valve.

22. Loosen but do not remove the four hydrostatic pump mounting cap screws. NOTE: The main hydrostatic pump weighs approximately 137 kg (303 lbs).

23. Securely attach the main hydrostatic pump to a tow motor. Remove the mounting cap screws and lift the pump from the combine. Store the pump in a suitable location.

86063011

24. Loosen the two hose clamps, 1, remove and cap the hydraulic lines from the gearbox. 25. Detach electrical connector, 2.

1 10012194

14 26. Disconnect and cap hydraulic line, 1, from the filler tube. Turn out the three cap screws, 2, and remove the filler tube, 3, from the gearbox.

1 2

86063012

14-6

SECTION 14 -- LIVE PTO -- CHAPTER 3 27. Turn out the four cap screws, 1, securing the manifold to the gearbox. Tie the manifold up away from the gearbox. Remove the O-rings.

1 1

10002717

16 28. Loosen all twelve gearbox mounting cap screws.

10002719

17 29. Several of the cap screws are better accessible from inside the grain tank.

86063001

14-7

SECTION 14 -- LIVE PTO -- CHAPTER 3 NOTE: The engine gearbox weights approximately 246 kg (543 lbs). NOTE: Make sure that the gearbox is properly supported. Too much or too little tension may cause the gearbox spline shaft, 1, to bend. 30. Securely attach the engine gearbox to a tow motor. Remove the mounting cap screws and lift the gearbox from the combine. Set the gearbox on the floor in a stable position.

10003679

19 Replacement NOTE: The engine gearbox weighs approximately 246 kg (543 lbs). 1. Lubricate the gearbox spine input shaft with an anti-seize compound. NOTE: Make sure that the gearbox is properly supported. Too much or too little tension may cause the gearbox spline shaft, 1, to bend.

2. Securely attach the engine gearbox to a tow motor and lift the gearbox to the engine mounting flange.

10003679

3. Slide the gearbox spline into the engine flywheel until the flanges are against each other. 4. Apply LoctiteR 242 to the cap screws and turn in all twelve gearbox mounting cap screws. Do not tighten any hardware until all cap screws have been started.

10002719

14-8

SECTION 14 -- LIVE PTO -- CHAPTER 3 5. Several of the cap screws are better accessible from inside the grain tank. 6. Tighten the gearbox mounting cap screws to 80-90 N⋅m (59 ft-lbs).

86063001

22 7. Lubricate and set into place on the gearbox six manifold O-rings. 8. Carefully rest the manifold on the gearbox and secure using four long cap screws, 1. Torque four cap screws to 28 N⋅m (21 ft-lbs).

1 1

10002717

23 9. Attach the oil filler tube, 3, to the gearbox with three cap screws, 2. Connect the hydraulic line, 1, to the filler tube.

86063012

14-9

SECTION 14 -- LIVE PTO -- CHAPTER 3 10. Secure the pump suction and gearbox drain lines, 1, to the appropriate fittings with hose clamps. 11. Attach the sump oil temperature sender connector, 2.

1 10012194

25 NOTE: The main hydrostatic pump weighs approximately 137 kg (303 lbs).

12. Lift the hydrostatic pump into place and attach to the gearbox with four cap screws. Torque the mounting cap screws to 190-210 N⋅m (140-155 ft-lbs). 13. Attach the hydraulic line, 1, to the hydrostatic pump. Plug the connector, 2, in the Electronic Displacement Control (EDC) valve. Connect the wire, 3, to the oil pressure switch.

3 86063011

26 14. Secure the main hydrostatic pump lines, 1, using four cap screws on each fitting (forward and reverse high pressure lines). If the combine has the powered rear axle option, install hoses, 2. Torque the cap screws to 159 N⋅m (117 ft-lbs). Secure hydraulic line, 3, and, 4, to the main hydrostatic pump.

3 2 1

56063010

4 27

14-10

SECTION 14 -- LIVE PTO -- CHAPTER 3 NOTE: The high/low pressure hydraulic pump weighs approximately 29 kg (63 lbs).

15. Using the appropriate lifting gear, set the hydraulic pump into place and secure using two mounting nuts and washers, 1.

16. Attach the four high pressure hydraulic pump lines, 2, to the pump.

86063008

28 17. Connect the two low pressure hydraulic pump lines, 1, to the pump.

86063009

29 18. Install the tensioner assembly, 1, to the combine. Install the three mounting bolts, 2, and tighten. 19. Install chopper drive and main drive belts.

20. Install chopper drive tensioner, 3, and tighten.

86063006

14-11

SECTION 14 -- LIVE PTO -- CHAPTER 3 21. Install the main drive belt tensioner to the combine. Install roll pin, 2, and clevis pin, 3, and tighten the tensioning spring, 1.

2 1 3

86063005

31 22. Install the belt tensioner to the unloading auger to the combine. Turn in cap screws, 1, and tighten. Cap screw, 2, may have to be loosened to gain access to the lower mounting cap screws.

2 86063004

32 23. Install the unloading auger belt and tighten the unloading auger belt tensioning spring, 1.

10012180

14-12

SECTION 14 -- LIVE PTO -- CHAPTER 3 24. Shut or verify shut the engine gearbox and hydraulic reservoir drain line connections. 25. Fill the engine gearbox with 11 liters (11.6 qts) of hydraulic oil. 26. Fill the hydraulic reservoir with 60 liters (16 gals) of hydraulic oil. 27. Start the engine and allow the oil level in the gearbox to stabilize. Fill the gearbox as necessary with hydraulic oil to maintain the level in the sight glass, but below the red full mark. 86063117

34 28. If the unloading auger is attached to the operating cylinder, rotate the auger into its standby position.

29. If the cylinder has been disconnected from the auger, carefully rotate the auger into its standby position. 30. Attach the rod end, 1, of the cylinder to the hinge point on the auger. Tighten or verify tight the hydraulic lines, 2, to the unloading auger cylinder.

2 40020127

35 31. Install rear hinge support, 1, and rear fixed shield, 2. 32. Install left-hand side shield as described in Section 90.

2 86063003

14-13

SECTION 14 -- LIVE PTO -- CHAPTER 3 FLEXPLATE Removal 1. Remove the engine gearbox in accordance with the “Gearbox-Removal” procedure in this section.

86063008

37 For CR9040 and 9060: 1. Turn out the eight cap screws with lock washers, 1. Lift the flexplate, 2, from the flywheel. 2. Clean all old thread locking compound from the cap screws.

20015718

14-14

SECTION 14 -- LIVE PTO -- CHAPTER 3 For CR9070: 1. Turn out the eight cap screws with lock washers, 1. Lift the flexplate, 2, from the flywheel. 2. Clean all old thread locking compound from the cap screws.

1 20015717

14-15

SECTION 14 -- LIVE PTO -- CHAPTER 3 Installation For CR9040 and 9060: 1. Apply LoctiteR 242 to the eight cap screws. 2. Set the gearbox flexplate, 1, on the engine flywheel with the flexplate cap screw heads, 2, oriented toward the gearbox. Secure using eight lock washers and cap screws, 3. Torque the cap screws to 45-50 N⋅m (33-37 ft-lbs).

3 2

20015718

14-16

SECTION 14 -- LIVE PTO -- CHAPTER 3 For CR9070: 1. Apply LoctiteR 242 to the eight cap screws. 2. Set the gearbox flexplate, 1, on the engine flywheel with the flexplate cap screw heads, 2, oriented toward the engine flywheel. Secure using eight lock washers and cap screws, 3. Torque the cap screws to 45-50 N⋅m (33-37 ft-lbs).

3 20015717

41 3. Install the engine gearbox in accordance with the “Gearbox-Installation” procedure in this section.

86063008

14-17

SECTION 14 -- LIVE PTO -- CHAPTER 3

14-18

SECTION 14 -- LIVE PTO -- CHAPTER 4

SECTION 14 - LIVE PTO Chapter 4 - Engine Gearbox Rebuild CONTENTS Section

Description

Page

14-1

SECTION 14 -- LIVE PTO -- CHAPTER 4 OVERHAUL GEARBOX Disassembly 1. Support the gearbox with the engine flange/input shaft pointing in the downward direction. 2. Using a wrench on the flats of the unloading sheave, 1, turn out the cap screw, 2.

1 2 10013330

1 NOTE: The unloading shaft is tapered. Heat may need to be applied to remove the sheave. 3. Remove the cap screw from the shaft and install a longer cap screw in its place. Use a shallow socket on cap screw head and attach a puller onto the unloading sheave. Remove the sheave from the shaft. NOTE: The longer cap screw and the socket will keep the pulley from flying off the shaft. 10013331

2 4. Using a wrench on the flats of the main output sheave, 1, turn out the cap screw, 2. If flats are not accessible, use a strap wrench on the sheave, 3.

2 3 1 10013332

14-2

SECTION 14 -- LIVE PTO -- CHAPTER 4 NOTE: The main output shaft is tapered. Heat may need to be applied to remove the sheave. 5. Remove the cap screw from the shaft and install a longer cap screw in its place. Use a shallow socket on cap screw head and attach a puller onto the main output sheave. Remove the sheave from the shaft.

10013333

4 6. Remove the unload shaft key, 1.

7. Remove the housing cover cap screws, 2.

10004281

5 8. Install jacking bolts, 1. Tighten the bolts until the housing cover, 2, has broken loose from the gearbox. Remove the housing cover.

NOTE: When taking off the housing cover, protect the radial seal, 3, against damage from the key way of the unload clutch shaft.

3 10004282

2 6

14-3

SECTION 14 -- LIVE PTO -- CHAPTER 4 9. Remove the threaded sensor, 1, from the gearbox.

IMPORTANT: DO NOT lose the shim washers. The washers will be required upon reassembly to maintain minimum acceptable clearance.

10004283

7 NOTE: The unload clutch shaft and main clutch shaft are heavy. Exercise care when removing the units from the gearbox.

10. Lift the main clutch shaft, 1, out of the gearbox.

10004284

8 11. Lift the unload clutch shaft, 1, out of the gearbox.

10004285

14-4

SECTION 14 -- LIVE PTO -- CHAPTER 4 12. Remove the drive housing, 1, from the gearbox.

10002713

10 13. Lift the hydrostatic drive from the gearbox. 14. Turn the gearbox over and support it with the engine flange/input shaft pointing in the upward direction.

10004286

11 15. Remove cap screws, 1, holding the engine flange onto the gearbox.

16. Separate the engine flange, 2, from the gearbox. NOTE: When removing the engine flange, protect the shaft seal against damage from the multi-spline profile of the spur gear shaft.

10004290

14-5

SECTION 14 -- LIVE PTO -- CHAPTER 4 17. Remove the input shaft assembly, 1, from the gearbox.

10004287

13 18. Turn the gearbox over and support it with the thresher shaft pointing in the upward direction.

19. Remove the thresher shaft key, 1.

20. Pry the thresher shaft seal, 2, from the gearbox. NOTE: Do not re-use the seal.

10004289

14 21. Using special tool 380000660, or a modified chisel, force the indented portion of the slotted nut from the shaft. Turn the nut from the thresher shaft. NOTE: It may be necessary to destroy the slotted nut to remove it from the thresher shaft.

10006346

14-6

SECTION 14 -- LIVE PTO -- CHAPTER 4 22. Remove plug, 1, to gain access to the cap screws with a long extension.

23. Secure the thresher shaft to keep it from turning by blocking the spur gear rim against the housing.

2 1

24. Turn out the cap screws, 2, holding the gear to the flanged shaft, 3. 25. Lift the thresher shaft drive gear, 4, from the gearbox. 26. Drive the flanged shaft out of the bearing seat in the housing neck towards the inside.

10004288

NOTE: The bearings have been heat shrunk to the shaft. Use a large sledge hammer and hardwood block to separate the shaft from the outer bearing. 27. Remove the flanged shaft from the gearbox. Inspection 1. Inspect all sealing surfaces, 1, for grooves or nicks.

56063761

14-7

SECTION 14 -- LIVE PTO -- CHAPTER 4 2. Check gears, 1, for broken or badly worn teeth.

1 1 56063761

18 3. Inspect the piston rings and cylinder bushings, 1, for grooves or nicks.

56063761

14-8

SECTION 14 -- LIVE PTO -- CHAPTER 4 Component Repair -- Bearing and Race Removal/ Installation If a tapered roller bearing requires replacement, the outer race must also be replaced at the same time. Some outer races are inserted on top of shim packs. These packs are installed to provide a pre-load to the bearings. The original shim pack should be used when replacing the bearing and race. Perform the measurement to determine if proper pre-load exists, and adjust the thickness of the shim pack appropriately. 10012217

All of the tapered roller bearings used in this gearbox are installed using an interference fit. Most bearings can be removed and installed using bearing pullers and presses. The thresher shaft bearings are heat shrunk onto the shaft. To install new bearings onto the shaft, heat them in a bearing oven, 80 - 85°C (170 - 180°F) for 30 - 45 minutes. Remove the bearing from the oven and carefully slide it onto the shaft in the proper orientation. Ensure that the bearing slides on evenly. When the bearing is in contact with the shaft, it will cool very quickly and start to shrink.

Component Repair -- Clutch Cylinder Bushing Removal/Installation 1. Using an internal puller, or other suitable tool, hook one oil port of the cylinder bushing and pull straight up to extract the bushing from the bore.

10006350

21 2. Press the cylinder bushing into the bore with the nib directed into the indent at the bottom of the bore, 1, using a brass punch and a hammer.

10006351

14-9

SECTION 14 -- LIVE PTO -- CHAPTER 4 Assembly 1. Heat the thresher shaft outer bearing, 1, in an oven to 80 - 85°C (170 - 180°F).

2. Insert the thresher shaft, 2, from inside the housing and brace it against the inner wall of the housing by means of blocking, 3. 3. Drop the heated bearing onto the installed shaft with the tapered end down. Ensure that the bearing slides down the shaft evenly.

CAUTION The bearing is very hot! Use a tool or heavy insulated glove to handle bearing. Failure to comply could cause serious injury.

1 10006336

4. Turn the slotted nut, 1, onto the thresher shaft finger tight. Mark the nut and shaft so that their relative positions can be monitored.

5. Turn the thresher shaft while applying light blows to the housing in order to set the bearings.

10006337

24 NOTE: The slotted nut must be tightened in small increments. Due to the tight fit of the bearing, it will be difficult to loosen the bearing if running torque becomes excessive. 6. Hold the shaft from turning with a pin spanner on the flanged end of the shaft. Tighten the slotted nut to produce a rolling torque on the thresher shaft of 1250 - 1500 N⋅mm (11 - 13 in-lb).

10006338

14-10

SECTION 14 -- LIVE PTO -- CHAPTER 4 7. Secure the nut by deforming the front collar into the shaft groove. NOTE: Securing the slotted nut: Swage the retaining edge of the adjusted slotted nut into the longitudinal groove of the shaft by means of a rounded mandrel. The retaining edge must be deformed evenly into the longitudinal groove until it is in contact with the mid-section of the groove bottom. The retaining edge must not tear. If necessary, it should therefore not be swaged entirely to the bottom of the groove. (Groove width - mandrel dia.; Approx. 2 mm.) 10006339

26 8. Place the spur gear, 4, on the centering of the flanged shaft, 3. Mount the gear with new cap screws, 2. Some of the cap screws will have to accessed through the hole, 4, with a long extension. Tighten to 110 - 120 N⋅m (81 - 88 ft-lb). Use a crowbar or large screwdriver to hold the gear in place while tightening the cap screws. Replace plug, 1.

2 1

IMPORTANT: For safety reasons, new M12 cap screws must be used for assembly. 10004288

27 9. Slide the previously removed shim pack, 1, and bearing race, 2, into the upper housing, 3.

10012217

3 28

14-11

SECTION 14 -- LIVE PTO -- CHAPTER 4 10. Set the hydraulic pump drive gear, 1, into the casing. Lubricate the O-ring, 2, with petroleum jelly and install it into the groove of the upper housing.

10006341

29 11. Orient the housing so that the oil feeding groove, 1, is located at the top. 12. Secure the housing, 2, to the gearbox with four nuts and washers, 3, and tighten to 190 - 210 N⋅m (140 - 155 ft-lb).

13. Turn the spur gear shaft while applying light blows to the housing in order to set the bearings.

10012214

3 30

14. Wrap a few turns of electrical tape around a 28 mm (1-1/8 in) socket and press the socket into the female spline of the gear.

10012215

14-12

SECTION 14 -- LIVE PTO -- CHAPTER 4 15. Check the roll torque of the hydraulic pump drive for compliance with the nominal value of 300 400 N⋅mm (2.6 - 3.5 in-lb).

10012216

32 16. If necessary, the shim thickness must be adjusted to reach the nominal value of 300 - 400 N⋅mm (2 - 3 in-lb). 17. After roll torque is complete, pull the hydraulic pump drive gear out and set aside.

10012217

33 18. Turn the housing over and support it with the opening for the engine flange pointing in the upward direction.

19. Install the inner bearing race and the previously removed shim pack at 1, if it had been removed.

10012219

14-13

SECTION 14 -- LIVE PTO -- CHAPTER 4 20. Insert the input shaft and gear, 1, into the housing.

21. Mount the outer race of the roller bearing into the engine flange, if it had previously removed. 22. Lubricate the O-ring with petroleum jelly and install it into the groove of the engine flange.

10006343

35 IMPORTANT: Use extreme care while installing the engine flange. The sealing O-ring can come out of the groove and become pinched.

23. Install the engine flange with the oil feeding groove, 1, toward the top of the gearbox. IMPORTANT: Use of any gasket compound on the engine flange will effect the bearing pre-load. 24. Secure the flange to the gearbox with cap screws, 2, and tighten to 80 - 90 N⋅m (59 - 66 ft-lb).

10004290

25. Turn the spur gear shaft, 3, while applying light blows to the housing in order to set the bearings. 26. Check the combined roll torque of the input shaft for compliance with the nominal valve 1400 1650 N⋅mm (12 - 14 in-lb).

10012218

14-14

SECTION 14 -- LIVE PTO -- CHAPTER 4 27. If necessary, the shim pack thickness under the input shaft outer race, 1, must be adjusted.

28. Turn the housing over and support it with the engine flange pointing downward. 29. Reinstall pump gear.

10012219

38 Clutch Installation 1. Insert outer race of tapered roller bearing into gearbox housing for the main clutch shaft and unloading clutch shaft. 2. Insert the main clutch shaft, 1, carefully into position (not damaging the seal) so as to insert the shaft seal rings, to ensure meshing of the gears, and center the main clutch shaft in the bearing race.

3. Insert the unload clutch shaft, 2, carefully into position (not damaging the seal) so as to insert the shaft seal rings, to ensure meshing of the gears, and center the unload clutch shaft in the bearing race. 4. Rotate shafts to seat the bottom bearings. 5. Install both bearing cups into cover. Apply flush with cover.

10004284

6. Set the housing cover on the gearbox, using the dowel pins in gearbox housing. Start six cap screws, 1, into the cover and gearbox and tighten. Torque to 27 - 54 N⋅m (20 - 40 ft-lb) to draw cover up tight to housing.

10013326

14-15

SECTION 14 -- LIVE PTO -- CHAPTER 4 Unloader Clutch Shimming Process 1. Check bearing not to have play by gently pushing unloader outer bearing cup down towards bearing cone. 2. Install shim pack and snap ring to get zero play. The 2 mm shim must be next to the snap ring. NOTE: Outer bearing ring, shims, and snap ring must be without any play (shims are not loose but without high axial force) - shims can still be moved a bit by a tool. 3. Remove and measure total shim thickness. 4. Add on 0.1 mm to total shim thickness. 5. Place shims and snap ring to the side for later installation. NOTE: The addition of the 0.1 mm shim is to provide 0 - 0.1 mm bearing preload. Main Clutch Shimming Installation 1. Install a 2 mm shim and the snap ring. 2. Set up a magnetic base dial indicator as shown on the main clutch pack. Measure the end play by pulling up on the shaft and noting the amount of needle deflection. Use a device or combination of tools that will allow raising the clutch pack from inside the female spline. 3. Measure the thickness of the shim removed from the main clutch pack. Using the formula provided, calculate the pre-load on the bearings. Original Shim Thickness

Final Shim Thickness

End play 0.15 +

10013329

4. Pre-load on the main clutch bearings is to be 0.1 - 0.2 mm (0.004 - 0.008 in). Set shim pack and snap ring aside for later installation. Be sure to set these aside, away from the unloader set. 5. Remove the six attaching cap screws and remove the cover. NOTE: The addition of the 0.1 mm shim is to provide 0.0 - 0.1 mm bearing preload.

14-16

SECTION 14 -- LIVE PTO -- CHAPTER 4 6. Install the shim pack and snap ring from each clutch in the appropriate center of the cover. Make sure the 2 mm shim, in each shim pack is placed next to the snap ring.

7. Turn cover over and press bearing cups tight against shim packs.

2 10013327

42 Assembly 1. Apply liquid seal on the sealing surface of the gearbox housing cover. Align cover to gearbox using the dowel pins in gearbox housing. Start the eleven cap screws, 1, into the cover and gearbox, torque consistently to 45 - 50 N⋅m (33 - 37 ft-lb).

2. Install lip seal on the unloader shaft.

10013326

43 Clutch Temperature Sender Shim Installation

1. Measure the distance from the machined surface of the clutch temperature sender bore, 1, to the main clutch pack.

10012220

14-17

SECTION 14 -- LIVE PTO -- CHAPTER 4 2. Measure the length of the clutch temperature sender from the shoulder outside the threads, to the tip.

10012221

45 3. Measure thickness of the shim washer. 4. Insert the measured values into the following equation and perform the calculation. Length of Temperature Sender

Effective Sender Length

Thickness of Shim -

The effective clutch temperature sender length is to be 2 - 2.5 mm (0.08 - 0.1 in) less than the depth of the bore.

10012222

46 5. Install the clutch temperature sender, 1, into the bore.

IMPORTANT: Do not over tighten the temperature sender. The unit is made of plastic and could break.

10004283

14-18

SECTION 14 -- LIVE PTO -- CHAPTER 4 Assembly 1. Install shaft key. 2. Set the main output sheave, 1, onto the shaft, and turn in cap screw, 2, installed with washers.

3. Torque to 345 - 405 N⋅m (254.46 - 298.71 ft-lb).

4. Strike the sheave with a hammer and retorque.

10013332

48 5. Install the shaft key.

6. Apply an anti-seize compound to the shaft. 7. Set the unloading sheave, 1, onto the shaft, and turn in cap screw, 2. 8. Torque to 95 - 105 N⋅m (70.06 - 77.44 ft-lb). 9. Strike the sheave with a hammer and retorque.

2 10013330

14-19

SECTION 14 -- LIVE PTO -- CHAPTER 4

14-20

SECTION 21 -- TRANSMISSION -- CHAPTER 1

SECTION 21 - TRANSMISSION Chapter 1 - Transmission CONTENTS Section

Description

Page

21-1

SECTION 21 -- TRANSMISSION -- CHAPTER 1 SPECIFICATIONS CR9040 CR9060

CR9070 CR9040/9060 Optional

Differential ratio

16/71

20/61

Differential lock

Yes/No

1st gear ratio

18/58

2nd gear ratio

35/62

3rd gear ratio

45/61

4th gear ratio

63/44

Max. input rpm (high idle)

3027

2752

Max. input rpm (full load)

3027

2752

632 N⋅m (466 ft-lb)

823 N⋅m (607 ft-lb)

977

1292

8242 N⋅m (6078 ft-lb)

7378 N⋅m (5441 ft-lb)

187 kW (250 hp)

221 kW (296 hp)

Brake disc diam.

330 mm (13 in)

400 mm (15.7 in)

Approx. total weight

402 kg (886 lb)

420 kg (926 lb)

Model Usage

Gear ratio

Max. input torque Max. output rpm (high idle) Max. output torque (1st gear) Max. power (motor - transmission input)

TIGHTENING TORQUES Nut on drive shaft

150 -- 170 N⋅m (111 -- 125 ft-lb)

Nut on input shaft

150 -- 170 N⋅m (111 -- 125 ft-lb)

Shifting disc shaft castle head lock nut

25 -- 30 N⋅m (19 -- 22 ft-lb)

Nut on indicator plate

8 -- 12 N⋅m (71 -- 106 in-lb)

Sensor bolts

4 -- 6 N⋅m (36 -- 53 in-lb)

Shifting disc housing insert

190 -- 210 N⋅m (140 -- 155 ft-lb)

Top cover bolts

45 -- 55 N⋅m (33 -- 41 ft-lb)

Drain plug

90 -- 110 N⋅m (66 -- 81 ft-lb)

Breather

90 -- 110 N⋅m (66 -- 81 in-lb)

21-2

SECTION 21 -- TRANSMISSION -- CHAPTER 1 SPECIAL TOOLS Nut Spanner Wrench (45 mm) Special Tool No. 380001074 Used for disassembly and assembly of the drive and input shafts.

50030182

21-3

SECTION 21 -- TRANSMISSION -- CHAPTER 1 SECTIONAL/EXPLODED VIEWS

TRANSMISSION COVER (EXPLODED VIEW) 1. 2. 3. 4. 5.

Bolt Cover Seal Pin Lever

6. 7. 8. 9. 10.

21-4

Retaining ring Differential lock control shaft O-ring Retaining ring Fork

SECTION 21 -- TRANSMISSION -- CHAPTER 1

GEARBOX SHAFTS (SECTIONAL VIEW) 1. 2. 3. 4.

Input shaft Drive shaft Differential Differential shafts

21-5

SECTION 21 -- TRANSMISSION -- CHAPTER 1

SHIFTING DIAGRAM (SECTIONAL VIEW) 1. 2. 3. 4.

Gear : 1 - 5 - 8 - 10 Gear : 2 - 6 - 8 - 10 Gear : 3 - 7 - 8 - 10 Gear : 4 - 9 - 8 - 10

21-6

SECTION 21 -- TRANSMISSION -- CHAPTER 1

SHIFTING DISC/DRIVE GEAR (SECTIONAL VIEW) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Bolt, M6 x 10 mm Special bolt, M6 Bolt, M6 x 30 mm Friction washer and retaining ring Drive gear housing Shifting drive gear O-ring Electric motor Nut Indicator plate

11. 12. 13. 14. 15. 16. 17. 18. 19.

21-7

Cotter pin Castle nut Bolt, M12 x 90 mm, countersunk head with nib Shifting disc housing Shifting disc Bushing O-ring Sensor Bolt, M6 x 16 mm

SECTION 21 -- TRANSMISSION -- CHAPTER 1 1 2

8 9

6 7

12 14

17 21

18 24

66070072

27 5

SHIFTING DISC/DRIVE GEAR (EXPLODED VIEW) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Nut, M12 Indicator Cover Cotter Pin Slotted Nut Bushing O--ring Bushing, Shifting Disc Threaded Bolt (M6 x 16) and Washer Sensor Bolt (M8 x 40) and Bushing Electric Motor Key Bolt (M6 x 10) and Lock Washer Disc Screw, M6 x 16 Countersunk

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

21-8

Retaining Ring Friction Washer Distance Screw Bolt (M6 x 16) and Lock Washer Bushing, Drive Gear Guide Retaining Ring and O--ring Shifting Disc Bolt, M12 x 90 CSH with locating nib O--ring Shifting Drive Gear Cap Guiding Block Yoke, LH Universal Joint Shaft Yoke, RH Universal Joint

SECTION 21 -- TRANSMISSION -- CHAPTER 1

DIFFERENTIAL (SECTIONAL VIEW) 1. 2. 3. 4. 5.

Bearing Bearing Bolt Lock plate Differential housing

6. 7. 8. 9. 10.

21-9

Differential output gear Planet gear shaft Planet gear Differential output gear Ring gear

SECTION 21 -- TRANSMISSION -- CHAPTER 1

DIFFERENTIAL (EXPLODED VIEW) 1. 2. 3. 4. 5.

Bearing Bearing Bolt Lock plate Differential housing

6. 7. 8. 9. 10.

21-10

Differential output gear Planet gear shaft Planet gear Differential output gear Ring gear

SECTION 21 -- TRANSMISSION -- CHAPTER 1

DIFFERENTIAL SHAFTS (EXPLODED VIEW) 1. 2. 3. 4. 5. 6. 7.

Differential shaft Seal Retaining ring Bearing Housing Bearing O-ring

8. 9. 10. 11. 12. 13. 14.

21-11

Differential shaft Housing Bearing Differential Spring Differential lock Retaining ring

SECTION 21 -- TRANSMISSION -- CHAPTER 1

DRIVE SHAFT/COVER (EXPLODED VIEW) 1. 2. 3. 4. 5.

Cover Seal Shim pack O-ring Drive shaft

21-12

SECTION 21 -- TRANSMISSION -- CHAPTER 1

DRIVE SHAFT (SECTIONAL VIEW) 1. 2. 3. 4. 5. 6. 7. 8. 9.

Bearing Drive shaft Gear Needle bearings Selector ring Selector housing Ball Spring Washer

10. 11. 12. 13. 14. 15. 16. 17.

21-13

Retaining ring Gear Needle bearings Washer Bearing Washer Lock washer Nut

SECTION 21 -- TRANSMISSION -- CHAPTER 1

DRIVE SHAFT (EXPLODED VIEW) 1. 2. 3. 4. 5. 6. 7. 8. 9.

Bearing Drive shaft Gear Needle bearings Selector ring Selector housing Ball Spring Washer

10. 11. 12. 13. 14. 15. 16. 17.

21-14

Retaining ring Gear Needle bearings Washer Bearing Washer Lock washer Nut

SECTION 21 -- TRANSMISSION -- CHAPTER 1

INPUT SHAFT AND BEARING CAPS (EXPLODED VIEW) 1. 2. 3. 4. 5. 6. 7. 8. 9.

Input shaft Oil baffle plate Threaded shaft Cap O-ring Seal Bearing Shims Cap

21-15

SECTION 21 -- TRANSMISSION -- CHAPTER 1

INPUT SHAFT (SECTIONAL VIEW) 1. 2. 3. 4. 5. 6. 7. 8.

Nut Lock washer Washer Bearing Washer Gear Needle bearing Retaining ring

9. 10. 11. 12. 13. 14. 15. 16.

21-16

Washer Selector ring Ball Spring Selector housing Gear Needle bearing Input shaft

SECTION 21 -- TRANSMISSION -- CHAPTER 1

INPUT SHAFT (EXPLODED VIEW) 1. 2. 3. 4. 5. 6. 7. 8.

Nut Lock washer Washer Bearing Washer Gear Needle bearing Retaining ring

9. 10. 11. 12. 13. 14. 15. 16.

21-17

Washer Selector ring Ball Spring Selector housing Gear Needle bearing Input shaft

SECTION 21 -- TRANSMISSION -- CHAPTER 1 OVERHAUL TRANSMISSION Removal

WARNING Always ensure transmission and rear axle sections of the tractor are fully supported to prevent any movement when the transmission is removed. Failure to comply could result in serious injury or death.

WARNING Lift and handle all heavy components using lifting equipment of appropriate lifting capacity. Ensure that units or parts are supported by suitable slings or hooks. Ensure that no-one is in the vicinity of the load to be lifted. Failure to comply could result in serious injury or death. 1. Remove half shafts. See Section 25 -- Chapter 1 -- “Final Drive -- Half-Shaft --Removal”. 2. Remove the lower fan shields.

First, remove the forward shield, 1, with two M8 x 20 cap screws with lock washers, 2, and two M8 x35 carriage bolts, 3, with clamp washer and locknut.

20013154

15 3. Remove the lower fan shield, 1, with five lock washers and M6 nuts, 2, and M8 x 20 carriage bolt, 3, with lock washer and nut.

20013155

21-18

SECTION 21 -- TRANSMISSION -- CHAPTER 1 4. With the lower fan shields, 4, removed, remove the two-piece hose clamp, 2.

First, remove the interlocking lower half of the clamp removing two M8 x 40 bolts, 3, and locknuts.

Remove the clamp upper half with two M8 x 25 bolts, 1, and lock nuts.

4 86072862

3 17

5. Drain the transmission oil into a suitable container for disposal. The transmission contains 19 L (5 U.S. gal). Remove the magnetic drain plug, 1, to drain oil. 6. Clean the drain plug and reinstall hand tight.

1 ZDA2797A

21-19

SECTION 21 -- TRANSMISSION -- CHAPTER 1 7. Remove the hydrostatic motor, 1, from the left rear side of the transmission, as follows: NOTE: Removal of the hydrostatic motor from the transmission does not require the disconnection of the hydraulic lines and loss of hydraulic fluid. Removal can be accomplished as long as the weight of the motor is well supported. In some cases it may be necessary to remove the left-hand traction wheel to allow the hose and motor assembly to be pulled outward from the transmission gearbox. If removing the motor for separate service; reference Section 29 –Hydrostatic Systems; Chapter 5 – Hydrostatic Pump and Motor Repair.

86072861

2 19

NOTE: The combine may be equipped with either a 100cc or 130cc size hydrostatic motor. The 100cc motor is shown in this figure. Each size motor is secured with different size hardware and with different torque specifications. The larger body 130cc motor is secured in the outer set of threaded holes, 3. Provide support for the motor with a jack or other means when the securing hardware is removed. 100cc motor Remove four M12 x 45 bolts with hardened flat washers, 2. Pull the motor straight out of the gearbox and provide the required support. Remove the pilot spacer ring from the gearbox if not extracted along with the motor removal. 130cc motor Remove four M16 x 45 bolts with hardened washers from location, 3. Pull the motor straight out of the gearbox and provide the required support. 8. Disconnect parking brake hydraulic line, 1.

ZDA3252A

21-20

SECTION 21 -- TRANSMISSION -- CHAPTER 1 9. Disconnect brake lines, 1. Remove the two M10 x 30 bolts and lock washers securing the caliper guards, 2, on both sides of the transmission.

ZDA2797C

21 10. If equipped with differential lock, disconnect the differential lock cable yoke end, 1, from the lock control lever, 2.

Disconnect the lock cable, 3, from the transmission cover mounting bracket, 4.

1 3

2 66060017

22 11. Disconnect brake shoe wear wires, 1, on both sides of the transmission.

ZDA3255B

21-21

SECTION 21 -- TRANSMISSION -- CHAPTER 1 12. Disconnect electrical connectors: • • •

Combine speed sensor Gear shift sensor Gear shift motor

WARNING The gearbox is heavy (420 kg [926 lb]). Use extreme caution when removing the gearbox. Use a supporting device which can handle this weight. Failure to comply could result in serious injury or death. 13. Install a suitable and safe support underneath the gearbox (e.g., a wooden pallet on a forklift).

ZDA3254A

14. Loosen three M16 x 50 bolts, 1, at left-hand side of transmission.

ZDA3255A

25 15. Loosen three M16 x 50 bolts, 2, at right-hand side of the transmission. 16. Lower the transmission and remove it from underneath the combine.

ZDA3256A

21-22

SECTION 21 -- TRANSMISSION -- CHAPTER 1 Disassembly 1. Remove service brakes. See Section 33 -Chapter 1, “Brakes and Controls”. 2. Remove parking brake. See Section 33 -- Chapter 1, “Brakes and Controls”. Transmission Cover

WARNING Raised equipment or machine movement without an operator can cause injury or death. Before you service this machine do the following: Park the machine on a level surface. Support or lower the equipment (backhoe, blade, boom, bucket, etc.) to the ground (if equipped). • Apply the parking brake (if equipped). • Stop engine. • Block the machine (wheels, tracks, etc.) to prevent machine movement. Failure to comply could result in serious injury or death. • •

3. Remove all M10 x 30 bolts, 1, and cover, 2.

ZDA3257A

21-23

SECTION 21 -- TRANSMISSION -- CHAPTER 1 4. If necessary, remove pin, 1, and differential lock control lever, 2. NOTE: Removal of the differential control lever and differential lock control shaft is necessary only if fork and/or O-ring need to be replaced.

ZDA3258A

28 5. Remove retaining ring, 1, and differential lock control shaft, 2.

ZDA3259A

29 6. Remove and discard O-ring, 1. 7. Remove retaining ring, 2, to remove fork, 3.

ZDA3260A

21-24

SECTION 21 -- TRANSMISSION -- CHAPTER 1 Differential and Shafts

WARNING Lift and handle all heavy components using lifting equipment of appropriate lifting capacity. Ensure that units or parts are supported by suitable slings or hooks. Ensure that no-one is in the vicinity of the load to be lifted. Failure to comply could result in serious injury or death. 8. On the left-hand side differential shaft, remove seal, 1, and discard. NOTE: It is not possible to remove seal, 1, without damaging it.

ZDA3262A

31 9. Remove retaining ring, 1.

ZDA3263A

32 10. Pull out shaft, 1, together with bearing, 2.

ZDA3264A

21-25

SECTION 21 -- TRANSMISSION -- CHAPTER 1 11. Remove bearing, 1, from the differential shaft, 2.

ZDA3271A

34 12. Remove six M12 nuts and lock washers, 1. 13. Remove two M10 x 12 cap screws and lock washers, 2.

ZDA3265A

35 14. Install two (M10 x 60 mm) bolts, 1, and tighten evenly to push bearing housing, 2, out of the gearbox housing, 3.

15. Remove the two (M10 x 60 mm) bolts.

ZDA3266A

3 36

21-26

SECTION 21 -- TRANSMISSION -- CHAPTER 1 16. Support the differential to prevent it from falling into the gearbox.

17. Remove four M12 nuts and lock washers, 1, on the right-hand side differential shaft housing.

18. Remove two M16 x 50 hex socket screws, 2. 19. Remove two M10 x 12 cap screws and lock washers, 3.

1 1 2

56060012

37 20. Install two (M10 x 60 mm) bolts, 2, and tighten evenly to push bearing housing, 1, out of the gearbox housing, 3.

NOTE: If transmission is equipped with optional differential lock, lock collar and spring will remain on shaft when bearing housing is removed.

21. Remove the two (M10 x 60 mm) bolts.

56060013

38 22. Remove bearing, 1, from the differential shaft, 2.

ZDA3271A

21-27

SECTION 21 -- TRANSMISSION -- CHAPTER 1 23. Remove the differential, 1.

56060016

40 24. Remove oil baffle plate, 1, by removing the four M8 x 16 cap screws and lock washers securing it.

ZDA3443A

41 Selector Shaft 25. Remove retaining ring, 1.

56060015

21-28

SECTION 21 -- TRANSMISSION -- CHAPTER 1 26. Remove retaining ring, 2.

ZDA3327A

43 27. Remove the selector shaft, 1, from the right-hand side of the transmission housing. If necessary, remove the selector shaft O-rings from both sides of the housing where the shaft was removed.

56060014

44 Drive Shaft NOTE: If the shifting disc is not removed from the transmission, first proceed with steps 44 -- 46 of “Shifting Disc and Drive Gear” further in this section, to bring the shifting disc in its highest position.

28. Remove five M12 nuts and lock washers, 1. 29. Remove the cover, 2, by tapping around the edges of the cover and/or radial tapping on the drive shaft, 3, with a soft face hammer. NOTE: Keep shim pack and O-ring with the cover.

3 56060011

21-29

SECTION 21 -- TRANSMISSION -- CHAPTER 1 30. Remove drive shaft, 1, and selector fork, 2, with a hoist.

ZDA3334A

46 31. If necessary, remove the bearing cup, 1.

ZDA3335A

47 Input Shaft 32. Remove selector fork, 2, from the input shaft.

ZDA3336A

21-30

SECTION 21 -- TRANSMISSION -- CHAPTER 1 33. Remove M12 threaded rod, 1, and seal ring.

ZDA3340 C

34. Remove oil baffle plate, 1, by turning out two M8 x 16 cap screws, 2.

ZDA3440A

50 35. Remove three M10 x 30 Allen screws, 1.

ZDA3339A

21-31

SECTION 21 -- TRANSMISSION -- CHAPTER 1 36. Remove seal housing, 2, with the lip-seal and the O-ring.

ZDA3339A

52 37. Remove five M10 nuts and lock washers, 1.

ZDA3340A

53 38. Remove cover, 1. NOTE: Keep shims and O-ring with the cover.

ZDA3341A

21-32

SECTION 21 -- TRANSMISSION -- CHAPTER 1 39. Support the input shaft on a hoist to avoid from falling into the gearbox. 40. Drive the shaft in the direction shown, toward the motor side of the transmission. Remove bearing cup, 1.

ZDA33342A

55 41. Pull bearing cone, 1, from the input shaft. 42. Remove the input shaft out of the gearbox.

ZDA3343A

56 43. If necessary, remove bearing cup, 1, from the bearing cover side of the input shaft.

ZDA3344A

21-33

SECTION 21 -- TRANSMISSION -- CHAPTER 1 Shifting Disc and Drive Gear

NOTE: It is possible to remove and to install the shifting disc and the shifting drive gear without disassembly of the gearbox shafts. 44. Remove nut, 1, and indicator plate, 2.

ZDA3344A

58 45. Remove five M6 x 16 bolts with flat washers, 1, and remove sensor, 2.

ZDA3344A

21-34

SECTION 21 -- TRANSMISSION -- CHAPTER 1 46. Bring the shifting disc up to the highest position by turning shifting disc housing, 1, outward until the shifting disc blocks are against the gearbox housing. NOTE: This step is only necessary when the drive shaft and the input shaft need to be removed from the transmission without removal of the shifting disc.

ZDA3331A

60 47. Remove four M6 x 10 bolts with lock washers, 1. Remove electric motor, 2.

ZDA3345A

61 48. Remove four M6 distance screws, 1, and M6 x 30 cap screw with lock washer, 2.

ZDA3346A

21-35

SECTION 21 -- TRANSMISSION -- CHAPTER 1 49. Remove retaining ring, 1, and the friction washer behind it. 50. Slide shifting drive gear, 3, out of housing, 2, and remove it from the inside of the transmission. Remove shifting drive gear housing, 2.

ZDA3347A

63 51. Remove and discard O-ring, 1, from the shifting drive gear, 2. Check the bottom of protective cap, 3 [see (Exploded View) item inspect transmission remove cap.

the gear to ensure the Shifting Disc/Drive Gear 26], is installed; if not, housing to locate and

ZDA3348A

2 64

21-36

SECTION 21 -- TRANSMISSION -- CHAPTER 1 52. Remove the cotter pin and castle nut, 1. Discard cotter pin. 53. Remove bolt, 3, and the shifting disc from the inside of the gearbox. 54. Remove shifting disc housing, 2.

ZDA3349A

65 55. Remove bushing, 3, from housing, 2. 56. If necessary, replace O-ring, 4, inside housing, 2.

ZDA3350A

21-37

SECTION 21 -- TRANSMISSION -- CHAPTER 1 Assembly Shifting Disc and Drive Gear 1. If necessary, replace O-ring, 4, inside shift disc housing, 2. Lubricate the O-ring with NH AMBRA GR9 multi-purpose grease prior to installation. Replace bushing, 3, if necessary, and install in housing, 2.

ZDA3350A

67 2. Apply a few drops of Loctite 242/243 threadlocker to the threaded insert, 1, of shifting disc housing, 2. Turn the shift disc housing, 2, into the gearbox and then torque to 190 -- 210 N⋅m (140 -- 155 ft-lb). If the M8 x 40 mm bolt, 3, is removed, apply Loctite 242/243 thread-locker, install the M8 x 40 mm bolt, 3, with the bushing, and then torque to 8 -- 12 N⋅m (71 -- 106 in-lb).

2 1

66070073

68 3. Install the shift disc from inside of the transmission housing with sensor target, 2, positioned in the middle of the gearshift sensor slot, 3. Install the M12 x 90 mm countersunk bolt, 4, with its nib on the countersunk head through the shift disc and shift disc housing. Ensure the nib is aligned into the slot on the shift disc when tightening. Install the castle nut, 5, with Loctite 515/573 gasket eliminator applied. Torque the castle nut, 5, to 25 -- 30 N⋅m (19 -- 22 ft-lb), and then torque further to align the castle nut slot to the cotter pin hole in bolt, 4. Install new cotter pin. IMPORTANT: Ensure that the followers on the selector forks are positioned into the notches on the shifting disc. NOTE: If the input shaft, the drive shaft and the differential are not assembled into the gearbox, bring the shifting disc up to the highest position by turning the shifting disc housing outward until the shifting disc blocks against the gearbox housing.

21-38

4 5

2 3 66070073

SECTION 21 -- TRANSMISSION -- CHAPTER 1 4. Lubricate the O-ring on the bottom of the sensor, 2, with NH AMBRA GR9 multi-purpose grease. Install the sensor, 2, with five M6 x 16 mm bolts and flat washers,1. Tighten and torque the bolts to 4 -- 6 N⋅m (35 -- 53 in-lb).

ZDA3330A

70 5. Install indicator plate, 2, and tighten nut, 1, to a torque of 8 -- 12 N⋅m (71 -- 106 in-lb).

ZDA3329A

71 6. Apply a continuous bead of Loctite 515/573 sealant around the mating surface and around the bolt holes. Spread evenly, with no gaps and then wipe off any excess from the edges.

ZDA3351A

21-39

SECTION 21 -- TRANSMISSION -- CHAPTER 1 7. Install shifting drive gear housing, 3. Apply Loctite 242/243 thread-locker to the four M6 distant screws, 1, and M6 x 30 mm cap screw with lock washer, 2. Install, tighten, and torque the five M6 housing bolts to 10 -- 11 N⋅m (89 -- 97 in-lb).

ZDA3346A

73 8. Ensure the inside of the drive gear is cleaned of any dirt and dust residue. Ensure the protective cap, 3 [see Shifting Disc/Drive Gear (Exploded View) item 26], is installed at the bottom of the drive gear. If cap requires replacement installation, apply Loctite 609 retaining compound and install into clean drive gear.

Apply NH AMBRA GR9 multi-purpose grease to a new O-ring, 1. Install the new O-ring on the shift drive gear, 2.

ZDA3348A

2 74

9. Insert the shifting drive gear, 3, from the inside of the gearbox through the drive gear housing, 2. Install the friction washer, 4. Install retaining ring, 1.

ZDA3347A

21-40

SECTION 21 -- TRANSMISSION -- CHAPTER 1 10. Install electric motor, 2. Install four M6 x 10 mm bolts with lock washers, 1. Torque the M6 x 10 mm bolts to 10 -- 11 N⋅m (89 -- 97 in-lb). NOTE: If necessary to change gears manually while assembling the input shaft, the drive shaft and the differential into the gearbox, wait for installing the electric motor until the end. ZDA3345A

76 Input Shaft

WARNING Lift and handle all heavy components using lifting equipment of appropriate lifting capacity. Ensure that units or parts are supported by suitable slings or hooks. Ensure that no-one is in the vicinity of the load to be lifted. Failure to comply could result in serious injury or death. 11. To install the input shaft in the transmission, first install shim pack, 2, of 1.5 mm (0.06 in), and then proceed as follows: Apply NH AMBRA GR9 multi-purpose grease to O-ring, 3. 12. Install O-ring, 3, on cover, 1.

ZDA3414A

77 13. Install bearing cup, 1.

ZDA3344A

21-41

SECTION 21 -- TRANSMISSION -- CHAPTER 1 14. Install cover, 2, with shim pack and O-ring. 15. Install and tighten the five sets of M10 nuts, 1, and lock washers. Torque the five M10 nuts to 46 -- 53 N⋅m (34 -- 38 ft-lb). Support the input shaft on a hoist with sling and move it into the transmission.

ZDA3329A

CAUTION Use insulated gloves or mittens when working with hot parts. Failure to comply may result in minor or moderate injury. 16. Heat bearing, 1, to 80 °C (176 °F) and install it on the input shaft.

ZDA3415A

80 17. Install bearing cup, 1.

ZDA3433A

21-42

SECTION 21 -- TRANSMISSION -- CHAPTER 1 18. If necessary, replace seal, 1, and O-ring, 2, on seal housing, 3.

Apply NH AMBRA GR9 multi-purpose grease to the seal and O-ring prior to install.

2 56060010

82 19. Install seal housing, 1. Apply Loctite 242/243 to the three M10 x 30 Allen screws, 1, and tighten. Torque Allen screws to 50 -- 60 N⋅m (37 -- 44 ft-lb).

ZDA3339A

83 20. Install a dial gauge, 2, in the gearbox housing and locate the probe perpendicular against the side of gear, 1. 21. Apply a load in one direction and oscillate the shaft several times while the load is applied. 22. Set the dial gauge to zero. 23. Apply the load in the opposite direction, oscillate and read the axial movement of the shaft. 24. Make three measurements at 120° of the input shaft. The average of the readings should be 0.1 -- 0.2 mm (0.004 -- 0.008 in). 25. If required, adjust the shims. To decrease the axial movement, decrease the quantity of shims. IMPORTANT: Be sure to measure on gear, 1, as the other gears are mounted on needle bearings.

21-43

ZDA3436A

SECTION 21 -- TRANSMISSION -- CHAPTER 1 26. Install selector fork, 1.

85 27. Install the oil baffle plate, 1, as shown. Insert the M12 threaded rod with sealing washer, 1 (Figure 87), and ensure it passes through the baffle. Position the baffle so it does not interfere with the input shaft, and then secure it by installing two M8 x 16 cap screws with lock washers, 2 (Figure 86). Rotate the input shaft to insure no contact with the baffle. Torque the M8 x 16 cap screws to 23 -- 26 N⋅m (17 -- 19 ft-lb). 86

IMPORTANT: After tightening of the nuts, rotate the input shaft and verify that the oil baffle does not interfere with the input shaft. 28. Torque the threaded rod, 1, to 50 -- 60 N⋅m (37 -44 ft-lb).

21-44

SECTION 21 -- TRANSMISSION -- CHAPTER 1 Drive Shaft

ZDA3335A

88 30. If necessary, replace the seal, 2. Apply NH AMBRA GR9 multi-purpose grease to the seal, and then install O-ring, 5, on cover, 1. Install bearing cup, 3. Install shim pack, 4, of 1.5 mm (0.06 in). Apply NH AMBRA GR9 multi-purpose grease to the O-ring, and then install O-ring, 5, on cover, 1. NOTE: Ensure the shim pack is installed before the O-ring.

89 31. Support the drive shaft, 1, on a hoist and bring it into the transmission.

NOTE: If the shifting disc, 3, is installed, the selector fork, 2, should be installed together with the drive shaft.

ZDA3334A

21-45

SECTION 21 -- TRANSMISSION -- CHAPTER 1 32. Install the cover, 2, with shims, seals and bearing cup, and then install and tighten the M12 nuts, 1, with lock washers.

33. Torque the M12 nuts to 80 --90 N⋅m (59 -- 66 ft-lb).

56060011

91 34. Install a dial gauge, 1, on the gearbox housing and locate the probe perpendicular against the side of gear, 2. 35. Apply a load in one direction and oscillate the shaft several times while the load is applied. 36. Set the dial gauge to zero. 37. Apply the load in the opposite direction, oscillate and read the axial movement of the shaft. 38. Make three measurements at 120° of the intermediate shaft. The average of the three readings should be 0.15 -- 0.25 mm (0.006 -- 0.01 in).

39. If required, adjust the shims. To decrease the axial movement, decrease the quantity of shims. IMPORTANT: Be sure to measure on gear, 2, as the other gears are mounted on needle bearings. Selector Shaft 40. Install new selector shaft O-rings into both sides of the gearbox housing, where the selector shaft, 1, is installed, if removed for replacement. Apply NH AMBRA GR9 multi-purpose grease to new or existing O-rings.

Install selector shaft, 1, from the right-hand side of the transmission into the transmission housing, 2. Guide the selector forks, 3, onto the shaft. Ensure fork guide blocks are installed on selector forks. 56060014

21-46

SECTION 21 -- TRANSMISSION -- CHAPTER 1 41. Install retaining ring, 2.

ZDA3327

94 42. Install retaining ring, 1.

56060015

21-47

SECTION 21 -- TRANSMISSION -- CHAPTER 1 Differential and Shafts

WARNING Lift and handle all heavy components using lifting equipment of appropriate lifting capacity. Ensure that units or parts are supported by suitable slings or hooks. Ensure that no-one is in the vicinity of the load to be lifted. Failure to comply could result in serious injury or death. 43. Install oil baffle plate, 1, with cap screws and lock washers. 44. Torque the M8 x 16 mm cap screws to 24 -- 26 N⋅m (17 -- 19 ft-lb).

ZDA3443A

96 45. Support the differential, 1, on a hoist and bring it into the gearbox.

56060016

97 46. On differential shaft housings, replace O-rings, 1. Apply NH AMBRA GR9 multi-purpose grease to the O-rings prior to installation.

ZDA3273A

21-48

SECTION 21 -- TRANSMISSION -- CHAPTER 1 47. Install a new bearing, 1, on each differential shaft, 2.

ZDA3271A

99 48. If transmission has differential lock option, insert the left-hand differential shaft into the left bearing housing. Slide the differential lock, 1, and spring, 2, onto the differential shaft and into the housing, 3.

ZDA3441A

100 49. Install both differential housings, 1 and 2, with the M12 nuts with lock washers, 4. Tighten the nuts for each housing evenly in order to draw the housings straight into the transmission gearbox. Torque the M12 nuts to 80 -- 90 N⋅m (59 -- 66 ft-lb). Apply Loctite 242/243 thread-locker to the M16 x 50 hex socket screws, 3. Install the hex socket screws on the right-hand side differential housing, 1. Torque the M16 x 50 hex socket screws to 90 -100 N⋅m (66 -- 74 ft-lb). Install the M10 x 12 mm (maintenance hole protection) cap screws with lock washers into both housings. Torque the M10 cap screws to 46 -- 52 N⋅m (34 -38 ft-lb).

21-49

101

SECTION 21 -- TRANSMISSION -- CHAPTER 1 50. Install shafts, 1, with bearings, 2, into the bearing housings, 3. If transmission is equipped with an optional differential lock, ensure that the differential lock collar and spring are assembled onto the left-hand differential shaft, inside the transmission housing, before the shaft engages the differential as described above.

3 ZDA3264A

102 51. Install retaining ring, 1.

ZDA3262A

103 52. Apply NH AMBRA GR9 multi-purpose grease to new bearing seals, 1. Install new seals, 1, recessed into bearing housings. Remove hoist and sling.

ZDA3262A

104

21-50

SECTION 21 -- TRANSMISSION -- CHAPTER 1 Transmission Cover 53. Apply NH AMBRA GR9 multi-purpose grease to new O-ring, 1, to fork shaft, 4, and lock control shaft, 5. 54. Install new O-ring, 1, onto control shaft, 5.

4 5

55. Install fork, 3, and secure with retaining ring, 2.

ZDA3260A

105 56. Install differential lock control shaft, 2. Install retaining ring, 1.

ZDA3259A

106 57. Install differential lock control lever, 2. Secure control lever with retaining pin, 1, as shown. NOTE: Control lever can be installed in two positions. The correct position is shown.

ZDA3258A

107

21-51

SECTION 21 -- TRANSMISSION -- CHAPTER 1 58. Install cover, 2. If equipped with differential lock control, ensure that the differential lock control fork is correctly positioned. Install M10 x 30 cover bolts, 1. Tighten and torque the cover bolts evenly, in a cross pattern, to 45 -- 55 N⋅m (33 -- 41 ft-lb).

ZDA3262A

Installation

108

WARNING Lift and handle all heavy components using lifting equipment of appropriate lifting capacity. Ensure that units or parts are supported by suitable slings or hooks. Ensure that no-one is in the vicinity of the load to be lifted. Failure to comply could result in serious injury or death. 1. Using a suitable jack, lift the transmission, 1, into its cradle in the machine. 2. Align the holes in the transmission housing with the holes of the transmission support brackets. Ensure alignment on left-hand side first.

Apply Loctite 242/243 thread-locker to the three M16 x 50 mm transmission mounting bolts, 1. Install the bolts on the left-hand side of the transmission. Hand tighten only at this time.

ZDA3255B

109

21-52

SECTION 21 -- TRANSMISSION -- CHAPTER 1 3. Align the right-hand transmission housing and support bracket bolt holes. Apply Loctite 242/243 thread-locker to the three M16 x 50 mm transmission mounting bolts, 2. Install the bolts on the right-hand side of the transmission. Tighten and torque all six M16 x 50 mm transmission mounting bolts to 235 -- 260 N⋅m (173 -- 192 ft-lb).

ZDA3256A

110 4. Connect the brake shoe wear wire, 1, on both sides of the transmission.

ZDA3255B

111 5. Connect the electrical connectors: Combine Speed Sensor, Gear Shift Sensor, and Gear Shift Motor.

ZDA3254A

112

21-53

SECTION 21 -- TRANSMISSION -- CHAPTER 1 6. If equipped with differential lock, connect the differential lock cable yoke end, 1, to the lock control lever, 2.

Connect the lock cable, 3, to the transmission cover mounting bracket, 4. NOTE: Adjustment to the differential lock cable is only necessary if; a new cable is installed, the cable is stretched resulting in no differential lock action or the lock self-disengages, or the shift yoke is worn.

1 3

2 66060017

113 7. Connect the brake lines, 1, on both sides of the transmission. Install the left and right-hand side caliper guards, 2, behind the brake shield, 3, using two M10 x 30 bolts and lock washers, 4, on each side. Tighten to standard torque.

4 3 ZDA2797C

114 8. Connect the hydraulic line, 1, for the parking brake.

ZDA3252A

115

21-54

SECTION 21 -- TRANSMISSION -- CHAPTER 1 9. Connect the half shaft drive axles, 1, to both sides of the transmission. See Section 25 -- Chapter 1 -- “Final Drive -- Half-Shaft -- Installation”.

ZDA3262A

116 10. Apply a coat of Molykote Type G-n Metal Assembly Paste to the hydrostatic motor splines, and then install the motor, 1, into the transmission, as follows: IMPORTANT: The hydrostatic motor spins at high speed and requires the above specified paste lubricant or equivalent applied to the splines for its high speed application, anti-sieze and anti-fretting properties. Do not substitute NH AMBRA GR75 MD GREASE or equivalent as this is for low speed applications. NOTE: The combine may be equipped with either a 100cc or 130cc size hydrostatic motor. The 100cc motor is shown in this figure. Each size motor is secured with different size hardware and with different torque specifications. The larger body 130cc motor is secured in the outer set of threaded holes, 3. 100cc motor Install the pilot spacer ring onto the motor. Insert the motor straight into the gearbox, and then install four M12 x 45 bolts with hardened flat washers, 2. Remove motor support. Tighten and torque hardware to 109 – 120 N⋅m (80 – 88 ft-lb). 130cc motor Insert the motor straight into the gearbox, and then install four M16 x 45 bolts with hardened flat washers, 2. Remove motor support. Tighten and torque hardware to 269 – 297 N⋅m (198 – 219 ft-lb).

21-55

86072861

2 117

SECTION 21 -- TRANSMISSION -- CHAPTER 1 11. Remove and clean the magnetic drain plug, 1. Install the drain plug. Torque drain plug to 90 -- 110 N⋅m (66 -- 81 ft-lb).

1 ZDA2797A

118 12. Remove the filler/breather plug, 2, from the transmission cover, 1. Fill the transmission with 19 L (5 U.S. gal) of NH AMBRA HYPOID 90 or oil with an SAE 80W90 EP API GL5 specification. Install the filler/breather plug, 2. Torque filler/breather plug to 90 -- 110 N⋅m (66 -81 ft-lb).

86070059

119 13. Install the two-piece hose routing clamp, 2. First, install the upper half with two M8 x 25 bolts, 1, and lock nuts.

With the hoses in place, interlock the lower half of the clamp and secure with two M8 x 40 bolts, 3, and locknuts.

Install the two lower fan shields, 4, as follows.

4 86072862

3 120

21-56

SECTION 21 -- TRANSMISSION -- CHAPTER 1 14. First, install the lower fan shield, 1, with five lock washers and M6 nuts, 2, and M8 x 20 carriage bolt, 3, with lock washer and nut.

20013155

121 15. Install the forward shield, 1, with two M8 x 20 cap screws with lock washers, 2, and two M8 x35 carriage bolts, 3, with clamp washer and locknut.

Bleed the service brakes. See Section 33 -Chapter 1 -- “Brakes and Controls; Bleeding the Brake System”.

Check all lines are secure and tight. Remove the blocks or wheel chocks from the unit. IMPORTANT: Be sure to check the fluid level of transmission fluid before operation, failure to do so could result in transmission failure.

20013154

122

DIFFERENTIAL Disassembly 1. Remove bearing, 1.

123

21-57

SECTION 21 -- TRANSMISSION -- CHAPTER 1 2. Turn over the differential and remove bearing, 1.

124 3. Unlock lock plates, 1, and remove eight M10 x 80 bolts, 2, and the lock plates.

125 4. Remove cover, 1, of the differential housing.

126

21-58

SECTION 21 -- TRANSMISSION -- CHAPTER 1 5. Remove differential output gears, 1 and 2. 6. Remove two planet gear shafts, 3, with the planet gears, 4.

4 ZDA3392A

127 Assembly 1. Replace thrust washers, bushings, gears and shafts as necessary. 2. Apply a coating of NH AMBRA GR75 MD Grease to all surfaces of the internal parts (bushings, thrust washers, differential output gears, planet gears, and thrust washers with the planet gear shafts). Assemble the lubricated internal components, 2, into the gear housing, 3. 3. Install differential housing cover, 1. NOTE: The two castings of the housing are machined together and are marked in this position. When reassembling, make sure that these marks are towards each other.

3 128

4. Install lock plates, 1, and eight M10 x 80 bolts, 2. Torque the M10 bolts to 46 -- 53 N⋅m (34 -- 38 ft-lb). 5. Secure bolts, 2, by bending the tabs of the lock plate to lock the head of the bolt.

129

21-59

SECTION 21 -- TRANSMISSION -- CHAPTER 1 6. Install bearing, 1.

130 7. Turn the differential over. Install bearing, 1.

131

DRIVE SHAFT Disassembly 1. Unlock lock washer, 2. 2. Remove nut, 1, using Tool No. 380001074, lock washer, 2, and washer, 3.

132

21-60

SECTION 21 -- TRANSMISSION -- CHAPTER 1 3. Remove gear, 2, and bearing, 1, together with a puller.

133 4. Remove needle bearings, 1.

134 5. Remove selector ring, 1, at the same time remove two balls, 2, and the springs behind them. NOTE: Balls, 2, are spring-loaded, do not lose them. 6. Remove retaining ring, 3, and the washer.

135

21-61

SECTION 21 -- TRANSMISSION -- CHAPTER 1 7. Remove housing, 1, and gear, 2.

136 8. Remove needle bearings, 1.

137 9. Remove and discard bearing cone, 1, on the opposite end. NOTE: Bearing cone, 1, will be damaged when it is removed. Replace bearing cup and cone with a new bearing set.

138

21-62

SECTION 21 -- TRANSMISSION -- CHAPTER 1 Assembly

CAUTION Use insulated gloves or mittens when working with hot parts. Failure to comply may result in minor or moderate injury. 1. Heat bearing, 1, to 80 °C (176 °F) and install it on the drive shaft.

139 2. Install needle bearings, 1. 3. Install gear, 2. 4. Install selector housing, 3. 5. Install washer, 4.

140 6. Install retaining ring, 3. 7. Install two springs. 8. Install two balls, 2, on the springs and at the same time install selector ring, 1. NOTE: Be careful not to lose the balls.

141

21-63

SECTION 21 -- TRANSMISSION -- CHAPTER 1 9. Install needle bearings, 1.

142 10. Install gear, 2.

CAUTION Use insulated gloves or mittens when working with hot parts. Failure to comply may result in minor or moderate injury. 11. Install washer, 3, and heat bearing, 4, to 80 °C (176 °F) and install it on the drive shaft.

143 12. Install washer, 3. 13. Install lock washer, 2. 14. Install nut, 1, using Tool No. 380001074, and tighten it to a torque of 150 -- 170 N⋅m (111 -- 125 ft-lb). 15. Secure nut, 1, by bending a lip of the lock washer in one of the notches of the nut.

144

21-64

SECTION 21 -- TRANSMISSION -- CHAPTER 1 INPUT SHAFT Disassembly 1. Unlock lock washer, 2. 2. Remove nut, 1, using Tool No. 380001074, lock washer, 2, and washer, 3, securing the bearing cone, 4.

145 3. Remove gear, 2, bearing, 1, and the washer between the two parts with a puller.

146 4. Remove needle bearings, 1. 5. Remove selector ring, 2, at the same time remove two balls, 3, and the springs behind it. NOTE: Balls, 3, are spring-loaded, do not lose them.

147

21-65

SECTION 21 -- TRANSMISSION -- CHAPTER 1 6. Remove retaining ring, 1. 7. Remove washer, 2, and selector housing, 3, at the same time. 8. Remove gear, 4.

148 9. Remove needle bearings, 1.

149 Assembly 1. Install needle bearings, 1. 2. Install gear, 2 3. Install selector housing, 3. 4. Install washer, 4.

150

21-66

SECTION 21 -- TRANSMISSION -- CHAPTER 1 5. Install retaining ring, 1.

151 6. Install the two springs and two balls, 3, and at the same time install selector ring, 2. NOTE: Be careful not to lose the balls. 7. Install needle bearings, 1.

152 8. Install gear, 1. 9. Install washer, 2.

153

21-67

SECTION 21 -- TRANSMISSION -- CHAPTER 1 CAUTION Use insulated gloves or mittens when working with hot parts. Failure to comply may result in minor or moderate injury. 10. Heat bearing, 4, to 80 °C (176 °F) and install it on the input shaft. 11. Install washer, 3 12. Install lock washer, 2. 13. Install nut, 1, using Tool No. 380001074, and tighten to a torque of 150 -- 170 N⋅m (111 -- 125 ft-lb). 14. Secure nut, 1, by bending a lip of the lock washer in one of the notches of the nut.

21-68

154

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1

SECTION 25 - FRONT MECHANICAL DRIVE Chapter 1 - Planetary Final Drive CONTENTS Section

Description

Page

25-1

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 GENERAL SPECIFICATION -- FINAL DRIVE SPECIFICATIONS Gear ratio

1/13.09

Maximum Input rpm 30 km/h (18.6 mph)

1300 rpm

Maximum Output rpm 30 km/h (18.6 mph)

100 rpm

Nominal input torque

1500 N⋅m (1140 ft-lb)

Nominal output torque

20500 N⋅m (15120 ft-lb)

Output shaft pre-load

0.35 mm (0.014 in)

Input shaft axial end play

0.01 -- 0.006 mm (0.0004 -- 0.0025 in)

Approximate total weight

340 kg (750 lb)

Oil capacity

6.70 L (1.77 US gal)

FINAL DRIVE -- TORQUE Torque List Bolts, Output (Wheel) Shaft

45 -- 55 N⋅m (34 -- 40 ft-lb)

Bolts, Input Shaft Cover

45 -- 55 N⋅m (34 -- 40 ft-lb)

Bolts, Gearbox Housing

305 -- 335 N⋅m (225 -- 247 ft-lb)

Threaded Studs, Housing Separator

15 -- 25 N⋅m (133 -- 221 in-lb)

Ring Nut, Output Shaft (Inner)

1300 N⋅m (959 ft-lb)

Ring Nut, Output Shaft (Outer)

300 N⋅m (221 ft-lb)

Bolts, Final Drive to Axle Mounting

635 -- 705 N⋅m (469 -- 520 ft-lb)

Plug, Oil Level Gauge (Always located at the lower 8 o’clock position of the inner housing)

8 -- 12 N⋅m (71 -- 106 in-lb)

Plug, Replacement (Always located at the upper 10 o’clock position of the inner housing)

5 -- 15 N⋅m (45 -- 132 in-lb)

Plug, Oil Magnetic Drain

60 -- 80 N⋅m (45 -- 59 ft-lb)

Plug, Oil Fill

60 -- 80 N⋅m (45 -- 59 ft-lb)

Plug, Oil Breather

15 -- 25 N⋅m (133 -- 221 in-lb)

Plug, (Wheel Stud) Maintenance

100 -- 120 N⋅m (74 -- 89 ft-lb)

Nuts, Wheel Mounting

710 -- 790 N⋅m (525 -- 580 ft-lb)

25-2

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 FINAL DRIVE -- SPECIAL TOOLS NOTE: SPECIAL TOOL NOT SHOWN. 380002654 -- Final Drive Bearing Ring Nut Spanner For removal and installation of the outer ring nut on the output shaft.

56072880

1 380002596 -- Final Drive Bearing Ring Nut Spanner For removal and installation of the inner ring nut on the output shaft.

ZEIL06SPT001A0A

25-3

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 FINAL DRIVE -- SECTIONAL VIEW

OVERVIEW

17 18 19

3 4 5 6

20 7

8 9 10 11 23 12

ZEIL05CX0516H0B

3 Planetary Final Drive -- Primary Components 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Input Shaft Cover, Input Shaft Reducer Spur Gear Sun Gear Cover, Drive Shaft Lock Plate, Two Bolt Mounting Lock Plate Locknut, (Outer) Bearing Ring Bearing, Tapered Roller Lock Plate Locknut, (Inner) Bearing Ring Bearing, Tapered Roller

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

25-4

Bearing, Tapered Roller O-ring, Ring Gear Ring Gear O-ring, Outer Housing Planet Gear Outer Housing Output (Wheel) Shaft Spacers, Distance Ring Bearing, Tapered Roller Mud Seals Planet Gear Carrier

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 FINAL DRIVE -- EXPLODED VIEW 1

4 12 11 13

18 19

22 23

25 26 27

ZEIL05CX0517H0B

31 4

Planetary Final Drive -- Assembly Bolt, M10 x 30 mm Cover, Input Shaft Shim Pack Input Shaft Cover, Drive Shaft Bolt, M16 x 45 mm (and lock washer) 7. Lock Plate, Two Bolt 8. Lock Plate, Mounting 9. Locknut, (Outer) Bearing Ring 10. Bearing, Tapered Roller 11. Threaded Stud (to separate housing) 1. 2. 3. 4. 5. 6.

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Inner Housing Dowel Pin Retaining Ring Lock Plate Locknut, (Inner) Bearing Ring Bearing, Tapered Roller Reducer Spur Gear Spacers, Distant Ring Bearing, Tapered Roller Retaining Ring Sun Gear

25-5

Retaining Ring Planet Gear Carrier (assembled) O-ring, Ring Gear Ring Gear O-ring, Outer Housing Outer Housing Bolt, M16 x 90 mm (and lock washer) 30. Bearing, Tapered Roller 31. Seal 32. Output Shaft 23. 24. 25. 26. 27. 28. 29.

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 FINAL DRIVE INPUT SHAFT -- EXPLODED VIEW 2 5

6 4

1 3

ZDA4350A

5 Input Shaft 1. 2. 3.

Input Shaft Housing Bearing

4. 5. 6.

Bearing Seal O-ring

FINAL DRIVE INPUT SHAFT -- OVERVIEW 3

1 2

zda4664a

6 Input Shaft 1. 2.

Bolt Cover with Seals

3. 4.

25-6

Shim Pack Input Shaft with Bearings

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 FINAL DRIVE REDUCER, SATELLITE AND PLANETARY -- EXPLODED VIEW 1. 2. 3. 4. 5. 6.

Planet Gear Carrier Retaining Ring Shaft Spacer Planet Gear Needle Roller

ZDA4033A

7 Planetary Carrier and Gears

25-7

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 REMOVAL CR Planetary Final Drive To remove a planetary final drive, proceed as follows:

WARNING Unexpected machine motion or moving parts can cut and crush. Apply parking brake and shut down the engine before working on the machine. Put the machine on blocks only if the surface is solid, even, and level. Make sure that any blocks used to support the machine are solid, one-piece units. Put blocks next to the tires that are not being raised to prevent movement of the machine. Failure to comply could result in serious injury or death.

WARNING A final drive is heavy. Take extreme caution when removing the final drive! Use a supporting device which can handle this weight! Failure to comply could result in serious injury or death. 1. Remove the drive tire from the combine. 2. Remove half-shaft, 1. See “Half-shaft -Removal.” It is only necessary to remove the one coupler from the final drive input shaft. Support the final drive with a hoist. NOTE: If the planetary final drive needs to be disassembled, drain the oil before the final drive is removed from the combine. (Refer to the Operator’s Manual, Section 4 -- “Lubrication and Maintenance.”) 20036405

1 8

3. Loosen the bolts, 1, from the flange and remove the final drive.

The final drive is piloted onto the axle by two dowel pins. When all the bolts are removed, pry the final drive away from the axle flange.

20036406

25-8

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 DISASSEMBLY 1. Drain the oil from the planetary final drive. (Refer to the Operator’s Manual, Section 4 -- “Lubrication and Maintenance.”) 2. Remove four M10 x 30 cap screws, 1, and lock washers. Remove cover, 2. NOTE: The seal in the cover will be damaged when it is removed.

66060018

10 3. Keep shim pack, 3, together with the cover, 2. Remove the input shaft, 4. NOTE: The bearings on the input shaft will be damaged when they are removed. NOTE: Refer to “FINAL DRIVE INPUT SHAFT -Disassembly” in this chapter for further disassembly of the input shaft.

ZDA4664A

11 4. Remove the output shaft cover, 1. Pry around the circumference of the cover to break the sealant bead (Loctite 638).

ZDA4665A

25-9

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 5. Unlock the bolt lock plate, 2, and remove the bolts, 1, and lock plate. Remove the mounting lock plate, 3.

ZEIL05CX0518A0B

CAUTION Use insulated gloves or mittens when working with hot parts. Failure to comply may result in minor or moderate injury. 6. Using special tool (380002654) remove the bearing ring locknut, 1, and torque multiplier, if available. NOTE: The locknut, 1, was assembled with Loctite 273, and torque exceeds 300 N⋅m (221 ft-lb). In addition, the assembly must be secured to prevent rotation; a suggested method is to install the lug nuts to prevent thread damage, and then insert a steel bar between the studs and chain or block the ends of the bar to prevent rotation as the ring nut is loosened. To facilitate nut removal, heat the nut to 170 -- 200 °C (338 -- 392 °F) until the Loctite breaks apart.

ZEIL05CX0519A0B

7. Place the final drive as shown and remove bolts, 1, and lock washers.

ZDA4639A

25-10

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 8. Identify three housing separator (hex socket) studs, 1.

Open the final drive by simultaneously tightening the hex socket threaded studs, 1, into the inner housing.

1 66060018

16 9. Lift the inner housing cover, 1, from the outer cover, 2. Remove the bearing cone from the removed inner housing section. Clean all sealant from the outer edges of both the inner and outer housing, Remove the housing separator studs. IMPORTANT: Steady the housing as lifted to prevent damage to the output shaft bearing.

2 ZDA4638A

CAUTION Use insulated gloves or mittens when working with hot parts. Failure to comply may result in minor or moderate injury. 10. Remove the retaining ring, 1, and the lock plate, 2. Remove the bearing ring locknut, 3, using special tool 380002596 and torque multiplier, if available. NOTE: The locknut, 1, was assembled with Loctite, 273, and then torqued to 1300 N⋅m (959 ft-lb). In addition, the assembly must be secured to prevent rotation; a suggested method is to install the lug nuts to prevent thread damage, and then insert a steel bar between the studs and chain or block the ends of the bar to prevent rotation as the ring nut is loosened. To facilitate nut removal, heat the nut to 170 -- 200 °C (338 -- 392 °F) until the Loctite breaks apart.

25-11

ZEIL05CX0520A0B

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 11. Remove the assembled reducer spur gear, 1, and the sun gear. NOTE: The sun gear is assembled to the reducer spur gear, and will be removed together with the reducer spur gear. Also, the reducer spur gear tapered roller bearings will be removed at the same time.

ZEIL05CX0521A0B

19 12. Check for free movement of the sun gear, 3, in the reducer spur gear, 1. If the sun gear moves freely, it is advised to not disassemble the two gears and to continue with step 14.

If determined as necessary to clean and service, proceed to step 13 to disassemble the sun gear from the reducer spur gear.

ZEIL05CX0524A0B

20 13. Remove the retaining ring, 2, to remove the sun gear, 3, from the reducer spur gear, 1. Push the retaining ring, 2, to the bottom of the groove (B) by inserting a small screw driver through the hole (A). Insert a weld wire at (W) with a diameter of 1 -- 1.5 mm (0.04 -- 0.06 in) above the retaining ring in the foot of the teeth of the sun gear, 3. Repeat this for every hole (A) in the reducer spur gear; there are eleven holes. Pull the sun gear, 2, out. Clean and service to obtain free movement when assembled.

25-12

ZEIL05CX0533A0B

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 14. Remove the distance rings, 1, and the bearing cone, 2.

ZEIL05CX0525A0B

22 15. Remove O-ring, 1, from ring gear, 2.

ZDA4362A

23 16. Install three M16 bolts, 3, into the threaded jack holes located around the face of the ring gear, 2.

Turn the bolts equally to raise the ring gear off of the planet gear carrier, 4. Remove the ring gear. Remove the two dowel pins, 1, from the inner or outer housing, as required. Remove the second ring gear O-ring from the outer housing cover.

ZDA4361A

25-13

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 17. Remove the retaining ring, 1, from the output shaft.

ZEIL05CX0522A0B

25 18. Remove planet gear carrier, 1, with planet gears. NOTE: Refer to “FINAL DRIVE REDUCER, SATELLITE AND PLANETARY -- Disassembly” in this chapter for further disassembly of the planet gear carrier.

ZEIL05CX0523A0B

26 19. Remove outer housing, 1, from output shaft, 2. Service the output shaft as described in Final Drive Output Shaft -- Disassembly. NOTE: The bearing on the output shaft will be damaged when it is removed. It is advised to use a lathe to remove the damaged bearing. Refer to “FINAL DRIVE OUTPUT SHAFT -- Disassembly” in this chapter for further disassembly of the output shaft. IMPORTANT: Ensure no damage occurs to the output shaft. NOTE: The seal in the planetary final drive housing will be damaged when it is removed, except for mud seals.

25-14

zda4357a ZDA4357A

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 ASSEMBLY NOTE: Prior to assembly of the Final Drive, the following operations must be performed: ----

Final Drive Input Shaft -- Assembly Final Drive Output Shaft -- Assembly Final Drive Reducer, Satellite and Planetary -Assembly

1 2

1. Before assembly of the final drive, perform the shimming of the reducer spur gear/sun gear assembly on the output shaft as follows: Install the bearing cups, 7, and, 2, in the reducer spur gear, 5. Install the sun gear, 4, in the reducer spur gear, 5, with the retaining ring, 3. Obtain from service parts two complete sets of the five available size distance rings. Available sizes are 4.60, 4.65, 4.75, 4.85, 4.90 mm (0.181, 0.183, 0.187, 0.191, 0.193 in). Select the two distance rings with a maximum thickness each of 4.90 mm (0.193 in). Combine the two distance rings, 6, and measure the effective height (X) of the two rings (18). Support the output shaft, 8, so the center line is vertical. On the output shaft, 8, install the bearing cone, 7, the reducer spur gear, the two distance rings, 6, the bearing, 2, and the bearing ring locknut, 1. Torque the locknut, 1, to 1300 N⋅m (959 ft-lb) using special tool 380002596. Put a ball (A) with diameter 8 mm (0.32 in) in the cleaned center hole of the output shaft, 8. Place a dial indicator (B) with its magnetic base on the reducer spur gear, 5, and its measuring needle, which is halfway its stroke, on the ball (A). Free rotate the reducer spur gear, 5, five rotations around the output shaft, 8. Reset the indicator of the dial indicator to zero.

25-15

3 4

8 ZEIL05CX0526B0B

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 2. Now support the reducer spur gear, 1, perfectly horizontal using a tripod without touching the dial indicator. Free rotate the output shaft, 2, five times around the reducer spur gear, 1. Now read the maximum axial play (Y) of the bearings on the dial indicator (A). Support the output shaft, 2, so the center line is vertical and remove the reducer spur gear/sun gear assembly from the output shaft.

ZEIL05CX0527B0B

29 3. Using the table below, combine two distance rings to obtain a measured height Z = (X -- Y) -0.075 mm (Z = (X -- Y) -- 0.003 in). Measure the selected pack. This may not deviate more than +/--0.25 mm (0.001 in) of (Z). NOTE: From the two sets of five distance rings, only two rings effectively get installed. Distance Ring Combinations Table Distance Ring Sizes

4.60 mm (0.181 in)

4.65 mm (0.183 in)

4.75 mm (0.187 in)

4.85 mm (0.191 in)

4.90 mm (0.193 in)

4.60 mm (0.181 in)

9.20 mm (0.362 in)

9.25 mm (0.364 in)

9.35 mm (0.368 in)

9.45 mm (0.372 in)

9.50 mm (0.374 in)

4.65 mm (0.183 in)

9.25 mm (0.364 in)

9.30 mm (0.366 in)

9.40 mm (0.370 in)

9.50 mm (0.374 in)

9.55 mm (0.376 in)

4.75 mm (0.187 in)

9.35 mm (0.368 in)

9.40 mm (0.370 in)

9.50 mm (0.374 in)

9.60 mm (0.378 in)

9.65 mm (0.380 in)

4.85 mm (0.191 in)

9.45 mm (0.372 in)

9.50 mm (0.374 in)

9.60 mm (0.378 in)

9.70 mm (0.382 in)

9.75 mm (0.384 in)

4.90 mm (0.193 in)

9.50 mm (0.374 in)

9.55 mm (0.376 in)

9.65 mm (0.380 in)

9.75 mm (0.384 in)

9.80 mm (0.386 in)

25-16

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 4. Install the bearing cup, 2, in the outer housing, 1. Ensure the bearing cup is fully seated in the outer housing. Install the seal, 3, in the outer housing, 1, and apply a light coat of NH AMBRA GR9 MULTI-PURPOSE GREASE between the oil lip and the dust lip of the seal. NOTE: If equipped with mud seals, proceed with steps 5 and 6. Otherwise proceed with step 7. ZDA4636A

30 IMPORTANT: Before installing the mud seal, degrease, clean, and ensure both the seal and housing containment ring are free of dirt and old oil residue. 5. If equipped with a pair of mud seals, install one mud seal, 1, with the metal face outward as shown in Figure 32.

1 ZDA4637A

31 6. Measure distance X mm (X in) in at least four places 90° apart.

The difference in height around the ring must not be more than 1 mm (0.04 in). X mm (X in) = the distance from mud seal surface to the top of the containment ring on the housing. Apply a light coat of new NH AMBRA HYPOIDE 90 gear oil to the metal face, 1, of the seal prior to assembly with the output shaft. ZDA4162B

25-17

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 7. If not equipped with mud seals, apply NH AMBRA HYPOIDE 90 to the standard seal and to the output shaft where the seal makes contact. If equipped with mud seals, apply a thin coat of NH AMBRA HYPOIDE 90 to the entire seal face of both seals. Oil must not contact surfaces other than the sealing faces. Install final drive outer housing, 1, on pre-assembled output shaft, 2.

ZDA4357A

33 8. Install the pre-assembled planet gear carrier, 1.

ZEIL05CX0523A0B

34 9. Install the retaining ring, 1, on the output shaft. NOTE: Tap radially on the retaining ring to be sure it seats well in the groove.

ZEIL05CX0522A0B

25-18

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 10. Apply a light coat of NH AMBRA GR9 MULTI-PURPOSE GREASE on O-ring, 1, and install O-ring, 1, in outer final drive housing, 2.

1 2 ZDA4360A

36 11. Insert two dowel pins, 1, in the ring gear, 2, and install the ring gear, 3, with the seal groove at the upper side on the gearbox housing.

3 ZEIL05CX0530A0B

37 12. Apply a light coat of NH AMBRA GR9 MULTI-PURPOSE GREASE on O-ring, 1, and install O-ring, 1, in ring gear, 2.

ZDA4362A

25-19

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 13. Install the bearing cone, 2, and the two distance rings, 1, with an overall thickness Z mm (Z in). NOTE: The value of Z mm (Z in) is determined in the first three steps of this assembly instruction. Reference Assembly instruction steps 1, 2, and 3.

ZEIL05CX0525A0B

39 14. Install the sun gear assembly, 1.

ZEIL05CX0521A0B

40 15. Install the bearing cone, 1.

ZEIL05CX0531A0B

25-20

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 16. Apply Loctite 273 to the thread of the lock nut, 1, and the corresponding thread on the output shaft, 2, as shown, five spots (A) on the thread of the nut and five spots (B) on the output shaft.

NOTE: Apply enough thread locking compound so that all clearance is filled up when installing the nut.

NOTE: Act rapidly after applying the thread locking component (Loctite 273), as the thread locking component hardens rapidly. ZEIL05CX0528A0B

A 42

17. Install the locknut, 3. Secure the hub to prevent rotation when applying torque. Using special tool 380002596, tighten and torque multiplier, if available, torque the nut to 1300 N⋅m (959 ft-lb). Install the lock plate, 2, so that there are always two lips lying in the cams of the nut, 3, without rotating the nut. Install the retaining ring, 1. NOTE: The lock plate, 2, has five installation positions on each side, a total of ten positions, and is designed in such a way that two lips can always be aligned into the cams of the nut, 2, no matter the position of the nut. 18. Install bearing cup, 2, into inner final drive housing, 1.

ZEIL05CX0520A0B

Ensure bearing cup is fully seated in the housing.

ZDA4352A

25-21

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 19. Install inner final drive housing, 1, onto ring gear, 2.

IMPORTANT: Steady the inner housing when lowering it over the output shaft as to not damage the shaft or bearing.

2 ZDA4638A

45 20. Apply Loctite 242/243 to bolts, 1. Install the twelve bolts, 1, with lock washers. Torque to 305 -- 335 N⋅m (225 -- 247 ft-lb).

ZDA4639A

46 21. Install the bearing cone, 1.

ZEIL05CX0532A0B

25-22

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 22. Install the locknut, 1. Secure the assembly to prevent rotation when applying torque. Use special tool (380002654) to tighten and torque the locknut to 300 N⋅m (221 ft-lb). Rotate the final drive housing one turn on the output shaft. Remove the locknut, 1.

ZEIL05CX0519A0B

48 23. Apply Loctite 273 to the thread of the lock nut, 1, and the corresponding thread on the output shaft, 2, as shown, five spots (A) on the thread of the nut and five spots (B) on the thread of the output shaft.

NOTE: Apply enough thread locking compound so that all clearance is filled up when installing the nut. NOTE: Act rapidly after applying the thread locking component (Loctite 273), as the thread locking component hardens rapidly.

A 66060027

49 24. Install the locknut, 1. Secure the assembly to prevent rotation when applying torque. Use special tool (380002654) to tighten and torque the locknut to 20 N⋅m (15 ft-lb or 177 in-lb). Rotate the final drive housing one turn. Repeat the torque and one turn procedures until the locknut, 1, does not rotate anymore at 20 N⋅m (15 ft-lb or 177 in-lb). Additionally tighten the locknut, 1, by turning it another 73 -- 77° (less than 90° quarter of a turn) on the shaft. ZEIL05CX0519A0B

IMPORTANT: Ensure the twelve housing bolts are tightened to the specified torque before performing the bearing preload adjustment.

25-23

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 25. Install the lock plate, 3, without rotating the installed locknut, in such a way that four lips can be bent into the cams of the nut. Install the lock plate, 2, and the bolts, 1. Tighten and torque the bolts to 45 -- 55 N⋅m (34 -- 40 ft-lb). Bend two lips per bolt after assembly. NOTE: The lock plate, 3, has five installation positions on each side, a total of ten positions, and is designed in such a way that four lips can always be bent into the cams of the locknut no matter the position of the nut.

ZEIL05CX0518A0B

NOTE: Install the bolt lock plate, 3, with its bend to the middle as shown, otherwise interference with the output shaft cover can occur. 26. Apply a continuous bead of Loctite 638 sealant to the inner rim/lip of the drive shaft cover, 1. Install the output shaft cover, 1, into the inner housing cover.

ZDA4665A

52 27. Ensure a new input inner bearing cup has been installed in the housing, and then install the input shaft, 4, into the housing. Assemble the shim pack, 3, with the cover, 2, and carefully install the cover over the splines of the input shaft to prevent seal damage. Install the four M10 x 30 cover bolts with lock washers, 1. Tighten and torque the cap screws to 45 -- 55 N⋅m (34 -- 40 ft-lb). Check bearing axial end play to measure between +0.01 -- +0.06. Adjust with shims as needed.

25-24

ZDA4664A

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 28. Apply Loctite 242/243 to the three threaded hex socket studs, 1.

Install the studs. Torque to 15 -- 25 N⋅m (133 -- 221 in-lb).

1 66060018

54 29. Apply a continuous bead of Loctite 5065 sealing paste, S, around and between the inner housing, 1, and the outer housing, 2, circumference.

ZEIL05CX0535A0B

25-25

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 INSTALLATION 1. Insert two dowel pins, 6, in the planetary final drive housing, 3. Install the planetary final onto the traction axle of the combine. Apply Loctite 242/243 on bolts, 7, to prevent them from loosening. Tighten bolts, 7, to a torque of 635 -- 705 N⋅m (469 -- 520 ft-lb). Ensure the magnetic plug, 5, is cleaned, installed, and torqued to 60 -- 80 N⋅m (45 -- 69 ft-lb).

8 1

2 3

66060021

Remove the fill plug, 8. Fill the planetary final drive with 6.7 L (1.77 US gal) of NH AMBRA HYPOIDE 90. Install the fill plug, 8. Torque to 60 -- 80 N⋅m (45 -- 59 ft-lb). If the breather plug, 2, was loosened, tighten and torque to 15 -- 25 N⋅m (11 -- 18 ft-lb). Ensure oil level is in the middle of the oil level gauge plug, 4. Drain or add as required. Install the drive wheel and tighten wheel nuts, 1, to a torque of 710 -- 790 N⋅m (525 -- 580 ft-lb). IMPORTANT: The final wheel nut torque specification, indicated above, must be obtained by following the proper tightening and progressive torque sequence procedure. The sequence is dependent on the drive wheel configuration. Reference the Operator’s Manual, Section 4 -- “Lubrication and Maintenance -- Drive Wheel Mounting.”

FINAL DRIVE INPUT SHAFT 1

Disassembly

1. Remove the input shaft, 1. Pry the input shaft inner bearing cup, 1, from the housing, 2, and discard. NOTE: The inner bearing cup has minimal space behind it for prying tools; if the cup is seated tightly, a suggested method for removal is to shrink the bearing cup by running a continuous 360° weld bead on the inner race surface. After cooling, the cup should remove easily.

66072921

3 57

25-26

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 2. Pull the bearing cone, 2, off of the input shaft, 1.

ZDA4347A

58 3. On the opposite end of the input shaft, 1, remove the bearing cone, 2.

ZDA4348A

59 4. Remove the O-ring, 4, bearing cup, 2, and sealing washer, 3, from the input shaft cover, 1.

1 3

2 66072920

25-27

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 Assembly

1. Heat the new bearing cone, 2, to 80 °C (176 °F) and install on input shaft, 1.

CAUTION

Use insulated gloves or mittens when working with hot parts. Failure to comply may result in minor or moderate injury.

ZDA4347A

61 2. Heat the new bearing cone, 2, to 80 °C (176 °F) and install on input shaft, 1.

ZDA4348A

62 3. Apply NH AMBRA GR9 MULTI-PURPOSE GREASE to O-ring, 1, and new oil seal, filling lips and cavity between the lips.

1 3

Install O-ring, 4, on input shaft bearing cover, 1. Install a new seal, 3, in bearing cover, 1. Install bearing cup, 2, in bearing cover, 1. Bearing cup must be fully seated in cover.

2 66072920

25-28

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 4. Install a new bearing cup, 3; press in, or tap in with a soft drift utility fully seated in the housing, 2. Install input shaft, 1.

66072921

FINAL DRIVE OUTPUT SHAFT 1

Disassembly 1. Carefully remove bearing cone, 2, from the output shaft, 1.

IMPORTANT: Do not damage the shaft when removing the bearing. If the bearing cone can not be pulled from the shaft, it may be necessary to use a lathe to remove the bearing.

66060019

65 2. As required, the wheel studs, 1, can be driven out of the shaft.

66060019

25-29

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 3. If equipped with mud seals, remove the mud seal.

IMPORTANT: Do not damage the mud seal containment ring, 1, when removing the bearing, 3, or the wheel studs, 2.

ZDA4632A

67 4. Remove all old thread locking compound from the thread-wells, A and B, of the bearing ring locknut, 1, and the corresponding threads on the output shaft, 2.

Use a wire brush to ensure deep cleaning of the thread wells.

Check cleanliness, by turning each ring nut onto the shaft. Each ring nut must turn on completely by hand (no tools) and with no binding. Degrease the thread-wells of the locknut and the shaft using Loctite 7063 degreasing compound. NOTE: Degreasing is successful when a white dull layer appears on the thread.

ZEIL05CX0528A0B

A 66060027

25-30

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 Assembly

CAUTION

Use insulated gloves or mittens when working with hot parts. Failure to comply may result in minor or moderate injury.

1. Heat the new bearing, 2, to 80 °C (176 °F) and install on output shaft, 1. IMPORTANT: Bearing cone, 2, must be fully seated on output shaft. 66060019

70 2. As required, install any removed or replacement wheel studs, 1. (Ten studs per output shaft.) Ensure the notch on the head of each wheel stud is aligned with the step on the output shaft.

66060019

71 3. If equipped with a pair of mud seals, install one mud seal as follows:

IMPORTANT: Do not damage the mud seal containment ring, 1, when installing the bearing, 3, or the wheel studs.

3 ZDA4632A

2 72

25-31

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 IMPORTANT: Before installing the mud seal, degrease, clean, and ensure both the seal and output shaft are free of dirt and old oil residue.

4. Install mud seal, 1, with the metal face outward as shown in Figure 74, on the output shaft.

66070070

73 5. Measure distance X mm (X in) in at least four places 90 ° apart.

1 X

The difference in height around the ring must not be more than 1 mm (0.04 in). X mm (X in) = the distance from mud seal surface to the top of the containment ring on the output shaft. Apply a light coat of new NH AMBRA HYPOIDE 90 gear oil to the metal face, 1, of the seal prior to assembly with the housing. 66070071

25-32

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 FINAL DRIVE REDUCER, SATELLITE AND PLANETARY Disassembly 1. Remove retaining ring, 1.

ZDA4041A

75 2. Push out the pin, 1, and then remove the planet gear, 2, the needle rollers, and the spacers on both sides of the planet gear. To prevent the needle bearings from dropping everywhere, locally obtain or manufacture a pin replacement shaft tool with a 50.5 mm (1.98 in) outer diameter x 47 mm (1.85 in) length. Use this shaft to displace the pin, 1, that holds the planet gear, 2, in the carrier. Ensure all needle bearings are cleared from the carrier. There are twenty-three (23) needles per planet gear. Repeat the procedure for the other two planet gears. NOTE: The shaft replacement tool described above is necessary for the assembly procedure.

25-33

ZDA4039A

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 Assembly 1. Apply NH AMBRA HYPOIDE 90 to the spacer, 1.

ZDA4034A

77 2. Apply NH AMBRA HYPOIDE 90 to the inside, 1, of the planet gear, 2, and place it onto the lubricated spacer, above.

3 1

Obtain or manufacture the described shaft, 3, below, for installation of the needle bearings and assembly of the planet gear into the carrier. Shaft diameter and length is 50.5 mm (1.98 in) OD x 47 mm (1.85 in). Place the tool, 1, in the middle of gear, 2.

ZDA4035A

78 3. Insert twenty-three (23) needle rollers, 1.

ZDA4036A

25-34

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 4. Apply NH AMBRA HYPOIDE 90 to the needle bearings, 1, and spacer, 2.

2 1

Place spacer onto gear, 3.

3 ZDA4037A

80 5. Insert pin, 2, into the planet gear carrier, 1, as shown. IMPORTANT: The shaft must be inserted from the side of the carrier with the flat shoulder.

1 2

50020124

81 6. Insert the planet gear, 1, with spacers and needle rollers. Insert the pin, 2, and remove the tool.

ZDA4039A

25-35

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 IMPORTANT: Make sure the notch (A) on the pin is in line with the notch on the planet gear carrier.

A ZDA4040A

83 7. Install retaining ring, 1. Repeat steps 1 -- 7 for the other two planet gears.

ZDA4041A

84 8. The pre-assembled planet gear carrier is heavy, use a lifting device to handle it.

ZDA4042A

25-36

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 FINAL DRIVE WHEEL STUD Replacement

WARNING Install a suitable and safe support underneath the combine traction axle to support the combine. Failure to comply could result in serious injury or death. NOTE: In order to position a specific wheel stud, 2, to the maintenance hole, 1, remove the half-shaft as described in “Half-shaft -- Removal.” It is only necessary to remove the one coupler from the final drive input shaft. 1. Remove the drive wheel. Turn the output shaft of the planetary final drive until wheel stud, 2, the stud to be replaced, is in front of maintenance plug, 1. Remove maintenance plug, 1. Drive out wheel stud, 2, into the maintenance hole. Remove the wheel stud. Insert the head of the new wheel stud, 2, into the maintenance hole, and then insert the threaded end into the output shaft. Ensure the notch on the wheel stud head is in line with the step on the output shaft. To fully seat the wheel stud in the output shaft, turn a wheel nut onto the stud. Tighten the nut until fully seated, and then remove nut. Repeat the procedure for each wheel stud to be replaced. Apply Loctite 242/243 to the maintenance plug, 1, and install. Tighten and torque the plug to 100 -- 120 N⋅m (74--89 ft-lb). Install the drive wheel. Tighten the wheel nuts and torque to 710 -- 790 N⋅m (525 -- 580 ft-lb). IMPORTANT: The final wheel nut torque specification, indicated above, must be obtained by following the proper tightening and progressive torque sequence procedure. The sequence is dependent on the drive wheel configuration. Reference the Operator’s Manual, Section 4 -- “Lubrication and Maintenance -- Drive Wheel Mounting.”

25-37

ZDA4662A

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 HALF-SHAFT Removal 1. Remove the bolts and nuts from the outer and inner half-shaft couplers. Slide both couplers, 1, completely outward, over the transmission and final drive shaft.

20036405

1 87

2. Slide the half-shaft, 1, completely toward the final drives, and slide the retaining ring, 2, from the groove to the smallest shaft diameter at the transmission end.

NOTE: Be careful to not over expand retaining ring during removal, to avoid deforming the retaining ring.

2 50021343

88 3. Slide the half-shaft completely towards the transmission and slide the retaining ring from the groove to the smallest diameter at the final drive end. NOTE: Be careful to not over expand retaining ring during removal, to avoid deforming the retaining ring. 4. Push both couplers, fully onto the half-shaft. 5. Remove the half-shaft assembly. 6. Remove the coupler and rings over the splined end of shaft. Do not remove retaining rings unless they will be replaced. 7. Repeat for the opposite side.

25-38

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 Installation IMPORTANT: Do not expand the retaining rings more than necessary to avoid deforming the retaining ring. 1. Slide both retaining rings, 3, over the splines, beyond the groove and position on the smallest diameter part of the half-shaft. 2. Slide the couplers, 1, completely over the splines with the undercut towards the retaining ring. 3. Place the pre-assembled half-shaft assembly between the output shaft of the transmission and input shaft of the final drive. 4. Slide both couplers completely outwards over the transmission and final drive shafts. 5. Slide the half-shaft completely towards the transmission and install the retaining ring at the final drive side in its groove, 2.

1 50021343

6. Slide the half-shaft completely towards the final drive and install the retaining ring at the transmission side in its groove. 7. Slide the half-shaft coupler, 1, in its middle position. Install the bolts and nuts. Tighten and torque the bolts and nuts to 5 N⋅m (44 in-lb). IMPORTANT: Do not over torque the coupler bolts, as the bolts may yield and cause coupler failure.

20036405

1 90

25-39

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1

25-40

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2

SECTION 25 - FRONT MECHANICAL DRIVE Chapter 2 - 11/111 Final Drives CONTENTS Section

Description

Page

25 000

25-1

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 SPECIFICATIONS Gear ratio

11/111

Max. input rpm (30 km/hr - 18.6 mph)

998 rpm

Max. output rpm (30 km/hr - 18.6 mph)

132

Nominal input torque

1630 N⋅m (1200 ft-lb)

Nominal output torque Output shaft pre-load

16500 N⋅m (12170 ft-lb) (Standard Seal) (Mud Seal)

0.27 -- 0.33 mm (0.011 -- 0.013 in) 0.27 -- 0.35 mm (0.011 -- 0.014 in)

Input shaft axial end play

0.08 -- 0.13 mm (0.003 -- 0.005 in)

Approximate total weight

274.3 kg (605 lb)

Oil capacity

7.85 L (2.07 US gal)

TIGHTENING TORQUES Bearing (only) -- Rolling Torque Range

9 -- 17 N⋅m (80 -- 150 in-lb)

Bolts, Input Shaft Covers (Inner & Outer) M10 x 30

54 -- 60 N⋅m (40 -- 44 ft-lb)

Bolts, Output Shaft M16 x 35 Locking

252 -- 278 N⋅m (186 -- 205 ft-lb)

Bolts, Final Drive to Axle Mounting

656 -- 725 N⋅m (484 -- 535 ft-lb)

Plug, Oil Magnetic Drain

90 -- 110 N⋅m (66 -- 81 ft--lb)

Plug, Breather/Fill

90 -- 110 N⋅m (66 -- 81 ft-lb)

Nuts, Wheel Mounting

710 -- 790 N⋅m (525 -- 580 ft-lb)

Screws, Housing Cover HSH M10 x 25

49 -- 60 N⋅m (36 -- 44 ft-lb)

Nuts, Half-shaft Coupler

5 N⋅m (44 in-lb)

SPECIAL TOOLS Description

Part Number

Output shaft Bearing Driver Steel Pipe 105 mm ID x 115 mm OD x 200 mm length

Procure Locally

Input shaft Bearing Driver Steel Pipe 43 mm ID x 51 mm OD x 127 mm length

Procure Locally

25-2

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 OVERVIEW FINAL DRIVE (STANDARD SEAL) -- SECTIONAL VIEW 1 25 2

24 23

6 19 18

7 8

16 9

10 11 66070061

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Front Cover Cap Screw, M10 x 25 Hex Socket Head (HSH) Wheel Stud Seal, Final Drive (Standard) Bearing, Tapered Roller -- 181 mm (7.125 in) Axle Hub Spacer Housing, Cast Final Drive Cover Plate, Input Outer Cap Screw, M10 x 25 Hex Head Gasket Seal Bearing, Tapered Roller -- 86 mm (3.4 in) O-ring Seal

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

25-3

Cover Plate, Input Inner Input Shaft Seal Shim(s) -- 0.05, 0.2, 0.5 mm (0.002, 0.008, 0.02 in) Gear Oil -- 7.85 L (8.3 qt) Bearing, Tapered Roller -- 141 mm (5.6 in) Shim(s) -- 0.05, 0.2, 0.5 mm (0.002, 0.008, 0.02 in) Hub Cap Bolt, Chemical Treated Locking M16 x 35 Washer Spacer Gear, Driven

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 FINAL DRIVE (MUD SEAL) -- SECTIONAL VIEW 1

19 18 17

7 8

16 15

9 10 11 66070062

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Front Cover Cap Screw, M10 x 25 Hex Socket Head (HSH) Wheel Stud Seal, Final Drive Mud Bearing, Tapered Roller -- 181 mm (7.125 in) Axle Hub Spacer Ring, (Mud) Seal Cover Plate, Input Outer Cap Screw, M10 x 30 Hex Head Gasket Seal Bearing, Tapered Roller -- 86 mm (3.4 in) O-ring Seal

13 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

25-4

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 WHEEL BOLT

OVERHAUL

Replacement NOTE: Left side shown, right side is similar. 1. Park the combine on a level surface. Engage the parking brake, turn the combine ignition switch to the “OFF” position and remove the key. Chock the tire on the opposite side of the wheel bolt that is to be removed. The front and rear of the tire must be chocked. 2. Using a jack with a minimum capacity of 907 kg (10 ton), raise the side of the combine the wheel bolt will be removed from. Support the front axle with a 907 kg (10 ton) minimum capacity jack stand. 3. Remove the drive wheel from the combine.

50030311

3 4. Remove the bolt, 4, from the half-shaft coupler, 1, and slide the coupler toward the final drive. Remove the retaining clip, 2, from the recess in the drive shaft. Once the retaining clip is removed, slide the coupler completely onto halfshaft, 3.

IMPORTANT: Be careful to not over extend retaining ring during removal, to avoid deforming the retaining ring.

50021343

4 5. Turn the input shaft of the final drive until the wheel bolt, 1, to be replaced is aligned with the notch, 2, in the final drive housing.

6. Drive the wheel bolt out of the output shaft wheel flange.

7. With the notch on the new wheel bolt aligned with the step on the wheel flange, pull the wheel bolt into the flange using a lug nut. 8. Connect the drive sleeve back to the final drive. 9. Install the drive wheel. Torque the lug nuts to 710 – 790 N⋅m (525 -- 580 ft-lb). IMPORTANT: The final wheel nut torque specification, indicated above, must be obtained by following the proper tightening and progressive torque sequence procedure. The sequence is dependent on the drive wheel configuration. Reference the Operator’s Manual, Section 4 -- “Lubrication and Maintenance -- Drive Wheel Mounting.”

25-5

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 FINAL DRIVE Removal NOTE: Left side shown, right side is similar. 1. Park the combine on a level surface. Engage the parking brake, turn the combine ignition switch to the “OFF” position and remove the key. Chock the tire on the opposite side of the final drive that is to be removed. The front and rear of the tire must be chocked. 2. Using a jack with a minimum capacity of 907 kg (10 ton), raise the side of the combine the wheel bolt will be removed from. Support the front axle with a 907 kg (10 ton) minimum capacity jack stand. 3. Remove the traction tire from the combine.

50030311

6 4. Drain the oil from the final drive unit by removing the magnetic drain plug, 1, from the bottom of the final drive. Have a suitable size container ready to catch the oil draining from the final drive. The final drive oil capacity is 7.85 l (2.07 US gal).

66070069

7 5. Remove the bolt, 4, from the half-shaft coupler, 1, and slide the coupler toward the final drive. Remove the retaining clip, 2, from the recess in the drive shaft. Once the retaining clip is removed, slide the coupler completely onto halfshaft, 3.

IMPORTANT: Be careful to not over extend retaining ring during removal, to avoid deforming the retaining ring.

50021343

25-6

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 WARNING Each final drive unit weighs approximately 274.3 kg (605 lb). Use care when handling the final drive unit to avoid bodily injury or equipment damage. Failure to comply could result in serious injury or death. 6. Using lifting straps or chains and a suitable lifting device, support the weight of the final drive. 7. Remove the eight mounting bolts which secure the final drive to the front axle beam. Separate the final drive from the axle beam, using a pry bar if necessary.

56070068

Disassembly

1. Place the final drive on a clean work area capable if supporting 274.3 kg (605 lb). The axle hub should face down.

2. Remove the two dowel pins, 1, from the final drive housing. 3. Remove the 18 M10 x 25 HSH cap screws, 2, which secure the front cover, 3, to the final drive housing. Pry the cover off the housing.

4. Pry the bearing cap, 4, out of the final drive housing.

56070063

10 5. Remove three M16 x 35 chemical treated lock bolts, 1, with retaining washer, 2. Save these used bolts for use when seating the bearings and determining axial play at reassembly.

IMPORTANT: Replace the chemical treated locking bolts with new treated locking bolts at final installation of the shaft hub bolts to ensure proper torque values are applied and full locking quality. 6. Remove the retaining washer, 2, from the hub.

2 66063416

25-7

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 7. Remove the shims, 1, located between the retaining washer and the hub. Use care not to lose any shims.

8. Drive the axle hub out of the final drive housing. The large outer bearing will remain on the hub, while the inner bearing will be forced off the hub. Two spacers will also be removed from the final drive housing when the hub is removed. 9. The large gear can then be removed from the final drive housing out of the front cover opening. 50021333

12 10. Remove the seal, 1, and bearing cups, 2, remaining in the final drive housing.

66070066

13 11. If the final drives are equipped with mud seals, a sealing ring, 2, located on the outer front portion of the housing must be removed.

2 1

66070065

25-8

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 12. Remove the eight M10 x 30 bolts and lock washers securing the input shaft end caps, 1, and 2, onto the final drive housing.

13. Remove the end caps.

66070064

15 14. Remove the shims, 1, located between the final drive housing and inner input shaft endplate. 15. Drive the input shaft, 2, out of the final drive housing using a dead blow hammer or other suitable mallet. Strike the splined end of the input shaft. The outer bearing race will be removed with the shaft.

2 1

16. Use a suitable hammer and punch to remove the race remaining in the housing.

50021334

16 Inspection

1. Clean all parts using a suitable solvent. Be sure to remove all gasket material from components. Allow the parts to air dry. 2. Inspect the bearing cones, 1, on the input shaft for damage or excessive play. Inspect the cups and cones for scoring, cracks, or excessive wear. If the bearing races are damaged, worn, or do not turn freely, replace the bearings as a set.

19991090

25-9

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 3. Use a bearing separator and press to remove the bearings from the input shaft. 4. Inspect the splines, teeth and body of the input shaft. Replace if damaged or worn.

19991091

18 5. Remove and replace the seal, 2, and O-ring, 1, from the inner end cap.

19991092

19 6. Apply petroleum jelly to the new O-ring, 1, then install an inner input shaft cap.

7. Apply NH AMBRA GR9 multi-purpose grease to a new seal, 2, filling the lips and cavity between lips, 3. Install seal as shown.

66070067

25-10

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 8. Inspect the axle hub splines, flange, and bearing surfaces for cracks, chips, and any other damage or excessive wear. Inspect the wheel bolts for damage or excessive wear. Replace components as necessary. 9. Check the inner and outer hub bearings and races for smooth rotation excessive axial play, scoring or any other damage. Remove and replace the bearings as a set, if necessary. 10. Inspect the final drive housing components for damage such as cracks, holes dents, etc. Replace as necessary.

50021335

21 Assembly 1. If the bearings, 1, were removed from the input shaft, press the bearings onto the shaft using a piece of pipe that has a minimum inner diameter of 43 mm (1.69 in), a maximum outer diameter of 51 mm (2.0 in) and a length of 127 mm (5.0 in). 2. Coat the bearings in NH AMBRA HYPOIDE 90 gear oil.

19991095

22 3. To aid installation, chill the input shaft bearing races in ice or a freezer for 15 minutes. Be sure the races are dry before installation. Install the input shaft into the final drive housing. Install the bearing races, 1, into the housing using a hammer and a brass punch to drive the races into the housing. Be sure the races are properly seated against the bearing.

19991096

25-11

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 4. Install the outer endplate, not shown, for the input shaft onto the drive housing, using a new gasket between the plate and housing. Apply Loctite 242/243 to the four M10 x 30 endplate mounting bolts and install the bolts with lock washers into drive housing. Torque the bolts to 54 -- 60 N⋅m (40 -- 44 ft-lb). 5. Place the inner endplate and shims, 1, for the input shaft onto the drive housing. Use care not to damage the O-ring oil seal when installing the plate. Torque the bolts to 54 -- 60 N⋅m (40 -44 ft-lb). This will seat the bearing races.

2 1

50021334

24 6. Use a dial indicator to check input shaft, 1, endplay. Endplay should be 0.08 – 0.13 mm (0.0032 – 0.0051 in). If the endplay is not as specified, add or remove shims as necessary to obtain the proper endplay. Shims are available in three different thickness’: • • •

0.05 mm (0.0019 in) 0.2 mm (0.0079 in) 0.5 mm (0.0197 in)

1 2

7. Once endplay is as specified, remove the four M10 x 30 inner endplate mounting bolts. 8. Re-install the endplate, 2, onto the final drive housing, using care not to damage the O-ring oil seal. Coat the M10 x 30 endplate mounting bolts with Loctite 242/243 and install them with lock washers into the endplate and housing. Evenly torque the bolts to 54 -- 60 N⋅m (40 -- 44 ft-lb).

50021337

9. Chill the new bearing cups for the axle hub in ice or a freezer for 15 minutes. Be sure the cups are dry before installing into the final drive housing.

10. Using a suitable hammer and brass drift, tap in the bearing cups, 1, for the axle hub.

66070066

25-12

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 IMPORTANT: Do not overheat the bearing inner race when installing the bearing onto the axle hub.

CAUTION Use insulated gloves or mittens when working with hot parts. Failure to comply may result in minor or moderate injury. 11. If the outer axle hub bearing, 1, was removed, install the bearing onto the axle hub. Heat the inner race of the bearing to 80 °C (176 °F). Using a piece of pipe that has an ID of 105 mm (4.150 in), an OD of 115 mm (4.5 in), and a length of 200 mm (8.0 in), press the bearing onto the axle hub.

2 1

50021338

12. Coat the bearings with NH AMBRA HYPOIDE 90 gear oil, then install the large spacer, 2, onto the axle hub. 13. If the final drive is equipped with mud seals (reference illustration: Mud Seal Final Drive; at the beginning of this chapter), proceed to step 15 (Figure 29), otherwise install the standard oil seal, 2, into the housing as described in the following step. (See detail -- Figure 28).

14. Before installing the new oil seal, 1, apply NH AMBRA GR9 multi-purpose grease to the seal, 1, filling the lips and cavity between lips, 2.

1 3

Seat the oil seal, 1, into the housing 6.5 -- 7.5 mm (0.25 -- 0.35 in) as indicated by, A. IMPORTANT: The oil seal must be carefully driven into the final driving housing to the specified depth between 6.5 -- 7.5 mm (0.25 -- 0.35 in).

66063383

A 28

Ensure the flat section of the seal, 1, faces outward, away from the housing, 3, and the lip of the seal faces inward toward the housing. 15. If the final drive is equipped with mud seals, 1; first apply Loctite 609 retaining compound to the sealing ring, 2, and then install the sealing ring into the final drive housing. Make sure the beveled portion of the sealing ring faces outward, away from the housing.

2 66070065

25-13

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 NOTE: The following two figures, 30 and 31, are of the planetary final drive output shaft, but closely represent the described procedure for the 11/111 final drive components.

IMPORTANT: Before installing the mud seal, degrease, clean, and ensure both the seal and output shaft are free of dirt and old oil residue. 16. Install mud seal, 1, with the metal face outward as shown in Figure 31, on the output shaft. 66070070

30 17. Measure distance X mm (X in) in at least four places 90° apart.

1 X

31 NOTE: The following two figures, 32 and 33, are of the planetary final drive housing, but closely represent the described procedure for the II/III final drive components. IMPORTANT: Before installing the mud seal, degrease, clean, and ensure both the seal and housing containment ring are free of dirt and old oil residue. 18. If equipped with a pair of mud seals, install one mud seal, 1, with the metal face outward as shown in Figure 33.

1 ZDA4637A

25-14

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 19. Measure distance X mm (X in) in at least four places 90° apart.

33 20. Install the large driven gear, 1, into the final drive housing. 21. Install the axle hub into the final drive housing and through the large gear, 1.

50021336

34 22. Position the final drive so the weight of the assembly is supported by the wheel flange on the axle hub (The wheel flange will be on the bottom.). 23. Install the small spacer, 1, onto the axle hub shaft.

CAUTION Use insulated gloves or mittens when working with hot parts. Failure to comply may result in minor or moderate injury. 24. Heat the inner race of the inside axle hub bearing to 80 °C (176 °F). Using heat resistant gloves, place the bearing, 2, onto the axle hub shaft.

25-15

50021339

1 35

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 25. Determine and shim the axle hub bearing pre-load as described in the following steps. IMPORTANT: Be aware of an important variable for this procedure; standard seal and mud seal units have a different pre-load range.

Preload: •

Standard seal -- 0.27--0.33 mm (0.012--0.013 in)

•

Mid seal -- 0.27--0.35 mm (0.012--0.014 in)

IMPORTANT: The 11/111 Final Drives use chemical treated lock bolts. Reuse the removed M16 x 35 bolts only for setting the axle pre-load, and then install new chemical treated bolts at final torque. 26. Install the large retaining washer, 1, onto the final drive and secure using the three M16 x 35 retaining bolts, 2. Torque the bolts to 90 N⋅m (66 ft-lb). This ensures the races are properly seated in the final drive housing. 27. Loosen the three bolts evenly to allow for free play. 28. Take a large dead blow hammer and strike the axle hub to create a small amount of endplay in the final drive axle hub. 29. Use a dial indicator to measure the amount of end play in the axle hub. Tighten the three retaining bolts evenly until zero end play is achieved. DO NOT tighten the bolts any more than what is necessary to achieve zero end play. 30. Remove the three bolts and retaining washer.

25-16

2 50021341

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 31. Measure the distance, X, between the end of the axle hub and the top, outer edge of the bearing. 32. To calculate shimming, subtract 0.5 mm (0.020 in) from X, the value obtained in step 31.

20021345

37 33. Install the appropriate amount of shims, 1, onto the axle hub to obtain a pre-load measurement as follows:. • •

For standard seal final drive -- 0.27 -- 0.33 mm (0.012 -- 0.013 in) For mud seal final drive -- 0.27 -- 0.35 mm (0.012 -- 0.014 in)

Shims are available in three thickness’: • 0.05 mm (0.0019 in) • 0.2 mm (0.0079 in) • 0.5 mm (0.0197 in)

50021333

38 34. Install the retaining washer, 1, onto the hub and secure using the three new M16 x 35 chemical treated lock bolts, 2. Torque the bolts to 252 -- 278 N⋅m (186 -- 205 ft-lb).

IMPORTANT: Do not reuse old locking bolts. Replace the chemical treated locking bolts with new treated locking bolts at final installation of the shaft hub bolts to ensure proper torque values are applied and full locking quality.

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25-17

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 35. Coat the two dowel pins, 1, with Loctite anti-seize. Install the pins into the final drive housing.

36. Coat the sealing edge of the bearing cover, 4, with Loctite 638. Install the bearing cover, 4, onto the final drive housing. 37. Clean all sealant compound residue from the mating surfaces of the front cover and drive housing. Coat both sides of a new front cover seal with Loctite 515 gasket sealant. Install the front cover, 3, and gasket onto the final drive housing. Coat the M10 x 25 HSH cover mounting bolts, 2, with Loctite 242/243 and thread them into the cover and final drive. Torque the bolts to 49 – 60 N⋅m (36 – 44 ft-lb), starting in the center of the cover and working out to the ends of the cover and final drive housing, alternating sides while tightening the bolts.

56070063

Installation

WARNING Each final drive unit weighs approximately 274.3 kg (605 lb). Use care when handling the final drive unit to avoid bodily injury or equipment damage. Failure to comply could result in serious injury or death. 1. Using lifting straps or chains and a suitable lifting device, support the weight of the final drive. 2. Raise the final drive up to the front axle beam, aligning the dowel pins with the proper holes in the axle beam. 3. Coat the eight M20 x 60 mounting bolts which secure the final drive to the axle beam with Loctite 242/243. Install the mounting bolts into the final drive and axle beam and torque to 656 -- 725 N⋅m (484 -- 535 ft-lb). 56070068

25-18

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2 IMPORTANT: Do not stretch the retaining ring more than necessary to avoid deforming the retaining ring.

4. Connect the half-shaft. Slide the couplers, 2, completely outwards over the final drive shaft, 4. 5. Install the retaining ring, 1, at the final drive side in its groove. 6. Install the bolt and nut, 3. Tighten and torque the bolt and nut to 5 N⋅m (44 in-lb).

1 4

50021343

42 7. Clean the magnetic drain plug, 1, and replace the O-ring. Install the drain plug and torque to 90 – 110 N⋅m (65 – 80 ft-lb). 8. Remove the breather/fill plug, 2. Clean plug and replace O-ring, and then fill the final drive with 7.85 L (2.07 US gal) NH AMBRA HYPOIDE 90 gear oil. NOTE: The magnetic drain plug, 1, and the breather/fill plug, 2, must always be located as shown on either side of final drives. 9. Install the drive wheel, torquing the lug nuts to 710 – 790 N⋅m (525 – 580 ft-lb). IMPORTANT: The final wheel nut torque specification, indicated above, must be obtained by following the proper tightening and progressive torque sequence procedure. The sequence is dependent on the drive wheel configuration. Reference the Operator’s Manual, Section 4 -- “Lubrication and Maintenance -- Drive Wheel Mounting.” 10. Check wheel motor mounting bolt torque and lug nut torque after 50 hours of operation.

25-19

66070069

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 2

25-20

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1

SECTION 29 -- HYDROSTATIC SYSTEM Chapter 1 -- Hydrostatic Drive System Introduction CONTENTS Section

Description

Page

29-1

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 Section

Description

Page

29-2

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 SPECIFICATIONS HYDROSTATIC OIL Specification (North America) Reservoir Capacity Total System Capacity (Hydraulic and Hydrostatic)

New Holland AMBRA MULTI G134 (M2C 134 -- D) Approximately 37 liters (9.77 US gals) Approximately 100 liters (26.4 US gals)

HYDROSTATIC PUMP (CR9040 AND 9060 MACHINES W/HD 11/111 FINAL DRIVES) Manufacturer Type Control Frame Size Direction of Rotation Displacement Minimum Speed Rated Speed Maximum Speed Charge Pump Displacement Charge Pump Pressure

Sauer Danfoss 90 Series Variable Displacement, Closed Circuit Electric Displacement Control (EDC) 130 Counterclockwise 110 cc/rev (mechanically limited) (6.7 in3/rev) 500 rpm 3100 rpm 3400 rpm 26 cc/rev (1.6 in3/rev) 38 bar (551 psi)

HYDROSTATIC PUMP (CR9040 AND 9060 MACHINES W/PLANETARY FINAL DRIVES) Manufacturer Type Control Frame Size Direction of Rotation Displacement Minimum Speed Rated Speed Maximum Speed Charge Pump Displacement Charge Pump Pressure

Sauer Danfoss 90 Series Variable Displacement, Closed Circuit Electric Displacement Control (EDC) 130 Counterclockwise 130 cc/rev (7.9 in3/rev) 500 rpm 3100 rpm 3400 rpm 26 cc/rev (1.6 in3/rev) 38 bar (551 psi)

HYDROSTATIC PUMP (CR9070 MACHINES) Manufacturer Type Control Frame Size Direction of Rotation Displacement Minimum Speed Rated Speed Maximum Speed Charge Pump Displacement Charge Pump Pressure

29-3

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 HYDROSTATIC DRIVE MOTOR (CR9040 AND 9060 MACHINES W/HD 11/111 FINAL DRIVES) Manufacturer Type Frame Size Direction of Rotation Displacement Rated Speed Maximum Speed System Pressure -- Rated System Pressure -- Maximum Flow at Rated Speed Case Pressure -- Continuous Case Pressure -- Maximum (Cold Start)

Sauer Danfoss 90 Series Fixed Displacement, Closed Circuit 100 Bi-Directional 100 cc/rev (6.7 in3/rev) 3300 rpm 3650 rpm 420 bar (6090 psi) 480 bar (6960 psi) 365 l/min (96.4 gal/min) 3 bar (43.5 psi) 5 bar (72.5 psi)

HYDROSTATIC DRIVE MOTOR (CR9040 AND 9060 MACHINES W/PLANETARY FINAL DRIVES; CR9070 MACHINES) Manufacturer Type Frame Size Direction of Rotation Displacement Rated Speed Maximum Speed System Pressure -- Rated System Pressure -- Maximum Flow at Rated Speed Case Pressure -- Continuous Case Pressure -- Maximum (Cold Start)

Sauer Danfoss 90 Series Fixed Displacement, Closed Circuit 130 Bi-Directional 130 cc/rev (7.9 in3/rev) 3100 rpm 3400 rpm 420 bar (6090 psi) 480 bar (6960 psi) 442 l/min (117 gal/min) 3 bar (43.5 psi) 5 bar (72.5 psi)

OIL COOLER BYPASS VALVE Manufacturer Maximum Operating Pressure Cooler Port Opening Temperature Cooler Port Fully Open Temperature Maximum Operating Temperature Minimum Operating Temperature Maximum Flow Rate Relief Valve Pressure

Parker 17.2 bar (249 psi) 46 -- 52°C (114.8 -- 125.6°F) 63°C (--145.4°F) 91°C (--195.8°F) -34°C (--29.2°F) 227 l/min. (60 gal/min) 2.8 to 3.4 bar (40.6 -- 49.3 psi)

29-4

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 INTRODUCTION The CR Combine Hydrostatic System contains five main components, an oil reservoir, hydrostatic pump, brake manifold, drive motor and oil cooler. Some machines are equipped with an optional powered rear axle (PRA).

OIL RESERVOIR

A single oil reservoir, 1, is used for both the hydraulic and hydrostatic systems. The reservoir is located at the upper left hand side of the machine behind the engine compartment. Each of the hydraulic and hydrostatic circuits have their own filtering systems.

A suction screen, 2, is mounted inside the reservoir to provide some filtration for the hydrostatic pump suction oil. 10020026

HYDROSTATIC PUMP

The hydrostatic pump, 1, is mounted to and driven by the engine gearbox. The hydrostatic pump assembly includes the charge pump, charge relief valve, charge pressure filter, 2, and charge pressure sensor (switch), 3. The hydrostatic pump also houses the servo displacement valve and multi function valves, 4.

If an optional powered rear axle is installed, the high pressure supply lines are connected to manifold blocks, 5, at the pump outlet ports.

5 2

86060572

29-5

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 HYDROSTATIC BRAKE (INTEGRATED) The hydrostatic drive integral brake is a device used to aid in deceleration and braking with combustion engines with low braking characteristics. Engines with large displacement and high compression have internal characteristics to prevent over-speeding from occurring. The integral brake feature allows the machine to have the characteristics of a larger engine, by having the capability to decelerate a vehicle of high weight or high speed. This high kinetic energy that occurs can also over-speed the engine through the hydrostatic pump, and overpower the service brakes. When over-speed is sensed, the integrated hydro brake feature prevents the machine from over-speeding the engine, over-speeding the hydrostatic pump, and allows the vehicle sufficient deceleration and braking.

56062059

HYDROSTATIC DRIVE MOTOR The hydrostatic motor, 1, is mounted to the main transmission and is driven hydraulically by the hydrostatic pump. The hydrostatic motor supplies the drive input to the main transmission.

The shuttle spool valve, 2, flushing relief valve, 3, and pressure release solenoid valve, 4, are all located in the backplate of the motor.

3 4 86054879

1 4

29-6

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 The hydraulic oil cooler, 1, is mounted under the engine radiator in the main cooler assembly. The oil cooler bypass valve, 2, is thermostatically controlled, and only directs oil to the cooler when the oil temperature is above 49°C (120°F).

BSC1259A

2 5

POWERED REAR AXLE (PRA) (OPTIONAL) Each wheel of the powered rear axle is driven independently by its own hydrostatic motor. Each motor is driven hydraulically by the hydrostatic pump and controlled by a single control valve. Refer to Section 29 Chapter 3 of this manual for more information on the powered rear axle.

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29-7

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 DESCRIPTION OF OPERATION The CR Combine Hydrostatic System contains a reservoir, Charge Pump, Hydrostatic Pump, Drive Motor and optional powered steering axle.

motor pistons, causing the drive motor output shaft to turn in the forward direction. The oil will return by the return line, 10, to the hydrostatic pump, 3.

The hydrostatic pump assembly incorporates the charge pump and is connected to and driven from the engine gearbox.

Also the increase in pressure will close the forward multi function valve charge check valve, preventing the charge pressure circuit receiving drive pressure from the hydrostatic pump, 3.

NEUTRAL

The charge pump, 2, will continue to charge the reverse high pressure line, 10, through the reverse multi function valve charge check valve to replace the oil used for lubrication and flushing and any oil lost through internal leakage.

With the engine running and the hydrostatic lever in neutral the charge pump receives oil from the reservoir, 1, through a 100 micron filter screen into the charge pump, 2. The oil is then pumped through filter, 4, to the multi function valves, 6 and 7. The charge pressure will open the check valves and allowing charge pressure to fill the hydrostatic pump, 3, high pressure lines, 9 and 10, and drive motor, 12. Charge pressure oil will also fill the servo valve assembly, 8, and servo cylinders.

The return oil from the drive motor, 12, is passed through the flow valves of the integrated brake and back to the pump.

The hydrostatic pump swash plate stands square to the input shaft. With no axial movement of the pistons there is no flow of high pressure oil in the high pressure lines, 9 or 10.

If there is more than a 13 bar (188.5 psi) pressure difference across the drive motor, 12, the drive pressure from the hydrostatic pump, 3, moves shuttle spool valve in the drive motor assembly, 12, connecting the return line, 10, to the flushing relief valve.

When the charge pump pressure in the system increases to 34 bar (493 psi) the charge pressure relief valve will open and oil will flow into the hydrostatic pump casing through the thermostatically controlled oil cooler bypass valve, 13, to the reservoir, 1.

The flushing relief valve will open at a lower pressure than the charge pressure relief valve causing some of the charge pressure oil to flow through the flushing relief valve to the drive motor case drain. The oil will then flow to the oil cooler through the pump case drain, cooling the motor and pump bodies.

If the oil temperature is below 49°C (120°F) the oil will flow directly to the reservoir, 1; when the oil temperature is above 49°C (120°F), the thermostatically controlled oil cooler bypass valve, 13, will move diverting the oil flow through the oil cooler, 14.

If the resistance on the drive motor, 12, increases (machine travelling up hill) then the pressure in the forward high pressure line, 9, will increase. As the pressure reaches 420 bar (6090 psi) (delta p) the pressure limiter valve will open allowing oil to flow to the hydrostatic pump reverse servo cylinder piston reducing the swash plate angle and pump flow, protecting the hydrostatic system from overpressure.

FORWARD When the hydrostatic lever is moved forward the servo solenoid will move the servo solenoid valve proportional to the position of the hydrostatic lever. Charge pressure oil can then flow to the forward side of the servo valve spool, moving the spool and allowing oil to flow to the forward servo cylinder.

To make sure the pressure acting on the reverse servo cylinder piston does not exceed charge pump pressure, as the oil flows through the pressure limiter valve the pressure (420 bar [6090 psi]) will open the check valve and the charge check valve allowing the oil to flow into the charge pressure circuit. In this circuit the pressure is limited by the charge pressure relief valve.

The charge pressure oil acting on the forward servo cylinder will move the hydrostatic pump swash plate creating axial movement of the pistons increasing the pressure in the forward high pressure line, 9, towards the drive motor, 12.

If the pressure in the high pressure line exceeds 450 bar (6525 psi) (shock) then the relief valve will open allowing oil to flow directly from the high pressure line, 9, into the return line, 10, through the charge check valve (the pump is bypassed in this instance).

The increased pressure in the forward high pressure line, 9, will create rotational movement of the drive

29-8

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 HYDROSTATIC DRIVE SCHEMATIC

4 5 8 9

13 7

1 66062990

7 Schematic Circuit for CR9040, 9060, and 9070 Machines with Integrated Braking Function

Schematic Legend 1. 2. 3. 4. 5. 6. 7. 8.

Reservoir Charge Pump Hydrostatic Pump Filter Charge Pressure Sensor (switch) Forward Multi Function Valve Reverse Multi Function Valve Servo Valve Assembly

9. 10. 11. 12. 13. 14. 15.

29-9

Forward High Pressure Line Reverse High Pressure Line Integrated Braking Components Hydrostatic Drive Motor Oil Cooler Bypass Valve Oil Cooler Temperature Sender

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 HYDROSTATIC BLOCK OPERATION (INTEGRATED BRAKE) The pressure regulator valve body, 1, is located in the pump’s end cap. It is held open (start position) by means of a compression spring, 2, above it. The pressure regulator valve becomes active when the pilot valve, 3, (high pressure relief valve, non-adjustable) opens due to increasing pressure and allows an oil flow through an axial orifice in the pressure regulator valve body, 1. This will cause a differential pressure on the valve body and the valve will move to the top against the spring force. While moving forward, it will increasingly throttle the oil flow in the circuit. In reverse driving direction, the check valve, 4, allows fluid to bypass the pressure regulator with low pressure drop. The bypass orifice, 5, is integrated into the pressure regulator valves body in the form of two radial bores. These bores will remain open although the pressure regulator may close the circuit completely. The travel of the pressure regulator valve is locked by means of a special spring guide, 6. This guide has two big radial bores and one small axial bore. When the pressure regulator valve contacts the spring guide, all the flow to the pilot valve has to pass through the small axial bores in the valve body and in the spring guide successively. This will restrict this flow. This saves the pilot relief valve if the high pressure is excessive and will prevent excessive loss of vehicle speed in reverse direction when opening the relief valve. The oil through the pilot valve goes back into the charge line.

REVERSE When the hydrostatic lever is moved to reverse the system operates the same as in forward other than high pressure line, 11, becomes the return line and high pressure line, 12, becomes the drive line. Also the drive pressure flows through the check valve, 15e, in the brake manifold block, 15. In reverse braking is achieved by the motor acting as a pump and its pressure is controlled by the multi function valve, 8, only and not by the brake manifold.

29-10

3 6 2 4 5

56062058

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1

6 3 2 1

20062052

20062053

9 Sectional View of Integrated Hydrostatic Brake

Position

Description

Pressure regulator valve body (with by-pass bores)

Spring on pressure regulator valve body

Spring Guide

Pilot Relief valve (SCR-type)

Check Valve

Spring on check valve

29-11

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1

3 6 2 5 1

56062054

10 Exploded View of Integrated Hydrostatic Brake

Position

Description

Pressure regulator valve body (with by-pass bores)

Spring on pressure regulator valve body

Spring Guide

Pilot Relief valve (SCR-type)

Check Valve

Spring on check valve

29-12

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1

4 1

56062051

11 Integrated Hydrostatic Brake Schematic

Item

Description

To hydrostatic pump

To pressure limiter

Check valve

Orifice

To charge pump

Pressure regulator valve

Pilot valve

29-13

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 GEAR CHANGING

TEMPERATURE CONTROL

When changing gear under certain conditions (i.e. changing gear while stood on a hill side) the pressure in the system may prevent the selection of a different drive gear.

The hydrostatic system also includes a high temperature control. The motor case drain line temperature sender monitors the temperature in the return line sending the information to the CCM1 Module.

To assist in the gear selection, when a gear change operation is required the drive motor, 16, electric solenoid is energized moving the pressure release solenoid valve, 16c, to connect the charge pressure line through the shuttle spool valve, 16a, to the pressure release spool, 16d. The pressure on the pressure release valve moves the spool, 16d, connecting the high pressure line to the return line relieving the pressure in the system. This will allow the gear selection to take place.

29-14

If the temperature exceeds 95°C (203°F), CCM1 will automatically reduce the current to the electric displacement proportional solenoid, reducing the swash plate angle independent of the hydrostatic lever position. An alarm message “A0008 HYDROSTATIC MOTOR TEMP HIGH” will be displayed to the operator on the instrument panel display. The temperature in the system will be reduced by the reduced power in the system.

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 MULTI FUNCTION VALVES The multi function valve has four functions, and three different valves. The valves with in the multi function valve are as follows: •

A Charge Pressure Check Valve to keep the system full of oil.

•

A Pressure Limiter Valve to make the work pressure (delta p) does not exceed 420 bar (6090 psi).

•

A High Pressure Relief Valve to protect the system from shock loads above 450 bar (6525 psi) (delta p).

The multi function valve also includes a bypass valve to enable the vehicle to be moved at very low speeds for short distances if an engine failure occurs. The bypass valve is a manually operated valve and oil flow generated by the drive motor (acting as a pump) is allowed to flow to the suction side of the motor.

29-15

A. Bypass Actuator B. Pressure Limiter Adjustment Screw C. Pressure Limiter Locknut D. Pressure Limiter Housing E. Pressure Limiter Spring F. Spring Seat G. Check Valve Carriage H. High Pressure Relief/check Valve Poppet J. Valve Seat K. Spring L. Pressure Limiter Poppet Seat M. Pressure Limiter Valve Poppet 8a -- 9a. Charge Check Valve 8b -- 9b.Pressure Limiter (420 bar) (6090 psi) 8c -- 9c. High Pressure Relief Valve (450 bar) (6525 psi) 8d -- 9d.Bypass Valve

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1

BSC1328A

12 Multi Function Valve Cross Section

BSC1299A

13 Multi Function Valve Schematic

29-16

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 Charge Check Valve 8a -- 9a When the charge pressure in port, Y, becomes higher than the pressure in the high pressure port, X, and enough to overcome the tension of spring, B, carrier, A, will move to he left taking along poppet C. Oil from the charge pump will flow from port, Y, to port, X, filling the system.

14 Pressure Limiter 8b -- 9b When high pressure exceeds 420 bar (6090 psi), poppet, D, will move to the left, compressing spring, E, due to the pressure behind the poppet pressurized oil will flow from port, X, into port, Z, to the main servo cylinder. The main servo cylinder will then move the swash plate of the hydrostatic pump towards neutral when the transmission is in drive mode and towards maximum displacement when the transmission is in brake mode.

29-17

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 High Pressure Relief Valve 8c -- 9c When the pressure limiter opens at 420 bar (6090 psi) a certain oil flow will escape through port, Z. If the pressure from the high pressure port, X, increases to 450 bar (6525 psi) due to shock loading, the pressure difference which is created over the plunger, C, will move the plunger towards the left against spring, B, and high pressure oil will be allowed to flow from port, X, to port, Y. In this phase, the pressure limiter function remains active as well (oil keeps flowing from port, X, to port, Z).

16 Bypass Valve 8d -- 9d When the bypass actuator, H, is turned 31/2 turns counterclockwise the force on poppet, J, is reduced. This sets the pressure limiter valve at near zero setting. When the pump is not turning but pressure is generated in the high pressure lines by the motor (motor acting as a pump), poppet, J, moves to the left, oil flows from port, X, through opening, G, to port, Z. Plunger, C, will also move easily to the left allowing the pressurized oil from port, X, to flow to port, Y. As pressure increases to the valve which equals spring B, plunger, C, will move to the left and allowing oil to flow directly from port, X, to port, Y, (oil keeps flowing from port, X, to port, Z).

29-18

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 SERVO VALVE System in Neutral Charge pump oil flows to both cavities, 20, from port, 21, oil also flows from port, 21, through the check valve orifice, 22, to the central land of servo spool valve, 28.

As the oil flow increases to the servo cylinder through port, 31, the displaced oil on the opposite servo cylinder will flow back through port, 32, and orifice, 33, past the spool, 28, through to the case drain through orifice, 34, and port, 35.

Charge pressure oil flows equally from cavity, 21, through the orifices, A and B, to cavity, 23, to the case drain. As the electric solenoid, 24, is not energized oil flow from cavities, 20, into cavity, 23, is the same, so the pressure in cavities, 25 and 27, will be equal and the spool assembly will remain in neutral.

NOTE: When the opposite direction of travel is selected spools, 26, and 28, will move to the left. The feed pressure to the servo cylinder will be through orifice, 33, and port, 32. Displaced oil from the opposite cylinder will flow to case drain through port, 36, and orifice, 37.

Servo Solenoid Valve 10a Energized Anchor, 29, of the servo solenoid valve 10a moves to the left when the solenoid is energized. The movement of anchor, 29, is proportional to the current through the solenoid dependant on the position of the hydrostatic lever.

As the swash plate moves the mechanical feed back linkage will move to the right compressing its internal spring when the spring force is equal to the pressure in cavity, 25, spool, 28, will move back to neutral holding the swash plate in its new position.

Oil flow from the left hand cavity, 20, to case drain cavity, 23, will decrease and the flow from the right hand cavity, 20, to cavity, 23, will increase. The pressure in cavity, 25, on the left side of the servo spool, 26, is higher than the pressure in cavity, 27, on the right hand side of the spool, 28, causing the spools, 26 and 28, to move to the right. The charge pump oil can now flow from the center of spool, 28, through the check valve orifice, 22, to the hydrostatic pump servo cylinder through orifice, 30, and port, 31, causing the pump swash plate to move.

Any movement of the swash plate or hydrostatic control lever will affect the balance of spring force and cavity pressure. The spool, 28, will then move to a position where the balance is restored If a shock load occurs in the system it will be felt by the pump swash plate and will create an increase in pressure in the servo cylinder lines and servo valve. To protect the servo valve from the increased pressure in the system the check valve 10c will open connecting the servo cylinder lined directly to the charge pressure circuit. In this circuit the pressure is limited by the charge pressure relief valve.

10. Servo Valve Assembly

28. Spool

10a. Servo Solenoid Valve

29. Anchor

10b. Orifice Check Valve

30. Servo Cylinder Port

10c. Servo Valve Spool

31. Orifice

20. Oil Cavity

32. Servo Cylinder Port

21. Oil Feed Port

33. Orifice

22. Check Valve Orifice

34. Orifice

23. Case Drain Cavity

35. Case Drain Port

24. Electric Proportional Solenoid

36. Case Drain Port

25. Spool Cavity

37. Orifice

26. Spool

38. Swash Plate Assembly (Feed Back)

27. Spool Cavity

29-19

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1

BSC1291A

18 Servo Valve Cross Section

BSC1290A

19 Servo Valve Schematic

29-20

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 HYDROSTATIC DRIVE MOTOR VALVES Shuttle Spool Valve When the pressure in either of the drive lines increases (forward or reverse selected) pilot pressure will act on one side of the shuttle spool valve, moving the spool valve to connect the return line to the flushing relief valve and pressure release solenoid valve. Flushing Relief Valve With the motor running in forward or reverse the pressure in the return line will act on the flushing relief valve opening the valve to case drain. Pressure Release Valve Circuit With the pump in neutral, pressure on each side of the motor may prevent gear changing (transmission lock up). When a gear change control is moved the pressure release solenoid, 16c, Figure 21, will energized, moving the solenoid valve, connecting the low pressure side of the circuit (through the shuttle spool valve) to the pressure release valve pilot. The pressure release valve will move connecting the motor drive lines to equalize the pressure in both lines allowing a smooth gear change to take place.

20 Drive Motor Shuttle Spool and Flushing Valve 16. Drive Motor 16a. Shuttle Spool Valve 16b. Flushing Relief Valve 16c. Pressure Release Solenoid Valve 16d. Pressure Release Spool

29-21

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1

21 Drive Motor Shuttle Spool and Flushing Valve

22 Drive Motor Schematic

29-22

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 OIL COOLER BYPASS VALVE The oil cooler bypass valve is thermostatically controlled and its function is to allow the hydrostatic system oil to reach maximum operating temperature in the shortest possible time. When the hydrostatic system oil temperature is below approximately 49°C (120°F) the oil cooler bypass valve thermostat assembly, 1, is closed and the oil will flow from port, A, down the center of sleeve, 2, and through port, B, to the oil reservoir. When the oil temperature rises above 49°C (120°F) the thermostat assembly, 1, will begin to open, moving sleeve, 2, down towards seal, 3. The oil will continue to flow from port, A, down the center of sleeve, 2, and through port, B, to the oil reservoir, it will also flow through open thermostat valve, 1, and through port, C, to the oil cooler. When the oil temperature reaches 63°C (145°F) the thermostat valve, 1, will be fully open and sleeve, 2, will seat against seal, 3, closing off the oil flow from port A to port B. The oil flow will now flow from port A through the thermostat valve, 1, through port, C, to the oil cooler. If the oil flow through the oil cooler becomes restricted and the cooler oil pressure rises to above approximately 3.1 bar (45 psi), the oil pressure acting though the center of sleeve, 2, onto seal, 3, will compress the spring, 4, allowing oil to flow through the center of sleeve, 2, through port, B, to the reservoir. 23 1. 2. 3. 4. A. B. C.

29-23

Thermostat Assembly Sleeve Seal Spring Inlet Port Reservoir Port Oil Cooler Port

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 HYDROSTATIC PUMP AND DRIVE MOTOR IDENTIFICATION NUMBERS Each pump has a name plate attached to the housing. The name plate will include the model number, model code and serial number. Model Code A The Sauer Danfoss model code defines the specific build configuration of each unit and must be used when ordering spare parts or a new pump. Model Number B The Sauer Danfoss model number is used by the factory in manufacturing. A new unit can be ordered by the model number. Serial Number C The Sauer Danfoss serial number identifies the location and date of manufacture and the unit sequence in the build. The letter coding indicates the location of original assembly “A” indicates assembly in Ames, Iowa, USA “N” indicates assembly in Neumunster, Germany. The first number (two digits) indicates the year of manufacture. For example, a unit built in 2001 would have the number “01” in this space. The second number (two digits) indicates the calendar week of manufacture, from week 1 to week 52. The third number (five digits) is the sequential build number identifying the specific unit.

29-24

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1

B A

BSC1349A

24 Pump Identification Name Plate

B A

BSC1348A

25 Motor Identification Name Plate

29-25

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 HYDROSTATIC PUMP The variable displacement pump is designed to convert an output power from the engine into hydraulic power. The input shaft turns the pump cylinder which contains a ring of pistons. The pistons run against a tilted plate (swash plate), this causes the pistons to compress the hydraulic oil which converts the input energy into the hydraulic oil. The high pressure oil then provides power to the motor.

The swash plate angle can be varied by the control piston, altering the swash plate angle varies the displacement of the oil. A larger angle causes greater displacement, a smaller angle reduces the displacement per revolution which in turn will result in a higher and also respectively lower speed of the motor.

6 7 8

9 DS00M007

26 Hydrostatic Pump 1. 2. 3. 4. 5. 6.

Charge Pump Cradle Hold Down Slider Block Servo Piston Servo Arm Servo Valve

7. 8. 9. 10. 11.

29-26

Feed Back Cradle Bearing Cradle Guide Cradle Cradle Lever

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 Pump Characteristics The pump characteristics can be found on the pump identification plate. (CR9040 and 9060 w/HD 11/111 Final Drives) 90 L 130 KP V BJ 8E L R F4 F 03 GB4 42 42 36 90 L 130 KP V BJ 8E L R F4 F 03 GB4 42 42 36

Series 90, closed circuit Left hand (counterclockwise rotation) Maximum displacement 130 cc/rev (7.9 in3/rev), Limited to 110 cc/rev (6.7 in3/rev) Electrical displacement control, Packard connector Pressure regulation Mounting pad End cap ports Integrated pressure filtering (long) Mechanical displacement limitation on both sides (non adjustable) Splined shaft -- 13 teeth -- pitch 8/16 Charge pump displacement 26 cc/rev (1.6 in3/rev) Control orifice dia P=0.81 mm (0.032″) Special hardware features 420 bar (6090 psi) high pressure setting port A 420 bar (6090 psi) high pressure setting port B 36 bar (522 psi) charge pressure setting at 1500 rpm [on the machine, approximately 38 bar (551 psi) will be measured at 2100 rpm]

(CR9040 and 9060 w/Planetary Final Drives) 90 L 130 KP V BJ 8E L 3 F4 F 03 GB4 42 42 36 90 L 130 KP V BJ 8E L 3 F4 F 03 GB4 42 42 36

Series 90, closed circuit Left hand (counterclockwise rotation) Maximum displacement 130 cc/rev (7.9 in3/rev) Electrical displacement control, Packard connector Pressure regulation Mounting pad End cap ports Integrated pressure filtering (long) No mechanical displacement limitation Splined shaft -- 13 teeth -- pitch 8/16 Charge pump displacement 26 cc/rev (1.6 in3/rev) Control orifice dia P=0.81 mm (0.032″) Special hardware features 420 bar (6090 psi) high pressure setting port A 420 bar (6090 psi) high pressure setting port B 36 bar (522 psi) charge pressure setting at 1500 rpm [on the machine, approximately 38 bar (551 psi) will be measured at 2100 rpm]

29-27

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 (CR9070) 90 L 130 KP V BJ 8E L 3 F4 F 03 GB4 42 42 36 90 L 130 KP V BJ 8E L 3 F4 F 03 GB2 42 42 36

Series 90, closed circuit Left hand (counterclockwise rotation) Maximum displacement 130 cc/rev (7.9 in3/rev) Electrical displacement control -- Packard connector Pressure regulation Mounting pad End cap ports Integrated pressure filtering (long) No mechanical displacement limitation Splined shaft -- 13 teeth -- pitch 8/16 Charge pump displacement 26 cc/rev (1.6 in3/rev) Control orifice dia P=0.81 mm (0.032″) Special hardware features 420 bar (6090 psi) high pressure setting port A 420 bar (6090 psi) high pressure setting port B 36 bar (522 psi) charge pressure setting at 1500 rpm [on the machine, approximately 38 bar (551 psi) will be measured at 2100 rpm]

29-28

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 HYDROSTATIC DRIVE MOTOR The fixed displacement motor is designed to convert input hydraulic power into output torque, it operates in reverse to the hydrostatic pump. The high pressure hydraulic oil enters through the input port, the oil pressure increases behind the pistons causing them to rotate down the swash plate (path of least resistance). As the piston rides up the swash plate again, the hydraulic oil is allowed to exit through the outlet port. The spinning pistons are housed in a cylinder which is connected to the output shaft, the output torque can be applied to the transmission input.

5 6

1 10

50050063

27 Hydrostatic Drive Motor Cutaway View 1. 2. 3. 4. 5.

Input shaft Valve plate Cylinder block Piston Swash plate

6. 7. 8. 9. 10.

29-29

Output shaft Loop flushing valve Charge relief valve Pressure release solenoid valve Pressure release spool

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1 Drive Motor Characteristics The drive motor characteristics can be found on the pump identification plate. (CR9040 and 9060 w/HD 11/111 Final Drives) 90 M 100 NC 0 N U N 0 F1 C 00 PAA 0000 H0 90 M 100 NC 0 N U N 0 F1 C 00 PAA 0000 H0

Series 90, closed circuit Fixed displacement bi-directional rotation Displacement 100 cc/rev (6.1 in3/rev) Standard Standard Standard Axial ports (SAE J518C code 62) (special end cap with FOI and increased flushing) Standard Standard Splined shaft -- 13 teeth -- pitch 8/16 Dual position loop flushing system Standard Hardware special feature -- longer endcap screw Standard Loop flushing orifice diameter 2.4 mm (0.094″), 16 bar (232 psi) opening pressure

(CR9040 and 9060 w/Planetary Final Drives; CR9070) 90 M 130 NC 0 N U N 0 F1 D 00 LAA 0000 NH 90 M 130 NC 0 N U N 0 F1 D 00 LAA 0000 NH

Series 90, closed circuit Fixed displacement bi-directional rotation Displacement 130 cc/rev (7.9 in3/rev) Standard Standard Standard Axial ports (SAE J518C code 62) -- special end cap with FOI and increased flushing Standard Standard Splined shaft -- 13 teeth -- pitch 8/16 Dual position loop flushing system Standard Hardware special feature -- longer end cap screw Standard Non adjustable orifice valve for loop flushing -- special execution

29-30

SECTION 29 - HYDROSTATIC SYSTEM - CHAPTER 2

SECTION 29 - HYDROSTATIC SYSTEM Chapter 2 - Filling the Hydrostatic System/Start-up Procedure CONTENTS Section

Description

Page

29 000

Filling the Hydrostatic System and Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

29-1

SECTION 29 - HYDROSTATIC SYSTEM - CHAPTER 2 FILLING THE HYDROSTATIC SYSTEM AND START-UP PROCEDURE To fill and start-up the hydrostatic system after repair or replacement of hydrostatic components, proceed as follows: NOTE: Before installing a new motor or a new pump, shipment oil should be drained from the new pump or motor case. IMPORTANT: Oil quality and cleanliness is of utmost importance for the reliability and life of the hydrostatic system. Deviation of the described oil specification may lead to severe damage and void the warranty! 1. Put suitable wheel chocks in front and behind the front wheels to prevent the machine from moving. For machines not equipped with powered rear axles also put blocks in front and behind the rear wheels. For machines equipped with a powered rear axle, the rear axle must be jacked up and placed on suitable jack stands so that the rear tires do not touch the ground. Turn the powered rear axle off using the switch in the cab.

DANGER Ensure the powered rear axle is securely suspended off the ground and is turned off to prevent unexpected movement of the combine. Failure to comply will result in death or serious injury. 2. Remove the half-shafts, 1. See Section 25 -Front Mechanical Drive -- Chapter 1 -- Planetary Final Drive -- Half-Shaft -- Removal.

29-2

SECTION 29 - HYDROSTATIC SYSTEM - CHAPTER 2 DANGER Before disconnecting the drive shafts, secure the machine safely in place by placing adequate wheel chocks against the front and rear of both traction and steering wheels. Failure to comply will result in death or serious injury.

3. Fill the hydrostatic system with oil through the oil reservoir, 1. Use oil with the following specification: All Markets Except North America NH Ambra Hydrosystem 46HV (ref. NH 646H), NH Ambra Hydrosystem 46 B10-S (ref. NH 646BS), NH Ambra Hydrosystem 46 B10-V (ref. NH 646BV)

BSC1264

North America Only M2C134-D or an oil meeting the following specification: DIN 51524 or ISO VG 46. The reservoir should hold approximately 50 L (13 US gal). 4. Loosen the suction line, 3, at the pump until oil leaks out. Tighten the suction line, 3.

86063009

3 5. Loosen the hydrostatic motor drain plug, 2.

1 2 4

29-3

SECTION 29 - HYDROSTATIC SYSTEM - CHAPTER 2 6. Disconnect hose between the hydrostatic pump and the oil cooler bypass valve at the pump, L2, port. Fill the pump with oil through port, L2, until oil leaks out of the hydrostatic motor.

7. Tighten the hydrostatic motor drain plug, 2, FigureNO TAG, to a torque of 34 N⋅m (25 ft-lb) and continue to fill up the pump to obtain maximum oil level in the pump case. 8. Connect and tighten hose from the oil cooler bypass valve to the hydrostatic pump at port L2. 86063011

5 CR9040, CR9060 and CR9070 9. Remove fuse F-28, 1, from the fuse panel to prevent the engine from running during cranking.

1 50020070

6 10. Install pressure gauges (range 0 - 600 bar) (0 9000 PSI) to the hydrostatic pump test ports M1, Figure 7, and M2, Figure 8. 11. Shift the transmission into neutral and crank the engine with the starter motor until a pressure gauge reading of 2.0 bar (29 PSI) is obtained. NOTE: Only crank the engine for a maximum of 30 seconds at a time. Wait at least 1 minute before recranking to avoid damaging the starter motor.

12. Fill the reservoir to the maximum level. Install fuse F-28, 1, Figure 6. Start and run the engine at low idle until a minimum pressure gauge reading of 20 bar (290 PSI) is obtained.

86063009

WARNING Make sure all people are clear and remain clear of the machine before starting the engine. Failure to comply could result in serious injury or death.

29-4

SECTION 29 - HYDROSTATIC SYSTEM - CHAPTER 2 WARNING

Never operate the engine in a closed building. Proper ventilation is required under all circumstances. Failure to comply could result in death or serious injury. 13. Shift the transmission into 4th gear and hold the brake pedals down. 14. Move the hydrostatic lever slightly forward until the forward (M1), Figure 7, pressure gauge reading is a minimum of 50 bar (725 PSI) and a maximum of 80 bar (1160 PSI). Do this for approximately 1 minute.

86063011

15. Move the hydrostatic lever slightly rearward until the reverse (M2), Figure 8, pressure gauge reading is a minimum of 50 bar (725 PSI) and a maximum of 80 bar (1160 PSI). Do this for approximately 1 minute. 16. Shut off the combine. Check the oil level, add oil if necessary. Check for oil leaks. 17. Restart the combine engine. Gearshift to neutral and engine speed on low idle. Position the hydrostatic lever at half stroke for one minute, both forward and reverse. 18. Gearshift remains in neutral and engine speed on high idle. Position the hydrostatic lever at maximum stroke for two minutes, both forward and reverse. 19. Gearshift to 4th gear and engine speed on high idle. Apply both brake pedals firmly. Apply maximum stroke on the control lever in forward position for a maximum of 10 seconds. Pressure should be 420 to 450 bar (6092 -- 6526 PSI). Repeat the procedure for reverse. 20. Switch off the engine. Remove the pressure gauges from the machine. Check the oil level, add oil if necessary. Check for oil leaks. 21. For machines equipped with powered rear axles continue to remove the air from the system. Refer to Section 41 -- Steering Axle -- Chapter 4 -Hydrostatic Motor -- Overhaul -- Bleeding the Rear Axle System. 22. For machines not equipped with powered rear axles, install the transmission half-shafts as described in Section 25 -- Front Mechanical Drives -- Chapter 1 -- Planetary Final Drive -Half-Shaft -- Installation.

29-5

SECTION 29 - HYDROSTATIC SYSTEM - CHAPTER 2

29-6

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3

SECTION 29 -- HYDROSTATIC SYSTEM Chapter 3 -- Powered Rear Axle CONTENTS Section

Description

Page

29-1

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 SPECIFICATIONS

56061400

1 1. 2.

Selector Valve Identification

Serial Number Build Date

Each selector valve has a Serial Number and a build date stamped in the side of the valve body.

SELECTOR VALVE Description

Specification

Valve Type

4 way, 2-position 1 spool, Pilot operated

Flow Rate

238 L/min (63 US gpm)

Maximum Operating Pressure

450 bar (6500 psi)

Cartridge Valve

3-way, 2-position 12 volts DC solenoid

29-2

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3

53061401

2 1. 2.

Flow Rate (gpm) Direction of regulated flow

Flow Regulator Identification

Each Flow Regulator shows the direction of regulated flow and has a flow rate (gpm) stamped in the outer housing. (Text on regulator may be different than shown.)

FLOW REGULATOR (OPTIONAL) Description

Specifications

Valve Type

Pressure compensated flow control, free flow return

Flow Rate

57 -- 152 L/min (15 -- 40 US gpm)

Maximum Operating Pressure

450 bar (6500 psi)

29-3

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 DESCRIPTION OF OPERATION 2WD--4WD HYDRAULIC SYSTEM -- OVERVIEW

1 3

66060571

3 Hydrostatic System with Powered Rear Axle -- Schematic 1. 2. 3. 4.

Hydrostatic Pump (mounted at PTO gearbox) Hydrostatic Motor (mounted at ground drive transmission) Powered Rear Axle Selector Valve (mounted in front of rear axle) Powered Rear Axle Wheel Motors

of oil flow to the powered rear axle will vary based on the path of least resistance; as the load against the hydrostatic motor, 2, increases as compared to the rear axle wheel motors, oil will be diverted to the powered rear axle wheel motors to provide additional tractive effort. In severe muddy or hilly conditions where rear axle slippage occurs, optional flow regulators may need to be installed to limit the amount of oil flow to the wheel motors.

The optional powered rear axle provides additional tractive effort when operating in muddy or hilly fields. The powered rear axle is connected in parallel with the hydrostatic system on the combine, and receives oil flow to the wheel motors from the hydrostatic pump, 1. When the powered rear axle is engaged, some of the hydrostatic system oil flow will be diverted through the powered rear axle selector valve, 3, to power the wheel motors, 4. The amount

29-4

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 The forward and reverse high pressure lines for the powered rear axle connect across the main drive lines of the hydrostatic pump. Each line is paralleled across its corresponding main drive line at adapter block, 1.

86060572

4 Case drain for the selector valve is returned directly to the hydraulic fluid reservoir at 1. Case drain for the PRA motors, 2, passes through the hydraulic cooling circuit before returning to the reservoir.

86060573

29-5

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 9

7 7 2 8

1 6 3

66060570

6 Powered Rear Axle System 1. 2. 3. 4. 5.

Selector Valve Right Wheel Motor Left Wheel Motor Forward High Pressure Inlet Line Reverse High Pressure Inlet Line

6. 7. 8. 9. 10.

29-6

Return to Tank (Reservoir) Line Motor Case Drain Line Case Drain to Cooling Circuit Line Hydraulic Fluid Reservoir Hydrostatic Pump

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 2WD-4WD HYDRAULIC SYSTEM -- DETAILED VIEW

4 5 6 3

A B C

56061422

7 Component Identification 1. 2. 3. 4. 5. 6.

Two speed valve Single speed valve Valve location on wheel hub Wheel motor top pin (hose connections) Two speed spool Wheel motor pistons

A. High Pressure B. Charge Pressure C. Pilot Pressure (From two speed or single speedvalve) D. Case Drain E. Grease cavities

On axles equipped with a two speed valve, 1, a solenoid valve is used to either allow the oil to drain from the spring end of the two speed spool, 5, or pilot pressure oil from the cartridge valve is directed to shift the two speed spool inwards against the spring to engage the “Full Speed -- Half Torque” operating mode.

Oil flow enters the wheel motors through the hose connections in the top pin, 4, of the wheel motors, and travels across the two speed spool, 5, to the wheel motor pistons, 6. On single speed axles, the valve, 2, allows oil to drain from the spring end of the two speed spool, 5, allowing the spring to keep the spool positioned in the “Full Torque -- Half Speed” position. Case drain oil from the wheel motor also flows through the valve and out the wheel motor top pin.

29-7

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 Forward Full Torque - Half Speed (All Axles)

A C

B D

56061423

8 Forward Full Torque (Half Speed) A. High Pressure B. Charge Pressure C. Pilot Pressure

D. Case Drain E. Grease Cavities

Oil flow from the forward high pressure lines passes through the wheel motor top pin, 3, and flows to the two speed spool, 4. The spring end of the spool is open to case drain through the single speed, 2, or two speed, 1, valve, so the spring positions the two speed valve to allow oil flow to half of the pistons in the

wheel motor at a time. Because the forward high pressure oil is acting on so many pistons, the wheels turn slowly but with high torque capabilities. In this operating mode, the two speed valve, 1, solenoid (optional) is not energized.

29-8

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 Forward Full Speed - Half Torque (Two Speed Axle Only)

A C

D E 56061424

9 Forward Full Speed (Half Torque) A. High Pressure B. Charge Pressure C. Pilot Pressure

D. Case Drain E. Grease Cavities

Charge pressure oil (or high pressure oil, depending on direction of travel) is supplied from the reverse high pressure side of the circuit to port (P) of the two speed valve. The cartridge valve, 2, acts as a regulator valve to reduce the pressure to a lower level for use as pilot pressure oil.

one quarter of the pistons are supplied with oil from the forward high pressure circuit. Because the forward high pressure oil is acting on fewer pistons, the wheels turn quickly but with lower torque capabilities. This can be useful for severe muddy or hilly field conditions where powered rear wheel slippage is a problem by reducing the drive torque at the wheel motors.

When the two speed valve solenoid, 1, is energized, pilot pressure supplied from the cartridge valve, 2, flows through the solenoid valve to the spring end of the two speed spool, 3, causing it to be shifted inwards against the spring. This blocks off one of the supply galleries to the wheel motor pistons, so only

The wheel motor pistons that are not supplied with oil simply pump the oil trapped in them back and forth between themselves.

29-9

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 Powered Rear Axle OFF (Free Wheeling Mode)

A C

B D

56061427

10 Powered Rear Axle OFF (Free Wheeling Mode) A. High Pressure B. Charge Pressure C. Pilot Pressure

D. Case Drain E. Grease Cavities

The high pressure lines, 4, of the wheel motors are connected directly to the hydraulic fluid reservoir through the case drain line on the powered rear axle selector valve (not part of the steerable motor). The wheel motor case drain, 3, however, is connected to the oil cooling circuit line in order to circulate the wheel motor case drain oil through the oil cooler.

Because of the slight [approximately 1.5 bar (22 psi)] pressure differential between the two case drain pressures, the pistons of the motor are pushed into the cylinder block to avoid hard contact between the piston rollers and the motor cam ring due to centrifugal force while driving.

29-10

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 Cam Lobe Motor Operation

20042895

11 Operation and Tests 1. 2. 3. 4. 5. 6.

Power Stroke Transition to Return Return Stroke Transition to Power Cam Carrier

7. 8. 9. 10. 11.

Pressure oil, 9, is routed through the inner cover to the manifold, 8. Each of the 16 passages in the manifold is timed to one ramp on the cam, 5.

Piston Manifold Pressure Oil Oil in Transition Return Oil

motor. This gives a force balance on the carrier and axle assembly. With motor engaged, one group of pistons, 1, is in power stroke. As the piston follower is forced down the cam ramp, the carrier is forced to turn. Group, 3, pistons push return oil, 11, back through the manifold. Pressure, 10, indicates oil in transition from one port to another. As carrier turns, pistons, 4, at the top of the lobes begin their power stroke and the pistons, 2, at the bottom begin their return stroke.

The oil manifold is pressed against the piston carrier, 6, with only a thin film of oil separating the manifold and the carrier surfaces. The piston carrier is splined to the axle. Pressure oil is fed from the pressure passages in the manifold through passages in the carrier and into the piston bores. Return oil, 11, is routed from piston bores, through the carrier passages and into the manifold return passages. The cam lobe motor is designed so there are two pistons (in a 10 piston motor) doing the same thing at equal (180 degrees) distances around the

As one group ends its power stroke another group has begun. This overlapping of strokes, both power and return, serve to smooth the power (torque) applied to the axle.

29-11

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3

20042891

12 Cam Lobe Motor Operation (Full Supply Position)

As the piston and roller, 1, makes its way toward the bottom (valley) of the cam lobe, 2, the Maximum (full) supply of high pressure hydraulic oil momentarily is directed through the aligned ports, 3, of the distributor, 4, (remaining stationary) and cylinder

block, 5, rotating, with continuation on to the piston, 1. The oil supply then begins to taper off as the piston approaches the bottom of the cam lobe, 2, toward the neutral (no drive power) position.

29-12

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3

20042892

13 Bottom Neutral Position

When the piston, 1, is at the bottom of the cam lobe, 2, the oil supply is cut off. The ports, 3, in the distributor, 4, and the cylinder block, 5, are NOT in alignment with each other. In this neutral piston the piston does NOT provide power to the cylinder block, however, the piston (and roller) remains in the

contact with the cam surface. In order to continue driving power, another piston must take over for the first one to drive the cylinder block in the direction shown, enabling the first to climb the next cam lobe in a smooth and uninterrupted manner.

29-13

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3

20042893

14 Discharge Position

As the piston, 1, starts to climb the next cam lobe, 2, ports (passages), 3, in the distributor, 4, and cylinder block, 5, begin to align with each other, thus starting

the discharge cycle. This allows the hydraulic oil (under charge pressure) to return to the pump as another piston takes over to continue the drive cycle.

29-14

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3

20042894

15 Top Neutral Position

During the final cycle of the piston, 1, the piston continues to climb another cam lobe, 2. As this happens, ports, 3, in the distributor, 4, and the cylinder block, 5, progressively close off return oil flow as the piston (and roller) reaches the top (neutral) position.

When the roller is at the top of the cam lobe, the ports are no longer in alignment, thus ending a full drive cycle. The piston and its roller will then repeat the cycle starting with a gradual supply of high-pressure oil, while other pistons continue their cycles in a similar manner.

29-15

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 Selector Valve - Exploded View

2 3 6

9 1 12 5 11 18

17 17

16 4 5 4 7

10 11

56061402

16 Selector Valve 1. 2. 3. 4. 5. 6. 7. 8. 9.

Solenoid, 12 volts with wire leads Connector Pin, Terminal (2) Plug, 02 ORB-M Hex Socket Head (5) Plug, 04 ORB-M Hex Socket Head (3) Seal (2) Forward Adapter Drain Adapter Plug, M33

10. 11. 12. 13. 14. 15. 16. 17. 18.

29-16

Check Ball (2) Roll Pin (2) Spool Valve Body, machined Spring Reverse Adapter Dowel Pin Flow Regulator (optional) (4) Seal Kit

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 Flow Regulator - Exploded View

1 2 3 4 5 6

53061403

17 Flow Regulator 1. 2. 3. 4.

Adapter, M33 Baffle, Flow Regulator Spring Washer, Hardened

5. 6. 7.

29-17

Piston, Flow Regulator Body, Flow Regulator, M33 O-ring M33 Boss

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 SELECTOR VALVE -- DYNAMIC DESCRIPTION Low Pressure Shuttle (Forward) The low-pressure shuttle system of the powered rear axle selector valve is a combination of two check valves between the forward and reverse sides of the hydrostatic circuit, ahead of the selector spool. The shuttle system provides pilot (control) pressure oil to passage (A) at all times; even when the powered rear axle is off. Passage (A) feeds to the solenoid cartridge valve which directs charge pressure oil to engage the selector spool. There is always charge pressure on the return side of the hydrostatic circuit; for example, in the forward operating mode there is system pressure oil in the pump forward (PF) cavity and charge pressure oil in the pump reverse (PR) cavity. In this situation, the system pressure will be higher than the charge pressure. In forward operation system pressure oil will close off check ball (B). When the check ball closes off, check ball (C) will open up due to the dowel pin between check balls (B) and (C). This pin will not allow both balls to seat at the same time. When check ball (C) opens, this allows charge pressure oil to flow from the return (reverse) side of the circuit, past the check ball (C), past the spacer and into passage (A).

B A C

1 2 53061404

18 1. 2.

29-18

Low Pressure Shuttle (Forward) System Pressure Charge Pressure

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 Low Pressure Shuttle (Reverse) In the reverse operating mode there is system pressure oil in the pump reverse (PR) cavity and charge pressure oil in the pump forward (PF)cavity. System pressure oil will close off check ball (C). When the check ball closes off, check ball (B) will open up due to the dowel pin between balls (B) and (C). This pin will not allow both balls to seat at the same time. When check ball (B) opens, this allows charge pressure oil to flow from the forward side of the circuit, past the check ball (B), past the spacer and into passage (A).

B A C

1 2 53061405

19 1. 2.

Solenoid Valve The solenoid valve is a 3-way valve that controls the positioning of the selector spool (A) using charge pressure from the low pressure shuttle (P). When the powered rear axle is turned “OFF”, the solenoid is de-energized, and the charge pressure from the low pressure shuttle (P) is blocked internally in the solenoid valve. Cavity (S) of the selector spool (A) is connected to tank (T).

Low Pressure Shuttle (Reverse) System Pressure Charge Pressure

2 A 56061406

20 Solenoid Valve Energized -- Selector Spool OFF 1. Drain 2. Charge Pressure

29-19

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 When the powered rear axle is turned “ON”, the solenoid valve is energized, and the charge pressure oil (P) is now directed to passage (S) of the selector spool (A), shifting it into the ON position.

1 2

A 53061407

21 Solenoid Valve Energized -- Selector Spool ON 1. Drain 2. Charge Pressure

The powered rear axle selector valve is designed for use on machines having nominal flow rates greater than 227 L/min (60 US gpm) to the rear wheel assist drives. The valve is a spool type valve incorporating ON-OFF control of the assist axle and can be equipped with optional flow regulators, 1, for improved traction control when required.

2 1

When the selector valve solenoid is not activated, the selector valve spool, 2, blocks the high pressure oil flow and all motor and valve cavities are connected to tank. 56061409

22 An ON-OFF switch on the right console in the operator’s cab sends a 12 volts signal into the right hand module (RHM). The RHM sends a message across the CAN bus to CCM1, which activates the electric solenoid valve. The solenoid valve directs pilot pressure to move the selector spool, 1. This movement of the spool opens up internal passages within the valve to permit high system pressure oil to flow to the wheel motors. The oil flow is split between the wheel motors.

56061408

29-20

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 Selector Spool (OFF Position)

1 2 3 S

D 53061410

24 Selector Spool -- OFF Position 1. 2. 3.

Drain System Pressure Charge Pressure

With the powered rear axle system OFF, charge pressure oil in the control valve is blocked at the solenoid valve. Cavity (S) is exposed to tank through the solenoid cartridge. The spring pressure in cavity (D) holds the spool (A) in the OFF position. The spool prevents system pressure oil from entering both the forward or reverse inlet port and the rest of the valve; therefore no high pressure oil is delivered to the wheel motors.

In the off position the spool cavities (PF) and (PR) are closed off from motor cavities (MF) and (MR). Cavities (PF) and (PR) are the forward and reverse pressure inlet cavities; they will always be exposed to either system pressure or return (charge) pressure oil depending on direction of the machine. Cavity (MF) opens an oil flow path to the forward pressure ports of the wheel motors. Cavity (MR) similarly opens an oil flow path to the reverse pressure ports of the motors.

29-21

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 Selector Spool (On Position)

1 2 3

D 53061411

25 Selector Spool -- On Position 1. 2. 3.

Drain System Pressure Charge Pressure

When the switch in the cab is in the ON position, the coil within the solenoid valve is energized. Passages in the solenoid valve cartridge are opened and charge pressure oil is delivered to cavity (S) and shifts the spool (A), compressing the spring in cavity (D). When the spool arrives at its full ON position, passage (PF) is open to passage (MF), which provides forward system pressure to the forward pressure inlet ports of the motors. Passage (MR) is

open to passage (PR), which allows return flow (at charge pressure) to come from the motors and back to the return side of the hydrostatic circuit. In the reverse operation mode, the process is switched; where passages (MR) and (PR) are open to each other to provide reverse system pressure to the reverse pressure inlet ports of the motor. Passages (PF) and (MF) allow return flow to come from the motors.

29-22

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 FLOW REGULATOR (OPTIONAL) The Flow Regulator purpose is to limit maximum flow to a wheel drive motor due to the loss of traction. The normal result of losing traction is wheel spin out at the affected wheel. The effect of this is that the speed of the spinning motor can increase to the limit of available system flow. The torque is lost at other wheels due to pressure reduction in the system. The Flow Regulator mounts in the hydraulic line to a wheel motor, and controls only the flow to that motor or axle in one direction of rotation. Free flow is permitted in the opposite direction, and allows a second regulator valve to separately control flow in the opposite direction.

56061422

Flow Regulator, Normal Operation (flow below regulated value) The sliding spool (A) is used to control the oil flow from the hydrostatic system to the wheel motor, and contains a fixed reference orifice in the outer end. As oil flow increases through the flow regulator, the pressure drop through that orifice will cause the sliding spool to move into the regulator. The space between the mating edges of the sliding spool and the baffle (B) act as a variable orifice to balance the movement of the sliding spool.

2 A

56061413

1 27

1. 2.

29-23

Forward Direction Operation Oil Flow from Hydrostatic Pump Oil Flow to Wheel Motor

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 Flow Regulator, Flow at Regulated Value As flow rate through the valve approaches the controlled value, the spool (A) and baffle (B) compress the spring reducing the flow path to control the flow rate. The valve constantly modulates to maintain constant flow at the design reference value.

B 2

1 56061414

28 Forward Direction Operation, Regulated Oil Flow from Hydrostatic Pump Oil Flow to Wheel Motor

1. 2.

Flow Regulator, Flow in Return Direction When flow returns in the reverse direction, the spool (A) slides freely to the right. The spool will extend past the end of the body and allows for additional orifices to open. This allows for free flow return through the flow regulator.

2 56061415

29 1. 2.

29-24

Reverse Direction Operation Oil Flow to Wheel Motor Oil Flow from Hydrostatic Pump

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 HYDRAULIC LINE -- PLUMBING SCHEMA PRA HOSES

5 1 3

4 2

86054620

30 Front Right View of PRA Selector Valve 1. 2. 3. 4. 5. 6. 7.

Forward High Pressure from Hydrostatic System Reverse High Pressure from Hydrostatic System Forward High Pressure to Right Wheel Motor Reverse High Pressure to Right Wheel Motor Left Wheel Motor Case Drain Right Wheel Motor Case Drain Case Drain from Selector Valve

29-25

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3

3 86054622

31 Left Side View of PRA Selector Valve 1. 2. 3.

Forward High Pressure to Left Wheel Motor Reverse High Pressure to Left Wheel Motor Case Drain from Selector Valve

Hose routing from the powered rear axle selector valve to the wheel motors is dependent on the tread width setting of the rear axle.

29-26

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3

3 2

56061420

32 Hose Routing, Tread Width Position 1, 2, 3, 4 1. 2. 3. 4.

Hose support loops Forward high pressure lines Reverse high pressure lines Wheel motor case drain lines

Tread Width Positions 1, 2, 3, 4 With the rear axle tread width set in one of the first four positions, the hose fittings at the wheel motors need to be angled to the rear, and the loop support,

1, must be mounted on the rear of the axle. The hose bundle from the wheel motors loops to the rear of the axle, then passes forward through the loop support and across the front of the axle to the selector valve.

29-27

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 2

4 3

2 3

53061421

4 33

Hose Routing, Tread Width Position 5, 6, 7 1. 2. 3. 4.

Hose support loops Forward high pressure lines Reverse high pressure lines Wheel motor case drain lines

Tread Width Positions 5, 6, 7 With the rear axle tread width set to the three widest positions, the hose fittings at the wheel motors must be angled to the front, and the loop support is positioned on the front of the rear axle, inside of the

steering cylinder mounts. The hose bundle from the wheel motors is routed across the front of the axle, through the loop support, and then to the selector valve.

29-28

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 Wheel Motor Connections Three hoses are connected to each wheel motor for forward and reverse high pressure, and for case drain. On the left wheel motor, the forward-most port, 1, is for the forward high pressure hose, the middle port, 2, is for case drain, and the rearward-most port, 3, is for the reverse high pressure hose.

53031264

34 On the right wheel motor, the hose connections are opposite of the left wheel motor. The forward-most port, 1, is for the reverse high pressure hose, the middle port, 2, is for case drain, and the rearward-most port, 3, is for the forward high pressure hose.

53031265

29-29

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 TESTING SELECTOR VALVE

WARNING Hydraulic oil leaking under pressure can penetrate the skin and cause infection or other injury. To Prevent Personal Injury: Relieve all pressure, before disconnecting fluid lines. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Make sure that the outside of the selector valve is free from any dirt or grease. Dirt must NOT be allowed to enter the valve when removing any of the valve components. 1. Install 700 bar (10000 psi) pressure gauges in both the forward, 1, and reverse, 2, inlet hoses to the valve.

86054620

36 2. Install 70 bar (1000 psi) pressure gauges in one of the charge pressure test ports, 1, and drain test port, 2.

2 1

3. With the powered rear axle “ON”, record pressure readings with machine moving in forward and then reverse, while applying the service brakes to load the system. Sluggish (poor) performance of machine may be caused when charge pressure drops below 7 bar (100 psi), indicating excessive internal leakage somewhere in the hydrostatic system. Loss of adequate charge pressure can prevent the hydrostatic system from reaching maximum system pressure.

56061416

29-30

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 4. Leakage from the selector valve should not exceed 7.5 L/min (2 US gpm) with the machine operating at system pressure. To check the selector valve leakage, disconnect the drain hose, 1, from bottom fitting on valve and plug the hose end. 5. Suspend a large pail or container under the valve, and operate the vehicle under load by applying the service brakes while timing the flow from the selector valve drain port into the container. After 1 or 2 minutes of operation, measure the volume of oil in the container to calculate the flow rate. If the flow rate exceeds 7.5 L/min (2 US gpm), disassemble the selector valve to determine the source of excessive leakage. Replace the valve if necessary.

56061416

NOTE: The flow rate may pulse when shifting the valve. 6. Leakage from the wheel motors will vary depending on the size and type of motor. In general, leakage should not exceed 7.5 L/min (2 US gpm) from each wheel motor. To test the case drain flow from the wheel motors, disconnect the left wheel motor hose, 1, or right wheel motor hose, 2, from the tee assembly beside the selector valve, and cap the port on the tee assembly.

7. Suspend a large pail or container under the valve to catch oil flow from the wheel motor hose. Operate the vehicle with the powered rear axle engaged and under load by applying the service brakes while timing the flow into the container. After 1 or 2 minutes of operation, measure the volume of oil in the container to calculate the flow rate. Repeat the test for the opposite wheel motor.

86054620

2 39

NOTE: The flow rate may pulse when shifting the valve. 8. If excessive leakage exists, the wheel motor is worn internally and requires service. Refer to Section 41, Chapter 4, “Hydrostatic Motor -Disassembly” for repair information. If leakage is within specification, then components with the hydrostatic transmission of the combine may have excessive leakage; refer to Section 29, Chapter 1, “Hydrostatic Transmission” for additional information on the hydrostatic system components.

29-31

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 Test Selector Spool

1 3

86054620

40 2. Install a 70 bar (1000 psi) pressure gauge in one of the charge pressure test ports, 1, in the selector valve.

2 1

56061416

29-32

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 3. Operate the combine while monitoring the pressure readings as follows: •

•

With the powered rear axle “ON”, record pressure readings with combine moving in forward and then reverse while applying some load with the service brakes. With the powered rear axle “OFF”, record pressure readings with combine moving in forward and then reverse while applying some load with the service brakes. The charge pressure should be approximately 22 bar (320 psi) with the powered rear axle “ON”, and less than 1 bar (15 psi) with the powered rear axle “OFF”. The forward and reverse pressures should be greater than 35 bar (500 psi) in the line related to the direction of travel, and approximately 22 bar (320 psi) (charge pressure) in the return line.

4. If charge pressure reading in the sector valve is not correct with the powered rear axle “ON”, then the solenoid valve should be checked to be sure that the valve is shifting properly. Refer to “Troubleshooting -- Selector Valve -- Electrical Circuit” in this chapter for testing information. 5. If charge pressure reading is correct, but the forward and reverse line pressures to the wheel motors are less than 1 bar (15 psi) with the powered rear axle “ON”, then the control spool in the selector valve is not shifting. Forward and reverse pressures should be the same as the combine system pressure and charge pressure. 6. Loosen and remove the drain hose connection(1) from the bottom of the valve. Plug the hose to prevent draining the reservoir.

56061416

1 42

29-33

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 7. Remove bottom fitting, 1, from the selector valve. Check for free movement of the selector spool, 2, in the bore. If spool does not move freely, remove spool from bore and check for excessive wear on the spool and the bore. 8. Reinstall spool in bore and check again for free movement. If spool continues to stick, replacement of the complete selector valve is necessary.

56061419

29-34

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 Test Flow Regulators

1 3

NOTE: Optional flow regulators not shown. Install gauges between flow regulators and hoses to wheel motors.

83054620

2 44

29-35

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 2. Install a 70 bar (1000 psi) pressure gauge in one of the charge pressure test ports, 1, in the selector valve.

2 1

3. Operate the combine while monitoring the pressure readings as follows: •

•

56061416

4. If charge pressure reading in the selector valve is not correct with the powered rear axle “ON”, then the solenoid valve should be checked to be sure that the valve is shifting properly. Refer to “Troubleshooting -- Selector Valve -- Electrical Circuit” in this chapter for testing information. 5. If charge pressure reading is correct, but the forward and reverse line pressures to the wheel motors are less than 1 bar (15 psi) with the powered rear axle “ON”, then the selector spool in the selector valve is not shifting. Forward and reverse pressures should be the same as the combine system pressure and charge pressure. Refer to “Testing -- Selector Valve” in this chapter for additional information.

29-36

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 6. If the solenoid valve and the selector spool are shifting properly, the optional flow regulators may not be functioning properly. Loosen and remove the drain hose connection, 1, from the bottom of the valve. Plug the hose to prevent draining the PTO gearbox through the control valve when the flow regulators are removed. 7. Remove the hoses from the flow regulators and the flow regulators from the selector valve.

56061416

46 8. Check for free movement of piston, 1, in the bore of each flow regulator. If a piston does not move freely, remove piston, 1, washer, 2, spring, 3, and baffle, 4, from the suspect flow regulator by removing hydraulic adapter. Check all parts and bore for excessive wear. Reinstall spool in bore and check again for free movement. If spool continues to stick, replacement of the flow regulator is necessary.

4 1

3 2 56061403

29-37

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 TROUBLESHOOTING 2WD-4WD HYDRAULIC SYSTEM

•

Operation If an operator reports problems with the powered rear axle, detailed information of the concern should be gathered before attempting service of the axle components. Use the chart below for reference when investigating the concern.

•

Troubleshooting •

•

With the engine of the combine shut off, check for evidence of external oil leakage around seals, housing or hose connections. Also check for pinched or kinked hoses that could restrict oil flow and cause excessive heat build-up in the hydraulic oil. Check hydraulic oil level in the hydraulic fluid reservoir and add the correct amount and type of hydraulic oil, if necessary. Problem

Performance of powered rear axle is sluggish (poor).

Powered rear axle operates in only one direction (either Forward or Reverse).

•

Check the quality of the oil; change if milky, dirty or discolored. Also smell the oil. A burned odor indicates excessive heat that can destroy the lubricating qualities of the oil. Again, the oil should be changed if this condition is found. Determine the cause of the excessive heat and correct it. Determine if the hydrostatic filter is plugged or damaged. A filter that has failed will permit oil to bypass the system, affecting system operation and tests. Check the maintenance records with the machine to determine if the recommended service procedures have been made at the proper intervals. Check for previous reports of unusual, frequent or similar failures.

Possible Cause

Correction

Operating with transmission gearing too low.

System is more effective in higher gear.

Incorrectly plumbed main high pressure lines (forward and reverse).

Verify lines are installed correctly. Refer to Hydraulic line -- Plumbing schema for proper hose routing information.

Weak high pressure relief valve in the hydrostatic pump.

Refer to Section 29, Chapter 5, “Testing -- Multifunction Valve” for testing information.

Excessive case leakage from the powered rear axle wheel motors or selector valve.

Refer to “Testing -- Selector Valve” for testing information.

Inadequate charge pressure.

Refer to “Testing -- Selector Valve” for testing information.

Optional flow regulators are sticking internally.

Refer to “Testing -- Selector Valve” for testing information.

Excessive case leakage.

Refer to “Testing -- Selector Valve” for testing information.

Electrical circuit malfunction.

Refer to “Troubleshooting -Selector Valve -- Electrical Circuit” for testing information.

Stuck selector spool in control valve.

Disassemble valve and clean spool. If spool is damaged, replace the valve.

29-38

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 Problem One wheel of powered rear axle is dragging or locked up.

Powered rear axle is not functioning.

2 Speed powered rear axle operates in one speed only (either low or high).

Possible Cause

Correction

Incorrectly mounted high pressure hoses on hydraulic wheel motors.

Refer to Hydraulic line -- Plumbing schema for proper hose routing and connections.

Hydraulic wheel motor is locked up due to internal component failure.

With the combine OFF and wheels properly blocked, raise the affected wheel off the ground, and attempt to rotate the wheel by hand. If the wheel will not rotate, the wheel motor has failed. Service or replace the wheel motor; refer to Section 41, Chapter 4, “Hydrostatic Motor -- Removal” and “Hydrostatic Motor -- Disassembly” for additional information.

Low hydrostatic system fluid level.

Check the PTO gearbox oil level, and correct if necessary. Purge any air from the powered rear axle system; refer to “Bleeding the Rear Axle System” in Section 41 Chapter 4 for instructions.

Electrical circuit to selector valve is not functioning.

Refer to “Troubleshooting -- Selector Valve -- Electrical Circuit” for testing information.

Stuck selector spool in selector valve.

Disassemble valve and clean spool. If spool is damaged, replace the valve.

Excessive wheel motor leakage.

Refer to “Testing -- Selector Valve” for testing information.

Electrical circuit to 2 speed valve is not functioning properly.

Refer to Selector valve Two speed valve -- Testing for testing information.

2 speed spool sticking in wheel motor.

Carefully remove and inspect the 2 speed spool. If scoring or other damage is found, replace the wheel motor.

29-39

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 SELECTOR VALVE -- ELECTRICAL No

Test Point

Expected Result

Other Result (Possible Cause)

Key on. Enter the display “DIAG” screen, and view the “ERROR HISTORY”. Check for the following fault code: E0066-11 -- Rear Axle On/Off Valve.

If this fault code is not present, Go to test 2

If fault is present, refer to diagnostic procedure at Section 55, Chapter 18 -- “CCM1 Fault Codes -- Fault Code E0066-11”

Key on. Enter the display “DIAG” screen. Select the “GROUND DRIVE” group menu, and select “2-Spd PRA SW”. Depress the rear wheel assist switch S-10 on the right hand console. The “GRAPH” screen should change to indicate a voltage increase.

If voltage increases to approximately 12 volts, the electrical circuits test okay. Check the selector valve solenoid cartridge and valve spool for sticking.

If there is not a voltage increase when the switch is depressed, Go to test 3

Key on. Enter the display If there is 12 volts, Go to test 4 “DIAG” screen. Select the “VOLTAGE” group menu, and select “RHM Key SW”. The “GRAPH” screen should indicate approximately 12 volts.

If there is not 12 volts, a power supply circuit to the right hand console has failed. Go to test 6

Key on. Open the right hand console. Use a multimeter to check for voltage at switch connector X051 pin 2. There should be 12 volts.

If there is 12 volts, Go to test 5

If there is not 12 volts, there is an open circuit in the right console (RC) harness between connector X051 and splice block W-02 pin D wire 366 orange. Locate the open and repair.

Key on. Open the right hand console. Use a multimeter to check for voltage at the switch connector X051 pin 3 while depressing the rear wheel assist switch S-10. There should be 12 volts.

If there is 12 volts, there is an open circuit in the right console (RC) harness between connector X051 pin 3 and the RHM connector X029 pin 17 wire 336 yellow. Locate the open and repair.

If there is not 12 volts, the rear wheel assist (S-10) switch has failed. Replace the switch.

29-40

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 No

Test Point

Expected Result

Other Result (Possible Cause)

Key off. Check fuse F-48.

If fuse F-48 is good, Go to test 7

If fuse F-48 has failed, replace the fuse. If the fuse immediately fails again, there is a short to ground in the cab main (CM) harness or right console (RC) harness that is causing the fuse to fail. Refer to Section 55, Chapter 3, “Electrical schematic frame 25” for information on the circuits that are connected to fuse F-48. Locate the short and repair.

Key on. Disconnect connector X001 from the bottom of the right console. Use a multimeter to check for voltage at the cab main (CM) harness end of connector X001 pin 3. There should be 12 volts.

If there is 12 volts, there is an open circuit in the right console (RC) harness wire 108 orange, or at the harness splice. Refer to Section 55, Chapter 3, “Electrical schematic frame 25” for information on the right console circuits powered by fuse F-48. Locate the open and repair.

If there is not 12 volts, there is an open circuit in the cab main (CM) harness between fuse F-48 and connector X001 wire 108 orange. Locate the open and repair.

29-41

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 TWO-SPEED VALVE -- ELECTRICAL No

Test Point

Expected Result

Other Result (Possible Cause)

Key on. Enter the display “DIAG” screen, and view the “ERROR HISTORY”. Check for the following fault code: E0059-11 -- 2-Speed Powered Rear Axle.

If this fault code is not present, Go to test 2

If fault is present, refer to diagnostic procedure in “Section 55, Chapter 18 -“CCM1 Fault Codes --Fault Code E0059-11.”

Key on. Enter the display “DIAG” screen. Select the “GROUND DRIVE” group menu, and select “2-Spd F Hydro SW”. Depress the rear wheel assist Dual Range switch S-11 on the right hand console. The “GRAPH” screen should change to indicate a voltage increase.

If voltage increases to approximately 12 volts, the electrical circuits test okay. Check the two speed valve solenoid cartridge and valve spool for sticking.

If there is not a voltage increase when the switch is depressed, Go to test 3

Key on. Enter the display “DIAG” screen. Select the “VOLTAGE” group menu, and select “RHM Key SW”. The “GRAPH” screen should indicate approximately 12 volts.

If there is 12 volts, Go to test 4

If there is not 12 volts, a power supply circuit to the right hand console has failed. Go to test 6

Key on. Open the right hand console. Use a multimeter to check for voltage at switch connector X050 pin 2. There should be 12 volts.

If there is 12 volts, Go to test 5

If there is not 12 volts, there is an open circuit in the right console (RC) harness between connector X050 and splice block W-03 pin E wire 367 orange. Locate the open and repair.

Key on. Open the right hand console. Use a multimeter to check for voltage at switch connector X050 pin 3 while depressing the rear wheel assist Dual Range switch S-11. There should be 12 volts.

If there is 12 volts, there is an open circuit in the right console (RC) harness between connector X050 pin 3 and the RHM connector X029 pin 6 wire 337 yellow. Locate the open and repair.

If there is not 12 volts, the rear wheel assist dual range switch S-11 has failed. Replace the switch.

29-42

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 No

Test Point

Expected Result

Other Result (Possible Cause)

Key off. Check fuse F-48.

If fuse F-48 is good, Go to test 7

Key on. Disconnect connector X001 from the bottom of the right console. Use a multimeter to check for voltage at the cab main (CM) harness end of connector X001 pin 3. There should be 12 volts.

If there is not 12 volts, there is an open circuit in the cab main (CM) harness between fuse F-48 and connector X001 wire 108 orange. Locate the open and repair.

29-43

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3 REPAIR

20042887

CONTROL VALVE

6. Remove the four M6 capscrews, 3.

Replacement

7. Remove the valve assembly, 4.

1. To remove and install the Single Speed and Two Speed control valve from the machine it can be done without removing the motor from the C-frame.

8. Remove and discard the four O-rings, 5.

CAUTION Before you do service under the machine, put the machine on a level surface, engage the parking brake and stop the engine. Put blocks at the front and rear of the tires. Failure to follow these instructions can cause injury. 2. Turn the wheel to the steering stop to gain access to the valve. 3. Release the pressure in the supply circuit. 4. Disconnect the drain line at the tank level to avoid siphoning.

9. Make sure the valve and motor mounting surfaces are clean. Install new O-rings, 5. 10. Install the new valve assembly, 4. 11. Torque four capscrews, 3, to 12.5 -- 15.5 N⋅m (9.3 -- 11.3 ft-lb). 12. Reconnect the drain line and pressurize the supply system. 13. Bleed air from system by loosening bleed screw, 6, approximately one turn. Re-tighten after all air is bled from the system. 14. Re-connect the electrical connection. Add cover, 1, and two capscrews, 2. Torque capscrews to 22.5 -- 27.5 N⋅m (16.6 -- 20.2 ft-lb) (Two Speed Valve Only).

5. Remove two cap screws, 2, and cover, 1. Disconnect the electrical connection (Two Speed Valve Only).

29-44

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3

20042888

49 Overhaul NOTE: The solenoid valve can be replaced without removing the motor from the C-frame. 1. Turn the wheel to the steering stop to gain access to the valve.

CAUTION Before you do service under the machine, put the machine on a level surface, engage the parking brake and stop the engine. Put blocks at the front and rear of the tires. Failure to follow these instructions can cause injury. 2. Release the pressure in the supply circuit. 3. Disconnect the drain line at the tank level to avoid siphoning. 4. Disconnect the electrical connection. 5. Remove the two capscrews, 2, and cover, 1.

6. Remove the Hex nut, 5, magnetic winding, 4, and cartridge valve, 3. 7. Make sure new cartridge valve is clean. Lubricate O-rings with hydraulic fluid. Install new cartridge valve, 3, and torque to 24-- 30 N⋅m (17.8 -- 22.2 ft-lb). 8. Install new magnetic winding, 4, and Hex nut, 5. Torque nut to 2.7 -- 3.3 N⋅m (2.0 -- 2.4 ft-lb). 9. Re-clamp electrical leads and reconnect the electrical connection. 10. Reconnect the drain line and pressurize the supply line. 11. Bleed air from system by loosening bleed screw, 6, approximately one turn. Tighten after all air is bled from the system. 12. Re-install cover, 1, with capscrews, 2. Torque the capscrews, 2, to 22.5 -- 27.5 N⋅m (16.6 -- 20.2 ft-lb).

29-45

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3

20042886

50 Single Speed Valve Replacement 1. 2. 3. 4. 5.

Bleed Screw Bleed Screw Seal Spool Cap Wheel motor case drain lines Spool Spring

6. 7. 8. 9. 10.

Spring Seat Valve Block Metered Set Screw M14 Plug M18 Plug

20042889

51 Two Speed Valve Replacement 1. 2. 3. 4. 5. 6. 7.

Bleed Screw Bleed Screw Seal Spool Cap Cartridge Valve Spool Spring Spring Seat Valve Block

8. 9. 10. 11. 12. 13.

29-46

Metered Set Screw M18 Plug Solenoid Hex Pug Solenoid Magnetic Winding Solenoid Valve Small Metered Set Screw

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3

20042890

TWO-SPEED VALVE Replacement NOTE: The two-speed spool can be replaced without removing the motor from the C-frame 1. Turn the wheel to the steering stop to gain access to the spool. 2. Release the pressure in the supply circuit. 3. Disconnect the drain line at the tank level to avoid siphoning. 4. Remove the plug, 1. 5. Extract the spool, 3, with snap ring, 2, washer, 4, and spring, 5.

6. Remove the spring, 5, washer, 4, and snap ring, 2, from spool, 3. 7. Install the snap ring, 2, washer, 4, and spring, 5, onto the new spool, 3. 8. Oil, then install new spool assembly. 9. Re-install plug, 1. Torque to 285 -- 380 N⋅m (210 -- 280 ft-lb). 10. Reconnect the drain line and pressurize the supply system. 11. Bleed air from system by loosening bleed screw, 6, approximately one turn. Re-tighten after all air is bled from the system.

29-47

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 3

29-48

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 4

SECTION 29 - HYDROSTATIC SYSTEM Chapter 4 - Pressure Testing and Troubleshooting CONTENTS Section

Description

Page

29 000

29-1

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 4 SPECIFICATIONS Charge Relief, Pump . . . . . . . . . . . . . . . . . . . . . . . 38 bar (550 PSI) Pressure Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 bar (6090 PSI) Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 bar (6525 PSI) Approximate system pressures expected during testing: Charge Pressure Low Idle

High Idle

Neutral

36 bar 522 PSI

40.8 bar 592 PSI

Forward

28.3 bar 410 PSI

Reverse Forward Brakes On

Servo Pressure Forward Servo

Reverse Servo

Neutral

32.9 bar 477 PSI

10 bar 145 PSI

Forward

29.5 bar 428 PSI

33.4 bar 484 PSI

14 bar 203 PSI

5 bar 73 PSI

Reverse

26 bar 377 PSI

31 bar 450 PSI

7 bar 102 PSI

10.5 bar 152 PSI

Reverse Pressure

Forward Pressure

Low Idle

High Idle

Neutral

35 bar 508 PSI

90 bar 1305 PSI

Forward

20 bar 290 PSI

25 bar 363 PSI

30 bar 435 PSI

Reverse

65 bar 943 PSI

80 bar 1160 PSI

450 bar 6525 PSI

456 bar 6612 PSI

Reverse Brakes On

450 bar 6525 PSI

456 bar 6612 PSI

Low Idle

High Idle

Neutral

35 bar 508 PSI

38 bar 551 PSI

Forward

65 bar 943 PSI

Reverse Forward Brakes On

29-2

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 4 SPECIAL TOOLS NEW HOLLAND PART NUMBER

DESCRIPTION Universal Pressure Test Kit

FNH02003

Quad Gauge

OEM1212

Hydrostatic Test Set

FNH03132

Pressure gauge 0-40 bar (0 - 600 PSI)

OEM 1459

Pressure gauge 0 - 60 bar (0 - 1000 PSI)

OEM 1460

Pressure gauge 0 - 150 bar (0 - 2500 PSI)

Pressure gauge 0 - 600 bar (0 - 9000 PSI)

OEM1465

Quick release (female)

FNH00535

Adaptor, quick release

FNH00035 PARKER HANNIFIN PART NUMBER

FITTINGS Coupler, male (9/16″-18 UNF) [NH Part #86596853]

29-3

PD361

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 4 MAIN HYDROSTATIC SYSTEM, PRESSURE TESTING

WARNING

Various pressure and vacuum gauge readings are necessary for troubleshooting problems with the main hydrostatic drive system.

Gauges, gauge fittings and hoses MUST have operating pressure ratings of at least 25 per cent higher than the highest pressure of the circuit being tested.

To check the high pressure settings of the multi function valves it will be necessary to connect high pressure gauges to the system.

CAUTION

Measuring the charge pump inlet vacuum assist in locating restrictions in the suction lines and filter screen.

Block the front and rear wheels with suitable blocks so the machine cannot move. Make sure everyone is clear of the machine before starting the engine.

Case pressure readings will assist in locating restrictions in the return lines, oil cooler and filter.

CAUTION

The pump and motor charge pressure must be checked and recorded during pressure testing.

Never operate the engine in a closed building. Proper ventilation is required under all circumstances.

To make sure accurate pressure readings are obtained, the system must be at normal operating temperature and at full rated engine speed. IMPORTANT: The interior of all test equipment must be exceptionally clean before being used to test the hydrostatic drive system. Make sure the test equipment is purged of all oil and foreign material to avoid contamination of the hydrostatic drive system.

29-4

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 4 CHARGE PRESSURE NEW HOLLAND PART NUMBER

SPECIAL TOOLS Pressure gauge 0 - 60 bar (0 - 1000 PSI)

OEM 1460

(or) Quad Gauge

OEM1212

(or) Hydrostatic Test Set

FNH03132

Quick release (female)

FNH00535

Adaptor, quick release

FNH00035 PARKER HANNIFIN PART NUMBER

FITTINGS Coupler, male (9/16″-18 UNF) [NH Part #86596853]

PD361

The minimum allowable charge pressure for the pump is 24 bar (350 PSI) above the case drain pressure. To determine the actual charge pressure, subtract the case drain pressure from the charge pressure reading. Check the charge pressure at test port located at the charge pressure filter housing, 1. Remove the plug and install the male quick coupler. Use a minimum 60 bar (1000 PSI) pressure gauge. The measured pressure at this test point is charge pressure plus case drain pressure. 86063011

1 1

The charge pressure can also be measured at the drive motor,1, at test port, M8. To find the actual charge pressure, check the case pressure and subtract the case pressure reading from the charge pressure reading. Charge Pressure Low Idle

High Idle

Neutral

36 bar 522 PSI

40.8 bar 592 PSI

Forward

28.3 bar 410 PSI

32.9 bar 477 PSI

Reverse

29.5 bar 428 PSI

33.4 bar 484 PSI

Forward Brakes On

26 bar 377 PSI

31 bar 450 PSI

M8 2

29-5

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 4 SERVO PRESSURE NEW HOLLAND PART NUMBER

SPECIAL TOOLS Pressure gauge 0 - 40 bar (0 - 600 PSI)

OEM 1459

(or) Quad Gauge

OEM1212

(or) Hydrostatic Test Set

FNH03132

Quick release (female)

FNH00535

Adaptor, quick release

FNH00035 PARKER HANNIFIN PART NUMBER

FITTINGS Coupler, male (9/16″-18 UNF) [NH Part #86596853]

PD361

Gauges should be installed into the X1, 1, and X2, 2, ports of the control unit, located at the top of the pump. Remove the plugs and install the male quick coupler.

1 2

In neutral the pressure should be equal. As the forward or reverse is activated a pressure rise on one gauge should be countered with a corresponding pressure drop on the other gauge. This test may determine the reason for a unit that creeps whilst the lever is in neutral. Joining the ports together should stop the creeping, if this is the case adjust the neutral position within the control unit. If the unit still creeps when the ports are joined the pump will require replacement.

86063011

Servo Pressure Forward Servo

Reverse Servo

Neutral

10 bar 145 PSI

Forward

14 bar 203 PSI

5 bar 73 PSI

Reverse

7 bar 102 PSI

10.5 bar 152 PSI

29-6

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 4 HIGH PRESSURE NEW HOLLAND PART NUMBER

SPECIAL TOOLS Pressure gauge 0 - 600 bar (0 - 9000 PSI)

OEM 1465

(or) Hydrostatic Test Set

FNH03132

Quick release (female)

FNH00535

Adaptor, quick release

FNH00035 PARKER HANNIFIN PART NUMBER

FITTINGS Coupler, male (9/16″-18 UNF) [NH Part #86596853] The high pressure is determined by the two multi function valves, 1. The relief valve setting is 450 bar (6525 PSI). The pressure limiter will start to destroke the pump servo cylinders at 420 bar (6090 PSI). The high pressure can be checked at pump test ports M1 for forward, 2, and test port M2 for reverse, 3. The pressure can also be checked at the drive motor. Forward high pressure at test port M1 and reverse high pressure at test port M2.

PD361

CAUTION Block the front and rear wheels with suitable blocks so the machine cannot move. Make sure everyone is clear of the machine before starting the engine.

86063009

29-7

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 4 With the gauges installed put the transmission in 4th gear, start and run the engine at high idle, hold the brake pedals down and move the hydrostatic control lever forward, then rearward. Record the pressure gauge readings. Only hold the system in the overpressure situation for a few seconds and return to neutral as soon as possible.

CAUTION Never operate the engine in a closed building. proper ventilation is required under all circumstances.

Forward Pressure Low Idle

High Idle

Neutral

35 bar 508 PSI

38 bar 551 PSI

Forward

65 bar 943 PSI

90 bar 1035 PSI

Reverse

25 bar 363 PSI

30 bar 435 PSI

Forward Brakes On

450 bar 6525 PSI

456 bar 6612 PSI

Reverse Pressure Low Idle

High Idle

Neutral

35 bar 508 PSI

Forward

20 bar 290 PSI

Reverse

65 bar 943 PSI

80 bar 1160 PSI

Reverse Brakes On

450 bar 6525 PSI

456 bar 6612 PSI

29-8

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 4 TROUBLESHOOTING PROBLEM Machine will not operate in either direction.

POSSIBLE CAUSES

REMEDY

1. Low hydrostatic oil.

1. Check and fill the reservoir to the correct oil level. Use specified oil only.

2. Blocked hydrostatic filter.

2. Replace filter.

3. Air in system.

3. Locate and repair leak.

4. Exceeding relief valve pressure.

4. Shift to lower gear.

5. Transmission gear not selected or 5. Check transmission for correct inoperative. gear selection and engagement. 6. Servo valve not operating.

6. Check for displayed error code. Carry out electrical repairs as per error code. Check for sticking solenoid valve and servo spool linkage.

7. Drive system unable to build up 7. Air in system. Air will also cause pressure. the system to be noisy. Check all fittings, especially around the filter, in the suction line and locate the point or points where air is being drawn into the system. Tighten fittings and joints where air leaks exist. Replace seal where necessary. 8. Charge pressure relief valve is 8. Repair charge pressure relief stuck open. valve. Combine does not move when hydrostatic control lever is moved moved.

1. Transmission gear selector in 1. Select required gear. neutral. 2. Selected transmission gear too 2. Change to lower gear. high to move combine activating pressure override. 3. Reservoir oil level very low.

3. Check and fill the reservoir to the correct oil level. Used specified oil only.

4. Air in system (may be due to low oil 4. Purge air from system. Refer to level). Section 29, Chapter 2.

Hard to select a transmission gear, or will not go into gear.

5. Hydrostatic lines leaking.

5. Check, tighten or replace as necessary.

6. Blocked hydrostatic filter.

6. Check and replace filter element as necessary.

7. Servo solenoid not operating.

7. Check for displayed error code. Carry out electrical repairs as per error code. Check for sticking solenoid valve and servo spool linkage.

1. Hydrostatic pump not in neutral 1. Calibrate hydrostatic lever. though hydrostatic control lever is in neutral.

29-9

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 4 PROBLEM

POSSIBLE CAUSES

REMEDY

Neutral is difficult or impossible to find.

1. Hydrostatic lever out of calibration. 1. Calibrate hydrostatic lever.

Ground travel speed erratic.

1. Oil level low.

1. Check for leaks and repair as necessary.

2. Blocked oil filter element.

2. Change filter element.

3. Exceeding relief valve pressure.

3. Shift to lower gear. Repair or replace relief valve.

4. Unable to pressure.

Ground speed or combine erratic and loses power. Also seems to lack power. power

maintain

charge 4. The charge pressure relief valve is damaged or stuck open. Internal damage to pump or motor.

5. Cold or low oil supply.

5. Check oil levels. Allow oil to warm.

1. Reservoir oil level low.

1. Check and fill the reservoir to the correct oil level. Used specified oil only.

2. Hydraulic lines leaking.

2. Check level, fill as necessary.

3. Blocked hydrostatic filter.

3. Check and replace filter element as necessary.

4. Internal leaks or malfunction in 4. Pressure test system, repair or pump or motor. replace motor or pump as required. Oil temperature too high.

1. Low oil level.

1. Fill to correct level and check for leaks.

2. Blocked oil cooler.

2. Clean / replace as required.

3. Blocked inlet filter.

3. Replace filter.

4. System pressure too high, relief 4. Pressure test system, inspect valve continually blowing. multi function valves. 5. Brake flow control valve setting too 5. Replace brake flow control valve. low.

29-10

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 4 PROBLEM System noisy.

POSSIBLE CAUSES

REMEDY

1. Air in system.

1. Check and fill the reservoir to the correct oil level. Use specified oil only.

2. Suction line between reservoir and 2. Repair leaks. charge pump, including suction filter, leaking and allowing air to be drawn into the system, indicated by considerable amount of foam in the reservoir. 3. End of return line within the 3. Check and fill the reservoir to the reservoir not below the oil level. correct oil level. Used specified oil only. 4. Hose or tubing insulated.

Acceleration and deceleration sluggish.

not properly 4. Make sure all hoses and tubes are correctly routed and secured. Make sure the hoses and tubes are clear of any metal that will act as a sound board for normal hydraulic hum. Insulate hose and tube clamps with rubber to absorb sound.

1. Filter or suction line from reservoir 1. Replace filter element and check to charge pump is blocked. and remove obstructions from suction line. 2. Control orifice plug is partially 2. Inspect and clean /replace as blocked. required.

Unit surges.

3. Blocked hydrostatic filter.

3. Check and replace filter element as necessary.

4. Air in system.

4. Check fittings for air leaks. Repair as necessary.

5. Low charge pressure.

5. Inspect filter and hoses. Inspect charge pump relief valve. Inspect the charge pump.

1. Air in system.

1. Check fittings for air leaks between reservoir and charge pump. Repair as necessary.

2. Low hydrostatic oil.

2. Check and fill the reservoir to the correct oil level. Used specified oil only.

3. Blocked hydrostatic filter.

3. Check and replace filter element as necessary.

4. Exceeding relief valve pressure.

4. Shift to lower gear.

5. Unable to pressure.

Combine engine over revs when braking or driving downhill.

maintain

charge 5. Repair or replace charge pressure relief valve.

6. System contaminated.

6. Flush system.

7. Faulty pump.

7. Repair or replace pump.

1. Brake flow control valve setting too 1. Replace brake flow control valve. high.

29-11

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 4

29-12

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5

SECTION 29 - HYDROSTATIC SYSTEM Chapter 5 - Hydrostatic Pump and Motor Repair CONTENTS Section

Description

Page

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 29 212

29 218

Shaft Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

29 218

Shaft Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

29 218

Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

29 218

Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

29 212

Charge Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

29 212

29 218

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

29 218

29 212

29 218

Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

29-1

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 Section

Description

Page

Shuttle Spool Valve -- 100 cc/rev Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Motor Pressure Relief Valve -- 130 cc/rev Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Shuttle Spool Valve -- 130 cc/rev Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Pressure Release Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Pressure Release Valve Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

29-2

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 REPAIR Op. 29 212

MAIN HYDROSTATIC PUMP Removal NOTE: Most minor repairs can be performed with the pump still attached to the combine. The pump must be removed for major repairs. Drain the hydraulic reservoir through hose, 1, and catch the oil in a suitable container. 86063117

1 Remove the hydraulic lines, 1, from the fan drive pump, and cap the lines and ports on the pump. Remove the two mounting bolts, 2, and pull the fan drive pump away from the main hydrostatic pump.

56070844

2 Disconnect and cap hydraulic lines, 1, from the main hydrostatic pump. Turn four cap screws out from each fitting, 2, to disconnect the hydraulic lines from the pump. Cap the lines just removed. NOTE: When disconnecting hydraulic lines, have a suitable container readily available to capture any residual hydraulic oil.

Disconnect and cap hydraulic line, 3, from the main hydrostatic pump.

Disconnect and cap hydraulic line, 4, from the valve body.

86063009

29-3

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 Disconnect and cap hydraulic line, 1, from the main hydrostatic pump. Detach the connector, 2, from the oil pressure switch. Unplug the connector, 3, from the Electronic Displacement Control (EDC) valve.

Turn off oil filter, 4. Loosen but do not remove the four hydrostatic pump mounting nuts and washers.

NOTE: The main hydrostatic pump weighs approximately 137 kg (303 lb).

86063011

Securely attach the main hydrostatic pump to a tow motor or other suitable lifting device with a lifting strap, 1, or chain. Remove the mounting nuts and washers, lift the pump from the combine.

Op. 29 212 Installation

NOTE: The main hydrostatic pump weighs approximately 137 kg (303 lb). Securely attach the main hydrostatic pump to a tow motor or other suitable lifting device with a lifting strap or chain. Lubricate and install a new O-ring onto the mounting flange of the pump. Raise the pump to the mounting flange on the gearbox and turn on the four mounting nuts and washers. Tighten the nuts to standard torque.

4 1

86063011

Connect the electrical sensing line to the oil pressure switch at 1. Plug in the EDC valve connector at 2. Attach hydraulic line, 3, to the main hydrostatic pump. Torque the fitting to 110 -- 120 N⋅m (81 -- 89 ft-lb).

Turn on a new oil filter, 4. Attach hydraulic line, 1, to the main hydrostatic pump. Torque the fitting to 110 -- 120 N⋅m (81 -- 89 ft-lb).

Attach hydraulic line, 2, to the valve body. Torque the fitting to 255 -- 325 N⋅m (188 -- 240 ft-lb). Lubricate and install new O-rings into the flat fittings of lines, 3. Secure the hydraulic lines to the valve body with four cap screws for each fitting. Torque the cap screws to 159 N⋅m (117 ft-lb).

1 2 3

Prepare the system for operation in accordance with Section 29, Chapter 2 “Filling the Hydrostatic System and Start-Up Procedure”.

86063009

29-4

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 Op. 29 218

Shaft Seal Removal NOTE: The same procedures for the replacement of the shaft seal apply to the pump and the motor (pump shown).

1 1

1. Remove the pump/motor in accordance with their appropriate sections. 2. Remove cap screws, 1, holding the seal cover and the seal retainer, 2.

19992161

7 3. After removal of the cap screws, the seal cover may move out of its bore by approximately 6 mm (0.25 in). An outward spring force on the shaft will tend to overcome the friction from the O-ring on the seal cover outside diameter. If the seal cover does not move from its bore upon removal of the cap screws, then gently pry it from the bore as shown.

56072241

CAUTION After the seal cover is removed, the shaft is free and can be removed or may fall out of the unit. Do not remove shaft. 4. Place the seal cover and seal in an arbor press and remove the old seal. 5. Inspect the seal cover, the new seal, and the O-ring for any damage or nicks. 19988777

29-5

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 Op. 29 218 Shaft Seal Installation 1. Using an arbor press, install the new seal into the cover, being careful not to damage the seal. 2. Inspect the sealing area on the shaft for rust, wear, or contamination.

19988778

10 3. Prior to assembly, lubricate the O-ring on the outside diameter of the seal cover and the inside diameter of the seal with petroleum jelly.

19988779

11 4. Wrap the spline or key end of the shaft with plastic film to prevent damage to the sealing lip on the seal during installation. 5. Assemble the seal cover and seal, 1, over the shaft, 2, and into the seal cover cavity.

1 2

56072242

29-6

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 6. Install the cap screws, 1, and torque to 10 N⋅m (7 ft-lb) on motors and torque to 13.5 N⋅m (10 ft-lb) on pumps. 7. Install the pump/motor in accordance with their appropriate sections.

56072243

13 Op. 29 218 Shaft Removal NOTE: The pump and motor must be removed to replace the shaft. NOTE: The same procedures for replacement of the shaft apply to the pump and motor (pump shown). 1. Drain the oil from the reservoir.

2. Remove the pump/motor in accordance with their appropriate sections. 3. Remove the cap screws holding the seal cover and seal retainer, 1.

1 1

19992161

14 4. After removal of the cap screws, the seal cover may move out of its bore by approximately 6 mm (0.25 in). An outward spring force on the shaft will tend to overcome the friction from the O-ring on the seal cover outside diameter. If the seal cover does not move from its bore upon removal of the cap screws, then pry it from the bore, and/or lightly tap the end of the shaft with soft mallet.

56072241

29-7

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 NOTE: The inside diameter of the bearing is a press fit on the shaft and the outside diameter of the bearing is a slip fit in the housing. 5. Place the unit on the end cap and remove the shaft bearing assembly, 1. With the seal removed, the shaft assembly is free to be pulled from the housing.

19992167

16 6. The motor shaft is shown removed. 7. Inspect the sealing area on the shaft for rust, wear, or contamination.

19988780

17 8. Remove snap ring, 1, and press the bearing off the shaft.

1 Op. 29 218 Shaft Installation NOTE: Installation of both the pump and motor shaft are similar (pump shown). 1. Press the bearing on the shaft and install snap ring, 1. Use caution to prevent damage to the sealing surface on the bearing.

19988780

29-8

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 2. Install the shaft and bearing assembly through the front of the housing, aligning the shaft spline with the cylinder block spline. Continue to lower the shaft into the unit and carefully align the end of the shaft with the end cap journal bearing. Then lower the shaft and bearing assembly into position. Rotate the shaft by hand. The assembly should rotate freely. If it does not, correct the problem before proceeding. The torque required to turn the shaft (after break away) is:

19992167

Pump - 10 --17.6 N⋅m (7.5 -- 13 ft-lb) Motor - 11.5 --19 N⋅m (8.5 -- 14 ft-lb) 3. Wrap the end of shaft with plastic film to prevent damage to the sealing lip on the seal during installation. 4. Prior to assembly, lubricate O-ring on the outside diameter of the seal cover and the inside diameter of the seal with petroleum jelly. 5. Assemble the seal cover and seal over the shaft and into the seal cover cavity.

56072242

20 6. Install the cap screws, 1, and torque to 9.5 N⋅m (7 ft-lb) on motors and torque to 13.5 N⋅m (10 ft-lb) on pumps. 7. Install the pump/motor in accordance with their appropriate sections.

8. Shut the drain valve and screw on the dust cap. Prepare the system for operation in accordance with Section 29, Chapter 2 “Filling the Hydrostatic System and Start-Up Procedure”. 56072243

1 21

29-9

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 Op. 29 212

Charge Pump Removal 1. Using a hex wrench, remove the six screws, 1, holding the charge pump cover retainer. Mark the cover orientation before disassembly. 2. Remove the retainer, 2.

56072244

2 22

3. Remove the charge pump cover, 1, using prybars. Remove the coupling, 2, from the charge pump shaft.

56072256

23 4. Remove the charge pump shaft, 1, and charge pump drive key. Note location of key to aid assembly.

1 56072258

29-10

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 5. Remove the charge pump gerotor assembly, 1.

1 56072259

25 6. Remove the inner port plates, 1, and alignment pin, 2. 7. Inspect the port plates, gerotor assembly, bushings, and charge pump shaft for abnormal wear, damage, or foreign material.

56072260

1 26

Op. 29 212 Charge Pump Installation 1. Prior to installation, apply a small quantity of petroleum jelly to the ID, OD and side faces of the gerotor assembly. NOTE: The charge pump rotation is determined by the orientation of the gerotor assembly outer eccentric ring and the location of the alignment pin in the end cap. The combine uses counterclockwise rotation.

29-11

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 2. Install the inner port plate and outer ring, 1. Use the alignment pin, 2, to achieve the correct orientation.

56072260

28 3. Install the gerotor assembly, 1.

56072261

29 4. Install the charge pump drive key, 1, into the charge pump shaft, 2. 5. Install the charge pump shaft. The internallysplined end of the shaft is inserted first into the cavity.

56072259

2 30

29-12

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 6. Insert coupling, 1, on the shaft with the larger diameter end in first. 7. Install charge pump cover, making sure alignment hole, 2, goes over alignment pin, 3. Use caution not to damage the cover O-ring during assembly.

56072257

2 31

8. Install the charge pump cover retainer and the six hex screws. NOTE: Shown is the proper torquing sequence. Improper installation can cause charge pump failure. 2

9. Tighten bolts finger tight. Torque bolts 1 through 6 to 13.5 N⋅m (10 ft-lb) in proper sequence.

4 1

56072244

32 Major Repairs Major repairs are those which require the removal of the end cap or side cover. Repairs of this type are to be performed only by Sauer-Sundstrand Authorized Service Centers and/or original equipment manufacturers who have personnel adequately trained to perform these repairs. Performing major repairs on the Sauer Series 90, 100 cc and 130 cc Hydrostatic Transmissions may affect the unit warranty status.

29-13

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 ELECTRIC DISPLACEMENT CONTROL (EDC) VALVE Removal 1. Thoroughly clean external surfaces prior to removal of the control valve. Disconnect the connector at 1.

56072245

33 2. Using a hex wrench, remove six cap screws from the control valve, 1.

56072246

34 3. Lift the valve, 1, away from the housing.

56072247

29-14

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 Op. 29 218 Inspection

CAUTION Protect exposed surfaces and cavities from damage and foreign material. 1. Check the surface for nicks or damage. Look for any cracks in the surface. 2. Check that the orifice, 1, is in position.

40013258

36 3. To check for a plugged orifice, remove the spring retainer, 1, spring, 2, and orifice, 3. Clean any foreign material from the orifice.

19988754

37 4. Install the orifice, spring and retainer, 1.

40013258

1 38

29-15

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 Op. 29 218 Installation 1. In preparation for installing the control valve, place a new gasket on the housing. Inspect to assure that the control orifice and spring are in the proper position in the control valve. 2. Engage the pin, 1, on the control linkage in the mating hole, 2, in the link attached to the swash plate. 3. Set control valve into place.

1 2 40013259

39 4. Move the control valve, 1, into place against the pump housing, align the gasket and install the cap screws.

5. Torque the cap screws, 1, to 16 N⋅m (12 ft-lb).

56072246

40 6. Attach the connector at 1.

56072245

29-16

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 Op. 29 218

MULTI-FUNCTION VALVE Adjustment NOTE: Although the pump is shown removed for clarity, most repairs and adjustments can be made without removing the hydrostat.

WARNING The machine must be operating to check system pressures. Make certain that everyone is clear of the machine and all gauges are secured.

CAUTION Raise the combine drive wheels off the ground to prevent the combine from traveling uncontrolled when making adjustments. Be sure to use suitable blocking or jack stands to support the weight of the combine.

CAUTION If equipped with powered rear axle make certain the switch is off. 1. In order to set the pressure on the limiter or relief valves, the motor output shaft must be locked so it does not rotate. This may be accomplished by locking the brakes.

WARNING Take necessary precautions that the motor shaft remains locked during the adjusting procedure. 2. Install two 690 bar (10,000 psi) pressure gauges in the high pressure gauge ports, 1 and 2. 3. Start the combine and operate at normal speeds.

2 56072244

29-17

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 4. Loosen locking nut (smallest hex on multi-function valve), 1.

56072248

43 5. Insert a hex wrench into the pressure adjusting screw, 1. NOTE: A plastic dust cap may be used in the adjusting screw. 6. Move the control lever so that pressure increases in the high pressure closed circuit to the pressure limiter setting. The limiter setting is reached when the pressure stops increasing and remains steady at a given level as shown on the gauges.

CAUTION Keep clear of all drives. Rotating elements may cause serious bodily injury.

56072249

44 7. Rotate the pressure adjusting screw with the hex wrench until the desired pressure level is established as shown on the gauges. NOTE: Clockwise rotation of the adjustment screw will increase the pressure setting, and counterclockwise rotation will decrease the pressure setting. Each complete rotation of the adjusting screw changes the pressure setting by 93 bar (1350 psi). 8. While holding the hex wrench and pressure adjusting screw in the same position, tighten the adjusting screw locknut, 1, to 27 N⋅m (20 ft-lb) (5 mm wrench). Do not over-torque.

9. Move the control lever so the pump returns to neutral position. The pressure in the high pressure circuit should return to the charge pressure setting. To verify the actual pressure setting, repeat step #6. 10. Shut down the combine and remove the two 690 bar (10,000 psi) gauges and install the gauge port plugs.

56072250

11. The same procedure is used for setting the pressure on the other multi-function valves, but the control lever must be activated or moved in the opposite direction so that the pressure develops in the opposite high pressure side of the closed circuit.

29-18

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 Op. 29 218 Removal 1. Turn the desired multi-function valve, 1, from the pump port.

1 56072251

46 2. Inspect cartridge, 1, for damage to parts and O-rings.

56072252

1 47

Show below are the components of the multi-function cartridge.

19988743

29-19

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 Op. 29 218 Installation 1. Install the cartridge, 1, in the multi-function valve cavity.

1 56072252

49 2. Torque to 89 N⋅m (66 ft-lb).

CAUTION Do not over torque the multi-function valve cartridge.

1 56072251

PUMP CHARGE PRESSURE RELIEF VALVE

Adjustment To measure the pump charge pressure relief valve setting, install a 35 bar (500 psi) gauge in port 1. Start the combine and, with the hydrostatic transmission in neutral, record the pressure.

CAUTION Block the wheels so the machine cannot move. make certain that everyone is clear of the machine. The charge pump pressure reading should be 20.1 -- 21.2 bar (291 -- 308 psi). The gauge will read 22 -23 bar (320 -- 340 psi). This includes case pressure. If the pump charge pressure is not within specifications, adjust the relief valve as follows:

56072244

1. Loosen the jam nut, 2. 2. Turn the adjusting screw, 3, clockwise to increase the pressure and counterclockwise to decrease the pressure. 3. When the charge pump relief valve setting is within specifications, tighten the jam nut to 52 N⋅m (38 ft-lb) and remove the gauge. NOTE: The pressure will change at a rate of approximately 3.4 bar (50 psi) per turn.

29-20

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 Removal

NOTE: Before removing the screw-adjustable relief valve plug, mark the plug, locknut, and housing to approximately maintain the original adjustment when assembling. 1. Remove the screw-adjustable charge relief valve plug by loosening the locknut with a 1-1/16″ wrench and unscrewing the plug, 1, with a large screwdriver. 56072253

52 2. Remove the spring, 1, and relief valve poppet, 2.

56072254

53 3. Inspect the poppet and mating seat in the end cap for damage or foreign material.

56072255

29-21

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 Op. 29 218

Installation 1. Install the poppet, 1, and spring, 2.

56072254

55 2. Install the plug with its locknut, aligning the marks made at disassembly, and torque the locknut, 1, to 52 N⋅m (38 ft-lb). The shim adjustable relief valves are torqued to 68 N⋅m (50 ft-lb).

3. Check and adjust the charge pressure if necessary.

56072253

56 Op. 29 212

DRIVE MOTOR

Removal 1. Drain the hydraulic reservoir. NOTE: During removal of the three hydraulic lines, up to five additional gallons of fluid can be expected. A suitable container must be positioned under the lines to capture the residual hydraulic fluid. 2. Remove the two main hydraulic lines, 1, by turning out eight cap screws.

86054879

29-22

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 3. Unplug electrical connector, 1, from the solenoid.

Disconnect the case drain line, 2, at the upper elbow union. Unplug electrical connector, 3, from the sensor.

2 1

66054880

58 4. Support the weight of the motor with a floor jack. 100cc Motor -- Remove the four M12 x 45 bolts with hardened flat washers at 1.

130cc Motor -- Remove the four M16 x 45 bolts with hardened flat washers at 1. NOTE: 130 cc motor shown. 100cc motor is similar.

66054881

1 59

5. Move the motor away from the transmission until the spline shaft is disengaged. Lower the motor from the combine. 100cc motor -- Remove the pilot spacer ring from the gearbox if not extracted along with the motor removal.

66054882

29-23

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 Op. 29 212 Installation

1. Apply a coat of Molykote Type G-n Metal Assembly Paste to the hydrostatic motor splines, and then install the motor, 1, into the transmission, as follows: IMPORTANT: The hydrostatic motor spins at high speed and requires the above specified paste lubricant or equivalent applied to the splines for its high speed application, anti-sieze and anti-fretting properties. Do not substitute NH AMBRA GR75 MD GREASE or equivalent as this is for low speed applications.

1 2

86072861

NOTE: The combine may be equipped with either a 100cc or 130cc size hydrostatic motor. The 100cc motor is shown in this figure. Each size motor is secured with different size hardware and with different torque specifications. The larger body 130cc motor is secured in the outer set of threaded holes, 3. 100cc motor Install the pilot spacer ring onto the motor. Insert the motor straight into the gearbox, and then install four M12 x 45 bolts with hardened flat washers, 2. Remove motor support. Tighten and torque hardware to 109 – 120 N⋅m (80 – 88 ft-lb). 130cc motor Insert the motor straight into the gearbox, and then install four M16 x 45 bolts with hardened flat washers, 2. Remove motor support. Tighten and torque hardware to 269 – 297 N⋅m (198 – 219 ft-lb). 2. Engage the line, 1, into the elbow and tighten the fitting. Torque to 110 -- 120 N⋅m (81 -- 89 ft-lb).

Plug in the sensor connector, 2.

Plug in the solenoid connector, 3.

66054880

29-24

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 3. Lubricate and install O-rings into the ends of the main hydraulic lines, 1. Attach the lines to the motor using four cap screws for each fitting. Torque the cap screws to 104 N⋅m (77 ft-lb).

Prepare the system for operation in accordance with Section 29, Chapter 2 “Filling the Hydrostatic System and Start-Up Procedure”.

86054879

63 Major Repairs Major repairs are those repairs which require the removal of the end cap or side cover. Repairs of this type are to be performed only by Sauer-Sundstrand Authorized Service Centers and/or original equipment manufacturers who have personnel adequately trained to perform these repairs. Performing major repairs on the Sauer Series 90 Hydrostatic Transmission may affect the unit warranty status. Cleanliness is a primary means of assuring satisfactory hydraulic motor life, on either new or repaired units. Cleaning parts by using a clean solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign materials and chemicals. Protect all exposed sealing surfaces and open cavities from damage and foreign material. During the assembly of the Sauer Series 90 variable motor, all surfaces, which have relative motion between two parts, should be coated with a film of clean hydraulic oil. This will assure that these surfaces will be lubricated during start-up. Replace all O-rings and gaskets. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly. All gasket sealing surfaces must be cleaned prior to installing new gaskets.

29-25

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 Op. 29 218

MOTOR CHARGE RELIEF VALVE -- 100 CC/REV MOTOR Check NOTE: The motor charge pump relief valve is not adjustable. To measure the motor charge pressure relief valve, 1, setting, install a 35 bar (500 psi) gauge in gauge port 2. Start the combine. Engage the parking brake, put transmission in fourth gear and the engine at high idle. Apply pressure to the foot brake and stroke the hydrostat lever.

10013271

1 64

CAUTION Block the wheels so the machine cannot move. Make certain that everyone is clear of the machine. The motor charge pressure reading must be 18.1 ± 1.4 bar (262 ± 20 psi). The gauge will read 21 ± 1.4 bar (302 ± 20 psi). This includes case pressure. If the motor charge pressure is not within specification, check the pump charge pressure and adjust as previously described. Recheck the motor charge pressure, and if it is still out of specification, replace the relief valve.

29-26

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 Op. 29 218 Replace 1. Drain the hydraulic reservoir. 2. Remove the motor charge pressure relief valve, 1. NOTE: Motor shown removed for clarity.

1 10013271

65 3. Turn in the new relief valve, 1. Torque the valve to 52 N⋅m (38 ft-lbs).

2 10013272

29-27

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 Op. 29 218

SHUTTLE SPOOL VALVE -- 100 CC/REV MOTOR Removal NOTE: The motor is shown removed for clarity. 1. Drain the hydraulic reservoir.

2. Remove the cartridges, 1 and 2, from both sides of the valve. 10013273

67 3. Push the spool, 1, out of the motor.

10013274

68 4. Inspect parts for damage or foreign material.

20015831

29-28

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 Op. 29 218 Installation 1. Install the flushing valve spool, 1.

10013276

70 2. Install the cartridges, 1, on each end of the spool and torque them to 41 N⋅m (30 ft-lbs).

1 1

20015831

29-29

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 MOTOR CHARGE RELIEF VALVE -- 130 CC/REV MOTOR

Replacement

83054875

1. Drain the PTO gearbox reservoir. 2. Using a 22 mm wrench, remove the threaded plug, 1, that holds the charge pressure relief valve. NOTE: Motor shown removed for clarity. 3. Remove the plug, 1, spring, 2, and valve, 3.

83054877

73 4. Place the new relief valve, 1, in the relief valve cavity. Put the spring, 2, in after it, then the threaded plug, 3. Finger tighten the threaded plug.

83054876

29-30

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 5. Torque the threaded plug to 52 N⋅m (38 ft-lb). 6. Refill the hydrostatic transmission as described in Section 29, Chapter 2.

63054878

29-31

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 SHUTTLE SPOOL VALVE -- 130 CC/REV MOTOR

Removal

83054884

2. Using a 26 mm wrench, remove the hex plugs, 1, from both sides of the valve.

NOTE: The motor is shown removed for clarity. 3. Remove the plugs, 1, O-rings, 2, springs, 3, and retaining sleeves, 4, from both sides of the shuttle spool, 5.

5 4 3

63054886

2 77

4. Push the spool, 1, out of the motor.

83054885

29-32

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 5. Inspect parts for damage or foreign material.

83054887

79 Installation

CAUTION 1

Before you do service under the machine, put the machine on a level surface, engage the parking brake and stop the engine. Put blocks at the front and rear of the tires. Failure to follow these instructions can cause injury. 1. Insert the shuttle spool, 1, fully into the loop flushing valve cavity in the motor end cap. NOTE: Motor shown removed for clarity.

83054888

80 2. Insert each spring, 1, in its retainer sleeve, 2, and install the springs and sleeves in each end of the loop flushing valve cavity. Screw in the hex plugs, 3, with O-rings, 4, and finger tighten.

2 1

63054886

4 81

29-33

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 3. Torque the hex plugs to 68 N⋅m (50 ft-lb). 4. Refill the hydrostatic transmission as described in Section 29, Chapter 2.

83054883

29-34

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 PRESSURE RELEASE VALVE SOLENOID

Removal

1. Using a 19 mm wrench, remove the nut, 1, that holds the solenoid coil, 2, in place. NOTE: 130 cc/rev motor shown. 100 cc/rev motor is similar.

83054894

83 2. Remove the coil, 1, from the solenoid valve stem.

83054895

84 3. Using a 22 mm box-end wrench, remove the nut, 1, that holds the solenoid pressure relief valve in place.

83054896

29-35

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 4. Remove the solenoid pressure release valve, 1, from its cavity.

83054897

86 Installation

CAUTION Before you do service under the machine, put the machine on a level surface, engage the parking brake and stop the engine. Put blocks at the front and rear of the tires. Failure to follow these instructions can cause injury. 1. Install the solenoid pressure release valve, 1, in its cavity, using care to prevent damaging the seals. 83054897

NOTE: 130 cc/rev motor shown. 100 cc/rev motor is similar.

2. Replace the nut, 1, that holds the valve in place. Snug firmly with a 22 mm wrench.

83054896

29-36

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 3. Replace the coil, 1, on the solenoid valve stem.

83054895

89 4. Replace the nut, 1, that holds the solenoid coil, 2, in place. Tighten with a 19 mm wrench.

1 2

83054894

29-37

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 PRESSURE RELEASE VALVE SPOOL Removal

CAUTION Before you do service under the machine, put the machine on a level surface, engage the parking brake and stop the engine. Put blocks at the front and rear of the tires. Failure to follow these instructions can cause injury. 1. Drain the hydraulic reservoir. NOTE: The motor is shown removed for clarity. 2. Using a 22 mm socket wrench, remove the bolt, 1, from the lower right-hand corner of the motor faceplate. This will provide access to the pressure release spool retaining plug.

NOTE: 130 cc/rev motor shown. 100 cc/rev motor is similar.

1 83054890

91 3. The pressure release spool retaining plug is accessible through the hole, 1, in the lower right side of the motor faceplate. Use an 8 mm hex wrench to unscrew the plug.

1 83054891

92 4. Remove the retaining plug, 1, and pressure release spool, 2.

83054892

29-38

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 5. Remove the spring, 1, from the rear of the pressure release spool cavity.

83054893

94 Installation 6. Inspect the spring, 1, and the pressure release valve spool, 2, for damage or dirt before replacing them in the pressure release valve cavity.

83054893

95 7. Insert the spring first, then the spool, 1, in the pressure release valve cavity.

1 83054892

29-39

SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 5 8. Place the retaining plug in the threaded end of the cavity and tighten securely, using an 8 mm hex wrench. NOTE: The threaded plug will need to overcome the pressure of the spring to mesh with the cavity threads. Use the hex wrench to push the plug in far enough for the threads to catch.

83054891

97 9. Replace the lower right-hand faceplate bolt. Using a 22 mm socket wrench, tighten the bolt securely. 10. Refill the hydrostatic transmission as described in Section 29, Chapter 2.

83054890

29-40

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1

SECTION 33 -- BRAKES AND CONTROLS Chapter 1 -- Brakes and Controls CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Brake Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Bleeding the Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Brake Caliper and Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Parking Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Parking Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Parking Brake Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Manual Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Parking Brake Piston Travel and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Parking Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Bleeding the Hydraulic Parking Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Parking Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Parking Brake Caliper -- Cross Section View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

33-1

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 SPECIFICATIONS Service brake disc diameter

CR9040, 9060: . . . . . . . . . . . . . . . . 330 mm (13.0 in) (Optional) CR9040, CR9060 . . . 400 mm (15.75 in) CR9070 . . . . . . . . . . . . . . . . . . . . . 400 mm (15.75 in)

Service brake fluid

SAE DOT 3 (Factory fill fluid) SAE DOT 4 (High temperature stability)

Parking brake piston travel

3 -- 5 mm (0.12 -- 0.20 in)

Parking brake disc diameter

224 mm (8.82 in)

TIGHTENING TORQUES Hex Socket Head Bolts, Brake Caliper

260 -- 270 N⋅m (192 -- 200 ft-lb)

Bleeder Screws, Service Brake

25 -- 35 N⋅m (19 -- 26 ft-lb)

Banjo Bolts, Service Brake Line

25 -- 35 N⋅m (19 -- 26 ft-lb)

End Fittings, Service Brake Line

13 -- 15 N⋅m (10 -- 11 ft-lb)

Bolts, Parking Brake Caliper Mounting

190 -- 210 N⋅m (140 -- 155 ft-lb)

Bolts, Parking Brake housing

127 N⋅m (94 ft-lb)

Bleed Screw, Parking Brake

15 -- 18 N⋅m (11 -- 13 ft-lb)

90° Elbow, Hydraulic (Hydraulic supply fitting into parking brake housing)

45 -- 50 N⋅m (34 -- 36 ft-lb)

Fitting, Hydraulic Hose End (Hydraulic supply hose end fitting into 90° Elbow at the parking brake)

43 -- 47 N⋅m (32 -- 34 ft-lb)

33-2

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON-METERS (FOOT POUNDS) FOR NORMAL ASSEMBLY APPLICATIONS

METRIC NON-FLANGED HARDWARE AND LOCKNUTS PLATED W/ZnCr

UNPLATED

PLATED W/ZnCr

LOCKNUT CL.8 W/CL8.8 BOLT

2.6 (23)*

3.4 (30)*

3.7 (33)*

4.8 (42)*

2.3 (20)*

7.6 (67)*

8.9 (79)*

12 (102)*

13 (115)*

17 (150)*

7.8 (69)*

14 (124)*

18 (159)*

22 (195)*

28 (248)*

31 (274)*

40 (354)*

19 (169)*

M10

28 (21)

36 (27)

43 (32)

56 (41)

61 (45)

79 (58)

38 (28)

M12

49 (36)

63 (46)

75 (55)

97 (72)

107 (79)

138 (102)

66 (49)

M16

121 (89)

158 (117)

186 (137)

240 (177)

266 (196)

344 (254)

164 (121)

M20

237 (175)

307 (226)

375 (277)

485 (358)

519 (383)

671 (495)

330 (243)

M24

411 (303)

531 (392)

648 (478)

839 (619)

897 (662)

1160 (855)

572 (422)

CLASS 5.8

CLASS 8.8

NOMINAL SIZE

UNPLATED

PLATED W/ZnCr

1.7 (15)*

2.2 (19)*

5.8 (51)*

UNPLATED

CLASS 10.9

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION HEX CAP SCREW AND CARRIAGE BOLTS CLASSES 5.6 AND UP MANUFACTURER’S IDENTIFICATION

PROPERTY CLASS

HEX NUTS AND LOCKNUTS CLASSES 05 AND UP MANUFACTURER’S IDENTIFICATION

86529681 REV F 5.1

PROPERTY CLASS

CLOCK MARKING

33-3

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON-METERS (FOOT POUNDS) FOR NORMAL ASSEMBLY APPLICATIONS

INCH NON-FLANGED HARDWARE AND LOCKNUTS SAE GRADE 2 NOMINAL SIZE

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

SAE GRADE 5

UNPLATED or PLATED SILVER

PLATED W/ZnCr

6.2 (55)* 13 (115)* 23 (17) 37 (27) 57 (42) 81 (60) 112 (83) 198 (146) 193 (142) 289 (213)

SAE GRADE 8

PLATED W/ZnCr

GOLD

UNPLATED or PLATED SILVER

8.1 (72)* 17 (149)* 30 (22) 47 (35) 73 (54) 104 (77) 145 (107) 256 (189) 248 (183) 373 (275)

9.7 (86)* 20 (178)* 35 (26) 57 (42) 87 (64) 125 (92) 174 (128) 306 (226) 495 (365) 742 (547)

LOCKNUTS

PLATED W/ZnCr

GOLD

UNPLATED or PLATED SILVER

13 (112)* 26 (229)* 46 (34) 73 (54) 113 (83) 163 (120) 224 (165) 397 (293) 641 (473) 960 (708)

14 (121)* 28 (250)* 50 (37) 80 (59) 123 (91) 176 (130) 244 (180) 432 (319) 698 (515) 1048 (773)

18 (157)* 37 (324)* 65 (48) 104 (77) 159 (117) 229 (169) 316 (233) 560 (413) 904 (667) 1356 (1000)

GOLD

GR.B w/GR5 BOLT

GR.C w/GR8 BOLT

NOMINAL SIZE

8.5 (75)* 17.5 (155)* 31 (23) 50 (37) 76 (56) 111 (82) 153 (113) 271 (200) 437 (323) 654 (483)

12.2 (109)* 25 (220)* 44 (33) 71 (53) 108 (80) 156 (115) 215 (159) 383 (282) 617 (455) 924 (681)

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION CAP SCREWS AND CARRIAGE BOLTS

SAE GRADE 2

SAE GRADE 5

SAE GRADE 8 REGULAR NUTS

SAE GRADE 5 HEX NUTS

SAE GRADE 8 HEX NUTS

LOCKNUTS

GRADE IDENTIFICATION

GRADE A NO NOTCHES

GRADE A NO MARKS

GRADE B ONE CIRCUMFERENTIAL NOTCH

GRADE B THREE MARKS

GRADE C TWO CIRCUMFERENTIAL NOTCHES

GRADE C SIX MARKS MARKS NEED NOT BE LOCATED AT CORNERS

86529681 REV F 5.2

GRADE A NO MARK GRADE B LETTER B GRADE C LETTER C GRADE IDENTIFICATION

33-4

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 OVERHAUL BRAKE PADS Replacement IMPORTANT: Always replace the upper and lower brake pads at the same time. Use genuine CNH brake pads, as they will provide the best performance. To replace the upper right-hand side or left-hand side brake pads, proceed as follows: 1. Block the wheels adequately to prevent runaway of the combine.

86060925

2. Raise the feeder and lower the header safety stop, 1, onto the cylinder. Stop the engine.

1 1

3. On the upper brake caliper, remove two bolts, 1, and cover, 2.

2 4. Disconnect the electric wires at 1.

NOTE: Only the upper brake caliper pads have electrical connectors.

33-5

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 5. Remove pins, 1, out of the brake caliper and take out the brake pads, 2.

1 4 NOTE: If the piston seals are replaced, then the brakes must be bled. Reference: Bleeding the Brake System, in this chapter.

6. Check the condition of the piston seals, 1. If necessary, replace them. 7. Push the brake pistons, 2, into their housing to allow the installation of new brake pads.

5 8. Install new CNH brake pads.

9. Secure the brake pads, 2, with pins, 1.

1 6

33-6

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 10. Connect electric wires at, 1.

7 To replace the lower brake pads on both sides:

NOTE: There is no cover installed on the lower brake caliper. 11. On the lower brake caliper, remove pins, 1, out of the brake caliper and take out the brake pads, 2. NOTE: If the piston seals are replaced, then the brakes must be bled. Reference: Bleeding the Brake System, in this chapter. 12. Check the condition of the seals. If necessary, replace them.

13. Push the brake pistons into their housing to allow the installation of new brake pads.

14. Install new CNH brake pads. 15. Secure the brake pads, 2, with pins, 1, Figure 8. 16. Use the same procedure to replace the brake pads on the opposite side of the combine. 17. Bleed the brake system if brake piston seals were replaced. 18. At the brake fluid reservoir, 1, check the fluid level, 2. Add or remove fluid as required to adjust fluid level to mark on reservoir. Use only SAE DOT 3 brake fluid, or SAE DOT 4 fluid for higher temperature stability. NOTE: SAE DOT 3 (factory installed grade) and SAE DOT 4 (higher temperature stability grade) are mutually compatible if mixed, but the higher stability temperature provided by the DOT 4 fluid will be lowered.

19. Check the brakes for proper operation.

86060937

1 9

33-7

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 BRAKE CYLINDERS The two main cylinders, 1, are mutually connected with connectors, 2 and 3, and further with pipe, 4, to the fluid reservoir, 13, and with pipes, 5, to the brake cylinders. Fluid from the fluid reservoir, 13, follows pipe, 4, and is distributed at connector, 3. The fluid enters the brake main cylinder through port, 6, (pedal not engaged).

10 When both brake pedals are engaged, port, 6, is shut off by seal, 7, and fluid is pressed through port, 8, and pipes, 5, to the brake cylinder. Ball, 9, is lifted up in both main cylinders, 1, by plunger, 10.

When only one brake pedal is engaged, port, 6, is also shut off by seal, 7, and fluid is pressed through port, 8, and pipe, 5 (Figure 10), to the brake cylinder. In the other main cylinder, ball, 9, is pressed down by the fluid pressure coming from the first cylinder through connector, 2 (Figure 10), and seat, 11. The fluid flow is stopped by seal, 12.

6 11

33-8

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 BLEEDING THE BRAKE SYSTEM NOTE: As the brake pedals must be depressed several times while bleeding, this job requires two people. To bleed the brake system, proceed as follows: 1. Block the wheels adequately to prevent runaway of the combine. Raise the feeder and lower the header safety stop, 1, onto the cylinder. 86060925

Stop the engine.

1 12

The bleed procedures described below are performed in the following order: 1. Check the brake fluid level, 2, at the brake fluid reservoir, 1. Add or remove brake fluid as required. Use only SAE DOT 3 or SAE DOT 4. 2. Bleed the left-hand side circuit. 3. Bleed the connection pipe between the two main cylinders

4. Bleed the right-hand side circuit. NOTE: Catch bleed brake fluid in a container. Dispose of used fluid per local regulations. Do not reuse.

86060937

1 13

NOTE: SAE DOT 3 (factory installed grade) and SAE DOT 4 (higher temperature stability grade) are mutually compatible if mixed, but the higher stability temperature provided by the DOT 4 fluid will be lowered.

33-9

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 Bleed the left-hand side circuit as follows: NOTE: Monitor the brake fluid level in the reservoir as fluid is repetitively bled from the system.

1. Ensure the brake fluid reservoir is filled to the maximum fluid indicator mark on the reservoir. 2. Remove rubber caps from left-hand side bleed screws, 1, 2 and 3. 3. Slide a transparent hose over bleed screw, 1, to direct bleed brake fluid into a catch container. 4. Open bleed screw, 1.

2 56070045

5. Depress and hold the left-hand side brake pedal until fluid escapes. Do not release pedal. 6. Close bleed screw, 1. 7. Release and depress the left-hand side brake pedal several times to build up a pressure. 8. Depress and hold left-hand side brake pedal depressed under pressure. 9. Open bleed screw, 1, slightly to allow air and fluid to escape. 10. Close bleed screw, 1, and release the brake pedal. 11. Repeat steps seven to ten until fluid, free of air bubbles, escapes through bleed screw, 1. 12. Remove the transparent hose from bleed screw, 1, and install the rubber cap. 13. Repeat steps one through twelve for each remaining bleed screw; the lower caliper bleed screw, 2, and then the upper caliper inner bleed screw, 3. 14. Bleed the connection pipe between the two main cylinders, as described in the following procedure.

33-10

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 Bleed the connection pipe between the two main cylinders as follows: NOTE: Monitor the brake fluid level in the reservoir as fluid is repetitively bled from the system.

1. Ensure the brake fluid reservoir is filled to the maximum fluid indicator mark on reservoir. 2. Remove rubber caps from right-hand side bleed screws, 1, 2 and 3. 3. Slide a transparent hose over outside bleed screw, 1, to direct bleed brake fluid into a catch container.

2 56070042

4. Open outside bleed screw, 1.

5. Depress and hold the right-hand side brake pedal until fluid escapes. Do not release pedal. 6. Depress the left-hand side brake pedal once, holding the pedal depressed. Do not release pedal. 7. Close bleed screw, 1 8. Release the right-hand side brake pedal and then the left-hand side brake pedal. 9. Repeat steps four to eight until brake fluid, free of air bubbles, escapes from bleed screw, 1. 10. Bleed the right-hand side circuit. Bleed the right-hand side circuit as follows: NOTE: Monitor the brake fluid level in the reservoir as fluid is repetitively bled from the system.

1. Ensure the brake fluid reservoir is filled to the maximum fluid indicator mark on reservoir. 2. Depress the right-hand side brake pedal several times to build up a pressure. 3. Keep the pedal depressed.

4. Open bleed screw, 1, slightly to allow air and fluid to escape. 5. Close bleed screw, 1, and release the brake pedal. 6. Repeat steps two to four until fluid, free of air bubbles, escapes through bleed screw, 1. 7. Remove the transparent hose from bleed screw, 1, and install the rubber cap. 8. Repeat steps one through six for each remaining bleed screw; the lower caliper bleed screw, 2, and then the upper caliper inner bleed screw, 3. 9. Ensure all bleed screw rubber caps are installed. 10. Torque all bleed screws to 25--35 N⋅m (19--26 ft-lb). 11. Check and adjust the brake fluid level. 12. Check the brakes for proper operation.

33-11

56070042

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 BRAKE CALIPER AND BRAKE DISC Removal NOTE: Catch bleed brake fluid in a container. Dispose of used fluid per local regulations. Do not reuse. NOTE: Cap or plug open brake lines to prevent dirt ingress.

IMPORTANT: Ensure the brake lines are not crimped or damaged when handling. To remove the brake caliper and brake discs on both sides of the transmission, proceed as follows: Remove the half-shafts. Reference Section 25, Chapter 1, “Half-shaft -- Removal.” 1. Disconnect the banjo bolts, 1, on brake line, 2, from the upper and lower brake calipers. 2. Disconnect brake line banjo bolt from the lower caliper feeding port, 3.

2 3 17

3. Turn disc, 1, until the holes in the disc aligns with hex socket head screws, 2 and 3. 4. Remove two hex socket head screws, 2 and 3. 5. Remove upper brake caliper, 4.

18 6. Remove bolt, 2, to free the lower caliper bleed line, 1. 7. If required, disconnect bleed line, 1, from the lower caliper at the banjo bolt, after the caliper is removed.

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33-12

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 8. Remove two hex socket head screws, 1 and 2. 9. Remove lower brake caliper, 3.

20 10. Remove retaining ring, 1.

21 11. Remove brake disc, 1. 12. Repeat the procedure for the opposite side.

1 22

33-13

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 Installation To install the brake calipers and brake discs on both sides of the transmission, proceed as follows: 1. Lubricate the output shaft splines with Molykote G-n paste. 2. Install brake disc, 1, on the output shaft of the transmission.

1 23 3. Secure the brake disc on the output shaft with retaining ring, 1.

24 4. If removed, connect the lower caliper bleed line to the lower caliper prior to installing the caliper as described below. 5. Tighten and torque the banjo bolt to 25 -- 35 N⋅m (19 -- 26 ft-lb). 6. Apply Loctite 242/243 on Hex Socket Head Screws, 1 and 2. 7. Install lower brake caliper, 3, and then tighten and torque the Hex Socket Head Screws, 1 and 2, to 260 -- 270 N⋅m (192 -- 200 ft-lb).

33-14

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 8. Secure the bleed line, 3, to the transmission with bolt, 1. Torque to 45 -- 55 N⋅m (33 -- 40 ft-lb.). If bleed line fittings, 2, were loosened, torque to 13 -- 15 N⋅m (10 -- 11 ft-lb).

1 2 3 56070043

26 9. Rotate the brake disc, 1, to align the hardware access holes to the caliper mounting holes in the transmission housing. 10. Apply Loctite 242/243, on Hex Socket Head Screws, 2 and 3. 11. Install upper brake caliper, 4, with the Hex Socket Head Screws. 12. Tighten and torque screws, 2 and 3, to 260 -- 270 N⋅m (192 -- 200 ft-lb).

27 13. Connect the banjo bolts, 1, of brake line, 2, to the upper and lower brake calipers. 14. Tighten and torque the banjo bolts to 25 -- 35 N⋅m (19 -- 26 ft-lb). 15. If the brake line fittings, 4, were loosened, torque the fitting to 13 -- 15 N⋅m (10 -- 11 ft-lb). 16. Connect the supply brake line banjo bolt to the supply port, 3, of the lower caliper. 17. Tighten and torque the banjo bolt to 25 -- 35 N⋅m (19 -- 26 ft-lb). 18. If the supply brake line fitting was loosened from the banjo bolt at the supply port, 3, torque the fitting to 13 -- 15 N⋅m (10 -- 11 ft-lb). 19. Repeat the procedure for the opposite side. Install the half-shafts. Reference Section 25, Chapter 1, “Half-shaft -- Installation.”

33-15

2 2 3 28

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 PARKING BRAKE CALIPER Removal NOTE: The parking brake caliper can be removed without removal of the service brake calipers and disc. To remove the parking brake caliper and parking brake disc, proceed as follows: 1. Disconnect the hydraulic oil supply line 90° elbow fitting, 1, from the parking brake caliper housing.

29 2. Remove two bolts, 1, and the parking brake caliper assembly. 3. Remove the four bushings, at 2, from the housing.

33-16

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 Installation To install the parking brake caliper, proceed as follows:

1. Apply grease to the bushings and fill the cavity of the two guides with NH AMBRA GR75 MD grease. 2. Install the bushings into the guides of the parking brake housing, at 2. NOTE: Ensure the grease seals, on OD of bushing, are properly installed and in good condition. Replace if needed. 31

3. Apply Loctite 242/243, to bolts, 1. 4. Install the parking brake caliper and tighten bolts, 1, to a torque of 190 -- 210 N⋅m (140 -- 155 ft-lb). NOTE: Ensure the parking brake caliper slides freely on the bushings. 5. Connect the 90° elbow fitting, 1, of the parking brake hydraulic supply line to the parking brake. 6. Torque the fitting to 45 -- 50 N⋅m (34 -- 37 ft-lb). 7. If the hydraulic supply hose end fitting was loosened, torque to 43 -- 47 N⋅m (32-- 34 ft-lb). 8. Bleed the parking brake cylinder as described in this chapter; “Bleeding the Hydraulic Parking Brake Caliper”.

PARKING BRAKE DISC Removal To remove the parking brake disc, proceed as follows: NOTE: To remove the parking brake disc, the brake calipers and the brake disc need to be removed. 1. Remove retaining ring, 1.

33-17

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 2. Remove parking brake disc, 1.

1 34 3. Remove retaining ring, 1.

1 35 Installation To install the parking brake disc, proceed as follows: 1. Install retaining ring, 1. 2. Apply Molykote G-n paste to the shaft splines.

1 36

33-18

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 3. Install parking brake disc, 1.

1 37 4. Install retaining ring, 1.

33-19

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 PARKING BRAKE OVERRIDE Manual Override

WARNING Be aware that the emergency brake does not operate when the brake is manually disengaged. Failure to comply could result in serious injury or death. 1. Raise the feeder and lower the safety stop onto the cylinder. Stop the engine. 2. Block the wheels adequately to prevent runaway of the combine.

3. Remove safety plate, 2, and rubber boot, 1. 4. Remove cotter pin, 1, and turn nut, 2, clockwise until the parking brake piston is completely pulled backwards to release the pressure on the parking brake disc.

5. To reset the parking brake, follow the procedure for Parking Brake Piston Travel and Adjustment that follows in this section.

1 40

33-20

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 PARKING BRAKE PISTON TRAVEL AND ADJUSTMENT

86060925

1 41

3. Remove safety plate, 2, and rubber boot, 1.

33-21

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 4. Measure distance X mm (X in).

43 5. Remove cotter pin, 2. 6. Turn nut, 1, clockwise until the parking brake piston is completely pulled backwards.

44 7. Measure distance Y mm (Y in). 8. The difference X -- Y mm (X -- Y in) is the piston travel and should be 3 -- 5 mm (0.12 -- 0.20 in). 9. If the piston travel exceeds 5 mm (0.20 in), the piston travel has to be adjusted by removing one or more sets of half-shims. 10. If piston travel is less than 3 mm (0.12 in) the piston travel must be adjusted by adding one or more sets of half-shims stored between the cover bolts and the housing.

33-22

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 11. Loosen housing cover bolts, 1, and remove or add as many half-shims sets as necessary. 12. Install any removed half-shim sets between the cover bolts and the housing, 3, to prevent loss of the shims. The removed shims will be reinstalled when the parking brake pads are replaced as part of the adjustment procedure.

13. It is not necessary to remove the bolts completely to remove or add a half-shim sets, 2. 14. Removing or adding one set of half-shims will reduce or increase the piston travel by 2 mm (0.078 in).

2 46

15. Tighten and torque the housing cover bolts, 1, 127 N⋅m (94 ft-lb). 16. Check piston travel. Readjust if necessary. 17. Unscrew nut, 4, to the cotter pin hole at the end of the shaft. 18. Turn nut, 1, counterclockwise to align with hole at the end of the central rod, and then secure nut, 1, with cotter pin, 2.

47 19. Re-install rubber boot, 1, and safety plate, 2. This procedure does not cover checking of the parking brake pad wear. It is the operator’s responsibility to check this on a regular basis. The brake pads must be replaced if the remaining thickness is less than 1 mm (0.039 in).

33-23

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 PARKING BRAKE PADS

DANGER Shut down the machine, remove key, be sure all moving parts have stopped and all pressure in the systems is relieved before cleaning, adjusting or lubricating the equipment. Failure to comply will result in serious injury or death.

49 4. Install a new set of pads, 5. 5. Re-install washers, 3, spring, 4, and shaft, 2. Secure with cotter pin, 1.

6. Check for correct piston travel and adjustment. (Refer to the “Parking Brake Piston Travel and Adjustment” portion of this chapter.

33-24

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 BLEEDING THE HYDRAULIC PARKING BRAKE CALIPER

WARNING If machine is on a slope and the above procedure is performed, the machine will roll. Perform the above procedure only when machine is on a flat surface or completely restrained by blocking the wheels. Failure to comply could result in serious injury or death. NOTE: Catch bleed hydraulic fluid in a container. Dispose of used hydraulic fluid per local regulations. Do not reuse. As a safety precaution, this bleed operation is performed with the combine engine stopped, and unit blocked to prevent rolling. This bleed procedure used only the hydraulic head pressure created by the elevated location of the hydraulic reservoir. 1. To bleed the hydraulic parking brake caliper, proceed as follows: 1. Park the combine on level ground and block the wheels adequately to prevent the combine from moving. 2. Remove rubber cap, 2, from bleed screw, 1. 3. Slide a transparent hose over the bleed screw, 1, to direct bleed hydraulic fluid into a catch container. 4. Open the bleed screw until the oil, free of air bubbles, escapes through the bleed screw. 5. Close the bleed screw. Torque bleed screw to 15 -- 18 N⋅m (11 -- 13 ft-lb). 6. Remove transparent hose and reinstall rubber cap, 1. 7. Exit from underneath the combine to check the parking brake operation. 8. Ensure no one is under the combine. Start the combine engine. 9. From the cab, electrically disengage and engage the parking brake a few times to verify operation. 10. Engage the parking brake and stop the engine. 11. If parking brake is not properly disengaging, repeat the bleed procedure. 12. Check the Hydraulic Reservoir for correct oil level. Add NH AMBRA MASTERTRAN as needed.

33-25

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 PARKING BRAKE CALIPER Parking Brake Caliper -- Cross Section view

1. 2. 3. 4. 5. 6. 7. 8. 9.

Housing Shaft Seal O-ring Piston O-ring Retaining ring Washer Nut

10. 11. 12. 13. 14. 15. 16. 17. 18.

33-26

Cotter pin Rubber cap Seal reinforcement O-ring O-ring Shims Spring Spring guide Lever

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 Disassembly To disassemble the parking brake caliper, proceed as follows:

2. Remove cotter pin, 2, and turn on nut, 1, until the parking brake piston is completely pulled backwards.

54 3. Loosen the cover bolts, 1, and remove all the half-shims, 2, between the cover and housing, and also, any shims stored between the cover bolts, 1, and the cover, 3.

4. Completely remove cover bolts, 1, with washers and the cover housing, 3.

2 55

33-27

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 5. Remove springs, 1.

1 56 6. Remove piston, 1.

1 57 7. Replace O-ring, 1, and seal reinforcement, 2. Apply lubricant when installing new O-ring.

8. Remove piston from rod and replace seal, 3.

33-28

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 9. In the housing, replace seal, 1, and O-ring, 2. NOTE: For better access to the seal, remove the housing from the transmission as described previously in this chapter.

2 59 Assembly To assemble the parking brake caliper, proceed as follows: 1. Place piston, 1, as shown.

1 60 2. Install springs, 1.

33-29

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 3. Install housing, 1, and washer, 2.

1 62 4. Screw on nut, 2, and tighten it until the piston is against housing, 1.

NOTE: Be careful not to damage the seal and the reinforcement in the piston.

63 5. Apply a cable tie, 2, around the seal and the seal reinforcement and position the piston in housing, 1.

33-30

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1 6. Insert four bolts, 2, and screw them simultaneously until the seals are in housing, 1.

7. Remove the cable tie.

65 8. Install all half-shim sets, 2, between the housing cover, 3, and the inner housing.

9. Tighten and torque the four housing cover bolts, 1, to 127 N⋅m (94 ft-lb). 10. Unscrew the castle nut, 4, until the slots align with the cotter pin hole in the shaft. NOTE: It is not necessary to install the cotter pin when the nut, 4, is aligned to the cotter pin hole as it is removed in the next operation of travel adjustment. 11. Check for correct piston travel and adjustment. (Refer to the “Parking Brake Piston Travel and Adjustment” portion of this chapter). 12. Bleed the parking brake as described in the “Bleeding the Hydraulic Parking Brake Caliper” portion of this chapter.

33-31

2 66

SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1

33-32

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

SECTION 35 -- HYDRAULIC SYSTEMS Chapter 1 -- Introduction CONTENTS Section

Description

Page

35-1

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 SPECIFICATIONS HIGH PRESSURE SYSTEM Main Hydraulic Pump Type Displacement Minimum Output @ engine rated speed Standby Pressure Maximum System Pressure

Variable Flow Closed Center Load Sensing Piston Pump 45 cc/rev (2.75 cu. in/rev) 117 l/min (30.8 US gpm) 19 bar (275 psi) 210 bar (3046 psi)

Inline Pressure Filter Type Nominal Rating (approx.)

Inline, serviceable 100 micron

Return Filter Type Nominal Rating

Cartridge, spin-on 10 micron

Priority Valve Priority flow to Steering Maximum Steering Pressure

35 l/min (9 US gpm) 185 bar (2683 psi)

Steering Motor Type Displacement

Load Sensing, Dynamic signal non-reactive neutral logic for cylinder workports 315 cc/rev (18.9 cu. in/rev)

Autoguidance Steering Valve Nominal Valve Flow Shock Relief Pressure Maximum Operating Pressure

30 l/min (8 US gpm) 185 bar (2683 psi) Port P 250 bar (3626 psi) Port R or S 20 bar (290 psi) Port A and B 280 bar (4060 psi)

35-2

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 Accumulator Valve Header Shock Relief Valve

210 bar (3046 psi)

Header Accumulator Precharge Pressure Volume

70 bar (1015 psi) 0.5 L (17 oz)

Lateral Float Accumulators Precharge Pressure, rod end accumulator Precharge Pressure, base end accumulator Volume

80 bar (1160 psi) 100 bar (1450 psi) 0.5 L (17 oz)

Rotor/Feeder Variator Circuits Pressure--compensated flow control valve

0.16 liters/min (5.4 fl oz/min)

Hydraulic Cleaning Fan Drive Relief valve

315 bar (4500 psi)

LOW PRESSURE SYSTEM Low Pressure Pump Type Displacement Minimum Output @ engine rated speed

Gear Type Pump 16 cc/rev (0.98 cu. in/rev) 40.5 l/min (10.7 US gpm)

Chaff Spreader Valve Chaff Spreader Motor Relief Valve

200 bar (2900 psi)

Chaff Spreader/PSD Valve Chaff Spreader/PSD Motor Relief Valve Differential Pressure Sensing Valve

190 bar (2750 psi) 11 bar (160 psi)

Chopper Infeed Roll Motor Valve Type

Bypass, manual rotary

Pressure Filter Type Nominal Rating

Cartridge, spin-on 10 micron

Low Pressure Valve Block Regulated System Pressure Cooler Bypass Valve Lubrication Pressure

25 bar (363 psi) 3.5 bar (50 psi) 2.75 bar (40 psi)

35-3

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 INTRODUCTION The hydraulic system on CR combines contains two separate circuits:

LOW PRESSURE CIRCUIT The low pressure circuit operates the main, unload and feeder engagement clutches, parking brake and optional chaff spreader. The circuit is fed by a gear pump, 1, mounted on and driven through the high pressure closed center load sensing (CCLS) variable displacement pump, used for the high pressure circuit.

86070842

1 The low pressure circuit uses the main gearbox oil for its reservoir. The oil is drawn from the gearbox and pumped through the chaff spreader motor valve block, 1, (if equipped) and the pressure filter, 2. A relief valve, 3, in the chaff spreader motor valve block, protects the chaff spreader motors and, if present, the positive straw discharge (PSD) motor or the chopper infeed roll motor. The relief valve is set at 200 bar (2900 psi).

2 3

10020028

2 Oil then flows to the low pressure valve block, 1, which is located on the left hand side of the combine on top of the engine gearbox. This valve block directs the oil, via solenoid valves, to the clutches and park brake. The low pressure valve block contains a relief valve, 2, which regulates the low pressure at 25 bar (363 psi). Excess oil from the relief valve passes through an oil cooler and is then directed to the lubrication circuits for the main and unloading clutches in the gearbox. The lubrication pressure is regulated by a check valve, 3, set at 2.75 bar (40 psi). Excess oil from the lube check valve is returned to the gearbox.

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1 3

35-4

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 HIGH PRESSURE CIRCUIT The high pressure circuit operates all of the work hydraulics and steering. The circuit is fed by a closed center load sensing (CCLS) variable displacement pump, 1, mounted on the engine gearbox. The pump draws oil from a cross that connects the main reservoir, cooler return and hydraulic return lines with the CCLS pump suction line. The CCLS pump pumps the oil through an inline pressure filter to the main frame valve stack.

86070843

4 The oil enters the main frame valve stack at the priority valve section, 1; this valve provides priority oil flow up to 35 l/min (9 US gpm) to the steering circuit, and also contains the steering circuit relief valve.

The secondary hydraulic functions in the main frame valve stack include the header height control valve, a header accumulator control valve, unloading auger swing, rotor variator valve, and feeder variator valve (if equipped).

10020031

5 The steering motor, 1, is mounted directly under the cab, and is connected to the bottom of the steering column. A fixed displacement steering motor is used.

35-5

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 If the combine is equipped with an autoguidance system (SMARTSTEER or INTELLISTEER*), the autoguidance steering valve, 1, takes over control of the vehicle steering under command of the autoguidance system. * SMARTSTEER and INTELLISTEER are registered trademarks of CNH America LLC.

1 56060534

7 The feeder stack valve is an extension of the main frame stack valve, and is connected with pressure, return and load sensing lines from the main frame stack valve. The feeder stack valve contains the feeder reverser valve, lateral flotation valve, reel lift, fore/aft and drive valves and stone trap valve sections. The bottom section of the feeder stack valve is a flush valve. This valve allows a small amount of oil flow through the stack valves, when no services are being operated, allowing warm oil to bring the stack valve assembly gradually up to operating temperature.

10020032

35-6

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 The circuit return oil flows through the return filter, 1, and then back to the pump or to the reservoir.

1 10020028

9 While the hydraulic cleaning fan drive is not technically part of the high pressure hydraulic circuit, it draws its supply oil from the hydraulic reservoir. The fan drive pump, 1, is mounted on, and driven by, the hydrostatic drive pump, 2. The pump draws oil from the hydraulic reservoir at inlet port, 3, and directs the oil to fan drive valve, 4, at inlet port P, 5. Oil flow to the hydraulic cleaning fan motor is controlled by a pulse width-modulated (PWM) solenoid valve, 6, to maintain a constant fan speed regardless of engine speed. Oil flow is directed to the fan motor from port A on the rear of the valve block. Return oil from the motor re-enters the valve at port B, also on the rear of the valve block, and exits the valve at port T, 7, from which it returns to the reservoir.

1 2 7 5

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35-7

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 HYDRAULIC SYMBOLS Engine

Gearbox

Hydraulic pump, single direction with variable displacement

Hydraulic pump single direction fixed displacement

Hydraulic pump, bi-directional with variable displacement

Steering motor (bi--directional)

Motor, single direction fixed displacement

Motor bi--directional fixed displacement

2 position valve

3 position valve

Proportional (PWM) valve

Pressure relief valve

Solenoid controlled movement

Proportional solenoid movement (Pulse Width Modulation)

Movement by or against spring tension

Movement by or against adjustable spring tension

Movement by or against oil pressure

Lock out valve

Non return valve

Non return valve, pressure controlled

Quick coupler with non return valve

Flexible hose

Restrictor

Thermostat

Hydropneumatic accumulator

Cylinder

Filter

Filler opening

Shuttle valve

Reservoir

Pressure sensor

Temperature sender Oil to air cooler

Electrical indicator

35-8

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 High Pressure Circuit Diagram, Main

CR 9040/9060/9070 1. Engine (min: 1300, max: 2100 rev/min)

16. Feeder stack valve top plate

2. Gearbox

17. Feeder and header reversing valve

3. Hydrostatic pump

18. Lateral flotation control valve

4. CCLS pump (114 l/min [30 gal/min])

19. Reel horizontal adjustment valve

5. Low pressure gear pump (43 l/min [11.4 gal/min])

21. Reel drive / speed adjustment valve (if equipped)

20. Reel vertical adjustment valve 22. Stone trap valve

6. Load sensing valve

23. Flush valve

7. High pressure relief valve -- 210 bar (3046 psi)

24. Thermostat valve

8. In-line high pressure filter

25. Cooler

9. Priority valve

26. Return filter with bypass

10. Header height control valve

27. Reservoir

11. Accumulator lock out valve

28. Hydraulic cleaning fan drive pump

12. Rotor variator valve

29. Hydraulic cleaning fan valve block

13. Unloading auger swing valve

30. Hydraulic cleaning fan motor

14. Feeder variator valve (if equipped) 15. Top plate

35-9

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

16 17

18 15 19

12 30

10 1 2

25 28 26 6

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35-10

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 High Pressure Circuit Diagram, Main (with Autoguidance Steering Valve)

CR 9040/9060/9070 1. Engine (min: 1300, max: 2100 rev/min)

17. Feeder and header reversing valve

2. Gearbox

18. Lateral flotation control valve

3. Hydrostatic pump

19. Reel horizontal adjustment valve

4. CCLS pump (114 l/min [30 gal/min])

20. Reel vertical adjustment valve

5. Low pressure gear pump (43 l/min [11.4 gal/min])

22. Stone trap valve

6. Load sensing valve 7. High pressure relief valve -- 210 bar (3046 psi) 8. In-line high pressure filter 9. Priority valve 10. Header height control valve 11. Accumulator lock out valve 12. Rotor variator valve 13. Unloading auger swing valve 14. Feeder variator valve (if equipped) 15. Top plate 16. Feeder stack valve top plate

21. Reel drive / speed adjustment valve (if equipped) 23. Flush valve 24. Thermostat valve 25. Cooler 26. Return filter with bypass 27. Reservoir 28. Hydraulic cleaning fan drive pump 29. Hydraulic cleaning fan valve block 30. Hydraulic cleaning fan motor 31. Autoguidance steering valve 32. Output to steering cylinders 33. To T return at steering motor

35-11

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

16 17 31 18 32

19 14 20 13 33 21

12 30

10 1

25 28

66070840

35-12

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 Main Frame Stack Valve

CR 9040/9060/9070 1. Priority valve

13. Header lower valve

2. Steering relief valve - 185 bar (2683 psi)

14. Header lift cylinders

3. Priority flow divider valve

15. Electronic control unit

4. Steering motor - 315 cc/rev (18.9 cu. in./rev) fixed

16. Rotor variator valve

5. Steering cylinders

17. Flow control valve - 0.16 L/min. (5.4 oz./min.)

6. Header height control valve

18. Rotor variator adjustment plunger

7. Accumulator lock out valve

19. Unloading auger swing valve

8. Header shock relief valve -- 220 bar (3190 psi)

20. Unloading auger cylinder lock out

9. Header suspension accumulator (pressure:70 bar [1015 psi], vol:0.5L [17 oz])

21. Unloading auger cylinder

10. Pressure sensor

23. Feeder variator adjustment plunger

11. Header lift pressure compensator valve 12. Header raise valve

22. Feeder variator valve 24. Top plate

35-13

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

20 21

19 17 16

2 3

8 10

11 7

6 15 12

35-14

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 Main Frame Stack Valve (with Autoguidance Steering Valve)

CR 9040/9060/9070 1. Priority valve

13. Header lower valve

2. Steering relief valve - 185 bar (2683 psi)

14. Header lift cylinders

3. Priority flow divider valve

15. Electronic control unit

4. Steering motor - 315 cc/rev (18.9 cu. in./rev) fixed

16. Rotor variator valve

5. Steering cylinders

17. Flow control valve - 0.16 L/min. (5.4 oz./min.)

6. Header height control valve

18. Rotor variator adjustment plunger

7. Accumulator lock out valve

19. Unloading auger swing valve

8. Header shock relief valve -- 220 bar (3190 psi)

20. Unloading auger cylinder lock out

9. Header suspension accumulator (pressure:70bar [1015 psi], vol:0.5L [17 oz])

21. Unloading auger cylinder

10. Pressure sensor

23. Feeder variator adjustment plunger

11. Header lift pressure compensator valve 12. Header raise valve

22. Feeder variator valve 24. Top plate 25. Autoguidance steering valve

35-15

15 6

66070841

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

35-16

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 Feeder Stack Valve

CR 9040/9060/9070 1. Feeder stack valve top plate

10. Reel horizontal adjustment cylinders

2. Feeder and header reversing valve

11. Reel vertical adjustment valve

3. Feeder and header reversing motor

12. Reel vertical adjustment cylinders

4. Lateral flotation control valve

13. Reel drive / speed adjustment valve

5. Lateral float pressure compensation valve

14. Reel pressure compensation valve

6. Lateral flotation cylinder

15. Reel drive motor

7. Lateral float accumulator (pressure: 80 bar [1160 psi], vol: 0.5L [17 oz])

16. Multi--line quick coupler

8. Lateral float accumulator (pressure: 100 bar [1450 psi], vol: 0.5L [17 oz])

18. Stone trap cylinder

9. Reel horizontal adjustment valve

17. Stone trap valve 19. Flush valve

35-17

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

10 6

15 4 8

9 11 13

16 14

18 19

20020029

35-18

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 COMPONENT LOCATIONS

2 7 5

4 6

66070849

16 1. 2. 3. 4.

Reservoir Closed center load sensing (CCLS) pump High pressure filter Main stack valve

5. 6. 7.

35-19

Steering motor Feeder stack valve Return filter

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 COMPONENT DESCRIPTIONS

Hydrostatic Pump, 1 Although not part of the high pressure system, the return oil from the hydrostatic system is used as charge pressure oil for the high pressure CCLS pump.

Closed Center Load Sensing (CCLS) Pump, 2 Provides the oil for the high pressure system. Will supply the pressure as demanded by the services in use due to its load sensing and variable displacement capability. Has the advantage over a fixed pump in that it reduces the engine power absorbed when maximum pump flow is not required.

86070843

Low Pressure Gear Pump, 3 Totally separate from the high pressure system. Mounted on the CCLS pump from where it takes its drive.

Flow Compensating Valve (mounted on CCLS pump), 1 Pressure Compensating Valve (mounted on CCLS pump), 2 Output from the CCLS pump is determined by adjusting the angle of the swash plate. The flow compensating valve senses the circuit operating pressure and adjusts the swash plate angle to control pump output. If pump output rises to 210 bar (3046 psi) the pressure compensating valve overrides the flow compensating valve and adjusts the swash plate angle to limit maximum system pressure.

86070851

In Line High Pressure Filter, 1 A replaceable filter located between the CCLS pump output and the high pressure system priority valve.

10020033

35-20

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 7 6

5 4 1

56070846

20 Main Frame Stack Valve Assembly

Priority Valve, 1

Rotor Variator Control Valve, 4

Located in the main frame stack valve, receives the output oil from the CCLS pump and will provide steering with the priority for oil. Balance of oil supply is allowed to flow into main gallery for remaining valves in stack. Also contains the steering circuit relief valve.

Controls the plunger within the rotor variator drive unit to provide adjustable variator speed. Solenoid operated valves either allow pressure oil to provide a speed increase or release oil pressure to decrease speed. Unloading Auger Swing Valve, 5

Accumulator Lock Out Valve, 2 Controls the pressure within the header height cylinders. Contains the header shock relief valve, accumulator lock out valve and pressure sensor. Header Height Control Valve, 3 Controls the raising and lowering of the header. Contains the PWM raise and lower valves and compensation valve.

Controls the unloading auger swing cylinder. Consists of two electrically operated solenoid valves. Feeder Variator Control Valve, 6 Controls the plunger within the feeder variator drive unit to provide adjustable variator speed. Solenoid operated valves either allow pressure oil to provide a speed increase or release oil pressure to decrease speed. Top Plate, 7 Provides pressure and load sense connections to feeder stack valve.

35-21

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 Main Stack Plumbing

1 -- Flow from CCLS pump

2 – Return from feeder stack valve

3 – Return flow (combined) to filter and reservoir 4 – Steering load sense

5 – Steering return flow 6 – Feeder stack valve load sense

2 4

7 – Flow to Feeder stack valve 8 -- Pressure--compensated flow control valve [0.16 liters/min (5.4 fl oz/min)]

56070846

Back of Main Stack

1 – Tubing to header lift cylinders 2 – Tubing to header accumulator

6 5

3 – Header shock relief valve 4 – Flow to steering motor

5 -- Rotor Increase solenoid

6 – Unload auger swing in solenoid 7 – Feeder increase solenoid

56070848

22 Front of Main Stack

1 – HHC Module Controls the header height via the head raise and lower solenoids, based on the signal sent by the operator cab controls, the feeder angle sensor and pressure sensor.

7 4

2 – Head Lower solenoid

3 – Head Raise solenoid

4 – Pressure sensor Measures the pressure in the header lift cylinders. Signal is supplied to the HHC module. 5 – Accumulator solenoid Disconnects the accumulator when raising the header to prevent delay in raise response. 6 – Steering relief valve 7 – Rotor Decrease solenoid 8 – Unload Auger Swing Out solenoid 9 – Feeder Decrease solenoid

35-22

56070847

1 23

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 Header Suspension Accumulator, 1 Absorbs the slight movement to the header encountered during normal operating. The accumulator is rated at 70bar (1015 psi) pressure with a volume of 0.5L (17 oz.).

10020034

24 Steering Motor, 1

Supplied oil via the priority valve in the main frame stack. The steering motor directs and controls oil to the steering cylinders, based on input via movement of the steering wheel.

25 Autoguidance Steering Valve, 1 If the combine is equipped with an autoguidance system (SMARTSTEER or INTELLISTEER), the autoguidance steering valve, 1, becomes active when the autoguidance system is turned on and controls the vehicle steering.

1 56060534

35-23

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 The autoguidance steering valve, 1, is plumbed so that its output lines are in parallel with those of the steering motor, 2. The supply oil to the valve is obtained through a T connection into the main pressure line between the main stack valve and the feeder valve stack.

2 86070845

27 Steering Cylinders, 1 Two steering cylinders are used on both the heavy duty adjustable axle and power rear axle (PRA).

28 Autoguidance Steering Cylinder, 1

If the combine is equipped with autoguidance, the left-hand steering cylinder is equipped with a sensor, 2, to provide rear wheel position information to the autoguidance system.

1 56060528

35-24

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 Header Lift Cylinders, 1

Stone Trap Door Latch Cylinder, 2

10020042

1 30

Rotor Variator Adjustment Plunger, 1

Operated via the rotor variator valve, the plunger is a hydraulic cylinder that operates a floating disc within the variator assembly to alter variator speed. The pressure-compensated flow control valve, 2, controls the flow to ensure smooth consistent speed changes.

2 10020038

35-25

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 Unloading Auger Lockout Valve, 1

Isolates the unloading auger cylinder from the control valve and pipework. Ensures that the unload auger will remain in the required position until the control valve is activated. When pressure oil is applied to the lock out valve, a bleed line is supplied to the opposite side which releases the lock valve and allows oil to escape. When the pressure oil is removed the lock out valves close and prevent cylinder movement. Unloading Auger Cylinder, 2

Moves the unloading auger, controlled by the unloading auger swing valve and lock out valve.

32 Feeder Variator Adjustment Plunger, 1 Operated via the feeder variator valve, the plunger is a hydraulic cylinder that operates a floating disc within the variator assembly to alter variator speed.

10020039

35-26

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

2 3

4 5 6 7 8 10020032

34 Feeder Valve Stack

Top Plate, 1

Reel Vertical Adjustment Valve, 5

Provides the connection point for the pressure, return and load sense lines.

Controls the vertical adjustment cylinders. Consists of two electrically operated solenoids and a lock out valve.

Feeder and Header Reversing Valve, 2 Controls the motor for the feeder and header reverser. Contains two electrically controlled solenoids which move a spool to obtain forward, reverse or a float position on the motor.

Reel Drive Valve, 6 Provides flow to the hydraulic reel drive motor used on headers. Consists of a single PWM solenoid and a pressure compensation valve.

Lateral Flotation Control Valve, 3

Stone Trap Valve, 7

Controls the lateral flotation cylinder. Consists of two electrically controlled solenoids, a pressure compensation valve and a lock out valve.

Controls the stone trap cylinder to open the stone trap.

Reel Horizontal Adjustment Valve, 4 Controls the horizontal position of the reel. The valve consists of two electrically operated solenoids and a lock out valve.

Flush Valve, 8 When there are no services in use, charge pressure oil is allowed to join the return circuit through the flush valve. This function allows a constant flow of oil through the header stack valve thereby circulating warm oil through the valves.

35-27

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 Feeder and Header Reversing Motor, 1

10020041

35 Lateral Flotation Cylinder, 1

Adjusts header angle in relation to the combine.

Lateral Float Accumulator -- Rod End, 2 [80 bar 1160 psi]

Lateral Float Accumulator -- Base End, 3 [100 bar 1450 psi] Header Hoses Quick Release Coupling, 4

4 10020040

36 Return Filter with Bypass, 1

10020028

35-28

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

PAGE INTENTIONALLY LEFT BLANK

35-29

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 LOW PRESSURE SYSTEM DESCRIPTION SCHEMATIC DIAGRAMS Low Pressure System CR 9040/9060/9070 1. Engine gearbox

8. Park brake cylinder

2. Low pressure gear pump (43 l/min. [11.4 US GPM])

10. Feeder clutch

9. Oil to air cooler 11. Unloading clutch

3. Suction filter, 100 micron

12. Main clutch

4. Chaff spreader valve*

13. Engine

5. Chaff spreader motors* 6. High pressure filter with bypass and a blocked filter switch 7. Low pressure valve block

14. Pressure sensor 15. Temperature sensor *Chaff spreader and valve are optional

35-30

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 9 10 8 6

7 4

5 12 11

2 20020027

35-31

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 Low Pressure System with Positive Straw Discharge CR 9040/9060/9070 1. Engine gearbox

10. Feeder clutch

2. Low pressure gear pump (43 l/min. [11.4 US GPM])

11. Unloading clutch

3. Suction filter, 100 micron

13. Engine

12. Main clutch

4. Chaff spreader/PSD valve*

14. Pressure sensor

5. Chaff spreader motors* 6. High pressure filter with bypass and a blocked filter switch 7. Low pressure valve block 8. Park brake cylinder

15. Temperature sensor 16. Positive straw discharge (PSD) motor* 17. Hydraulic cleaning fan drive pump *Chaff spreader/PSD and valve are optional

9. Oil to air cooler

35-32

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 9 10 8 6 7 4

5 12 13 11 17

2 66060555

35-33

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 Low Pressure System with Chopper Infeed Roll CR 9040/9060/9070 1. Engine gearbox

10. Feeder clutch

2. Low pressure gear pump (43 l/min. [11.4 US GPM])

11. Unloading clutch

3. Suction filter, 100 micron

13. Engine

12. Main clutch

4. Chaff spreader valve*

14. Pressure sensor

5. Chaff spreader motors* 6. High pressure filter with bypass and a blocked filter switch 7. Low pressure valve block 8. Park brake cylinder 9. Oil to air cooler

15. Temperature sensor 16. Chopper infeed roll motor* 17. Hydraulic cleaning fan drive pump *Chaff spreader and valve are optional Chopper infeed roll motor is optional

35-34

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 16

9 10

8 6 7 4

5 12 11

17 15

2 56060563

35-35

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 COMPONENT LOCATION

5 2 3 4

66070849

41 1. 2. 3.

Engine gearbox Low pressure gear pump Chaff spreader valve

4. 5. 6.

35-36

High pressure filter Low pressure valve block Oil cooler

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 COMPONENT DESCRIPTIONS Engine Gearbox, 1

Mounted onto the rear of the engine on the left hand side of the vehicle. Output from the engine directly drives the gearbox with subsequent drives to the Hydrostatic pump, CCLS and low pressure pump, main clutch and unloading mechanism clutch.

56070844

42 Low Pressure Gear Pump, 1 Mounted on the CCLS pump from where it takes its drive. Draws oil from the engine gearbox via a suction filter located in the bottom of the gearbox. The pump output is directed to the chaff spreader valve, if fitted, then through the pressure filter and onto the low pressure valve block.

Suction Filter, 2 Located in the gearbox, filters the oil being drawn into the low pressure pump.

10020033

Gearbox Oil Temperature Sensor, 3

43 Chaff Spreader Valve, 1 Located at the rear of the vehicle on the left hand side. This is an optional item, fitted first in line in the low pressure circuit. The valve assembly incorporates an electrically actuated solenoid, to direct oil to the motors, and a relief valve for the chaff motor circuit. High Pressure Filter with Bypass and a Blocked Filter Switch, 2 A replaceable filter located between the pump output (and chaff spreader valve if fitted) and the low pressure system valve block.

10020028

2 44

35-37

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 Chaff Spreader/PSD Valve If the combine is equipped with the positive straw discharge (PSD) system, the chaff spreader valve, 1, has additional ports for feeding the PSD motor. This motor is in series with the chaff spreader motors.

66060557

45 Chaff Spreader Motors Located at the rear of the vehicle, one on each side. Controlled by the chaff spreader valve, they provide drive to the spreader rotors. Positive Straw Discharge (PSD) Motor, 1 Located just forward of the chopper, this motor drives the PSD conveyor to positively discharge residue into the chopper. It is in series with the spreader motors and is controlled by the chaff spreader/PSD valve.

1 66060558

46 Chopper Infeed Roll Motor, 1 If the combine is equipped with a chopper infeed roll, its drive motor is located at the rear of the combine on the right-hand side of the straw chopper. The roller motor is in series with the chaff spreader motors.

NOTE: Combines equipped with a chopper infeed roll do not have positive straw discharge (PSD) and vice-versa.

56060564

35-38

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 2

7 48

Low Pressure Valve Block

Low Pressure Valve Block, 1

Solenoid Valve -- Park Brake, 4

Located on the engine gearbox. Houses the solenoid valves for the unloading clutch, feeder clutch, handbrake and main clutch. Also houses the low pressure relief/control valve, lube pressure check valve, oil cooler bypass and oil pressure sensor.

Solenoid Valve -- Main Clutch, 5 Low Pressure Relief/Control Valve, 6 Pressure Sensor, 7 Reservoir Filler cap, 8

Solenoid Valve -- Unloading Clutch, 2 Solenoid Valve -- Feeder Clutch, 3

35-39

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 Park Brake Cylinder, 1 Solenoid is normally on when running allowing hydraulic pressure to disengage the brake. When the park brake is applied or the ignition is off, the park brake is engaged under spring pressure.

49 Feeder Clutch, 1

20016286

50 Oil Cooler, 1 Hydraulic oil cooler, mounted with the engine cooler on the right hand side of the vehicle.

35-40

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

SECTION 35 -- HYDRAULIC SYSTEMS Chapter 2 -- Description of Operation CONTENTS Section

Description

Page

35-1

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 DESCRIPTION OF OPERATION CLOSED CENTER LOAD SENSING (CCLS) VARIABLE DISPLACEMENT PUMP

The closed center load sensing pump assembly, 1, is mounted directly onto the engine driven gearbox, 2, located high on the left hand side of the combine.

56070844

1 1

The assembly consists of 2 pumps, the load sensing piston pump, 1, providing oil to the high pressure hydraulic system, and a fixed displacement gear pump, 2, providing oil to the low pressure hydraulic system.

The pump drive shafts are linked by a coupler and lubricated by the case drain oil of the load sensing pump.

86070843

2 The pump is controlled by the flow, 1, and pressure, 2, compensating valves located on the pump casing.

86070851

35-2

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

1 4

56070852

5 4

Variable Displacement Piston Pump--Sectional Drawing 1. 2. 3. 4. 5.

Pump End Plate Swash Plate Servo Piston Swash Plate Swash Plate Return Spring Driveshaft

6. 7. 8. 9.

Slipper (9 off) Piston and Barrel Inlet Port Outlet Port

The variable displacement piston pump in hydraulic systems therefore has distinct power loss advantages over fixed displacement gear type pumps, which continually provide oil flow and absorb engine power even when the hydraulic circuits do not require the total pump output.

Principal of Pump Operation -- Fixed vs. Variable Displacement The operating principal of the fixed displacement gear pump is to provide a constant oil flow directly related to the rotation speed of the pump. The operating principal of a variable displacement piston pump is to provide oil flow on demand and minimises the engine power absorbed in driving the hydraulic pump when the hydraulic circuits do not require maximum pump flow.

The feed oil for the variable displacement piston pump is called the charge oil. The charge oil is supplied by the return flow of the hydrostatic drive system. This supplies 60 l/min (16 gal/min) of oil via the oil cooler. Only under high demand situations, 60--114 l/min (16--30 gal/min), does an under pressure develop in the charge supply line.

35-3

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 Variable Displacement Piston Pump The major components of the variable flow piston pump with closed centre load sensing are: 1. A rotating group containing the main pumping elements. 2. A plate mechanism (swash plate) to adjust piston stroke and corresponding pump output. 3. A load sensing valve which monitors the requirements of the hydraulic circuits and signals the pump to increase or decrease hydraulic oil flow accordingly. The rotating group is cylindrical in shape and has a number of barrels, into each of which, is installed a piston. On the end of each piston is pressed a slipper which always remains in contact with the face of the swash plate located at the front of the pumping head. The drive shaft, which is driven by the pump drive gear, rotates the pumping head. As the pumping head rotates, the pistons move in and out of their barrels, following the contour of the swash plate. For every revolution of the drive shaft each piston completes one pumping cycle. The swash plate, which does not rotate but pivots about the front of the pumping head, is the control mechanism that limits the stroke of each piston and works in conjunction with the pressure and flow compensating valves in the load sensing line. As the pumping head rotates each barrel passes over the inlet and then the outlet ports of the pump. During the inlet cycle for each piston and barrel, oil is pumped into the barrel pushing the piston forward so that it always remains in contact with the swash plate. The stroke of each piston and volume of oil charged into its barrel is therefore dependent on the angle of the swash plate. After a piston and barrel has completed the inlet stroke, further rotation of the head aligns the barrel with the outlet port. Oil within the barrel is then forcibly ejected by the piston through the exhaust port to the hydraulic circuits.

35-4

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 1

4 5

6 8

9 13

15 16

12 17

11 18 19 10

56070857

5 Flow and Pressure Compensating Valves 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Plug and O-ring Housing Sense Input Adapter Flow Compensating Spool Seat Spring Seat Adjuster Collar Adjuster O-ring

11. 12. 13. 14. 15. 16. 17. 18. 19.

Locknut Protective Cap Pressure Compensating Spool Seat Spring, Inner Spring, Outer Seat Adjuster Collar Adjuster

Flow and Pressure Compensating Valves (CCLS Pump Load Sensing Valve) If pump output and circuit pressure rises to 210 bar (3046 psi) the pressure compensating valve overrides the flow compensating valve and adjusts the swash plate angle to limit maximum system pressure.

Output from the variable flow piston pump is determined by adjusting the angle of the swash plate in the pump. The flow compensating valves senses the circuit operating pressure and adjusts the swash plate angle to control pump output.

35-5

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 HYDRAULIC CIRCUIT OPERATION The variable flow closed center load sensing (CCLS) hydraulic pump operates progressively in 4 modes: •

Low Pressure Standby

•

High Pressure Circuit Maximum Demand

•

High Pressure Circuit Low Demand

•

Maximum System Pressure (High Pressure Standby)

Low Pressure Standby With Reference to Figure 6 Low pressure standby is the system pressure 19 bar (275 psi) maintained by the hydraulic pump when high pressure hydraulic circuits are not being operated. During engine start up, standby pressure has not been generated and both the flow and pressure compensating valves are held to the left by spring pressure. While the spools are held to the left oil pressure generated by the pump cannot be applied to the swash plate servo piston. The swash plate consequently remains in the maximum flow position until the pump has developed sufficient flow to produce pressure at low pressure standby. As pump output pressure increases to 19 bar (275 psi), this pressure is sensed in gallery, E, and applied to the flow compensating spool, 4. The spool gradually moves against the spring allowing oil flow from gallery, E, to gallery, D. The controlled pressure rise in gallery, D, operates the swash plate servo piston, changing the angle of the swash plate in relation to the pumping head. The change in angle reduces the operating stroke of the pistons and output of the pump. As pump output decreases and the pressure in gallery, E, reduces to less than 19 bar (275 psi), the flow compensating valve gradually moves under spring pressure to the left, bleeding gallery, D, to sump through gallery, C. This reduces the control pressure applied to the servo piston, allowing the servo piston to retract at a controlled rate under pressure from the swash plate return spring and re-adjust the angle of the swash plate to increase pump output. This control process continues, maintaining pump output pressure at 19 bar (275 psi) (low pressure standby) until a high pressure circuit is operated and pump system pressure needs to be increased to operate the service.

35-6

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 B E

B 3

C D 5 1

56070853

Low Pressure Standby

1. 2. 3.

Standby Pressure @ 19 bar (275 psi)

Return to Reservoir

Control Pressure

Charge Pressure

Straw elevator stack valve (In Neutral) Main frame stack valve (in neutral) Pressure Compensating Valve

4. 5. 6.

35-7

Flow Compensating Valve Swash Plate Return from Hydrostatic motors

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 High Pressure Circuit High Demand

B E

B 3

C D 5 1

2 E

56070854

High Pressure Circuit High Demand

Charge Pressure

Standby Pressure @ 190bar (2755 psi) Return to Reservoir

1. 2. 3.

Straw elevator stack valve Main frame stack valve Pressure Compensating Valve

4. 5. 6.

Flow Compensating Valve Swash Plate Return from hydrostatic motors

pressure in gallery, E, preventing the flow of oil to the swash plate servo piston through gallery, D.

When a high pressure service is operated the pressure rise in the hydraulic circuit is sensed by the load sensing line, B. The pressure in the sensing line is now applied to the spring loaded end of the flow compensating valve.

The movement of the spool opens gallery, D, to the return to sump gallery, C, allowing the servo piston to retract under pressure from the swash plate return spring and adjust the angle of the swash plate to increase pump output.

The combined pressure from the pilot line and flow compensating valve return spring causes the flow compensating spool, 4, to move against the standby

35-8

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 High Pressure Circuit Low Demand

B 3

C D 5

56070855

High Pressure Circuit Low Demand

1. 2. 3.

Standby Pressure @ 210 bar (3046 psi)

Return to Reservoir

Control Pressure

Charge Pressure

Straw elevator stack valve Main frame stack valve Pressure Compensating Valve

4. 5. 6.

Flow Compensating Valve Swash Plate Return oil from hydrostatic motors

servo piston and changes the swash plate angle to reduce pump output according to demand.

When output from the pump is meeting the demand of the hydraulic circuit the output pressure of the hydraulic pump in gallery, E, will continue to rise unless the flow from the pump is controlled.

It can now be seen that whenever the differential pressure between system and load sensed pressures approaches 19 bar (275 psi) the flow compensator valve will operate to control the angle of the swash plate and consequently pump flow (output).

As pump pressure increases the differential between system pressure, E, and load sensed pressure, B, will similarly increase. When this differential rises towards 19 bar (275 psi) the pressure in gallery, E, causes the flow compensator spool to move back against the spring and load sense pressure in Gallery, B, to open gallery, E, to gallery, D. The controlled pressure rise in gallery, D, operates the swash plate

The load sensing shuttle valves will always allow the service requiring the highest pressure to pass that pressure onto the flow compensating valve.

35-9

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 Controlling Maximum System Pressure

B 3

C D 1

2 E

56070856

Controlling Maximum System Pressure

1. 2. 3.

Standby Pressure @ 190bar (2755 psi)

Return to Reservoir

Control Pressure

Charge Pressure

Straw elevator stack valve Main frame stack valve Pressure Compensating Valve

4. 5. 6.

To limit the maximum output pressure of the piston pump and prevent consequential damage that may occur due to excessive pressures, a pressure compensating valve, located adjacent to the flow compensator valve, is incorporated in the swash plate control circuit. This valve limits the pressure to 210 bar (3046 psi) and operates as follows: As the pressure in gallery, E, increases to 210 bar (3046 psi) the pressure compensator valve spool, 3, moves against the valve return spring and opens gallery, E, to gallery, D. The pressure in gallery, D, is

Flow Compensating Valve Swash Plate Return oil from hydrostatic motors

now applied to the servo piston, which changes the swash plate angle to reduce pump output to minimum flow. This operating mode is referred to as high pressure standby. Functions requiring sensitive control, like the header height, lateral flotation and hydraulic reel drive have an additional pressure compensation valve in their circuit to ensure that the operational speed is constant, whatever the pump pressure (see high pressure circuit diagram).

35-10

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 MAIN STACK Priority Valve, 1 Accumulator Lockout Valve, 2 Header Height Control Valve, 3

Rotor Variator Control Valve, 4

Unloading Auger Swing Valve, 5

Feeder Variator Control Valve, 6 Top Plate, 7

3 56070846

FEEDER VALVE STACK Top Plate, 1

Feeder and Header Reversing Valve, 2 Lateral Flotation Control Valve, 3 Reel Horizontal Adjustment Valve, 4 Reel Vertical Adjustment Valve, 5

Reel Drive Valve, 6 (NA only)

Stone Trap Valve, 7 Flush Valve, 8

5 6 8

10020032

35-11

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 STACK VALVES

2 1

50020011

PRIORITY VALVE The priority flow divider assembly is comprised of a metering spool, 1, spring, 2, and relief valve assembly, 3. The spool is held shifted to the right by the spring when the system is at rest. The inlet port, 4, of the flow divider is open to the steering priority port, 5, in this position.

35-12

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 2

50020043

13 Steering Neutral When the steering valve is in neutral, the inlet to the steering valve is blocked and the pressure will increase in the priority port. The pressure is felt on the right end of the spool through an internal passage, 1. The pressure at the end of the spool will overcome the spring and shift the spool to the left and close the path from the inlet, 2, to the priority port, 3, and open the path from the inlet to the main pressure gallery, 4, in the main stack valve. The signal from the steering valve, 5, which is open to the spool spring chamber, will be near 0 bar (0 psi) and therefore will not assist the spring in opposing the spool. Because the steering system does not require any flow, all flow is available to the main and feeder stack valves. The steering system uses a dynamic signal non-reactive neutral logic steering motor; this motor allows a small amount of oil to “leak” through the motor from the priority port to the load sense port. As a result, there is typically always a 7 – 10 bar (100 – 145 psi) pressure in the load sense line, even when all circuits are in neutral. This flow accomplishes two things: it provides some flow of oil through the motor at all times to warm up the components, and it provides improved steering system response.

35-13

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

1 2

5 50020052

14 Steering Priority When steering is used, a passage in the steering valve opens. The pressure in the steering priority port, 1, and the cavity on the right end of the spool drops. The spring, 2, will shift the spool, 3, to the right and meter oil to the priority port. The load sense line from the steering valve is connected to the load sense port, 4, on the flow divider. This will determine the exact positioning of the spool to achieve a pressure balance between the inlet port and load sense port from steering, plus the 14 bar (203 psi) spring. In addition, the load sense pressure is directed through the load check poppets, 5, to the flow compensator on the CCLS pump to ensure the pump responds to the steering system demand. The pressure in the priority port will drop when the demand for steering increases. The load sense pressure will then shift the spool further to the right and allow more oil to the priority port. This will occur up to the maximum system requirement of 35 l/min (9 US gpm).

35-14

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 4

50020044

15 Inlet Flow Dividing In the flow dividing mode, the control spool, 1, will give the priority to the steering circuit. When another stack valve function is activated, the pressure at the inlet, 2, will decrease. This decrease will allow the pressure in the spring chamber (steering load sense plus the spring) to shift the spool further to the right, to return the steering flow back up to the level required (priority to the steering). When the steering flow requirements are met, any additional flow available will be allowed to pass through the valve to the main stack pressure gallery, 3. The load sense signal, 4, from the steering valve will continuously adjust the position on the control spool to maintain the flow required by the steering.

35-15

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

50020045

16 Steering Relief Valve Activated The maximum pressure in the steering circuit is limited by the relief valve, 1. The relief valve monitors the load sense pressure from the steering valve. If the pressure in the load sense circuit increases above 185 bar (2683 psi), the poppet will unseat and direct the load sense pressure, 2, to the return port, 3. The priority pressure will then shift the spool to the left against the spring and limit the oil flow from the inlet to the priority port. System flow is available to the main stack pressure gallery even when the steering system is at relief pressure. The pump compensator is set at 210 bar (3046 psi), 25 bar (363 psi) above steering relief pressure.

35-16

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

50020010

HEADER HEIGHT CONTROL VALVE The header height control valve consists of two distinct grouping of components, one set for controlling header raising, the other for controlling header lowering. Either set of components is controlled by a pulse width modulated (PWM) solenoid, which can accurately position the components to provide a specific raise or lower rate. The head raise component group consists of a header lift pressure compensator, 1, header lift flow control, 2, and a load check valve, 3. The head lower component group consists of a pilot operated header lower flow control spool, 4.

35-17

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

5 4 3

50020046

18 Header Raise To raise the head, the Head Raise PWM solenoid, 1, is powered, and shifts the header lift flow control spool, 2, to the right. This allows oil to flow from the main stack pressure gallery, 3, past the flow control spool into the supply gallery. The load sense circuit, 4, is connected to the supply gallery, so this pressure is also fed back to the pump compensator to put the pump into stroke. The supply gallery is blocked by the load check valve, 5, which is used to trap oil in the header lift cylinders. Once system pressure exceeds the header lift cylinder pressure, the load check valve opens and oil flows to the header lift cylinders. The header lift flow control spool land is tapered, so the oil flow from the pump is restricted based on how

far the solenoid has moved the flow control spool. The amount of this restriction will cause a pressure drop between the main stack pressure gallery and the header lift supply gallery. A greater restriction (due to little spool movement) will result in a greater pressure drop across the flow control spool, and reduced flow to the header lift cylinders for a slow raise. Less restriction (due to greater spool movement) will result in a small pressure drop across the flow control spool, and higher flow to the header lift cylinders for a fast raise. When the header lift control spool is returned to the neutral position, the header supply gallery is connected to the return gallery, 6; this dumps the pressure in the supply gallery to destroke the pump and allow the load check valve to close positively.

35-18

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

3 1

50020047

19 Pressure Compensation The header lift pressure compensator, 1, is fitted in the header valve to ensure that the header raise rate remains constant irregardless of pressure in the main stack gallery, 2, due to other circuit demands. If another valve is activated which has a higher pressure requirement (such as header tilt or unload auger swing) than the header raise, the higher pressure could result in a higher flow rate across the header lift flow control spool, resulting in the header lift speed varying with the pressure in the main or feeder stacks. The lift pressure compensator is balanced with main system pressure on one end acting against a spring, 3, plus header supply gallery pressure on the other end. If system pressure increases, that higher pressure will shift the lift pressure compensator spool against the combined spring and supply gallery pressure to restrict oil flowing from the main stack gallery into the header lift valve. As the main stack pressure drops, the spring and header supply gallery pressure can shift the compensator spool to allow more flow into the valve. This ensures a consistent flow rate into the valve irregardless of the system pressure.

35-19

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 3 1

50020048

20 Header Lower In the neutral position, the head lower flow control spool is held against its seat by a combination of the spring loaded pilot spool, 1, and lift cylinder pressure, which acts through an orifice and drilling, 2, to the right side of the spool. To lower the head, the Head Lower PWM solenoid, 3, is powered, and pushes the pilot spool, 1, to the right, lifting it off of its seat in the lower flow control spool, 4. This allows oil to be released from behind the flow control spool faster than oil can be replenished through the orifice. The resulting pressure drop behind the flow control spool allows the spool to be lifted off its seat allowing oil to flow to return, 5.

The header lower rate is directly controlled by how far the Head Lower PWM solenoid moves the pilot spool. If the pilot spool is moved a small amount to the right, as the flow control spool lifts off its seat, it will start to close the pilot valve. This causes oil to once again be trapped behind the spool, and try to close it. The spool will balance itself in a position that only allows a small amount of oil to escape from the header lift cylinders to return, causing the head to drop slowly. If the pilot spool is moved a large amount to the right, the flow control spool can open a much larger distance before it starts to close the pilot valve, resulting in much higher flow to return for a fast header drop.

35-20

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

3 4

50020012

ACCUMULATOR VALVE The accumulator valve is used to hold header height components that are not fitted in the header height valve, such as the pressure transducer, 1, header shock relief valve, 2, and the accumulator control spool, 3, and solenoid, 4. The header shock relief valve is connected directly to the outlet port, 5, to the header lift cylinders, so it is always exposed to lift cylinder pressure, while the pres-

sure transducer is connected to the outlet port, 6, to the accumulator. The pressure transducer provides feedback to the header height control module on the actual lift cylinder pressure, while the header shock relief valve protects the cylinders against pressure spikes that may occur, such as when carrying a heavy header over rough ground, irregardless of the operating position of the header height control valve.

35-21

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

3 1 2

50020049

22 The accumulator control spool, 1, and solenoid, 2, are used to connect and disconnect the header accumulator from the header lift cylinder circuit when raising the header, to ensure quick response. The center gallery of the spool is exposed to the header lift cylinder outlet port, and the spool is drilled such that cylinder pressure is exposed to both ends of the spool. A spring, 3, is used to bias the spool against the sole-

noid, and shift the spool to the left whenever the solenoid is deenergized. During normal operation, the solenoid is energized to shift the spool to the right. This connects the lift cylinder outlet port, 4, to the accumulator, 5, so that the accumulator can provide some cushioning or flotation effort to the cylinders during field operation.

35-22

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

2 1

50020012

23 When the header is raised, the accumulator solenoid, 1, is deenergized, and the accumulator spool, 2, is shifted to the left by the spring, blocking off the accumulator, 3, from the lift cylinders, 4. This allows all pump flow to go to the header lift cylinders for raising, rather than some oil being used to charge or fill the accumulator, resulting in a delayed header response.

A small orifice drilling, 5, in the spool is used to provide some “equalization” to the accumulator during the raising cycle to ensure that the accumulator is charged up when the header raise is stopped. This prevents the header from dropping slightly when the accumulator is reconnected to the lift cylinders after the raise is completed.

35-23

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

10020019

FUNCTION CONTROL VALVES Each control valve in the stack valve has its own unique configuration, however, they all function in essentially the same way. Double acting valves have a solenoid, 1, on either end of the valve spool, 2, along with a centering spring assembly, 3, on the right end of the spool. Single acting valves have a single solenoid positioned on the left end of the spool, with just the centering spring assembly located on the right end.

With the valve in the neutral position, the flow control land, 4, seals the pressure gallery, 5, in the stack from the supply gallery, 6, in the valve. At the same time, the main control lands, 7, on the spool trap the oil in either work port to hold the circuit stationary.

35-24

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

2 1

6 5

50020050

25 When a solenoid, 1, is energized to move the valve, the spool is shifted sideways by the solenoid. This allows oil flow from the stack pressure gallery, 2, across the flow control land into the supply gallery, 3. The oil flow, and resulting pressure, is picked up through the load sense gallery, 4, and fed back to the pump compensator through the load check circuit to put the pump into stroke. As the spool is shifting, the main control lands, 5, will connect one work port to the supply gallery, while the

other work port is connected to the return gallery to allow oil to flow through the circuit. The flow control land, 6, in each valve is machined to provide a specific amount of flow for that valve, to ensure consistent operation of each circuit. If the pump tries to provide too much oil to the valve, the resulting pressure drop across the flow control land is fed back through the load check circuit to the pump causing it to destroke to provide less oil.

35-25

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

50020037

26 Load Check Poppet Function When a valve spool is shifted and pressure is fed into the load sense gallery, the pressure pushes that valve’s load check poppet against the opposite valve section, sealing the load sense gallery from those valve sections. Pressure is then fed to the next valve section, pushing that load check poppet into that valve section, which seals that valve section from the load sense gallery. Pressure continues in this manner until it reaches the accumulator valve section, where

it exits the valve stack and is connected to the pump compensator. If more than one valve section is activated at once with differing pressure requirements, the highest pressure requirement will be fed to the pump compensator, as the higher pressure signal overcomes the others via the load check poppets. This ensures that the pump compensator always reacts to the highest demand.

35-26

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

1 5

1 4

50020053

27 Load Check Valves Several valves are equipped with load check valves, 1, to positively trap oil in the circuit to prevent the circuit from “drifting” when the valve is in neutral. When the valve is activated, oil pressure will build in the supply gallery until it can overcome the trapped pressure in the circuit. Once system pressure exceeds the cir-

cuit pressure, the load check valve opens and oil flows to the circuit. The load check valves consist of many smaller components, including the unload spool, 2, pilot pins, 3, balls, 4, and springs, 5.

35-27

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

1 2

50020054

28 On double-acting valves with two load check valves (one on each work port), the oil pressure in the supply gallery not only lifts the load check valve, 1, off its seat, but also shifts the unload spool, 2, against the pilot pin, 3, in the opposite load check valve. This action lifts the ball, 4, off of its seat, allowing oil to drain

from the back side of the valve faster than it can be replenished through the orifice drilling, 5, in the side of the valve. The pressure drops behind the spool, allowing the return pressure to push the load check valve open on the return side of the circuit.

35-28

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 1

50020051

29 Pressure Compensator Spool Some valves are equipped with a pressure compensator spool, 1, to ensure that the flow rate through the valve remains constant irregardless of pressure in the main gallery, due to other circuit demands. If another valve is activated which has a higher pressure requirement (such as header raise or unload auger swing), the higher pressure could result in a higher flow rate across the valve flow control land, 2, resulting in the circuit operation varying with the pressure in the main or feeder stacks.

The pressure compensator spool is balanced with main system pressure on one end acting against a spring, 3, plus supply gallery pressure on the other end. If system pressure increases, that higher pressure will shift the pressure compensator spool against the combined spring and supply gallery pressure to restrict oil flowing from the main gallery into the valve. As the main pressure drops, the spring and supply gallery pressure can shift the compensator spool to allow more flow into the valve. This ensures a consistent flow rate into the valve irregardless of the system pressure.

35-29

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 ROTOR VARIATOR/FEEDER VARIATOR/REEL RAISE--LOWER The rotor variator, feeder variator and reel lift valves are all similar in specification, varying only in the specific flow rate setting. In order to provide precise flow control on both variator circuits, two pressure-compensated flow control valves are used in the external circuits to limit the flow rate to and from the variator cylinders to 0.16 liters/min (5.4 fl oz/min). This ensures a consistent change of speed (20 seconds to move from one end of the speed range to the other) for precise speed setting.

10020016

These are double acting valves, equipped with a load check valve on the single work port. When lowering the reel, or reducing variator speed, pump flow is required to pressurize the valve in order to shift the unload spool to open the load check valve in the work port.

UNLOADING AUGER SWING/FEEDER REVERSER VALVE The unloading auger swing and feeder reverser valves are very similar in operation, with one exception being the rated flow through the valve; the unloading auger has a set flow rate of 7.5 liters/min (2 US gpm), while the feeder reverser valve has a set flow rate of 38 liters/min (10 US gpm). The other significant difference is that the feeder reverser valve connects both work ports to the return gallery when the valve is in neutral, rather than trapping the oil in the circuit as the unloading auger swing valve does. This ensures that the reverser motor can coast to a stop, rather than be stopped suddenly, which may cause damage to the rotating components, or pressure spikes within the hydraulics.

10020019

These valves are not equipped with load check valves; they are not desired on a hydraulic motor circuit, such as the feeder reverser circuit. The unloading auger swing circuit has the load check valves integrated into a manifold block on the unloading swing cylinder itself.

LATERAL FLOAT VALVE/REEL FORE--AFT VALVE/AUTOGUIDANCE STEERING VALVE

The lateral float, reel fore/aft and autoguidance steering valves are double acting valves equipped with load check valves. The main difference is that the lateral float and autoguidance steering valves are each equipped with a pressure compensator, 1, to ensure smooth, consistent operation at all times.

10020018

35-30

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 REEL DRIVE VALVE The reel drive valve is a single acting valve that is used to drive the reel on headers. When the valve returns to neutral, both motor work ports are connected to the return gallery to allow the reel to coast to a stop to prevent damage due to forcing a sudden stop. There are no load check valves required. The reel drive valve is equipped with a pressure compensator to prevent the reel speed from surging or changing due to other functions being activated while the reel drive is in operation. 10020015

STONE TRAP VALVE The stone trap valve is a single acting valve that is used to control the latching cylinder for the feeder stone trap system. When the valve goes to neutral, both ends of the cylinder are connected to return. The back pressure in the return gallery is enough to ensure that the cylinder is held in the extended position, due to the differences in area between the rod end v. the base end of the cylinder. This keeps the stone door latched. When the stone trap valve solenoid is energized, the valve directs oil from the main gallery to the rod end to retract the cylinder and open the stone trap; the base end of the cylinder remains connected to return.

35-31

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 HYDRAULIC CLEANING FAN DRIVE

While the hydraulic cleaning fan drive is not technically part of the high pressure hydraulic circuit, it draws its supply oil from the hydraulic reservoir. The fan drive pump, 1, is mounted on, and driven by, the hydrostatic drive pump. The pump draws oil from the hydraulic reservoir and directs the oil to fan drive valve at inlet port P, 2.

2 56070844

34 Oil flow to the fan motor is modulated by a solenoid valve, 1, operated by a pulse width-modulated (PWM) signal from controller CCM1, and working in conjunction with a proportional valve, to maintain a constant fan speed regardless of engine speed. Oil flow is directed to the fan motor from port A, 2. Return oil from the motor re-enters the valve at port B, 3, and exits the valve at port T, 4, and returns to the reservoir. The proportional valve also serves as a bypass valve in a condition where the thresher is not turned on, but the cleaning fan pump, driven by the hydrostatic pump, continues to supply oil to the valve through port P, 5. Under this condition, the solenoid valve is closed and oil is routed around it to the proportional valve. The pressure of the incoming oil acts on the pilot input of the proportional valve, causing its spool to shift, routing the oil flow to the T, 4, port and back to the reservoir.

35-32

1 4

66060560

2 35

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 LOW PRESSURE SYSTEM CHAFF SPREADER VALVE The chaff spreader valve consists of three main components; the solenoid valve, 1, the adjustable flow control valve, 2, and the relief valve, 3. Oil from the low pressure gear pump enters the valve at 4. If the solenoid is not activated, oil exits the valve at 5, and flows through the filter, 6, before travelling to the low pressure valve on the engine gearbox.

1 5

10020028

36 NOTE: If the solenoid valve, 1, is activated, oil is directed to the adjustable flow control valve, 2. Oil that can flow through the flow control valve exits the valve at 3 where it travels through a quick coupler to the two chaff spreader motors (connected in series). Oil returning from the chaff spreader motors enters the valve, joins bypass oil from the flow control valve, and exits the valve at 4. In the event that the chaff spreader becomes blocked, the relief valve, 5, will open, directing oil from the valve inlet, 6, to the valve outlet, 4. A diagnostic port is fitted to the valve at 7 to allow testing.

1 4

3 7 10020028

5 37

CHAFF SPREADER/PSD VALVE The chaff spreader/positive straw discharge (PSD) valve consists of three main components: the solenoid valve, 1, the adjustable flow control valve, 2, and the relief valve, 3. Oil from the low pressure gear pump enters the valve at port IN, 4. If the solenoid is not activated, oil exits the valve at port T1, 5, and flows through the pressure filter, 6, before traveling to the low pressure valve on the engine gearbox.

1 4

2 6 66060557

5 3 38

35-33

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 If the solenoid valve, 1, is activated, oil is directed to port C OUT, 2, from which it flows to the positive straw discharge (PSD) motor. Oil returning from the PSD motor re-enters the valve at port C IN, 3, and is directed to the adjustable flow control valve, 4. Oil that can flow through the flow control valve exits the valve at port S OUT, 5, from which it flows through a quick coupler to the two chaff spreader motors (connected in series). Oil returning from the chaff spreader motors enters the valve through a quick coupler at port T2, 6. If the chaff spreader becomes blocked, the relief valve, 7, will open, directing oil from the valve input port IN, 8, to the outlet port, T1, 9. A diagnostic port D1, 10, permits testing at the valve input. Diagnostic port D2, 11, permits testing at the output of the PSD motor.

10 11

3 2

4 7

66060557

6 39

CHOPPER INFEED ROLL MOTOR VALVE Combines that are equipped with a chopper infeed roll have a small hydraulic motor, 1, to drive the roller. This motor is in series with the chaff spreader motors and is controlled by the chaff spreader motor valve.

NOTE: Combines that are equipped with the chopper infeed roll do not have positive straw discharge and vice versa.

56060564

35-34

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 LOW PRESSURE VALVE

The low pressure valve controls several functions that do not require the high pressures generated by the high pressure hydraulic systems, such as clutch engagement and park brake disengage. The low pressure valve also provides pressure lubrication for several areas in the engine gearbox. Oil from the low pressure pump enters the low pressure valve at 1. The low pressure valve contains the unload clutch solenoid valve, 2, feeder clutch solenoid valve, 3, park brake solenoid valve, 4, and the thresher clutch solenoid valve, 5. Pressure for the engagement circuits is regulated at 25 bar (363 psi) by the relief valve, 6, and monitored by the electrical system using the pressure sensor, 7. An external lube oil line, 8, connects to the engine gearbox filler neck to directly lube the hydrostatic pump drive gear in the gearbox.

There are several hose and tubing connections to the back of the low pressure valve. They are used for flow out to the cooler, 1, return from the cooler, 2, supply to the park brake release cylinder, 3, and supply to the feeder clutch, 4. Diagnostic port, 5, permits lube pressure testing. Supply oil for the thresher and unload clutches travel from the valve down into the engine gearbox through internal drillings. Note that the oil cooler for the low pressure circuit is contained in the same cooler assembly, but is separate from the oil cooler for the hydrostatic and hydraulic system.

5 7

8 6 10004669

1 3 4

50020055

5 42

35-35

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

3 9 5

50020056

43 Oil flows into the valve from the low pressure pump, and is supplied to all solenoid valves through a central gallery, 1. The pressure in this gallery is regulated by the relief valve, 2, at the bottom of the inlet port. The pressure sensor, 3, is mounted on one end of the gallery to monitor the pressure, while a cross drilling directs pressure oil to the diagnostic coupler, 4. Once all circuit requirements are met, the relief valve, 2, will open and direct oil out of the low pressure valve via, 5, to the oil cooler. Return oil from the cooler enters the low pressure valve at, 6, to supply the lube oil gallery, 7. In the event of excessive restriction in the oil cooler circuit, the cooler relief valve, 8, will open and allow oil to flow directly to the lube oil gallery.

The lube oil gallery directs oil to the engine gearbox components at, 9, for cooling and lubrication. Two drillings directly off of the lube oil gallery supply oil directly to the unload and thresher clutches, while an external oil line carries oil to the filler neck and down to lubricate the hydrostatic pump drive gear. The pressure in the lube oil gallery is regulated by the lube pressure relief valve, 10. If the lube oil gallery pressure exceeds 2.75 bar (40 psi), the lube pressure relief valve will open and allow oil to dump directly into the engine gearbox sump.

35-36

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 The park brake circuit in the low pressure valve is equipped with two extra components; a 0.5 mm (0.020″) orifice, 1, and a check valve, 2. The check valve allows rapid flow of oil through the solenoid valve for releasing the park brake. However, in the event that pump flow is lost while the park brake solenoid is energized, the check valve will close, forcing oil to escape through the orifice. This provides for a slow, progressive re-engagement of the park brake and prevents a sudden, unexpected stop. The low pressure valve is fitted with several diagnostic ports to allow for troubleshooting. A coupler, 3, is connected to the high pressure gallery for quick testing, while plugs are installed in the following test ports: Unload clutch pressure, 4 Thresher clutch pressure, 5 Lube pressure, 5, Figure 42 If necessary, the cooler relief valve may be removed from the valve block for inspection by removing plug, 5, Figure 42, while the lube pressure relief valve may be removed by removing plug, 6.

35-37

4 50020057

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

35-38

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

SECTION 35 - HYDRAULIC SYSTEMS Chapter 3 - Pressure Testing and Fault Finding The High and Low Pressure Hydraulic Systems CONTENTS Section

Description

Page

Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special Tools

................................................................ 3

Specifications - Closed Center Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Low Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CCLS Pump Pressure and Flow Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CCLS Pump Low Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CCLS Pump High Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 CCLS Pump Load Sensing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 CCLS Pump Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Steering Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Steering Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Steering Relief Valve Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Hydraulic Cleaning Fan Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Low Pressure System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Low Pressure System – Chaff Spreader Pressure Test . . . . . . . . . . . . . . . . . . . . . 18 Chaff Spreader/PSD Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Low Pressure System – Regulated Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Low Pressure System – Individual Circuit Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Low Pressure System – Pump Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

35-1

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 DESCRIPTION AND OPERATION This chapter describes the procedure for fault finding the high and low pressure hydraulic systems and performing pressure tests.

The hydraulic pump is the heart of the hydraulic system and the chapter describes in detail the tests necessary to confirm that pump output is to specification. Once specified pump output has been confirmed attention can be focused on the appropriate pressure testing of individual components in the hydraulic circuit.

Before commencing hydraulic pressure testing perform the fault finding checks on Page 4 followed by the fault finding procedure for the type of concern identified. Following these checks may identify an obvious cause for the concern and prevent unnecessary component disassembly.

35-2

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 SPECIAL TOOLS DESCRIPTION

NEW HOLLAND PART NUMBER OEM1459 OEM1463 OEM1464 OEM1212 FNH02003 FNH00535 FNH00035 FNH02760

Pressure Gauge 0-40 bar (0-600 psi) Pressure Gauge 0-250 bar (0-5000 psi) Pressure Gauge 0-400 bar (0-6000 psi) Quad Gauge Universal Pressure Test Kit Quick release (Female) Adaptor, Quick Release Flow Meter 120 ltr/min (0-50 gal/min) minimum O-RING FACE SEAL FITTINGS

Blanking Cap (9/16″-18 ORFS) - CCLS Pump Low Pressure Standby . . . . . . . . . . . . . Plug (9/16″-18 ORFS) - CCLS Pump Low Pressure Standby . . . . . . . . . . . . . . . . . . . . . Tee Piece (9/16″-18 ORFS swivel run) - CCLS Pump Load Sensing . . . . . . . . . . . . . . . Tee Piece (13/16 UNF fittings) - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elbow (13/16 UNF fittings) - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Release Fitting (9/16 UNF Female) - CCLS Pump Load Sensing . . . . . . . . . . . . Quick Release Fitting (13/16 UNF Female) - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . Coupler, Male (M14x1.5) [NH Part #84320565] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARKER HANNIFIN PART NUMBER 4FNL 4PNLO or 4PNMLO 4R6LOS or 4R6MLOS 8R6LOS or 8R6MLOS 8ELOS or 8EMLOS PD34BTL PD38BTL PD367A

CCLS Pump Flow - need Fittings to go from 13/16″-16 ORFS (-8 Size) to your Flow Meter for Pressure Hose, and 1″-14 ORFS (-10 Size) to your Flow Meter for Return Hose. Low Pressure Pump Flow - Use 1/2″ ISO Couplers (1 Male, 1 Female) to attach Flow Meter to Chaff Spreader Couplers. For units not equipped with Chaff Spreader, need Fittings to go from 1″-14 ORFS (-10 Size) to your Flow Meter.

35-3

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 SPECIFICATIONS - CLOSED CENTER SYSTEMS MAIN HYDRAULIC PUMP Type

Variable Flow Closed Center Load Sensing Piston Pump 117 L/min (30.8 US gpm) 19 bar (275 psi) 210 bar (3046 psi) 35 Ltr/min (9 US gal/min) 185 bar (2683 psi)

Minimum Output @ engine rated speed Standby Pressure Maximum System Pressure Flow to Steering Motor Steering Pressure

LOW PRESSURE PUMP Type Minimum Output @ engine rated speed Chaff Spreader Motor relief valve Regulated System Pressure Cooler Bypass Valve Lubrication Pressure

Gear Type Pump 40.5 L/min (10.7 US gpm) 200 bar (2900 psi) 25 bar (363 psi) 3.5 bar (50 psi) 2.75 bar (40 psi)

4 2

9 6

86063008

1 1. 2. 3. 4. 5.

High Pressure CCLS Hydraulic Pump and Low pressure Gear Pump Installation Flow and pressure compensating valves 6. Low pressure pump output tube Load sensing line 7. Low pressure gear pump CCLS pump casing 8. Low pressure pump inlet Pump case lubrication drain 9. CCLS pump high pressure output CCLS pump inlet

35-4

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 GENERAL FAULT FINDING Is the reservoir oil at the correct level ?

Add oil to reservoir

YES

Is oil contaminated with dirt, water or anti-freeze?

YES

Have oil filters been replaced at correct service interval?

Investigate cause of contamination. Drain and replace oil Replace all filters in system

YES

Is the low pressure system warning light ON NO

YES

Refer to Low Pressure system Warning Light ‘On’ fault finding chart

Identify functions not operating correctly and refer to appropriate fault finding Chart

35-5

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 Low Pressure Warning ‘ON’ Alarm “A0012 Control Pressure LOW”

86063007

Perform the low pressure circuit regulated pressure test. Is the pressure 25 bar (362 psi)?

YES

Suspect a faulty pressure sensor. Replace and check operation.

Was the pressure measured 0 Bar (0 psi)?

YES

Suspect the drive link between the CCLS and low pressure pumps. Remove the low pressure pump and inspect. Is the drive link okay? YES

Suspect a leak within the low pressure block. Perform individual low pressure circuit tests. Clean or replace solenoid valves as required. Check the operation. Is the pressure to the specification?

Remove and Inspect the relief valve in the low pressure block. The valve may be stuck open. Clean or replace as required, and recheck the operation. Is the pressure to the specification? NO

Suspect a faulty pump. Perform the Low Pressure Pump Flow Test. Repair or replace the pump as required and recheck.

35-6

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

1 10020028

4 Low Pressure Filter Restriction Warning Alarm “A0010 Gearbox Filter BLOCKED”

Is the gearbox oil at correct level on sight glass?

Add oil to engine gearbox.

YES

Replace filter, 1. Fault cleared?

Disconnect wiring to filter restriction warning light switch warning is extinguished?

YES

Locate and repair short circuit to chassis in intake filter restriction switch wiring

Replace intake filter restriction switch

Engine Gearbox Oil Overheating Alarm “A0006 Gearbox Temperature HIGH”

Is the gearbox oil at correct level on sight glass?

Add oil to engine gearbox.

Clean oil cooler.

YES

Is oil cooler free of dirt and chaff build-up? YES

Suspect a faulty pump. Perform the Low Pressure Pump Flow Test. Repair or replace the pump as required.

35-7

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 1

5 Power Steering Not Working or Working Incorrectly

Do the other high pressure functions operate?

YES

Fault in the CCLS pump circuit. Perform Load sense circuit test, Low pressure standby test and high pressure standby test

Pressure test at steering motor, 1. Is approximately 200 bar (2900 psi) measured at motor ’P’ port when steering wheel rotated? (gauge tee’d into line)

YES

Fault lies in steering motor. Perform steering motor tests and refer to Section 41 steering systems

Suspect a fault within the Priority valve. Inspect the priority valve spool for sticking

General Faults No Steering and No Other High Pressure System Functions Fault in CCLS pump circuit. Perform tests for CCLS pump

Steering Working Okay but No Other High Pressure System Functions Fault in priority valve. Inspect spool for jamming in the valve housing.

35-8

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 All high pressure system functions affected:

A fault common to all functions, possibly the CCLS pump is faulty, the system relief valve is stuck open or a blocked pressure filter.

Both the high and low pressure systems are affected: A common fault affecting the pumps, possibly a pump drive fault or a fault in the gearbox.

Only one function affected, other functions operating normally: Fault specific to that function. Is an error code displayed on the Infoview™ Monitor? If an error code is displayed, investigate the error code and eliminate before proceeding. Determine if fault is electrical or hydraulic. If the solenoid has a manual push button, activate; if function operates okay, the fault is electrical. If the function does not operate with the manual button check the hydraulic circuit. If possible install a pressure gauge to the component being operated. If pressure is indicated this may suggest a seized or non-functioning component. If there is no output pressure from the valve then there may be a fault within that valve slice. Remove the valve and inspect for sticking spools, broken springs or dirt ingress in galleries.

A function will only operate in one direction: Is an error code displayed on the Infoview™ Monitor? If an error code is displayed investigate the error code and eliminate before proceeding. Determine if fault is electrical or hydraulic. If the solenoid has a manual push button, activate, if function operates okay, the fault is electrical. If the function does not operate with the manual button check the hydraulic circuit. If possible install a pressure gauge to the component being operated. If pressure is indicated this may suggest a seized or non-functioning component. If there is no output pressure from the valve then there may be a fault within that valve slice. Remove the valve and inspect for sticking spools, broken springs or dirt ingress in galleries.

35-9

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 Oil overheating (high pressure system): Relief valve continually blowing, check for broken spring or dirt ingress and reset. Oil cooler blocked or thermostatic bypass valve faulty not allowing oil to circulate around the cooler. If hydrostatic temperature control system (TCS) is limiting hydrostat operation, hydrostatic system overload is causing oil overheat. Shift transmission to lower gear to reduce load on hydrostatic system.

Jerky or inconsistent operation: On functions requiring consistent and fine control, the system pressure is maintained by a pressure compensation valve located within the valve slices. If these stick and fail to operate, jerky or inconsistent operation may result.

Components may drop gradually or move gradually out of position without being operated: Functions that contain lock-out valves may drop or move if the seals within that function are slightly worn and the lock out valve is not functioning. This may be due to dirt ingress or the valve sticking open. If the lock out valve sticks closed this may lead to a function not operating or operating very slowly.

Accumulator faults: An accumulator is installed into a circuit to absorb spikes created in the hydraulic system, i.e., generated by forces acting on a raise/lower cylinder. If an accumulator fails, the system will become rigid and the component will have no damping.

35-10

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 CCLS PUMP PRESSURE AND FLOW TESTING IMPORTANT: Before performing any pressure or flow testing operate the combine until the oil is at normal operating temperature, 65-70°C (150-160°F). The following tests check operation of the hydraulic pump and associated high pressure circuits. CCLS Pump Low Pressure Standby Special Tools Pressure Gauge 0 – 40 bar (0 - 600 psi) (or) Quad Gauge Quick release (Female) Adaptor, Quick Release

OEM1459 OEM1212 FNH00535 FNH00035

Fittings Required Blanking Cap (9/16″-18 ORFS) Plug (9/16″-18 ORFS)

Parker Hannifin # 4FNL 4PNLO or 4PNMLO

1. Attach the pressure gauge to the coupling, 1, in the priority valve slice in the main stack valve.

IMPORTANT: If a 0 – 40 bar (0 – 600 psi) pressure gauge is used, ensure that no hydraulic functions, including steering, are activated while testing low pressure standby, or the pressure gauge will be damaged. 2. Have an operator start the engine and set engine speed to maximum. Record the value on the pressure gauge. The reading should be approximately 28 bar (408 psi). Note that the low pressure standby is actually higher than that listed in the specifications, due to the dynamic bleed that occurs in the steering motor. If the pressure gauge reading is significantly higher or lower than 28 bar (408 psi), continue the test with steps 3 through 7 to confirm the fault. 3. Disconnect the load sense line, 2, from the fitting on the main stack valve. Install the blanking cap onto the fitting on the stack valve, and the plug in the load sense line. 4. Attach the pressure gauge to the coupling, 1, in the priority valve slice in the main stack valve. 5. Have an operator start the engine and set engine speed to maximum. Record the value on the pressure gauge. The pressure reading should be approximately 19 bar (275 psi).

2 10020036

35-11

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 6. If the pressure reading is marginally away from specification, adjust the flow compensating valve, 1, on the CCLS pump. If the reading is excessively high, examine the flow compensating valve spool, 1, for sticking. 7. Remove the blanking cap and plug, and reinstall the load sense line to the main stack valve.

86070851

9 CCLS Pump High Pressure Standby Special Tools Pressure Gauge 0 – 250 bar (0 - 5000 psi) (or) Pressure Gauge 0 – 400 bar (0 – 6000 psi) (or) Quad Gauge Quick release (Female) Adaptor, Quick Release

OEM1463 OEM1464 OEM1212 FNH00535 FNH00035

NOTE: The load sense line must be connected for this test.

1. Attach the pressure gauge to the coupling, 1, in the priority valve slice in the main stack valve. 2. Have an operator start the engine and set engine speed to maximum. 3. Operate either the reel horizontal adjustment valve or reel vertical adjustment valve to the maximum travel of the cylinders and hold to read the pressure obtained in the system. 4. The pressure reading should rise to 210 bar (3046 psi), and is the ‘High Pressure Standby’. 5. If reading is not to specification adjust pressure compensating valve, 2. If the pressure reading is low, and cannot be adjusted to specification with the pressure compensating valve, 2, there may be a fault in the load sense circuit. Perform the “Load Sensing Circuit Test”.

86070851

35-12

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 CCLS Pump Load Sensing Circuit Special Tools Pressure Gauge 0 – 250 bar (0 - 5000 psi) (or) Pressure Gauge 0 – 400 bar (0 – 6000 psi) (or) Quad Gauge Quick release (Female) Adaptor, Quick Release Fittings Required Tee, Swivel Run (9/16″-18 ORFS) Quick release fitting (9/16″-18 ORFS Female)

OEM1463 OEM1464 OEM1212 FNH00535 FNH00035 Parker Hannifin # 4R6LOS or 4R6MLOS PD34BTL

The load sensing circuit test checks the load sense pressure that is fed back to the CCLS pump to put it into stroke. If a circuit is not operating correctly, or if it is not possible to set the high pressure standby on the pump with the high pressure compensator, there may be excessive leakage in the load sense circuit, which is preventing the signal from reaching the pump. 1. Remove the load sense line, 1, from the fitting on the CCLS pump compensator valve. Install the swivel run tee between the line and fitting in compensator. Install the quick release fitting to the tee, and attach the pressure gauge to the quick release fitting. 2. Have an operator start the engine and set engine speed to maximum. 3. With no functions being operated, there should be approximately 7 - 10 bar (101 – 145 psi) pressure in the load sense line; this is the pressure from the dynamic bleed in the steering motor. Operate each of the functions of the high pressure system one at a time. As each valve is operated, the pressure should rise to the maximum required by the function being operated, and will rise to approximately 210 bar (3046 psi) when the circuit stalls (cylinder hits end of stroke, etc). NOTE: Some circuits, such as reel drive or feeder reverser, will not stall unless overloaded, or if the lines to the appropriate motor are uncoupled, or removed and capped. If a circuit does not generate relief pressure in the sense line when stalled, this is an indication of leakage in the load sense circuit. Determining which circuits are affected by this leakage should help determine which load check poppet is leaking.

35-13

86063008

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 CCLS Pump Flow Test If the CCLS pump is capable of developing the proper high standby pressure, but several circuits operate very slowly when loaded heavily (such as slow header raise with large headers), the CCLS pump may be worn internally, and be incapable of developing sufficient flow rate under high pressure. To flow test the CCLS pump, it is recommended that the output is checked at the hoses to the header stack valve. Special Tools Flow meter, 120 L/min (0-50 gpm) minimum FNH02760 Fittings Fittings are required to go from 13/16″ – 16 ORFS (-8 size) to your flow meter for the pressure hose, and 1″ – 14 ORFS (-10 size) to your flow meter for the return hose. 1. Note: A reverse flow check valve in the return filter head will prevent the reservoir from draining when the return line is removed, however, some oil in the lines will be lost. Have a catch pan ready when removing the lines to catch any oil loss. Remove the pressure line from the elbow on top side of the feeder stack. Install the appropriate adapter fitting, and attach the line to the inlet hose of the flowmeter. Remove the return line from the top rear of the feeder stack. Install the appropriate adapter fitting, and attach the line to the outlet hose of the flowmeter. 2. Ensure that the load valve on the flowmeter is fully “Open”. Start the engine, and run the engine at high idle for several minutes. Shut off the engine. Check the hydraulic reservoir for proper fluid level, and top off as required. 3. Have an operator start the engine and run at high idle. Engage and hold the unload auger swing in; this will force pump oil through the system. Gradually adjust the load valve on the flowmeter to a pressure reading of approximately 35 bar (507 psi). Record the oil flow through the flowmeter; it should be approximately 117 L/min (30.8 US gpm). If the flow is significantly less, the suction lines may be restricted to the CCLS pump, or the pump may be damaged internally. 4. Gradually adjust the load valve on the flowmeter to a pressure reading of approximately 190 bar (2756 psi) while monitoring the oil flow through the flowmeter. The flow rate should remain relatively stable at approximately 117 L/min (30.8 US gpm), and should not fall off significantly. If the flowrate does drop significantly [23 L/min (6 US gpm) or more], this is an indication of a worn or damaged CCLS pump.

35-14

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 STEERING TESTING The following practical test will determine if steering pump output is sufficient to allow satisfactory operation of the steering system. Steering Test 1. Start the engine, and set engine speed to high idle. 2. Turn steering quickly from lock to lock. If steering is operating correctly the reaction should be immediate with no time delay between turning the steering wheel and movement of the wheels. 3. At full lock the relief valve in the main frame valve stack should be heard to blow. The steering wheel should not continue to turn at full lock; if the steering can be rotated somewhat, this is an indication of possible steering cylinder leakage across the piston seals. Steering Relief Valve Pressure Test Special Tools Pressure Gauge 0 – 250 bar (0 - 5000 psi) (or) Pressure Gauge 0 – 400 bar (0 – 6000 psi) (or) Quad Gauge Quick release (Female) Adaptor, Quick Release

OEM1463 OEM1464 OEM1212 FNH00535 FNH00035

1. Attach the pressure gauge to the coupling, 1, in the priority valve slice in the main stack valve.

35-15

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 2. Start the engine, and set engine speed to maximum. Rotate the steering wheel in one direction to full lock, and hold in position. The reading on the pressure gauge should be approximately 185 bar (2683 psi).

If the reading is significantly higher or lower than specification, adjust the steering pressure by adjusting the relief valve, 1, on the priority valve slice. 10020036

17 Hydraulic Cleaning Fan Flow Test This test is used to determine the efficiency of the cleaning fan hydraulic drive pump. The pump will wear internally over time, causing the fan speed to decrease. 1. Disconnect the hose from the input (top) connector of the cleaning fan motor. This is the motor input hose from the cleaning fan valve. Connect the hose to the input of the flow meter. Disconnect the hose from the output (bottom) connector of the motor. This is the output hose back to the return port of the cleaning fan valve. Connect this hose to the output connector of the flow meter. NOTE: If the flow meter does not include a pressure gauge, a separate pressure gauge may be connected to diagnostic port M on the cleaning fan valve block. This port is located on the inboard side of the valve block. 2. Open the restriction valve on the flow meter completely. 3. Start the engine and engage the combine’s separator. Using the cleaning fan speed rocker switch on the right-hand console, set the fan speed to the minimum setting and run the engine at high idle. 4. While monitoring the flow meter, gradually increase the fan speed to maximum. This will verify correct operation of the solenoid valve and software operation. The cleaning fan pump’s output flow should reach approximately 77 l/min (20 gal/ min), which is the pump’s maximum theoretical flow rate for this application.

35-16

56060566

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 5. Slowly turn in the flow meter’s restriction control to increase the system pressure and verify that the system’s relief valve is working correctly. The valve should open at 210 bar (3000 psi). 6. Slowly reopen the restriction valve until the pressure drops to approximately 21 bar (300 psi) below the relief valve setting: 210 – 21 = 189 bar (3000 – 300 = 2700 psi). The flow rate should be greater than 65 l/min (17 gal/min), which is the minimum flow specification. If Flow is Below Minimum Specifications 1. Check the oil level in the hydraulic systems reservoir. A low oil level can starve the system during peak demands by other systems. 2. Inspect the suction (input) hose of the cleaning fan hydraulic motor. An aging hose can tend to buckle when the motor draws oil, restricting the oil flow. 3. Check for worn relief valve and solenoid valve Orings. 4. There could be a problem with the control solenoid valve. The only sure way to test this is to re-

place the valve block assembly with a known good assembly. 5. The pump could be worn excessively. NOTE: If the flow is below specifications, the output of the pump alone can be checked by connecting the flow meter directly to the pump. However, the following CAUTION should be strictly observed.

CAUTION Use extreme caution if this procedure is used. There is no relief valve in the system when testing in this manner. The pump could be damaged and flying pieces could cause injury. Be absolutely sure the flow meter restrictor is open when starting the combine engine. Once the machine is started, increase to full throttle and very slowly turn in the restrictor. DO NOT let the pressure exceed 200 bar (2900 psi). If the flow rate is less than 65 l/min (17 gal/min), the pump is worn excessively and must be replaced.

35-17

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 LOW PRESSURE SYSTEM TESTING The low pressure system provides oil flow and pressure for three important functions; it provides power for the chaff spreader, it provides oil pressure for clutch engagement, and it provides flow through the cooler for cooling the engine gearbox. Low Pressure System – Chaff Spreader Pressure Test Special Tools Pressure Gauge 0 – 250 bar (0 - 5000 psi) (or) Pressure Gauge 0 – 400 bar (0 – 6000 psi) (or) Quad Gauge Quick release (Female) Adaptor, Quick Release

OEM1463 OEM1464 OEM1212 FNH00535 FNH00035

1. Attach the pressure gauge to the test fitting, 1, located on the side of the chaff spreader valve. Uncouple one of the quick couplers, 2, that connect the chaff spreader motors to the valve. 2. Start the engine, and engage the thresher. Momentarily set the engine to high idle until a pressure gauge reading is obtained, then reduce engine speed and disengage the thresher. IMPORTANT: As soon as the thresher is engaged, the low pressure system is pushing all oil flow over the relief valve in the chaff spreader valve. Do not run the thresher for any longer than is required to obtain a stable gauge reading, or pump damage may occur.

3 2 10020028

3. The reading on the pressure gauge should be approximately 200 bar (2900 psi). If the pressure gauge reading is not correct, replace the relief valve, 3. Chaff Spreader/PSD Pressure Test If the combine is equipped with the positive straw discharge (PSD) system, a different chaff spreader valve is used. In this case, attach the pressure gauge to test fitting D1, 1, located on the front face of the valve block, above the manual rotary valve knob. Follow the steps above to perform the pressure test.

66060557

35-18

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 Low Pressure System – Regulated Pressure Test Special Tools Pressure Gauge 0 – 40 bar (0 - 600 psi) (or) Quad Gauge Quick release (Female) Adaptor, Quick Release

OEM1459 OEM1212 FNH00535 FNH00035

1. Attach the pressure gauge to the test fitting, 1, located on the low pressure valve. Start the engine, and check the pressure gauge reading at low engine idle. The reading on the pressure gauge should be approximately 25 bar (363 psi). If the pressure reading is low, this is a possible indication of excessive leakage in one of the clutch engagement circuits, a faulty relief valve, or a worn or damaged pump.

2. Increase the engine speed to high idle, and check the pressure gauge reading. The reading on the pressure gauge should be approximately 25 bar (363 psi).

If the reading is still low, this is a possible indication of a faulty relief valve or a worn or damaged pump. Replace the relief valve and retest the circuit. If the pressure reading is still low, the pump must be removed for inspection and repair. Low Pressure System – Individual Circuit Testing If a particular circuit is not operating correctly, it is possible to test it individually from the other circuits. Special Tools Pressure Gauge 0 – 40 bar (0 - 600 psi) (or) Quad Gauge Quick release (Female) Adaptor, Quick Release Fittings Required Quick release fitting (M14 x 1.5) [NH part# 84320565] (or) Quick release fitting (13/16″-16) 1. Install a quick release fitting into the appropriate port for the circuit to be tested, as follows:

OEM1459 OEM1212 FNH00535 FNH00035 Parker Hannifin # PD367A PD38BTL

Unload clutch pressure, 1 (M14 x 1.5 ORB port) Thresher clutch, 2 (M14 x 1.5 ORB port) Remove the plug, and install a quick release fitting [NH part # 84320565 (Parker #PD367A)], or remove the regulated pressure test fitting, 3, and switch positions with the plug.

2 1 50020057

35-19

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 Park brake pressure, 1 Feeder clutch pressure, 2 These two ports are both M14 x 1.5 ORB, but have a nipple installed to 13/16″ – 16 ORFS (-8 size) for the hoses. Remove the hose from the fitting, and install a quick release fitting (Parker #PD38BTL). Alternatively, remove the hose and nipple, and install a quick release fitting [NH part # 84320565 (Parker #PD367A)] directly into the valve. 2. Start the engine, and run at low idle. Engage the circuit to be tested, and check the pressure gauge reading. The reading on the pressure gauge should be approximately 25 bar (363 psi). If the pressure reading is low, this is a possible indication of excessive leakage in the clutch engagement circuits, due to damaged seals in the solenoid valve. On the unload and thresher clutch circuits, this could also indicate a leak at the seal rings on the clutch shaft in the engine gearbox.

50020055

3. Increase the engine speed to high idle, and check the pressure gauge reading. The reading on the pressure gauge should be approximately 25 bar (363 psi). If the reading is still low, this is a possible indication of a faulty relief valve or a worn or damaged pump. Replace the relief valve and retest the circuit, If the pressure reading is still low, the pump must be removed for inspection and repair. Low Pressure System – Pump Flow Test Consistently low pressures in the low pressure valve, even after the relief valve has been replaced, may indicate a worn or damaged low pressure pump. In addition, the reduced flow from a worn pump may result in insufficient flow through the oil cooler, causing engine gearbox oil overheating. If engine gearbox oil overheating is a consistent problem, the low pressure pump flow rate should be tested. Special Tools Flow meter, 120 L/min (0-50 gpm) minimum

FNH02760

Fittings If unit is equipped with chaff spreader option, use standard ISO couplers (1 male, 1 female) to connect the flowmeter to the couplers on the chaff spreader valve. If unit is not equipped with chaff spreader option, fittings are required to go from 1″ – 14 ORFS (-10 size) to your flow meter for both hoses.

35-20

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 1. Note: Some oil in the lines will be lost. Have a catch pan ready when removing the lines to catch any oil loss. If equipped with chaff spreader:

Disconnect the chaff spreader quick couplers, 1. Connect the flowmeter inlet hose to the female coupler on the chaff spreader valve, and the flowmeter outlet hose to the male coupler on the chaff spreader valve. If not equipped with a chaff spreader:

1 10020028

Remove the pressure line, 2, from the side of the filter. Install the appropriate adapter fitting, and attach the line to the inlet hose of the flowmeter. Install the appropriate adapter fitting to the fitting in the filter head, and attach the outlet hose of the flowmeter. 2. Ensure that the load valve on the flowmeter is fully “Open”. Start the engine, and run the engine at high idle for several minutes. Shut off the engine. Check the engine gearbox for proper fluid level, and top off as required. IMPORTANT: On units not equipped with a chaff spreader, use caution when adjusting the flowmeter load valve, as there is no relief protection between the pump and flowmeter. Excessive pressure buildup will result in pump failure. 3. Have an operator start the engine and run at high idle. Gradually adjust the load valve on the flowmeter to a pressure reading of approximately 35 bar (507 psi). Record the oil flow through the flowmeter; it should be approximately 40.5 L/min (10.7 US gpm). If the flow is significantly less [11 L/min (3 US gpm) or more], the suction line to the pump may be restricted, or the pump may be damaged internally. 4. Gradually adjust the load valve on the flowmeter to a pressure reading of approximately 190 bar (2756 psi) while monitoring the oil flow through the flowmeter. The flow rate should remain relatively stable, or may drop slightly to approximately 36 L/min (9.5 US gpm), but should not fall off significantly. If the flowrate does drop significantly to 32 L/min (8.5 US gpm) or less, this is an indication of a worn or damaged pump.

35-21

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

35-22

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

SECTION 35 - HYDRAULIC SYSTEMS Chapter 4 - Stack Valves Overhaul CONTENTS Section

Description

Page

35-1

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 REPAIR MAIN STACK VALVE Removal IMPORTANT: Be sure the area around the stack valves is clean before removing them. Dirt contamination will cause hydraulic component damage and/or failure. Use caution while washing to keep electrical components as dry as possible. 1. Remove plug from drain hose, 1, and drain the hydraulic oil into clean suitable containers.

86063117

1 IMPORTANT: Lines and fittings must be capped and plugged when disconnected to avoid contamination. Dirt contamination will cause hydraulic component damage and/or failure. 2. Loosen and disconnect the hydraulic line fittings from the stack valve. Cap and plug all lines and fittings.

10020036

2 NOTE: Mark all electrical connector locations for proper connection during assembly.

3. Disconnect all electrical connectors from the valve solenoids, 2, and valve stack. 4. Disconnect the main electrical connector, 1, from the ECU.

1 10020036

35-2

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 5. Loosen and remove the four cap screws, 1, securing the stack valve to the support brackets, 2. (only two screws are shown).

6. Remove the stack valve from the support bracket.

2 50021213

4 Installation

1. Install the stack valve onto the support brackets, 1. 2. Install the four cap screws, 2, securing the stack valve to the support brackets, 1. 3. Tighten the cap screws securely.

1 50021213

5 4. Connect the main electrical connector, 1, to the ECU.

5. Connect the electrical connectors to the valve solenoids, 2.

1 10020036

35-3

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 6. Remove all caps and plugs from the hydraulic lines and fittings. 7. Connect the hydraulic line fittings to the stack valve. Tighten the fittings securely.

10020036

7 8. Reinstall plug in drain hose, 1. 9. Fill the hydraulic reservoir with the proper type and amount of hydraulic fluid. 10. Start the engine and cycle the appropriate features controlled by the main stack valve. 11. Check for proper operation of all functions of the main stack valve.

12. Check all connections for leaks.

86063117

8 Disassembly NOTE: Illustrations do not show optional feeder variator valve. 1. Loosen and remove the three nuts, 1, from the tie rods.

20015980

35-4

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 2. Carefully lift the base plate, 1, from the unloading auger valve, 2.

1 2

20015981

10 3. Carefully lift the unloading auger valve, 1, from the rotor variator valve, 2.

20015982

11 4. Carefully lift the rotor variator valve, 1, from the priority valve, 2.

2 1

20015983

35-5

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 5. Carefully lift the priority valve, 1, from the accumulator valve, 2.

2 20015986

13 6. Lay the remaining parts of the stack valve assembly on the workbench. 7. Remove the three socket head cap screws, 1, from the header lift valve, 2.

20015984

2 14

8. Carefully lift the accumulator valve, 1, from the header lift valve, 2.

20015985

15 Inspection 1. Check all O-rings for cuts, nicks or deformity. Replace as necessary. 2. Check mating surface of valve sections for nicks, burrs, or other damage. Repair or replace as necessary. 3. Inspect tie rods for straightness. Replace as necessary.

35-6

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 Assembly NOTE: Illustrations do not show optional feeder variator valve.

1. Lubricate O-rings with New Holland Ambra Multi G134 hydraulic oil and install onto the header lift valve, 1.

2. Assemble the accumulator valve, 2, to the header lift valve, 1. 20015985

16 3. Install the three socket head cap screws, 1, through the header lift valve, 2, into the accumulator valve.

4. Tighten the cap screws securely.

20015984

2 17

5. Lubricate O-rings with New Holland Ambra Multi G134 hydraulic oil and install onto the connecting plate, 2.

6. Carefully install the priority valve, 1, onto the accumulator valve, 2.

2 20015986

35-7

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 7. Lubricate O-rings with New Holland Ambra Multi G134 hydraulic oil and install onto the priority valve, 2. 8. Carefully install the priority valve, 1, onto the rotor variator valve, 2.

2 1

20015983

19 9. Lubricate O-rings with New Holland Ambra Multi G134 hydraulic oil and install onto the rotor variator valve, 2. 10. Carefully install the unloading auger valve, 1, onto the rotor variator valve, 2.

20015982

20 11. Lubricate O-rings with New Holland Ambra Multi G134 hydraulic oil and install onto the unloading auger valve, 2.

1 2

12. Carefully install the base plate, 1, onto the unloading auger valve, 2.

20015981

35-8

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 13. Install the three nuts, 1, onto the tie rods. 14. Tighten and torque the nuts to 25 N⋅m (18.5 ft-lb).

20015980

35-9

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 FEEDER STACK VALVE Removal IMPORTANT: Be sure the area around the stack valves is clean before removing them. Dirt contamination will cause hydraulic component damage and/or failure. Use caution while washing to keep electrical components as dry as possible. 1. Disconnect the hydraulic supply and return lines, 1.

2. Cap and plug all fittings to avoid dirt contamination of the hydraulic system.

10021116

23 IMPORTANT: Lines and fittings must be capped and plugged when disconnected to avoid contamination. Dirt contamination will cause hydraulic component damage and/or failure. IMPORTANT: Mark all lines for proper connection during installation. 3. Loosen and disconnect the hydraulic line fittings from the feeder stack valve. Cap and plug all lines and fittings. 10020032

24 IMPORTANT: Mark all electrical connector locations for proper connection during assembly. 4. Disconnect the electrical connectors, 1, from the front side of the valve solenoids.

5. Disconnect the electrical connectors, 2, from the rear of the valve solenoids.

10020032

35-10

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 6. Loosen and remove the four cap screws, 1, securing the stack valve to the feeder, 2. (only two screws are shown). 7. Remove the stack valve from the support brackets.

2 20015990

26 Installation 1. Install the stack valve onto the feeder, 1. 2. Install the four cap screws, 2, securing the stack valve to the support bracket. (only two screws are shown).

3. Tighten the cap screws securely.

1 20015990

27 4. Connect the electrical connectors, 2, to the valve solenoids at the rear of the stack valve assembly. 5. Connect the electrical connectors, 1, to the valve solenoids at the front of the stack valve assembly.

10020032

35-11

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 6. Remove all caps and plugs from the hydraulic lines and fittings. 7. Connect the hydraulic line fittings to the stack valve. Be sure all lines are attached to their proper locations. Tighten the fittings securely.

10020032

29 8. Remove the caps and plugs from coupler fittings.

9. Connect the hydraulic supply and return lines, 1, to the feeder stack valve. 10. Start the engine and cycle the appropriate features controlled by the feeder stack valve. 11. Check for proper operation of all functions of the feeder stack valve. 12. Check all connections for leaks.

10021116

30 Disassembly

NOTE: Illustrations do not show stone ejection valve. 1. Loosen and remove the three nuts, 1, from the tie rods.

20015991

35-12

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 2. Carefully lift the end plate, 1, from the reel drive valve, 2.

1 2

20015992

32 3. Carefully lift the reel drive valve, 1, from the reel up\down valve, 2.

2 20015993

33 4. Carefully lift the reel up\down valve, 1, from the reel fore/aft valve, 2.

2 20015994

35-13

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 5. Carefully lift the reel fore/aft valve, 1, from the lateral tilt valve, 2.

20015995

35 6. Carefully lift the lateral float valve, 1, from the reverser valve, 2.

20015996

36 7. Carefully lift the reverser valve, 1, from the accumulator valve, 2.

1 2 20015997

37 Inspection 1. Check all O-rings for cuts, nicks or deformity. Replace as necessary. 2. Check mating surface of valve sections for nicks, burrs, or other damage. Repair or replace as necessary. 3. Inspect tie rods for straightness. Replace as necessary.

35-14

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 Assembly NOTE: Illustrations do not show stone ejection valve. 1. Lubricate O-rings with New Holland Ambra Multi G134 hydraulic oil and install onto the accumulator valve, 2. 2. Assemble the reverser valve, 1, onto the accumulator valve, 2.

1 2 20015997

38 3. Lubricate O-rings with New Holland Ambra Multi G134 hydraulic oil and install onto the reverser valve, 2.

4. Assemble the lateral float valve, 1, onto the reverser valve, 2.

20015996

39 5. Lubricate O-rings with New Holland Ambra Multi G134 hydraulic oil and install onto the lateral float valve, 2.

6. Assemble the reel fore\aft valve, 1, onto the lateral float valve, 2.

20015995

35-15

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 7. Lubricate O-rings with New Holland Ambra Multi G134 hydraulic oil and install onto the reel fore\aft valve, 2.

8. Assemble the reel up\down valve, 1, onto the reel fore\aft valve, 2.

2 20015994

41 9. Lubricate O-rings with New Holland Ambra Multi G134 hydraulic oil and install onto the reel up\down valve, 2.

10. Assemble the reel drive valve, 1, onto the reel up\down valve, 2.

2 20015993

42 11. Lubricate O-rings with New Holland Ambra Multi G134 hydraulic oil and install onto the reel drive valve, 2. 12. Assemble the end plate, 1, onto the reel drive valve, 2.

1 2

20015992

35-16

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 13. Install the three nuts, 1, onto the tie rods.

14. Tighten and torque the nuts to 25 N⋅m (18.5 ft-lb).

20015991

35-17

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 LOW PRESSURE VALVE BLOCK Removal IMPORTANT: Be sure the area around the low-pressure manifold is clean before disconnecting lines or removing from the gearbox. Dirt contamination will cause hydraulic component damage and/or failure. Use caution while washing to keep electrical components as dry as possible. 1. Disconnect the solenoid wire connector plug, 1. 2. Loosen the fittings, 2, and remove the hydraulic lines from the sides and top of the manifold block.

1 2

50020055

45 3. Disconnect the wire connector, 3, to the pressure sensor, 2.

4. Loosen and remove the four cap screws, 1. Remove the low-pressure manifold from the top of the gearbox (only two are shown). 5. Remove the O-rings between the gearbox and manifold block mating surfaces.

50023224

46 Installation 1. Install the O-rings between the gearbox and manifold block mating surfaces.

2. Install the low-pressure manifold onto the top of the gearbox. Install and tighten the four cap screws, 1 (only two are shown). 3. Torque the cap screws to 28 N⋅m (21 ft-lb). 4. Connect the wire connector, 3, to the pressure sensor, 2.

50023224

35-18

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4 5. Connect the solenoid wire connector plug, 1. 6. Connect the hydraulic lines on the sides and top of the manifold block and tighten the fittings, 2.

1 2

50020055

2 48

7. Check the oil level on level gauge, 1, (combine should be on level surface). Add New Holland Ambra Multi G134 hydraulic oil if necessary. 8. Start the engine and cycle the appropriate features controlled by the low-pressure manifold block.

9. Check for proper operation of all functions of the low-pressure manifold. 10. Check all connections for leaks. Recheck gear box level and add New Holland Ambra Multi G134 hydraulic oil if necessary.

86063130

35-19

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

35-20

SECTION 41 -- STEERING AXLE -- CHAPTER 1

SECTION 41 - STEERING AXLE Chapter 1 - Axle, General CONTENTS Section

Description

Page

41-1

SECTION 41 -- STEERING AXLE -- CHAPTER 1 INTRODUCTION AND GENERAL INFORMATION AXLE TYPES The combine steering axle is available in two configurations, Heavy Duty Adjustable Steering Axle and Powered Rear Axle. Both axle configurations use an adjustable common axle center section and components; axle extensions, 1, center axle, 2, pivot pin, 3, steering cylinders, 4, tie rod, 5, and attaching hardware.

3 1

4 5

66070032

1 Axle Center Section The purpose of the axle center section is to attach the wheels to the combine and provide a center pivot allowing the combine to run over rough terrain with minimal movement of the machine. The center section is also a mounting point for the two power steering cylinders used for manual or auto steering system (if equipped) directional control.

3 4

The axle center section, 1, attaches to the combine lower frame with an axle pivot pin, 2. Pivot pin wear is minimalized by installed grease seals, 3, and bushings, 4, into the grease filled pivot pin tube, 5.

6 8

66070031

A pivot pin collar, 6, is installed at the front of the axle to position the axle to the rear of the lower frame, which is required for all tire sizes listed in the Operator’s Manual -- Section 8 -- Specifications. The pivot pin uses shims, 7, for a clearance specification, and is secured through the lower frame and axle with a washer, castellated nut, and cotter pin, 8. Service and adjustment made to the axle center section are the same for both steering axles; only one procedure is described.

41-2

SECTION 41 -- STEERING AXLE -- CHAPTER 1 Heavy Duty Adjustable Steering Axle (HDASA) The Heavy Duty Adjustable Steering Axle is designed to support the weight of the combine and provide directional control to the operator.

66070029

3 Powered Rear Axle (PRA) The Powered Rear Axle is designed to support the weight of the combine, provide directional control to the operator and increase traction by the addition of two hydrostatic motors, 1, to drive the steering axle tires.

66070030

1 4

41-3

SECTION 41 -- STEERING AXLE -- CHAPTER 1 OVERHAUL CENTER SECTION

Removal Raise the combine with the proper sized jack. Support the weight of the combine with jack stands positioned under the center axle section. Remove both tires from the combine. Disconnect the tie rod, 1, and steering cylinders, 2, from both sides.

10010489

5 If removing a powered wheel motor, label, disconnect and plug the three hydraulic lines, 1 (reverse), 2 (drain), 3 (forward), at each straight connector.

1 2

NOTE: The order and description of the hydraulic lines shown is for the right-hand wheel motor. The order is reversed for the left-hand motor.

66070044

41-4

SECTION 41 -- STEERING AXLE -- CHAPTER 1 NOTE: Mark the location of installed extension and cylinder support hardware for re-installation if removal is for service only and the axle extension width or tire tread width is not changing. NOTE: Ensure attention and/or notation of washer and bushing locations. On each side of the center axle, remove three M20 x 260 bolts, 1, washers and locknuts from the cylinder support, 2.

3 1

Remove two M20 x 180 bolts, bushing, washer, 3, along with washers and locknuts. On PRA units additionally remove an M20 x 240 bolt and hose guide. NOTE: The hardware is torqued to 440 -- 485 N⋅ m (324 -- 358 ft-lb).

3 67060033

Use the appropriate lifting gear and remove the axle extensions, 2, from the center section.

NOTE: The hub casting or powered rear axle elements do not need to be removed, but appropriate lifting gear must be used to support the weight.

WARNING Raise and lower the combine evenly on both sides. Because of the center pin axle mount, the combine will shift toward the side that is lower. Failure to keep the combine level may result in the unit falling off a jack stand. Failure to comply could result in serious injury or death. Raise the combine as required and set jack stands under the left and right sides of the main frame directly forward of the axle stops as shown. Lower the combine frame carefully onto the jack stands.

10010505

8 Remove the four M16 x 60 cap screws and lock washers, 2, from the hitch mount.

Turn out the two M16 x 60 cap screws, lock washers, and washers at 1, from the upper portion of the hitch. While turning out the final cap screws, ensure the weight of the hitch is properly supported.

2 2

66063402

41-5

SECTION 41 -- STEERING AXLE -- CHAPTER 1 Set a hydraulic floor jack under the center section.

Remove the cotter pin, 1, and slotted nut, 2, from the center section pivot pin. Remove the washer and shims.

10010508

10 Adjust the height of the jack as required and pull the center section pivot pin, 1, from the axle mount. Capture the pivot pin collar from between the front of the axle and lower frame.

Inspect the pin for unusual wear characteristics, replace if required. Raise, lower or remove the center section as required. If simply raising or lowering the center section, line up the mounting holes for installation of the pivot pin.

86070034

NOTE: The axle must be installed in the upper pivot pin hole location, 1, for all tire combinations. The axle must be installed in the lower pivot hole, 2, when combine is equipped with tracks.

Installation Inspect the seals and bushings at 1, for unusual wear characteristics.

Replace the seals and bushings as required. Install the seal rings with the lip outward and press into the bore until the seal rings contact the bushings. Apply a generous layer of New Holland Ambra GR9 Multi-purpose Grease to the tube cavity, bushings, and seals.

Position the center section under the combine and raise it up to the appropriate mounting hole.

10010513

41-6

SECTION 41 -- STEERING AXLE -- CHAPTER 1 Coat the pivot pin, 1, with NH GR9 grease.

Lift the axle center section, 5, to align the pivot tube, 3, to the upper pivot hole, 2, on the lower frame.

Partially insert the pivot pin, from the rear, in the combine forward direction of travel, A.

Insert the pivot pin collar, 6, between the front of the axle and the frame, as shown, and then completely push the pivot pin through the collar and the front frame hole, 7.

66070035

NOTE: The pivot pin collar, 6, is positioned at the front of the axle center section for all tire and track applications

NOTE: The lower pivot pin hole, 4, is used only for combine models equipped with tracks; primarily European combine models. Install the shims, 4, washer, 3, onto the end of the pivot pin, 5. Shim to provide 0.0 -- 0.5 mm (0.0 -- 0.19 in) clearance, A.

Turn on the slotted nut, 1, and torque to 115 -- 127 N⋅m (85 -- 94 ft-lb). Install the cotter pin, 2, to secure the nut into place.

NOTE: If cotter pin cannot be installed within the torque range, loosen the nut to align the next hole.

3 4

66070036

14 Set the hitch into place, and then install first, the four M16 x 60 cap screws and lock washers, 2. Do not tighten the hardware.

Install the two M16 x 60 cap screws, 1, with large flat washers, and lock washer into the slotted holes of the hitch mount. Do not tighten the hardware.

2 2

First, tighten to standard torque, the four cap screws, 2, attaching the hitch to the combine. Second, tighten to standard torque, the two cap screws, 1, in the upper holes of the hitch mount.

66063402

41-7

SECTION 41 -- STEERING AXLE -- CHAPTER 1 WARNING Raise and lower the combine evenly on both sides. Because of the center pin axle mount, the combine will shift toward the side that is lower. Failure to keep the combine level may result in the unit falling off a jack stand. Failure to comply could result in serious injury or death. Raise the combine as required and set jack stands under the center section. Lower the combine carefully onto the jack stands. Remove the stands used to hold up the frame.

10010505

16 Set the axle extensions, 1, into place as previously installed or to new position if axle width or tire tread width has changed. Reference the Operator’s Manual charts and illustrations in Section 4 and Section 8 to determine axle extension position.

10010512

17 Install three M20 x 260 cylinder support bolts, 1, ensuring installation of washer between support and axle at inner most bolt, 2.

3 1

Install two M20 x 180 bolts with bushing and washer, 3. Secure the cylinder support and extension bolts with washers and locknuts.

2 3 66070033

41-8

SECTION 41 -- STEERING AXLE -- CHAPTER 1 Torque the M20 locknuts, 1, to 440 -- 485 N⋅m (324 -- 358 ft-lb). If working with a powered rear axle, attach the three hydraulic lines, 1, to each wheel motor in their original locations.

Reference Operator’s Manual -- Section 4 -Lubrication and Maintenance -- Hose Routing.

10010488

TOE IN ADJUSTMENT Tie Rod Attach one end of the tie rod, 1, to the hub casting with the threaded portion of the ball joint pointing up.

Torque the slotted nut to 250 -- 280 N⋅m (184 -- 201 ft-lb). Remove three M10 x 90 cap screws, clamp washers and locknuts from the telescoping section of the tie rod, 2.

Expand or contract the tie rod as required, so that the wheel hubs are straight ahead and parallel with each other.

66070038

Insert the three M10 x 90 cap screws, clamp washers and locknuts into the nearest holes and tighten to 49 -- 60 N⋅m (36 -- 44 ft-lb).

41-9

SECTION 41 -- STEERING AXLE -- CHAPTER 1 Insert the opposite end into the hub casting with the threaded portion of the ball joint pointing up. Tighten the slotted nut with a wrench not to exceed the final torque.

NOTE: The following measurements must be measured at 300 mm (11-13/16 in) from the wheel drive center at the horizontal center of the wheel drive. Measure the distance between the front of the hubs, A. Measure the distance between the back of the hubs, B. The difference between the two measurements, (A -- B), must be 8 -- 12 mm (5/16 -- 15/32 in) with the front hub measurement being the smaller of the two values.

B 10010494

Loosen the tie rod end lock nut on both sides. Remove the end of the tie rod that does not have torque applied, and perform the adjustment. If the front of the hubs must be adjusted in, turn in both tie rod ends equally. If the front of the hubs must be adjusted out, turn out both tie rod ends equally. NOTE: Both tie rod ends are threaded alike. To adjust the toe-in, one end must be dropped from its mount and turned independently of the other. IMPORTANT: The tie rod ends must have a minimum thread engagement of 38 mm (1-1/2 in) into the tie rod. When the adjustment is complete, torque the tie rod end lock nut to 290 -- 320 N⋅m (214 -- 236 ft-lb). Torque the loose tie rod end into the hub casting to 250 -- 280 N⋅m (184 -- 206 ft-lb) ensuring alignment of the cotter pin hole and nuts slot within the torque range. Install cotter pins to secure the nuts in place. Loosen the barrel end hydraulic line, 1, and fully collapse both steering cylinders. NOTE: Since the barrel end hydraulic lines from both cylinders are connected to a common tee, only one line needs to be loose to collapse the cylinders.

41-10

1 10010490

SECTION 41 -- STEERING AXLE -- CHAPTER 1 Steering Cylinders Reference the previously determined Height Position value.

Cylinder Adjustments HDASA - Standard For a value of (1), adjust the collapsed length, A, of both steering cylinders to 728 mm (28-21/32 in). For values of (2), (3), or (4), adjust the collapsed length of both steering cylinders to 722 mm (28-7/16 in). PRA - Standard For a value of (1), adjust the collapsed length, A, of both steering cylinders to 759 mm (29-7/8 in). For positions (2), (3), and (4), the collapsed length must be 753 mm (29-21/32 in).

66070041

Auto Guidance System Equipped NOTE: If the combine is equipped with an autoguidance system, the left-hand steering cylinder contains a sensor, 1. Because of this, the stroke of this cylinder is 10 mm shorter than that of the right-hand cylinder. To compensate for this, the collapsed length of the left-hand cylinder must be adjusted to 10 mm more than that of the right-hand cylinder. HDASA - With Sensor For a value of (1), adjust the collapsed length, A, of the left-hand steering cylinders to 738 mm (29-1/16 in). For values of (2), (3), or (4), adjust the collapsed length of the left-hand steering cylinders to 732 mm (28-13/16 in). PRA - With Sensor For a value of (1), adjust the collapsed length, A, of the left-hand steering cylinders to 769 mm (29-9/32 in). For values of (2), (3), and (4), the collapsed length must be 753 mm (30-1/32 in).

41-11

66070039

SECTION 41 -- STEERING AXLE -- CHAPTER 1 Ball Joint Adjustment While adjusting the overall collapsed length of the steering cylinders, the following criteria must also be met:

HDASA Dimension “A” must be 50 -- 80 mm (2 -- 3-5/32 in). Dimension “B” must be 120 mm (4-23/32 in) maximum, no minimum value is specified.

PRA Dimension “A” must be between 70 -- 80 mm (2.75 -- 3.15 in). The length of dimension “B” must be no longer than 120 mm (4.72 in). When the adjustments are complete, expand or collapse the cylinders without changing the adjustments made. Set the cylinders into place in the hub castings with the threaded ends pointing down. Install the slotted nuts, check to confirm the maximum steering angle can be achieved. Steering stop bolts must contact the HDASA arm or PRA motor frame, as equipped, during maximum LH and RH turns. If the steering cylinders limit turning, the cylinder ball joints must be adjusted until the steering stop bolts limit turning. Reference Operator’s Manual -- Section 4 -Lubrication and Maintenance -- Steering Axle -Setting Steering Stops; for additional information. Torque to 250 -- 280 N⋅m (184 -- 206 ft-lb) ensuring alignment of the cotter pin hole and nuts slot within the torque range. Install cotter pins to secure the slotted nuts in place. Tighten all hydraulic lines that have been loosened. NOTE: Install steering cylinder with ports, 1, facing forward and rotated to 15° -- 35° above the horizontal plane. Install the tires onto the combine noting the direction of travel as marked on the tire. For HDASA units, install lug nuts and torque to 410 -- 492 N⋅m (302 -- 363 ft-lb). For PRA units, install spacers and bolts, then torque to 550 -- 610 N⋅m (406 -- 450 ft-lb). Reference the Operator’s Manual -- Section 4 -Lubrication and Maintenance -- Steering Axle for additional torque procedure guidance. Remove the jack stands from under the combine and lower it to the ground.

41-12

66070040

SECTION 41 -- STEERING AXLE -- CHAPTER 2

SECTION 41 -- STEERING AXLE Chapter 2 -- Wheel Bearings (HDASA) CONTENTS Section

Description

Page

41-1

SECTION 41 -- STEERING AXLE -- CHAPTER 2 INTRODUCTION AND GENERAL INFORMATION As determined based on conditions and environment, the rear wheel bearings should be cleaned and repacked with New Holland Ambra GR9 multi-purpose grease every 500 hours of operation, or once each season. NOTE: Prior to raising the combine, it is advisable to pivot the wheels at least half way to the steering stop. If raising the right wheel, turn to the right. If raising the left wheel, turn to the left. This ensures ample working area during assembly of the wheel bearing. NOTE: A new outer bearing must be available when replacing the grease seal. The bearing is pressed onto the spindle and must be destroyed to be removed.

41-2

SECTION 41 -- STEERING AXLE -- CHAPTER 2 OVERHAUL WHEEL BEARING Disassembly Raise the combine with the proper sized jack. Support the weight of the combine with a jack stand positioned under the axle. Remove the tire from the combine wheel hub, 1.

10010518

1 Pry off the dust cover, 1.

Remove the cotter pin, 2, and turn off the slotted nut, 3.

3 66070026

2 Slide the washer, 1, and inner bearing cone, 2, from the spindle, 3.

NOTE: The clearance between the spindle and inner bearing race is very close.

66070021

3 3

41-3

SECTION 41 -- STEERING AXLE -- CHAPTER 2 Separate the hub casting, 1, from the spindle assembly (spindle, bearing and seal), 2, by striking around the spindle bolt flange, 3, with a mallet.

Inspect the residual grease for contamination and the condition of bearing and seal. Grease contamination may indicate a failed seal and need to replace the bearing and seal as described in the following steps.

If the bearing and seal are in good condition proceed to the Repacking and Assembly procedures in this chapter.

66070022

4 Remove the outer bearing, 1, from the spindle, 3.

NOTE: The outer bearing has been press fit onto the spindle. To remove the bearing from the spindle it will have to be cut off. Slide the grease seal, 2, from the spindle.

66070023

2 5

Use a punch to remove the bearing cups, 1 and 3, from the hub casting, 2. Only if the inner bearing is being replaced, punch out the inner bearing cup, 1.

Punch out and discard the outer bearing cup, 3, as the outer bearing cannot be reused.

66070024

41-4

SECTION 41 -- STEERING AXLE -- CHAPTER 2 Repacking Clean all old grease out of the bearing cups and cones. Clean all old grease out of the hub casting. Completely dry the bearing and casting. NOTE: Applying grease to a bearing that is still wet with solvent will reduce the lubricating properties of the grease. Pack the inner and outer wheel bearings with New Holland Ambra GR9 multi-purpose grease. Apply a generous layer of grease to the outside of the bearings. Assembly Install the inner and outer bearing cup, 1 and 3, into the hub casting, 2, with the cupped side facing away from the casting as shown. Lubricate the outer diameter of the cups before installing.

NOTE: To make installation easier, set the cups in a freezer for approximately thirty minutes to reduce the outer diameter. Remove the races from the freezer and install immediately, minimizing the time they are allowed to warm up. Apply a generous layer of grease to the inside diameter of the installed cups.

66070024

7 Slide the grease seal, 2, onto the spindle, 4, with the cupped side, 3, facing up.

Press the outer bearing cone, 3, onto the spindle with the tapered side of the bearing facing up.

NOTE: When setting the spindle assembly into the hub casting, the grease seal must line up properly with the seal seating area in the hub.

66070023

41-5

SECTION 41 -- STEERING AXLE -- CHAPTER 2 Insert the spindle assembly, 2, into the hub casting, 1.

66070022

9 While holding the assembly in position, set the inner bearing cone, 2, onto the spindle, 3, with the tapered side in.

Slide the washer, 1, on behind the bearing.

66070021

4 10

Install the slotted nut, 1. Tighten the nut to draw the seal into place, do not exceed 60 N⋅m (44 ft-lb). Remove the nut and washer, 1 and 3. Give the spindle assembly a slight tug to ensure that the seal is properly seated in the hub. If the seal comes out of the hub easily, repeat this step until the assembly will remain in place.

1 2

Remove the inner bearing cone, 2, Figure 10, from the spindle. Fill the bearing cavity, 4, Figure 10, with New Holland Ambra GR9 multi-purpose grease.

Set the inner bearing cone, 2, Figure 10, onto the spindle with the tapered side in. Slide the washer, 3, Figure 11, on behind the bearing.

66070025

Degrease the spindle threads, 2, and the internal threads of the slotted nut, 1. Apply Loctite 262 (high strength -- red) thread locker to the nut threads and install immediately. Tighten the nut to 60 N⋅m (44 ft-lb).

41-6

SECTION 41 -- STEERING AXLE -- CHAPTER 2 Install the cotter pin, 3. If cotter pin cannot be installed, loosen nut, 4, to align with closest slot and hole.

Bend the cotter pin legs, 5, around the nut to prevent interference with the cover, 1. Clean the mating surfaces, 2, of the dust cap and spindle housing, and then apply Loctite 638 retaining compound to the cap. Tap the dust cap on, 1.

Install the tires onto the combine noting the direction of travel as marked on the tire. Torque the lug nuts to 410 -- 492 N⋅m (302 -- 363 ft-lb). Remove the jack stands from under the combine and lower it to the ground.

4 66070026

NOTE: Check wheel hardware torque after one hour of operation, then after ten hours of operation for one week and thereafter on a weekly basis. Reference: Operator’s Manual -- Section 4 -- Lubrication and Maintenance -- Steering Axle.

41-7

SECTION 41 -- STEERING AXLE -- CHAPTER 2

41-8

SECTION 41 -- STEERING AXLE -- CHAPTER 3

SECTION 41 -- STEERING AXLE Chapter 3 -- Steering Pivot (HDASA) CONTENTS Section

Description

Page

41-1

SECTION 41 -- STEERING AXLE -- CHAPTER 3 OVERHAUL HUB AND KINGPIN CASTING Hub and Kingpin -- Exploded View

1 2 3

4 9 5

10 7 6 5 8 2 66070027

1. 2. 3. 4. 5.

M6 x 10 cap screw Seal ring Upper kingpin bushing Disc bushing Bore bushing

6. 7. 8. 9. 10.

41-2

Grease seal Hub and kingpin casting Lower kingpin bushing M24 x 50 hex socket head cap screws M24 x 70 hex socket head cap screws

SECTION 41 -- STEERING AXLE -- CHAPTER 3 Disassembly Raise the combine with the proper sized jack. Support the weight of the combine with jack stands positioned under the axle. Remove the tire from the combine. Disconnect the tie rod, 1, and steering cylinder, 2, from the hub casting.

1 10010489

2 Attach lifting gear to support the hub casting.

Remove four M24 x 60 cap screws and washers, 1. NOTE: The cap screws are torqued to 780 -- 860 N⋅m (575-- 684 ft-lb). Rotate the hub casting so that it is upside down.

1 10010485

3 Install the hub casting upside down to the axle extension with two M24 x 60 cap screws and washers, 1, as shown.

Remove four hex socket head screws, 2 and 5.

NOTE: Position of two different length HSH screws; there are two M24 x 50 screws, 2, and two M24 x 70 screws, 5.

NOTE: The HSH screws have locking compound applied and are torqued to 590 -- 650 N⋅m (435-- 480 ft-lb).

2 10010499

Remove the two M6 x 10 cap screws and seals, 3, at the top and bottom bushing castings.

1 4

Pull the lower bushing casting, 4, from the hub and kingpin casting.

41-3

SECTION 41 -- STEERING AXLE -- CHAPTER 3 Lift the hub, 1, from the upper casting, 2.

2 10010500

5 Inspection

NOTE: It is recommended that the grease seals, bore bushings, and disc bushings be replaced when the hub and kingpin assembly is disassembled. Inspect the machined ends, 1, of the steering hub and kingpin for roundness wear, scratches and gouges. If the assembly exhibits excessive play when assembled, disassemble the wheel spindle from the assembly, as described in Section 41 -Steering Axle -- Chapter 2 -- Wheel Bearings, and then replace the hub and kingpin.

10010503

BUSHING REPLACEMENT

Removal Pry the seal, 1, and bushing, 2, from the lower casting.

Clean all residual grease, dirt or contaminant from the lower bushing.

10010501

41-4

SECTION 41 -- STEERING AXLE -- CHAPTER 3 From the upper bushing, pry the seal, 1, bushing, 2. Clean all residual grease, dirt or contaminant from the upper bushing.

1 2

3 10010502

8 Installation Acquire or fabricate a bushing driver tool to assist in installing the new bushing. The inner diameter of the upper and lower castings is 90.0 -- 90.035 mm (3.543 -- 3.544 in). The inner diameter of the installed bushing is 80.40 -- 80.45 mm (3.165 -- 3.167 in).

2 1

Install the disc bushing, 3, bottom of the upper bushing, 4. Using the bushing driver tool, insert the bushing, 1, and press it against the disc bushing, 3, at the bottom of the bore. To apply a generous coating of New Holland Ambra GR9 multi-purpose grease to the bottom disc bushing and the inner diameter of the ring bushing.

10010502

Install the seal, 2, with the lip outward. Using the locally fabricated tool, insert the bushing, 1, and press bushing at the bottom of the bore.

2 1

10010501

41-5

SECTION 41 -- STEERING AXLE -- CHAPTER 3 Apply a generous coating of New Holland Ambra GR9 multi-purpose grease to the inside diameter of the ring bushing and fill the cavity, 2, between the bottom of the installed bushing and inside bottom of the kingpin bushing with the same grease. Install the seal, 1, with the cupped side up.

66070028

11 Assembly Apply a generous layer of New Holland Ambra GR9 multi-purpose grease to the machined ends of the kingpin. Set the steering kingpin, 1, into place on the upper bushing.

NOTE: The assembly is upside down. Insert the kingpin into the upper bushing with the tie rod and steering cylinder connections toward the rear of the combine.

10010500

12 Install the lower bushing, 4, onto the kingpin. Apply Loctite 242/243 to the four HSH cap screws, and then secure the bushing with two M24 x 50 HSH cap screws at, 2, and two M24 70 HSH cap screws at, 5.

Torque the four HSH cap screws to 590 -- 650 N⋅m (435 -- 480 ft-lb).

4 3

Install the two M6 x 10 cap screws with new seal rings, 3, into the top and bottom of the upper and lower bushings.

Support the assembled hub casting with lifting equipment. Remove the two cap screws and washers, 1.

10010499

1 13

41-6

SECTION 41 -- STEERING AXLE -- CHAPTER 3 Rotate the hub casting so that it is right-side up. Verify the axle height position for the tire in use, and then install the four M24 x 60 cap screws and washers, 1. Torque the four cap screws to 780 -- 860 N⋅m (575 -634 ft-lb).

1 10010485

14 Connect the steering cylinder, 1, and tie rod, 2. Install the steering cylinder with the hydraulic ports forward and rotated to 15--35° above the horizontal plane.

Install the slotted nuts, 3, and tighten the nut and align the cotter pin hole and slot within the torque range of 250 -- 280 N⋅m (184 -- 492 ft-lb). Install cotter pins, 4, to secure the castellated nuts in place.

Install the wheel onto the combine and torque the lugs nuts to 410 -- 492 N⋅m (302 -- 363 ft-lb).

10010504

Remove the jack stand from the combine.

IMPORTANT: Check wheel hardware torque after one hour of operation, then after ten hours of operation for one week and thereafter on a weekly basis. Reference: Operator’s Manual -- Section 4 -Lubrication and Maintenance -- Steering Axle.

41-7

SECTION 41 -- STEERING AXLE -- CHAPTER 3

41-8

SECTION 41 -- STEERING AXLE -- CHAPTER 4

SECTION 41 - STEERING AXLE Chapter 4 - Hydrostatic Motor CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Valve Retainer Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Split Ring Assembly Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bushing Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Bushing Driver Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assembly, Shaft Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Wheel Motor Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Parts Specifications - Shaft Removal Tool and Rotational Torque Tool . . . . . . . . . . . 9 Rotational Torque Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Bar, Rotational Torque Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Radial Clip Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Setting Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Tool Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Hydrostatic Motor - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Bleeding the Rear Axle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Hydrostatic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

41-1

SECTION 41 -- STEERING AXLE -- CHAPTER 4 SPECIFICATIONS Displacement

2100 cc

Number of Pistons

Type of piston (Standard or Stepped)

Standard

Rated Speed (rpm)

60 rpm

Maximum Operating Pressure

6500 psi (450 bar)

Maximum Disengaged Speed (rpm) [Dependent on drain pressure in motor]

195 rpm

TIGHTENING TORQUES Item

Specification

Torque

Top and Bottom Pins to C-frame

M10 x 25

68 - 75 N⋅m (50 - 55 ft-lb)

Top and Bottom Seal Cover to C-frame

M6 x 35

16 - 19 N⋅m (12 - 14 ft-lb)

Valve (Single/Two Speed) Block Fasten Bolts

M6 x 40

12.5 - 15.5 N⋅m (9.3 - 11.3 ft-lb)

22.5 - 27.5 N⋅m (16 - 19 ft-lb)

Cartridge Valve lube with hydraulic oil.

24 - 30 N⋅m (18 - 22.2 ft-lb)

Magnetic Winding Hex Nut

Nut

2.7 - 3.3 N⋅m (24 - 29 in-lb)

Spool Valve Plug

Plug

285 - 380 N⋅m (210 - 280 ft-lb)

M16 x 100

320 - 390 N⋅m (236 - 288 ft-lb)

Use Special Tool

49 - 91 N⋅m (37 - 67 ft-lb)

M8 x 10

18 - 25 N⋅m (13 - 18 ft-lb)

Valve Cover cap screws Solenoid Valve Cartridge Valve

Motor Bolts Rotational Rolling Torque of the Bearing Support Assembly Valve Retainer Tool Plug

41-2

SECTION 41 -- STEERING AXLE -- CHAPTER 4 SPECIAL TOOLS Valve Retainer Tool

56070046

1 A. Hex Head Bolt, Zinc B. Drill Diameter for Press Fit Depth

Shaft and handle material: Shaft: 1/8″ Drill Rod Handle: 1/4″ Round Bar Hot Rolled

41-3

SECTION 41 -- STEERING AXLE -- CHAPTER 4 Split Ring Assembly Hood

56070047

2 A. Chamfer

Material: Round Bar Cold Finished 4140 ASTM A331

41-4

SECTION 41 -- STEERING AXLE -- CHAPTER 4 Bushing Driver

56070048

3 A. Chamfer @ Four Places

Material: Round Bar Cold Finished 1018 ASTM A 108

41-5

SECTION 41 -- STEERING AXLE -- CHAPTER 4 Bushing Driver Ring

A 56070049

4 A. Chamfer

Material: Round Bar Cold Finished 1018 ASTM A 108

41-6

SECTION 41 -- STEERING AXLE -- CHAPTER 4 Assembly, Shaft Removal Tool

A B C

F 56070050

5 A. B. C. D. E. F.

Hex Nut 3/4-10 Rod, All Thread 3/4-10 Wheel Motor Bar Spacer (Qty. 2) Rod, All Thread 5/8-11 (Qty. 2) Hex Nut 5/8-11 (Qty. 8)

NOTE: Specifications for Wheel Motor Bar, All Thread Rod, and Spacer, are detailed on the following pages.

41-7

SECTION 41 -- STEERING AXLE -- CHAPTER 4 Wheel Motor Bar

B 56070051

6 A. Drill Through & Tap B. Drill Through - 2 Places

Material: Flat Bar Hot Rolled A36

41-8

SECTION 41 -- STEERING AXLE -- CHAPTER 4 Parts Specifications - Shaft Removal Tool and Rotational Torque Tool

56070052

7 A. Rod, All Thread 3/4-10 B. Rod, All Thread 5/8-11 C. Spacer

Spacer Material: Round Mechanical Tube ∅ 1.00 x 0.188 Wall

41-9

SECTION 41 -- STEERING AXLE -- CHAPTER 4 Rotational Torque Tool

D 56070053

8 A. B. C. D.

Bar, Rotational Torque Tool Spacer (Qty. 2) Rod, All Thread 5/8-11 (Qty. 2) Hex Nut 5/8-11 (Qty. 7)

NOTE: Specifications for Rotational Torque Tool Bar are on the following page; specifications for the All Thread Rod and Spacer are on the previous page.

41-10

SECTION 41 -- STEERING AXLE -- CHAPTER 4 Bar, Rotational Torque Tool

56070054

9 A. Drill through - 2 places

Material: Flat Bar Hot Rolled A36

41-11

SECTION 41 -- STEERING AXLE -- CHAPTER 4 Radial Clip Installation Tool

B D

C 56070055

10 A. B. C. D. E.

Setting Tool Tool Holder Socket Head Set Screw Set Depth For Clip Installation This Surface Against Piston Block

NOTE: Specifications for Setting Tool and Tool Holder on the following pages.

41-12

SECTION 41 -- STEERING AXLE -- CHAPTER 4 Setting Tool

56070057

11 A. Radius Range B. Radius Minimum

Material: Round Bar Cold Formed

41-13

SECTION 41 -- STEERING AXLE -- CHAPTER 4 Tool Holder

56070056

12 A. Drill and Tap B. Radius Minimum

Material: Round Bar Cold Formed

41-14

SECTION 41 -- STEERING AXLE -- CHAPTER 4

REAR AXLE

DESCRIPTION AND OPERATION

The powered rear axle is available as a factory installed or field installed option. This system will provide additional traction when the machine is operated in tough field conditions. The system can be engaged or disengaged electronically by a switch in the operators cab. Both rear wheels are driven by hydraulic motors and the system receives its oil supply directly from the hydrostatic pump. The high pressure lines from the hydrostatic pump (brake manifold) supply the wheel motors through a control valve mounted near the rear axle. The powered rear axle system operates as a function of the main hydrostatic drive system. A standard hydrostatic system utilizes one pump and one drive motor (transmission mounted), whereas the powered rear axle system utilizes one pump and three motors (one transmission mounted and two wheel mounted).The wheel motors are cam lobe type units with a fixed displacement. The amount of wheel torque obtained from the wheel motors is directly related to the

41-15

hydrostatic system pressure. The higher the system pressure the greater the wheel torque will be. NOTE: It is not necessary to synchronize the front wheels (transmission mounted pump driven) with the rear wheels (wheel motor driven) as the system pressure and hydraulic fluid flow hydraulic will do this automatically. It is very important to maintain traction to the front wheels. If a front wheel loses traction and begins to slip, the system pressure will lower. The spinning wheel requires less pressure to rotate. The oil in the pressure lines will take the least path of resistance, therefore the amount of power assistance from the rear wheels will be reduced because of the lower pressure. Shifting to a higher gear (if possible) will reduce the amount of torque at the front wheels to stop the wheel slippage. Also, lightly touching the brakes will help.

SECTION 41 -- STEERING AXLE -- CHAPTER 4 Hydrostatic Motor - Exploded View

41-16

SECTION 41 -- STEERING AXLE -- CHAPTER 4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Cylinder Block Assembly Piston Kit (8) Piston Retainer Kit Cam Ring Plus O-Rings O-Ring - Cam Ring (2) Valve Housing Cover (2) Socket Head Cap Screw, M16 x 100 (16) Distributor Valve Distributor Seal Kit Plug Spring (12) Spool, 2 Speed Washer Snap Ring Spring Grease Zerk, 90 (2) Seal Washer (3) Socket Head Cap Screw, M8 x 10 (3) Bearing Support Assembly Bearing Support Shaft Seal (inner) Bearing (outer)

23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.

41-17

Bearing (inner) Shaft Seal Kit Retainer Ring Split Ring Outer Shaft Seal Deflector Shaft Pin (top) Pin (bottom) Socket Head Cap Screw, M10 x 25 Outer Pipe (with seals) Inner Pipe (with seals) Bushing Thrust Washer Seal Cover, Protector Socket Head Cap Screw, M6 x 35 Seal (Top Pin) Environmental Seal Valve Block Single Speed or Two Speed Socket Head Cap Screw, M6 x 40 O-Ring

SECTION 41 -- STEERING AXLE -- CHAPTER 4 OVERHAUL

WARNING

BLEEDING THE REAR AXLE SYSTEM A specific start up procedure must be performed after servicing the powered rear axle system. This ensures adequate flushing or bleeding after a component of the powered rear axle system has been serviced or replaced. The following procedure serves to bleed air out of the powered rear axle system and flush any contamination of the system out. Air in the powered rear axle system is pushed out of the hydrostatic system through the hydrostatic fluid reservoir. It is imperative to follow the exact procedure described; otherwise, the purpose of the procedure will be defeated. Steps 1 through 7 of the procedure are to be performed with the rear wheels off the ground and the front wheels of the machine securely blocked. IMPORTANT: If air is introduced into the powered rear axle system at any time during the following procedure, restart the procedure at step one.

Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Tighten all of the connections before starting the engine. If hydraulic fluid has penetrated the skin, seek medical assistance immediately.

WARNING Use care not to exceed the 13 mm (0.5 inch) movement of the hydrostatic control lever in order to avoid excessive oil flow from the Powered Rear Axle system.

WARNING Make sure the hydraulic fluid in the reservoir is at the proper level at all times. Failure to maintain the proper fluid level may cause damage to the machine hydrostatic components. IMPORTANT: If air is introduced into the system at any time during the following procedure, restart the procedure at step 1.

41-18

SECTION 41 -- STEERING AXLE -- CHAPTER 4 1. Raise the rear wheels from the ground and support with jack stands. 2. Bleed air from entire system - Run the engine at half throttle. Select neutral on the gear selector. Activate the powered rear axle. Move the hydro control lever to neutral. run the combine for a duration of 3 minutes. 3. Flush forward main system - Run the engine at HIGH idle. Select neutral on the gear selector. Deactivate the powered rear axle. Move the Hydro control lever 13 mm (0.5 inch) forward. Run the combine for a duration of 2 minutes. 4. Flush reverse main system - Run the engine at high idle. Select neutral on the gear selector. Deactivate the powered rear axle. Move the Hydro control lever 13 mm (0.5 inch) reverse. Run the combine for a duration of 2 minutes. 5. Check correct rotation of powered rear axle wheels (See Note).

NOTE: If wrong rotation - correct forward/reverse circuit - go to Step 1. B. Run the engine at low idle. Select high gear and hold brakes. Activate the powered rear axle. Move the Hydro control lever 13 mm (0.5 inch) reverse maximum. Run the combine for a maximum of 15 seconds. 6. Flush forward powered rear axle system - Run the engine at high idle. Select high gear and hold brakes. Activate the powered rear axle. Move the Hydro control lever 13 mm (0.5 inch) forward. Run the combine for 4 minutes. 7. Flush reverse powered rear axle system - Run the engine at high idle. Select high gear and hold brakes. Activate the powered rear axle. Move the Hydro control lever 13 mm (0.5 inch) reverse. Run the combine for 4 minutes. 8. Lower the rear wheels onto the ground.

A. Run the engine at high idle. Select neutral on the gear selector. Activate the powered rear axle. Move the Hydro control lever 13 mm (0.5 inch) reverse. Run the combine for a maximum of 30 seconds.

9. Forward pressure check for leaks - Run the engine at 1/2 throttle. Select high gear and hold brakes. Activate the powered rear axle. Move the Hydro control lever 6 mm (0.25 inch) forward. Run the combine for a maximum of 15 seconds.

NOTE: If wheel(s) rotate in reverse - go to Step 5.B.

10. Reverse pressure check for leaks - Run the engine at 1/2 throttle. Select high gear and hold brakes. Activate the powered rear axle. Move the Hydro control lever 6 mm (0.25 inch) reverse. Run the combine for a maximum of 15 seconds.

NOTE: If no rotation - check proper operation of selector valve (refer to Section 29, Chapter 3, Testing Selector Valve). Restart bleed procedure at Step 1.

41-19

SECTION 41 -- STEERING AXLE -- CHAPTER 4 HYDROSTATIC MOTOR

NOTE: Procedures for service of the Hydrostatic Single and Two-speed Valve Block are located in Section 29 - Hydrostatic System.

4 2

Removal

WARNING The motor and components are heavy. Use proper lifting equipment to prevent injury. Failure to comply could result in serious injury or death.

3 4 66070044

NOTE: The motor can be removed from the axle with or without the C-frame attached. It is recommended that the C-frame be removed from the axle with the motor for easier disassemble on a bench. The motor can also be removed with or without the steering bracket.

1. To remove the motor and steering bracket, disconnect and cap the hydraulic lines, 1, leading to the motor. NOTE: Do not remove the ORFS connectors from the ring pin. NOTE: Use a marker or paint pen to label to hoses and ports. Remove the steering cylinder, 2, and the steering cross tube, 3, from the steering bracket on the motor. Remove the steering bracket from the wheel motor by removing the four M20 x 70 bolts, 4. 2. Use a hoist and a chain, 1, to support the motor from the C-frame, 2, when removing it. To remove the motor from the axle remove the four M24 x 60 bolts, 3, attaching it.

20015305

41-20

SECTION 41 -- STEERING AXLE -- CHAPTER 4 3. With the motor on a solid work surface, support the C-frame with a chain hoist so that it cannot drop or rollover when pins are removed. Remove the nine M10 x 25 HSH cap screws, 1, and grease zerks, 2. 4. Use M10 bolts in threaded hole to separate or back away the pins from the C-frame. 5. Remove top pin and bottom pin from inner cover. Support C-frame during removal to prevent damage. 20041977

16 6. Inspect the top pin seal, 1, replace as necessary.

20041979

17 7. Remove the inner, 1, and outer pipes, 2, with seals. NOTE: Inner rings and seals on the inner, 1, and outer pipe, 2, are not serviceable. If seals are damaged, pipe and seal assemblies must be replaced.

20041980

41-21

SECTION 41 -- STEERING AXLE -- CHAPTER 4 Remove four M6 x 35 HSH cap screws, 1, from top and bottom of C-frame, 2. Remove C-frame, 2, seal cover, 3, environmental seal, 4, thrust washer, 5, and bushing, 6. IMPORTANT: Do not damage the bushing bores in the housing. IMPORTANT: Do not damage the thrust washer contact surface.

20041978

19 8. Inspect the bushings for wear and replace as necessary. Remove the bushing, 1, from bore by peeling the bushing at seam with chisel.

20041983

41-22

SECTION 41 -- STEERING AXLE -- CHAPTER 4 Disassembly

WARNING The motor and components are heavy. Use proper lifting equipment to prevent injury. Failure to comply could result in serious injury or death. IMPORTANT: Cleanliness is most important when servicing cam lobe motors. Always use clean tools and work in a clean environment. Wash all internal parts in clean solvent and dry thoroughly with compressed air. Do not use rags or paper towels. Wrap parts in clean paper and keep them in a clean area prior to assembly. If more than one motor is being serviced, work on each one separately. Do not mix parts. 1. Place motor on a stable repair stand or work bench. Drain and properly dispose of the hydraulic oil from the motor before beginning disassembly. Loosen the sixteen M16 x 100 motor bolts, 1.

20042859

21 2. Position the motor on the bearing support as shown for disassembly. Before separating the motor components mark the outside of the components with an alignment mark, 3, for re-assembly. Remove the M8 x 10 cap screw and washer, 1, and install the Valve Retainer Tool, 2. Remove the sixteen M16 x 100 mm HSH cap screws, 4, from the motor.

20042860

41-23

SECTION 41 -- STEERING AXLE -- CHAPTER 4 3. Remove the valve cover, 1, and discard O-ring, 2. Remove the cam ring, 3. Lift the cylinder block, 5, from the bearing support shaft, 6, and then remove and discard the O-ring, 4.

20042861

23 4. To disassemble the cylinder block piston assemblies; first, inspect the splines, 1, in the cylinder block for excessive wear or damage. Inspect lapped surface, 2, of block for damage. Remove retaining clip, 5, piston retainers, 3, and piston assembly, 4. In the event that a retainer clip breaks while removing it from the cylinder block use a 10-32 tap, small ball peen hammer and adjustable wrench to remove it. IMPORTANT: Do not reuse piston retaining clip, 5. Inspect pistons for excessive wear pattern.

20042865

41-24

SECTION 41 -- STEERING AXLE -- CHAPTER 4 5. To disassemble the distributor valve first remove the special tool, 2, (Valve Retainer Tool) and note the position of the distributor valve in relation to the valve cover. NOTE: Ensure the reference marks, 3, correspond with each other for both Left and Right wheel motors.

20042860

25 6. Remove the distributor valve by carefully prying at the locating tabs, 1. IMPORTANT: DO NOT damage mating surfaces of the distributor valve block or O-ring grooves of the valve cover.

20042862

26 7. Remove the distributor valve, 1, and twelve springs, 2, from the valve cover. Remove and discard backup rings, 3, and O-rings, 4, from the valve cover.

20042863

41-25

SECTION 41 -- STEERING AXLE -- CHAPTER 4 8. Disassemble the bearing support, 3. Remove the thrust washer, 1, by prying it up off the split rings, 2.

20042868

3 28

9. Use the special tool (Split Ring Assembly Hood), 1, to press down on the inner bearing and remove the split rings, 2.

20042869

29 10. Use the special tool (Shaft Removal Tool), 1, to press the shaft and outer bearing out of the bearing support.

20042870

41-26

SECTION 41 -- STEERING AXLE -- CHAPTER 4 11. After pressing out the shaft, 4, remove the bearing cone, 1, and bearing cup, 2, from the bearing support, 3.

20042871

31 12. Press out the seal support, 1, and lip seal, 2, from the bearing support, 3. Discard the lip seal, 2. Remove outer bearing cup, 4.

20042872

41-27

SECTION 41 -- STEERING AXLE -- CHAPTER 4 13. Cut bearing cage, 1, and, 2, separate and remove from shaft. Do not cut into shaft or flange.

20042873

33 14. Pull the inner race, 1, off the shaft. Pull the seal, 2, and remove the deflector, 3. Check the contact surface of the inner seal on the shaft, 5, and the condition of the splines, 4.

20042874

34 Assembly NOTE: Ensure all parts are clean before assembly. 1. Start with the pre-assemble of the bearing support. Install the deflector, 1, onto the shaft.

20042875

41-28

SECTION 41 -- STEERING AXLE -- CHAPTER 4 2. Install seal, 1, into bearing support, 2.

20042876

36 3. Remove old backup ring and O-ring from seal support, 3. Install new O-ring, 2, and backup ring, 1, into seal support, 3. Apply Loctite 454 to the outside diameter surface only, indicated on seal support, 4.

20042877

37 4. Press seal support, 1, and inner bearing cup, 2, into bearing support.

20042878

41-29

SECTION 41 -- STEERING AXLE -- CHAPTER 4 5. Press outer bearing cup, 3, of outer bearing into bearing support, 4.

Coat the bearing cup surface with grease. Pack the outer bearing cone with grease and install in the outer cup. Coat the outer surface of the seal, 1, with grease and press into the bearing support, 4. Coat the lips of the seal, 1, with grease.

20042879

39 6. Install bearing support, 2, onto shaft, 4. Be careful not to damage shaft seals. Install the inner bearing cone, 1, into the inner bearing cup, 3.

3 4

20042879

41-30

SECTION 41 -- STEERING AXLE -- CHAPTER 4 7. Use the special tool (Split Ring Assembly Hood), 1, and a press. Pre-load inner bearing to 170,000 N (38,220 lb) of force. Reduce force to 20,000 N (4,500 lb) of force. Check bearing position by rotating bearing housing a minimum of five revolutions clockwise and five revolutions counter-clockwise. While maintaining 20,000 N (4,500 lb) of force, install the split rings, 2.

20042881

41 8. Increase force on bearing to 170,000 N (38,220 lb). Use a feeler gauge to measure the distance between top of the split ring and the shaft spline. Reduce force to 20,000 N (4,500 lb) and remove split rings. Increase force to 170,000 N (38,220 lb). Install new split rings that are closest to the measured distance. Release the force and remove the Split Ring Assembly Hood Tool, 1. Ensure the gaps between the split rings are the same on each side of the shaft. 20042882

42 9. Install thrust washer, 1, over split rings, make sure the thrust washer is pressed securely against the bearing.

20042883

41-31

SECTION 41 -- STEERING AXLE -- CHAPTER 4 10. Use a torque wrench on nut, 2, of special tool (Rotational Torque Tool), 1, to check the final rotational torque of the bearing support assembly. The torque should be within 49 - 91 N⋅m (37 - 67 ft-lb). If the torque is correct then continue assembly. If it is not correct then readjust the bearing support to obtain correct torque.

20042884

44 11. Ensure that all parts and seal grooves are clean before assembly. Assemble the distributor valve, 1, and springs, 2, by lubricating the grooves in the valve cover. Install the O-rings, 4, in the valve cover. Install the backup rings, 3, in the valve cover.

20042863

45 12. Fill the spring cavities in the distributor valve cover with NH Ambra GR9 Multi-purpose grease, 1, and install the springs.

20042864

41-32

SECTION 41 -- STEERING AXLE -- CHAPTER 4 13. Lubricate the distributor valve backup ring contact surface. 14. Align locating tabs, 1, with slots in valve cover and press distributor into valve cover.

20042862

47 15. Install special tool, 1, (Valve Retainer Tool) into valve cover as previously shown.

20041987

48 16. To install a piston, 1, back into the cylinder block, coat the piston with clean NH Ambra Multi G 134 hydraulic oil before installing into the bore. Compress wiper ring to be able to insert piston assembly into cylinder bore.

20042866

41-33

SECTION 41 -- STEERING AXLE -- CHAPTER 4 17. Once piston is in the cylinder block with the retaining assembly use special tool, 2, (Retaining Clip Installation Tool) to install the new retaining clip, 1.

20042867

50 18. Install new O-ring, 2, coated with NH Ambra GR9 Multi-purpose grease in groove of valve cover, 1. Install the cylinder block, 5, onto bearing support, 6. Install new O-ring, 4, coated with NH Ambra GR9 Multi-purpose grease into groove of bearing support, 6. Install the cam ring, 3, onto the bearing support, 6, and align the alignment marks, as shown in Figure 52. Set the valve cover, 1, onto the assembled bearing support, valve block, and cam ring.

20042861

51 19. Align marks, 3, made prior to disassembly and install cam ring and valve cover onto the bearing support. Install sixteen M16 x 100 HSH cap screws, 4. Tighten, but do not torque. Remove Valve Retainer Tool, 2. Replace and torque M8 x 10 HSH cap screw and washer, 1. Torque the M8 x 10 HSH cap screw, 1, to 18 - 25 N⋅m (13 - 18 ft-lb). Torque the M16 x 100 socket head cap screws, 4, to 320 - 390 N⋅m (236 - 288 ft-lb). 20042860

41-34

SECTION 41 -- STEERING AXLE -- CHAPTER 4 20. Install the wheel motor, 1, to the C-frame, 2, as described in “Hydrostatic Motor - Installation.”

2 1

66070037

53 Installation 1. To install new pivot pin bushings, 1, in the motor use special tool (Bushing Installer), 2 and 3, until the bushing is pressed flush into the housing. NOTE: Be sure the holes in the bushing align with the holes in the housing. IMPORTANT: Ensure not to damage the bushing bores or the bushing when installing. 20041984

54 2. Apply Loctite 454 to smooth side of thrust washer, 1, and install on motor. Install environmental seal, 2, on motor housing with seal lips toward motor. Coat the seals with NH Ambra GR9 Multi-purpose grease. Install seal covers, 3, over environmental seals.

3 1

66070037

41-35

SECTION 41 -- STEERING AXLE -- CHAPTER 4 3. Place the C-frame, 2, on a flat surface. Prepare the motor wheel flange, 1, in a sling using a hoist to lift the motor over the C-frame. Apply Loctite 515 around holes and threads to the inside faces, 3, of the top and bottom ears of C-frame. Install C-frame, 2, into motor.

20015310

56 4. Install and torque M6 x 35 HSH cap screws, 1, to 16 - 26 N⋅m (12 - 19 ft-lb) to hold seal covers, 2, to the top and bottom ears of C-frame.

5. Lubricate rings and seals of the outer pipe, 3, and inner pipe, 4, with petroleum jelly. Install the outer pipe. Install the inner pipe.

6. Apply Loctite 515 to top pin mounting surface of C-frame, 5.

5 2

3 66070037

1 57

7. Lubricate the top pin seal, 1, with NH Ambra GR9 Multi-purpose grease. Install the top pin and bottom pin.

20041979

41-36

SECTION 41 -- STEERING AXLE -- CHAPTER 4 8. Apply Loctite 271 to the M10 x 25 HSH cap screws, 1. Install and torque to 68 - 75 N⋅m (50 - 55 ft-lb). With the C-frame mounted to the motor, install grease zerks, 2. Pump NH Ambra GR9 Multi-purpose grease into the top and bottom grease zerks until grease protrudes from the seal area. Clean excess grease from the area and zerks.

20041977

59 9. Use a hoist and a chain, 1, to lift the motor to the axle flange. Mount the motor and C-frame, 2, to the axle with four M24 x 60 bolts, 3, and torque to 780 - 860 N⋅m (575 - 634 ft-lb).

20015305

60 10. Attach the steering bracket, 2, to the wheel motor and torque bolts, 1, to 577 - 678 N⋅m (426 - 500 ft-lb). Install the steering cylinder, 4, and tie rod, 3, if they were removed.

Torque the castellated nuts to align with the cotter pin hole within the torque range of 250 - 280 N⋅m (184 - 206 ft-lb). Install and secure cotter pins at, 2, and, 3.

4 2 1

20070044

41-37

SECTION 41 -- STEERING AXLE -- CHAPTER 4 11. Connect the three hydraulic lines (forward, case drain, and reverse) to the motor and torque each end fitting to its specified torque listed below. If the king pin hydraulic connector fittings were removed, install and torque the straight ORFS connectors first as listed below. NOTE: Figures 62 and 63 show the right and left-hand motor connectors for tread width configurations 5, 6, and 7, as described in the Operator’s Manual - Section 4 - Lubrication and Maintenance Hose Routing. Specified straight ORFS connector to king pin torques: • • •

A = Reverse = (16 mm x ORFS x 27 ORB) = 170 - 187 N⋅m (125 - 138 ft-lb) B = Case drain = (12 mm x ORFS x 18 ORB) = 70 - 77 N⋅m (52 - 57 ft-lb) C = Forward = (20 mm x ORFS x 27 ORB 170 - 187 N⋅m (125 - 138 ft-lb)

50031268

62 Specified hose end fittings to king pin ORFS connector torques: • • •

A = Reverse hose = 60 - 68 N⋅m (44 - 50 ft-lb) B = Case drain hose = 43 - 47 N⋅m (32 - 35 ft-lb) C = Forward hose = 88 - 99 N⋅m (65 - 73 ft-lb)

Mount the steering tires and follow the torque procedure described in the Operator’s Manual Section 4 - Lubrication and Maintenance Steering Axle.

50031267

41-38

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1

SECTION 50 -- CLIMATE CONTROL Chapter 1 - Heating, Ventilation and Air-Conditioning CONTENTS Section

Description Page Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 A/C Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Air Conditioning Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Climate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Automatic Temperature Control (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Problem Solving Pressure Test Results and Temperature/Pressure Chart . . . . . . 10 Air-conditioning Temperature/Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Ventilation System Separator Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Ventilation System Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Electrical Control Temperature Control Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Electrical Control Blower Speed Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electrical Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Electronic HVAC Control -- Display Data Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Electronic HVAC Control -- ATC Control Switch and Mode Control Switch . . . . . . . . . 24 Electronic HVAC Control -- ATC Controller Power Supply . . . . . . . . . . . . . . . . . . . . . . . 25 Sensing System High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Sensing System Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Sensing System Outlet Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Sensing System Cab Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Sensing System Evaporator Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Evacuating the Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

50-1

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 SPECIAL TOOLS Part No.

Description

FNH00855

Refrigerant Gas Leak Detector

OEM1598

R-134 Recovery/Recycle and Recharging Station

OEM1662

Thermometer

OEM1419

Service Gauge Set - 134A

FNH02343B

Sanko/Sanden Compressor Tools

TIGHTENING TORQUES Hose End Tubing O-Ring Connection Torque Metal Tube Outside Diameter

Thread Size

Torque

Condenser large hose, steel to brass

3/4--16

24 -- 30 N⋅m (18 -- 22 ft-lb)

Condenser small hose, steel to brass

5/8--18

18 -- 23 N⋅m (13 -- 17 ft-lb)

Receiver/dryer hoses, steel to steel, inlet and outlet

5/8--18

31 -- 36 N⋅m (23 -- 27 ft-lb)

Cab TXV small hose, steel to aluminum

5/8--18

18 -- 23 N⋅m (13 -- 17 ft-lb)

Cab TXV large hose, steel to aluminum

7/8--18 NS

30 -- 37 N⋅m (22 -- 27 ft-lb)

Compressor hose, steel to aluminum

1--14 UNS

45 -- 52 N⋅m (33 -- 38 ft-lb)

Compressor Tightening Torques Torque Screw securing air-conditioner compressor drive belt automatic tightener to crankcase M8 x 1.25

24 -- 28 N⋅m (212 -- 247 ft-lbs)

Screw securing air-conditioner compressor mount to engine block M8 x 1.25

22 -- 27 N⋅m (194 -- 238 ft-lbs)

Screws (4) securing air-conditioning compressor to mount M8 x 100

50-2

20 -- 26 N⋅m (16 -- 20 ft-lbs)

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 INTRODUCTION Prompted by environmental concerns, New Holland North America is now producing equipment with Non-chlorofluorocarbon (non-cfc) air-condition systems. The refrigerant used is R-134a, a hydrofluorocarbon that has no ozone consuming chlorine molecule. NOTE: Follow all local and governmental regulations regarding the handling of HFC materials before performing any work on systems using HFC compounds.

CAUTION This air-conditioning system uses R-134a refrigerant. Use only R-134a refrigerant and compatible lubricants in this system. Gases and lubricants of R-134a and R-12 are not compatible with each other, they must be handled separately and not mixed. Vehicles with R-134a system components are distinguished from others that use R-12 by an ID tag mounted on or near the compressor mounting location. The function of the climate control system is to provide a comfortable environment for the operator by raising or lowering the air temperature, reducing the humidity level and removing dust and pollen within the cab compartment.

3 1

The Automatic Temperature Control (ATC) system manages the operation of the compressor, blower fan, and heater valve to maintain cab air temperature at the value set by the operator. The components of the climate control system are located at various points on the combine. The control panel is in the headliner of the operators’ cab at 1. Directly behind the cab is the central air handling, 2, unit which houses the blower fan, heater core, evaporator core and water valve. A separator fan, 3, is located behind the shielding outside the left cab door. The compressor, condenser and receiver/drier are mounted in and around the engine compartment at 4.

BSC1361

50-3

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 A/C CYCLE

2 liquid. Then, when it reaches the evaporator coils, it begins to cool, absorbing heat from the air drawn across the coils and fins by the blower. The refrigerant now changes from a cold low-pressure liquid to a cool low-pressure vapor and leaves the evaporator outlet moving to the suction (low-pressure) side of the compressor to repeat the cycle.

Air Conditioning Process Refrigerant is drawn into the compressor as a cool, low-pressure vapor, compressed and then moves out as a hot, high-pressure vapor to the condenser. As the hot, high-pressure vapor passes through the condenser core, it gives off heat to the cooler outside air being drawn past the condenser cooling fins.

As the heat loss is taking place, moisture (humidity) in the air will condense on the outside of the evaporator and drain off as water through the drain hoses attached to the evaporator drain pan, thereby reducing the humidity level of the cab. Also, dust or pollen not removed by the cab filters will collect on the wet evaporator fins and coils and may require periodic cleaning depending on operating conditions.

The vapor is condensed to a liquid by giving off heat to the outside air. This liquid moves to the receiver/dryer under high pressure. Hot, high-pressure liquid is stored in the receiver/ dryer until it is released to the evaporator by the expansion valve. The liquid refrigerant passes through a metered orifice in the expansion valve and into the evaporator coil. As the refrigerant passes through the orifice in the expansion valve, the refrigerant changes from a high-pressure liquid to a low-pressure atomized

In summary, the heat in the cab is removed by the refrigerant in the evaporator and is transferred from the refrigerant to the outside air by the condenser unit.

50-4

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 CLIMATE CONTROL

Automatic Temperature Control (ATC)

Temperature Control, 1 The temperature control gives the operator control over the cab interior temperature. Turning the control clockwise will increase the temperature of the air and turning the control counter-clockwise will lower the temperature of the air. Display Unit, 2 The display provides the operator with information about the systems performance. •

It provides the desired cab temperature reading selected by the operator. The display reading may be in Fahrenheit or Celsius. To make the changed between reading there is a ground wire located under the left rear corner of the cab at the main ground boss. Attaching the wire to the ground provides for Celsius readings.

•

It illuminates an icon “A”, when the system is operating in the automatic climate mode.

•

When the “A” is not illuminated the blower motor speed MUST be manually controlled and “Auto” mode will only control the water valve and compressor, while trying to maintain the set temperature.

•

It illuminates an icon of a windshield the system is in the Defog mode.

•

It illuminates a snowflake when the air conditioning compressor is running.

•

It illuminates an icon of a book when the system is not operating correctly. Along with the book icon a fault code will also be displayed to assist the technician making the correct repairs.

56063539

when

The range for ATC is from a setpoint of 16°C (61°F) to 30°C (89°F). The setpoint of 16°C (60°F) or 32°C (90°F) will be displayed and the “A” icon on the display will be off when the system is in maximum mode.

56063540

50-5

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 Blower Speed Control, 3 The blower speed control gives the operator control over the speed of the blower motor. Turning the blower control clockwise will increase the speed of the blower, producing more airflow out of the cab vents, turning the control counter clockwise will reduce the air flow.

If the ATC control button has been pressed, the blower speed control position will have NO effect over the blower’s speed. The ATC controller will increase or decrease the blower motor speed as needed to maintain the desired cab temperature. If the blower motor control is adjusted, the controller will release the automatic control over the blower motor speed. The blower motor will only operate in the manual mode if the “A” is NOT displayed. The ATC control button must be toggled OFF and back ON to reset the automatic blower motor operating mode. The automatic temperature control will always be operating whether the “A” is displayed or not. The blower control is a potentiometer rated at 10K 10% ohms.

56063539

When operating in the Auto Climate or Defog mode, the blower will make a speed increase for every 2°F difference there is between the temperature set point and the actual cab temperature sensed by the cab temperature sensor. If the evaporator sensor senses that the evaporator temperature is below 80°F (26°C), and system is calling for heat, the blower speed will not be increased until the evaporator temperature has increase. Defog Control, 4 Once the operator has activated the ATC control, the mode button is pressed to toggle the Defog on and off. The digital display window will be illuminated with the symbol displayed when the Defog is on. The system will run the A/C compressor full time and warm the air to defog the windows and the display will be illuminated. ATC Control, 5 The operator selects ATC Control by pressing the left hand button one time, the digital display window will be illuminated. When illuminated, the mode of operation will be displayed along with the desired temperature. The button toggles between two modes: •

•

“O” = OFF, the cab blower motor may be run, but the air will not be conditioned and the display will NOT be illuminated. “A” = Auto, the system will warm or cool the air as needed to maintain the cab temp and the display will be illuminated.

56063539

5 6

50-6

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 TROUBLESHOOTING GENERAL Problem

Possible Cause

Correction

Fault Code indicated in display window.

System problem.

Troubleshooting Fault Codes

No cooling.

A/C Mode switch not on.

Turn A/C Mode switch on.

Loss of refrigerant.

Overhaul -- Pressure Test

Insufficient air flow through evaporator.

Check air filter. Check evaporator core and clean as necessary. Check blower motor operation. Refer to “Blower Motor -- Testing”

Loose or broken compressor drive belt.

Check belt and tension. Adjust or replace as necessary.

Compressor clutch does not engage.

Electrical Control Relay -- Testing

Faulty expansion valve.

Expansion Valve -- Testing

Faulty compressor and/or compressor clutch.

Compressor Magnetic Clutch -- Testing

Defrost on.

Press Mode Control Button to turn defrost off.

Dirty evaporator coil and/or filter.

Visually inspect. Clean as necessary.

Dirty condenser core.

Visually inspect. Clean as necessary.

Compressor drive belt slipping.

Visually inspect. Adjust as necessary.

Faulty cab temperature sensor.

Sensing System Cab Temperature Sensor -- Testing

Faulty expansion valve operation.

Expansion Valve -- Testing

Evaporator icing up.

Overhaul -- Pressure Test

Low refrigerant charge.

Overhaul -- Pressure Test

Heater Valve leak through.

Operate engine at 1500 rpm for 15 minutes to warm engine coolant. Operate the A/C system at maximum cooling. Install stem thermometer in mid-cab louver and record temperature. Close heater core supply valve at engine. Wait a few minutes and check the temperature. If the temperature drops, valve leak through is the problem; replace heater valve. Refer to “Heater Valve -- Removal.”

Insufficient cooling

50-7

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 Problem No heat

Possible Cause

Correction

Heater core supply and return valves located at the engine closed.

Open valves.

Heater Control Valve malfunction.

Heater Valve -- Testing

Heater valve problem.

Heater Valve -- Testing

Mode Control Button faulty.

ATC Control Switch and Mode Control Switch -- Testing

System in automatic temperature control and cab temperature approximately equal to temperature setpoint.

System operating properly.

Cab air filter dirty.

Clean cab air filter.

Blower motor inoperable.

Ventilation System Motor -- Testing

Noisy system.

Faulty compressor clutch.

Compressor Magnetic Clutch -- Testing

Negative pressure in cab (Air is entering cab through doors and other openings; cab air is dirty)

Separator fan not operating.

Ventilation System Separator Fan -Testing

Defrost not working

No air flow/reduced air flow.

50-8

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 FAULT CODES Problem Fault #1 -- High Pressure Switch

Possible Cause

Correction

High Pressure in system.

Overhaul -- Pressure Test

Faulty High Pressure Switch electrical circuit.

Sensing System High Pressure Switch -- Testing

Low Pressure in system.

Overhaul -- Pressure Test

Faulty Low Pressure Switch electrical circuit.

Sensing System Low Pressure Switch -- Testing

Fault #3 -- Blower Speed Select Potentiometer

Faulty Blower Speed Select Pot electrical circuit.

Electrical Control Blower Speed Potentiometer -- Testing

Fault #4 -- Temperature Select Potentiometer

Faulty Temperature Select Pot electrical circuit.

Electrical Control Temperature Control Potentiometer -- Testing

Fault #2 -- Low Pressure Switch

Fault #7 -- Cab Temper- Faulty Cab Temperature Sensor electriature Sensor cal circuit.

Sensing System Cab Temperature Sensor -- Testing

Fault #8 -- Evaporator Temperature Sensor

Faulty Evaporator Temperature Sensor electrical circuit.

Sensing System Evaporator Temperature Sensor -- Testing

Fault #9 -- Outlet Temperature Sensor

Faulty Outlet Temperature Sensor electrical circuit.

Sensing System Outlet Temperature Sensor -- Testing

Fault #19 -- No data from Control Module

Faulty electrical circuit between Control Module and Auto Operation Display unit.

Display Data Line Testing

50-9

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 TESTING Problem Solving Pressure Test Results and Temperature/Pressure Chart Air-Conditioning Temperature/Pressure Chart Ambient Temperature °C (°F)

% Relative Humidity

Louver Temps* °C (°F)

Normal Low Side Pressure kPa (psi)

Normal High Side Pressure kPa (psi)

Low RH

High RH

Low RH

High RH

Low RH

High RH

Low RH

High RH

21(70)

19 to 21

81 to 89

4 (40)

11(51)

62 to 62 (9 to 9)

83 to 97 (12 to 14)

779 to 862 (113 to 125)

807 to 889 (117 to 129)

27(80)

18 to 20

69 to 77

8(46)

14 (57)

69 to 83 (10 to 12)

103 to 117 (15 to 17)

917 to 1014 (133 to 147)

993 to 1103 (144 to 160)

32 (90)

16 to 18

58 to 64

12 (53)

18 (64)

90 to 103 (13 to15)

131 to 145 (19 to 21)

1089 to 1200 (158 to 174)

1207 to 1331 (175 to 193)

38(100)

14 to 16

48 to 53

16(60)

21(70)

117 to 131 (17 to 19)

165 to 179 (24 to 26)

1276 to 1413 (185 to 205)

1427 to 1579 (207 to 229)

43(110)

12 to 14

36 to 40

19(66)

25(77)

152 to 165 (22 to 24)

200 to 228 (29 to 33)

1510 to 1669 (219 to 242)

1662 to 1841 (241 to 267)

49(120)

10 to 12

26 to 28

23(73)

28(83)

200 to 221 (29 to 32)

248 to 276 (36 to 40)

1779 to 1972 (258 to 286)

1910 to 2117 (277 to 307)

Perform the Following: 1. If the pressures obtained in the pressure test fall within the range above, your system problem is not a pressure related problem. Further electrical testing may be in order. 2. Compare gauge readings from the pressure test to the Air Conditioning Temperature/Pressure Chart above. Problem Low Side Pressure is low and High Side Pressure is normal

Low Side Pressure is low and High Side Pressure is low.

Possible Cause

Correction

Fault #4 -- Temperature Select Pot

Electrical Control Temperature Control Potentiometer -- Testing

Fault #8 -- Evaporator Temperature Sensor

Sensing System Evaporator Temperature Sensor -- Testing

Low Air Flow

Check evaporator seals.

Air in System

Overhaul -- Leakage test

Refrigerant excessively low.

Overhaul -- Leakage test

Improper operation of expansion valve (stuck closed).

Expansion Valve -- Testing

Restrictions in the high side of the system.

Check for crimped hoses/tubes or other restrictions.

50-10

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 Problem Low Side Pressure is high and High Side Pressure is high.

Possible Cause

Correction

Condenser not operating correctly.

Check belt tension. Loose or worn drive belts could cause excessive pressures in the compressor head. Check for air flow restrictions in condenser.

Possible air in system.

Perform Leakage Test.

System overcharged.

Recover and Recharge. Refer to “Overhaul -- Evacuating the Refrigerant” and “Overhaul -- Charging”

Possible clogged condenser.

Check condenser for plugging.

Expansion valve malfunction (stuck open).

Expansion Valve -- Testing

Low Side Pressure is high and High Side Pressure is low.

Compressor Malfunction.

Repair/Replace compressor.

Compressor cycles on at 34 psi (2.3 bar) and off at 28 psi (1.9 bar) indicated pressure on the Low Side Pressure gauge and High Side Pressure is normal.

Evaporator Temperature sensor is defective.

Replace Evaporator Temperature Sensor. Make sure temperature sensing line is installed in the same position and depth in the evaporator core as previous bulb.

50-11

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 HEATER VALVE NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered light can cause damage to components in this system.

Test Point

Expected Result

Other Result (Possible Cause)

Run engine at 1500 Warm air comes out ventilation lourpm for 15 minutes to vers. warm engine coolant. System operating properly. Keyswitch ON and ATC Switch in AUTO. Turn Temperature Control to maximum heat setting.

Go to test 2

Keyswitch ON and ATC Switch in AUTO. Observe slot on front of valve. Turn Temperature Control from max cool to max heat setting.

Slot on front of valve rotates clockwise. Check for obstructions in the coolant supply and return hoses.

Go to test 3

Disconnect connector X151 at heater valve. Check continuity through valve motor from pin “A” to pin “C”.

Less than 1 ohms. Go to test 4

Valve motor open. Replace heater control valve assembly.

Disconnect connector Control voltage varies from 11.5 -X151 at heater valve. 1.5 volts Keyswitch ON and ATC Go to test 5 Switch in AUTO. Test voltage from pin “D” at X151 to chassis ground while turning Temperature Control from max cool to max heat setting.

Go to test 8

Check voltage at pin “A” at connector X151.

Go to test 6

12 volts Go to test 7

50-12

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 No

Test Point

Expected Result

Other Result (Possible Cause)

Check voltage at Connector X397 pin “17” at ATC Control Module.

12 volts Open in voltage supply circuit AC-924-OR between heater valve and ATC Control Module. Repair or replace.

Faulty ATC Control Module. Repair or replace.

Measure resistance be- Less than 1 ohms. tween Connector X151 System operating properly. Retest. at Heater Control Valve and ground.

Open in ground circuit AC-954-BK. Repair or replace.

Test voltage from Connector X397 pin “3” at ATC Control Module (A15) to chassis ground while turning Temperature Control from max cool to max heat setting.

Faulty ATC Control Module (A15). Repair or replace.

Control voltage varies from 11.5 -1.5 volts Open in control circuit AC-955-YE between heater valve and ATC Control Module (A15). Repair or replace.

50-13

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 EXPANSION VALVE No

Test Point

Expected Result

Other Result (Possible Cause)

Disconnect Low PresLow pressure gauge shows desure Switch. crease in pressure. Connect the pressure Go to test 2 test gauge manifold as described in “Overhaul -- Pressure Test.” Remove insulation material from top of expansion valve. With engine running and A/C on maximum cooling, cool the top of the expansion valve with ice.

Expansion Valve defective. Replace as described in “Expansion Valve --Removal” and “Expansion Valve -Installation.”

Allow the top of the expansion valve to warm.

If there is little or no change in pressure, replace the expansion valve as described in “Expansion Valve -Removal” and “Expansion Valve -Installation.”

The valve opens and the pressure rises on the low pressure gauge.

50-14

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 VENTILATION SYSTEM SEPARATOR FAN NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered light can cause damage to components in this system.

Test Point

Expected Result

Other Result (Possible Cause)

Keyswitch ON.

Separator fan running. If fan is running, but cab does not have positive pressure, clean separator fan intake filter. Retest.

Go to test 2

Keyswitch OFF. Check condition of Fuse F-17.

Fuse good. Go to test 3

Replace Fuse F-17.

Disconnect connector X143 at Separator Fan. Measure resistance across Separator Fan pins A and B.

Less than 1 ohms. If good reading, Go to test 4

Separator Fan Motor faulty. Replace.

Disconnect connector X143 at Separator Fan. Keyswitch ON. Measure voltage at Separator Fan connector X143, pin A.

12 volts. If good reading, Go to test 5

Go to test 6

Disconnect connector Less than 1 ohms. If good reading, X143 at Separator Fan. Go to test 6 Measure resistance between Separator Fan connector X143, pin B and ground.

Open in ground circuit AC-933-BK between Separator Fan connector X143 and ground. Repair or replace.

Remove Separator Fan 12 volts. If good reading, Relay K-09. Go to test 9 Keyswitch ON. Measure voltage at Separator Fan Relay K-09, pin 1.

Go to test 7

Measure voltage at inline connector X003, pin 5.

Go to test 8

12 volts. If good reading, open in circuit CM-902-WH between Separator Fan Relay K-09 and in-line connector X003. Repair or replace circuit.

50-15

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 No

Test Point

Expected Result

Other Result (Possible Cause)

Measure voltage at ATC Control Module connector X128, pin C-4.

12 volts. If good reading, open in circuit CM-902-WH between ATC Control Module connector X128 and in-line connector X003. Repair or replace circuit.

ATC Control Module A09 faulty. Replace control module.

Separator Fan Relay K-09 removed. Keyswitch OFF. Measure voltage at Separator Fan Relay K-09, pin 3.

12 volts. If good reading, Go to test 10

Open circuit in line CM--930--RD between Fuse F--17 and Separator Fan Relay K--09. Repair or replace.

Measure resistance be- Less than 1 ohms. If good reading, tween Separator Fan Go to test 11 relay K--09, pin 2 and ground.

Measure resistance be- Less than 1 ohms. If good reading, Go to test 12 tween Separator Fan Replace Separator Fan Relay K-09. relay K-09, pin 5 and ground.

Measure resistance between in-line connector X006, pin B and ground.

Less than 1 ohms. If good reading, open in ground circuit CM-926-WH between Separator Fan relay K-09 and in-line connector X006. Repair or Replace.

50-16

Open in ground circuit between Separator Fan relay K--09 and ground. Repair or replace.

Open in ground circuit AC-926-RD between Separator Fan connector X143 and in-line connector X006. Repair or Replace.

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 VENTILATION SYSTEM BLOWER MOTOR NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered light can cause damage to components in this system.

Test Point

Expected Result Blower running. Go to test 2

Other Result (Possible Cause)

Keyswitch ON. Blower speed set to any speed.

Keyswitch ON. ATC ConBlower speed changes. trol Switch is OFF. Blower operating properly. Rotate Blower Speed Control knob.

Blower Speed Control inoperable. Go to Electrical Control Blower Speed Potentiometer -- Testing.

Keyswitch OFF. Check condition of Fuse F-18.

Replace Fuse F-18.

Measure resistance beLess than 1 ohm. If good readtween Blower Motor Relay, ing, Go to test 5 K13, pin 2 and ground.

Open in ground circuit CM-942-BK between Blower Motor Relay, K13, pin 2 and ground. Repair or replace.

Remove Blower Motor 12 volts. If good reading, Go to Relay. test 6 Keyswitch ON. Measure voltage at Blower Motor Relay, K13, pin 3.

Open in B+ supply circuit CM-938-RD to Blower Motor Relay. Repair or replace.

Measure voltage at Blower 12 volts. If good reading, Go to Motor Relay, pin 1. test 9

Open in circuit CM-906 between Blower Motor Relay and HVAC Control Module. Go to test 7

Measure voltage at in-line connector X003 (pin 9).

12 volts. If good reading, Open in circuit CM-906-WH between Blower Motor Relay and in-line connector X003. Repair or replace circuit.

Open in circuit CM-906 between inline connector X003 and HVAC Control Module. Go to test 8

Measure voltage at in-line connector X128 (pin C-9).

12 volts. If good reading, Open in Replace HVAC Control Module. circuit CM-906-WH between inline connector X003 and in-line connector X128. Repair or replace circuit.

Fuse good. Go to test 4

50-17

Go to test 3

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 No

Test Point

Expected Result

Other Result (Possible Cause)

Disconnect Blower Motor 12 volts. If good reading, Go to from harness. test 13 Measure voltage at Blower Motor connector, pin 1.

Measure voltage at in-line connector X152 (pin 1).

12 volts. If good reading, Open in Go to test 11 circuit BL-926 between in-line connector X152 (pin 1) and Blower Motor. Repair or replace circuit.

Measure voltage at in-line connector X006 (pin G).

12 volts. If good reading, Open in Go to test 12 circuit AC-926 between in-line connector X152 (pin 1) and inline connector X006 (pin G). Repair or replace circuit.

Measure voltage at Blower 12 volts. If good reading, Open in Faulty Blower Motor Relay. Repair Motor Relay pin 5. circuit CM-926 between in-line or replace Blower Motor Relay. connector X152 (pin 1) and Blower Motor Relay pin 5. Repair or replace circuit.

Measure resistance across Blower Motor terminals A and B.

Less than 1 ohm. If good reading, Go to test 14

Blower Motor windings open. Replace Blower Motor.

Measure resistance between Blower Motor terminal B and ground.

Less than 1 ohm. If good reading, Blower Motor circuit operating properly.

Open in ground circuit between Blower Motor and ground. Repair or replace circuit

50-18

Go to test 10

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 ELECTRICAL CONTROL TEMPERATURE CONTROL POTENTIOMETER NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered light can cause damage to components in this system.

Test Point

Expected Result

Keyswitch ON and ATC switch in AUTO. Defrost OFF. Turn Temperature Control Pot while observing Auto Operation Display.

Fault Code #4 displays only in certain locations. Probable faulty Temperature Control Pot. Go to test 2

Go to test 3

Keyswitch OFF. ATC OFF. Disconnect HVAC Control Module (A20) connector X128. Resistance check the temperature control pot between pins C-16 and D1 on the HVAC Control Module.

Resistance changes smoothly between 0 -- 10K ohms as the pot is turned from full CCW to full CW. Go to test 3

Replace the HVAC Control Module (A20).

HVAC Control Module (A20) connector X128 disconnected. Keyswitch ON. Check for voltage at connector X128, pin D1.

Voltage reading >3.0 volts. Open in Temperature Control Pot circuit. Replace HVAC Control Module.

Problem in ATC Controller circuit.

50-19

Other Result (Possible Cause)

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 ELECTRICAL CONTROL BLOWER SPEED POTENTIOMETER NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered light can cause damage to components in this system.

Test Point

Expected Result

Other Result (Possible Cause)

Keyswitch ON and ATC switch in AUTO. Defrost OFF. Turn Blower Speed Control Pot while observing Auto Operation Display.

Fault Code #3 displays only in certain locations. Probable faulty Blower Speed Control Pot. Go to test 3

Go to test 2

Keyswitch ON and ATC switch in AUTO. Defrost OFF. Check Temperature Control Pot for proper operation.

Temperature setpoint changes in display as Temperature Control Pot is turned. Go to test 3

Open in Blower Speed and Temperature Control Pot ground circuit. Replace HVAC Control Module.

Keyswitch OFF. ATC OFF. Disconnect HVAC Control Module (A20) connector X128. Resistance check the blower speed control pot between pins C15 and C16 on the HVAC Control Module.

Resistance changes smoothly between 0 -- 10K ohms as the pot is turned from full CCW to full CW. Go to test 4

Replace the HVAC Control Module (A20).

Disconnect HVAC Control Module (A20) connector X128. Keyswitch ON. Check for voltage at connector X128, pin C15.

Voltage reading >3.0 volts. Problem in ATC Control Module circuit. Open in Blower Speed Control Pot circuit. replace HVAC Control Module.

50-20

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 ELECTRICAL CONTROL RELAY NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered light can cause damage to components in this system.

Test Point

Expected Result

Other Result (Possible Cause)

Ignition switch in “IGN” position. Blower speed set to any fan speed. Cycle Defrost Switch On and Off.

Compressor clutch is heard engaging and disengaging. If good reading, A/C Clutch Control circuits are operating properly.

Go to test 2

Ignition switch in “OFF” Check condition of Fuse F-19.

Fuse good. Go to test 3

Replace Fuse F-19.

Measure resistance between A/C Clutch Relay, pin 2 and ground.

Less than 1 ohm. If good reading, Go to test 4

Open in ground circuit CM-945-BK between A/C Clutch Relay, pin 2 and ground. Repair or replace.

Remove A/C Clutch Relay. 12 volts. If good reading, Go to Ignition Switch in “IGN” test 5 position. Blower speed set to any fan speed. Measure voltage at A/C Clutch Relay, pin 3.

Open in B+ supply circuit CM-087-RD to A/C Clutch Relay. Repair or replace.

Measure voltage at A/C Clutch Relay, pin 1.

12 volts. If good reading, Go to test 8

Open in circuit CR-900 between A/C Clutch Relay and HVAC Control Module. Go to test 6

Measure voltage at in-line connector X003 (pin3).

12 volts. If good reading, Open in circuit CR-900-WH between A/C Clutch relay and in-line connector X003. Repair or replace circuit.

Open in circuit CR-900 between inline connector X003 and HVAC Control Module. Go to test 7

Measure voltage at in-line connector X128 (pin C-3).

12 volts. If good reading, Open in Replace HVAC Control Module. circuit CR-900-WH between inline connector X003 and and inline connector X128. Repair or replace circuit.

50-21

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 No

Test Point

Expected Result

Other Result (Possible Cause)

Ignition switch in “OFF” Less than 1 ohm. If good readposition. A/C system OFF. ing, Replace A/C Clutch Relay. A/C Clutch Relay installed. Measure resistance between A/C Clutch Relay, pin 5 and ground.

Open in ground circuit between A/C Clutch Relay and Ground. Go to test 9

Measure resistance between in-line connector X005 (pin 9) and ground.

Less than 1 ohm. If good reading, Open in ground circuit CM-178-WH between in-line connector X005 (pin 9) and A/C Clutch Relay. Repair or replace circuit.

Open in ground circuit between inline connector X005 (pin 9) and Ground. Go to test 10

Measure resistance between in-line connector X010 (pin 11) and ground.

Less than 1 ohm. If good reading, Open in ground circuit MF-178-WH between in-line connector X005 (pin 9) and in-line connector X010 (pin 11). Repair or replace circuit.

Open in ground circuit between inline connector X010 (pin 11) and Ground. Go to test 11

Measure resistance between A/C Clutch connector X215 (pin A) and ground.

Less than 1 ohm. If good reading, Open in ground circuit EN-178-WH between in-line connector X010 (pin 11) and A/C Clutch connector X215 (pin A). Repair or replace circuit.

Open in ground circuit between A/C Clutch connector X215 (pin A) and Ground. Go to test 12

Measure resistance between A/C Clutch connector X215 (pin B) and ground.

Less than 1 ohm. If good reading, Open in A/C Clutch coil. Repair or replace A/C Clutch.

Open in ground circuit between A/C Clutch connector X215 (pin B) and Ground. Repair or replace circuit

50-22

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 ELECTRONIC HVAC CONTROL -- DISPLAY DATA LINE NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered light can cause damage to components in this system.

Test Point

Expected Result

Engine stopped. A/C OFF. Measure resistance between HVAC Control Module (A09) connector X128, pin D-10 and in-line connector X003 pin 26.

Less than 1 ohm. If good reading, Go to test 3

Open in data circuit between HVAC Control Module (A09) connector X128, pin D-10 and in-line connector X003 pin 26. Repair circuit.

Measure resistance between in-line connector X003 pin 26 and in-line connector X006 pin “T”.

Less than 1 ohm. If good reading, Go to test 4

Open in data circuit between in-line connector X003 pin 26 and in-line connector X006 pin “T”. Repair circuit.

Measure resistance between in-line connector X006 pin “T” and ATC Control Module (A15) connector X398 pin “20”.

Less than 1 ohm. If good reading, ATC Control Module faulty. Repair or replace.

Open in data circuit between in-line connector X006 pin “T” and ATC Control Module (A15) connector X398 pin “20”. Repair circuit.

50-23

Other Result (Possible Cause)

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 ELECTRONIC HVAC CONTROL -- ATC CONTROL SWITCH AND MODE CONTROL SWITCH NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered light can cause damage to components in this system.

Test Point

Expected Result

Other Result (Possible Cause)

Keyswitch ON and ATC Control Switch in AUTO. Mode Control Switch in AUTO.

Auto Operation Display window illuminated. Go to test 2

Go to test 4

Keyswitch ON and ATC Control Switch in AUTO. Mode Control Switch in DEFOG.

Auto Operation Display window illuminated. Go to test 3

Go to test 4

Keyswitch ON and ATC Control Switch in OFF.

Auto Operation Display window not illuminated. ATC Control Switch and Mode Control Switch operating properly.

Go to test 4

Keyswitch OFF. ATC Control Switch in AUTO. Mode Control Switch in AUTO. Disconnect HVAC Control Module (A20) connector X128. Measure resistance across pins C16 and D5 on HVAC Control Module.

Less than 1 ohm. If good reading, Go to test 5

Replace HVAC Control Module.

HVAC Control Module (A20) connector X128 disconnected. Keyswitch ON. Measure voltage at HVAC Control Module connector X128 pin D5.

>3 volts. If good reading, Go to test 6

Problem in ATC Controller circuit.

HVAC Control Module (A20) connector X128 disconnected. Keyswitch ON. Measure voltage at HVAC Control Module connector X128 pin D7.

>3 volts. If good reading, Open in Problem in ATC Controller circuit. B+ supply circuit to Mode Control Switch. Replace HVAC Control Module.

50-24

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 ELECTRONIC HVAC CONTROL -- ATC CONTROLLER POWER SUPPLY NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered light can cause damage to components in this system.

Test Point

Expected Result

Keyswitch ON. Measure voltage at HVAC Control Module connector X128 pin C2.

12 volts. If good reading, Go to test 2

Open in Switched Ignition Power Supply to HVAC Unit. Repair or replace circuit.

Keyswitch OFF. Measure resistance between HVAC Control Module connector X128 pin D14 and ground.

Less than 1 ohm. If good reading, Repair or replace HVAC Control Module.

Open in ground circuit to HVAC Unit. Repair or replace circuit.

50-25

Other Result (Possible Cause)

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 SENSING SYSTEM HIGH PRESSURE SWITCH NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered light can cause damage to components in this system.

Test Point

Expected Result

Other Result (Possible Cause)

Engine stopped. Less than 1 ohm. If good readDisconnect HVAC Control ing, Go to test 12 Module connector X128. Measure resistance between connector X128, pin D-3 and D-4.

Open in high pressure switch circuit. Go to test 2

Reconnect HVAC Control Module connector X128. Disconnect connector X216 from high pressure switch. Measure resistance across switch terminals.

Less than 1 ohm. If good reading, Go to test 3

A/C High Pressure switch failed. Replace A/C High Pressure switch.

Measure resistance between A/C High Pressure Switch connector X216 (pin B) and in-line connector X010 (pin22).

Less than 1 ohm. If good reading, Go to test 4

Open in high pressure ground circuit EN-916-BL. Repair or replace this circuit.

Measure resistance between in-line connector X010 (pin22) and in-line connector X005 (pin28).

Less than 1 ohm. If good reading, Go to test 5

Open in high pressure ground circuit MF-916-BL. Repair or replace this circuit.

Measure resistance between in-line connector X005 (pin28) and in-line connector X003 (pin19).

Less than 1 ohm. If good reading, Go to test 6

Open in high pressure ground circuit CM-916-BL. Repair or replace this circuit.

Measure resistance between in-line connector X003 (pin19) and in-line connector X128 (pin D-3).

Less than 1 ohm. If good reading, Go to test 7

Open in high pressure ground circuit CR-934-BL. Repair or replace this circuit.

50-26

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 No

Test Point

Expected Result

Reconnect all connectors. Start engine with A/C on. Measure voltage at HVAC High Pressure Switch connector X126 (pin A).

12 volts. If good reading, Electrical portion of High Pressure Switch circuit operating properly.

Measure voltage at in-line connector X010 (pin25).

12 volts. If good reading, Open in Open in B+ supply circuit to conB+ circuit EN-917-YE between nector X010. high pressure switch connector Go to test 9 X216 (pin A) and in-line connector X010 (pin25). Repair or replace this circuit.

Measure voltage at in-line connector X005 (pin29).

12 volts. If good reading, Open in B+ circuit MF-917-YE between in-line connector X010 (pin25) and in-line connector X005 (pin29). Repair or replace this circuit.

Open in B+ supply circuit to connector X005. Go to test 10

Measure voltage at in-line connector X003 (pin20).

12 volts. If good reading, Open in B+ circuit CM-917-YE between in-line connector X005 (pin29) and in-line connector X003 (pin20). Repair or replace this circuit.

Open in B+ supply circuit to connector X003. Go to test 11

Measure voltage at in-line connector X128 (pin D-4).

12 volts. If good reading, Open in B+ circuit CR-917-YE between in-line connector X003 (pin20) and in-line connector X128 (pin D-4). Repair or replace this circuit.

Open in B+ supply circuit to connector X128. Go to test 12

Engine running and A/C on. Disconnect HVAC Control Module connector X128. Measure voltage at HVAC Control Module, pin D-4.

12 volts. If good reading, Go to test 13

Repair or replace HVAC Control Module (A-20).

Engine off and A/C off. Measure resistance between HVAC Control Module, pin D-3 and ground.

Less than 1 ohm. If good reading, Electrical portion of high pressure operating properly.

Repair or replace HVAC Control Module (A-20).

50-27

Other Result (Possible Cause) Open in B+ supply circuit to high pressure switch. Go to test 8

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 SENSING SYSTEM LOW PRESSURE SWITCH NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered light can cause damage to components in this system.

Test Point

Expected Result

Engine stopped. Disconnect HVAC Control Module (A-15) connector X397. Disconnect HVAC Control Module (A-09) connector X128. Measure resistance between connector X397, pin 35 and connector X128, pin D6.

Less than 1 ohm. If good reading, Go to test 2

Open in low pressure switch circuit. Go to test 3

Engine off and A/C off. Measure resistance between HVAC Control Module (A-15), pin 35 and ground.

Less than 1 ohm. If good reading, Go to test 9

Open in ground circuit to HVAC Control Module (A-15), repair or replace.

Reconnect HVAC Control Module (A-15) connector X397 and HVAC Control Module (A-09) connector X128. Disconnect connector X217 from A/C Low Pressure switch. Measure resistance across switch terminals.

Less than 1 ohm. If good reading, Go to test 4

A/C Low Pressure switch failed. Replace A/C Low Pressure switch.

Measure resistance between A/C Low Pressure Switch connector X217 (pin B) and ground.

Less than 1 ohm. If good reading, Go to test 6

Open in A/C Low Pressure ground circuit. Go to test 5

50-28

Other Result (Possible Cause)

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 No

Test Point

Expected Result

Engine off and A/C off. Measure resistance between HVAC Control Module (A-15), pin 35 and ground.

Less than 1 ohm. If good reading, Open in A/C Low Pressure ground circuit AC-950-BL between connector X397, pin 35 and connector X217, pin B. Repair or replace this circuit.

Open in ground circuit to HVAC Control Module (A-15), repair or replace.

Reconnect all connectors. Start engine with A/C on. Measure voltage at HVAC Low Pressure Switch connector X217 (pin A).

12 volts. If good reading, Electrical portion of Low Pressure Switch circuit operating properly.

Open in B+ supply circuit to low pressure switch. Go to test 7

Measure voltage at in-line connector X006 (pin H).

12 volts. If good reading, Open in Open in B+ supply circuit to B+ circuit AC-910-YE between connector X006. Low Pressure switch connector Go to test 8 X217 (pin A) and in-line connector X006 (pin H). Repair or replace this circuit.

Measure voltage at in-line connector X003 (pin 13).

12 volts. If good reading, Open in Open in B+ supply circuit to B+ circuit CM-910-YE between connector X003. in-line connector X006 (pin H) Go to test 9 and in-line connector X003 (pin 13). Repair or replace this circuit.

Measure voltage at HVAC Control Panel (A-09) connector X128 (pin C-13).

12 volts. If good reading, Open in Open in B+ supply circuit to HVAC B+ circuit CR-910-YE between Control Panel (A-09), repair or in-line connector X003 (pin 13) replace control panel. and HVAC Control Panel (A-09) connector X128 (pin C-13). Repair or replace this circuit.

50-29

Other Result (Possible Cause)

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 SENSING SYSTEM OUTLET TEMPERATURE SENSOR NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered light can cause damage to components in this system.

Test Point

Expected Result

Engine off and A/C off. Disconnect connector from Outlet Temperature Sensor. Measure resistance across sensor terminals.

15K -- 30K ohms, with an ambient temperature between 90 -- 60 °F (31 -- 16 °C). If good reading, Go to test 2

Outlet Temperature Sensor faulty. Repair or replace sensor.

Measure resistance between Outlet Temperature Sensor connector pin B and ground.

Less than 1 ohm. If good reading, Go to test 3

Open in Outlet Temperature Sensor ground circuit. Repair.

Measure resistance between ATC Control Module (A-15) pin 22, and ground.

15k -- 30k ohms, with an ambient temperature between 90 -- 60°F (31 -- 16°C). If good reading, faulty ATC Control Module (A-15). Repair or replace.

Open in circuit AC-958-WH between ATC Control Module (A-15) and outlet temperature sensor. Repair or replace.

50-30

Other Result (Possible Cause)

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 SENSING SYSTEM CAB TEMPERATURE SENSOR NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered light can cause damage to components in this system.

Test Point

Expected Result

Other Result (Possible Cause)

Engine off and A/C off. Disconnect connector X149 from Cab Temperature Sensor. Measure resistance across sensor terminals.

15K -- 30K ohms, with an ambient temperature between 90 -- 60 °F (31 -- 16 °C). If good reading, Go to test 2

Cab Temperature Sensor faulty. Repair or replace sensor.

Measure resistance between Cab Temperature Sensor connector X149 (pin B) and ground.

Less than 1 ohm. If good reading, Go to test 3

Open in Cab Temperature Sensor ground circuit. Repair.

Measure resistance between ATC Control Module (A-15), pin 21 and ground.

15k -- 30k ohms, with an ambient temperature between 90 -- 60°F (31 -- 16°C). If good reading, faulty ATC Control Module (A-15). Repair or replace.

Open in circuit AC-952-BL between ATC Control Module (A-15) and cab temperature sensor. Repair.

50-31

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 SENSING SYSTEM EVAPORATOR TEMPERATURE SENSOR NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered light can cause damage to components in this system.

Test Point

Expected Result

Other Result (Possible Cause)

Engine off and A/C off. Disconnect connector X150 from Evaporator Temperature Sensor. Measure resistance across sensor terminals.

15K -- 30K ohms, with an ambient temperature between 90 -- 60 °F (31 -- 16 °C). If good reading, Go to test 2

Evaporator Temperature Sensor faulty. Repair or replace sensor.

Measure resistance between Evaporator Temperature Sensor connector X150 (pin 2) and ground.

Less than 1 ohm. If good reading, Go to test 3

Open in Evaporator Temperature Sensor ground circuit. Repair.

Measure resistance between ATC Control Module (A-15), pin 23 and ground.

15k -- 30k ohms, with an ambient temperature between 90 -- 60°F (31 -- 16°C). If good reading, faulty ATC Control Module (A-15). Repair or replace.

Open in circuit A-951-BL between ATC Control Module (A-15) and evaporator temperature sensor. Repair.

50-32

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 OVERHAUL EVACUATING THE REFRIGERANT 1. Recovered refrigerant passes through an oil separator and filter-drier before entering the refrigerant tank. The moisture indicator will turn green when dry refrigerant passes over it. 2. If possible, run the air conditioning system for ten minutes before starting the recovery process. Turn the system off before proceeding. 3. Clean the external surfaces of the compressor and hoses. Remove the caps from the service ports, 1, on the suction and pressure hoses.

1 83054617

7 4. Make sure the charging station manifold gauge valves are in the closed position. Connect the hose from the low pressure gauge to the port on the suction hose. Connect the hose from the high pressure gauge to the port on the discharge hose. Turn in both thumbscrews to depress the service valves. 5. Open the high and low valves.

83060848

8 6. Make certain the refrigerant tank gas and liquid valves are open.

83060842

50-33

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 7. Connect the main power plug to a 115 volt AC outlet. Move the main power switch to the ON position and depress the recovery start switch. The compressor will shut OFF automatically when recovery is complete. Wait for five minutes and observe the manifold pressure gauges for a pressure rise. If pressure rises above zero PSI, depress the hold/cont switch. Then wait for the compressor to automatically shut OFF.

83060846

10 8. Drain the oil separator of the A/C system oil. Open the air purge valve long enough to let some of the compressor discharge pressure back into the separator.

83060843

11 9. Slowly open the oil drain valve and drain the oil into the reservoir. When the oil stops draining, close the oil drain valve completely.

83060844

50-34

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 10. Fill the A/C compressor with fresh SP-20 PAG oil equal to the amount in the reservoir.

83060845

13 11. Disconnect the hoses from the service ports, 1, and install the caps. 12. Replace the receiver-drier if one or more of the following conditions occurs before you remove the air and moisture from the system: •

The system has been opened for service before.

•

Receiver-drier has operated two or more years.

•

Disassembly of compressor shows small particles of moisture removing material (gold or brown particles).

•

Large system leak (broken hose, break in line).

•

Too much air or moisture in system.

•

Removal of compressor caused the system to be open (uncapped) longer than 5 minutes.

50-35

1 83054617

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 13. Make sure the charging station manifold gauge valves are in the closed position. Connect the hose from the low pressure gauge to the port on the suction hose, 1. Connect the hose from the high pressure gauge to the port on the discharge hose, 2. Turn in both thumbscrews to depress the service valves. 14. Removal of air and moisture from the system is necessary after the refrigerant has been removed from the system after the system has been opened for maintenance. Air enters the system when the system is opened. Air has moisture that must be removed to prevent damage to the system components.

1 2 83054617

15. Air and moisture are removed from the system by a vacuum pump. A vacuum pump is on the only equipment made that will lower the pressure in a system enough to change the moisture to a vapor so that the moisture can be removed. NOTE: Refer to the vacuum pump manufacturer ’s user manual for additional information. 16. Connect the main power plug to a 115 volt AC outlet. Move the main power switch to the ON position. If program and vacuum do not appear at the top of the display press the vacuum key. Program a minimum of 45 minutes and press the Enter key. The display will flash once indicating the programmed data has been accepted.

83060847

16 17. Press the Charge Key. Program and Charge will appear on the display.

83060849

50-36

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 18. Program 1.6 kg (3.52 lb) and press the enter key. The display will flash once indicating the programmed data has been accepted.

83060847

18 19. Full open the low and high pressure valves.

83060848

19 20. Open the red (vapor) and blue (liquid) valves on the tank. 21. Press the Vacuum key. Automatic will show on the display and after a slight delay, the vacuum pump will start. The display will show the amount of time programmed and begin a countdown to zero.

83060842

50-37

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 22. When the programmed time has elapsed, an automatic hold occurs. Check the low pressure gauge to see that the A/C system maintains a 28 -- 29-1/2 in of mercury (Hg). The low pressure gauge must not increase faster than one inch of mercury (Hg) in 15 minutes. If the system will not hold vacuum, a leak exists that must be corrected before recharging can begin. See “Overhaul -Leakage Test” for a leak test.

83060847

PRESSURE TEST NOTE: The compressor end plate is stamped with a “D” and “S” to indicate the discharge and suction ports. 1. Connect the pressure test gauge manifold to the test connections at the compressor. Connect the high side hose to the discharge side, 1, and the low side hose to the suction side, 2.

2 1 83054617

22 2. On the pressure test gauge manifold, close the high side valve, 1, and the low side valve, 2. 3. Close the cab windows and doors, set the parking brake. 4. Start the engine and run at fast idle speed (approximately 1500 rpm). 5. Set A/C mode switch to “on.”

6. Operate the system at maximum cooling, with the blower fan at high speed for 10 minutes to stabilize all components. 7. Check the manifold high and low pressure gauges and compare the reading to the pressure indicated on the Air Conditioning Temperature/ Pressure Chart. Refer to “Problem Solving Pressure Test Results and Temperature/Pressure Chart.”

50-38

23060841

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 LEAKAGE TEST 1. Shut off the engine.

WARNING When refrigerant comes in contact with an open flame, it forms phosgene gas, a severe respiratory irritant. Never breathe these fumes. Failure to comply could result in serious injury or death. 2. Use electronic leak detector OEM1437 to inspect all connections. Use instructions from manufacturer of leak finding tool. NOTE: When checking compressor seal for a leak, remove the dust cover and rotate the clutch shaft clockwise. NOTE: To properly check the expansion valve for leaks, remove the insulation tape. 3. Check Compressor oil level. Refill as necessary. 4. Repair all leaks and recharge the system.

CHARGING 1. Press the charge key to begin refrigerant charging. Automatic and Charge will appear on the display. The display shows the programmed amount and counts down to zero as charging proceeds. When charging is completed, the display shows CPL.

83060847

24 2. Completely close the high and low pressure manifold valves. 3. Start the engine and run at 1500 rpm. Operate the air conditioner system at maximum cooling setting and blower speed with the doors and windows open. NOTE: The compressor will not operate if the system pressure is too low or too high. If the compressor fails to operate and the condenser blowers also fail to operate when you actuate the A/C switch, check the system pressure to determine if refrigerant is present. Check for continuity at the pressure switch located at the receiver-dryer and the temperature switch located at the evaporator.

50-39

83060848

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1 4. Observe the pressure gauge readings to determine that the correct amount of refrigerant has entered the system. See table on “Testing -Problem Solving Pressure Test Results,” for temperature and pressure variations. IMPORTANT: Check the OEM equipment manual before performing this step to avoid damaging recovery unit. Pressure reading should be obtainable with valves closed. Damage may occur if the machine is started with the valves accidently open or if either or both valves are opened while the A/C system operating.

83060850

26 5. Stop the engine, close any open valves and carefully remove the manifold gauge hoses. 6. Install the caps on the service ports, 1, on the suction and discharge hoses.

1 83054617

50-40

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 2

SECTION 50 - CLIMATE CONTROL Chapter 2 - Air Filters CONTENTS Section

Description

Page

50-1

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 2 DESCRIPTION OF OPERATION The combine is provided with two mechanisms for filtering the air entering and circulating through the cab. Intake air is drawn down the left, rear cab frame post into the separator filter, 1, by the separator fan. The separator filter and fan are located inside the cavity next to the left cab door. Air entering the separator is directed into a circular path around the paper element filter. Centrifugal force will cause the heavier material to move toward the outside. An outlet port is provided on the cap of the separator to allow continuous removal of the material separated. The separating action of the unit extends the life of the paper filter. 10008334

1 1

The Recirculation Air Filter, 1, located behind the operators’ control console filters the air circulating inside the cab. The paper element filter removes small particles from the air to prevent clogging of the air conditioning system evaporator located directly behind the filter. NOTE: Operating the combine with the cab door open will cause premature filter plugging.

1 10008336

50-2

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 2 OVERHAUL RECIRCULATION AIR FILTER

Removal Locate the recirculation air filter inside the cab, behind the operators console. Move the operators seat all the way forward. Simultaneously push down while pulling out on the locking tabs, 1. A prying device may have to be used.

10008336

3 Pull the grate and filter from the cavity.

10008337

50-3

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 2 Installation Clean the evaporator core of any accumulated dust. Insert the filter into the grate with the gasket positioned toward the cores.

10008337

5 Set the grate and filter into place in the cavity. Push the grate until the locking tabs, 1, snap into place.

1 1

10008336

SEPARATOR FILTER

Removal Locate the separator/air filter housing inside the cavity next to the left cab door.

Release the housing end cap lock, 1, by pulling it away from the filter. Rotate the housing end cap, 2, counter-clockwise until it can be removed.

10008334

50-4

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 2 Pull the filter element, 1, out of the filter housing.

10008335

8 Installation Clean the inside of the filter housing to prevent foreign material from entering the clean air side of the filter element. Insert the air filter, 1, into the housing base.

10008335

9 Set the end cap, 1, onto the filter housing and rotate clockwise until the two components are held tightly together. Secure the end cap into place by pushing in the lock, 2.

10008334

50-5

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 2

50-6

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 3

SECTION 50 - CLIMATE CONTROL Chapter 3 - Blower Fans CONTENTS Section

Description

Page

50-1

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 3 DESCRIPTION OF OPERATION Two fans are installed to bring in and circulate the cab air. The recirculating fan, 1, mixes air from outside and inside the cab. Air is discharged from the fan to the outlet plenum and directed to various points within the cab.

1 10008347

1 Near the bottom of the outlet plenum, a port, 1, is installed to direct air under the operators’ seat. The vents can direct air across the cab floor and towards the windshield.

Connections, 2 and 3, provide cool air to the right hand storage container behind the operator’s chair. Articles that require cooling can be placed in this container.

2 3

10008340

2 The outlet plenum runs vertically near the right rear corner of the cab directing the airflow into the headliner distribution plenum, 1. Main directional vents, 2, can be adjusted by the operator for maximum comfort. Defrosting vents, 3, are adjusted to clear the inside of the windows of condensation.

FRONT

3 3

2 1

50010477

50-2

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 3 OVERHAUL CIRCULATION FAN

Removal Remove the five cap screws, 1, holding the ventilation system shield in place. Lift the shield from the combine.

1 1 10008343

4 Remove the bench top behind the drivers seat at the hinges. Remove the eight machine screws, 1, holding the right side storage compartment in place. Lift the compartment and store in a suitable location.

10008339

1 5

Take off under seat ventilation duct at 1. Remove cap screws 2 and 3. Detach electrical connector, 4.

3 10008340

50-3

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 3 Remove water valve mounting cap screws, 1. Carefully move the water valve out of the way of the blower housing.

10008341

7 Disconnect ventilation duct, 1. Remove plenum cap screw, 2. Detach electrical connector, 3. Remove the four blower motor mounting cap screws, 4.

1 2

10008346

8 Carefully slide the blower motor assembly from the ventilation housing.

10008347

50-4

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 3 Installation Install new seals, and slide the blower motor assembly into the ventilation housing.

10008347

10 Secure the blower using four cap screws, 1. Install plenum cap screw, 2. Attach electrical connector, 3. Install a new seal, and connect ventilation duct at 4.

4 2

10008346

11 Mount the water control valve using two cap screws, 1.

10008341

50-5

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 3 Install cap screws, 1 and 2. Connect ventilation duct at 3. Attach electrical connector, 4.

1 10008340

13 Install new seals, and install the storage compartment. Secure in place with eight machine screws, 1. Secure the bench top behind the drivers seat at the hinges.

10008339

1 14

Set the ventilation system shield into place and secure using five cap screws, 1.

1 1

1 1 10008343

50-6

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 3 SEPARATOR FAN

Removal Disconnect the power wires, 1, from the motor. Cover the exposed electrical connectors with tape to prevent shorting them out.

Loosen hose clamp, 2. Remove the three cap screws, 3, and remove the fan from the combine.

10008377

16 The separator fan can be removed from the mounting frame by removing the three screws, 1.

Remove the adaptor ring from the fan by removing the four screws, 2.

10008378

2 17

Inspect the gasket, 1, and hose, 2, for deterioration. Replace if necessary.

10008379

2 18

50-7

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 3 Installation Install the adaptor ring on the fan using four screws, 1.

NOTE: The correct screws must be used to avoid damaging the plastic fan housing.

Secure the fan into position in the mounting frame using three screws, 2.

10008378

19 Set the fan, 1, into position and secure using three cap screws, 2. Attach the hose to the fan outlet and tighten clamp, 3.

4 2

Attach the power wires, 4. The white wire is to be connected to the positive terminal, and the black wire is to be connected to the negative terminal of the motor. Only the positive terminal is marked.

10008377

50-8

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 4

SECTION 50 – CLIMATE CONTROL Chapter 4 – Compressor CONTENTS Section

Description

Page

50-1

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 4 DESCRIPTION OF OPERATION The compressor, mounted inside the engine compartment, is driven by the crankshaft pulley. Refrigerant and oil is moved through the air conditioning system by the compressor, which lubricates and cools the unit during operation. An electromagnetic clutch is used to engage or disengage the compressor as required when operating the air conditioning system. The clutch is of a stationary coil type and forms an integral part of the compressor pulley assembly. When the coil is energized, the clutch plate is pulled against the rotating pulley. De-energizing the coil will allow the plate to return to a standby position.

86063829

50-2

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 4 OVERHAUL COMPRESSOR Removal NOTE: The CR9040, CR9060 is shown. Compressor removal on the CR9070 is similar. Recover refrigerant in accordance with the Refrigerant Recovery Procedure in this section. NOTE: A 1/2I drive cutout square is provided in the arm of the idler pulley to be used to release tension on the belt. Use a 1/2″ drive long handle breaker bar, 1, to release tension from the serpentine belt. Remove the belt from the compressor pulley.

10008351

2 Detach the compressor clutch electrical connector, 1. Disconnect the suction and discharge lines, 2. Cap the line side to prevent moisture or foreign material from entering the system. Remove the compressor mounting bolts, 3, and washers and lift the compressor from the combine.

3 1 86063829

50-3

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 4 Installation Set the compressor on its mount and secure into place using four cap screws and washers, 1. Torque to 20 -- 26 N⋅m (14.75 -- 19.2 ft-lbs). Replace the O rings, and lubricate them with PAG oil. Connect the refrigerant suction and discharge lines, 2, and torque to 45 -- 52 N⋅m (33 -- 38 ft-lbs). Attach the clutch electrical connector, 3.

1 3 86063829

4 Insert a 1/2″ long handle breaker bar, 1, into the idler pulley bracket and rotate it enough to route the serpentine belt around the compressor pulley. Recharge the refrigerant system in accordance with the Recharge/Refilling procedure.

10008351

CLUTCH Removal NOTE: It is highly recommended to remove the compressor from the system before replacing the clutch. Insert the two pins of the front plate spanner into any two threaded holes of the clutch front plate. Hold the clutch plate stationary. Remove the hex nut with a 19 mm socket.

20018359

50-4

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 4 Remove the clutch plate using a puller. Align the puller center bolt to the compressor shaft. Thumb tighten the three puller bolts into the threaded holes. Turn the center bolt clockwise until the front plate is loosened.

20018360

7 Remove the shaft key by lightly tapping it loose with a slot screwdriver and hammer.

20018361

8 Remove the internal bearing snap ring.

20018362

50-5

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 4 Remove the front housing external snap ring.

20018363

10 Insert the lips of the jaws into the internal bearing snap ring groove. Place the rotor puller shaft protector over the exposed shaft.

20018364

11 Align the thumb head bolts to the puller jaws and turn till finger tight.

20018365

50-6

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 4 Turn the puller center bolt clockwise until the rotor pulley is free.

20018366

13 Loosen the core lead wire from the clip on top of the compressor front housing.

20018367

14 Remove the snap ring and the field coil.

20018368

50-7

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 4 Installation Install the field coil. The coil flange protrusion must match the hole in the front housing to prevent coil movement and the lead wire must be correctly located. Replace the rotor pulley.

20018369

16 Support the compressor on the four mounting ears at the compressor rear side. If using a vise, clamp only the mounting ears, never the compressor body itself. Align the rotor assembly squarely on the front housing hub. Using a hammer and a special tool, tap until the rotor bottoms to the compressor front housing hub.

20018370

17 Reinstall the internal bearing snap ring. Reinstall the front housing external snap ring.

20018371

50-8

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 4 Check that the original clutch shims are in place on the compressor shaft. Replace the compressor shaft key. Align the front plate key way to the compressor shaft key. Using a shaft protector, tap the front plate to the shaft until it has bottomed to the clutch shims.

20018372

19 Replace the shaft hex nut and torque to 35 – 40 N⋅m (26 – 30 ft-lbs). Check the air gap with a feeler gauge 0.4 to 0.8 mm (0.016 – 0.032I). If the air gap is not consistent around the circumference, lightly pry up at the minimum variations. Lightly tap down at points of maximum variation. If the compressor had been removed, install the compressor in accordance with the Compressor Installation procedure in this section. 20018373

50-9

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 4

50-10

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 5

SECTION 50 - CLIMATE CONTROL Chapter 5 - Condenser CONTENTS Section

Description

Page

50-1

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 5 DESCRIPTION OF OPERATION The condenser, 1, is located on the inside of the rotary dust screen door. The condenser consists of a number of turns of continuous coil mounted in a series of thin cooling fins to provide maximum heat transfer in a minimum amount of space.

The condenser receives the hot, high-pressure refrigerant vapor from the compressor. As the hot vapor passes through the coils, outside air is drawn around the coils by the engine fan. Heat is transferred from the hot refrigerant vapor into the cooler outside air flowing across the coils and fins. The refrigerant condenses inside the unit and becomes a high pressure liquid.

86063135

50-2

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 5 OVERHAUL CONDENSER Removal Recover refrigerant in accordance with the Refrigerant Recovery Procedure in this section. Open the rotary dust screen door, 1, to gain access to the air conditioning condenser.

2 Disconnect and cap the refrigerant lines, 1, from the condenser. The fittings are different sizes, labeling should not be required. IMPORTANT: Use a wrench on the condenser tube nut to prevent twisting the condenser tube.

Support the weight of the condenser with blocking or some other method. Detach the condenser from the outside mount by removing the two cap screws and nuts, 2. Lift the inside edge off the two hinge pins, 3, and remove the condenser from the combine.

86063625

1 3

50-3

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 5 Installation Open the rotary dust screen door, 1, to gain access to the mounting area for the air conditioning condenser.

4 Align the hinge pin mounts, 1, with the hinge pins on the inside edge of the rotary dust screen door and set the condenser in place. Secure the condenser outside edge to the rotary dust screen door using two cap screws, lock washers and nuts, 2.

Replace the O rings, and lubricate them with PAG oil. Attach the hoses, 3, to the condenser, and torque the smaller hose to 18 -- 23 N⋅m (13 -- 17 ft-lb), and the larger hose to 24 -- 30 N⋅m (17 -- 22 ft-lb). 86063625

IMPORTANT: Use a wrench on the condenser tube nut to prevent twisting the condenser tube.

3 5

NOTE: The fittings are different sizes. Recharge the refrigerant system in accordance with the Recharge/Refilling procedure.

50-4

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 6

SECTION 50 - CLIMATE CONTROL Chapter 6 - Cool Box CONTENTS Section

Description

Page

50-1

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 6 DESCRIPTION OF OPERATION Climate control system has connections to provide cool air to the right hand storage container behind the operator’s chair. Articles that require cooling can be placed in this Cool Box. When the cab temperature is low enough to open the hot water valve, the cool box damper is shut to keep heated air from circulating through it.

50-2

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 6 OVERHAUL COOL BOX DAMPER ACTUATOR

Removal Remove the bench top behind the drivers seat at the hinges. Remove the eight machine screws, 1, holding the right side storage compartment in place. Lift the compartment and store in a suitable location.

10008339

1 1

Shown is an actuator that has been removed. Note the location of the three mounting machine screws, 1.

1 1

1 10008380

2 Detach the electrical connector, 1, for the cool box damper actuator. Remove the three machine screws, 2, holding the actuator to the mount. Slide the actuator off of the damper.

2 1 2

NOTE: There is a shaft coupler used between the actuator and damper. Use caution to prevent losing this coupler.

10008340

50-3

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 6 Installation Shown is an actuator that has been removed. Note the location of the three mounting machine screws, 1.

1 1

1 10008380

4 NOTE: To aid in starting the machine screws, petroleum jelly can be used.

Install the shaft coupler on the actuator shaft, and slide the actuator onto the damper stem. Secure the actuator in place using three machine screws, 1.

2 1

CAUTION The actuator casing is made of plastic, do not over torque the mounting screws. Attach the actuator electrical connector, 2.

10008340

5 Install the storage compartment and secure in place with eight machine screws, 1. Secure the bench top behind the drivers seat at the hinges.

10008339

1 6

50-4

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 7

SECTION 50 - CLIMATE CONTROL Chapter 7 - Evaporator CONTENTS Section

Description

Page

50-1

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 7 DESCRIPTION OF OPERATION The evaporator is located in the ventilation housing behind the combine cab. Similar to the condenser, the evaporator core consists of numerous tubes mounted in a series of thin aluminum cooling fins. The fins and tubing are designed to transfer heat from the cab air to the cold refrigerant liquid as it moves through the evaporator tubing. The low-pressure liquid inside the tubes remove heat from air passing around them. As the refrigerant absorbs heat, it boils and flashes to a vapor. The low-pressure vapor then flows to the compressor to repeat the refrigerant cycle.

10008342

50-2

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 7 OVERHAUL EVAPORATOR CORE

Removal Remove the five cap screws, 1, holding the ventilation system shield in place. Lift the shield from the combine.

1 1 10008343

2 Remove the recirculation filter by simultaneously pushing down while pulling out on the locking tabs, 1. A prying device may have to be used. Pull the grate and filter from the cavity.

1 1

10008336

3 Remove the mounting cap screw, 1.

10008338

50-3

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 7 Remove the bench top behind the driver’s seat at the hinges. Remove the eight machine screws, 1, holding the right side storage compartment in place. Lift the compartment away and store in a suitable location.

10008339

5 Lift the thermal sensing bulb, 1, from the evaporator core. If it is planned to completely remove the evaporator core from the combine, recover refrigerant in accordance with the Refrigerant Recovery Procedure in this section. NOTE: The evaporator core may be slid out of the ventilation housing without disconnecting the refrigerant hoses.

10008340

6 Disconnect the refrigerant lines, 1, from the evaporator. Cap the ends to prevent foreign material and moisture from entering the system. Remove the four cap screws, 2, holding the evaporator to the ventilation system housing.

1 2 10008341

2 7

50-4

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 7 Carefully pull the evaporator core from the housing.

10008342

8 Installation Install a new seal, and slide the evaporator core into the ventilation housing with the ports of the thermal expansion valve facing down.

10008342

9 Secure the evaporator core to the housing using four cap screws, 1. Lubricate the O rings with refrigerant oil and connect the supply and return lines, 2, if they had been previously removed. Torque the smaller line to 18 -- 23 N⋅m (13 -- 17 ft-lbs) and the larger line to 30 -- 37 N⋅m (22 -- 27 ft-lbs).

2 1 10008341

1 10

50-5

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 7 Carefully insert the thermal sensing probe, 1, into the evaporator core. Attach the electrical connector if it had been unplugged.

10008340

11 Install new seals, and install the storage compartment and secure in place with eight machine screws, 1. Secure the bench top behind the drivers seat at the hinges.

10008339

1 12

Secure the core into position using cap screw, 1.

10008338

50-6

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 7 Set the grate and filter into place in the cavity. Push the grate until the locking tabs, 1, snap into place.

1 1

Charge the refrigerant system in accordance with the Recharge/Refilling procedure in this section. If the evaporator core had been completely removed from the combine.

10008336

14 Set the ventilation system shield into place and secure using five cap screws, 1.

1 1

1 1 10008343

50-7

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 7

50-8

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 8

SECTION 50 - CLIMATE CONTROL Chapter 8 - Heater Core CONTENTS Section

Description

Page

50-1

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 8 DESCRIPTION OF OPERATION The heater core, 1, is located in the ventilation housing behind the combine cab. Similar to the evaporator, the heater core consists of numerous tubes mounted in a series of thin aluminum cooling fins. The fins and tubing are designed to transfer heat from the heated engine coolant to the cab air as it moves across the tubing.

10010480

1 A water valve,1, is located in the ventilation housing behind the combine cab. The valve is installed to control the flow of hot engine coolant through the core. Combines equipped with the Automatic Temperature Control system operate the water valve to satisfy the temperature as set by the operator. Manual Temperature Control systems position the water valve according to the setting of the temperature knob.

10008341

50-2

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 8 OVERHAUL HEATER CORE Removal It is possible to completely remove the heater core from the ventilation housing without removing the coolant and lines. If the heater core is to be removed from the combine, shut the heater core supply and return valves located at the engine.

9L ENGINE (CR9040, CR9060)

Supply to cab Return from cab

86062996

86063823

10.3L ENGINE (CR9070) Supply to cab

Return from cab 20018349

50-3

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 8 Remove the five cap screws, 1, holding the ventilation system shield in place. Lift the shield from the combine.

1 1

1 1 10008343

5 Remove the recirculation filter by simultaneously push down while pulling out on the locking tabs, 1. Pull the grate and filter from the cavity.

1 1

10008336

6 Remove the mounting cap screw, 1, for the evaporator core.

10008338

50-4

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 8 Remove the bench top behind the driver’s seat at the hinges. Remove the eight machine screws, 1, holding the right side storage compartment in place. Take out the compartment and store in a suitable location.

10008339

8 Lift the thermal sensing bulb, 1, from the evaporator core.

10008340

9 Remove the four cap screws, 1, holding the evaporator to the ventilation housing.

1 10008341

1 10

50-5

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 8 Carefully pull the evaporator core from the housing with the refrigerant lines still attached.

10008342

11 Remove the mounting cap screw, 1, for the heater core from the inside of the ventilation housing.

1 10008345

12 NOTE: When removing heater hoses, residual coolant will drain.

If the heater core is to be completely removed from the combine, remove hoses, 1 and 2, from the heater core.

Remove the mounting cap screws, 3. Pull the core from the housing.

3 10008344

50-6

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 8 Installation Orient the core so that the notched corner is on the bottom. Install new seals, and slide the heater core into place. Secure the heater core using cap screws, 1. Attach hoses 2 and 3, if they were previously removed.

3 1

10008344

1 14

Secure the core into place with cap screw, 1.

1 10008345

15 Install new seals, and slide the evaporator core into the housing with the refrigerant supply and return lines oriented down.

10008342

50-7

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 8 Install four cap screws, 1.

1 1

10008341

17 Secure the core into place with cap screw, 1.

10008338

18 Carefully insert the thermal sensing probe, 1, into the evaporator core. Attach the electrical connector if it had been unplugged.

10008340

50-8

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 8 Set the grate and filter into place in the cavity. Push the grate until the locking tabs, 1, snap into place.

1 1

10008336

20 Install new seals, and install the storage compartment and secure in place with eight machine screws, 1. Secure the bench top behind the drivers seat at the hinges.

10008339

1 21

Set the ventilation system shield into place and secure using five cap screws, 1.

1 1

1 1 10008343

50-9

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 8 Open the water supply and return valves. Refill the coolant reservoir as required.

9L ENGINE (CR9040, CR9060)

Supply to cab Return from cab

86062996

86063823

10.3L ENGINE (CR9070) Supply to cab

Return from cab

20018349

50-10

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 8 WATER VALVE Removal Shut the heater core supply and return valves located at the engine.

9L ENGINE (CR9040, CR9060)

Supply to cab Return from cab

86062996

86063823

10.3L ENGINE (CR9070) Supply to cab

Return from cab

20018349

50-11

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 8 Remove the five cap screws, 1, holding the ventilation system shield in place. Lift the shield from the combine.

1 1

1 1 10008343

27 NOTE: When removing heater hoses, residual coolant will drain.

Detach electrical connector, 1. Disconnect hoses 2 and 3. Remove the mounting cap screws, 4. Lift the water valve from the unit.

3 2

10008341

28 Installation Mount the water valve to the housing using two cap screws, 1. Attach electrical connector, 2. Connect heater hoses 3 and 4.

2 4 3

10008341

50-12

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 8 Set the ventilation system shield into place and secure using five cap screws, 1.

1 1

1 1 10008343

50-13

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 8 Open the water supply and return valves. Refill the coolant reservoir as required.

9L ENGINE (CR9040, CR9060)

Supply to cab Return from cab

86062996

86063823

10.3L ENGINE (CR9070) Supply to cab

Return from cab

20018349

50-14

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 8 WATER VALVE ACTUATOR Removal NOTE: The actuator can be removed without removing the water valve. Remove the five cap screws, 1, holding the ventilation system shield in place. Lift the shield from the combine.

1 1

1 1 10008343

33 Detach the electrical connector at 1. Remove the three screws, 2, holding the actuator to the valve. Lift the actuator from the valve.

1 2

Check the condition of the shaft coupler between the actuator and water valve. Replace if cracked or worn.

10010481

50-15

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 8 Installation Install the shaft coupler on the actuator shaft, and slide the water valve actuator onto the water valve stem. Turn in the three screws, 1. Attach the electrical connector at 2.

10010481

35 Set the ventilation system shield into place and secure using five cap screws, 1.

1 1

1 1 10008343

50-16

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 9

SECTION 50 -- CLIMATE CONTROL Chapter 9 -- High/Low Pressure Cutout Switch CONTENTS Section

Description

Page

50-1

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 9 DESCRIPTION OF OPERATION The high pressure cutout switch, 1, monitors the operating pressure on the high pressure side of the A/C system. The function of this switch is to prevent the compressor from operating when the pressure on the high side exceeds the preset operating limits. When actuated at 28.96 -- 26.20 bars (420 -- 380 psi) increasing, the electrical contacts in the switch open and secure power to the compressor clutch. The pressure switch will reset at 20.69 -- 17.93 bars (300 -- 260 psi) decreasing. The set point is not adjustable.

The low pressure cutout switch, 2, monitors the operating pressure on the low pressure side of the A/C system. The function of this switch is to prevent the compressor from operating when pressure on the low side is less than the preset operating limits. When actuated at .070 -- .482 bars (1 -- 7 psi) decreasing, the electrical contacts in the switch open and stop power to the compressor clutch. The pressure switch will reset at 2.134 -- 2.686 bars (31 -- 39 psi) increasing. The set point is not adjustable.

10008350

1 1

50-2

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 9 OVERHAUL HIGH PRESSURE SWITCH 1

Removal Recover refrigerant in accordance with the Refrigerant Recovery Procedure in this section. Remove the high pressure switch, 1, from the system. Installation Install the high pressure switch, 1, into the system. Recharge the refrigerant system in accordance with the Recharge/Refilling procedure in this section.

10008350

LOW PRESSURE SWITCH Removal Recover refrigerant in accordance with the Refrigerant Recovery Procedure in this section. Remove the low pressure switch, 1, from the system. Installation Install the low pressure switch, 1, into the system. Recharge the refrigerant system in accordance with the Recharge/Refilling procedure in this section.

10008350

1 3

50-3

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 9

50-4

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 10

SECTION 50 - CLIMATE CONTROL Chapter 10 - Receiver/Dryer CONTENTS Section

Description

Page

50-1

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 10 DESCRIPTION OF OPERATION The receiver/dryer, 1, located or on the right side of the cab platform is a storage tank that receives the high-pressure liquid refrigerant from the condenser through an inlet line. The refrigerant exits the receiver/dryer through an outlet connection and flows to the thermostatic expansion valve.

NOTE: Any moisture in the air conditioning system is extremely harmful. Moisture not absorbed by the dryer will circulate with the refrigerant. Droplets may collect and freeze in the thermostatic expansion valve restricting refrigerant flow. The moisture circulating in the system may also react with the refrigerant to form hydrochloric acid.

40021747

NOTE: In general, the receiver/dryer should be replaced any time the system is opened for service.

50-2

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 10 OVERHAUL RECEIVER/DRYER

Removal Recover the refrigerant in accordance with the Refrigerant Recovery Procedure in this section. Disconnect and cap the refrigerant lines, 1, from the receiver/dryer. Loosen the clamp, 2, holding the unit in place. Remove the unit from the combine.

40021747

2 Installation Set the receiver/dryer in place and secure by tightening clamp, 1. Inspect the O rings and replace if necessary. Lubricate the O rings with PAG oil, and uncap and connect refrigerant lines, 2. Tighten the lines to the correct torque of 31 -- 36 N⋅m (23 -- 27 ft-lbs).

Recharge the refrigerant system in accordance with the Recharge/Refilling procedure. 40021747

50-3

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 10

50-4

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 11

SECTION 50 - CLIMATE CONTROL Chapter 11 - Thermal Expansion Valve CONTENTS Section

Description

Page

50-1

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 11 DESCRIPTION OF OPERATION The thermal expansion valve, 1, is on the pressure line leading from the drier/receiver into the evaporator. The valve changes the liquid refrigerant from high to low pressure without a change from liquid to vapor. A thermostatically controlled valve within the expansion valve body controls the volume of liquid refrigerant passing through the orifice and makes sure the refrigerant is fully vaporized within the evaporator by sensing the amount of superheat of the vapor leaving the evaporator. Liquid refrigerant would damage the compressor.

10008352

The valve responds to changes in the cooling requirements of the system. When increased cooling is required, the valve opens to increase the refrigerant flow. When less cooling is required, the valve closes and decreases the refrigerant flow.

TEMPERATURE SENSOR

FROM EVAPORATOR

TO COMPRESSOR

TO EVAPORATOR

FROM CONDENSER

BALL AND SPRING

2 All of the needed temperature and pressure sensing functions are consolidated into this unit. No other external tubes are required for its operation.

50-2

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 11 When the compressor is off, pressure, (system plus spring pressure), below the actuating diaphragm, 1, is greater than the pressure above it. The metering ball, 2, is held tightly against the seat by the spring, and no flow is present through the valve.

70-610-1172

2 3

Upon initial startup of the compressor, the pressure drops rapidly in area 1. The pressure above the diaphragm is now greater than that below. The actuating rod pushes down, unseating the ball and allowing refrigerant to flow to the evaporator.

During operation, the pressure below the diaphragm will change and adjust valve position to maintain eight degrees superheat of the refrigerant flowing from the evaporator.

70-610-1173

50-3

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 11 OVERHAUL THERMAL EXPANSION VALVE

Removal Remove the five cap screws, 1, holding the ventilation system shield in place. Lift the shield from the combine.

Recover refrigerant in accordance with the Refrigerant Recovery Procedure in this section.

1 1 10008343

5 Fold back the insulation from the thermal expansion valve. Disconnect refrigerant lines, 1, and cap them to prevent moisture or foreign material from entering the system. Remove the cap screws, 2, and remove the valve from the core.

10008352

1 6

50-4

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 11 Installation Set the thermal expansion valve into position and secure it with two cap screws, 1. Apply refrigerant oil to the O rings and connect the four refrigerant lines, 2. Torque the lines to 31 -- 36 N⋅m (23 -- 27 ft-lbs).

Wrap the valve and attached lines with insulation.

Recharge the refrigerant system in accordance with the Recharge/Refilling procedure in this section.

10008352

7 Set the ventilation system shield into place and secure using five cap screws, 1.

1 1

1 1 10008343

50-5

SECTION 50 -- CLIMATE CONTROL -- CHAPTER 11

50-6

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 1 -- General Information CONTENTS Section

Description

Page

55-1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 Section

Description

Page

55-2

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 OVERVIEW

BSC1362

1 All of the modules communicate information from the combine sensors, switches and operator controls to each other and to the IntelliView (II or Plus II) display, and then drive the appropriate outputs, such as solenoids and actuators. The operator instructs the electronic modules what to do, the modules interpret the commands, and direct the combine sub systems to complete the functions as required. In addition, the modules check for faults and display or store this information as required for reference in servicing. The modules also provide built-in diagnostics, allowing the technician to monitor activity, or test devices directly through the modules.

The CR combines use the latest technology in electronics to provide excellent reliability and serviceability, and to provide enhanced functionality. The system consists of several electronic modules, along with conventional copper wiring to all devices and sensors. The electronic modules are connected together using a special twisted copper wire pair, that allows the modules to communicate with each other using two Controller Area Networks (CAN 1 and 2) technology. This technology allows the modules to perform many functions through the use of shared input and output resources, thus minimizing sensors and wiring components on the combine.

55-3

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 10

9 3

4 5

7 50020058

6 2

The CR combine is equipped with a minimum of 7 electronic modules, and may be equipped with as many as 11 modules, depending on the configuration and options installed. These modules are:

from the feeder angle and lift pressure sensors on the combine and height sensors on the header, and controls the accumulator, header raise/lower and header tilt solenoids.

Main Display Module (MDM), 1, or IntelliView (II or Plus II) monitor; provides the main display of information for the operator.

Advanced stone protection (ASP) module, 6, is located on the left side of the feeder. It processes signals from the ASP sensors, and opens the stone door when necessary.

Right Hand Module (RHM), 3; most operator inputs, including from the multi-function handle (MFH), are fed into this module, which then reports this information to the other modules in the network for action.

Chassis Control Module 3 (CCM3), 7, [optional] is installed and used to control certain options on the combine, such as the precision farming devices.

Chassis Control Module 1 (CCM1) and 2 (CCM2), 4; these modules drive most of the actuators and solenoids, and monitor most of the sensors and switches on the combine.

Differential GPS module, 9, [optional] is available with some precision farming systems, and provides location data to be recorded with the harvest data for mapping purposes (navigation control module).

Header Height Control (HHC), 5, module is located on the main stack valve assembly. It receives inputs

Engine Control Unit (ECU), 10, is installed to provide enhanced engine control and performance.

55-4

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 A Diagnostic and Maintenance (DAM) connector, 1, allows the NH Electronic Service Tool (EST) to be connected to the network, in order to load new operating software into the modules, and to provide more detailed testing and diagnostic abilities.

55-5

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 INTRODUCTION TO TROUBLESHOOTING FAULT CODES AND FAULT FINDING Troubleshooting and fault finding of the electrical system should always be carried out in a logical and planned sequence. Many apparent faults associated with electronic components are often hastily diagnosed and result in the replacement of expensive components. An extra few minutes confirming the apparent fault will result in a more positive and cost effective repair. The CR combines have a built in diagnostic capabilities to assist the operator and service technician to identify and locate the source of electrical system concerns. The IntelliView (II or Plus II) monitor is used to indicate, in coded format, any malfunction detected in the electrical and electronic systems. Two different coded formats are used to indicate concerns; alarms and errors. An alarm is an indication of some mechanical condition on the vehicle, and alerts the operator to perform necessary maintenance, or to change operating conditions to correct the alarm condition. Examples of alarms would be to indicate an engine overheat condition, blocked filters, or improper control operation. Alarms are not used to indicate faults with electrical circuits.

20072409

4 An error is an indication of a fault with an electrical circuit or component, and alerts the operator that the circuit or component is no longer functioning. Examples of error messages include open circuits, shorts to ground, or short to high voltage. These errors are typically the result of wire harness damage, or sensor misadjustment or failure. When investigating an electrical concern, the first step is to fully understand the problem. Get a clear description of the concern from the operator, and if possible, operate the vehicle to confirm the problem. 20072367

55-6

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 Once the problem is clearly identified, use the “Diagnostic” screens of the IntelliView (II or Plus II) monitor to determine if any alarm or error messages exist that relate to the problem. If related error messages are found, a diagnostic screen showing voltage, current or frequencies for that specific circuit are available to assist in pinpointing the source of the problem. In most cases, circuit testing may be accomplished using only the on-board diagnostic capabilities. Diagnostic procedures for each error code are detailed in this manual. Most of the procedures will contain reference to using the “Graph” screen as the first step in the process.

20072394

NOTE: Use of the “Diagnostic” screens, monitoring and activation capabilities, is discussed in the next chapter of this Repair Manual. Where the fault finding procedure requires checks for continuity, a visual inspection of the wiring should be made prior to conducting any test to ensure that obvious ‘mechanical’ damage has not occurred to the harness or connectors. In some cases, use of a multimeter will be necessary to locate the source of the fault. A good quality multimeter, capable of measuring voltage, current, and resistance of at least 20,000 ohms, is an essential item to perform fault finding. IMPORTANT: Use of powered test lights or any 12 volt source to test or activate electrical circuits may result in internal failure of the computer modules. Never apply a 12 volt source directly to a solenoid or other device to prevent damage to the combine electrical system. When using a multimeter, it is good practice to select a high range and work downwards to avoid damaging the instrument. Refer to the Operator’s manual supplied with the meter, and to the ‘Basic Multimeter Use” section of this chapter for further details. IMPORTANT: Care should be taken when using the multimeter. Use the instrument only as instructed to avoid damage to the internal elements of the microprocessors on the combine. When checking the continuity of wiring, sensors or switches, it is necessary to isolate the combine modules and ensure the key switch is turned off to prevent possible further damage. The key switch should only be switched on and the combine modules connected where specifically instructed in the fault finding procedure.

55-7

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 During fault finding, it will often be necessary to uncouple connectors for inspection, or to provide access for testing. When using the combine on-board diagnostics, uncoupling connectors as directed in the fault finding procedures will often be necessary to locate the source of the fault. Unless specifically noted, connectors should not be back-probed using test spoons or other tools, to prevent damage to the connector and wire seals.

50032238

CAUTION

The CR combine is comprised of a variety of electrical--mechanical and electrical--hydraulic configurations used to control or monitor the functions of the combine. The electrical devices, therefore, may provide fault indications that are not electrical. If a mechanically operated switch or sensor is not indicating properly the fault may be in the mechanical actuator assembly or the distance and/or orientation of the sensor. In the case of the non-contact sensors that are actuated by a target (usually ferrous material) metallic debris and/or filings suspended in fluid can cause a fault condition. Some of the sensors incorporate magnetic properties to function and therefore may attract and collect ferrous particles, thus provide improper signals. Solenoids used to operate valves to control directions and flow of air or fluids (hydraulics) may be functioning properly electrically, however loose connections, crimped or blocked tubing or hoses, insufficient, contaminated or incorrect fluids may cause certain functions to operate improperly or not at all. Electric motors and actuators may not operate or operate improperly (over current) because of bound, misaligned, or damaged mechanical components directly or indirectly controlled by the electrical device. It is important to take these and other possibilities into consideration when troubleshooting the combine’s complex systems.

Never couple or uncouple electrical connectors while the engine is running, to prevent machine damage and personal injury due to electrical shock.

WARNING To avoid personal injury, never attempt to access electrical connectors under the cab while the engine is running. Accidental contact with the feeder angle sensor or inappropriate access to the electrical circuits to the modules may cause the feeder to move unexpectedly, resulting in personal injury or death. IMPORTANT: The under-cab connectors to the chassis control modules (CCM’s) do not normally need to be accessed for diagnostic purposes. Repeated coupling and uncoupling of these connectors will result in seal and connector damage, causing electrical circuit failures. If it is found necessary to clean the connectors a contact spray should be used. DO NOT USE ANY OTHER METHOD FOR CLEANING TERMINALS. Do not use a cleaner that contains Trichloro-ethylene, this solvent will damage the plastic body of the connector.

55-8

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 THE DIGITAL MULTI-METER NOTE: This section is only intended as a general guide to using a digital multimeter. Always refer to the manufacturer’s operators manual for correct operation.

A multimeter is an electronic measuring device. The different types of measurement that can be made depend upon the make and model of the multimeter. Most types of multimeter have the capacity to measure: • • • •

Current (A) ac or dc Resistance (Ω) Voltage (V) ac or dc Continuity (Buzz test)

More expensive multimeters have other functions, such as the capacity to measure frequency (Hz) and test diodes.

General Operation Before proceeding with a test, decide on what is going to be measured (Voltage, Current etc.). Rotate the dial until the pointer is within the relevant zone. Within each zone there are different scales. The scale that is selected will represent the maximum value that the multimeter will read. Always select a scale which is greater than the value that you intend to measure. If you are unsure of the value to be measured, always select the highest scale and then reduce the scale once you have an idea of the measured value.

9 The closer that the scale is to the measured value, the more accurate the reading will be: e.g., if measuring the voltage of a battery with the scale set at 200V, the display may read 12V. However, if the scale was set to 20V the display may read a more accurate reading of 12.27V.

55-9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 Measuring Voltage (Volts) Set the range dial to either ac or dc volts. Connect the Black test probe to the “COM” terminal and the Red test probe to the “V/Ω” terminal. Place the test probes across the component to be measured with the circuit complete (closed). Read off the display value

11 Measuring Current (Amps) Set the range dial to either ac or dc current. When measuring current up to 2 amps, connect the Red test probe to the “A” terminal. When measuring current up to 10 amps, connect the Red test probe to the 10 “A” terminal. Always connect the Black test probe to the “COM” terminal. When taking measurement of current, always break the circuit and connect the multi meter in series with the circuit. Read off the display value. NOTE: For protection, multi meters are usually fused at 10A.

12 Measuring Resistance (Ohms) Set the range dial to the desired Q position. Connect the Red test probe to the “V/Ω” terminal. Connect the Black test probe to the “COM” terminal. If the resistance being measured is connected in a circuit, then turn off the power to the circuit. Connect the test probes to the measuring point and read off the display value.

55-10

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 Continuity (Buzzer) Test Set the range dial to the “Buzz” position. Connect the Red test probe to the “V/Ω” terminal. Connect the Black test probe to the “COM” terminal. Connect the test probes to the measuring point. In general, if the resistance is less than 50Ω then the buzzer will sound, indicating continuity.

14 NOTE: Buzzers on different multi meters will sound at different ohmic values, depending on the quality of the meter. This can often be misleading. For example, when checking a corroded earth point, a poor quality multi meter may buzz at 150Ω, indicating continuity and no problem. When using a higher quality multi meter for the same test, it would not buzz due to the high resistance. When carrying out such tests, we should always check the value of resistance as well as listening out for the buzz. A good connection gives low resistance. A bad connection gives high resistance.

15 Summary When measuring: Voltage (V) Connect across the component with the circuit closed. Current (A) Connect in series with the circuit. Circuit closed. Resistance (Ω) Connect across the component with the circuit open. Continuity (Buzz) Connect the meter across the component with the circuit open. (Always check the value of resistance as well!!).

55-11

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 ELECTRICAL TEST PROCEDURES Four electrical tests will be required to properly troubleshoot electrical concerns on the combine. Each test is described in detail. Ensure that all steps are reviewed and followed when testing. 1. 2. 3. 4.

Continuity Test, Short to ground Voltage measurement, short to 12 volts Resistance test for components Continuity test, Open circuits

ELECTRICAL TEST PROCEDURE 1: CONTINUITY TEST - SHORT TO GROUND 1. Power OFF, Keyswitch OFF, (sometimes battery disconnected or fuse pulled out if specified in procedure). 2. Connectors at each end or ends of circuit disconnected to prevent false readings. 3. Set meter to measure resistance or ohms, and measure circuit resistance. Use black lead to make contact with a plated metal part on the chassis such as a jump start post if fitted. Make sure the surface of the part is not corroded. Use the red meter lead to touch the connector pins, one pin at a time, and avoid contact with the case of metal connectors. 4. Determine if measured resistance falls within guidelines specified in the procedure. 3 to 4 ohms indicates a direct short to chassis ground and must be located and repaired. Higher resistances usually indicate circuit paths through modules, and that an additional connector needs to be disconnected to perform the test. More than 100K ohms indicates that the circuit is free of shorts to ground. NOTE: Most of the input and output devices use a reference or chassis ground, therefore it is important to remove this intended circuit ground before testing for a “Short to Ground” condition. If the circuit is not isolated from intended ground, readings of 3 to 4 ohms to ground could be acceptable.

55-12

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 ELECTRICAL TEST PROCEDURE 2: VOLTAGE MEASUREMENT OR SHORT TO POSITIVE SUPPLY VOLTS 1. Keyswitch ON (sometimes OFF, if specified in procedure). 2. Connectors at sensor, switch or potentiometer end disconnected. All other connectors must be reconnected to perform test. 3. Set meter to measure DC VOLTS, and measure circuit voltage as illustrated. Use the red meter lead to touch the connector pins, one pin at a time, and avoid contact with the case of metal connectors. Use the black lead to make contact with a plated metal part on the chassis such as a jump start post if fitted. Make sure the surface of the part is not corroded. 4. Determine if measured voltage falls within guidelines specified in the procedure.

ELECTRICAL TEST PROCEDURE 3: RESISTANCE TEST FOR ELECTRICAL PARTS 1. Disconnect part by unplugging electrical connectors to expose the part assembly connector for testing. 2. Set electrical meter to measure resistance or Ohms and insert test probes into connector terminals specified in procedure. When checking potentiometers, measure from wiper terminal to each of the other terminals while TURNING THE POT SHAFT. This will ensure no open spots escape detection. When checking rocker or rotary switches, actuate the switch while measuring for opens and shorts. 3. Compare measured values to values specified in the fault code procedures. Allow plus or minus 5 percent of range tolerance for all measurements. NOTE: Many input and output devices can be tested using a Digital Multi-meter to test resistance of the device. However this is not true in all cases. Some devices, mostly electronic, are considered active devices which means they require power to function. The DVOM may not provide the required power (voltage / current) to accurately test the device or may require multiple lead configurations to source and test the device.

55-13

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 ELECTRICAL TEST PROCEDURE 4: CONTINUITY TEST - CHECK FOR OPEN CIRCUITS 1. Keyswitch OFF (sometimes disconnect battery or pull fuses). 2. Connectors at both ends of the circuit disconnected. All other connectors must be reconnected to perform test. 3. Set meter to measure resistance or ohms, and measure circuit resistance as illustrated. Use the red meter lead to touch the connector pins, one pin at a time, and avoid contact with the case of metal connectors. Use the black lead to make contact with the connector pin at the other end of the circuit. Avoid contact with other pins in the connector and the connector case, if it is metal. 4. Determine if measured resistance falls within guidelines specified in the procedure. If the resistance is no more than 3 to 4 ohms, the circuit is continuous. More resistance usually indicates dirty or corroded terminals in connectors, and 100K ohms or greater indicates an open circuit. NOTE: Testing continuity as shown from one end to the other of a circuit is often not possible. The alternate method used in the troubleshooting procedures in this Repair Manual require a jumper lead (wire). One end of the circuit would be grounded with the jumper and the other end of the circuit would be tested to ground.

55-14

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 CIRCUIT COMPONENTS - BASIC DESCRIPTION AND TESTING FUSES Fuses protect circuits with thin pieces of metal and wire which heat up and melt to open up the circuit when too much current flows through them. The combine fuse panel, 1, is located in the left rear corner of the cab, behind a removable panel. Fuses are used to protect the circuit from overload. This can occur in the event of a short circuit or by connecting equipment which demands a current greater than the circuit is designed to carry. There are several types of fuses, but they all consist of a metal conductor which is capable of carrying a limited current. If the specified current is exceeded then the metal conductor will overheat, causing it to melt and break. This will in turn cause an open circuit.

50020070

20 The rating of the fuse relates to the current that the fuse can carry continuously. If a fuse blows, it must be replaced with a fuse of the correct rating, and if it blows again, then the cause must be investigated. A fuse may be tested by checking continuity across the fuse on the two exposed terminals, 1. NOTE: Care must be taken in performing continuity tests of fuses in the panel (circuit). Some fuses are connected to battery supply voltage (B +12v). A preferred test for these would be a voltage test to ground from one of the exposed fuse terminals and then the other, battery voltage should be seen on both tests (terminals).

55-15

1 50014700

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 SWITCHES Switches are a vital part of an electric circuit, providing a method of controlling the circuit itself. One switch can control a number of different circuits at the same time. This is achieved by having several separate connections and/or multi-connector switches (several switch positions’). There are several types of switches, and they may incorporate a warning light.

22 Switches can be as simple as that used to turn on an implement lamp or as complex as the ones used to operate the starting and lighting systems. Checking the operation of switches is usually just a matter of testing for power going into the switch and for power leaving the switch at the appropriate contacts when the switch is operated. One of the most common type of switches is the pressure switch, a switch opened or closed by a fluid pressure. An example of this type of switch is the charge pressure switch, a simple on/off device that opens (or closes) when oil pressure rises or lowers past a preset value.

FLASHERS Flashers work automatically to interrupt and connect the flow of current. In the flasher, a heating element warms a bimetallic strip. The strip bends, breaking contact with the power source. When it cools, the bimetallic strip once again makes contact and the process begins again.

55-16

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 RESISTANCE DEVICES A number of electrical components alter or make use of electricity through their resistance to current flow. Resistors are components which are generally used to regulate the supply of voltage and current to other electrical components. In some cases, the purpose of resistance in an electrical circuit is to provide light or heat. Lamps and cigar lighters are examples. Lamps convert electricity into light, and cigar lighters convert it into heat. Both lamps and lighters make use of the same physical principle, that is Ohms Law. The engine grid heater and heated cab mirrors are other examples of resistance devices designed to convert electricity into heat.

FLUID LEVEL SENDER It operates by varying resistance through the movement of a float. An example is the fuel level sender.

POTENTIOMETERS Potentiometers are variable resistors which are dependant on mechanical movement, i.e. Lateral float movement, to vary the resistance of the component and therefore alter the output voltage. In order to verify the correct operation of a potentiometer, the resistance should be measured at the minimum and maximum positions and a smooth and continuous change of resistance should be observed between. As the resistance varies with temperature, the test specifications are usually given at 20 °C. 27

55-17

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 POTENTIOMETER ADJUSTMENT When installing potentiometers, it is important to ensure that they do not bottom out in either direction, to prevent damage. Most potentiometers have slotted mounting holes to allow some adjustment. Before tightening the mounting hardware, operate the attaching linkage fully in both directions to confirm proper potentiometer positioning. The feeder angle sensor, 1, and optional header stubble height potentiometers (not shown) require further adjustment to provide proper HHC operation as follows: a. Enter the IntelliView (II or Plus II) monitor Diagnostic screen for the potentiometer. b. Adjust the potentiometer so that the indicated voltage on the screen stays within a range of 2.5V to 7.5V throughout the normal operating motion of the potentiometer. In practice, this is most easily accomplished by raising the feeder fully, and adjust the potentiometers so that the diagnostic screen indicates less than 7.5V.

55-18

40025215

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 ELECTROMAGNETIC DEVICES In general, they use the magnetic field created by flowing current to move metal parts within the components.

RELAYS The relay is an electromagnetic switch that uses a small amount of current to switch a larger amount on and off. When the operator closes a switch, current flows through the relay’s control circuit. In this circuit there are windings surrounding an iron core which is fixed in place. Current turns the iron core into an electromagnet. The core then attracts an arm which has a contact point on it. When the point on the arm contacts the stationary point, current flows through the power circuit. Relays are basically electrically operated switches. They are used to switch a circuit on/off in similar way to a manual switch. Two circuits are connected to the relay: •

A work circuit, which is switched on/off by the relay, and provides the supply for the equipment to be operated, i.e., bulbs, solenoids, etc.

•

A control circuit, switched on/off by manual switches, used to operate the relay.

The part of the relay which is connected to the control circuit consists of the winding of an electro-magnet. When the control circuit is switched off, the contacts are kept apart by a return spring. When the control circuit is switched on, a current flows through the coil and a magnetic force is produced. This force, which is stronger than the spring pressure, pulls the contacts of the relay together, causing the work circuit to operate.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 A switch-relay system has two main advantages over a simple switch: •

The current that flows through the switch is not the same as all the current requested by the equipment to be operated, but usually by a smaller current: this allows the usage of smaller and less expensive switches.

•

The distance from the supply, to the equipment, can be made as short as possible to minimize voltage drop.

30 There are five styles of relays used on the CR combine. The micro relay, 1, is the most commonly used relay, and is used on all but two locations on the fuse panel in the cab. One mini relay, 2, is used in the top left position of the fuse panel in the cab, while a time delay relay, 3, is used in the top right position of the fuse panel for controlling the cab interior light and side lights. The fourth style of relay is the start relay, 4, which is located in the engine compartment. The fifth style of relay is the grid heater relay (not shown) located on the engine. On the relay cover there are 4 or 5 terminal markings: • 3 or 30: input terminal direct from battery positive, normally live. • 2 or 85: winding output terminal, usually to ground. • 1 or 86: winding input terminal. • 4 or 87: output terminal for normally closed contact. • 5 or 87a: output terminal for normally open contact.

2 1 50004701

SOLENOIDS Solenoids work in much the same way as relays, except that the iron core is not fixed in place. As a result, the windings in the control circuit cause the iron core to move. In the starting system, for example, the movement of this core is used to send large amounts of current to the starter motor. A solenoid is basically a winding around an iron core. In the centre of the core there is a plunger which is free to move through the core. When an electrical current passes through the winding an electro-magnetic force is produced which causes the plunger to move through the core. If the current is switched off, the magnetic force is stopped and the plunger is returned by a spring.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 The solenoid plunger may have different uses: the most common are moving a hydraulic spool or a mechanical lever. The MOST COMMON FAULTS that can occur are: •

Short circuit winding: if a section of the winding allows the current to pass directly from positive (+) to negative (--) terminals without passing through the winding, this will cause the relevant circuit fuse to blow.

•

Broken winding: causing an open circuit, it will not allow the current to pass through the winding, so the solenoid will not operate.

•

Seized plunger (and/or connected components): the solenoid will only move the plunger if all components are free to move.

PWM SOLENOID VALVES Whenever it is necessary to provide proportional control to the solenoid valves, it is much better to use a principle of operation called pulse width modulation (PWM). PWM is a variable DC voltage signal that is used to control the solenoid valves. The voltage signal is pulsed on and off many times a second (at a constant frequency of 500 Hz) at a constant supply voltage of 12 V.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 The CCM modules contain transistors that are supplied with a constant input voltage which is switched on and off to achieve the variable input range. In this way the control module is able to limit the armature movement, so the hydraulic output flow of the solenoid is proportional to the average DC voltage. The lower voltage also allows the solenoid to operate with less residual magnetism and so the entire circuit will operate smoother. The variable DC voltage signal level is determined by varying the duration of the ON pulse relative to the OFF pulse. The ratio between the ON time and the cycle time is called duty cycle and is stated as a percentage of one complete cycle. Diagrams, 1 to 3, show the normal operating range of the PWM valve, and diagram 4, shows the initial 12V programming and fill time only. The diagrams in column A show the voltage signal that is sent to the valve, whereas column B shows the relevant spring pressure and column C the reading on a voltmeter connected to the solenoid valve. Diagram, 1, shows the OFF position: no signal is directed to the valve, which means no spring pressure in the valve at all and results in a zero voltage reading. Increasing the duty cycle causes some pressure to be made on the circuit (Diagram 2), which results in a voltmeter reading increase. Diagram, 3, shows the maximum signal that is used during the normal activity of the valve: its duty cycle is around 0.5, which results in a spring pressure for the half of its run and in an indication of a 6 volt average DC current. The electrical circuit to the solenoids can be checked by using a digital or analogue DC voltmeter, which will indicate the average voltage readings.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 SENSORS A sensor is the primary component of a measurement chain that converts the input variable (temperature, capacitance, reluctance) into a signal suitable for measurement. The relationship between the input variable and the measured signal is a characteristic of the sensor. In the above mentioned measurement chain the signal is filtered and treated in order to adapt it to its use. It consists of three elements: the sensor itself; the converter, which converts the output signal from the sensor (in most of the cases into an electric signal); and the conditioner, which transforms the output signal from the converter in the most suitable form. Generally the term sensor indicates the entire measurement chain.

TEMPERATURE SENSORS Generally based on a simple circuit with a thermistor. A thermistor is a resistor that changes its resistance according to the temperature. There are two groups of thermistors: NTC (Negative Temperature Coefficient) and PTC (Positive Temperature Coefficient). In the first case the higher the temperature, the lower is the resistance, and for the PTC the higher the temperature, the higher the resistance. The NTC are often used as sensors to indicate temperature change in fluids, such as the engine coolant fluid. An example of these type of sensors is the coolant temperature sensor. The changes in its resistance (which varies with temperature) are relayed to the IntelliView (II or Plus II) monitor, which operates the bargraph and the warning indicators accordingly.

PRESSURE SENSOR A pressure sensor receives a supply signal and it varies it according to the (oil) pressure. An example is the oil pressure sensor, which receives a 5 volt signal and varies it according to the oil pressure. The appropriate module keeps track of these variations and changes its readouts and warnings accordingly.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 SPEED AND POSITION SENSORS The speed sensors and some of the position sensors used on the CR combine are a two-wire active (requires an electrical source to function) device, therefore a source and ground are supplied to the sensor. Non-contact sensing of the target (ferrous material) is performed by the sensor in different ways (generally electro-magnetic coupling) which affects the source (typically a switch like affect, from one level to another). The altered source may or may not be conditioned by the sensor. The module monitoring the sensor uses the sensor signal (affected source) to produce on and off signals for digital processing. For speed sensing this would relate to how many pulses (off to on or on to off transitions) during an established period of time and for position sensing the level of the signal (on or off). In the example when the unload tube is not cradled the source level is 7.3 volts, 1 and when cradled the source level is 6.9 volts, 2. These sensors can not be effectively checked out-of-circuit with only a DVOM. If the sensor is faulty and the sensor circuit is complete, use the diagnostic capability of the display monitor to test the sensor functionality in-circuit.

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20072410

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 ELECTRONIC MODULES (CCM’S) OVERVIEW The electronic modules are the “black boxes” that provide control on many of the functions of the combine. These functions may vary according to the options that are fitted on the combine. Inside these “black boxes” there is a processor, the “thinking part” of the module, and inside some of them there is one or more memories, which may allow the module to store calibration values, the configuration of the vehicle (which optional tools or devices have been installed) and the error codes. 38 A processor has a series of pins, which are electrical contacts. There are three main types of pins: for the inputs of the signals, for the outputs and for the processor supply. The processor, the memories and the link between them form the hardware of the module, its “physical” part. Then some software is needed, to handle the communication between the processor and the memories and to manage the various signals going into and out of the processor. The software is designed to operate in a different way for every module, and is called functional code. The electronic modules are often blamed as responsible for most of the problems of the modern vehicles, while they are for certain among the most protected parts of the vehicle. In fact, the pins of the module are protected against spikes (high pulses) of current, and the signals are filtered by the hardware and by the software in input and in output to give the best handling of information.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 CCM POWER AND GROUND SUPPLIES

Each CCM module has two main power supplies. Keep Alive power is supplied to the module at interior connector pin 1, while the main power supply is provided from the key switch at the interior connector pin 4. The module will shutdown if the voltage drops below 9V or exceeds 18V on either of these two circuits. Key switch power is also used to supply the 5V and 8V regulators for voltage outputs to sensors and potentiometers. Each CCM module has three main ground wires to provide a ground path for all sensors and most valve outputs. These three ground wires are linked together internally, but provide a solid ground path for the module. The module may continue to function if one or two of these ground wires are broken, but sensor reading and other functions may become erratic.

Some circuits on the CCM’s provide their own power supply through the engaging switch. This ensures that if power is ever lost through the switch into the module, the output from the module is immediately disengaged. These circuits are the ground speed hydrostat circuit (power supplied through the S22 Neutral switch), thresher engage and feeder engage circuits. H-bridge circuits in the modules are used to power high current draw components, such as motors and actuators, and have their own dedicated power supplies and grounds, as listed in the charts below.

CCM1 Module Power Supply

Ground

Components Affected

X018 pin 1 (F39)

Keep Alive power

X018 pin 4 (F38, key switch)

Main power; all potentiometers, speed and position sensors X018 pin 8, X019 pins 12 & 18 Main module grounds

X020 pins 29 & 30 (F22)

X020 pins 9 & 10

Shoe Leveling Actuator

X020 pin 7 (F24)

X020 pin 16

Feeder Reverser actuator

X019 pin 11 (F24)

X019 pin 3

Concave Clearance motor Covers motor

X019 pin 2 (F43)

Chaff Spreader fan drive solenoid

X019 pin 9 (F43)

Backup Alarm Feeder Increase Feeder Decrease Rear Wheel Assist

X020 pin 11 (F44)

Feeder Jog Forward Feeder Jog Reverse Fan/Reverser relay Dual Range

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 CCM2 Module Power Supply

Ground

Components Affected

X015 pin 1 (F39)

Keep Alive power

X015 pin 4 (F38, key switch)

Main power; all potentiometers, speed and position sensors X015 pin 8, X016 pins 12 & 18 Main module grounds

X017 pins 29 & 30 (F25)

X017 pins 9 & 10

Transmission Shift motor

X017 pin 7 (F23)

X017 pin 16

Reel Speed motor

X016 pin 11 (F23)

X016 pin 3

Rotary Screen Brush

X016 pin 2 (F36)

Unload Tube clutch Brake Limiting Park Brake Disengage

X016 pin 9 (F37)

Unload Tube In Unload Tube Out Rotor Increase Rotor Decrease

X017 pin 11 (F36)

Reel Fore Reel Aft Reel Up Reel Down Reel Drive Pressure Release

CCM3 Module Power Supply

Ground

Components Affected

X012 pin 1 (F39)

Keep Alive power

X012 pin 4 (F38, key switch)

Main power; all potentiometers, speed and position sensors X012 pin 8, X013 pins 12 & 18 Main module grounds

X014 pins 29 & 30 (F26)

X014 pins 9 & 10

Turntable Actuator (EU)

X014 pin 7 (F27)

X014 pin 16

Spreader Plates motor

X013 pin 11 (F27)

X013 pin 3

Upper Sieve actuator Lower Sieve actuator

X013 pins 2 & 9 (F47)

Sample motor Vertical knives (EU)

X014 pin 11 (F47)

Steer Right solenoid Steer Left solenoid Steer Enable solenoid

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 COMBINE CONTROL MODULE (CCM) REMOVAL AND INSTALLATION The CCM’s are located under the storage box of the instructional seat. The instructional seat must be removed to access the CCM’s. The CCM’s should be disconnected from the harness before removing. The harness connectors are located under the cab floor. CCM Identification ITEM

DESCRIPTION

CCM 1

CCM 2

CCM 3 (If equipped)

1 3

10004693

40 Instructional Seat Removal 1. Raise bottom cushion and attach strap 1. 2. Loosen two bolts, 2, at bottom of seat back. 3. Lift seat back assembly up and forward to remove from rear of cab. 4. Remove storage box 3.

1 3

50021851

2 41

Removal of CCM The connectors, 1, are located under the cab floor left of the center line of the combine.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 1. Peel back connector boots, 1. IMPORTANT: Before removing, if connectors are not marked, label the connections for proper installation.

2. Unthread the captured connector screws, 2, and remove connectors. 3. Remove the two mounting nuts and lock washers, 3.

3 1

50032237

43 4. To disconnect connector,1, unthread captured screw, 2.

5. Carefully remove module from combine. NOTE: It may be necessary to remove the seven screws, 3, from the base of the instructional seat to provide clearance to remove the CCM.

3 1

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2 44

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 CCM Installation 1. Inspect the gaskets that seal the connector slots in the cab floor for signs of deterioration, replace as required.

2. Place the CCM mounting studs through the floor of the cab. Connect the appropriate connector, 1, to the CCM. Tighten captured screw, 2, to secure connector to CCM.

3 1

10004693

45 3. Install lock washers and thread nuts, 1, onto mounting studs of CCM. Tighten nuts to standard torque.

4. Inspect the seals on the connectors, clean or replace as required. 5. Install the connector with the corresponding decal on the underside of the cab floor. Thread in captured screw of connector, 2, and tighten to standard torque.

1 3

6. Fold protective boots, 3, around connectors. 50032237

Software Installation IMPORTANT: The CCM must be loaded with software.

Refer to the appropriate Electronic Service Tool User’s Guide for software download instructions. Instructional Seat Installation 1. Tighten the seven screws that secure the base of the instructional seat to the cab frame. 2. Insert the storage box, 3.

3. Slide seat onto the 4 bolts by pushing the seat back and downward against the rear of the cab. Make sure the top two bolts fit into the notches on the seat back.

4. Tighten two bolts, 2, at the bottom of the seat back. 5. Release the strap, 1, on the seat cushion.

50021851

2 47

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 SPECIAL TOOLS

WIRING HARNESS REPAIRS

Europe Only Description

Tool No.

Harness Repair Kit (Except North America)

294070

Test Probe Kit (Except North America)

297448

Pin Removal Tool, Bosch Module Connector

84021087

Deutsch Extraction Tool

84400044

Deutsch Contact Crimp Tool

84400045

Deutsch Retraction Tool, DT Series Wedge

84400046

Packard Contact Crimp Tool

84400047

Packard Terminal Removal Tool

84400048

North America Only FNH01000 Electrical Repair Tool Kit

20013704

48 Digital Multimeter OEM 1428A.

55-31

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 TEMPORARY WIRING HARNESS REPAIR The following method to repair wiring is a temporary expedient only. Wiring should be replaced as soon as possible. Do not attempt to repair the wire on any system sensors as these are sealed and should only be replaced with a new component. NOTE: When conducting a cable repair it is important that only RESIN CORED SOLDER is used. Use of other types of solder may result in further cable damage. To carry out a temporary repair, proceed as follows: 1. Locate damaged portion of cable then cut away outer protective cover on both sides of the damaged area.

50 2. Peel back the cable from both ends of the damaged area and carefully cut away the inner cable cover at the damaged area and strip about 13 mm (1/2″) of insulation from the wires. Do not cut away any wire strands. 3. Using a suitable solvent, clean about 2 inches (50 mm) from each cover end. Clean the grey cable cover and the individual leads. 4. Twist two bare leads together for each damaged lead, being careful to match wire colours, then solder the leads using resin cored solder. Tape each repaired lead with vinyl insulation tape. 51

55-32

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 5. Wind a layer of vinyl insulation tape up to the grey cable cover at each end of the repair section. Make a paper trough, then apply silicon rubber compound (non hardening sealant) over the repaired section up to the cover ends. Sufficient sealant must be used to fill the ends of the cut away area.

52 6. Allow the compound to cure then cover the area with insulating tape taking the tape well over each end of the repair. An overlap of at least 2 inches (50 mm) of tape at each end is necessary. 7. Check to ensure the repair is satisfactory and secure the repaired cable so that repeat damage is avoided. NOTE: This is a temporary repair only. Ensure the damaged cable is replaced as soon as possible to prevent ingress of water or chemicals. 53

HARNESS WIRE REPLACEMENT If a wire within the harness is found to be beyond repair or is open circuit, a jumper wire may be installed as a temporary repair until such time when a new harness assembly can be installed. Use the following procedure to install an additional wire: 1. Locate the faulty wire using the procedures described in the fault code charts. 2. Disconnect the affected connectors. 3. If fitted carefully roll back the seal between the connector and harness outer covering. 4. Remove the pins from the connector blocks of the affected wire using the appropriate removal tool found in the harness repair kit. NOTE: Use the instructions supplied with the kit to ensure correct pin removal.

55-33

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 5. From the harness repair kit select the correct pin for the connectors. Obtain locally the correct cross-sectional size wire and measure out the length required by following the harness routing. 6. Join the new wire to the new pins as described in the harness repair kit and install one of the pins into its connector. 7. If possible attempt to run the new wire within the existing harness outer covering, if this is not possible run the wire along the harness, securing regularly with suitable ties. With the wire correctly routed install the second terminal into its connector block. Replace the connector seal if removed. 8. To ensure that the repair has been effective check for continuity of the new wire using a suitable multi-meter. NOTE: This is a temporary repair only. Ensure the damaged cable is replaced as soon as possible to prevent ingress of water or chemicals.

55-34

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 CAB ELECTRICAL CONNECTORS X002 AND X003 Connectors X002 and X003 are the main connectors from the Fuse Panel to the Upper Cab Roof harness and the Outer Cab Roof Harness. The connectors are located in the upper left rear corner of the cab along with the Cab Roof Ground. Removal of the rear speaker panel is required to gain access to the connectors for troubleshooting and cab roof removal. Removal of Rear Speaker Panel 1. The rear speaker panel, 1, is located at the upper rear of the interior of the cab. Clothing hanger, 2, is the first item to be removed.

40015780

56 2. Using a flat bladed screwdriver or knife, pry the screw cover, 1, from the hanger. Turn out the two screws holding the hanger in place. Store the hanger and screws in a suitable location.

40015779

57 3. Turn out seven screws, 1, from panel, 2. Allow the panel to hang inside the cab.

2 40015780

55-35

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1 Connector Locations 1. Connector X002 2. Connector X003

3. Cab Roof Ground

50032236

59 Installation of Rear Speaker Panel

1. Set rear panel, 1, into place and secure to the headliner and cab roof using the seven screws, 2.

1 40015780

60 2. Install the hanger using two screws. Push the cover, 1, into place.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 2 -- IntelliViewt (II or Plus II) Monitor Diagnostic Functions CONTENTS Section

Description

Page

55 000

55-1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 DESCRIPTION OF OPERATION INTRODUCTION The CR combine electrical system provides two different menu options in the IntelliViewt (II or Plus II) monitor to assist in troubleshooting electrical concerns. The “Fault Archive” screen provides information regarding Active Alarms, Active Errors and Error History for the electrical system, while the “Graph” screen allows independent monitoring, testing and control of electrical circuits and devices. To access these two screens, from the “Main” menu select the “Diagnostic” icon, 1.

20072360

1 Then select the “Fault” tab on the navigation bar to display the “Fault Archive” screen.

20072361

2 Or select the “Settings” tab on the navigation bar to choose a “Group”, 1 then “Item”, 2 for display on the “Graph” screen. Selecting the “Graph” tab on the navigation bar will then display the status of the “Item” selected.

1 2

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55-2

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 FAULT ARCHIVE SCREEN When the “Fault” tab is selected from the navigation bar in “Diagnostic”, selecting the “Fault Archive” box displays the “Fault Archive – sub menu”. Choosing “Select List” provides selection to display: Active Alarms Active Errors Display Error History 20072363

4 Active Alarms Active alarms are displayed in Red on the “Fault Archive” screen along with a time and date stamp of the occurrence. An alarm is an indication of some mechanical condition on the vehicle, and alerts the operator to perform necessary maintenance, or to change operating conditions to correct the alarm condition. Examples of alarms would be to indicate an engine overheat condition, blocked filters, or improper control operation. Alarms are not used to indicate faults with electrical circuits.

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55-3

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 The alarm message uses a unique number to identify each alarm, 1, and by selecting the alarm code box information about the alarm can be obtained when “Fault Info”, 2, is selected.

In this example the combine fuel level is low and should be attended to before an out of fuel condition exists.

2 20072365

6 In this example the combine fuel level is low and should be attended to before an out of fuel condition exists.

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55-4

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 Active Errors An error is an indication of a fault with an electrical circuit or component, and alerts the operator that the circuit or component is no longer functioning. Examples of error messages include open circuits, shorts to ground, or short to high voltage. Each error message includes a unique identifying number, a brief text message indicates the component affected, and the type of error detected. All errors that are currently active on the combine will be displayed. If there are more active errors than can be displayed on the screen, the scroll bar will appear on the right side of the screen to indicate that additional errors are available. When the error is corrected, it will automatically change color from red to green, from “Fault” to “OK” and disappear from the list at the next key cycle.

20072367

Error messages are displayed on the screen in the order that they occurred. To review the active errors list, use the arrow keys to enter the list, and scroll up or down (if scroll bar appears). To select the Active Errors list, from the Main menu, choose Diagnostic (Icon) > Fault (tab) > Fault Archive (box) > Select List (on pop-up) > Active errors (on pop-up).

20072368

9 In the example there are only two active errors. The “upper and lower sieve sensors” “Failed” at “9:41 AM Jan 23, 2007. They each have a unique error code “E0287 and E0290”. The “-05” is FMI (Failure Mode Identifier) which indicates that they both have a “Line Disconnected” type of failure.

20072369

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 Additional information may be displayed for each error message. Select the desired error message by selecting the error code box, 1. A pop-up appears providing a “Fault info” option or “X” to return.

20072370

11 Fault info displays the component name at the top of the box, while the error number, and type of error is listed below.

20072371

12 Use the “Scroll bar” to access the next page of the Fault info which provides the number of times the fault has occurred, a time and date stamp of the last occurrence and when the event was cleared last (if available). For purposes of troubleshooting the Title: name of the component (“Item” on the Diagnostic>Settings screen) and Info: type of failure (an indication of what to expect on the Diagnostic>Graph screen) is all that is required. The troubleshooter needs to determine from the name of the component which “Group” (on the Diagnostic>Settings screen) would contain the “Item” in question.

20072372

55-6

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 After working in the Active errors screen for some time, the screen may no longer accurately reflect all active errors, possibly due to a module being connected to the network after the other modules had already powered up and reported their errors. In order to ensure that all active errors are being displayed, select the “Active errors” box. A pop--up appears providing a “Refresh List” selection.

20072373

14 Error History To select the Error history list, from the main menu, Diagnostic>Fault>Fault Archive>Select List>Error history (select “Diagnostic” then select the “Fault” tab then the “Fault Archive” box then choose “Select List” and then “Error history”). All errors that have been detected active on the combine in the past will be displayed. If there are more errors than can be displayed on the screen, the scroll bar will appear on the left side of the screen to indicate that additional errors are available. Errors will remain in the history list until they are erased. 20072374

The Error history list is not a real-time list, and displays only those errors recorded at the time the screen is opened. The error history is updated each time the screen is selected, or may be reloaded (refresh list) while working in the screen in order to retrieve the latest information from all modules.

Additional information may be displayed for each error message. This is accomplished by selecting the appropriate error code box and selecting “Fault Info” from the pop-up that appears. The same information previously mentioned appears. “Fault Info” can be accessed from the Display, Active errors and Error history screens.

20072375

55-7

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 Service Setup Screen To select the Service Setup screen, Main>Toolbox> Service (from the “Main” screen, select the “Toolbox” icon then the “Service” tab). This screen displays the total engine hours and threshing hours recorded for the combine, and also shows the date and time set in the combine electrical system.

Additionally, this screen displays four configurable service intervals with selectable service ranges from 20 to 600 hours: Range 1 = 20, 30, 40, or 50 Range 2 = 50, 60, 80, or 100 Range 3 = 125, 150, 175, or 200 Range 4 = 300, 400, 500, or 600

20072376

A brief description of some of the activities needing to take place at the service interval can be displayed by selecting the interval, 1 (shown in the next two figures).

20072377

20072378

55-8

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 Display Setup Screen If the current time displayed is not correct, the time may be adjusted to the correct setting on the “Display Setup” screen. (Main>Toolbox>Disp). Select the Month, Day, Year, Hour or Minute, 1 to display a numeric keypad.

20072379

20 Select the appropriate numbers, one at a time, then select “Enter”. Selecting “Day/Night” provides a selection box for AM and PM.

20072380

21 CAN Status Screen Main>Diagnostic>CAN accesses the “CAN Status” screen. A list of all modules on the combine will be displayed, along with information on their hardware and software revision level. If a module is not reporting on the network for some reason, its “Status” will display “Offline” or “Not Detected”. The Network menu is typically used to find the current revision level of the modules and the software in the electrical system. This information may be required when reporting certain electrical errors to engineering, or to determine if software updates are required or appropriate.

20072381

55-9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 Settings Screen Main >Diagnostic>Settings accesses the “Settings” screen which allows the selection of electrical components that can be then monitored on the “Graph” screen.

20072382

23 If the “Graph” screen is accessed before the selection of a Group and an Item an informational box, 1 appears and must be acknowledged, by selecting the “OK”, before continuing.

20072383

24 Choosing the “Group” box provides a selection list of the different Combine groups. Each group contains the Items (electrical components) related to that group. Therefore locating a device that needs to be monitored, to aid in troubleshooting, requires knowledge of the devices function.

20072384

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 Use of the scroll panel, 1 on the screen provides access to the remainder of the available groups.

20072385

26 Once a group has been selected, an Item can be chosen by selecting the “Item” box. This provides a list of the items (electrical components) contained with in the group.

20072386

27 Again, if the list doesn’t fit on a single screen the scroll panel is used to access the remaining items.

20072387

55-11

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 Once a “Group” and “Item” are selected, relevant information about the device chosen is displayed on the Settings screen: Module – the electronic control device that accepts the signal from (inputs) or controls the activation of (outputs) the “Item” selected. As shown, for the case of the Brake pressure switch, it provides an input signal to CCM2. SPN (Specific Product Number) – is the unique identifier used in the Error Code, i.e. E0134--xx for the Brake pressure switch. As there can be more than one error code for a single device, this information can be used to verify that correct “Item” has been selected. Schematic IO Name – is specific to the Module and used to identify functionality for the hardware and or software within the electronic control device. Connector and pin – is the hardware pin--out assignment for the Item selected. This is the physical location associated with an Error Code and the termination point for the circuit wiring. As shown, one wired connection of the Brake pressure switch is terminated at J2--34. Other wiring, as required by the device, could be connected to other devices, a power source, a grounding location, etc. Electrical component – is the nomenclature used on the electrical schematics (Frames) provided in the Repair Manual. Referring to the electrical schematics provides the additional information as to how the device is wired into the control circuitry. Inputs Inputs include supply voltages, switches (operator or machine-controlled), sensors (position, loss or speed) and senders (pressure, temperature or level). On any of the input diagnostic screens, a simple voltage bar graph and time based recording chart are displayed, which may be used to determine the condition of the circuit. The bar graph also has several arrows positioned along the left side to separate the graph into ranges; each range is represented by a letter, such as “A”, “B”, “C”, etc. These ranges each have a specific meaning depending on the type of circuit that is being monitored. The recording chart may have voltage, current or percent values as gradients on the vertical axis and tracks the signal level along the time based horizontal axis. The chart will scroll from the right and may be started and stopped using the “Start / Stop” box in the upper right corner above the chart.

55-12

20072388

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 Proximity and Speed Sensors Proximity and speed (RPM) sensors generally will have five ranges, as follows: A = 0 to 0.25v/0.5v (short to ground) B = 0.25v/0.5v to 5.6v (normal operation, no metal present) C = 5.6v to 7.6v (normal operation, metal present) D = 7.6v to 9v (open circuit) E = >9v (short to high voltage)

20072389

In the example shown, the Unload Tube sensor circuit is currently displaying 6.9 volts, and is in the “C” range, indicating that a normal operation, metal present circuit condition exists with this circuit.

Temperature/Fuel Level Senders Temperature and fuel level sensors will generally have four ranges, as follows: A = 0 to 0.25v/0.5v (short to ground) B = 0.25v/0.5v to 4.9v (normal operating range) C = 4.9v to 5.2v (open circuit) D = >5.2v (short to high voltage) In the example shown, the Hydraulic Reservoir Temperature sender circuit is currently displaying 4.4 volts, and is in the “B” range, indicating normal operation.

20072390

Potentiometers/Pressure Senders/ Grain Bin Level Potentiometers, pressure senders, such as engine oil pressure, control pressure or air filter restriction, and the grain bin level senders all operate on similar circuits, however there are some minor variation in the exact voltages between the ranges. Refer to the troubleshooting charts for each item for specific information on that component. A = 0 to 0.1v/0.2v (short to ground) B = 0.1/0.2v to 4.7v/4.9v/5.2v (normal operation) C = > 4.7v/4.9v/5.2v (short to high voltage)

55-13

20072391

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 Switches Switches may be generally divided into two separate groups, in terms of how they function. Operator-controlled switches in the cab are typically switched to 12 volts when they are engaged, while switches on the combine, such as filter bypass switches, are typically switched to ground when they engage. Operator switched circuits are normally open; when the operator moves the switch, it passes a 12 volt signal to the module. The various ranges for these switches are: 20072392

A = <0v (short to ground) B = 0v to 4v (normal, switch off/open) C = >4v (normal, switch on)

55-14

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 External switches on the combine, such as the filter bypass or brake pressure switches, are switched to a ground when they are activated, so the module sees the circuit change from an open circuit to a ground. The ranges for these switches are: A = <1.8v (normal, switch closed) B = 1.8v to 10v (normal, switch open) C = >10v (short to high voltage)

20072393

34 The Multi Function Handle (MFH) Position Input diagnostic screens provide two different bar graphs to test the MFH potentiometer; “Relative Position” and “Voltage”. The Relative Position bar graph provides a graphical representation of handle movement. In the example shown, the handle is in neutral, and the percentage at the top left corner of the screen indicates 0%. Moving the MFH forward will cause the bar graph to increase gradually, and the percentage will also increase, as shown. Moving the handle rearward, the graph decreases, and a negative percentage is indicated. This bar graph may be used to verify a steady, linear signal is received from the MFH potentiometer while it is moved, without any hesitation or spikes. In addition, the bar graph should not move beyond 100% in either direction; if it does, this is an indication that the MFH should be recalibrated. Refer to the “Calibration” section of the Operator’s manual for more information.

20072394

The “Voltage” screen shows the voltage signal from the MFH potentiometer when it is moved. The bar graph should be in the “D” range when the handle is moved forward, or in the “B” range when the handle is moved in reverse. A voltage reading in the “A” range would indicate a short to ground, while a reading in the “E” range would indicate a short to high voltage. The “C” range indicates the neutral position. 20072395

55-15

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 The Gear Select Input switch is unique in that it is a five position, rotary switch. The first diagnostic screen, “Gear”, gives an indication of the detected switch position, either 1, 2, N, 3 or 4.

20072396

37 The voltage bar graph has several ranges to indicate the various switch positions. In general, the different switch positions relate to the middle four ranges, as follows: A range = short to low source B range = 1st gear position (bottom portion of the range) 2nd gear position (top portion of the range) C range = 2nd gear position (bottom portion of the range) Neutral position (top portion of the range) D range = Neutral position (bottom portion of the range) 3rd gear position (top portion of the range) E range = 3rd gear position (bottom portion of the range) 4th gear position (top portion of the range) F range = short to high source

55-16

20072397

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 Outputs The modules on the combine take information from the various sensors and operator controls (inputs), and then turn on or engage outputs to perform the desired functions on the combine. These outputs include things such as engaging relays, solenoids (12v or PWM), and driving motors and actuators. The circuits in the modules are designed to handle different types of outputs, so the diagnostic screens for the outputs generally reflect the type of output. NOTE: The output diagnostic screens may NOT be accessed while the engine is running, in order to prevent accidental engagement of outputs, resulting in machine damage or personal safety concerns. Relays and Solenoids Relays and normal solenoids are driven by module outputs that simply switch 12 volts on or off, and are limited to 3 amps maximum current draw. Since these outputs are grounded locally, and the ground is not back through the module, there is a limitation on the values that may actually be monitored. All relay and normal solenoid diagnostic screens will default to a “Digital” screen, but in some cases, an additional “Status” screen is also available. 20072398

39 On the “Digital” screen, an indication is given of the actual condition of the output, either “Off” or “On”. While in this screen, if the output is activated through normal means, this will be visible when the output condition changes. The output may also be controlled directly from the diagnostic screen, allowing the circuit to be activated for testing purposes. To directly control the output, use the toggling “On/Off” switch box (bottom center); the condition (On/Off) statement in the top left corner of the screen will change to indicate that the circuit is now activated. The toggling switch box will also change. NOTE: When the circuit is manually activated, the software control is automatically bypassed, and the circuit will no longer be activated by normal means until the diagnostic screen is closed.

55-17

20072399

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 The “Status” screen, if available, provides some indication if the module detects an error on the circuit, typically either a short to ground or open circuit. Select the “Status” screen by pressing the down arrow key to highlight “Status”. The status of the circuit will be indicated as either “Ok” or “Error”, depending on the detected condition. As in the “Digital” screen, the output may be manually controlled in the “Status” screen also, simply by pressing the “Enter” key to change the position of the switch icon on the bottom right of the screen. 20072400

41 PWM Solenoids PWM solenoids are used where progressive engagement of the solenoid is desired, such as for the thresher, feeder and unload clutches, chaff spreader valve and header controls. Most PWM solenoids are grounded locally, but where precise control of the solenoid is required, the solenoid is grounded back through the module. This feedback allows additional monitoring of the current flow through the circuit. The PWM outputs are limited to 3 amps maximum current flow. PWM outputs have two diagnostic screens available, if grounded locally, or three, if the solenoid is grounded back through the module. The “PWM” screen contains a bar graph that provides a reference of the amount of output that the software is attempting to drive the solenoid at. When monitoring the output, it is possible to see the progressive engagement of the output on the bar graph. NOTE: If the circuit is shorted to ground, the bar graph will continue to indicate a rise in output, even though the module has shut off the output in order to protect the output driver.

55-18

20072401

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 The amount of PMW applied is selectable in the Bar Graph. Move the line to the desired level. The amount (percent of activation) is displayed in the bottom left corner of the Graph screen display area. In the example this is 25 (percent).

20072402

43 Use the toggling switch box to command the PWM output. The 25 (percent) selected in the example is applied to the solenoid. The Bar Graph fills to the selected level, the Recording Chart displays and tracks the selected level of application and the selected amount is displayed as a percent in the upper left corner of the Graph screen display area. NOTE: If the circuit being manually controlled is shorted to ground, the bar graph will continue to indicate a rise in output, even though the module will shut off the output in order to protect the output driver. 20072403

44 The “Current” screen, if available, measures the current flow on the circuit. In general, a properly functioning circuit should draw approximately 1 to 1.5 amps continuous when the solenoid is fully powered (100% output). If the circuit is shorted to ground, the bar graph should indicate high current flow until the module shuts the circuit off to protect the output driver. If the circuit is open, the bar graph will not indicate any current flow even though the “PWM” screen is indicating that the software is driving the output. 20072404

55-19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 H-Bridge Outputs H-bridge outputs are used to control motors and actuators, where the ability to drive the component in both directions is required. H-bridge circuits have two connector pins associated with them to control both sides of the circuit, and function by connecting one pin to ground when the opposite pin is connected to power. To reverse direction of the output, the power and ground connections are switched. This type of output control allows the module to operate motors and actuators in both directions. H-bridge circuits are limited to 3 amps for low power circuits, 20 amps for medium power circuits, and 30 amps for high power circuits. Low Power H-bridge (3 amp max) Ground Speed Hydrostat (EDC valve) Medium Power H-bridge (20 amp max) Feeder Reverser motor Concave Clearance motor Grain Bin Covers motor Header Reel Speed motor Rotary Screen Brush motor Spreader Plates motor Upper & Lower Sieve motors High Power H-bridge (30 amp max) Leveling Shoe motor Transmission Shift motor H-bridge circuits have three or four available diagnostic screens. The “H-bridge” screen provides a graphic representation of the state of the circuit. In the example shown, the circuit is currently in the “Brake” mode (both sides of circuit to ground). When the circuit is activated by the software, the statement in the top left corner of the graph screen display area will change to reflect the current output state of the circuit.

20072405

55-20

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2 The output to the motor is manually controlled by selecting one of the four command boxes provided. These are from top center clockwise to left center on the Graph screen display area; Free (coast), Clockwise rotation, Brake and Counter clockwise rotation. Manual activation is sustained for as long as the selection is maintained. Once the output has been controlled manually, the module software control has been bypassed, and the circuit will no longer operate normally. Once the command box is unselected, the output will return to the “Brake” mode, but the Brake icon on the lower right of the screen will now be lit, indicating the circuit is operating under manual control only.

20072406

The “Current” screen measures the current flow on the circuit. Refer to the chart above to determine the maximum amperage for each motor. In general, a circuit should not draw more than 30% to 50% of max rated amperage during normal operation. Excessive amp draw is generally an indication of short to ground or excessive mechanical load, due to worn or binding linkage, or lack of lubrication. If the circuit is shorted to ground, the bar graph should indicate high current flow until the module shuts the circuit off to protect the output driver. If the circuit is open, the bar graph will not indicate any current flow even though the “H-bridge” icon is indicating that the software is driving the output.

20072407

The “Voltage” screen is used to display the feedback from the potentiometer that is built into some of the actuators used, such as the leveling shoe or concave clearance actuators. As the actuator is operated, the voltage scale will change to reflect the changing position of the actuator. This bar graph is essentially a duplication of the input seen on each specific position sensor diagnostic screens, and is provided for reference (provides feedback that actuator is actually moving).

20072408

55-21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 2

55-22

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 3 -- Electrical Schematics CONTENTS Section 55 000

Description

Page

55-1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 INTRODUCTION The electrical schematic index is organized into groupings of components. Each component on the combine is assigned a unique alpha-numeric code that is used in all documentation, and uniquely identifies that component. To locate a specific component in the schematic, use the chart below to determine the label prefix for that component type, and look in that component group in the index to determine which frame the component is located on. Label Prefix

Component Type

Electronics (Modules)

Sensors

Lights (Lamps)

Fuses

Generators (Alternator, batteries)

Audio (Horns, speakers)

Outlets (Power, diagnostics)

Relays

Solenoids

Motors (actuators)

Resistive (Potentiometers)

Switches

Splice blocks

20010925

Schematic Frames The electrical schematic is divided into page-sized frames, and are numbered sequentially. The schematic frames are ordered by system, as follows: Starting Engine Drives Hydraulic Header Feeder Thresher Cleaning Unload Trash Auto Guidance/ Precision Distribution CAN Network Distribution/ Auto Guidance Lighting Accessory HVAC

Fr 1 -- 3 Fr 4 -- 6 Fr 7 -- 9 Fr 10 Fr 11 -- 14 Fr 15, 16 Fr 16, 17 Fr 17, 18 Fr 22 Fr 23

20020068

Fr 24 Fr 25 -- 29 Fr 30, 31 Fr 32 Fr 33 -- 43 Fr 44 -- 46 Fr 47, 48

55-2

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 To accurately determine the location of a particular circuit, use the index to locate circuits by component label. A box at bottom of each frame lists all devices shown on that frame, with their label. In most cases, circuits are contained completely within the frame. However, in some cases, wires can cross frame borders to the previous or next frame.

20020068

3 Power runs across the top of each frame, while grounds generally occur at the bottom. Labels are used to identify the power supply on the power wires at the top of the frame. The top wire label “B +12V” indicates this wire is directly supplied by the batteries, while the wires below are supplied by the K26 and K24 relays respectively. Grounds are identified with a circled number which indicates a specific ground location on the combine. An absence of this circled number indicates that the device is grounded locally. 20013708

There are five grounding locations on the combine, as listed.

A minimal number of jumpers, 1, are used to extend circuits to other frames in the schematic. These jumpers are shown as a wire terminating in a square box, with a letter-identifier and a frame number that the wire is jumping to. To continue following the circuit, flip to the identified frame number, and look for a jumper box with the same letter-identifier.

1 2

Connectors in the schematic are shown as a dotted box around a component, or around connections in a wire, in the case of an inline connector between harnesses. The connector number will be identified in one corner of the box.

200110927

55-3

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 If only part of the connector is shown, a wavy dotted line, 1, will be shown at one or both ends of the box to indicate that part of the connector is missing, and located in another frame of the schematic. The connectors will identify pins or sockets in each connector.

Bolted connections, 2, such as to batteries or alternators, will not have a dotted box surrounding the connection. In most cases, an entire component is shown on a single frame of the schematic. In some cases, however, the component (typically a computer module), 2, Figure 5, may be shown on several frames of the schematic. If only part of the component is shown, a solid wavy line will be shown at one, or both ends of the component to indicate part of the component is missing, and is located in another frame of the schematic.

20010928

Power Distribution For layout purposes, all switch and sensor power and ground sources are grouped in the schematic on frames 25 -- 27. Common power and ground sources are identified with a circled number for reference purposes. When viewing a switch or sensor in the schematic, this circled number provides a reference back to the actual power or ground source on frames 25 -- 27. Note that the power wires are identified with a flat bar on the end of the wire, and an indication of the voltage level. A reference ground wire (ground back through a module) will have a triangle on the end of the wire.

20031021

7 Machine Options In some cases, the wiring may have slight differences from one machine to another, depending on the specific options that are installed. In these cases, the schematic will show a reverse arrow head on one wire, with two or more arrow heads available to “plug in”. These arrow heads have a number in them to identify the specific option or configuration they represent. The arrow head options are listed at the bottom of the first Index frame for reference. In the example shown, the engine control units A-01 and A-16 used with the Iveco and Cummins electronic engines.* The options used in the schematic are: IVECO 10L CUMMINS 9.0L *

20064148

Are connected to the CAN 1 network as shown with the Cummins engine, an external termination resistor is used while the IVECO engine provides this internally.

55-4

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 Harnesses A two digit alpha code is assigned to each harness used on the combine (with the exception of two or three wire jumper harnesses). This label is used on each wire on the schematic to identify which harness any given wire is located in. The harness codes are: Code

Harness

MAIN FRAME

FRONT FRAME

LOWER FRAME

CAB MAIN

RIGHT HAND CONSOLE

STEERING COLUMN

CAB ROOF

OUTER ROOF

HVAC

FEEDER

ASP SENSORS BOTTOM

FEEDER VALVE STACK

MAIN VALVE STACK

GRAIN TANK

GEARBOX

ENGINE

EXPANSION

STRAW HOOD, FRONT

STRAW HOOD

LOWER FRAME REAR

HEADER

CHOPPER RPM AND RETURNS RPM

BIN COVERS

FLIP UP CORN HEADER

UNDERSHIELD LIGHTING, LEFT

UNDERSHIELD LIGHTING, RIGHT

UNDERSHIELD LIGHTING, ENGINE

UNLOAD TUBE LIGHT

MARKER LTS FRONT RH

MARKER LTS FRONT LH

TAIL LTS

MARKER LTS (AUSTRIA)

LICENSE PLATE LTS (EU)

20010929

55-5

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 Wire Harness Designations 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 77 79 80 81

= = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = =

MV FF CM CR RC SC FE GT GB EN AC EX HH VK SW SH OR FV FB FT MV LF ST SB LR PH FC UL UR UE BC SR CH TL MR ML MT MA LP TO SE IE AL RG CN GA DA

MAIN FRAME HARNESS FRONT FRAME HARNESS CAB MAIN HARNESS CAB ROOF HARNESS RH CONSOLE HARNESS STEERING COLUMN HARNESS FENDER HARNESS GRAIN TANK HARNESS GEARBOX HARNESS ENGINE HARNESS HVAC HARNESS EXPANSION HARNESS HEADER HARNESS VERTICAL KNIFE HARNESS STRAW HOOD FRONT HARNESS STRAW HOOD HARNESS OUTER ROOF HARNESS FEEDER VALVE STACK ASD SENSORS BOTTOM ASD SENSORS TOP MAIN VALVE STACK LOWER FRAME HARNESS STRAW HOOD TOP HARNESS STRAW HOOD BOTTOM HARNESS LOWER FRAME REAR HARNESS PLATFORM HARNESS FLIP UP CORN HEADER HARNESS UNDER SHIELD LIGHTING LEFT HARNESS UNDER SHIELD LIGHTING RIGHT HARNESS UNDER SHIELD LIGHTING ENGINE HARNESS BIN COVERS HARNESS SPREADER RPM HARNESS CHOPPER RPM AND RETURNS RPM HARNESS UNLOAD TUBE LIGHT HARNESS MARKING LTS FRONT RH HARNESS MARKLING LTS FRONT LH HARNESS TAIL LTS HARNESS MARKING LTS HARNESS (AUSTRIA) LICENSE PLATE LTS HARNESS (EU) TRAILER OUTLET HARNESS SEAT HARNESS IVECO ENGINE HARNESS ALTERNATOR HARNESS ROOF AUTO GUIDANCE HARNESS CERES NAVIGATION HARNESS GPS ANTENNE HARNESS DISPLAY ADAPTER HARNESS

55-6

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 All wires in the schematic are labeled to indicate the specific harness they are in, the circuit number, the wire color (see chart below), and the wire size, indicated in square mm cross-section. On the combine, the appropriate circuit number is printed on each wire approximately every 50 mm (2″) to identify it. Wire Size Chart Square mm AWG 0.5 20 0.8 18 1.0 16 2.0 14 3.0 12 5.0 10 8.0 8

20010929

In addition, the wire colors used identify the function of the wire, depending on the type of component that the wire is connected to. The following wire colors are used for the CR combine wiring harnesses:

Color Black Blue White Gray Orange Yellow Red Purple Pink

Color Code BK BL WH GY OR YE RD PU PK

Function Ground, Chassis Printed Circuit Ground Increasing Actuation Decreasing Actuation Power After Ignition Signal Wires Battery Voltage Lighting Reference Voltage

The following tables identify the specific wiring colors and functions, as well as the standard connector location for each wire type for each component group. Sensors 3 Wire Sensors (eg. Potentiometers) Signal

Harness Color

Power

3 or A

Pink

Ground

1 or B

Blue

Signal

2 or C

Yellow

Wire

20064149

55-7

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2 Wire Sensors (eg. Speed Sensors) Signal

Harness Wire Color

Ground

1 or A

Blue

Power

2 or B

Yellow

20010931

12 Actuators Linear Actuators (eg. Shoe) Signal

Harness Wire Color

Increase

1 or A

White

Decrease

2 or B

Gray

20010932

13 Solenoids w/Current Sensing (eg. Header Raise/Lower) Signal

Harness Wire Color

High Side

1 or A

White

Current Sense

2 or B

Blue

Solenoids w/o Current Sensing (eg. Reel Fore) Signal

Harness Wire Color

High Side

1 or A

White

Low Side

2 or B

Black

20010933

55-8

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 HARNESS ROUTING

50020058

15 Ground Locations 1. 2. 3. 4. 5.

Rear Frame Ground Front Frame Ground Cab Floor Ground Cab Roof Ground Engine Frame Ground (left rear mount)

NOTE: Cab Floor Ground is shown as two locations. Upper location on rear deck is main ground point. Location at bottom attaches ground strap from cab to front frame ground, 2.

55-9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3

8 9

5 4 2 1 7 3

50020066

16 Main Frame (MF) Wire Harness 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Connector X016, CCM2 -- J2 Connector X019, CCM1 -- J2 Connector X008 to Front Frame harness Connector X004 to Cab Main harness Connector X005 to Cab Main harness Connector X009 to Grain Tank harness Connector X034, X219 to Expansion harness Connector X195 to Tank Extensions jumper harness Connector X010 to Engine harness Connector X011 to Gearbox harness Connector X024 to Straw Hood

55-10

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3

7 6 12

9 10

50020062

17 Front Frame (FF), Lower Frame (LF) and Feeder (FE) Wire Harnesses 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Connector X017, CCM2 -- J3 Connector X020, CCM1 -- J3 Connector X031 to Cab Main harness Connector X008 to Main Frame harness Front Frame (FF) wire harness Connector X023 to Lower Frame harness Lower Frame (LF) wire harness Connector X007 to Feeder harness Connector X021 to Feeder Valves harness Feeder (FE) wire harness Connectors X082, X086 to ASP module Connector X032 to Header harness

55-11

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 4 6 3

7 9

8 10

50020065

18 Main Stack Valves (MV), Engine (EN), Gearbox (GB) and Lower Frame Rear (LR) Wire Harnesses 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Connector X281 to Bosch HHC module Main Stack Valves (MV) wire harness Connector X010 to Engine harness Engine (EN) wire harness Connector X011 to Gearbox harness Gearbox (GB) wire harness Connector X285 to Straw Hood Front harness Trailer plug wire harness Connector X072 to Straw Hood Front harness Lower Frame Rear (LR) wire harness

55-12

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3

3 2

50020064

19 Straw Hood Front (SW) and Straw Hood Rear (SH) Wire Harnesses 1. 2. 3. 4. 5. 6. 7.

Connector X024 to Main Frame harness Connector X025 to Expansion harness Straw Hood Front (SW) wire harness Connector X071 to Straw Hood Rear harness Straw Hood Rear (SH) wire harness Connector X285 to Trailer harness Connector X072 to Lower Frame Rear harness

55-13

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 9

8 7

3 1

2 4

50020063

20 Expansion (EX), Grain Tank (GT) and Unload Tube Light Wire Harnesses 1. 2. 3. 4. 5. 6. 7. 8. 9.

Connector X014, CCM3 -- J3 Connector X013, CCM3 -- J2 Connectors X034, X219 to Main Frame harness Expansion (EX) wire harness Connector X025 to Straw Hood Front harness Connector X009 to Main Frame harness Grain Tank (GT) wire harness Connector X105 to Unload Tube Light harness Unload Tube Light wire harness

55-14

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3

14 12 13 1

4 5

10 9

50020059

21 Cab Main (CM) Wire Harness 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Fuse Panel Connector X005 to Main Frame harness Connector X031 to Front Frame harness Connector X004 to Main Frame harness Connector X006 to HVAC harness Connector X018, CCM1 -- J1 Connector X015, CCM2 -- J1 Connector X012, CCM3 -- J1 Connector X033 to Steering Column harness Connector X256 to Road Light switch (S26) Connector X001 to RH Console To Start Panel Connector X002 to Cab Roof harness Connector X003 to Cab Roof harness

55-15

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3

50020060

22 HVAC (AC) Wire Harness 1. 2. 3. 4. 5.

Connector X006 to Cab Main harness To separator blower fan Cab Floor Ground (3), outside of cab HVAC (AC) wire harness To cab blower fan

55-16

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3

3 6 5

50020061

23 Cab Roof (CR) Wire Harness 1. 2. 3. 4. 5. 6. 7. 8.

Cab Roof Ground (4) Connector X003 to Cab Main harness Connector X002 to Cab Main harness Connector X128 to HVAC Control Panel Door Switch (S40) Connector X036 to Outer Roof harness Connector X140 to FM Radio Dome Light (E34)

55-17

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3

50010892

24 Outer Roof (OR) Wire Harness 1.

Connector X036 to Cab Roof harness

55-18

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 COMPONENT INDEX, 2007 PRODUCTION -- SN HAJ110001 AND ABOVE Code Name Frame Electronics A--01 ENGINE CONTROL UNIT FR--02 A--01 ENGINE CONTROL UNIT FR--04 A--01 ENGINE CONTROL UNIT FR--29 A--01 ENGINE CONTROL UNIT FR--31 A--02 DISPLAY MODULE FR--30 A--02 DISPLAY MODULE FR--32 A--04 RADIO FR--46 A--05 FLASHER MODULE FR--33 A--05 FLASHER MODULE FR--36 A--07 HHC MODULE (EMR--OBE) FR--14 A--07 HHC MODULE (EMR--OBE) FR--31 A--08 ASP AMPLIFIER FR--15 A--08 ASP AMPLIFIER FR--31 A--09 HVAC CONTROL MODULE FR--47 A--09 HVAC CONTROL MODULE FR--48 A--11 DGPS MODULE FR--30 A--11 DGPS MODULE FR--32 A--14 BLOWER SPEED CONTROL FR--47 A--15 ATC MODULE FR--47 A--16 CUMMINS ECU (9.0L) FR--02 A--16 CUMMINS ECU (9.0L) FR--05 A--16 CUMMINS ECU (9.0L) FR--31 A--23 CROP EDGE SCANNER A--24 NAVIGATION MODULE FR--30 A--24 NAVIGATION MODULE FR--32 Sensors B--01 ROTOR RPM FR--18 B--02 LATERAL INCLINATION FR--20 B--05 ENGINE FLYWHEEL RPM (10.3 L) FR--04 B--06 LEFT RETURNS RPM FR--20 B--07 ENGINE CAMSHAFT RPM (10.3 L) FR--06 B--08 CLEAN GRAIN ELEVATOR RPM FR--20 B--09 REVERSER DISENGAGED FR--16 B--10 CHOPPER RPM FR--23 B--12 MOISTURE SENSOR FR--24 B--14 FEEDER RPM FR--16 B--15 REEL RPM FR--13 B--16 CLEANING FAN RPM FR--19 B--17 GROUND SPEED RPM FR--09 B--18 HYD OIL RESERVOIR TEMP FR--10 B--19 LEFT ROTOR LOSS FR--20 B--20 RIGHT ROTOR LOSS FR--20 B--21 SIEVES LOSS FR--19 B--22 REAR LADDER FR--03 B--24 STONE DOOR CLOSED FR--16 B--26 CAB TEMP SENSOR FR--47 B--27 OUTLET TEMP SENSOR FR--47 B--28 EVAPORATOR TEMP SENSOR FR--47 B--29 HEADER LIFT PRESSURE FR--14 B--32 GEARBOX TEMPERATURE FR--10 B--35 LOW CONTROL PRESSURE FR--10 B--36 FUEL TEMP (10.3 L) FR--06 B--37 TRANS SHIFT POSITION FR--09 B--38 UNLOAD CRADLE FR--22 B--39 RIGHT RETURNS RPM FR--20 B--41 AIR TEMP/ BOOST PRESS (10.3 L) FR--04 B--44 COOLANT TEMP (10.3 L) FR--06

Code B--45 B--46 B--47 B--48 B--49 B--53 B--59 B--61 B--62 B--63 B--64 B--65 B--66 B--67 B--68 B--69 B--70 B--74 B--75

Name GEARBOX CLUTCH TEMP HYDROSTAT MOTOR TEMP COVERS OPEN RH BOTTOM ASP SENSOR LH BOTTOM ASP SENSOR PARK BRAKE PRESSURE (FUTURE) WATER IN FUEL COOLANT TEMP (9.0L) INTAKE AIR TEMP (9.0L) AMBIENT AIR PRESS (9.0L) FLYWHEEL RPM (9.0 L) CAM POSITION (9.0 L) ENGINE OIL PRESSURE (9.0 L) FUEL PRESSURE (9.0 L) BOOST PRESSURE (9.0 L) STEERING WHEEL POSITION REAR AXLE ANGLE PSD RPM OIL TEMP/PRESS (10.3 L)

Frame FR--17 FR--08 FR--22 FR--15 FR--15 FR--09 FR--02 FR--05 FR--05 FR--05 FR--05 FR--05 FR--05 FR--05 FR--05 FR--24 FR--24 FR--23 FR--04

E--01 E--02 E--03 E--04 E--05 E--06 E--07 E--08 E--09 E--10 E--11 E--12 E--13 E--14 E--15 E--16 E--17 E--18 E--19 E--20 E--21 E--22 E--23 E--24 E--25 E--26 E--27 E--28 E--29 E--30 E--31 E--32 E--33 E--34 E--35 E--37 E--38

LH HEADER FLASHING LMP (NA) RH HEADER FLASHING LMP (NA) LH FRONT HAZARD LAMP LH FRONT HAZARD LAMP LH REAR FLASHING LAMP (EU) RH REAR FLASHING LAMP (EU) LH NASO FLASHING LAMP RH NASO FLASHING LAMP TURN INDICATOR HIGH BEAM INDICATOR LH BRAKE / MARKER LAMP RH BRAKE / MARKER LAMP LH ROAD LIGHT RH ROAD LIGHT LH CAB OUTER WORK LIGHT RH CAB OUTER WORK LIGHT LH CAB INNER WORK LIGHT RH CAB INNER WORK LIGHT LH CAB MID WORK LIGHT RH CAB MID WORK LIGHT LH HEADER LIGHT RH HEADER LIGHT LH LOWER WORK LIGHT RH LOWER WORK LIGHT LH SIDE WORK LIGHT RH SIDE WORK LIGHT LH REAR WORK LIGHT RH REAR WORK LIGHT UNLOAD TUBE LIGHT GRAIN TANK LIGHT LH FRONT BEACON RH FRONT BEACON REAR BEACON DOME LIGHT CONSOLE LIGHT SIEVE LIGHT CENTER WORK LIGHT

FR--33 FR--33 FR--34 FR--34 FR--35 FR--35 FR--33 FR--33 FR--33 FR--33 FR--35 FR--35 FR--36 FR--36 FR--41 FR--41 FR--41 FR--41 FR--41 FR--41 FR--40 FR--40 FR--40 FR--40 FR--43 FR--43 FR--42 FR--42 FR--40 FR--40 FR--39 FR--39 FR--39 FR--38 FR--38 FR--43 FR--40

Lights

55-19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 Code E--39 E--40 E--41 E--42 E--43 E--44 E--45 E--46 E--49 E--50 E--51 E--52 E--53 E--54 E--55 E--56 Fuses F--01 F--02 F--03 F--04 F--05 F--06 F--07 F--08 F--09 F--10 F--11 F--12 F--13 F--14 F--15 F--16 F--17 F--18 F--19 F--20 F--21 F--22 F--23 F--24 F--25 F--26 F--27 F--28 F--29 F--30 F--31 F--32 F--33 F--34 F--35 F--36 F--37 F--38 F--39 F--40 F--41 F--42 F--43

Name Frame UNLOAD TUBE MARKER LMP (FR) FR--34 HEADER LH MARKER LAMP (EU) FR--33 HEADER RH MARKER LAMP (EU) FR--33 LH FRONT SHIELD LT FR--38 LH REAR SHIELD LT FR--38 RH FRONT SHIELD LT FR--38 RH REAR SHIELD LT FR--38 ENGINE LT FR--38 RH POSITION MARKER LT (EU) FR--34 LH POSITION MARKER LT (EU) FR--34 RH FLASHING LT (EU) FR--34 LH FLASHING LT (EU) FR--34 RH FRONT AUSTRIA MARKER LT FR--34 LH FRONT AUSTRIA MARKER LT FR--34 RH REAR AUSTRIA MARKER LT FR--35 LH REAR AUSTRIA MARKER LT FR--35 ECU POWER FUSE ACCESSORY 2 FUSE ACCESSORY 1 FUSE WIPER FUSE CIGAR LIGHTER FUSE LH CAB WORK LTS FUSE RH CAB WORK LTS FUSE ACCESSORY OUTLET FUSE WASHER / MIRROR FUSE -- NOT USED -RADIO FUSE -- NOT USED -TRANSCEIVER POWER FUSE SERVICE LTS FUSE SERVICE SOCKETS FUSE SEAT PUMP FUSE SEPARATOR BLOWER FUSE MAIN BLOWER FUSE A/C CLUTCH FUSE LH MARKER LIGHTS FUSE RH MARKER LIGHTS FUSE SHOE LEVELING MOTOR FUSE ROTARY SCREEN BRUSH FUSE FAN / REVERSER FUSE TRANSMISSION SHIFT FUSE STARTING FUSE SIEVE / SPREADER FUSE FUEL PUMP FUSE DISTANCE WORK LTS FUSE HEADER WORK LTS FUSE CAB ROOF WORK LTS FUSE HIGH BEAM FUSE LOW BEAM FUSE UNDER SHIELD LTS RADIO KAPWR CCM--2A FUSE CCM--2B FUSE KEY SWITCH FUSE MEMORY (KAPWR) CCM--1 POWER FUSE CCM--2 POWER FUSE CCM--3 / CAB POWER FUSE CCM--1A FUSE

Code F--44 F--45 F--46 F--47 F--48 F--49 F--50 F--51 F--52 F--53 F--54 F--55 F--56 F--64 Generators G--01 G--02 G--03 Audio H--01 H--02 H--04 H--05 H--06 H--07 H--08 Outlets J--02 J--03 J--05 J--06 J--07 J--08 J--09 J--10 J--10 Relays K--01 K--02 K--03 K--04 K--05 K--06 K--07 K--08 K--09 K--10 K--11 K--12 K--13 K--14 K--15 K--16 K--17 K--18 K--19 K--20 K--21 K--22

FR--02 FR--46 FR--45 FR--45 FR--45 FR--41 FR--41 FR--45 FR--45 FR--45 FR--46 FR--30 FR--46 FR--43 FR--39 FR--46 FR--48 FR--48 FR--48 FR--34 FR--34 FR--19 FR--03 FR--16 FR--09 FR--02 FR--21 FR--03 FR--41 FR--40 FR--41 FR--36 FR--36 FR--38 FR--46 FR--28 FR--28 FR--29 FR--29 FR--28 FR--28 FR--28 FR--26

55-20

Name CCM--1B FUSE HHC MODULE FUSE ASP POWER FUSE CCM--3 FUSE RH CONSOLE FUSE CAB FUSE SIDE LTS FUSE HORN / MARKER LTS FUSE DOME / BRAKE LT FUSE BEACON LTS FUSE LOWER WORK LTS FUSE REAR WORK LTS FUSE HAZARD LIGHTS FUSE SWITCH BYPASS FUSES

Frame FR--26 FR--31 FR--15 FR--24 FR--25 FR--27 FR--40 FR--36 FR--38 FR--39 FR--40 FR--42 FR--33 FR--44

ALTERNATOR FRONT BATTERY REAR BATTERY

FR--02 FR--01 FR--01

AUDIO ALARM HORN REAR LEFT SPEAKER FRONT LEFT SPEAKER REAR RIGHT SPEAKER FRONT RIGHT SPEAKER BACK UP ALARM

FR--25 FR--36 FR--46 FR--46 FR--46 FR--46 FR--08

LH FT SERVICE SOCKET RH SIDE SERVICE SOCKET ENGINE SERVICE SOCKET ACCESSORY SOCKET TRANSCEIVER POWER OUTLET ACCESSORY OUTLET TRAILER OUTLET DIAGNOSTIC OUTLET DIAGNOSTIC OUTLET

FR--39 FR--39 FR--39 FR--45 FR--46 FR--45 FR--35 FR--29 FR--30

CAB ROOF WORK LTS RELAY LIGHT CONTROL RELAY ACCESSORY 2 RELAY HIGH BEAM RELAY LOW BEAM RELAY WIPER RELAY FUEL PUMP RELAY ACCESSORY 1 RELAY SEPARATOR BLOWER RLAY A/C CLUTCH RELAY MAIN BLOWER RELAY LOW MAIN BLOWER RELAY MED MAIN BLOWER RELAY HIGH -- NOT USED -STARTING RELAY CONCAVE / COVERS RELAY FAN / REVERSER RELAY UPPER / LOWER SIEVE RELAY -- NOT USED -TIME DELAY MODULE DISTANCE WORK LTS RELAY HEADER WORK LTS RELAY

FR--41 FR--36 FR--46 FR--36 FR--36 FR--45 FR--03 FR--45 FR--48 FR--48 FR--48 FR--48 FR--48 FR--02 FR--02 FR--17 FR--16 FR--21 FR--16 FR--38 FR--41 FR--40

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 Code K--23 K--24 K--25 K--26 K--27 K--28 K--29 K--30 K--31 K--32 K--33 K--34 K--35 K--38 K--39 K--42 K--43 Solenoids L--01 L--03 L--04 L--05 L--06 L--07 L--08 L--10 L--11 L--12 L--13 L--14 L--15 L--16 L--17 L--18 L--19 L--20 L--21 L--22 L--23 L--24 L--26 L--27 L--28 L--29 L--30 L--31 L--32 L--34 L--35 L--36 L--37 L--38 L--39 L--44

Name NEUTRAL START RELAY CCM--1 POWER RELAY CCM--2 POWER RELAY CCM--3 / CAB POWER RELAY ROAD LIGHTS RELAY (AF) THRESHING LATCHING BEACON LIGHTS RELAY LOWER WORK LTS RELAY REAR WORK LTS RELAY UNLOAD TUBE LIGHT RELAY BRAKE LIGHTS RELAY TIMED SIDE WORK LIGHT RELAY SIDE WORK LIGHT RELAY 24V START RELAY GRID HEATER RELAY (10.3 L) RH VERTICAL KNIFE RELAY (OP) LH VERTICAL KNIFE RELAY (OP)

Frame FR--02 FR--28 FR--28 FR--28 FR--41 FR--18 FR--39 FR--40 FR--42 FR--40 FR--38 FR--43 FR--43 FR--01 FR--02 FR--12 FR--12

NEUTRAL LOCK SOLENOID UNLOAD TUBE IN UNLOAD TUBE OUT PRESSURE RELEASE HDR HEIGHT ACCUMULATOR A/C CLUTCH UNLOAD TUBE CLUTCH PARK BRAKE DISENGAGE FEEDER INCREASE FEEDER DECREASE REEL DOWN REEL UP REEL AFT REEL FORE REEL DRIVE LATERAL FLOAT CW LATERAL FLOAT CCW FEEDER JOG FORWARD FEEDER JOG REVERSE GEARBOX CLUTCH GROUND SPEED HYDROSTAT FEEDER CLUTCH REAR WHEEL ASSIST DUAL RANGE CHAFF SPREADER / BLOWER ROTOR INCREASE ROTOR DECREASE STONE DOOR OPEN BRAKE LIMITING FUEL ACTUATOR 1 (CYL 1) FUEL ACTUATOR 2 (CYL 4) FUEL ACTUATOR 3 (CYL 2) FUEL ACTUATOR 4 (CYL 6) FUEL ACTUATOR 5 (CYL 3) FUEL ACTUATOR 6 (CYL 5) FAN DRIVE SOLENOID

FR--07 FR--22 FR--22 FR--08 FR--14 FR--48 FR--22 FR--09 FR--15 FR--15 FR--12 FR--12 FR--12 FR--12 FR--12 FR--14 FR--14 FR--16 FR--16 FR--18 FR--09 FR--16 FR--08 FR--08 FR--23 FR--18 FR--18 FR--15 FR--09 FR--04 FR--04 FR--04 FR--04 FR--04 FR--04 FR--19

Code L--57 L--58 L--59 Motors M--02 M--03 M--04 M--05 M--06 M--07 M--09 M--10 M--11 M--12 M--15 M--16 M--17 M--18 M--19 M--20 M--21 M--22 M--23 M--24 M--25 M--26 M--27 M--28 M--29 M--30 M--31 M--35 Resistive R--01 R--02 R--03 R--04 R--05 R--06 R--08 R--09 R--10 R--11 R--12 R--13 R--14 R--15 R--16 R--17 R--20 R--24 R--25 R--26 R--27

55-21

Name STEER LEFT SOLENOID STEER RIGHT SOLENOID STEER ENABLE SOLENOID

Frame FR--32 FR--32 FR--32

TRANSMISSION SHIFT MOTOR SHOE LEVELLING ACTUATOR CONCAVE CLEARANCE MOTOR CLEANING FAN ADJUST MOTOR UPPER SIEVE ACTUATOR LOWER SIEVE ACTUATOR REEL SPEED MOTOR FEEDER REVERSER ACTUATOR SPREADER PLATE MOTOR COVERS MOTOR COLD BOX DOOR MOTOR WATER VALVE MOTOR MAIN BLOWER MOTOR SEPARATOR BLOWER MOTOR RH MIRROR UP / DOWN RH MIRROR IN / OUT LH MIRROR UP / DOWN LH MIRROR IN / OUT FUEL PUMP WIPER WASHER MOTOR WIPER MOTOR SEAT PUMP MOTOR ROTARY SCREEN BRUSH SAMPLE MOTOR 24V STARTER (10.3 L) GERMAN MIRROR UP / DOWN GERMAN MIRROR IN / OUT TURNTABLE ACTUATOR

FR--09 FR--19 FR--17 FR--16 FR--21 FR--21 FR--12 FR--16 FR--23 FR--17 FR--47 FR--47 FR--47 FR--48 FR--44 FR--44 FR--44 FR--44 FR--03 FR--45 FR--45 FR--46 FR--03 FR--24 FR--01 FR--44 FR--44 FR--24

FUEL LEVEL LATERAL FLOAT POT FEEDER ANGLE POT GROUND SPEED POT YIELD SENSOR CONCAVE POSITION CIGAR LIGHTER ENGINE GRID HEATER (10.3 L) RH MIRROR HEAT LH MIRROR HEAT LH STUBBLE HEIGHT RH STUBBLE HEIGHT GERMAN MIRROR HEAT AIR FILTER SWITCH RESISTOR ENG CAN TERMINATION (9.0L) CAN 1 TERMINATION (CAB) HEADER TYPE MODULE REEL HORIZONTAL POSITION REEL VERTICAL POSITION CAN 2 TERMINATION (CAB) CAN 2 TERMINATION (DGPS)

FR--03 FR--14 FR--14 FR--07 FR--24 FR--17 FR--45 FR--02 FR--44 FR--44 FR--14 FR--14 FR--44 FR--05 FR--31 FR--30 FR--13 FR--13 FR--13 FR--30 FR--30

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 Code Switches S--02 S--03 S--04 S--05 S--06 S--07 S--08 S--09 S--10 S--11 S--12 S--13 S--14 S--15 S--16 S--17 S--18 S--19 S--20 S--21 S--22 S--23 S--24 S--25 S--26 S--27 S--28 S--29 S--30 S--31 S--32 S--33 S--34 S--35 S--36 S--37 S--38 S--39 S--40 S--41 S--42 S--43 S--44 S--45 S--46 S--47 S--48 S--49 S--51 S--54 S--55 S--56 S--57

Name

Frame

KEY SWITCH MULTIFUNCTION HANDLE HEADER HEIGHT MODE SEAT SWITCH HHC FINE ADJUST FEEDER REVERSER REEL SPEED MODE PARK BRAKE REAR WHEEL ASSIST DUAL RANGE ON THE ROAD SWITCH UPPER SIEVE LOWER SIEVE FAN SPEED CONCAVE CLEARANCE ROTOR SPEED FEEDER SPEED MIRROR HEAT SWITCH WIPER SWITCH ALTERNATE SETTINGS NEUTRAL SWITCH SPREADER PLATE GEAR SELECT HAZARD SWITCH ROAD LIGHT SWITCH MIRROR ADJUST SWITCH GRAIN BIN 3/4 FULL GRAIN BIN FULL THRESHER ENGAGE FEEDER ENGAGE RETURNS FILTER BYPASS HYDRAULIC RESERVOIR LEVEL GEARBOX FILTER BYPASS UPPER SIEVE REAR ADJUST ENGINE THROTTLE CHARGE PRESSURE WASHER SWITCH BRAKE PRESSURE LH DOOR SWITCH BEACON LIGHT SWITCH TANK COVERS SWITCH WORK LIGHT SWITCH REAR WORK LIGHT SWITCH SEAT ADJUST SWITCH LOWER SIEVE REAR ADJUST A/C HIGH PRESSURE A/C LOW PRESSURE BRAKE FLUID LEVEL SWITCH VERTICAL KNIVES SIEVE LIGHT SWITCH LH BRAKE WEAR SWITCH RH BRAKE WEAR SWITCH MIRROR SELECT SWITCH (DE)

FR--29 FR--11 FR--11 FR--27 FR--11 FR--15 FR--11 FR--07 FR--07 FR--07 FR--07 FR--19 FR--19 FR--19 FR--17 FR--10 FR--10 FR--44 FR--45 FR--11 FR--09 FR--23 FR--07 FR--33 FR--36 FR--44 FR--22 FR--22 FR--18 FR--16 FR--10 FR--10 FR--10 FR--21 FR--03 FR--09 FR--45 FR--09 FR--38 FR--39 FR--22 FR--42 FR--42 FR--46 FR--21 FR--48 FR--48 FR--08 FR--11 FR--43 FR--08 FR--08 FR--44

Code S--61 S--63 S--64 S--65 S--67 S--79 S--80 S--81

Name AIR FILTER SWITCH LEFT SHIELD LT SW ENGINE LT SW RIGHT SHIELD LT SW COOLANT LEVEL SW ROTARY ENCODER SWITCH DISPLAY HOME SWITCH DISPLAY ESCAPE SWITCH

Splice Blocks W--01 SPLICE BLOCK A W--02 SPLICE BLOCK B W--03 SPLICE BLOCK C W--05 SPLICE BLOCK E W--06 SPLICE BLOCK F

FR--25 FR--25 FR--27 FR--25 FR--25

REAR FRAME GROUND

FR--48

FRONT FRAME GROUND

FR--48

CAB FLOOR GROUND

FR--48

CAB ROOF GROUND

FR--48

ENGINE GROUND

FR--48

CCM--1 REFERENCE GROUND “A”

FR--26

CCM--1 REFERENCE GROUND “B”

FR--26

CCM--1 REFERENCE VOLTAGE “A”

FR--26

CCM--1 REFERENCE VOLTAGE “B”

FR--26

CCM--2 REFERENCE GROUND “A”

FR--27

CCM--2 REFERENCE GROUND “B”

FR--27

131 CCM--2 REFERENCE VOLTAGE “A”

FR--27

CCM--2 REFERENCE VOLTAGE “B”

FR--27

CCM--3 REFERENCE GROUND

FR--26

CCM--3 REFERENCE VOLTAGE

FR--26

BACK LIGHTING “A”

FR--27

BACK LIGHTING “B”

FR--25

RH CONSOLE +12 VOLTS

FR--25

CAB +12 VOLTS

FR--27

14 15

55-22

Frame FR--05 FR--38 FR--38 FR--38 FR--03 FR--32 FR--32 FR--32

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

G-02 = FRONT BATTERY G-03 = REAR BATTERY K-38 = 24V START RELAY M-29 = 24V STARTER

STARTING FRAME--1

55-23

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

55-24

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0 L

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

B-22 = REAR LADDER F-23 = SCREEN BRUSH FUSE F-28 = FUEL PUMP FUSE K-07 = FUEL PUMP RELAY

M-23 = FUEL PUMP M-27 = ROTARY SCREEN BRUSH R-01 = FUEL LEVEL S-36 = ENGINE THROTTLE

S-61 = AIR FILTER SWITCH S-67 = COOLANT LEVEL

STARTING FRAME--3

55-25

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

10.3L ENGINE FRAME--4

A-01 = ENGINE CONTROL UNIT B-05 = ENGINE FLYWHEEL RPM B-07 = ENGINE CAMSHAFT RPM B-36 = FUEL TEMP

B-41 = AIR TEMP/BOOST PRESS B-44 = COOLANT TEMP B-75 = OIL TEMP/PRESS

55-26

L-34 = FUEL ACTUATOR 1 (CYL 1) L-35 = FUEL ACTUATOR 2 (CYL 4) L-36 = FUEL ACTUATOR 3 (CYL 2) L-37 = FUEL ACTUATOR 4 (CYL 6)

L-38 = FUEL ACTUATOR 5 (CYL 3) L-39 = FUEL ACTUATOR 6 (CYL 5)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

A-16 = CUMMINS ECU (9.0 L) B-61 = COOLANT TEMP (9.0 L) B-62 = INTAKE AIR TEMP (9.0 L) B-63 = AMBIENT AIR PRESS (9.0 L)

B-64 = FLYWHEEL RPM (9.0 L) B-65 = CAM POSITION (9.0 L) B-66 = ENGINE OIL PRESSURE (9.0 L) B-67 = FUEL PRESSURE (9.0 L)

B-68 = BOOST PRESSURE (9.0 L) L-34 = FUEL ACTUATOR 1 (CYL 1) L-35 = FUEL ACTUATOR 2 (CYL 4) L-36 = FUEL ACTUATOR 3 (CYL 2)

55-27

L-37 = FUEL ACTUATOR 4 (CYL 6) L-38 = FUEL ACTUATOR 5 (CYL 3) L-39 = FUEL ACTUATOR 6 (CYL 5)

9.0L ENGINE FRAME--5

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

ENGINE FRAME--6

55-28

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

L-01 = NEUTRAL LOCK SOLENOID R-04 = GROUND SPEED POT S-09 = PARK BRAKE S-10 = REAR WHEEL ASSIST

S-11 = DUAL RANGE S-12 = ON THE ROAD SWITCH S-24 = GEAR SELECT

DRIVES FRAME--7

55-29

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

DRIVES FRAME--8

B-46 = HYDROSTAT MOTOR TEMP H-08 = BACK UP ALARM L-05 = PRESSURE RELEASE L-26 = REAR WHEEL ASSIST

L-27 = DUAL RANGE S-49 = BRAKE FLUID LEVEL SWITCH S-55 = LH BRAKE WEAR SWITCH S-56 = RH BRAKE WEAR SWITCH

55-30

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

55-31

S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME--9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

HYDRAULIC FRAME--10

B-18 = HYD OIL RESERVOIR TEMP B-32 = GEARBOX TEMPERATURE B-35 = LOW CONTROL PRESSURE S-17 = ROTOR SPEED

S-18 = FEEDER SPEED S-32 = RETURNS FILTER BYPASS S-33 = HYDRAULIC RESERVOIR LEVEL S-34 = GEARBOX FILTER BYPASS

55-32

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-33

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

HEADER FRAME--12

K-42 = RH VERTICAL KNIFE RELAY (OP) K-43 = LH VERTICAL KNIFE RELAY (OP) L-13 = REEL DOWN L-14 = REEL UP

L-15 = REEL AFT L-16 = REEL FORE L-17 = REEL DRIVE M-09 = REEL SPEED MOTOR

55-34

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

B-15 = REEL RPM R-20 = HEADER TYPE MODULE R-24 = REEL HORIZONTAL POSITION R-25 = REEL VERTICAL POSITION

HEADER FRAME--13

55-35

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

HEADER FRAME--14

A-07 = HHC MODULE B-29 = HEADER LIFT PRESSURE L-06 = HEADER HEIGHT ACCUMULATOR L-18 = LATERAL FLOAT CW

L-19 = LATERAL FLOAT CCW R-02 = LATERAL FLOAT POT R-03 = FEEDER ANGLE R-12 = LEFT STUBBLE HEIGHT

55-36

R-13 = RIGHT STUBBLE HEIGHT

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

A-08 = ASP AMPLIFIER B-48 = RH BOTTOM ASP SENSOR B-49 = LH BOTTOM ASP SENSOR F-46 = ASP POWER FUSE

L-11 = FEEDER INCREASE L-12 = FEEDER DECREASE L-31 = STONE DOOR OPEN S-07 = FEEDER REVERSER

FEEDER FRAME--15

55-37

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

FEEDER FRAME--16

B-09 = REVERSER DISENGAGE B-14 = FEEDER RPM B-24 = STONE DOOR CLOSED F-24 = FAN, REVERSER FUSE

K-17 = FAN/REVERSER RELAY K-19 = NOT USED L-20 = FEEDER JOG FORWARD L-21 = FEEDER JOG REVERSE

55-38

L-24 = FEEDER CLUTCH M-05 = CLEANING FAN ADJUST MOTOR (EU) M-10 = FEEDER REVERSER ACTUATOR S-31 = FEEDER ENGAGE

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

B-45 = GEARBOX CLUTCH TEMP K-16 = CONCAVE/COVERS RELAY M-04 = CONCAVE CLEARANCE MOTOR M-12 = COVERS MOTOR

R-06 = CONCAVE POSITION S-16 = CONCAVE CLEARANCE

THRESHER FRAME--17

55-39

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

THRESHER FRAME--18

B-01 = ROTOR RPM K-28 = THRESHER LATCHING L-22 = GEARBOX CLUTCH L-29 = ROTOR INCREASE

L-30 = ROTOR DECREASE S-30 = THRESHER ENGAGE

55-40

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

B-16 = CLEANING FAN RPM B-21 = SIEVES LOSS F-22 = SHOE LEVELING MOTOR FUSE L-44 = FAN DRIVE SOLENOID

M-03 = SHOE LEVELING ACTUATOR S-13 = UPPER SIEVE S-14 = LOWER SIEVE S-15 = FAN SPEED

55-41

CLEANING FRAME--19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

CLEANING FRAME--20

B-02 = LATERAL INCLINATION B-06 = LEFT RETURNS RPM B-08 = CLEAN GRAIN ELEVATOR RPM B-19 = LEFT ROTOR LOSS

B-20 = RIGHT ROTOR LOSS B-39 = RIGHT RETURNS RPM

55-42

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

F-27 = SIEVE/SPREADER FUSE K-18 = UPPER/LOWER SIEVE RELAY M-06 = UPPER SIEVE ACTUATOR M-07 = LOWER SIEVE ACTUATOR

S-35 = UPPER SIEVE REAR ADJUST S-46 = LOWER SIEVE REAR ADJUST

55-43

CLEANING FRAME--21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

UNLOAD FRAME--22

B-38 = UNLOAD CRADLE B-47 = COVERS CLOSED L-03 = UNLOAD TUBE IN L-04 = UNLOAD TUBE OUT

L-08 = UNLOAD TUBE CLUTCH S-28 = GRAIN BIN 3/4 FULL S-29 = GRAIN BIN FULL S-42 = TANK COVERS SWITCH

55-44

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

B-10 = CHOPPER RPM L-28 = CHAFF SPREADER M-11 = SPREADER PLATE MOTOR S-23 = SPREADER PLATE

B-74 = PSD RPM

TRASH FRAME--23

55-45

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

AUTO GUIDANCE/ PRECISION FRAME--24

B-12 = MOISTURE SENSOR B-69 = STEERING WHEEL POSITION B-70 = REAR AXLE ANGLE F-47 = CCM-3 FUSE

M-28 = SAMPLE MOTOR M-35 = TURNTABLE ACTUATOR R-05 = YIELD SENSOR

55-46

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

F-48 = RH CONSOLE FUSE H-01 = AUDIO ALARM W-01 = SPLICE BLOCK A W-02 = SPLICE BLOCK B

W-05 = SPLICE BLOCK E W-06 = SPLICE BLOCK F

DISTRIBUTION FRAME--25

55-47

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-48

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME--27

55-49

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

DISTRIBUTION FRAME--28

F-36 = CCM-2A FUSE F-37 = CCM-2B FUSE F-40 = CCM-1 POWER FUSE F-41 = CCM-2 POWER FUSE

F-42 = CCM-3, CAB POWER FUSE K-24 = CCM-1 POWER RELAY K-25 = CCM-2 POWER RELAY K-26 = CCM-3, CAB POWER RELAY

55-50

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-51

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

CAN NETWORK FRAME--30

A-02 = DISPLAY MODULE A-11 = DGPS MODULE A-23 = CROP EDGE SCANNER A-24 = NAVIGATION MODULE

F-12 = NOT USED J-10 = DIAGNOSTIC OUTLET R-17 = CAN 1 TERMINATION (CAB) R-26 = CAN 2 TERMINATION (CAB)

55-52

R-27 = CAN 2 TERMINATION (DGPS)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

A-01 = ENGINE CONTROL UNIT A-07 = HHC MODULE A-08 = ASP AMPLIFIER A-16 = CUMMINS ECU

F-45 = HHC MODULE FUSE R-16 = ENG CAN TERMINATION (9.0 L)

55-53

IVECO 10 L

CUMMINS 9.0 L

CAN NETWORK FRAME--31

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

DISTRIBUTION/ AUTO GUIDANCE FRAME--32

A-02 = DISPLAY MODULE A-11 = DGPS MODULE A-24 = NAVIGATION MODULE L-57 = STEER LEFT SOLENOID

L-58 = STEER RIGHT SOLENOID L-59 = STEER ENABLE SOLENOID S-78 = AUTOGUIDANCE SWITCH S-79 = ROTARY ENCODER SWITCH

55-54

S-80 = DISPLAY HOME SWITCH S-81 = DISPLAY ESCAPE SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

A-05 = FLASHER MODULE E-01 = LH HEADER FLASHING LT (NA) E-02 = RH HEADER FLASHING LT (NA) E-07 = LH NASO FLASHING LT (NA)

E-08 = RH NASO FLASHING LT (NA) E-09 = TURN INDICATOR E-10 = HIGH BEAM INDICATOR E-40 = HEADER LH MARKER LT (EU)

55-55

E-41 = HEADER RH MARKER LT (EU) F-56 = HAZARD LIGHTS FUSE S-25 = HAZARD SWITCH

LIGHTING FRAME--33

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

LIGHTING FRAME--34

E-03 = LH FRONT HAZARD LIGHT E-04 = RH FRONT HAZARD LIGHT E-39 = UNLOAD TUBE MARKER LT (FR) E-49 = RH POSITION MARKER LT (EU)

E-50 = LH POSITION MARKER LT (EU) E-51 = RH FLASHING MARKER LT (EU) E-52 = LH FLASHING MARKER LT (EU) E-53 = RH FRONT AUSTRIA MARKER LT

55-56

E-54 = LH FRONT AUSTRIA MARKER LT F-20 = LH MARKER LIGHTS FUSE F-21 = RH MARKER LIGHTS FUSE

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

E-05 = LH REAR FLASHING LIGHT (EU) E-06 = RH REAR FLASHING LIGHT (EU) E-11 = LH BRAKE/TAIL LIGHT E-12 = RH BRAKE/TAIL LIGHT

E-55 = RH REAR AUSTRIA MARKER LIGHT E-56 = LH REAR AUSTRIA MARKER LIGHT J-09 = TRAILER OUTLET

55-57

LIGHTING FRAME--35

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

LIGHTING FRAME--36

A-05 = FLASHER MODULE E-13 = LH ROAD LIGHT E-14 = RH ROAD LIGHT F-32 = HIGH BEAM FUSE

F-33 = LOW BEAM FUSE F-51 = HORN, MARKER LTS FUSE H-02 = HORN K-02 = LIGHT CONTROL RELAY

55-58

K-04 = HIGH BEAM RELAY K-05 = LOW BEAM RELAY S-26 = ROAD LIGHT SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

LIGHTING FRAME--37

55-59

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

LIGHTING FRAME--38

E-34 = DOME LIGHT E-35 = CONSOLE LIGHT E-42 = LH FRONT SHIELD LT E-43 = LH REAR SHIELD LT

E-44 = RH FRONT SHIELD LT E-45 = RH REAR SHIELD LT E-46 = ENGINE LT F-34 = UNDERSHIELD LIGHTS

55-60

F-52 = DOME/BRAKE LT FUSE K-20 = TIME DELAY MODULE K-33 = BRAKE LIGHTS RELAY S-40 = LH DOOR SWITCH

S-63 = LEFT SHIELD LT SW S-64 = ENGINE LT SW S-65 = RIGHT SHIELD LT SW

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

E-31 = LH FRONT BEACON LIGHT E-32 = RH FRONT BEACON LIGHT E-33 = REAR BEACON LIGHT F-15 = SERVICE SOCKETS FUSE

F-53 = BEACON LT FUSE J-02 = LH FT SERVICE SOCKET J-03 = RH SIDE SERVICE SOCKET J-05 = ENGINE SERVICE SOCKET

55-61

K-29 = BEACON LIGHT RELAY S-41 = BEACON LIGHT SWITCH

LIGHTING FRAME--39

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

LIGHTING FRAME--40

E-21 = LH HEADER LIGHT E-22 = RH HEADER LIGHT E-23 = LH LOWER WORK LIGHT E-24 = RH LOWER WORK LIGHT

E-29 = UNLOAD TUBE LIGHT E-30 = GRAIN TANK LIGHT E-38 = CENTER WORK LIGHT F-30 = HEADER WORK LTS FUSE

55-62

F-50 = SIDE LTS FUSE F-54 = LOWER WORK LTS FUSE K-22 = HEADER WORK LTS RELAY K-30 = LOWER WORK LTS RELAY

K-32 = UNLOAD TUBE LIGHT RELAY

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

E-15 = LH CAB OUTER WORK LIGHT E-16 = RH CAB OUTER WORK LIGHT E-17 = LH CAB INNER WORK LIGHT E-18 = RH CAB INNER WORK LIGHT

E-19 = LH CAB MID WORK LIGHT E-20 = RH CAB MID WORK LIGHT F-06 = LH CAB WORK LTS FUSE F-07 = RH CAB WORK LTS FUSE

F-29 = DISTANCE WORK LTS FUSE F-31 = CAB ROOF WORK LTS FUSE K-01 = CAB ROOF WORK LTS RELAY K-21 = DISTANCE WORK LTS RELAY

55-63

K-27 = ROAD LIGHTS RELAY

LIGHTING FRAME--41

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

LIGHTING FRAME--42

E-27 = LH REAR WORK LIGHT E-28 = RH REAR WORK LIGHT F-55 = REAR WORK LTS FUSE K-31 = REAR WORK LTS RELAY

S-43 = WORK LIGHT SWITCH S-44 = REAR WORK LIGHT SWITCH

55-64

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

E-25 = LH SIDE WORK LIGHT E-26 = RH SIDE WORK LIGHT E-37 = SIEVE LIGHT F-14 = SERVICE LTS FUSE

K-34 = TIMED SIDE WORK LIGHT RELAY K-35 = SIDE WORK LIGHT RELAY S-54 = SIEVE LIGHT SWITCH

55-65

LIGHTING FRAME--43

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

ACCESSORY FRAME--44

F-64 = SWITCH BYPASS FUSES M-19 = RH MIRROR UP/DOWN M-20 = RH MIRROR IN/OUT M-21 = LH MIRROR UP/DOWN

M-22 = LH MIRROR IN/OUT M-30 = GERMAN MIRROR UP/DOWN M-31 = GERMAN MIRROR IN/OUT R-10 = RH MIRROR HEAT

55-66

R-11 = LH MIRROR HEAT R-14 = RH GERMAN MIRROR HEAT S-19 = MIRROR HEAT SWITCH S-27 = MIRROR ADJUST SWITCH

S-57 = MIRROR SELECT SWITCH (D)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

F-03 = ACCESSORY 1 FUSE F-04 = WIPER FUSE F-05 = CIGAR LIGHTER FUSE F-08 = ACCESSORY OUTLET FUSE

F-09 = WASHER/MIRROR FUSE F-10 = NOT USED J-06 = ACCESSORY SOCKET J-08 = ACCESSORY OUTLET

K-06 = WIPER RELAY K-08 = ACCESSORY 1 RELAY M-24 = WIPER WASHER MOTOR M-25 = WIPER MOTOR

55-67

R-08 = CIGAR LIGHTER S-20 = WIPER SWITCH S-38 = WASHER SWITCH

ACCESSORY FRAME--45

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

ACCESSORY FRAME--46

A-04 = RADIO F-02 = ACCESSORY 2 FUSE F-11 = RADIO FUSE F-13 = TRANSCEIVER FUSE

F-16 = SEAT PUMP FUSE F-35 = RADIO KAPWR FUSE H-04 = REAR LEFT SPEAKER H-05 = FRONT LEFT SPEAKER

55-68

H-06 = REAR RIGHT SPEAKER H-07 = FRONT RIGHT SPEAKER J-07 = TRANSCEIVER OUTLET K-03 = ACCESSORY 2 RELAY

M-26 = SEAT PUMP MOTOR S-45 = SEAT ADJUST SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

A-09 = HVAC CONTROL MODULE A-14 = BLOWER SPEED CONTROL A-15 = ATC MODULE B-26 = CAB TEMP SENSOR

B-27 = OUTLET TEMP SENSOR B-28 = EVAPORATOR TEMP SENSOR M-15 = COLD BOX DOOR M-16 = WATER VALVE

55-69

M-17 = MAIN BLOWER S-48 = A/C LOW PRESSURE

HVAC FRAME--47

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 3 2007 PRODUCTION -- SN HAJ110001 AND ABOVE

HVAC FRAME--48

A-09 = HVAC CONTROL MODULE F-17 = SEPARATOR BLOWER FUSE F-18 = MAIN BLOWER FUSE F-19 = A/C CLUTCH FUSE

K-09 = SEPARATOR BLOWER RELAY K-10 = A/C CLUTCH RELAY K-11 = MAIN BLOWER RELAY LOW K-12 = MAIN BLOWER RELAY MED

55-70

K-13 = MAIN BLOWER RELAY HIGH L-07 = A/C CLUTCH M-18 = SEPARATOR BLOWER S-47 = A/C HIGH PRESSURE

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 4 -- CAN Data Bus Network CONTENTS Section

Description

Page

55-1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 Section

Description

Page

55-2

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 DESCRIPTION OF OPERATION

56070858

CAN NETWORK The CAN network is a multiplex system which follows the guidelines established in SAE J1939. Multiplexing simply stated is linking two or more digital devices through a network. In the past, if an RPM sensor’s information was needed by a tachometer, an engine controller and a transmission, all three devices would need to be hard wired to the RPM sensor. Through the CAN Data Bus only one wire is needed. The information is then accessed through the network by other systems that need it. Any other system on the network that does not care about RPM data ignores the message on the network. On today’s high tech machinery, the complexity of wiring can be greatly reduced through the use of the CAN data bus network.

On the CR combine, one of these termination resistors is located across the CAN terminals of the diagnostics and maintenance (DAM) outlet X065. The termination resistance at the other end of the network is located across the CAN terminals of the engine control unit (ECU).

The network is made up of a twisted pair of wires, identified as CAN HI (yellow) and CAN LO (green). These two wires are used to form a “linear bus” network, in that the wires run in parallel from one end of the vehicle to the other, and each module is connected to both wires as a “node”. These two wires are connected together at each end of the network using a 120 ohm resistor, which is known as a “termination” resistor. Because there is a 120 ohm resistor at each end of the network, the resistance should always be 60 ohms between the CAN HI and CAN LO wires.

Each control module “tees” into the network, and acts as a separate “node” on the network. As a control module receives data from sensors, switches and potentiometers, it broadcasts this information on the network for other modules to pick up and use as needed. Each module knows which information it needs through the software programmed into it.

A secondary CAN bus (CAN 2) is used when the optional differential GPS (DGPS) receiver and NAV II navigation controller are installed in the CR combine. This bus has its own set of termination resistors at each end. One is located across the CAN 2 terminals on DAM outlet X065; the other is located across the CAN terminals of the DGPS receiver.

55-3

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 When the network is initially powered up (operator turns key on), each module on the network sends out a message announcing its existence, and “looks” for messages from other modules on the network. After this initial message, each control module sends out data messages as necessary, and, if necessary, it will send out another broadcast message announcing its existence if it has not sent any messages within the last 5 seconds. This is done in order to monitor each module’s status on the network; if a certain module has not transmitted any messages for more than 5 seconds, then the other modules on the network will generate an alarm message indicating that the module is “offline”. NOTE: If a control module never powers up and broadcasts its initial message, the other modules will not be aware that it exists, and no “offline” alarm will be generated. When optional control modules, such as the DGPS receiver or harvest guidance sensor (HGS), are installed, the alarm option on the module’s setup screen must be set to “Yes” to become active. And, like the other modules, they must be powered up at start-up and transmit a message in order to be recognized as being on the network.

56070868

55-4

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 ALARMS The network is capable of diagnosing itself and generating alarm messages to the operator when problems are detected. The combine may continue to function when a network alarm message appears, but systems related to that module will no longer function. The alarm messages that are related to the CAN network are listed below.

56070859

3 Alarm message

Priority

Description/Symptom

A2000 Communication Lost

High

CAN Hi & CAN LO wires are shorted together. Combine engine will not start.

A2001 MDM Offline

Med

IntelliView™ monitor is offline; monitor will not respond to keypad.

A2002 CCM1 Offline

Med

CCM1 module is offline.

A2003 CCM2 Offline

Med

CCM2 module is offline.

A2004 CCM3 Offline

Med

CCM3 module is offline.

A2005 RHM Offline

Med

RHM module is offline.

A2007 ECU Offline

Med

ECU module is offline.

A2008 HHC Offline

Med

HHC module is offline.

A2009 GPS Offline

Med

GPS module is offline.

A2011 ASP Offline

Low

ASP module is offline.

55-5

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 Checking Controller Status On the main screen, press the Diagnostics icon to access the diagnostic screens.

56070866

4 Press CAN in the navigation bar to display the CAN Status screen. This screen reports the status and source address for every controller on the CAN bus, including the vehicle controllers. This example shows the CCM1 and CCM2 controller status. The current status for any controller can be one of five states: Status

Meaning

online

Controller is functioning normally.

offline

Controller was detected, but is no longer communicating.

not detected

Controller is not detected on the CAN bus.

degraded

Controller is operating in a degraded state.

disabled

Controller has disabled itself and is reporting its disabled condition.

56070865

The vehicle determines whether the serial number, bootcode, hardware and software versions for the controller are communicated to the display.

55-6

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 TROUBLESHOOTING TROUBLESHOOTING A MODULE OFFLINE ALARM

A “not detected” indication for a controller means that the network has not “seen” the controller. Either the controller never sent its initial message to indicate its existence, or the CAN bus branch to that controller is open. An “offline” indication means that the controller initially reported its existence to the network but has since stopped communicating.

The status “degraded” could be due to a defective controller or a marginally functioning CAN link, possibly due to an intermittent open or short on the line. The status “disabled” indicates that the controller itself is defective. There are three general conditions that may cause an individual controller to go “not detected” or “offline”: a) defective controller, b) loss of power to the controller, or c) CAN-related faults. Each controller requires a power supply and ground to operate. If either of these is lost at startup, the controller will be unable to report its status and will be considered “not detected”. If power fails during operation, the controller can no longer communicate and will be shown as “offline”. CAN-related faults include bad or open connections to the CAN HI and CAN LO network wires as a result of damaged wiring. Internal problems may include a failure of the CAN controller itself (the device that actually does the “communicating” on the network), or the module may be “bussing off” due to excessive error messages. Whenever a module transmits or receives a faulty message, it keeps a record of that error. After its error history fills up, the CAN controller assumes that it is faulty, and will stop transmitting on the network (module has gone “Bus Off”); this will set the alarm off. This error history is erased and reset at zero when the module is powered down. Troubleshooting Steps 1. Verify module is offline by navigating to the “CAN Status” screen.

56070867

55-7

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 NOTE: If the IntelliView™ monitor module (MDM) is offline, monitor will be non-responsive to keypad. 2. Turn the key switch off, and back on again. Immediately navigate back to the “CAN Status” screen, and recheck the module status. A. If affected module is initially online, and then goes offline after a short period of time, it is bussing off due to excessive error messages. The excessive number of error messages could be due to bad electrical connections to the network, or a problem with the CAN controller in the module. Continue with step 5.

56070865

B. If the module is offline immediately after the network is powered up, continue with step 3. 3. A quick way to verify if a module has a power and ground connection is to activate a function within that module that does not require other CAN message information (function is controlled entirely by affected module). If the function operates, then the module is powered up, and the alarm is due to a CAN fault. See available functions by module below. If the module that is offline is not listed below, continue with step 4. RHM:

Depress Multi Function Handle (MFH) button to activate neutral lock solenoid. If solenoid activates, the RHM module is powered up and functioning.

CCM1: Turn on Road Lights or Work Lights. If lights come on, CCM1 is powered up and functioning. CCM2: Turn on Beacon Lights (EU, ROW) or depress brake pedal to activate brake lights. If lights come on, CCM2 is powered up and functioning. CCM3: Use remote Sieve Adjust switches to activate sieve actuators. If sieves operate, CCM3 is powered up and functioning. MDM:

IntelliView™ monitor is non-responsive to keypad.

A. If the module function operates, the module is powered up, and the fault is in the CAN network. Continue with step 5. B. If the module function does not operate, the module may not be powered up. Continue with step 4.

55-8

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 4. Testing indicates that module is not powering up. Refer to the power and ground chart below for the specific power and ground sources for each module. Use a multimeter to test for continuity to ground on the ground path, and for 12V power on the supply wires. If the module power and ground supplies are good, but the module is still offline, continue with step 6. Module Power

Ground

Comments

MDM

• KAM* power @ connector • Connector X502 pin 14 wire • KAM power from fuse F39 X502 pin 13 wire 1276 red 1213 black • Main power from fuse F42 through cab power relay K26 to fuse F48. • Main power at connector X502 pin 15 wire 1209 orange • Refer to schematic frames 25, 29 & 32

RHM

• KAM* power @ connector • Connector X026 pins 15 & 20 • Main power from fuse F42 through X026 pin 13 wire 307 red Cab power relay K26 to fuse F48 wires 389 & 352 black and through splice block B, W02 • Main power @ connector X026 pins 4 & 5 wires 098 & 089 • Ground path though splice block orange A, W01 • Refer to schematic frames 25, 28 & 29

CCM1

• KAM* power @ connector • Connector X018 pin J1-8 wire • KAM power from fuse F39 X018 pin J1-1 wire 052 red 215 black • Main power from fuse F38 through • Main power @ connector X018 • Connector X019 pin J2-12 & 18 key switch pin J1-4 wire 099 red wires 686 & 687 black • Refer to schematic frames 17 & 29

CCM2

• KAM* power @ connector • Connector X015 pin J1-8 wire • KAM power from fuse F39 X015 pin J1-1 wire 050 red 216 black • Main power from fuse F38 through • Main power @ connector X015 • Connector X016 pin J2-12 & 18 key switch pin J1-4 wire 100 orange wires 688 & 689 black • Refer to schematic frames 3 & 29

CCM3

• KAM* power @ connector • Connector X012 pin J1-8 wire • KAM power from fuse F39 X012 pin J1-1 wire 049 red 217 black • Main power from fuse F38 through • Main power @ connector X012 • Connector X013 pin J2-12 & 18 key switch pin J1-4 wire 101 red wires 690 & 691 black • Refer to schematic frames 21 & 29

ASP

• Main power @ connector X082 • Connector X082 pin 1 wire 720 • Main power from fuse F41 through pin 4 wire 580 white black CCM2 power relay K25 to Fuse F46 • Refer to schematic frames 15 & 28

55-9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 Module Power ECU

Ground

Comments

IVECO 10 L • Connector X193 pins 2, 3, 8, 9, • Connector X193 pins 5, 6, 10, • Power from fuse F01 11 wires 815, 816, 1627, 1628 wires 810, 811, 1625, 1626 white black Cummins 9.0 L • Connector X415 pins 3, 4 white • Connector X415 pins 1, 2 black • Refer to schematic frame 2 1627, 1628 black

DGPS

GPS Receiver • Connector X321 pin 10 wire • Connector X321 pin 11 wire • Power from fuse F42 through cab 1239 black power relay K26 to fuse F48 1238 orange Nav II Controller • Connector X496 pin 11 wire • Connector X496 pin 1 wire • Refer to schematic frames 32 & 25 1237 black 1236 orange

HHC

• Connector X281 pin 1 wire 781 • Connector X281 pin 3 wire 438 • Power from fuse F40 through orange black CCM1 power relay K24 to fuse F45 • Refer to schematic frames 14 & 31

HGS

• Connector X468 pin 6 wire • Connector X468 pin 3 wire • Power from fuse F42 through cab 1708 orange 1707 black power relay K26 to fuse F49 • Refer to schematic frames 27, 28 & 30

NOTE: KAM* = Keep Alive Memory; constant, key-off power.

55-10

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 5. Testing has determined that the module is offline due to a CAN fault, either with the CAN controller inside the module, or with the physical wiring to the network. Use a multimeter to check for continuity between the two wires that connect the module to the network. NOTE: Several modules are connected to the network through internal solder paths on the circuit boards, and cannot be tested as described. These modules include the RHM, CCM1, CCM2, and the Engine Control Unit (ECU) [CR9070 only]. If one of these modules is offline, continue with step 6.

A. If there is continuity between the two network wires, and the resistance measured is 60 ohms, the external wiring is okay, and the fault is internal to the module. Continue with step 6. B. If there is continuity between the two network wires, but the resistance is very high (> 70 ohms), there is a bad connection in the external wiring to the network. Check the harness and connectors for damage and repair as necessary. C. If there is no continuity between the two network wires, there is an open circuit in one of the two wires. Locate the open and repair.

Module

Network Connection

ECU

IVECO 10 L Connector X193 pin 35 wire 819 yellow (CAN HI) and • Connects to network at splice in main frame (MF) harness through connector X010 pin 34 wire 820 green (CAN LO)

Comments

• Terminating resistor is internal Cummins 9.0 L Connector X423 pin 46 wire 1145 yellow (CAN HI) • Connects to network at splice in main frame (MF) harness through connector X010 and pin 47 wire 1146 green (CAN LO) • Terminating stub connects to network at splice in engine (EN) harness through connector X422 • Refer to schematic frame 31 CCM3

Connector X012 pin J1-14 wire 133 yellow (CAN HI) • Connects to network at CCM2 connector X015 pins and pin J1-13 wire 134 green (CAN LO) J1-20 (CAN HI) and J1-19 (CAN LO) • Refer to schematic frame 30

ASP

Connector X082 pin 6 wire 729 yellow (CAN HI) and • Connects to network at splice in feeder (FE) harness pin 7 wire 730 green (CAN LO) through connector X007 • Refer to schematic frame 31

HHC

Connector X281 pin 12 wire 544 yellow (CAN HI) and • Connects to network through connector X008 to pin 6 wire 545 green (CAN LO) splice in main frame (MF) harness. • Refer to schematic frame 31

HGS

Connector X468 pin 4 wire 1700 yellow (CAN HI) and • Connects to network at splice in cab roof (CR) pin 5 wire 1701 green (CAN LO) harness through connector X469 • Refer to schematic frame 30

6. CAN fault is internal to the module. Use the Electronic Service Tool to reload the correct version software in the module. A. If module now functions properly, fault was due to corrupt software. Fault should be resolved. B. If module still remains offline after software is reloaded, the module has failed internally, and must be replaced to repair the fault.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 The following modules communicate via the secondary CAN bus, referred to here as CAN 2. Two of the modules, the MDM and the Nav II navigation controller, have connections to both the main CAN bus (CAN 1) and CAN 2. As a separate network, CAN 2 has its own set of terminating resistors, one across diagnostic and maintenance (DAM) connector X065 pins J and H, the other, across the CAN terminals at the GPS receiver. Steps A, B and C of paragraph 5 apply also to CAN 2.

Module

Network Connection

MDM

CAN 1 Connector X502 pin 1 wire 1171 yellow (CAN HI) and • Connects to CAN 1 network at splice in RH console pin 2 wire 1172 green (CAN LO) harness (RC) through connector X506

Comments

CAN 2 Connector X502 pin 5 wire 1227 yellow (CAN HI) and • Connects to CAN 2 network through connector X506 pins C and D pin 6 wire 1226 green (CAN LO) • Refer to schematic frame 30 DGPS

GPS Receiver Connector X321 pin 1 wire 1241 yellow (CAN HI) and • Connects to CAN 2 network at splice in combine navigation CN harness through connector X499 pin 12 wire 1240 green (CAN LO) • CAN 2 terminating stub connects to network at splice in GPS antenna GA harness through Nav II Controller connector X501 CAN 1 Connector X497 pin 5 wire 1217 yellow (CAN HI) and • Nav II controller connects to both CAN 1 and CAN 2 networks through splices in display DA harness pin 11 wire 1218 green (CAN LO) through connector X498 CAN 2 Connector X496 pin 3 wire 1245 yellow (CAN HI) and • Refer to schematic frame 30 pin 13 wire 1244 green

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 TROUBLESHOOTING “A2000 COMMUNICATION LOST” ALARM The alarm message “A2000 Communication Lost” indicates that the CAN HI and CAN LO network wires are shorted together, or that there is an open in one of the two wires. To confirm whether CAN HI and CAN LO are shorted or open, make the following check at the diagnostic port connector X065 on the B-post console.

1. Use a multimeter to check the resistance between pin D and pin C on connector X065, 1. This will quickly verify whether there is a short or open in the system.

A. A reading of 0 ohms confirms that CAN HI (yellow wire) is shorted to CAN LO (green wire). Continue with Step 2. B. A reading of 120 ohms indicates an open in either CAN HI or CAN LO. Continue with Step 5. C. A reading of 60 ohms indicates that the network wiring is okay.

X065 DIAGNOSTICS AND MAINTENANCE

To check the secondary CAN bus (CAN 2), measure resistance across pins H and J on connector X065. A. A reading of 0 ohms indicates that CAN Yellow) 2 HI is shorted to CAN 2 LO (green). Continue with “Troubleshooting CAN 2, Short Circuit” in this section. B. A reading of 120 ohms indicates an open in either CAN 2 HI or CAN 2 LO. Continue with “Troubleshooting CAN 2, Open Circuit” in this section. C. A reading of 60 ohms indicates that the CAN 2 wiring is OK.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 2. Access the three CCM modules under the training seat. Remove connector X018, 1, from module CCM1. This essentially splits the CAN network in half. Connector X018, pins J1-19 and J1-20 will be referred to as LEG 1. Connector X018 pins J1-13 and J1-14 will be referred to as LEG 2. Use a multimeter to measure the resistance across pins J1-19 and J1-20 on the harness end of connector X018. A. A reading of 0 ohms indicates that the short circuit is in LEG 1. Continue with “Troubleshooting LEG 1, Short Circuit” in this section.

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B. A reading of 120 ohms indicates that LEG 1 is okay. Go to Step 3.

3. Using the multimeter, measure the resistance across pins J1-13 and J1-14 on the harness end of connector X018. A. A reading of 0 ohms indicates that the short circuit is in LEG 2. Continue with “Troubleshooting LEG 2, Short Circuit” in this section. B. A reading of 120 ohms indicates that LEG 2 is okay. Go to Step 4.

DEUTSCH_DRC16_24S_PLUG

10 4. Using the multimeter, measure the resistance across pins J1-19 and J1-20 on the CCM1 side of connector X018. A. A reading of 0 ohms indicates that the short circuit is in CCM1. Replace CCM1. B. A high or infinite (OL) resistance reading indicates that the short is not in CCM1. Reconnect connector X018 and retest the system. 5. Using the multimeter, measure the resistance across pins J1-19 and J1-20 on the harness end of connector X018. A. A reading of OL (overload – open circuit) indicates that the open circuit is in LEG 1. Continue with “Troubleshooting LEG 1, Open Circuit” in this section. B. A reading of 120 ohms indicates that LEG 1 is okay. Go to Step 6. 6. Measure the resistance across pins J1-13 and J1-14 on the harness end of connector X018. A. A reading of OL (overload – open circuit) indicates that the open circuit is in LEG 2.

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Continue with “Troubleshooting LEG 2, Open Circuit” in this section. B. A reading of 120 ohms indicates that LEG 2 is okay. Go to Step 7. 7. Measure the resistance across pins J1-14 and J1-20 on the CCM1 side of connector X018. A. A reading of OL (overload – open circuit) indicates that the open circuit is in CCM1. Replace CCM1. B. A reading of 0 ohms indicates continuity of the CAN HI circuit through CCM1. Go to Step 8. 8. Measure the resistance across pins J1-13 and J1-19 on the CCM1 side of connector X018. A. A reading of OL (overload – open circuit) indicates that the open circuit is in CCM1. Replace CCM1. B. A reading of 0 ohms indicates continuity of the CAN LO circuit through CCM1. Reconnect X018 and retest the circuit.

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 TROUBLESHOOTING LEG 1 (Refer to schematic Frames 30 and 31 in this section)

SHORT CIRCUIT Preliminary troubleshooting has indicated that there is a short circuit in LEG 1. Use the following procedure to locate the short.

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11 IntelliView Monitor Branch 1. Disconnect connector X502, 1, from the bottom of the IntelliView monitor. Measure the resistance across pins J1-19 and J1-20 on the harness end of connector X018. A. If the reading is OL (overload – open circuit) there is a fault in the IntelliView monitor. Replace the monitor. B. A reading of 0 ohms indicates that the short is still present. Go to Step 2.

1 AMP_2--1437285--3

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 CAN DATA BUS CONNECTOR LOCATIONS 2

4 3 1

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Connector X001 Connector X003 Connector X281 Connector X193/423 Connector X010 Connector X008 Connector X007 Connector X018 Connector X015 Connector X012 Connector X082

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 CAN DATA BUS CAB CONNECTOR LOCATIONS

2 1

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1. 2.

Connector X502 Connector X065

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Connector X001

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 HARVEST GUIDANCE SYSTEM (HGS) CONNECTOR LOCATIONS

50032236B4

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1. 2.

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Connector X003 Connector X469

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Connector X468

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 DGPS Branch NOTE: This step applies only if the optional GPS receiver and NAV II navigation controller are installed. If this option is not installed, go on to Step 3. 2. Disconnect connector X498, 1, which is located under the right side of the right-hand console. Measure the resistance across pins J1-19 and J1-20 on the harness end of connector X018. A. If the reading is OL (overload – open circuit) there is a fault in the DGPS circuit. Go to “CAN 2 Troubleshooting” in this section.

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B. A reading of 0 ohms indicates that the short is still present. Go to Step 3.

PACKARD_12064769

17 RHM Branch 3. Open the service door on the right side of the cab and disconnect connector X001, 1, located under the right-hand console. Measure the resistance across pins J1-19 and J1-20 on the harness end of connector X018.

A. A reading of 0 ohms indicates that the short is in the cab main (CM) harness between X018 and X001, wires 129 (CAN HI) and 130 (CAN LO). Locate and repair the short. B. If the reading is OL (overload – open circuit), go to Step 4.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 4. Measure the resistance between pins 8 and 9 on the right-hand console end of connector X001.

A. A reading of 0 ohms indicates that the short is in the right-hand console, either in the right-hand console (RC) harness, the display (DA) harness, or the right-hand module (RHM). Locate and repair the short. B. If the reading is OL (overload – open circuit), go to Step 5.

AMP_206837--1

AMP_206838--1

20 Diagnostic Jack Branch 5. Measure the resistance between pins 6 and 7 on the harness end of connector X001. A. A reading of 0 ohms indicates that the short is in the cab main harness between X001 and diagnostic jack X065, 1, wires 127/271/143 (CAN HI) or 128/270/144 (CAN LO) . Locate and repair the short. B. If the reading is OL (overload – open circuit), replace all the connectors and retest the system.

1 56060933

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 OPEN CIRCUIT Preliminary troubleshooting has indicated that there is an open circuit in LEG 1. Use the following procedure to locate the open.

1. Open the service door on the right side of the cab and disconnect connector X001. Measure the resistance between pin 20 of the harness end of connector X018 and pin 8 of the harness end of X001. A. A reading of 0 ohms indicates that wire 129 yellow (CAN HI) between X018 and X001 is okay. Continue with Step 2. B. If the reading is OL (overload – open circuit), wire 129 is open. Locate and repair the open circuit. 2. Measure the resistance between pin 19 of the harness end of connector X018 and pin 9 of the harness end of X001. A. A reading of 0 ohms indicates that wire 130 green (CAN LO) between X018 and X001 is okay. Continue with Step 3. B. If the reading is OL (overload – open circuit), wire 130 is open. Locate and repair the open circuit. 3. Measure the resistance between pins 6 and 8 of the right-hand console side of X001. A. A reading of 0 ohms indicates that the CAN HI circuit through the right-hand console -wire 129/1299/127 yellow -- is okay. Continue with Step 4. B. If the reading is OL (overload – open circuit), the CAN HI through the right-hand console is open. This could be in the right-hand console (RC) harness or in the right-hand module (RHM). Locate and repair the open circuit.

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22 4. Measure the resistance between pins 7 and 9 of the right-hand console side of X001. A. A reading of 0 ohms indicates that the CAN LO circuit through the right-hand console -wire 130/1298/128 green -- is okay. Continue with Step 5. B. If the reading is OL (overload – open circuit), the CAN LO through the right-hand console is open. This could be in the right-hand console (RC) harness or in the right-hand module (RHM). Locate and repair the open circuit. 5. Measure the resistance between pins 6 and 7 of the harness end of X001. A. A reading of 120 ohms indicates that there is circuit continuity to diagnostic jack J10. Replace all connectors and retest the system. B. If the reading is OL (overload – open circuit), there is an open circuit between X001 and the diagnostic jack J10 – wires 271/127/143 yellow (CAN HI) and 270/128/144 green (CAN LO). Locate and repair the open circuit.

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 TROUBLESHOOTING LEG 2 (Refer to schematic Frames 30 and 31 in this section)

SHORT CIRCUIT ECU Branch Cummins 9.0L Engine 1. Disconnect connector X423 from the engine control unit (ECU). Use a multimeter to check for continuity between pins J1-13 and J1-14 of the harness end of X018.

5. Disconnect the main frame (MF) harness at connector X008. Use a multimeter to check for continuity between connector X018 pins J1-13 and J1-19.

B. If there is no continuity, there is a fault in the ECU. Replace the ECU.

A. If there is no continuity, there is a short in the main frame (MF) harness between connector X281 and connector X008 wires 544/674 yellow and 545/675 green, or between X008 and X010 wires 819 yellow and 820 green. Locate the short and repair.

A. If there is continuity, continue with Step 3. IVECO 10.0L Engine 2. Disconnect connector X193 from the engine control unit (ECU). Use a multimeter to check for continuity between pins J1-13 and J1-14 of the harness end of X018. A. If there is no continuity, there is a fault in the ECU. Replace the ECU. B. If there is continuity, continue with Step 3.

B. If there is continuity, continue with step 6. ASP Branch 6. Disconnect the feeder (FE) harness from the ASP module at connector X082. Use a multimeter to check for continuity between connector X018 pins J1-13 and J1-14.

3. Disconnect the engine (EN) harness at connector X010. Use a multimeter to check for continuity between connector X018 pins 13 and 14.

A. If there is no continuity, there is a fault in the ASD module. Replace the module.

A. If there is no continuity, there is a short in the engine (EN) harness between connector X193 and connector X010 wires 819 yellow and 820 green. Locate the short and repair.

7. Disconnect the feeder harness at connector X007. Use a multimeter to check for continuity between connector X018 pins J1-13 and J1-14.

B. If there is continuity, continue with step 4. HHC Branch 4. Disconnect the main frame (MF) harness from the HHC module at connector X281. Use a multimeter to check for continuity between connector X018 pins 13 and 14. A. If there is no continuity, there is a fault in the HHC module. Replace the module. B. If there is continuity, continue with step 5.

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B. If there is continuity, continue with step 7.

A. If there is no continuity, there is a short in the feeder (FE) harness between connector X082 and connector X007 wires 729 yellow and 730 green. Locate the short and repair. B. If there is continuity, continue with step 8.

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 Front Frame Harness 8. Disconnect the front frame harness from the main frame harness at connector X008. Install jumper wires on the main frame half of connector X008 between pins 1 & 3 and between pins 2 & 4. Use a multimeter to check for continuity between connector X018 pins J1-13 and J1-14. A. If there is no continuity, there is a short in the front frame (FF) harness between connector X007 and connector X008 on one of the following pairs of wires: Wires 729 yellow and 730 green from connector X007 pins 8 & 9 to FF harness splice. Wires 674 yellow and 675 green from connector X008 pins 1 & 2 to FF harness splice. Wires 744 yellow and 746 green from FF harness splice to connector X008 pins 3 & 4.

11. With X015 still disconnected, disconnect main frame (MF) connector X008 and CCM3 connector X012. Use a multimeter to check for continuity between pins J1-13 and J1-14 of the CCM2 side of connector X015. A. If there is continuity, there is a short in the main frame (MF) harness between connector X008 and CCM2 connector X016 wires 744 yellow and 746 green. Locate the short and repair. B. If there is continuity, continue with Step 12. Cab Main Harness 12. Remove the jumper wires from the cab main (CM) half of connector X015. Use a multimeter to check for continuity between connector X018 pins J1-13 and J1-14. A. If there is no continuity, there is a short in the cab main (CM) harness between connector X012 and connector X015 wires 133 yellow and 134 green. Locate the short and repair.

Locate the short and repair. B. If there is continuity, continue with step 9. CCM3 Branch 9. Disconnect the cab main (CM) harness from the CCM3 module at connector X012. Use a multimeter to check for continuity between connector X018 pins J1-13 and J1-14. A. If there is no continuity, there is a fault in the CCM3 module. Replace the module. B. If there is continuity, continue with step 10. CCM2 Branch 10. Disconnect the cab main (CM) harness from the CCM2 module at connector X015. Install jumper wires on the cab main half of connector X015 between pins J1-13 & J1-19 and between pins J1-14 & J1-20. Use a multimeter to check for continuity between connector X018 pins J1-13 and J1-14. A. If there is no continuity, there is a fault in the CCM2 module. Replace the module. B. If there is continuity, continue with step 11.

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B. If there is continuity, continue with step 13. NOTE: This procedure applies only if the optional SmartSteer harvest guidance system (HGS) module is installed. If it is not, continue with Step 14. 13. Reconnect all connectors except CCM1 connector X018. Remove connector X468 from the HGS module, which is mounted under the left-hand roof extension. Use a multimeter to check for continuity between pins J1-13 and J1-14 of the harness end of connector X018. A. If there is no continuity, there is a fault in the HGS module. Replace the module. B. If there is continuity, continue with Step 14.

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 Cab Roof Harness 14. Disconnect the cab roof harness from the cab main harness at connector X003 (it will be necessary to remove the upper trim panel in the cab to gain access to this connector). Install jumper wires on the cab main end of connector X003 between pins 1 & 4 and between pins 2 & 6. Use a multimeter to check for continuity between connector X018 pins J1-13 and J1-14. A. If there is no continuity, there is a short in the cab roof (CR) harness between connector X469, connector X468 or connector X003 on one of the following pairs of wires: Wires 1700 yellow and 1701 green from connector X468 pins 4 & 5 to CR connector X469 pins 3 and 2. Wires 1700 yellow and 1701 green from connector X469 pins 3 & 2 to CR harness splice. Wires 131 yellow and 132 green from connector X003 pins 1 & 2 to CR harness splice. Wires 137 yellow and 138 green from CR harness splice to connector X003 pins 4 & 6. Locate the short and repair. B. If there is continuity, continue with step 15. 15. Remove the jumper wires from the cab main half of connector X003. Use a multimeter to check for continuity between connector X018 pins J1-13 and J1-14. A. If there is no continuity, there is a short in the cab main (CM) harness between connector X015 and connector X003 wires 131 yellow and 132 green. Locate the short and repair. B. If there is continuity, continue with step 21. CCM1 Branch 16. Disconnect the cab main (CM) harness at X003. Use a multimeter to check for continuity between connector X018 pins J1-13 and J1-14. A. If there is continuity, there is a short in the cab main (CM) harness between connector X003 and connector X018 wires 137 yellow and 138 green. Locate the short and repair. B. If there is no continuity, replace all the connectors and retest the system.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 OPEN CIRCUIT Cab Roof Harness 1. Disconnect connector X015 from CCM2. Disconnect X018 from CCM1. Short out pins J1-13 and J1-14 of X018, harness end, with a wire jumper. Use the multimeter to check for continuity across pins J1-13 and J1-14 on the harness end of X015. A. If there no continuity, continue with step 2. B. If there is continuity, continue with Step 5. 2. Disconnect the cab roof harness from the cab main harness at connector X003 (it will be necessary to remove the upper trim panel in the cab to gain access to this connector). Install a jumper wire on the cab roof end of connector X003 between pins 1 & 2. Use a multimeter to check for continuity between connector X003 pins 4 & 6 (cab roof end). A. If there is no continuity, there is an open circuit in the cab roof (CR) harness between connector X003 pins 1 & 4 wire 131 yellow and 137 yellow or between connector X003 pins 2 & 6 wires 132 green and 138 green. Locate the open and repair. B. If there is continuity, continue with step 3. 3. Short out pins J1-13 and J1-14 of CCM1 connector X018, harness end, with a wire jumper. Use the multimeter to check for continuity across pins 4 and 6 of X003, harness end. A. If there no continuity, there is an open circuit in the cab main (CM) harness between X003 and X018 wire 137 yellow or wire 138 green. Locate the open and repair.

CCM2 Branch 5. Disconnect the main frame harness from the CCM2 module at connector X016. Use a multimeter to check for continuity between connector X016 pins J2-23 & J2-32, harness end. A. If there is continuity (approx. 120 ohms), there is a fault in the CCM2 module. Replace the module. B. If there is no continuity, continue with step 6. 6. Disconnect the front frame harness from the main frame harness at connector X008. Install a jumper wire in the main frame harness end of connector X008 between pins 3 & 4. Use a multimeter to check for continuity between connector X016 pins J2-23 & J2-32. A. If there is no continuity, there is an open circuit in the main frame (MF) harness between connector X016 and connector X008 wires 744 yellow and 746 green. Locate the open and repair. B. If there is continuity, continue with step 7. 7. Install a jumper wire in the front frame harness end of connector X008 between pins 3 & 4. Use a multimeter to check for continuity between connector X008 pins 1 & 2. A. If there is no continuity, there is an open circuit in the front frame (FF) harness between connector X008 pins 1 & 3 wires 744 yellow or 674 yellow or between connector X008 pins 2 & 4 wires 746 green or 675 green. Locate the open and repair. B. If there is continuity, continue with step 8.

B. If there is continuity, continue with Step 4. 4. Reconnect connector X003. Short out pins J1-13 and J1-14 of CCM2 connector X015, harness end, with a wire jumper. Measure for continuity across pins J1-13 and J1-14 of CCM1 connector X015, harness end. A. If there no continuity, there is an open circuit in the cab main (CM) harness between X003 and X015 wire 131 yellow or wire 132 green. Locate the open and repair. B. If there is continuity, continue with Step 5.

ECU Branch 8. Disconnect the main frame harness from the engine harness at connector X010. Use a multimeter to check for continuity on the engine harness end of connector X010 between pins 19 & 21. A. If there is continuity (approx. 120 ohms), there is an open circuit in the main frame (MF) harness between connector X008 and connector X010 wires 674 or 819 yellow and 675 or 820 green. Locate the open and repair. B. If there is no continuity, continue with step 9.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 IVECO 10L Engine 9. Disconnect the engine (EN) harness from the ECU module at connector X193. Use a multimeter to check for continuity between pins 34 and 35 on the ECU side of connector X193.

10. Disconnect the main frame (MF) harness from the engine (EN) harness at connector X010. Use the multimeter to measure for continuity across pins 19 and 21 on the EN harness end of connector X010.

A. If there is continuity (approx. 120 ohms), there is an open circuit in the engine (EN) harness between connector X010 and connector X193 wires 819 yellow and 820 green. Locate the open and repair.

A. If there is continuity (approximately 120 ohms) the circuit to the terminator is okay. Replace all connectors and retest the system.

B. If there is no continuity, there is a fault in the ECU module. Replace the module. Cummins 9.0L Engine NOTE: Unlike on the IVECO engine, the terminator for the CAN bus is external to the ECU. It is stubbed across the ECU on a branch of the engine (EN) harness.

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B. If there is no continuity, there is an open circuit in the EN harness between connector X010 and X422 wires 819 and 1147 yellow or wires 820 and 1148 green. Locate the open and repair. NOTE: The terminator stub plugs into connector X422. Make sure that the stub is firmly seated in the connector.

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 CAN 2 TROUBLESHOOTING SHORT CIRCUIT NOTE: The secondary CAN bus is used when the optional DGPS receiver and NAV II navigation controller modules are installed.

4. Disconnect combine navigation (CN) harness from GPS antenna (GA) harness at connector X499. Use the multimeter to measure resistance between pins C and D on the CN harness end of connector X499.

Preliminary troubleshooting has determined that there is a short circuit on the secondary CAN bus (CAN 2). Proceed as follows to locate the short.

A. If the reading is 0 ohms, continue with Step 5.

1. Disconnect the display (DA) harness from the combine navigation (CN) harness at connector X498 (under right-hand side of right-hand module). Using the multimeter measure resistance across pins H and J of the diagnostics jack X065. A. If the reading is 0 ohms, continue with Step 2. B. If the reading is 120 ohms, continue with Step 4. 2. Disconnect connector X502 from the bottom of the IntelliView monitor. Use the multimeter to measure for continuity between pins H and J of diagnostics jack X065. A. If the reading is 120 ohms, there is a fault in the IntellivVew monitor. Replace the monitor. B. If the reading is 0 ohms, continue with Step 3. 3. Disconnect connector X001 from the right-hand console. Use the multimeter to measure resistance between pins H and J of diagnostics jack X065. A. If the reading is 0 ohms, there is a short in the cab main (CM) harness between X001 and X065 wires1221/1225/1257 yellow and wires 1222/1224/1256 green. Locate the short and repair. B. If the reading is 120 ohms, there is a short circuit within the right-hand console, either in the RC harness wires 1225 yellow and 1224 green, or display (DA) harness wires 1225/1227/1229 yellow and 1224/1226/1228 green. Locate the short and repair.

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B. If the reading shows high resistance or OL (overload – open circuit), continue with Step 6. 5. Disconnect connector X496 from the NAV II navigation controller module. Use the multimeter to measure resistance between pins C and D on the CN harness end of connector X499. A. If the reading shows OL (overload – open circuit), there is a fault in the NAV II navigation controller module. Replace the module. B. If the reading shows 0 ohms, there is a short circuit in CN harness wires 1231/1245/1229 yellow and 1230/1244/1228 green. Locate the short and repair. 6. Disconnect connector X321 from the rear of the GPS receiver (mounted on the front grain tank extension). Measure the resistance between pins 1 and 12 of connector X321, harness end. A. If the reading shows 120 ohms, there is a fault in the GPS receiver module. Replace the module. B. If the reading shows 0 ohms, there is a short in GA harness wires 1241/1231/ 1243 yellow and 1240/1230/1242 green. Locate the short and repair.

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 DGPS (CAN BUS 2) CONNECTOR LOCATIONS

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Connector X498 Connector X499 Connector X496

4. 5. 6.

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Connector X497 Connector X321 Termination resistor R-27/X501

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4 OPEN CIRCUIT Preliminary troubleshooting has indicated that there is an open circuit in the CAN 2 network. Proceed as follows to locate the open. 1. Disconnect the display (DA) harness from the combine navigation (CN) harness at connector X498. (Under right-hand side of the right-hand console). Use a wire jumper to short out pins C and D of the DA harness end of connector X498. Use the multimeter to check for continuity between pins H and J of diagnostics connector X065. A. If there is no continuity, continue with Step 2. B. If continuity is indicated, the circuit is okay between X065 and X498. Continue with Step 3. 2. Disconnect the cab main (CM) harness and right-hand console (RC) harness at connector X001 (under right-hand console). Use the multimeter to check for continuity between pins 4 and 5 of the cab main (CM) harness end of X001. A. If the reading is 120 ohms, there is an open circuit within the right-hand console, either in right-hand console (RC) harness wires 1225 yellow and 1224 green or in display (DA) harness wires 1225/1229 and 1224/1228. Locate the open and repair. B. If the reading is OL (overload – open circuit), there is an open circuit between X001 and X065 wires 1221/1225/1257 yellow and wires 1222/1224/1256 green. Locate the open and repair. 3. Disconnect GPS antenna (GA) harness from combine navigation (CN) harness at connector X499. Use the multimeter to check continuity between pins C and D of the GA end of connector X499. A. If the reading is 120 ohms, there is an open circuit in the CN harness between X498 and X499 wires 1229/1231 yellow and 1228/1230 green. Locate the open and repair. B. If the reading is OL (overload – open circuit), there is an open circuit between X499 and the GPS termination resistor connector X502 wires 1231/1243 yellow and 1230/1242 green. Locate the open and repair. NOTE: The terminating stub plugs into connector X501. Make sure the stub is firmly seated in the connector.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4

CAN NETWORK FRAME--30

A-02 = DISPLAY MODULE A-11 = DGPS MODULE A-23 = CROP EDGE SCANNER A-24 = NAVIGATION MODULE

F-12 = NOT USED J-10 = DIAGNOSTIC OUTLET R-17 = CAN 1 TERMINATION (CAB) R-26 = CAN 2 TERMINATION (CAB)

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R-27 = CAN 2 TERMINATION (DGPS)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4

A-01 = ENGINE CONTROL UNIT A-07 = HHC MODULE A-08 = ASP AMPLIFIER A-16 = CUMMINS ECU

F-45 = HHC MODULE FUSE R-16 = ENG CAN TERMINATION (9.0 L)

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IVECO 10 L

CUMMINS 9.0 L

CAN NETWORK FRAME--31

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 4

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 5 -- Engine Systems CONTENTS Section

Description

Page

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General Engine Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 9.0L CNH Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 10.3L IVECO Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 24V Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Starting System -- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A -- Key Switch Power Supply Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 B -- Key Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 C – Neutral Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 D – Neutral Start Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 E -- 24 V Start Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F -- 24V Starter Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 G -- Starting Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Alternator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Charging System -- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A -- Charging System Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Grid Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

55-1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 Section

Description

Page

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grid Heater Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Grid Heater Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 CCM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Engine Control Unit (ECU) -- IVECO 10.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Right Hand Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ECU Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Engine-Related Error Codes -- Automatic Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 ECU Related Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 CNH 9.0L Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 IVECO 10.3 L sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Engine Oil Temperature/Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Engine Camshaft RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Engine Flywheel RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Air Temperature /Boost Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Fuel Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 All Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Rotary Screen Brush Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Air Filter Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Fuel Pump Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

55-2

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 OVERVIEW GENERAL ENGINE SYSTEMS This section describes the electrical systems specifically related to the engine: There are two types of engines available in the CR Series combine. 9.0L CNH Engine The CR9040 and CR9060 combines use a 9.0L 6 cylinder, 24 valve CNH engine with a high pressure common rail fuel system. Information regarding an overview of operation and basic testing of fuel system components may be found in TECH COM 2006--1. Engine removal and installation is covered in this manual. For engine repair and testing information, refer to the “8.3 & 9.0L 6 Cylinder, 24 Valve CNH Engine with High Pressure Common Rail Fuel System” Repair Manual.

86061133

1 10.3L Iveco Engine The CR9070 combine uses a 10.3L 6 cylinder IVECO cursor engine. The governor on the IVECO engine is electronically controlled. A low-pressure pump controls fuel flow to the engine. Information regarding an overview of operation and timing may be found in TECH COM 2006--6. Engine removal and installation is covered in this manual. For engine repair and testing information, refer to the “Cursor 10.3L Engine” Repair Manual. 20030057

55-3

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 STARTING SYSTEM The CR Series combines are equipped with a 24 volt starting system.

DESCRIPTION OF OPERATION

Normally open contacts 31A and 30, and 30A and 50 are now closed. This places the two batteries in series through the following path: G-03 negative terminal remains grounded, either directly or through battery switch S-52; G-03 positive terminal connects to G-02 negative terminal through K-38 contacts 30 and 31A; G-02 positive terminal connects to B+ terminal of starter motor M-29. The voltage present at this terminal is now 24 volts.

24V Starting Circuit Refer to schematic Frames 1, 2, 3, 9 and 29. For engine starting, the key switch S-02 (Frame 29) is moved to the START position. Assuming neutral switch S-22 (Frame 9) is on (multifunction handle in NEUTRAL), Neutral start relay K-23 is energized, providing a path from the key switch to the coil of starting relay K-15, which energizes, applying +12 volts from fuse F-26 (Frame 2) to 24V start relay K-38.

At the same time, the 24 volts at M-29’s B+ terminal is applied to M-29’s S terminal via wire 832, K-38 contacts 30A and 50, and wire 834. This energizes the start solenoid in M-29, and the engine cranks.

When K-38 energizes, the normally closed contacts now open, opening the connections between K-38 pins 30A and 30, and 31A and 31. This removes the parallel connections between the two batteries.

55-4

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 ELECTRICAL SCHEMATICS

G-02 = FRONT BATTERY G-03 = REAR BATTERY K-38 = 24V START RELAY M-29 = 24V STARTER

STARTING FRAME--1

55-5

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0L

55-6

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5

B-22 = REAR LADDER F-23 = SCREEN BRUSH FUSE F-28 = FUEL PUMP FUSE K-07 = FUEL PUMP RELAY

M-23 = FUEL PUMP M-27 = ROTARY SCREEN BRUSH R-01 = FUEL LEVEL S-36 = ENGINE THROTTLE

S-61 = AIR FILTER SWITCH S-67 = COOLANT LEVEL

STARTING FRAME--3

55-7

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME--9

55-8

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 STARTING SYSTEM -- TROUBLESHOOTING PRELIMINARY CHECKS Before troubleshooting the starting system, make sure that the following conditions are met: 1. The batteries are fully charged and all the connections are clean and tight. 2. Check fuses F-26, F-38, F-42, F-48.

55-10

3. Transmission in neutral, brake lock on. 4. Battery switch closed. 5. Check the two 80A fusible links on 24V start relay K-38 (Figure 8).

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 SYMPTOM CHART NOTE: The batteries must be fully charged and all the connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual.

CAUTION

DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system. Symptom

Possible Cause

Engine g does not crank when key y is Fuse #38 t turned d to t start t t Key Switch

Reference/Test A -- Key Switch Power Supply Test, test point 1 A -- Key Switch Power Supply Test. B – Key Switch Test, test points 1 and 2. C – Neutral Switch Test.

Neutral Switch

Refer to Transmission Section of Service Manual and check neutral switch adjustment. Neutral Start Relays y

D – Neutral Start Relay K-23 Test G – Starting Relay K-15 Test

Start Relay

E – 24V Start Relay Test

Starter Motor

F-- 24V Starter Motor Test

Click is heard when key y is turned Starter Motor b t engine but i does d nott crank k Start Relay

F --24V Starter Motor Test E -- 24V Start Relay Test

Neutral Start Relays y

D – Neutral Start Relay K-23 Test G – Starting Relay K-15 Test

Engine g cranks slowly y

Starter Motor

F --24V Starter Motor Test, test points 1 -- 5, 8 and 9.

Engine mechanical problem Refer to Engine Repair Manual. Starter motor continues to operate Key Switch y is released from START to when key RUN position iti Start Relay

B -- Key Switch Test, and Confirm that switch opens when key is released. E -- 24V Start Relay Test (24V System), test point 5, and confirm that relay opens when key is released.

Neutral Start Relays y

D – Neutral Start Relay K-23 Test, test point 5. G – Starting Relay K-15 Test, test point 5, and confirm that relay opens when the key is released.

Starter motor continues to operate Starter Solenoid when key is released from START to RUN position

55-11

F – 24V Starter Motor Test, test point 2 and confirm that 24 volts are not present at “S” terminal when the key is released. If starter continues to run when 24 volts are removed, replace starter.

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 DIAGNOSTIC TESTS NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.

A – Key Switch Power Supply Test Test Point 1

Good Reading

Measure for 12 volts at Key Switch 12 volts Connector X068 (pin 1).

Possible Cause of Bad Reading Open circuit 053 (RD) between fuse #38 and Key Switch connector X068 (pin 1).

If good reading, go to the next test Go to the next test point. point. 2

Key Switch in “IGN/ACC” position.

12 volts

Key Switch

Measure for 12 volts at Key Switch If good reading, go to next test point. connector X068 (pin 6 and 4). 3

Key Switch in “START” position. 12 volts Key Switch Measure for 12 volts at Key Switch If good reading, Key Switch operating connector X068 (pin 2). normally.

B – Key Switch Test Test Point 1

Good Reading

Remove electrical Connector from Continuity Key Switch.

Possible Cause of Bad Reading Key Switch

While holding Key Switch in “START” If good reading, go to the next test position, Check for continuity be- point. tween (pin 1 and 2). 2

While holding Key Switch in “START” Continuity Key Switch position, Check for continuity beIf good reading, go to the next test tween (pin 1 and 6). point.

Key Switch in “IGN/ACC” position, Continuity Key Switch check for continuity between (pin 1 If good reading, go to the next test and 6). point.

Key Switch in “IGN/ACC” position, Continuity Key Switch check for continuity between (pin 1 If good reading, go to the next test and 4). point.

Key Switch in “ACC” Position, check Continuity Key Switch for Continuity between (pin 1 and 4). If good reading, go to the next test point.

Key Switch in “OFF” Position, check No continuity Key Switch for Continuity between (pin 1) and If good reading, Key Switch operating (pins 2, 4, 6). properly.

55-12

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 C – Neutral Switch Test 1

Test Point

Good Reading

Key Switch in “IGN” position.

12 volts

Possible Cause of Bad Reading

Open circuit 300 (OR) or 108 (OR) between Fuse #48 and Neutral Measure for 12 volts at Neutral If good reading, go to the next test Switch connector X059 (pin 1). Switch connector X059 (pin 1). point. Check in-line connector X001 (pin 3) for connection. Blown Fuse #48 (refer to Power Distribution section for testing).

Place Neutral Switch in the “Closed” 12 volts position.

Neutral Switch

Measure for 12 volts at Neutral If good reading, go to the next test Switch connector X059 (pin 3). point. 3

Place Neutral Switch in the “open“ 12 volts position.

Neutral Switch

Measure for 12 volts at Neutral If good reading, Neutral Switch okay. Switch connector X059 (pin 2).

D – Neutral Start Relay K-23 Test 1

Test Point

Good Reading

Possible Cause of Bad Reading

Key Switch in “START” position.

12 volts

Neutral Start Relay

Hydrostat handle in “NEUTRAL” position. Measure for 12 volts at Neutral Start If good reading, Neutral Start Relay Go to next test point. Relay (pin 5). operating properly. 2

Key switch in “START” position. 12 volts Remove the Neutral Start Relay.

Open or short to ground in circuit 91 (OR) between Key Switch connector X068 (pin 2) and Neutral Start Relay Measure for 12 volts at Neutral Start If good reading, go to next test point. (pin 3). A short to ground will blow Relay (pin 3). Fuse #38.

Key Switch in “ON” position.

12 volts

Open circuit 93 (WH) between Neutral Switch and Neutral Start Relay.

Hydrostat handle in “NEUTRAL” position.

Measure for 12 volts at Neutral Start If good reading, go to the next test Neutral Switch. Perform C -- Neutral Relay (pin 1). point. Switch Test 4

Key Switch in “OFF” position.

Less than 1 ohm

Open in circuit 094 (BK) between Neutral Start Relay (pin 2) and IMPORTANT: When performing con- If good reading, replace the Neutral ground. tinuity test on this circuit, ensure that Start Relay. the cable is disconnected from the battery positive terminal. Failure to do so can result in damage to the test meter. Measure resistance from Neutral Start Relay (pin 2) to ground.

Key Switch in “OFF” position. Re- Pins 3 & 4 -- Less than 1 ohm move the Neutral Start Relay. Measure resistance between relay Pins 3 & 5 -- Infinite resistance (open pins 3 & 4, and between pins 3 & 5. circuit)

55-13

If readings are incorrect, replace relay.

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 E – 24 V Start Relay Test The 24V start relay K-38, 1, is located on the left rear of the combine, just aft of the batteries. It has two 80A fusible links, 2.

56060574

Test Point

Good Reading

Possible Cause of Bad Reading

Key Switch in “START” position.

24 volts

24V Start Relay K-38.

Measure for 24 volts at 24V Start If good reading, relay is operating Open fusible link at 30A on K-38. Relay K-38 (pin 50). properly. Go to next test point. 2

Key Switch in “START” position.

12 volts

Open circuit 804 (WH) between 24V Start Relay (pin 50A) and Start Relay Measure for 12 volts at 24V Start If good reading, go to next test point. (pin 87). Relay K-38 (pin 50A).

Key Switch in “START” position.

24 volts

Open circuit 832 (RD) between 24V Starter and 24V Start Relay (pin 30A).

Measure for 24 volts at 24V Start If good reading, go to the next test Relay K-38 (pin 30A). point. 4

Key Switch in “OFF” position.

Less than 1 ohm

IMPORTANT: When performing If good reading, go to the next test continuity test on this circuit, ensure point. that the cable is disconnected from the battery positive terminal. Failure to do so can result in damage to the test meter.

Open in circuit 833 (BK) between 24V Start Relay and ground.

Measure resistance from 24V Start Relay K-38 (pin 31) to ground. 5

Key Switch in “OFF” position.

Less than 1 ohm.

Measure resistance from 24V Start Relay K-38 (pin 31A) to ground. If good reading, go to the next test point. 6

Key Switch in “OFF” position.

12 volts

Measure for 12 volts at 24V Start Relay (pin 30). If good reading, go to the next test point. 7

Key Switch in “START” position.

12 volts

Measure for 12 volts at 24V Start 24V Start Relay is operating properly. Relay (pin 31A).

55-14

Open fusible link at terminal 31 on K-38.

Open circuit between Rear Battery, G-03, and 24V Start Relay (pin 30).

24V Start Relay failed. Replace 24V Start Relay.

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 F – 24V Starter Motor Test 1

Test Point

Good Reading

Possible Cause of Bad Reading

Battery switch, S-52, if present, in ON position for these tests.

24 volts

Key Switch in START position.

If good reading, go to test point 3.

Open between 24V Starter B+ terminal and Front Battery, G-02, positive terminal.

Measure voltage on B+ terminal of 24V Starter M-29. 2

24V Start Relay, K-38. Go to next test point.

Key Switch in START position.

12 volts

Measure voltage on Front Battery, G-02, negative terminal.

If good reading, check that Front Battery, G-02, terminals are clean and tight.

Key Switch in START position.

24 volts

Measure voltage on 24V Starter, M-29, terminal S.

If good reading, go to test point 5.

Key Switch in START position.

24 volts

Measure voltage on 24V Start Relay, K-38, pin 50.

If good reading, repair open in circuit 834 (WH) to 24V Starter, terminal S.

Key Switch in OFF position.

Less than 1 ohm.

IMPORTANT: When performing continuity test on this circuit, ensure that the cable is disconnected from the battery positive terminal. Failure to do so can result in damage to the test meter.

If good reading, go to next test point.

Open circuit between Front Battery, G-02, negative terminal, and 24V Start Relay, K-38, pin 31A. 24V Start Relay, K-38. Perform 24V Start Relay Test. Open circuit 834 (WH) between 24V Start Relay, K-38, pin 50, and 24V Starter, M-29, pin S. Go to next test point. 24V Start Relay, K-38. Perform 24V Start Relay Test.

Check contact surface of 24V Starter, M-29, with engine. Assure that starter is mounted securely. Check ground strap between engine and chassis.

Measure resistance from case of 24V Starter, M-29, to ground. 6

Set DVOM to read voltage.

Attach positive lead of DVOM to battery positive terminal.

If less than 0.4 volts Shown, and 24V More than 0.4 volts showing on Starter does not operate, replace 24V Voltmeter, replace cable between Starter. battery positive terminal and 24V Starter B+ terminal.

Attach negative lead of DVOM to B+ terminal of 24V Starter. Turn key to “START” position. Less than 0.4 volts should show on voltmeter.

55-15

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 G -- Starting Relay K-15 Test

Test Point

Good Reading

Possible Cause of Bad Reading

Key Switch in START position.

12 volts

Starting Relay, K-15.

Measure voltage on Starting Relay, K-15, pin 5

If good reading, Starting Relay, K-15, is working correctly.

Go to next test point.

Key Switch in START position. Remove the Starting Relay.

12 volts

Open circuit between Starting Relay, K-15, and fuse F-26.

Measure voltage on Starting Relay, K-15, pin 3.

If good reading, go to next test point.

Fuse F-26 blown.

Key Switch in START position. Remove the Starting Relay.

12 volts

Open circuit 502 (WH) between Starting Relay, K-15, pin 1, and Neutral Start Relay, K-23, pin 5.

Measure voltage on Starting Relay, K-15, pin 1.

If good reading, go to next test point.

Neutral Start Relay, K-23. Perform D - Neutral Start Relay Test.

Key Switch in OFF position.

Less than 1 ohm.

Open circuit 148 (BK) between Starting Relay K-15, pin 2, and ground.

IMPORTANT: When performing continuity test on this circuit, assure that the cable is disconnected from the battery positive terminal. Failure to do so can result in damage to the test meter. Measure resistance from Starting Relay, K-15, pin 2, to ground. 5

Key Switch in “OFF” position. Re- Pins 3 & 4 -- Less than 1 ohm move the Starting Relay. Measure resistance between relay Pins 3 & 5 -- Infinite resistance (open pins 3 & 4, and between pins 3 & 5. circuit)

55-16

If readings are incorrect, replace relay.

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 CHARGING SYSTEM DESCRIPTION OF OPERATION The Alternator (B+) connector X213A, 1, is connected to the battery via terminal B+ on the Starter Motor and is grounded to the engine through connector X213B, 2.

NOTE: Alternator installation is shown on IVECO 10.3L engine. Installation on CNH 9.0L engine is similar. The Alternator is self exciting and does not require an excitation circuit. Charging system output is controlled by an integral voltage regulator/brush assembly. The regulator is set to 14.2 volt regulation. The Alternator is temperature compensated so that output will drop as the Alternator warms up.

1 86063848

Refer to schematic frames 1 and 2.

ALTERNATOR SPECIFICATIONS Brand and Part #

Leece--Neville 8SC2282V

Volts/Amps

12V/185A

Adjustable

Internal or External Regulator

Internal

Excitation: Ignition/ Self Excite

Self Excite

Regulator Sense

Local Sense

Lamp Driver (Y/ N)

Adjusting Ear: Style/ Thread Size

1/2--13UNC--2A

Termination Requirements: (Size, SAE, Metric)

B+ 7/16--14UNC preferred(5/16--24UNF sample), Lamp 10--24 UNC , Neg 7/16--14UNC preferred (1/4--28UNF sample)

Shaft Diameter (5/8, 7/8, 17mm)

7/8″

55-17

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 ELECTRICAL SCHEMATICS

G-02 = FRONT BATTERY G-03 = REAR BATTERY K-38 = 24V START RELAY M-29 = 24V STARTER

STARTING FRAME--1

55-18

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0L

55-19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 CHARGING SYSTEM -- TROUBLESHOOTING PRELIMINARY CHECKS

SYMPTOM CHART

Before troubleshooting the charging system make sure that the following operating conditions are met:

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual.

A. The batteries are fully charged connections are clean and tight.

and all

B. Check all alternator connectors for full installation, as well as loose, corroded, pushed out, or bent terminals.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.

Symptom

Possible Cause

System y not charging g g or Charging g g Alternator belt poorly. Battery goes dead. B+ circuit

System overcharging

Reference/Test Replace belt and/or tensioner. A -- Charging System Output Test, test points 2--4

Alternator

A -- Charging System Output Test, test points 4--6.

Alternator

A -- Charging System Output Test, test points 2--4.

55-20

CAUTION

DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.

A -- Charging System Output Test 1

Test Point

Good Reading

Place transmission in PARK.

Measure voltage at battery, should be High resistance between Battery and 12.8--14.5 volts. B+ terminal at Alternator.

Start engine and set at 1200 rpm.

Possible Cause of Bad Reading

If good reading, charging system is operating properly. Go to next test point.

Place negative lead of DVOM to Less than 0.4 volts. High resistance between Battery and Battery positive terminal and positive starter B+ terminal. lead to starter B+ terminal. If good reading, circuit is good. Go to Repair/replace wiring as needed. Read voltage. next test point.

Attach positive lead of DVOM to B+ Less than 0.4 volts High resistance in circuit 802 (RD). terminal of Alternator and negative If good reading, go to the next test Repair/replace wiring as needed. lead to starter B+ terminal. point. Read voltage.

Measure for 12 volts at the B+ Voltage varies between 12.8 and 14.5 Alternator terminal of the Alternator, while volts in response to load applied. Go to next test point. turning various load on and off (lights, If good reading, charging system is heater fans etc.) operating properly

Stop engine, Key Switch in “OFF” Less than 1 ohm position.

High resistance on circuit 803 (BK) from Alternator to engine ground. Clean surfaces at Alternator and engine block.

Measure resistance between Alter- If good reading, repair or replace Ensure that all mountings are clean Alternator. nator housing and engine ground. and tight.

55-21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 GRID HEATER DESCRIPTION The grid heater, 1, Figures 12 and 13, heats the air entering the intake manifold for easier starting in cold climates. The grid heater is controlled by the ECU through relay K-39, 2. Figure 12 shows the grid heater position on the IVECO 10.3L engine. Figure 13 shows the grid heater on the CNH 9.0L engine. Removal NOTE: The removal procedure may vary slightly for different engine types.

3 1

2 86063848

1. Disconnect the battery. 2. Disconnect the air temp/boost pressure sensor connector, 3, Figure 12, on the IVECO 10.3L engine only. 3. Remove the power leads, 4, from the grid heater unit.

56061158

4 13

NOTE: There is a dry gasket on either side of the grid heater. Observe the proper orientation and position of the grid gaskets for installation.

4. Unthread the bolts, 2, to remove the air intake manifold, 3, and the grid heater, 1, from the engine head.

NOTE: During grid heater removal, make sure no dirt and debris enter the engine head. Cover the engine head whenever the grid heater is not in place. 20030059

55-22

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 ELECTRICAL SCHEMATICS Grid Heater Circuit

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0L

55-23

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 GRID HEATER TROUBLESHOOTING Test Points Test Point

Schematic Good Reading Reference

Grid Heater Relay

K--39

When energized, 12 volts at relay Open circuit in wire EN-818-WH-0.8 terminal 1 wire EN-818-WH-08. from ECU.

Grid Heater Relay

K--39

When energized, continuity ground at wire EN-822-BK-08.

Engine Grid Heater

R--09

Resistance between two terminals Defective Grid Heater requires should be approximately 0.5 ohms. replacement.

GRID HEATER FAULT CODES IVECO 10.3L Engine (CR9070) E1551-03

Main Relay SCBATT

E1552-04

Main Relay SCGND

E1558-03

Grid Heater Always Switched On

CNH 9.0L Engine (CR9040, CR9060) E1831-03

Inlet Air Heater Driver #1

E1831-04

Inlet Air Heater Driver #1

55-24

Possible Cause of Bad Reading

to Open circuit in wire EN-822-BK-0.8 to ECU.

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 CONTROL MODULES

LOCATION Item

Description

CCM1

CCM2

CCM3 (If Equipped)

1 3 2 10004693

16 Item

Description

Engine Control Unit (Iveco 10.3L)

86063848

17 Item

Description

Engine Control Unit (CNH 9.0L)

5 56061163

55-25

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 Item

Description

Right hand Control Module

40025230

DESCRIPTION This section describes how the control modules relate to the engine components. CCM2 Ref

Component

Connectors

CCM2 Input/ Output

Circuit

Description

R--01

Fuel Level Sensor

X184 X016

J2--17

MF--427--YE--0.8

The fuel level sensor monitors the amount of fuel within the fuel tank and delivers the information to CCM2.

S--61

Air Filter Sensor

X202 X010 X016

J2--29

EN--864--YE--0.8 EN--420--YE--0.8 MF--420--YE--0.8

The air filter sensor monitors the amount of air flow through the engine air intake system.

S--67

Coolant Level Switch

X439 X010 X016

J2--27

EN--504--YE--0.8 MF--504--YE--0.8

The coolant level switch closes when the coolant level in the shunt tank drops below the switch.

55-26

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 Engine Control Unit (ECU) -- IVECO 10.3L

B--05 B--07

Component

Connectors

ECU Input/ Output

Circuit

Description

Engine Flywheel RPM

X516

Pin 23

WH--1.0

X519

Pin 19

BK--1.0

Measures how fast the engine flywheel is rotating for timing control.

X516

Pin 10

WH--1.0

X518

Pin 9

BK--1.0

Engine Camshaft RPM

B--36

Fuel Temperature Sensor X516

Pin 18

OR/BK--1.0

X372

Pin 35

WH/RD--1.0

B--41

Air Temp/Boost Pres Sensor

X210

Pin 25

WH--1.0

X516

Pin 36

OR--1.0

Pin 34

GN--1.0

Pin 33

RD--1.0

B--44

B--75

L--34

Coolant Temperature Sensor

X516

Pin 15

PK--1.0

X373

Pin 26

YE--1.0

Oil Temperature/ Pressure Sensor

X516

Pin 24

WH--1.0

X517

Pin 27

GN--1.0

Pin 28

OR--1.0

Fuel Actuator

Pin 32

RD--1.0

X515

Pin 13

RD--1.25

X471

Pin 4

WH--1.25

X515

Pin 3

BL--1.25

X471

Pin 14

GY--1.25

X515

Pin 11

YE--1.25

X471

Pin 6

RD--1.25

X515

Pin 15

GY--1.25

X471

Pin 2

BK--1.25

X515

Pin 5

GN--1.25

X471

Pin 12

RD--1.25

X515

Pin 1

PU--1.25

X471

Pin 16

GY--1.25

X376 L--35

Fuel Actuator

X377 L--36

Fuel Actuator

X378 L--37

Fuel Actuator

X379 L--38

Fuel Actuator

X380 L--39

Fuel Actuator

X381

If Electronic Control Unit failure is suspected, inspect the ECU by using the Electronic Service Tool (EST). Refer to the Electronic Service Tool User Guide for more information on proper testing procedures.

55-27

Measures how fast the engine camshaft is rotating for timing purposes. Monitors fuel temperature for engine timing control. Monitors boost pressure and intake air temperature for fuel delivery purposes.

Measures coolant temperature for grid heater actuation and fuel delivery purposes. Monitors engine oil temperature and pressure. Engine oil temperature is used in comparison with coolant temperature for fuel delivery purposes. Each fuel actuator controls start and duration of fuel delivery into an individual combustion chamber.

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 Right Hand Control Module Ref

Component

Connectors

S--36

Throttle Increase / X060 X029 Decrease Switch

RHM Input/ Output

Circuit

Description

Pin 13 (high idle)

RC--318--YE--0.8 RC--369--OR--0.8

The engine throttle switch sends current to either pin 13 (high idle) or pin 4 (low g idle)) of the right--hand control module (RHM) (RHM).

Pin 4 (low RC--322--YE--0.8 idle) RC--369--OR--0.8

ECU POWER SUPPLY The engine control unit (ECU) on either the CNH 9.0L or Iveco 10.3L engines is supplied with power from two sources: CNH 9.0L (CR9040, 9060) Battery power through fuse F-01 to connector X415 pins 3 & 4. Switched power from keyswitch to connector X414 pin 39. IVECO 10.3L (CR9070) Battery power through fuse F-01 to connector X193 pins 2, 3, 8 & 9. Switched power from keyswitch to connector X193 pin 40. When the keyswitch is turned to the “ON” or “START” position, the switched power signals the ECU to “wake-up” in preparation for engine starting. As long as the switched power source to the ECU remains constant, the ECU will remain powered up to control engine functions. If the operator turns the key off, this cuts off the power supply to the ECU connector. When this power supply is lost, the ECU starts its “shut down” routine, including saving files and operating information to memory, and shuts down the engine fuelling system to stop the engine. After several seconds, the ECU will power off. Engine shutdown in the event of machine problems, or for an operator-signaled “kill-stall”, is handled by sending a message to the ECU through CAN, and the ECU shuts down the engine without powering itself off in the process.

55-28

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 ELECTRICAL SCHEMATICS

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0L

55-29

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-30

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 ENGINE-RELATED ERROR CODES -AUTOMATIC SHUTDOWN Description The following alarms/error codes cause the engine to automatically shut down. An alarm message is generated to the operator when each condition occurs; at the same time, an unerasable error message is recorded in the error history as a permanent record. Alarm Messages Alarm Message

Error Message E0135--01

A0081

Hydrostatic Charge Pressure Valid Below Normal

Hydrostatic Charge Pressure Low

E0162--01

A0012

Control Pressure Valid Below Normal

Control Pressure Low

E1565--12 (CR9070) E1796--01 (CR9040, CR9060)

A0002 Engine Oil Pressure Low

A0000 Engine Coolant Temperature High

Engine Shutdown

Pressure below 20 bar (290 Will occur only if the engine is psi) for 2 seconds after engine running for 5 seconds; will shut runs for 3 seconds. down after alarm is present for 2 seconds.

Pressure is below 1 bar (14 psi) Will shut down after alarm is for 3 seconds after engine runs present for 7 seconds. for 10 seconds.

Engine Oil Pressure Valid Below Normal E1567--12 (CR9070 Only)

A0001 Engine Oil Temperature High

Alarm Condition

<5 bar (73 psi) pressure (switch Will occur only if engine is closes) closes). running for at least 4 seconds; will shut down after alarm is present for 2 seconds.

Engine Oil Temperature Valid Above Normal

Temperature greater than Will occur only if engine is 126°C (260°F) for 3 seconds. running for at least 3 seconds; will shut down after alarm is present for 2 seconds.

Temperature is greater than Will occur only if engine is E1801--00 (CR9040, CR9060 Only) 110°C (230°F) for 2.0 seconds. running for at least 3 seconds; will shut down after alarm is Engine Coolant present for 2 seconds. Temperature Valid Above Normal

ECU Related Fault Codes Display Fault Code

Error String

Effect On Engine

E0385

ECU defect

Engine disabled

55-31

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 ENGINE SENSORS NOTE: Use this section in conjunction with the Electronic Service Tool for information regarding the engine components.

CNH 9.0L SENSORS Refer to the “8.3 & 9.0L 6 Cylinder, 24 Valve CNH Engine with High Pressure Common Rail Fuel System” Repair Manual for a description and location of engine sensors on the CNH 9.0L engine, as used in the CR9040 and CR9060 combines.

IVECO 10.3 L SENSORS Engine Oil Temperature/Pressure Sensor Schematic Reference: B--75 Schematic Frame: 4 Connector: X517 The Engine Oil Temperature/Pressure Sensor, 1, monitors the oil temperature and pressure and sends the information to the ECU. When the engine oil exceeds safe operating temperatures, the ECU prompts an alarm code (see below). The ECU monitors the engine oil pressure in an effort to prevent major engine damage, and will warn the operator of insufficient oil pressure. If the oil pressure drops to harmful levels, the engine will shut down automatically. Refer to Engine-related Error Codes -- Automatic Shutdown for more information.

86063850

22 Alarm Code - Engine Oil Temperature Alarm Code

Description

A0001 A0002

Priority

Module

Check Condition

Activation

Resetting

Engine Oil Temperature High High

ECU

Engine Running

3 sec > 110° C

2sec <110° C

Engine Oil Pressure Low High

ECU

Engine Running 3 sec < 1 bar for 10 seconds.

55-32

.5 sec < 1 bar

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 Engine Camshaft RPM Schematic Reference: B--07 Schematic Frame: 4 Connector: X518 The engine camshaft RPM sensor, 1, monitors the camshaft speed for timing purposes. It is connected to pins 9 and 10 of the ECU.

86063853

23 Engine Flywheel RPM Schematic Reference: B--05 Schematic Frame: 4 Connector: X519 The engine flywheel RPM sensor, 1, monitors the flywheel speed for timing purposes. The flywheel sensor is connected to pins 19 and 23 of the ECU.

86063854

55-33

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 Air Temperature/Boost Pressure Sensor Schematic Reference: B--41 Schematic Frame: 4 Connector: X210 The air temperature/boost pressure sensor, 1, measures the pressure and temperature of the air in the intake manifold. It is connected to pins 25, 33, 34, and 36 of the ECU.

86063848

25 Coolant Temperature Sensor Schematic Reference: B--44 Schematic Frame: 4 Connector: X373 The coolant temperature sensor, 1, monitors the temperature of the engine coolant. It is connected to pins 15 and 26 of the ECU.

86063851

55-34

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 Fuel Temperature Sensor Schematic Reference: B--36 Schematic Frame: 4 Connector: X372 The fuel temperature sensor, 1, monitors the temperature of the fuel. It is connected to pins 18 and 35 of the ECU.

86063852

27 Fuel Actuators The fuel actuators, 1, are an integral fuel injector and solenoid assembly mounted in the cylinder head. The fuel injectors are operated by rocker arms and the camshaft. The timing and duration of fuel delivery is controlled by the solenoid.

MID0302A

Fuel Actuator 1 Schematic Reference: L--34 Schematic Frame: 4 Connector: X376

Fuel Actuator 4 Schematic Reference: L--35 Schematic Frame: 4 Connector: X377

Fuel Actuator 2 Schematic Reference: L--36 Schematic Frame: 4 Connector: X378

Fuel Actuator 5 Schematic Reference: L--37 Schematic Frame: 4 Connector: X379

Fuel Actuator 3 Schematic Reference: L--38 Schematic Frame: 4 Connector: X380

Fuel Actuator 6 Schematic Reference: L--39 Schematic Frame: 4 Connector: X381

55-35

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5

10.3L ENGINE FRAME--4

A-01 = ENGINE CONTROL UNIT B-05 = ENGINE FLYWHEEL RPM B-07 = ENGINE CAMSHAFT RPM B-36 = FUEL TEMP

B-41 = AIR TEMP/BOOST PRESS B-44 = COOLANT TEMP B-75 = OIL TEMP/PRESS

L-34 = FUEL ACTUATOR 1 (CYL 1) L-35 = FUEL ACTUATOR 2 (CYL 4) L-36 = FUEL ACTUATOR 3 (CYL 2) L-37 = FUEL ACTUATOR 4 (CYL 6)

L-38 = FUEL ACTUATOR 5 (CYL 3) L-39 = FUEL ACTUATOR 6 (CYL 5)

55-36

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 ALL ENGINES Rotary Screen Brush Actuator Schematic Reference: M--27 Schematic Frame: 3 Connector: X206 The Rotary Screen Brush Actuator, 1, controls the engagement of the brush to the rotary screen.

10004648

30 Starting at the top of the diagram, the Rotary Screen brush is in the “Brush Off” state, which is defined in the dotted box as being that the brush motor is off. In order to change to the next state, the unloading system has to be engaged AND it has to have been at least 10 minutes since the last time the rotary screen brush was last engaged OR it is the first time the unloading system has been engaged since the combine was started up.

Rotary Screen brush logic brush not installed

Brush off

unload in progress AND

When those conditions occur, the module will activate the rotary screen brush (“Brush in” state), by powering the brush actuator motor in. After 7 seconds (the next condition to change states), the module shuts off the power to the actuator motor, and the system is now in the “Brush on” state. After 0.05 seconds, the system moves to the “Brush out” state, and the module once again powers the actuator, this time to retract the brush from the rotary screen. After 7 seconds of powering the actuator, the system moves back to the “brush off” state, and the brush actuator motor is shut off. The system will now wait at least 10 minutes for the next unloading system cycle before re-engaging the brush circuit.

Brush motor OFF

After 10 minutes OR first time after startup

Brush in

After 7 seconds

Brush motor IN

After 7 seconds

Brush on

Brush motor OFF

Fault Code - Rotary Screen Brush Display Fault Code

Description

E0172--06

Curr Sense Rot Scr Brush Short Circuit

E0206--11

Rotary Screen Brush Motor Unidentified Failure Code

After 0.05 seconds after contact key on

Brush out

Brush motor OUT

55-37

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 Fuel Level Sensor Schematic Reference: R--01 Schematic Frame: 3 Connector: X184 The fuel level sensor, 1, monitors the amount of fuel inside the fuel tank and sends the signal to pin J2--17 of CCM2. As the fuel level rises and lowers inside the fuel tank, the variable resistance through the sensor changes. CCM2 monitors this variable resistance and sends the information to the fuel gauge in the display.

10010875

32 Alarm Code - Fuel Level Sensor Alarm Code

Description

Priority

Module

Check Condition

Activation

Resetting

A0004

Fuel Level

Low

CCM2

4 sec < 20 bar

4 sec < 12%

Fault Code - Fuel Level Sensor Display Fault Code

Description

E0154--03

Fuel Level Sensor Shorted to High Source

E0154--04

Fuel Level Sensor Shorted to Low Source

E0154--05

Fuel Level Sensor Line Disconnected

55-38

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5 Air Filter Pressure Switch Schematic Reference: S--61 Schematic Frame: 3 Connector: X202 The air filter pressure switch, 1, monitors the air pressure inside the intake manifold. When the pressure drops below safe levels, the sensor sends the information to pin J2--24 of CCM2.

86063817

33 Alarm Code - Air Filter Switch Alarm Code

Description

Priority

Module

Check Condition Activation

Resetting

A0005

Air Filter Blocked

Low

CCM2

2 sec < 61 mbar

10 sec < 61 mbar

Fault Code - Air Filter Switch Display Fault Code

Description

E0163--03

Engine Air Filter Sensor Shorted to High Source

E0154--05

Engine Air Filter Sensor Line Disconnected

Fuel Pump Actuator Schematic Reference: M--23 Schematic Frame: 3 Connector: X183 The fuel pump, 1, delivers fuel to the engine injection pump. The fuel pump is powered from fuse F28 through the fuel pump relay K07 whenever the key switch is in the “ON” position.

10010875

55-39

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 5

B-22 = REAR LADDER F-23 = SCREEN BRUSH FUSE F-28 = FUEL PUMP FUSE K-07 = FUEL PUMP RELAY

M-23 = FUEL PUMP M-27 = ROTARY SCREEN BRUSH R-01 = FUEL LEVEL S-36 = ENGINE THROTTLE

S-61 = AIR FILTER SWITCH S-67 = COOLANT LEVEL

STARTING FRAME--3

55-40

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

SECTION 55 - ELECTRICAL SYSTEMS Chapter 6 - Power Distribution and Lighting CONTENTS Section

Description Page Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuse/Relay Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Fuse/Circuit Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Power Distribution: Unswitched and Switched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Power Distribution Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Power Distribution Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Lighting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Circuit/Fuse Lighting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 CR NA Lighting - Steering Column Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 CR Australian Lighting - Steering Column Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 CR NA Lighting - Rocker Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 CR Australian Lighting - Rocker Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Lighting Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Hazard Light Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Marker Light Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Road Lights - Low Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Road Lights - High Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Brake Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Beacon Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Front Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Rear Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Side Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Stubble Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Grain Tank Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Unload Tube Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Header Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Center Work Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 Section

Description

Page

55-2

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 POWER DISTRIBUTION With the two batteries in parallel, 12-volt supply voltage is made available to the power distribution network at K-38 pin 30, via wire RD-50-0 to the buss bar in the fuse/relay panel, and via wire AL-802 to the B terminal of alternator G-01. Connection is also made to the B+ terminal of grid heater relay K-39 via wire EN-RD-16.0.

Description Refer to schematic Frames 1, 2, 9 and 29. Two 12-volt batteries, normally wired in parallel, supply power for the combine 12-volt power distribution system. Terminal 30 of 24-volt start relay K-38 serves as the 12-volt supply terminal for the combine power distribution network. This power is made available, via heavy-gauge wire RD-5.0, at the buss bar within the fuse/relay panel in the cab. The 12-volt supply voltage is then distributed to the combine electrical/ electronics systems through fuses.

Start Mode For engine starting, the key switch S-02 (Frame 29) is moved to the START position. Assuming neutral switch S-22 (Frame 9) is on (multifunction handle in NEUTRAL), neutral start relay K-23 (Frame 2) is energized, providing a current path from the key switch to the coil of relay K-15. K-15 energizes and, in turn, energizes the 24-volt start relay K-38 by applying +12 volts from fuse F-26 to its coil.

Throughout the power distribution system, ground return wires are tied to the nearest ground terminal. Charging voltage from alternator G-01 is also applied to the batteries at terminal 30 of K-38.

When K-38 energizes, the normally closed contacts now open, opening the connections between K-38 pins 30A and 30, and 31A and 31. This removes the parallel connections between the two batteries.

The power distribution system works in two modes: run and start. The 24-volt start relay K-38 switches between the two modes.

Normally open contacts 31A and 30, and 30A and 50 are now closed. This places the two batteries in series through the following path: G-03 negative terminal remains grounded; G-03 positive terminal connects to G-02 negative terminal through K-38 contacts 30 and 31A; G-02 positive terminal connects to B+ terminal of starter motor M-29. The voltage present at this terminal is now 24 volts.

Run mode is for normal operation, when the system batteries are supplying 12 volts to the power distribution network. Start mode is for engine starting, when the batteries supply 24 volts to the starter motor. Run Mode In normal operation, the front (G-02) and rear (G-03) batteries are wired in parallel. This requires that the positive terminal of G-02 be connected to the positive terminal of G-03. Likewise, the negative terminals of both batteries must be connected together.

At the same time, the 24 volts now present a G-02’s positive terminal is applied to M-29’s S terminal via wire 832, K-38 contacts 30A and 50, and wire 834. This energizes the start solenoid in M-29, and the engine cranks. The starter motor M-29 is the only component in the combine electrical system that uses 24 volts.

When relay K-38 (Frame 1) is de-energized, the positive terminal of G-02 connects to the positive terminal of G-03 through this path: G-02 positive terminal to the B+ terminal of starter motor M-29 via wire RD-70-0; wire 832 from M-29 B+ to K-38 pin 30A; through the normally closed contacts to pin 30, and wire RD/WH-70.0 to G-03 positive.

NOTE: Even when K-38 has reconfigured the batteries for series operation, the 12-volt bus is still powered from battery G-03 via wires RD/WH-70.0 and RD-50.0. The ground reference is through the fixed connection from G-03’s negative terminal to ground via wire BK-70.0.

The negative terminals connect together through this path: G-02 negative via wire BK-70.0 to K-38 pin 31A, through normally closed contacts to pin 31, via wire 833 to G-03 negative terminal, and to ground through wire BK-70.0.

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

55-7

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 1

50024376

50020070

50024375

5 3

40020079 50031001

50031002

50024378

1. 2. 3. 4.

Starter Motor M29 Rear Frame Ground 24 V Start Relay K38 Front Battery G02

5. 6. 7.

55-8

Rear Battery G03 Front Frame Ground 12 V Connection to Fuse Panel

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 FUSE/RELAY PANEL

7.5 A 7.5 A

55-9

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 FUSE/CIRCUIT CHART Fuse #

Power Type

Circuit Number to power

Circuit Energized

Unswitched

016 (RD)

ECU power

Unswitched

018 (RD)

Accessory 2 relay, K-03

Unswitched

020 (RD)

Accessory 1 relay, K-08

Unswitched

070 (RD)

Wiper relay, K-06

Unswitched

085 (OR)

Cigar lighter, R-08

Switched

058 (OR)

Left-hand cab outer work light, E-15; mid work light, E-19

Switched

059 (OR)

Right-hand cab outer work light, E-16; mid work light, E-20

Switched

084, 086 (OR)

Accessory outlets, J-06, 08

Switched

079 (OR)

Switches, washer, S-38; mirror heat, S-19; mirror adjust, S-27

Switched

1002 (OR)

Not used

Switched

081 (OR)

Radio, A-04

Switched

082 (OR)

Not used

Switched

083 (OR)

Auxiliary radio power connector, M-26

Switched

604 (OR)

Sieve light switch, S-54

Unswitched

068 (RD)

Service sockets, J-02, J-03, J-05

Unswitched

080 (OR)

Seat adjust switch, S-45

Unswitched

930 (RD)

Separator blower relay, K-09

Unswitched

938 (RD)

Main blower relays, K-11, K-12, K-13

Unswitched

087 (RD)

A/C clutch relay, K-10

Switched

177 (PU)

Left-hand marker lights, E-03, 11, 39, 50

Switched

176 (PU)

Right-hand marker lights, E-04, 12, 49

Unswitched

024 (RD)

CCM1. Shoe leveling actuator

Unswitched

025, 028 (RD)

CCM2. Throttle/brush

Unswitched

026, 027 (RD)

CCM1. Reverser/fan

Unswitched

029 (RD)

CCM2. Transmission gearshift motor

Unswitched

030, 525 (RD)

Start fuse

Unswitched

031 (RD)

CCM3. Sieve/spreader

Unswitched

205 (RD)

Fuel pump relay, K-07

Unswitched

060 (RD)

Distance work lights relay, K-21

Unswitched

062 (RD)

Header work lights relay, K-22

Unswitched

022 (RD)

Cab Roof work lights relay, K-01

Unswitched

185 (RD)

High beam relay, K-04

Unswitched

236 (RD)

Low beam relay, K-05

Unswitched

214, 215 (RD)

Under shield lights switches, S-63, S-64, S-65

Unswitched

048 (RD)

Radio KAPWR

Switched

037, 038 (OR)

CCM2A

Switched

039 (OR)

CCM2B

55-10

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 Fuse #

Power Type

Circuit Number to power

Circuit Energized

Unswitched

053 (RD)

Key switch, S-02

Unswitched

047 (RD)

Memory (KAPWR)

Unswitched

012 (RD)

CCM1 power relay, K-24

Unswitched

014 (RD)

CCM2 power relay, K-25

Unswitched

010 (RD)

CCM3, cab power relay, K-26

Switched

032, 033 (OR)

CCM1A

Switched

034 (OR)

CCM1B

Switched

013 (OR)

HHC module, A-07

Switched

580 (OR)

ASP amplifier, A-08

Switched

035, 036 (OR)

CCM3, moisture sensor, B-12; sample motor, M-28; yield sensor, R-05

Switched

108 (OR)

Splice block B, neutral switch, S-22; thresher engage switch, S-30; latching relay, K-28

Switched

045, 046, 061, 213 (OR)

Work light switch, S-43, rear work light switch, S-44, beacon light switch, S-41, HVAC control, A-09, tank extensions switch, S-42, seat switch, S-05.

Unswitched

073, 074 (RD)

Unload tube light relay, K-32; timed side work light relay, K-34.

Unswitched

214 (RD)

Road light switch, S-26; horn, H-02

Unswitched

056 (RD)

Brake lights relay, K-33, time delay module, K-20, dome light, E-34.

Unswitched

069 (RD)

Beacon light relay, K-29

Unswitched

064 (RD)

Lower work lights relay, K-30

Unswitched

066 (RD)

Rear work lights relay, K-31

Unswitched

054 (RD)

Hazard switch, S-25

55-11

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 POWER DISTRIBUTION: UNSWITCHED AND SWITCHED Power is supplied to the system in two modes: unswitched and switched.

K-06, wiper relay, supplying power to wiper switch S-20.

1. Unswitched power is that which is available to the system at all times, regardless of the position of the ignition switch. In this mode, the battery voltage is applied directly to the power buss bar in the electrical system fuse/relay panel, located in the cab. Those circuits intended to be energized at all times get their power from this buss.

K-08, accessory 1 relay, supplying power to fuses F-08, F-09 and F-10. NOTE: K-03, K-06 and K-08 are energized in both ACC and IGN positions of key switch S-02. K-24, CCM1 power relay, supplying power to fuses F-43, F-44 and F-45.

Unswitched power is supplied to these fuses: F-1 to F-5 F-15 to F-19 F-22 to F-35 F-38 to F-42 F-50 to F-56

K-25, CCM2 power relay, supplying power to fuses F-36, F-37 and F-46.

2. Switched power is supplied to the system only when ignition switch S-02 is turned on. This switches battery power to the following relays, which, when energized, supply battery power to the fuses listed:

K-01, cab roof lights relay, supplying power to F-06 and F-07.

K-26 CCM3/cab power relay, supplying power to fuses F-47, F-48 and F-49. Other fuses receive switched power by way of the following relays switched from CCM1:

K-03, accessory 2 relay, supplying power to fuses F-11, F-12, F-13, and F-14.

K-02, light control relay, supplying power to F-20 and F-21. The Fuse/Circuit Chart lists the system fuses, their power feed mode (unswitched or switched) and the circuits they supply.

POWER DISTRIBUTION CIRCUIT TROUBLESHOOTING When starting out to troubleshoot a problem in the power distribution system, checking for obvious things first can save time. 1. First of all, for safety purposes, make sure all operating controls are in neutral or park lock position. 2. Make sure the batteries are fully charged and all connections are clean and tight. 3. If the problem circuit is a switched circuit, make sure the key switch is on.

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4. Check the fuse supplying the problem circuit. If blown, replace. If the fuse blows again, further troubleshooting is needed to find the cause of the excessive current. 5. Check the electrical connectors supplying the problem circuit for loose, corroded or pushed-out terminals. Check also for pulled-out or broken wires. Make sure the connectors are fully seated.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 POWER DISTRIBUTION SYMPTOM CHART NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.

DIAGNOSTIC TESTS Symptom

Possible Cause

Reference/Test

No power at one fuse.

Power supply to fuse

Go to fuse/circuit chart to determine power supply circuit.

No power at switched fuses F-47, F-48, F-49.

CCM3 Cab Power Relay K-26

A - CCM3 Cab Power Relay Test.

No power at switched fuses F-36, F-37, F-46.

CCM2 Cab Power Relay K-25

B - CCM2 Power Relay Test.

No power at switched fuses F-43, F-44, F-45.

CCM1 Cab Power Relay K-24

C - CCM1 Power Relay Test.

No power at switched fuses F-08, F-09, F-10.

Accessory 1 Relay K-08

D - Accessory 1 Relay Test.

No power at switched fuses F-11, F-12, F-13, F-14.

Accessory 2 Relay K-03

E - Accessory 2 Relay Test.

55-13

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.

A - CCM3/CAB POWER RELAY TEST Test Point

Good Reading

Possible Cause of Bad Reading

Check for 12 volts at CCM3/Cab power relay K-26 (pin 3).

12 volts If good reading, continue with next step.

Blown Fuse #42. Open circuit 10 (RD) between CCM3/Cab power relay K-26 (pin 3) and Fuse #42.

Key Switch S-02 in the “ON” position. Check for 12 volts at CCM3/Cab power relay K-26 (pin 1).

12 volts If good reading, continue with next step.

Open circuit 104 (OR), 103 (OR), 095 (OR) or 096 (OR) between Key Switch S-02 connector X068 (pin 6) and CCM3/Cab power relay K-26 (pin 1). 12 volts not available from Key Switch S-02 connector X068 (pin 6), refer to Key Switch Test, Section 55, Chapter 5, Table B.

At CCM3/Cab power relay, K-26 ground (pin 2) and check for 12 volts at CCM3/Cab power relay K-26 (pin 5).

12 volts If good reading, CCM3/ Cab power relay is operating properly. If good reading continue with next step.

Faulty CCM3/Cab power relay K-26. Short to ground in circuit 007 (RD). A short to ground will blow Fuse #42.

At CCM1, ground (pin J1-23) and check for 12 volts at CCM3/Cab power relay K-26 (pin 5).

12 volts If good reading, replace CCM1.

Open circuit 107 (BK) between CCM1 (pin J1-23) and CCM3/Cab power relay K-26 (pin 2).

55-14

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 B - CCM2 POWER RELAY TEST Test Point

Good Reading

Possible Cause of Bad Reading

Check for 12 volts at CCM2 power relay K-25 (pin 3).

12 volts If good reading, continue with next step.

Blown Fuse #41. Open circuit 14 (RD) between CCM2 power relay K-25 (pin 3) and Fuse #41.

Key Switch S-02 ON. Check for 12 volts at CCM2 power relay K-25 (pin 1).

12 volts If good reading, continue with next step.

Open circuit 103 (OR), 095 (OR) or 096 (OR) between Key Switch S-02 Connector X068 (pin 6) and CCM2 power relay K-25 (pin 1). 12 volts not available from Key Switch S-02 Connector X068 (pin 6), refer to Key Switch test, Section 55, Chapter 5, Table B.

At CCM2 power relay K-25, ground (pin 2) and check for 12 volts at CCM2 power relay K-25 (pin 5).

12 volts If good reading, CCM2 power relay K-25 is operating properly. Continue with next step.

Faulty CCM2 power relay K-25.

Key Switch S-02 OFF. Check resistance of circuit 106 (BK) between CCM2 power relay K-25 (pin 2) and CCM3/Cab power relay K-26 (pin 2).

Less than 1 ohm resistance. If good reading, replace CCM1.

Open circuit106 (BK) between CCM2 power relay K-25 (pin 2) and CCM3/Cab power relay K-26 (pin 2).

C - CCM1 POWER RELAY TEST Test Point

Good Reading

Possible Cause of Bad Reading

Check for 12 volts at CCM1 Power Relay K-24 (pin 3).

12 volts If good reading, continue with next step.

Blown Fuse #40. Open circuit 12 (RD) between CCM1 Power Relay K-24 (pin 3) and Fuse #40.

Key Switch S-02 ON. Check for 12 volts at CCM1 Power Relay K-24 (pin 1).

12 volts If good reading, continue with next step.

Open circuit 095 (OR) or 096 (OR) between Key Switch S-02 connector X068 (pin 6) and CCM1 Power Relay K-24 (pin 1). 12 volts not available from Key Switch S-02 connector X068 (pin 6), refer to Key Switch test, Section 55, Chapter 5, Table B.

At CCM1 Power Relay K-24, ground (pin 2) and check for 12 volts at CCM1 Power Relay K-24 (pin 5).

12 volts If good reading, CCM1 Power Relay K-24 is operating properly. Continue with next step.

Faulty CCM1 Power Relay K-24.

Key Switch S-02 OFF. Check resistance of circuit 105 (BK) between CCM1 Power Relay K-24 (pin 2) and CCM2 Power Relay K-25 (pin 2).

Less than 1 ohm resistance. If good reading, replace CCM1.

Open circuit 105 (BK) between CCM1 Power Relay K-24 (pin 2) and CCM2 Power Relay K-25 (pin 2).

55-15

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 D - ACCESSORY 1 RELAY TEST Test Point

Good Reading

Possible Cause of Bad Reading

Key Switch S-02 “ON” Measure for 12 volts at Accessory 1 Relay K-08 (pin 5).

12 volts If good reading, relay is operating properly.

Accessory 1 Relay K-08. Adjacent circuits. Go to next test point.

Check for 12 volts at Accessory 1 Relay K-08 (pin 3).

12 volts If good reading, continue with next step.

Blown Fuse #3. Open circuit 20 (RD) between Accessory 1 Relay K-08 (pin 3) and Fuse #3.

Key Switch S-02 “ON”. Check for 12 volts at Accessory 1 Relay K-08 (pin 1).

12 volts If good reading, continue with next step.

Open circuit 241 (OR) between Key Switch S-02 connector X068 (pin 6) and Accessory 1 Relay K-08 (pin 1). If 12 volts not available from Key Switch S-02 connector X068 (pin 6), refer to Key Switch test, Section 55, Chapter 5, Table B.

Check resistance of circuit 150 (BK) between Accessory 1 Relay K-08 (pin 2) and ground.

Less than 1 ohm resistance.

Open circuit 150 (BK) between Accessory 1 Relay K-08 and ground.

E - ACCESSORY 2 RELAY TEST Test Point

Good Reading

Possible Cause of Bad Reading

Key Switch S-02 “ON” Measure for 12 volts at Accessory 2 Relay K-03 (pin 5).

12 volts If good reading, relay is operating properly.

Accessory 2 Relay K-03. Adjacent circuits. Go to next test point.

Check for 12 volts at Accessory 2 Relay K-03 (pin 3).

12 volts If good reading, continue with next step.

Blown Fuse #2. Open circuit 18 (RD) between Accessory 2 Relay K-03 (pin 3) and Fuse #2.

Key Switch S-02 “ON”. Check for 12 volts at Accessory 2 Relay K-03 (pin 1).

12 volts If good reading, continue with next step.

Open circuit 126 (OR), 241 (OR) or 123 (OR) between Key Switch S-02 connector X068 (pin 4) and Accessory 2 Relay K-03 (pin 1). If 12 volts not available from Key Switch S-02 connector X068 (pin 4), refer to Key Switch test.

Key Switch S-02 “OFF”. Check resistance of circuit 149 (BK) between Accessory 2 Relay K-03 (pin 2) and ground.

Less than 1 ohm resistance.

Open circuit 149 (BK) between Accessory 2 Relay K-03 and ground.

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 LIGHTING SYSTEM Brake Lights Beacon Lights Front Work Lights Rear Work Lights Side Work Lights Under Shield/Service Lighting Backlighting

The CR Series combines are equipped with several lighting circuits to provide illumination as required for different operations. Lighting packages may vary depending on country. The lighting circuits may be generally grouped as follows: Hazard Lights Marker Lights Road Lights Turn Signals

E-20

E-32

E-17

E-18

E-19

E-31

E-15

E-16 E-38

E-23

E-25

E-26 E-22

E-04

E-03

E-23

E-24 E-14

E-13

56060944

2 North American – Front View E-03

LEFT-HAND FRONT HAZARD LIGHT

E-21

LEFT-HAND HEADER LIGHT

E-04

RIGHT-HAND FRONT HAZARD LIGHT

E-22

RIGHT-HAND HEADER LIGHT

E-13

LEFT-HAND ROAD LIGHT

E-23

LEFT-HAND STUBBLE LIGHT

E-14

RIGHT-HAND ROAD LIGHT

E-24

RIGHT-HAND STUBBLE LIGHT

E-15

LEFT-HAND CAB OUTER WORK LIGHT

E-25

LEFT-HAND SIDE WORK LIGHT

E-16

RIGHT-HAND CAB OUTER WORK LIGHT

E-26

RIGHT-HAND SIDE WORK LIGHT

E-17

LEFT-HAND CAB INNER WORK LIGHT

E-31

LEFT-HAND FRONT BEACON

E-18

RIGHT-HAND CAB INNER WORK LIGHT

E-32

RIGHT-HAND FRONT BEACON

E-19

LEFT-HAND CAB MID WORK LIGHT

E-38

CENTER WORK LIGHT

E-20

RIGHT-HAND CAB MID WORK LIGHT

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 E-33

E-29

E-08

E-07

E-12

E-11

E-27

E-28

56060591

3 North American – Rear View E-07

LEFT-HAND NASO FLASHING LIGHT

E-11

LEFT-HAND BRAKE/TAIL LIGHT

E-08

RIGHT-HAND NASO FLASHING LIGHT

E-28

RIGHT-HAND REAR WORK LIGHT

E-12

RIGHT-HAND BRAKE/TAIL LIGHT

E-29

UNLOAD TUBE LIGHT

E-27

LEFT-HAND REAR WORK LIGHT

E-33

REAR BEACON

55-18

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 E-16

E-32

E-31

E-17

E-15

E-25

E-26 E-18 E-22

E-38

E-19

E-21

E-20

E-49 E-50

E-03 E-04 E-23 E-24

E-14

E-13

56065460

4 Australian – Front View E-03

LEFT-HAND FRONT HAZARD LIGHT

E-22

RIGHT-HAND HEADER LIGHT

E-04

RIGHT-HAND FRONT HAZARD LIGHT

E-23

LEFT-HAND STUBBLE LIGHT

E-13

LEFT-HAND ROAD LIGHT

E-24

RIGHT-HAND STUBBLE LIGHT

E-14

RIGHT-HAND ROAD LIGHT

E-25

LEFT-HAND SIDE WORK LIGHT

E-15

LEFT-HAND CAB OUTER WORK LIGHT

E-26

RIGHT-HAND SIDE WORK LIGHT

E-16

RIGHT-HAND CAB OUTER WORK LIGHT

E-31

LEFT-HAND FRONT BEACON

E-17

LEFT-HAND CAB INNER WORK LIGHT

E-32

RIGHT-HAND FRONT BEACON

E-18

RIGHT-HAND CAB INNER WORK LIGHT

E-38

CENTER WORK LIGHT

E-19

LEFT-HAND CAB MID WORK LIGHT

E-49

RIGHT-HAND POSITION LIGHT

E-20

RIGHT-HAND CAB MID WORK LIGHT

E-50

LEFT-HAND POSITION LIGHT

E-21

LEFT-HAND HEADER LIGHT

55-19

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

E-33

E-29

E-28

E-27 E-05

E-11

E-06

E-12

56060590

5 Australian – Rear View E-05

LEFT-HAND REAR FLASHING LIGHT

E-27

LEFT-HAND REAR WORK LIGHT

E-06

RIGHT-HAND REAR FLASHING LIGHT

E-28

RIGHT-HAND REAR WORK LIGHT

E-11

LEFT-HAND BRAKE/TAIL LIGHT

E-29

UNLOAD TUBE LIGHT

E-12

RIGHT-HAND BRAKE/TAIL LIGHT

E-33

REAR BEACON

55-20

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 NOTE: The exact lighting configurations on the CR combine are affected by the specific marker configurations, refer to the following chart to identify the lights installed by market:

LIGHTING CHART NORTH AMERICA

AUSTRALIA

LEFT-HAND HEADER FLASHING

E-01

RIGHT-HAND HEADER FLASHING

E-02

LEFT-HAND FRONT HAZARD

E-03

RIGHT-HAND FRONT HAZARD

E-04

LEFT-HAND REAR FLASHING

E-05

RIGHT-HAND REAR FLASHING

E-06

LEFT-HAND NASO FLASHING

E-07

RIGHT-HAND NASO FLASHING

E-08

TURN INDICATOR

E-09

HIGH BEAM INDICATOR

E-10

LEFT-HAND BRAKE/MARKER

E-11

RIGHT-HAND BRAKE/MARKER

E-12

LEFT-HAND ROAD LIGHTS

E-13

RIGHT-HAND ROAD LIGHTS

E-14

LEFT-HAND CAB OUTER WORK

E-15

RIGHT-HAND CAB OUTER WORK

E-16

LEFT-HAND CAB INNER WORK

E-17

RIGHT-HAND CAB INNER WORK

E-18

LEFT-HAND CAB MID WORK

E-19

RIGHT-HAND CAB MID WORK

E-20

LEFT-HAND HEADER LIGHTS

E-21

RIGHT-HAND HEADER LIGHTS

E-22

LEFT-HAND LOWER WORK

E-23

RIGHT-HAND LOWER WORK

E-24

LEFT-HAND SIDE WORK

E-25

RIGHT-HAND SIDE WORK

E-26

LEFT-HAND REAR WORK

E-27

RIGHT-HAND REAR WORK

E-28

UNLOAD TUBE LIGHT

E-29

GRAIN TANK LIGHT

E-30

LEFT-HAND FRONT BEACON

E-31

RIGHT-HAND FRONT BEACON

E-32

REAR BEACON

E-33

DOME LIGHT

E-34

CONSOLE LIGHT

E-35

COLD START INDICATOR

E-36

55-21

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 LIGHTING CHART NORTH AMERICA

AUSTRALIA

SIEVE LIGHT

E-37

CENTER WORK LIGHT

E-38

LEFT-HAND FRONT SHIELD

E-42

LEFT-HAND REAR SHIELD

E-43

RIGHT-HAND FRONT SHIELD

E-44

RIGHT-HAND REAR SHIELD

E-45

ENGINE LIGHT

E-46

RIGHT-HAND POSITION LAMP

E-49

LEFT-HAND POSITION LAMP

E-50

55-22

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 CIRCUIT/FUSE LIGHTING CHART CIRCUIT

FUSE #

Left-hand Cab Outer Work Light (E-15) Left-hand Cab Mid Work Light (E19)

FUSE-06,31

Right-hand Cab Outer Work Light (E-16) Right-hand Cab Mid Work Light (E-20)

FUSE-07,31

Sieve Light (E-37)

FUSE–14

Left-hand Front Hazard Lamp (E-03) Unload Tube Marker Light (E-39) Left-hand Position FUSE-20,49 Lamp (E-50) Left-hand Tail Light (E-11) Right-hand Front Hazard Lamp (E-04) Right-hand Position Lamp (E-49) Right-hand Tail Light (E-12)

FUSE-21,49

Left-hand Cab Inner Work Light (E-17) RIGHT-HAND Cab Inner Work Light (E-18)

FUSE-29

Left-hand Header Light (E-21) RIGHT-HAND Header Light (E-22) Center Work Light (E-38)

FUSE-30

Left-hand Cab Work Lights Fuse (F-06) Right-hand Cab Work Lights Fuse (F-07) Left-hand Cab Outer Work Light (E-15) Right-hand Cab Outer Work Light (E-16) Left-hand Cab Mid Work Light (E-19) Right-hand Cab Mid Work Light (E-20)

FUSE-31

Right-hand Road Lights (E-13/14) High Beams

FUSE-32,49,51

Left-hand Road Lights (E-13/14) Low Beams

FUSE-33,49

Left-hand Front Shield Light (E-42) Right-hand Front Shield Light (E-43) Right-hand Front Shield Light (E-44) Right-hand Rear Shield Light (E-45) Engine Light (E-46)

FUSE-34

Side Work Light (E-25) Side Work Light (E-26)

FUSE-50,52

Unload Tube Light (E-29)

FUSE-50

Left-hand Brake Light (E-11) Right-hand Brake Light (E-12) Dome Light (E-34)

FUSE-52

Left-hand Front Beacon Light (E-31) Right-hand Front Beacon Light (E-32) Rear Beacon Light (E-33)

FUSE-53,49

Left-hand Stubble Light (E23) Right-hand Stubble Light (E24) Grain Tank Light (E-30)

FUSE-54

Left-hand Rear Work Light (E-27) Right-hand Rear Work Light (E-28)

FUSE-55

Left-hand Header Flashing Lamp (E-01) Right-hand Header Flashing Lamp (E-02) Left-hand NASO Flashing Lamp (E-07) Right-hand NASO Flashing Lamp (E-08) Turn Indicator (E-09) High Beam Indicator (E-10) Left-hand Rear Flashing Lamp (E-05) Right-hand Rear Flashing Lamp (E-06) Left-hand Front Hazard Lamp (E-03) Right-hand Front Hazard Lamp (E-04)

FUSE-56

55-23

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 LIGHTING CONTROLS The following switches and controls are used by the operator to select and control the lighting on the combine:

a1 b1 a2

ZDA3953B

CR NA LIGHTING - STEERING COLUMN CONTROL CONTROL STALK, 1, POSITION (Figure 6) ROAD MODE a1 – Lever up Right turn indicators flash. Left turn indicators illuminated, but not flashing. a2 – Lever down

Left turn indicators flash. Right turn indicators illuminated, but not flashing.

b1 – Twist to position 1 b2 – Twist to position 2

Marker lights on. Headlights and marker lights on. Headlights on low beams Headlights on high beams

FIELD MODE Side work lights turn on. NOTE: Front work lights must be on. Side work lights turn on. NOTE: Front work lights must be on. Marker lights on. Headlights and marker lights on. Headlights on low beams Headlights on high beams

ROAD MODE Hazard lights on

FIELD MODE Hazard lights on

c1 – Pull to rear c2 – Push to front HAZARD LIGHT SWITCH, 2, (Figure 6) Press to turn on NOTE: If hazard light switch is on, the following lights are disabled: Cab inner work lights Rear work lights Stubble lights, Unload tube light Grain tank light Header lights Center work light

55-24

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

a1 b1 a2

b2 c2

CR AUSTRALIAN LIGHTING - STEERING COLUMN CONTROL CONTROL STALK, 1, POSITION (Figure 7)

ROAD MODE

FIELD MODE

a1 – Lever up

Right turn indicators flash. Left turn indicators not illuminated.

Side work lights turn on. NOTE: Front work lights must be on.

a2 – Lever down

Left turn indicators flash. Right turn indicators not illuminated

Side work lights turn on. NOTE: Front work lights must be on.

b1 – Twist to position 1

Marker lights on.

b2 – Twist to position 2

Headlights and marker lights on.

c1 – Pull to rear

Headlights on low beams

c2 – Push to front

Headlights on high beams

HAZARD LIGHT SWITCH, 2, (Figure 7) Press to turn on NOTE: If hazard light switch is on, the following lights are disabled: Cab inner work lights Center work light Stubble lights Rear work light Grain tank light Unload tube light Header lights

ROAD MODE Hazard lights on

55-25

FIELD MODE Hazard lights on

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

CR NA LIGHTING - ROCKER SWITCHES ROCKER SWITCH (Figure 8) 1 Work lights

LIGHTS ACTIVATED Cab outer work lights Cab mid work lights Cab inner work lights Stubble lights Header lights Center work light Grain tank light

POSITION 1

POSITION 2

ROAD

FIELD

ROAD

FIELD

ON ON OFF OFF OFF OFF OFF

ON ON OFF ON ON ON ON

ON ON OFF OFF OFF OFF OFF

ON ON ON ON ON ON ON

ROAD

FIELD

2 Rear work lights

Rear work lights (Combine in reverse, front work lights on)

OFF ON

ON ON

3 Beacon lights NOTE: Beacon lights also come on at: Initial startup (3 s) Grain tank 3/4 full (10 s) Grain tank full (10 s)

Beacons

55-26

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 CR AUSTRALIAN LIGHTING - ROCKER SWITCHES ROCKER SWITCH

LIGHTS ACTIVATED

2 Rear work lights

3 Beacon lights

POSITION 2

ROAD

FIELD

ROAD

FIELD

Cab outer work lights

Cab mid work lights

Cab inner work lights

OFF

Stubble lights

OFF

Header lights

OFF

Center work light

OFF

Grain tank light

OFF

(Figure 8) 1 Work lights

POSITION 1

ROAD

FIELD

Rear work lights

OFF

(Combine in reverse, front work lights on)

Beacons

NOTE: Beacon lights also come on at: Initial startup (3 s) Grain tank 3/4 full (10 s) Grain tank full (10 s)

55-27

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 LIGHTING CIRCUITS HAZARD LIGHT CIRCUITS NOTE: Failed bulbs, poor connections, or broken circuitry may cause the flashers to flash on and off at an irregular rate. If trailer lights are connected, the lighting system will function differently. For example, when trailer lights are connected to the lighting circuit, a bulb failure will have less effect on the operation of the circuit.

Pin 3 supplies pulsing voltage to the hazard lights on the left side of the combine: Left-hand front hazard light E-03 Left-hand rear flashing light E-05 (Australia) Left-hand header flasher E-01

Circuit Operation Refer to Hazard Light Circuits functional diagram Figure 9. For detailed circuit tracing, refer to schematic Frames 33, 34 and 35.

Pin 4 supplies pulsing voltage to the hazard lights on the right side of the combine: Right-hand front hazard light E-04 Right-hand rear flashing light E-06 (Australia) Right-hand header flasher E-02

Closing hazard switch S-25 (“On” position) applies +12 volts to pin 2 of flasher module A-05. At the same time, S-25 applies voltage to its internal light-emitting diode (LED) indicator, which illuminates. The voltage at pin 2 of A-05 activates the module, and pulsing voltage appears at output pins 3 and 4. These pulsing voltage signals cause the LED indicators in turn indicator E-09 to flash on and off. At the same time, A-05 pins 3 and 4 supply pulsing voltage to the combine’s hazard lights (Figs. 2, 3, 4, 5), causing them to flash.

55-28

Voltage from pin 3 is also made available for a trailer at trailer outlet J-09 pin L.

Voltage from pin 4 is also made available for a trailer at trailer outlet J-09 pin R.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

66065518

55-29

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 MARKER LIGHT CIRCUITS Refer to Marker Light Circuits functional diagram Figure 10. For detailed circuit tracing, refer to schematic Frames 33, 34, 35, 36 and 37. The operator activates the marker lights via road light switch S-26, located in the control stalk on the left side of the steering column. When the stalk is rotated to the first position (Marker Lights), the internal contacts close, connecting S-26 pin 5 to pin 1, applying +12 volts to relay K-02. At the same time, +12 volts is applied to CCM1, J1-21, causing CCM1 to activate the backlighting circuits. K-02 energizes, applying +12 volts to fuses F-20 and F-21. Voltage from fuse F-20 illuminates these marker lights: E-03 E-11 E-50

Left-hand front hazard light Left-hand brake/tail light Left-hand position light (EU models)

55-30

Voltage from F-20 is also made available for a trailer at trailer outlet J-09 pin 58L. Voltage from fuse F-21 illuminates these marker lights: E-04 E-12 E-49

Right-hand front hazard light Right-hand brake/tail light Right-hand position light (EU models)

Voltage from F-21 is also made available for a trailer at trailer outlet J-09 pin 58R.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

66065519

55-31

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 ROAD LIGHTS – LOW BEAM NOTE: When the road light circuit is active, power is also applied to the marker lights and backlighting circuits. Refer to the marker light and backlighting circuit descriptions for additional information. Refer to Road Lights – Low Beam functional diagram Figure 11. For detailed circuit tracing, refer to schematic Frame 36. The operator rotates the control stalk, located on the left side of the steering wheel, to the second position to turn on the road lights. As long as the stalk is in the rear position, the road lights will be on low beam. Figure 11 shows the circuit configuration for this mode. Road light switch S-26 is switched through from pin 5 to pin 1, for marker lights and backlighting, and also to pin 7, which applies 12 volts to low beam relay K-05. Relay K-05 energizes, applying 12 volts to the low-beam (terminal B) lamp of Left-hand road light E-13 and Right-hand road light E-14.

55-32

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

60050031

55-33

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 ROAD LIGHTS – HIGH BEAM NOTE: When the road light circuit is active, power is also applied to the marker lights and backlighting circuits. Refer to the marker light and backlighting circuit descriptions for additional information. Refer to the Road Lights – High Beam functional diagram Figure 12. For detailed circuit tracing, refer to schematic Frame 36. The operator rotates the control stalk, located on the left side of the steering wheel, to the second position to turn on the road lights. As long as the stalk is in the rear position, the road lights will be on low beam. To turn on the high beams, the operator pushes the stalk to the forward position. Figure 12 shows the circuit configuration for this mode. Road light switch S-26 is switched through from pin 5 to pin 1, for marker lights and backlighting, and also to pin 4, which applies 12 volts to high beam relay K-04. Relay K-04 energizes, applying 12 volts to the high-beam (terminal A) lamp of Left-hand road lamp E-13 and Right-hand road lamp E-14. At the same time, voltage from S-26 pin 4 is applied to high beam indicator E-10, which illuminates.

55-34

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

60050032

55-35

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 TURN SIGNALS NOTE: Failed bulbs, poor connections, or broken circuitry may cause the flashers to flash on and off at an irregular rate. If trailer lights are connected, the lighting system will function differently. For example, when trailer lights are connected to the lighting circuit, a bulb failure will have less effect on the operation of the circuit. NOTE: If the road/field mode switch is in the FIELD position and the work lights are switched on, activating a turn signal turns on the side work lights, illuminating the sides of the combine. This enhances visibility when turning in low-light conditions. Refer to Turn Signals functional diagram Figure 14. For detailed circuit tracing, refer to schematic Frames 36, 33, 34 and 35. The turn signals are activated from the control stalk located on the left side of the steering column. Pushing the stalk down (toward the floor) activates the left turn signal; pushing the stalk up (toward the roof) activates the right turn signal. The turn signal contacts are part of road switch S-26. When key switch S-02 is in the ignition (IGN) position, +12 volts is available at pin 6 of S-26. If a left turn signal is selected, contacts 6 and 3 of S-26 close, applying +12 volts to pin 8 of flasher module A-05. If a right turn is selected, contacts 6 and 2 close, applying +12 volts to pin 7 of A-05. Pins 3 and 2 of S-26 are also tied to CCM1, pins J1-2 and 9, respectively, to inform the system that a turn signal has been selected. Flasher module A-05 produces the pulsing voltages that are applied to the lights involved in indicating a turn. NOTE: The turn signal indications behave differently, depending on whether the combine is configured for North American (NASO) or Australian use. In NASO configuration, the lights on the side for which the turn is indicated flash on and off, while the lights on the opposite side glow steadily. In Australian configuration, the lights on the side for which the turn is indicated flash on and off, while the lights on the opposite side are dark. A voltage from CCM2 J1-5, applied to A-05 pin 9, determines whether A05 operates in NASO or Australian mode.

55-36

NASO Mode If a left turn is selected (+12 volts on A-05 pin 8), A-05 puts out a pulsing voltage on pins 3 and 10. This causes these lamps to flash on and off: E-01 E-03 E-07

Left-hand Header Flashing Light Left-hand Front Hazard Light Left-hand NASO Flashing Light

At the same time, A-05 puts out a steady DC voltage on pins 4 and 11. This causes these lamps to glow steadily: E-02 E-04 E-08

Right-hand Header Flashing Light Right-hand Front Hazard Light Right-hand NASO Flashing Light

The signals from A-05 pins 3 and 4 also go to turn indicator E-09. The light-emitting diodes (LEDs) in E-09 illuminate in accordance with the applied signal, whether flashing or steady. The signal voltages are also made available for trailer lights at trailer jack J-09. If a right turn is selected (+12 volts on A-05 pin 7), A-05 puts out a pulsing voltage on pins 4 and 11, and a steady voltage on pins 3 and 10. This reverses the light operation just described, causing the right-hand lights to flash and the left-hand lights to glow steadily. Australian Mode If a left turn is selected (+12 volts on A-05 pin 8), A-05 puts out a pulsing voltage on pin 3. This causes these lights to flash on and off: E-01 E-03 E-05

Left-hand Header Flashing Light Left-hand Front Hazard Light Left-hand Rear Flashing Light

A-05 puts out 0 volts on pin 4, and the right-hand signal lights are dark: E-02 E-04 E-06

Right-hand Header Flashing Light Right-hand Front Hazard Light Right-hand Rear Flashing Light

If a right turn is selected (+12 volts on A-05 pin 7), A-05 puts out a pulsing voltage on pin 4 and 0 volts on pin 3. The situation is now reversed, with the right-hand lights flashing and the left-hand lights dark.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

66065520

55-37

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 BRAKE LIGHTS The brake lights are activated by depressing the brake pedal or pulling back quickly on the multifunction control lever. Refer to Brake Lights functional diagram Figure 15. For detailed circuit tracing, refer to schematic Frames 9, 7, 38 and 35. The brake light in each of the brake/tail light assemblies E-11 and E-12 illuminates in the circumstances mentioned above. If the brake pedal is depressed, brake pressure switch S-39 closes, applying ground to pin J2-34 of combine control module CCM2. CCM2, in turn, applies +12 volts to the coil of brake lights relay K-33. K-33 energizes, closing contacts 3 and 5, which switches +12 volts from fuse F-52 to the brake lights (pin 1) in E-11 and E-12. This causes the brake lights to illuminate. Brake light voltage is also made available for a trailer at trailer jack J-09, terminal 54. Ground speed pot R-04 tracks the position of the multifunction control lever, applying this information to the right-hand module (RHM) at X027 pin 1 in the form of a changing analog voltage. If the operator pulls the multifunction control lever back quickly, the RHM senses the sudden change in voltage and reports it to CCM2 via the CAN bus. CCM2 then activates the brake lights as described above.

55-38

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

66065521

55-39

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 BEACON LIGHTS The CR Combine is equipped with three beacon lights. There are two beacon lights mounted on the cab roof and one mounted at the rear railing of the combine, on the engine platform. Three things can cause the beacon lights to become active: •

Beacon switch S-41 switched on.

•

Initial startup – Beacon lights illuminate for about three seconds when key switch S-02 is moved from the OFF position.

•

Grain tank filling up - The combine is equipped with a lower (3/4) and upper (full) grain tank level sensor. When the thresher is engaged and the material in the tank reaches the lower sensor, the beacons will flash. The flashing beacons inform a grain truck operator to prepare for unloading the grain bin. If the work lights are on, the beacons will only flash for about 10 seconds. They flash for 10 seconds again when the upper sensor detects material.

Refer to Beacon Lights functional diagram Figure 16. For detailed circuit tracing, refer to schematic Frame 39. CCM2 activates the beacon lights in response to any of the three conditions described above. Figure 13 shows the beacon light switch S-41 in the ON position. CCM2 applies +12 volts to beacon light relay K29, which energizes, closing contacts 3 and 5. This switches +12 volts from fuse F-53 to beacon lights E-31, E-32 and E-33.

55-40

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

60050036

55-41

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 FRONT WORK LIGHTS The front work lights are mounted in the front of the cab roof (Figures 2 and 4). They are controlled by work light switch S-43. Refer to Front Work Lights functional diagram Figure 17. For detailed circuit tracing, refer to schematic Frames 41 and 42.

Position 2 - Selecting position 2 of S-43 closes the circuit between pins 5 and 6, applying ground to the B terminals of inner work lights E-17 and E-18. At the same time, +12 volts from F-29 is made available to the A terminals of E-17 and E-18 through contacts 3 and 5 of relay K-21 and contacts 3 and 5 of road lights relay K-27.

Work light switch S-43, located in the upper right-hand switch panel, has three positions:

Relay K-21 is energized whenever S-43 is in position 1 or 2. However, relay K-27 is energized only under these conditions:

OFF – No work lights are illuminated.

•

Road/Field switch S-12 switched to FIELD.

Position 1 – When ignition switch S-02 is switched to IGN, +12 volts is present at pin 2 of work light switch S-43. Selecting position 1 of S-43 switches this voltage to J1-3 of CCM1. Voltage applied to CCM1 at this point not only activates the front work light circuits, it also activates the backlighting circuits. See BACKLIGHTING for details.

•

Hazard lights switch S-25 OFF.

CCM1 applies +12 volts from J1-11 to the coil of cab roof work lights relay K-01 (pin 86). K-01 energizes, closing the circuit between pins 30 and 87, and switching +12 volts from fuse F-31 to fuses F-06 and F-07. This voltage illuminates these work lights: Left-hand cab outer work light E-15 Right-hand cab outer work light E-16 Left-hand cab mid work light E-19 Right-hand cab mid work light E-20 At the same time, the voltage from CCM1 J1-11 energizes distance work lights relay K-21.

55-42

If these conditions are met, CCM1 places +12 volts on pin J1-5. This energizes K-27, which switches +12 volts to the A terminals of E-17 and E-18. The following front work lights are now illuminated: Left-hand cab outer work light E-15 Right-hand cab outer work light E-16 Left-hand cab inner work light E-17 Right-hand cab inner work light E-18 Left-hand cab mid work light E-19 Right-hand cab mid work light E-20

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

60050037

55-43

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 REAR WORK LIGHTS The rear work lights illuminate the rear of the combine for better visibility in low-light conditions. They can be activated in either of two ways: •

Rear work light switch S-44 placed in ON position.

•

Combine in reverse, with front work lights on.

Rear work light switch S-44 is located in the upper right-hand switch panel. Refer to Rear Work Lights functional diagram, Figure 18. For detailed circuit tracing, refer to schematic Frame 42. When ignition switch S-02 is switched to IGN, +12 volts is present at pin 2 of switch S-44. Turning on S-44 closes contacts 1 and 3, applying +12 volts to pin J1-3 of CCM1. CCM1 then energizes rear work lights relay K-31 via pin J1-18. K-31’s contacts 3 and pin 5 close, switching +12 volts from fuse F-55 to the A terminals of Left-hand rear work light E-27 and Right-hand rear work light E-28, causing them to illuminate. NOTE: Rear work lights do not illuminate when combine is in ROAD mode.

55-44

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

60050038

55-45

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 SIDE WORK LIGHTS The side work lights illuminate the sides of the combine for better visibility in low-light conditions. The side work lights can be activated in three ways: 1. Door – The side work lights will turn on automatically if the key switch is off and the left side door is opened or closed. 2. Control Stalk – The control stalk can be used to turn on the side work lights if the key switch is on, the combine is in field mode, and the front work lights are turned on. In this case, the operator moves the control stalk as if indicating a left or right turn. 3. Header Height – The side work lights turn on if the front work lights are on, the combine is in field mode, the front work lights are on and the header is above the maximum stubble height. Refer to Side Work Lights functional diagram Figure 19. For detailed circuit tracing, refer to schematic Frame 43. Door Operation Time delay relay K-20 is powered by +12 volts directly from the battery via fuse F-52. This voltage also powers dome light E-34. Pin 86 of K-20 is connected to door switch S-40. Pin 2 of dome light E-34 also connects to S-40 at this point. When the key switch S-02 is turned to IGN, +12 volts is available at pin 30 of K-20.

55-46

If the key switch is off (no power to pin 30), time delay relay K-20 will start its time cycle anytime door switch S-40 changes state (either opens or closes). This change of state is applied to K-20 pin 86, which initiates the time cycle. Pin 87 of K-20 goes positive, energizing timed side work light relay K-34. Contacts 3 and 5 of K-34 close, illuminating Left-hand side work light E-25 and Right-hand side work light E-26. K-20’s time cycle is approximately 60 seconds, during which time K-34 stays energized and E-25 and E-26 remain on. If the key switch is turned on during that time (+12 volts to K-20 pin 30), K-20’s time cycle is interrupted and the voltage at pin 87 goes away. K-34 will drop out, causing E-25 and E-26 to turn off. If the key switch is on, K-20 will not cycle based on door switch S-40 changing state. Control Stalk Operation When the key switch is on, the combine is in field mode and the front work lights are turned on, moving the control stalk to either left or right turn signal positions will cause the side work lights to turn on. CCM1 controls this, applying +12 volts from pin J1-24 to side work lights relay K-35, which energizes. Contacts 3 and 5 close, applying +12 volts from fuse F-50 to Left-hand side work light E-25 and Right-hand side work light E-26, which illuminate. Header Height When the key switch is on, the combine is in field mode, the front work lights are turned on, and the header is above the operator-set maximum stubble height, CCM1 energizes K-35 via pin J1-24. This illuminates E-25 and E-26, as described in Control Stalk Operation.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

60050039

55-47

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 STUBBLE LIGHTS

HEADER LIGHTS

The stubble lights E-23 and E-24 are located on the lower portion of the front of the cab, just outboard of the road lights E-13 and E-14 (Figures 2 and 4).

Header lights E-21 and E-22 illuminate the header under low-light or after-dark conditions. They are located under the front cab roof overhang, just below the front work lights (Figures 2 and 4).

Refer to Work Lights functional diagram Figure 20. For detailed circuit tracing, refer to schematic Frames 40, 41 and 42. The stubble lights turn on whenever the front work lights are on, providing these conditions exist: •

Road/Field switch S-12 switched to FIELD.

•

Hazard lights switch S-25 OFF.

When key switch S-02 is switched to IGN, work light switch S-43 is turned on, and the above conditions are met, CCM1 places +12 volts on pin J1-5. This energizes lower work lights relay K-30, which switches +12 volts from fuse F-54, via closed contacts 3 and 5, to Left-hand stubble light E-23 and Right-hand stubble light E-24.

GRAIN TANK LIGHT The grain tank light E-30 provides the operator with visibility into the grain tank, through the rear window, in after-dark conditions. It is located on the front inside wall of the grain tank. Refer to Work Lights functional diagram Figure 20. For detailed circuit tracing, refer to schematic Frames 40, 41 and 42. E-30 is wired in parallel with stubble lights E-23 and E-24. The circuit description under STUBBLE LIGHTS applies to E-30 as well.

UNLOAD TUBE LIGHT When the unload tube is swung out from its cradle, sensor B-38 sends a signal to pin J3-36 of CCM1. CCM1, in turn, places +12 volts on pin J1-12, which energizes unload tube light relay K-32. This relay switches +12 volts from fuse F-50, via closed contacts 3 and 5, to unload tube light E-29, which illuminates.

55-48

Refer to Work Lights functional diagram Figure 20. For detailed circuit tracing, refer to schematic Frames 40, 41 and 42. The header lights turn on whenever the front work lights are on, providing these conditions exist: •

Road/Field switch S-12 switched to FIELD.

•

Hazard lights switch S-25 OFF.

When key switch S-02 is switched to IGN, work light switch S-43 is turned on, and the above conditions are met, CCM1 places +12 volts on pin J1-5. This energizes header work lights relay K-22, which switches +12 volts from fuse F-30, via closed contacts 3 and 5, to Left-hand header light E-21 and Right-hand header light E-22.

CENTER WORK LIGHT Center work light E-38 is an optional additional work light. If present, it is located under the front cab roof overhang, just to the left of the windshield wiper arm (Figures 2 and 4). Refer to Work Lights functional diagram Figure 20. For detailed circuit tracing, refer to schematic Frames 40, 41 and 42. Center work light E-38 is wired in parallel with header lights E-21 and E-22. The circuit description in HEADER LIGHTS applies to E-38 as well.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

60050040

55-49

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 SERVICE LIGHTS The optional under-shield service lights provide illumination under the combine’s protective side shields when the shields are raised for service or maintenance of the mechanisms beneath. There are two service lights under each panel, one toward the front of the combine, the other toward the rear. In addition, a service light is provided for illumination while servicing the engine under low-light conditions. This light is located on the rear deck, just under the rear beacon light E-33. Refer to Service Lights functional diagram Figure 21. For detailed circuit tracing, refer to schematic Frame 38. For location of service lights switches, refer to CR Operator’s Manual, Section 2. The service lights are powered by +12 volts directly from the battery, through fuse F-34. Turning on left shield light switch S-63 places +12 volts on the A terminals of Left-hand front shield light E-42 and Left-hand rear shield light E-43, causing them to illuminate. Right shield light switch S-65, when turned on, switches +12 volts to Right-hand front shield light E-44 and Right-hand rear shield light E-45, which illuminate. Engine light switch S-64 turns on engine light E-46.

55-50

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

60050041

55-51

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 BACKLIGHTING Description The backlighting circuit is controlled by the internal network on the CR Series combines. The backlighting circuit is energized whenever the following circuits are activated (see the corresponding circuit description for more information): Marker Light Circuit Road Light Circuit Front Work Light Circuit Side Work Light Circuit Rear Work Light Circuit

CCM 2 Direct Backlighting Feed Pin ID

Frame #

Circuit

J1-11

Accessory Outlet

J-08

J1-11

Cigar Lighter

R-08

NOTE: All of these components are grounded at the cab roof location. To gain access to the cab roof wiring, remove the rear center speaker panel.

When these circuits are activated, information is sent through the network to switch on the backlighting circuit. CCM2 and the RHM then provide power to the backlighting circuit. The network also sends a signal to the Infoview monitor to cause it to dim. This gives the operator better visibility in low light conditions. Refer to schematic frames 27 and 25.

CCM2 Frame #27 When the backlighting circuit is activated, current is sent from CCM2 pin J1-11 to splice block C (W-03). This provides power to the following backlighting systems: The cab upper control console (left side of cab interior) The center control console The console light Use the chart below to identify the splice block C (W03) pins that provide power to the corresponding light in the backlighting circuit. CCM 2 Pin ID (Backlighting) Pin ID

Two additional backlighting circuits come directly from CCM2 J1-11 as follows:

Frame #

Circuit

Pin A

Console Light

E-35

Pin B

CCM2

J1-11

Pin C

Rear Work Light Sw.

S-44

Pin D

Work Light Sw.

S-43

Pin E

Wiper Sw.

S-20

Pin F

Beacon Light Sw.

S-41

Pin G

Tank Extensions Sw.

S-42

Pin H

Mirror Heat Sw.

S-19

Pin J

Washer Sw.

S-38

Pin K

Pin L

Pin M

HVAC Control Module A09

55-52

RHM Frame #25 When the backlighting circuit is activated, current is sent from RHM pin 18 to splice block F (W-06). The splice block distributes current to the Right-hand control cluster backlighting. This causes the backlighting on the Right-hand control cluster to illuminate. Use the chart below to identify the splice block F, W06 pins that provide power to the corresponding light in the backlighting circuit. RHM Pin ID (Backlighting) Pin ID

Frame #

Circuit

Pin A

HHC Fine Adjust Sw.

S-06

Pin A

Header Height Mode Sw. S-04

Pin A

Engine Throttle Sw.

S-36

Pin B

Rear Wheel Assist Sw. S-10

Pin C

Dual Range Sw.

S-11

Pin D

Road Mode Sw.

S-12

Pin E

Vertical Knives

S-51

Pin F

Feeder Reverser Sw.

S-07

Pin G

Alternate Settings Sw.

S-21

Pin H

RHM

X027-18

Pin J

Reel Speed Sw.

S-08

Pin K

Parking Brake Sw.

S-09

Pin L

Spreader Plate Sw.

S-23

Pin M

Autopilot Sw.

S-78

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

55-53

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

55-54

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 EXTERIOR LIGHTING SYSTEM CIRCUIT TROUBLESHOOTING Before troubleshooting the Exterior Lighting system make sure that the following conditions are met: A. The batteries are fully charged and all connections are clean and tight. B. Check for applicable active fault codes. C. Check all connectors for full installation, loose, corroded, pushed out, or bent terminals. D. If one of the work lamp circuits is not working, try swapping a relay from a working system for a quick and easy relay check. Otherwise, follow the circuit diagnostic tests to determine the fault. E. If a bulb is not working, substitute with a known good bulb to verify circuit operation.

FUSE/CIRCUIT LIGHTING CHART FUSE #

CIRCUITS

FUSE-06

Left-hand Cab Outer Work Light (E-15) Left-hand Cab Mid Work Light (E19)

FUSE-07

Right-hand Cab Outer Work Light (E-16) Right-hand Cab Mid Work Light (E-20)

FUSE–14

Sieve Light (E-37)

FUSE-20

Left-hand Front Marker Lamp (E-03) Left-hand Position Lamp (E-50) Tail Light (E-11)

FUSE-21

Right-hand Front Marker Lamp (E-04) Right-hand Position Lamp (E-49) Tail Light (E-12)

FUSE-29

Left-hand Cab Inner Work Light (E-17) Right-hand Cab Inner Work Light (E-18)

FUSE-30

Left-hand Header Light (E-21) Right-hand Header Light (E-22) Center Work Light (E-38)

FUSE-31

FUSE-32

Road Lights (E-13 and E-14) High Beam

FUSE-33

Road Lights (E-13 and E-14) Low Beam

FUSE-34

Left-hand Front Shield Light (E-42) Left-hand Rear Shield Light (E-43) Right-hand Front Shield Light (E-44) Right-hand Rear Shield Light (E-45) Engine Light (E-46)

FUSE-50

Side Work Light (E-25) Timed Side Work Light (E-26) Unload Tube Light (E-29)

FUSE-51

Road Light Switch (S-26) Horn (H-02)

FUSE-52

Left-hand Brake Light (E-11) Right-hand Brake Light (E-12) Dome Light (E-34)

FUSE-53

Left-hand Front Beacon Light (E-31) Right-hand Front Beacon Light (E-32) Rear Beacon Light (E-33)

FUSE-54

Left-hand Lower Work Light (E23) Right-hand Lower Work Light (E24) Grain Tank Light (E-30)

FUSE-55

Left-hand Rear Work Light (E-27) Right-hand Rear Work Light (E-28)

FUSE-56

Left-hand Header Flashing Lamp (E-01) Right-hand Header Flashing Lamp (E-02) Left-hand NASO Flashing Lamp (E-07) Right-hand NASO Flashing Lamp (E-08) Turn Indicator (E-09) High Beam Indicator (E-10) Hazard Switch (S-25) Left-hand Flashing Lamp (E-05) Right-hand Rear Flashing Lamp (E-06)

55-55

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 Lighting System Fault Codes Before beginning to test an individual circuit for faults, check for fault codes using the Diagnostic menu to determine if there are any active fault codes that may affect the circuit being investigated. The following fault codes apply to the lighting circuits: Marker lights, road lights

E0011-04 Road Lights signal Shorted to low source

Hazard lights

E0008-04 Left Turn signal Shorted to low source E0012-04 Right Turn signal Shorted to low source E0201-11 Flasher System Selection Unidentified Failure Code

Side lights

E0072-11 Side Work Lights relay Unidentified Failure Code

Work lights, general

E0073-11 Field Lights Relay Unidentified Failure Code

Front work lights

E0009-04 Front Work Lights switch Shorted to low source E0070-11 Front Work Lights relay Unidentified Failure Code

Rear work lights

E0010-04 Rear Work Lights switch Shorted to low source E0071-11 Rear Work Lights relay Unidentified Failure Code

Unload tube light

E0068-11 Unload Tube Light relay Unidentified Failure Code

Beacon lights

E0136-04 Beacon Lights switch Shorted to low source E0200-11 Beacon Lights relay Unidentified Failure Code

Backlighting lamps

E0198-11 Backlighting lamps Unidentified Failure Code

Brake lights

E0199-11 Brake Lights relay Unidentified Failure Code

55-56

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 EXTERIOR LIGHTING SYSTEM SYMPTOM CHART NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.

WARNING Before performing any of the electrical tests, be sure all operating controls are in neutral or park lock position. This will eliminate accidental movement of the machine or start-up of power driven equipment. Symptom Left-hand and Right-hand NASO Flashing Lamps do not operate.

Left-hand and Right-hand Header Flashing Lamps do not operate.

Left-hand and Right-hand Front Hazard Lamps (Hazard Bulbs) do not operate.

Left-hand and Right-hand Front Marker Lamps (Marker Bulbs) do not operate.

Left-hand and Right-hand Rear Flashing Lamps do not operate.

Left-hand and Right-hand Brake/Tail Lamps (Marker Bulbs) do not operate.

Possible Cause

Reference/Test

Bulbs

C - Left-hand NASO Flashing Lamp Test D - Right-hand NASO Flashing Lamp Test

Flasher Module

B - Flasher Module Test

Hazard Switch

A - Hazard Switch Test

Bulbs

E - Left-hand Header Flashing Lamp Test F - Right-hand Header Flashing Lamp Test

Flasher Module

B - Flasher Module Test

Hazard Switch

A - Hazard Switch Test

Bulbs

G - Left-hand Front Hazard Lamp Test H - Right-hand Front Hazard Lamp Test

Flasher Module

B - Flasher Module Test

Hazard Switch

A - Hazard Switch Test

Bulbs

I - Left-hand Front Marker Lamp Test (Marker Bulb) J - Right-hand Front Marker Lamp Test (Marker Bulb)

Road Light Switch

Q - Road Light Switch Tests 1,2 and 10

Bulbs

K - Left-hand Rear Flashing Lamp Test L - Right-hand Rear Flashing Lamp Test

Flasher Module

B - Flasher Module Test

Hazard Switch

A - Hazard Switch Test

Bulbs

M - Left-hand Brake/Tail Lamp Test (Marker Bulb) N - Right-hand Brake/Tail Lamp Test (Marker Bulb)

Road Light Switch

Q - Road Light Switch Tests 1, 2 and 10

55-57

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 Symptom Left-hand and Right-hand Brake/Tail Lamps (Brake Bulbs) do not operate.

Left-hand and Right-hand Road Lights (Low Beam Bulbs) do not operate.

Left-hand and Right-hand Road Lights (High Beam Bulbs) do not operate.

Left-hand and Right-hand Rear Work Lights do not operate.

Sieve Light does not operate. Rear Beacon Light does not operate.

Left-hand and Right-hand Front Beacons do not operate.

Side Work Light does not operate.

Timed Side Work Light does not operate.

Possible Cause

Reference/Test

Bulbs

O - Left-hand Brake/Tail Lamp Test (Brake Bulb) P - Right-hand Brake/Tail Lamp Test (Brake Bulb)

Brake Lights Relay

Y - Brake Lights Relay Test

Bulbs

T - Left-hand Road Light Test (Low Beam Bulb) U - Right-hand Road Light Test (Low Beam Bulb)

Low Beam Relay

R - Low Beam Relay Test

Road Light Switch

Q - Road Light Switch Tests 1, 2 and 11

Bulbs

V - Left-hand Road Light Test (High Beam Bulb) X - Right-hand Road Light Test (High Beam Bulb)

High Beam Relay

S - High Beam Relay Test

Road Light Switch

Q - Road Light Switch Tests 3,4 and 9

Bulbs

AA - Left-hand Rear Work Light Test BB - Right-hand Rear Work Light Test

Rear Work Lights Relay

Z - Rear Work Lights Relay Test

Rear Work Light Switch

GGG - Rear Work Light Switch Test

Bulbs

HH - Sieve Light Test

Sieve Light Switch

GG - Sieve Light Switch Test

Bulbs

DD - Rear Beacon Test

Beacon Light Relay

CC - Beacon Light Relay Test

Beacon Light Switch

HHH - Beacon Light Switch Test

Bulbs

EE - Left-hand Front Beacon Test FF - Right-hand Front Beacon Test

Beacon Light Relay

CC - Beacon Light Relay Test

Beacon Light Switch

HHH - Beacon Light Switch Test

Bulb

LL - Side Work Light Test

Side Work Light Relay

II - Side Work Light Relay Test

Work Light Switch

FFF - Work Light Switch Test

Bulb

MM - Timed Side Work Light Test

Timed Side Work Light Relay

JJ - Timed Side Work Light Relay Test

Work Light Switch

FFF - Work Light Switch Test

55-58

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 Symptom Unload Tube Light does not operate.

Grain Tank Light does not operate.

Left-hand and Right-hand Lower Work Lights do not operate.

Left-hand and Right-hand Header Lights do not operate.

Left-hand and Right-hand Cab Outer Work Lights do not operate.

Left-hand and Right-hand Cab Mid Work Lights do not operate.

Left-hand and Right-hand Cab Inner Work Lights do not operate.

Possible Cause

Reference/Test

Bulb

NN - Unload Tube Light Test

Unload Tube Light Relay

KK - Unload Tube Light Relay Test

Bulb

PP - Grain Tank Light Test

Lower Work Lights Relay

OO - Lower Work Lights Relay Test

Work Light Switch

FFF - Work Light Switch Test

Bulbs

QQ - Left-hand Lower Work Light Test RR - Right-hand Lower Work Light Test

Lower Work Light Relay

OO - Lower Work Lights Relay Test

Work Light Switch

FFF - Work Light Switch Test

Bulbs

TT - Left-hand Header Light Test UU - Right-hand Header Light Test

Header Work Lights Relay

SS - Header Work Lights Relay Test

Work Light Switch

FFF - Work Light Switch Test

Bulbs

XX - Left-hand Cab Outer Work Light Test ZZ - Right-hand Cab Outer Work Light Test

Cab Roof Work Lights Relay

VV - Cab Roof Work Lights Relay Test

Work Light Switch

FFF - Work Light Switch Test

Bulbs

YY - Left-hand Cab Mid Work Light Test AAA - Right-hand Cab Mid Work Light Relay Test

Cab Roof Work Lights Relay

VV - Cab Roof Work Lights Relay Test

Work Light Switch

FFF - Work Light Switch Test

Bulbs

DDD - Left-hand Cab Inner Work Light Test EEE - Right-hand Cab Inner Work Light Test

Work Light Switch

FFF - Work Light Switch Test

Distance Work Lights Relay

BBB - Distance Work Lights Relay Test

55-59

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 EXTERIOR LIGHTING SYSTEM DIAGNOSTIC TESTS NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) or an unpowered test light for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.

A - HAZARD SWITCH TEST Test Point

Good Reading

Possible Cause of Bad Reading

Measure for 12V at Hazard Switch S-25 connector X259 (pin 2).

12 volts If good reading, go to test point 3.

Open circuit 40 (RD) or 54 (RD) between Hazard Switch S-25 connector X259 (pin 2) and Fuse #56. Short to ground between Hazard Switch S-25 connector X259 (pin 2) and Fuse #56. A short to ground will blow Fuse #56. Go to next test point.

Disconnect the Flasher Module. Measure for 12V at Hazard Switch S-25 connector X259 (pin 2).

12 volts If good reading, check Flasher Module.

Short to ground in circuit 102 (RD) between Flasher Module A-05 connector X255 (pin 1) and Fuse #56. A short to ground will blow Fuse #56.

Place Hazard Switch S-25 in the closed position. Measure for 12V at Hazard Switch S-25 connector X259 (pin 3).

12 volts If good reading, go to next test point.

Hazard Switch S-25.

Measure for 12V at Hazard Switch S-25 connector X259 (pin 9).

12 volts If good reading, go to next test point.

Hazard Switch S-25.

Place Hazard Switch S-25 in the open position. Measure resistance from Hazard Switch S-25 connector X259 (pin 9) to ground.

Less than 1 ohm.

Open circuit 220 (BK) or 219 (BK) between Hazard Switch S-25 connector X259 (pin 9) and ground.

55-60

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 B - FLASHER MODULE TEST Test Point

Good Reading

Possible Cause of Bad Reading

Measure for 12 volts at Flasher Module A-05 connector X255 (pin 1).

12 volts If good reading, go to next test point.

Open in power feed circuit between Flasher Module A-05 connector X255 (pin 1) and Fuse #56. Short to ground between Flasher Module A-05 connector X255 (pin 1) and Fuse #56 (see test A-Hazard Switch Test, steps 1-4). A short to ground will blow Fuse #56.

Close the Hazard Switch S-25. Measure for 12 volts at Flasher Module A-05 connector X255 (pin 2).

12 volts If good reading, go to next test point.

Open in circuit 207 (PU) or 179 (PU) between Flasher Module A-05 connector X255 (pin 2) and Hazard Switch S-25 (pin 3). Perform Hazard Switch Test.

Place Road Light Switch in “LEFT” turn position. Measure for 12 volts at the Road Light Switch S-26 connector X256 (pin 2).

12 volts If good reading, go to next test point.

Perform Road Light Switch Test.

Measure for 12 volts at Flasher Module A-05 connector X255 (pin 7).

12 volts If good reading, go to next test point.

Open in circuit 201 (PU) or 203 (PU) between Flasher Module A-05 connector X255 (pin 7) and Road Light Switch S-26 connector X256 (pin 2).

Place Road Light Switch in “RIGHT” turn position. Measure for 12 volts at the Road Light Switch S-26 connector X256 (pin 3).

12 volts If good reading, go to next test point.

Perform Road Light Switch Test.

Measure for 12 volts at Flasher Module A-05 connector X255 (pin 8).

12 volts If good reading, go to next test point.

Open in circuit 197 (PU) or 202 (PU) between Flasher Module A-05 connector X255 (pin 8) and Road Light Switch S-26 connector X256 (pin 3).

Disconnect the Flasher Module A-05. Measure resistance on circuit 141 (BK) between Flasher Module A-05 connector X255 (pin 6) and ground.

Less than 1 ohm.

Open in circuit 141 (BK) between the Flasher Module A-05 connector X255 (pin 6) and ground.

Reconnect the Flasher Module A-05. Place Hazard Switch S-25 in the “ON” position. Measure for voltage at Flasher Module A-05 connector X255 (pins 3 and 4).

0 to 12 volts, off and on at flash rate. If good reading, go to test point 13.

Flasher Module A-05. Short to ground on circuit 199 (PU), 200 (PU), 195 (PU) or 196 (PU) between Flasher Module A-05 connector X255 (pins 3 and 4) and Turn Indicator E-09 and flashing lamps. Go to next test point.

55-61

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 Test Point

Good Reading

Possible Cause of Bad Reading

Disconnect the Flasher Module A-05. Place a jumper wire across pins 1 and 4 of the Flasher Module A-05 connector X255.

Left-hand flashing lamps illuminate. If good reading, go to next test point.

Short to ground will blow Fuse #56. Repair short to ground.

Disconnect the Flasher Module A-05. Place a jumper wire across pins 1 and 3 of the Flasher Module A-05 connector X255.

Right-hand flashing lamps illuminate. If good reading, go to next test point.

Short to ground will blow Fuse #56. Repair short to ground.

Reconnect the Flasher Module A-05. Place Hazard Switch S-25 in the “ON” position. Measure for voltage at Turn Indicator E-09 connector X257 (pins 7 and 10).

0 to 12 volts, off and on at flash rate. If good reading, go to next test point.

Open circuit 199 (PU) or 196 (PU) between Flasher Module A-05 connector X255 (pins 3 and 4) and Turn Indicator E-09 connector X257 (pins 7 and 10).

Measure resistance on circuit 209 (BK) between Turn Indicator E-09 connector X257 (pin 9) and ground.

Less than 1 ohm.

Turn Indicator E-09 Open in circuit 141 (BK) between the Flasher Module A-05 connector X255 (pin 6) and ground.

Measure 12 volts at Flasher Module A-05 connector X255 (pin 5).

12 volts If good reading, go to text point 16.

Flasher Module A-05. Short to ground on circuit 208 (PU) between Flasher Module A-05 connector X255 (pin 5) and High Beam Indicator E-10 connector X258 (pin 7). Go to next test point.

Disconnect the Flasher Module A-05. Place a jumper wire across pins 1 and 5 of the Flasher Module A-05 connector X255.

High Beam Indicator E-10 illuminates. If good reading, go to next test point.

Short to ground on circuit 208 (PU) will blow Fuse #56. Repair short to ground between Flasher Module A-05 connector X255 (pin 5) and High Beam Indicator E-10 connector X258 (pin 7).

Measure resistance on circuit 221 (BK) between High Beam Indicator E-10 connector X258 (pin 9) and ground.

Less than 1 ohm If good reading, check High Beam Indicator E-10.

Open circuit 221 (BK) between High Beam Indicator E-10 connector X258 (pin 9) and ground.

Place Hazard Switch S-25 in the “ON” position. Measure the voltage at Flasher Module A-05 connector X255 (pin 10).

0 to 12 volts, off and on at flash rate. If good reading, go to test point 17.

Flasher Module A-05. Short to ground on circuit 243 (PU) between Flasher Module A-05 connector X255 (pin 10) and Left-hand NASO Flashing Lamp E-07 connector X242 (pin A). Go to next test point.

If good reading, go to next test point.

55-62

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 Test Point

Good Reading

Possible Cause of Bad Reading

Disconnect the Flasher Module A-05. Place a jumper wire across pins 1 and 10 of the Flasher Module A-05 connector.

Left-hand NASO Flashing Lamp E-07 illuminates. If good reading, go to next test point.

Short to ground on circuit 243 (PU) will blow Fuse #56. Repair short to ground on circuit 243 (PU) between Flasher Module A-05 connector X255 (pin 10) and Left-hand NASO Flashing Lamp E-07 connector X242 (pin A).

Measure the voltage at Flasher Module A-05 connector X255 (pin 11).

0 to 12 volts, off and on at flash rate.

Flasher Module A-05. Short to ground on circuit 244 (PU) between Flasher Module A-05 connector X255 (pin 11) and Right-hand NASO Flashing Lamp E-08 connector X245 (pin A). Go to next test point.

Disconnect the Flasher Module A-05. Place a jumper wire across pins 1 and 11 of the Flasher Module A-05 connector X255.

Right-hand NASO Flashing Lamp E-09 illuminates. If good reading, replace the Flasher Module A-05.

Short to ground on circuit 244 (PU) will blow Fuse #56. Repair short to ground on circuit 244 (PU) between Flasher Module A-05 connector X255 (pin 11) and Right-hand NASO Flashing Lamp E-08 connector X245 (pin A).

C - LEFT-HAND NASO FLASHING LAMP TEST 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Hazard Switch S-25 in the “ON” position. Measure the voltage at Left-hand NASO Flashing Lamp E-07, connector X242 terminal A.

0 to 12 volts, off and on at flash rate.

Open circuit 243 (PU) between Flasher Module A-05 connector X255 (pin 10) and Left-hand NASO Flashing Lamp E-07 connector X242 (pin A). Short to ground on circuit 243 (PU) between Flasher Module A-05 connector X255 (pin 10) and Left-hand NASO Flashing Lamp E-07 connector X242 (pin A). See Test B- Flasher Module A-05 step 16. Go to next test point.

Disconnect the Left-hand NASO Flashing Lamp E-07. Measure resistance on circuit 679 (BK) between Left-hand NASO Flashing Lamp E-07 connector X242 (pin B) and ground.

Less than 1 ohm. If good reading, replace the bulb.

If good reading, go to test point 2.

55-63

Open circuit 679 (BK) between Left-hand NASO Flashing Lamp E-07 connector X242 (pin B) and ground.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 D - RIGHT-HAND NASO FLASHING LAMP TEST 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Hazard Switch S-25 in the “ON” position. Measure the voltage at Right-hand NASO Flashing Lamp E-08, connector X245 terminal A.

0 to 12 volts, off and on at flash rate.

Open circuit 244 (PU) between Flasher Module A-05 connector X255 (pin 11) and Right-hand NASO Flashing Lamp E-08 connector X245 (pin A). Short to ground on circuit 244 (PU) between Flasher Module A-05 connector X255 (pin 11) and Right-hand NASO Flashing Lamp E-08 connector X245 (pin A). See Test B- Flasher Module A-05 step 18. Go to next test point.

Disconnect the Right-hand NASO Flashing Lamp E-08. Measure resistance on circuit 680 (BK) between Right-hand NASO Flashing Lamp E-08, connector X245 (pin B) and ground.

Less than 1 ohm. If good reading, replace the bulb.

If good reading, go to test point 2.

Open circuit 680 (BK) between Right-hand NASO Flashing Lamp E-08 connector X245 (pin B) and ground.

E - LEFT-HAND HEADER FLASHING LAMP TEST 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Hazard Switch S-25 in the “ON” position.

0 to12 volts, off and on at flash rate.

Measure the voltage at Left-hand Header Flashing Lamp E-01 connector X303 (pin A).

If good reading, go to next test point.

Open circuit 613 (PU) between Flasher Module A-05 connector X255 (pin 3) and Left-hand Header Flashing Lamp E-01 connector X303 (pin A). Short to ground on circuit 613 (PU) between Flasher Module A-05 connector X255 (pin 3) and Left-hand Header Flashing Lamp E-01 connector X303 (pin A). See text B-Flasher Module Test step 8. Go to next test point.

Disconnect the Left-hand Header Flashing Lamp E-01. Measure the resistance on circuit 775 (BK) and 776 (BK) between the Left-hand Header Flasher Lamp E-01 connector X303 (pin B) and ground.

Less than 1 ohm. If good reading, replace the bulb.

55-64

Open in circuit 775 (BK) or 767 (BK) between Left-hand Header Flashing Lamp E-01 connector X303 (pin B) and ground.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 F - RIGHT-HAND HEADER FLASHING LAMP TEST 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Hazard Switch S-25 in the “ON” position.

0 to12 volts, off and on at flash rate.

Measure the voltage at Right-hand Header Flashing Lamp E-02 connector X304 (pin A).

If good reading, go to next test point.

Open circuit 618 (PU) between Flasher Module A-05 connector X255 (pin 4) and Right-hand Header Flashing Lamp E-02 connector X304 (pin A). Short to ground on circuit 613 (PU) between Flasher Module A-05 connector X255 (pin 4) and Right-hand Header Flashing Lamp E-02 connector X304 (pin A). See text B-Flasher Module Test step 8. Go to next test point.

Disconnect the Right-hand Header Flashing Lamp E-02. Measure the resistance on circuit 775 (BK) and 776 (BK) between the Right-hand Header Flasher Lamp E-02 connector X304 (pin B) and ground.

Less than 1 ohm. If good reading, replace the bulb.

Open in circuit 775 (BK) or 767 (BK) between Right-hand Header Flashing Lamp E-02 connector X304 (pin B) and ground.

G - LEFT-HAND FRONT HAZARD LAMP TEST 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Hazard Switch S-25 in the “ON” position. Measure the voltage at Left-hand Front Hazard Lamp E-03 connector X357 (pin B).

0 to 12 volts, off and on at flash rate.

Open circuit 615 (PU) between Flasher Module A-05 connector X255 (pin 3) and Left-hand Front Hazard Lamp E-03 connector X357 (pin B). Short to ground on circuit 615 (PU) between Flasher Module A-05 (pin 3) and Left-hand Front Hazard Lamp E-03 (pin B). See Test B-Flasher Module Test step 8. Go to next test point.

Disconnect the Left-hand Front Hazard Lamp E-03. Measure the resistance on circuit 620 (BK) between Left-hand Front Hazard Lamp E-03 connector X357 (pin C) and ground.

Less than 1 ohm.

If good reading, go to next test point.

If good reading, replace the hazard bulb of the Left-hand Front Hazard Lamp E-03.

55-65

Open in circuit 620 (BK) between Left-hand Front Hazard Lamp E-03 connector X357 (pin C) and ground.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 H - RIGHT-HAND FRONT HAZARD LAMP TEST 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Hazard Switch S-25 in the “ON” position. Measure the voltage at Right-hand Front Hazard Lamp E-04 connector X356 (pin B).

0 to 12 volts, off and on at flash rate.

Open circuit 616 (PU) between Flasher Module A-05 connector X255 (pin 4) and Right-hand Hazard Lamp E-04 connector X356 (pin B). Short to ground on circuit 616 (PU) between Flasher Module A-05 connector X255 (pin 4) and Right-hand Front Hazard Lamp E-04 connector X356 (pin B). See Test B-Flasher Module Test step 8. Go to next test point.

Disconnect the Right-hand Front Hazard Lamp E-04. Measure the resistance on circuit 621 (BK) between Right-hand Front Hazard Lamp E-04 connector X356 (pin C) and ground.

Less than 1 ohm.

If good reading, go to next test point.

If good reading, replace the hazard bulb of the Right-hand Front Hazard Lamp E-04.

Open in circuit 621 (BK) between Right-hand Front Hazard Lamp E-04 connector X356 (pin C) and ground.

I - LEFT-HAND FRONT HAZARD LAMP (MARKER BULB - AUSTRALIA) Test Point

Good Reading

Possible Cause of Bad Reading

Turn Road Light Switch S-26 to Marker Lights position. Measure for 12 volts at Fuse #20.

12 volts If good reading, go to next test point.

Perform Road Light Switch Test.

Measure for 12 volts at Left-hand Front Hazard Lamp E-03 connector X357 (pin A).

12 volts

Open circuit 624 (PU) between Fuse #20 and Left-hand Front Hazard Lamp E-03 connector X357 (pin A). Short to ground on circuit 624 (PU) and 177 (PU) between Fuse #20 and Left-hand Front Hazard Lamp E-03 connector X357 (pin A). Any short to ground will blow the Fuse #20.

Disconnect the Left-hand Front Hazard Lamp E-03. Measure the resistance on circuit 620 (BK) between Left-hand Front Hazard Lamp E-03 connector X357 (pin C) and ground.

Less than 1 ohm.

If good reading, go to next test point.

If good reading, replace the marker bulb of the Left-hand Front Hazard Lamp E-03.

55-66

Open in circuit 620 (BK) between Left-hand Front Hazard Lamp E-03 connector X357 (pin C) and ground.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 J - RIGHT-HAND FRONT HAZARD LAMP (MARKER BULB - AUSTRALIA) Test Point

Good Reading

Possible Cause of Bad Reading

Turn Road Light Switch S-26 to Marker Lights position. Measure for 12 volts at Fuse #21.

12 volts If good reading, go to next test point.

Perform Road Light Switch Test.

Measure for 12 volts at Right-hand Front Hazard Lamp E-04 connector X356 (pin A).

12 volts

Open circuit 627 (PU) between Fuse #21 and Right-hand Front Hazard Lamp E-04 connector X356 (pin A). Short to ground on circuit 627 (PU) and 176 (PU) between Fuse #21 and Right-hand Front Hazard Lamp E-04 connector X356 (pin A). Any short to ground will blow the Fuse #21.

Disconnect the Right-hand Front Hazard Lamp E-04. Measure the resistance on circuit 621 (BK) between Right-hand Front Hazard Lamp E-04 connector X356 (pin C) and ground.

Less than 1 ohm.

If good reading, go to next test point.

If good reading, replace the marker bulb of the Right-hand Front Hazard Lamp E-04.

Open in circuit 1550 (BK) between Right-hand Front Hazard Lamp E-04 connector X356 (pin C) and ground.

K - LEFT-HAND REAR FLASHING LAMP TEST - AUSTRALIA 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Hazard Switch S-25 in the “ON” position.

0 to 12 volts, off and on at flash rate.

Measure the voltage at Left-hand Rear Flashing Lamp E-05 connector X301 (pin 1).

If good reading, go to test point 2.

Open circuit 619 (PU) between Flasher Module A-05 connector X255 (pin 3) and Left-hand Rear Flashing Lamp E-05 connector X301 (pin 1). Short to ground on circuit 619 (PU) between Flasher Module A-05 connector X255 (pin 3) and Left-hand Rear Flashing Lamp E-05 connector X301 (pin 1). See test B-Flasher Module Test step 8. Go to next test point.

Disconnect the Left-hand Rear Flashing Lamp E-05. Measure the resistance on circuit 634 (BK) between Left-hand Rear Flashing Lamp E-05 connector X301 (pin 2) and ground.

Less than 1 ohm. If good reading, replace the bulb.

55-67

Open in circuit 634 (BK) between Left-hand Rear Flashing Lamp E-05 connector X301 (pin 2) and ground.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 L - RIGHT-HAND REAR FLASHING LAMP TEST - AUSTRALIA 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Hazard Switch S-25 in the “ON” position.

0 to 12 volts, off and on at flash rate.

Measure the voltage at Right-hand Rear Flashing Lamp E-06 connector X302 (pin 1).

If good reading, go to test point 2.

Open circuit 622 (PU) between Flasher Module A-05 (pin 4) and Right-hand Rear Flashing Lamp E-06 connector X302 (pin 1). Short to ground on circuit 622 (PU) between Flasher Module A-05 connector X255 (pin 4) and Right-hand Rear Flashing Lamp E-06 connector X302 (pin 1). See test B-Flasher Module Test step 8. Go to next test point.

Disconnect the Right-hand Rear Flashing Lamp E-06. Measure the resistance on circuit 635 (BK) between Right-hand Rear Flashing Lamp E-06 connector X302 (pin 2) and ground.

Less than 1 ohm. If good reading, replace the bulb.

Open in circuit 635 (BK) between Right-hand Rear Flashing Lamp E-06 connector X302 (pin 2) and ground.

M - LEFT-HAND BRAKE/TAIL LAMP TEST (MARKER BULB) Test Point

Good Reading

Possible Cause of Bad Reading

Turn Road Light Switch S-26 to Marker Lights position. Measure for 12 volts at Fuse #20.

12 volts If good reading, go to next test point.

Perform Road Light Switch Test.

Measure for 12 volts at Left-hand Brake/Tail Lamp E-11 connector X299 (pin 3).

12 volts

Open circuit 412 (PU) between Fuse #20 and Left-hand Brake/Tail Lamp E-11 connector X299 (pin 3). Short to ground in circuit 412 (PU), 625 (PU) and 177 (PU) between Fuse #20 and Left-hand Brake/Tail Lamp E-11 connector X299 (pin 3). Any short to ground will blow the Fuse #20.

Disconnect the Left-hand Brake/Tail Lamp E-11.

Less than 1 ohm.

Measure the resistance on circuit 634 (BK) between Left-hand Brake/Tail Lamp E-11 connector X299 (pin 2) and ground.

If good reading, replace the marker bulb of the Left-hand Brake/Tail Lamp E-11.

If good reading, go to next test point.

55-68

Open circuit 634 (BK) between Left-hand Brake/Tail Lamp E-11 connector X299 (pin 2) and ground.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 N - RIGHT-HAND BRAKE/TAIL LAMP TEST (MARKER BULB) Test Point

Good Reading

Possible Cause of Bad Reading

Turn Road Light Switch S-26 to Marker Lights position. Measure 12 volts at Fuse #21.

12 volts If good reading, go to next test point.

Perform Road Light Switch Test.

Measure for 12 volts at Right-hand Brake/Tail Lamp E-12 connector X300 (pin 3).

12 volts

Open circuit 421 (PU) between Fuse #21 and Right-hand Brake/Tail Lamp E-12 connector X300 (pin 3). Short to ground in circuit 421 (PU), 626 (PU) and 176 (PU) between Fuse #21 and Right-hand Brake/Tail Lamp E-12 connector X300 (pin 3). Any short to ground will blow the Fuse #21.

Disconnect the Right-hand Brake/Tail Lamp E-12.

Less than 1 ohm.

Measure the resistance on circuit 635 (BK) between Right-hand Brake/Tail Lamp E-12 connector X300 (pin 2) and ground.

If good reading, replace the marker bulb of the Right-hand Brake/Tail Lamp.

If good reading, go to next test point.

Open in circuit 635 (BK) between Right-hand Brake/Tail Lamp E-12 connector X300 (pin 2) and ground.

O - LEFT-HAND BRAKE/TAIL LAMP TEST (BRAKE BULB) Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Depress brake pedal. Measure for 12 volts at Brake Light Relay K-33 (pin 5).

12 volts If good reading, go to next test point.

Perform Brake Light Relay Test.

Depress brake pedal. Measure for 12 volts at Left-hand Brake/Tail Lamp E-11 connector X299 (pin 1).

12 volts

Open circuit 629 (PU) between Brake Light Relay K-33 (pin 5) and Left-hand Brake/Tail Lamp E-11 connector X299 (pin 1). Short to ground on circuit 629 (PU) between Brake Light Relay K-33 (pin 5) and Left-hand Brake/Tail Lamp E-11 connector X299 (pin 1). Any short to ground will blow the Fuse #52.

Disconnect the Left-hand Brake/Tail Lamp E-11.

Less than 1 ohm.

Measure the resistance on circuit 634 (BK) between Left-hand Brake/Tail Lamp E-11 connector X299 (pin 2) and ground.

If good reading, replace the brake bulb of the Left-hand Brake/Tail Lamp E-12.

If good reading, go to next test point.

55-69

Open in circuit 634 (BK) between Left-hand Brake/Tail Lamp E-11 connector X299 (pin 2) and ground.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 P - RIGHT-HAND BRAKE/TAIL LAMP TEST (BRAKE BULB) Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Depress brake pedal. Measure for 12 volts at Brake Light Relay K-33 (pin 5).

12 volts If good reading, go to next test point.

Perform Brake Light Relay Test.

Depress brake pedal. Measure for 12 volts at Right-hand Brake/Tail Lamp E-12 connector X300 (pin 1).

12 volts

Open circuit 630 (PU) between Brake Light Relay K-33 (pin 5) and Right-hand Brake/Tail Lamp E-12 connector X300 (pin 1). Short to ground on circuit 630 (PU) between Brake Light Relay K-33 (pin 5) and Right-hand Brake/Tail Lamp E-12 connector X300 (pin 1). Any short to ground will blow the Fuse #52.

Disconnect the Right-hand Brake/Tail Lamp E-12. Measure the resistance on circuit 635 (BK) between Right-hand Brake/Tail Lamp E-12 connector X300 (pin 2) and ground.

Less than 1 ohm.

If good reading, go to next test point.

If good reading, replace the brake bulb of the Right-hand Brake/Tail Lamp E-12.

55-70

Open circuit 635 (BK) between Right-hand Brake/Tail Lamp E-12 connector X300 (pin 2) and ground.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 Q - ROAD LIGHT SWITCH TEST Test Point

Good Reading

Possible Cause of Bad Reading

Measure for 12 volts at Road Light Switch S-26 connector X256 (pin 5).

12 volts If good reading, go to test point 3.

Open or short to ground on circuit 213 (RD) between Road Light Switch S-26 connector X256 (pin 5) and Fuse #49. A short to ground will blow Fuse #49.

Disconnect Road Light Switch S-26. Measure for 12 volts at Road Light Switch S-26 connector X256 (pin 5).

12 volts

Open or short to ground on circuit 213 (RD) between Road Light Switch S-26 connector X256 (pin 5) and Fuse #49. A short to ground will blow Fuse #49.

Reconnect Road Light Switch S-26. Measure for 12 volts at Road Light Switch S-26 connector (pin 8).

12 volts If good reading, go to test point 5.

Open or short to ground on circuit 214 (RD) between Road Light Switch S-26 connector X256 (pin 8) and Fuse #51. A short to ground will blow Fuse #51.

Disconnect Road Light Switch S-26. Measure for 12 volts at Road Light Switch S-26 connector X256 (pin 8).

12 volts

Open or short to ground on circuit 214 (RD) between Road Light Switch S-26 connector X256 (pin 5) and Fuse #51. A short to ground will blow Fuse #51.

Place Key in “ON” position. Measure for 12 volts at Road Light Switch S-26 connector X256 (pin 6).

12 volts If good reading, go to test point 7.

Open or short to ground on circuit 096 (OR) or 055 (OD) between Road Light Switch S-26 connector X256 (pin 6) and Key Switch S-02 connector X068 (pin 6).

Disconnect Road Light Switch S-26. Measure for 12 volts at Road Light Switch S-26 connector X256 (pin 6).

12 volts

Open or short to ground on circuit 096 (OR) or 055 (OD) between Road Light Switch S-26 connector X256 (pin 6) and Key Switch S-02 connector X068 (pin 6).

Place Key in “ON” position and Road Light Switch S-26 in the “RIGHT” turn position. Measure for 12 volts at Road Light Switch S-26 connector X256 (pin 3).

12 volts If good reading, go to next test point.

Road Light Switch S-26 bad. Short to ground on circuit 197 (PU) between Road Light Switch S-26 connector X256 and CCM1 (pin J1-2) and Flasher Module A-05 connector X255 (pin 8). A short here will blow fuse F-38.

Place Key in “ON” position and Road Light Switch S-26 in the “LEFT” turn position. Measure for 12 volts at Road Light Switch S-26 connector X256 (pin 2).

12 volts If good reading, go to next test point.

Road Light Switch S-26 bad. Short to ground on circuit 201 (PU) between Road Light Switch S-26 connector X256 (pin 2) and CCM1 (pin J1-9) and Flasher Module A-05 connector X255 (pin 7). A short here will blow fuse F-38

If good reading, replace Road Light Switch.

55-71

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6

Test Point

Good Reading

Possible Cause of Bad Reading

Place Road Light Switch S-26 in marker light position (first twist position on stalk). Measure voltage at Road Light Switch S-26 connector X256 (pin 1). Place Road Light Switch S-26 in headlights position (second twist position on stalk). Place the stalk in low beams position (pull to rear). Measure voltage at Road Light Switch S-26 connector X256 (pin 7). With S-26 still in headlights position, place the stalk in high beams position (push to front). Measure voltage at Road Light Switch S-26 connector X256 (pin 4).

12 volts If good reading, Road Light Switch S-26 is working properly. Go to next text point.

Road Light Switch S-26 bad. Short to ground on circuit 173 (OR) between Road Light Switch S-26 connector X256 (pin 1) and K-02 Light Control Relay (pin 5). A short to ground will blow Fuse #49.

12 volts

Road Light Switch S-26 bad. Short to ground on circuits 169 (YE) between Road Light Switch S-26 connector X256 (pin 7) and Low Beam Relay K-05 (pin 1). A short to ground will blow Fuse #49.

If good reading, Road Light Switch S-26 is working properly.

12 volts If good reading, Road Light Switch S-26 is working properly. Go to next text point.

Road Light Switch S-26 bad. Short to ground on circuits 218 (YE), 43 (YE) and 191 (YE) between Road Light Switch S-26 connector X256 (pin 4) and High Beam Relay K-04 (pin 1) or High Beam Indicator. A short to ground will blow Fuse #49.

R - LOW BEAM RELAY TEST 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Road Light switch S-26 in headlights position (second twist position on stalk). Place the stalk in low beams position (pull to rear). Measure for 12 volts at Low Beam Relay K-05 (pin 5). Road Light Switch S-26 still in low beam position.

12 volts

Low Beam Relay K-05 bad.

If good reading, relay is functioning properly.

Adjacent circuits.

Measure for 12 volts at Low Beam Relay K-05 (pin 1).

If good reading, go to next test point.

Measure for 12 volts at Low Beam Relay K-05 (pin 3).

12 volts

Go to next test point. 12 volts

If good reading, go to next test point. 4

Disconnect the Low Beam Relay K-05. Measure resistance on circuit 156 (BK) between Low Beam Relay K-05 (pin 2) and ground.

Less than 1ohm. If good reading, replace Low Beam Relay K-05.

55-72

Open or short to ground in circuit 169 (YE) between Low Beam Relay K-05 (pin 1) and Road Light Switch S-26 connector X256 (pin 7). A short to ground will blow the Fuse #49. Road Light Switch S-26. Open circuit 236 (RD) between Low Beam Relay K-05 (pin 3) and Fuse #33. A short to ground will blow the Fuse #33. Open in circuit 156 (BK) between Low Beam Relay K-05 (pin 2) and ground.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 S - HIGH BEAM RELAY TEST 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Road Light Switch S-26 in headlights position (second twist position on stalk). Place the stalk in high beams position (push to front). Measure for 12 volts at High Beam Relay K-04 (pin 5). Road Light Switch S-26 still in high beam position.

12 volts

High Beam Relay K-04.

If good reading, relay is functioning properly.

Adjacent circuits.

Measure for 12 volts at High Beam Relay K-04 (pin 1). Measure for 12 volts at High Beam Relay K-04 (pin 3).

If good reading, go to next test point.

Disconnect the High Beam Relay K-04. Measure resistance on circuit 192 (BK) between High Beam Relay K-04 (pin 2) and ground.

Go to next test point. 12 volts

12 volts

If good reading, go to next test point. Less than 1ohm.

Open or short to ground in circuit 191 (YE) or 218 (YE) between High Beam Relay K-04 (pin 1) and Road Light Switch S-26 connector X256 (pin 4). A short to ground will blow the Fuse #49. Road Light Switch S-26. Open circuit 185 (RD) between High Beam Relay K-04 (pin 3) and Fuse #32. A short to ground will blow the Fuse #32. Open in circuit 192 (BK) between High Beam Relay K-04 (pin 2) and ground.

If good reading, replace the High Beam Relay K-04.

T - LEFT-HAND ROAD LIGHT TEST (LOW BEAM BULB) 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Road Light Switch S-26 in headlights position (second twist position on stalk). Place the stalk in low beams position (pull to rear).

12 volts

Perform Low Beam Relay Test.

Measure for 12 volts at Low Beam Relay K-05 (pin 5). Measure the voltage at Left-hand Road Light E-13 connector X164 (pin B).

If good reading, go to next test point.

12 volts If good reading, go to next test point.

Disconnect the Left-hand Road Light E-13.

Less than 1 ohm.

Measure the resistance on circuit 642 (BK) between Left-hand Road Light E-13 connector X164 (pin C) and ground.

If good reading, replace the low beam bulb of the Left-hand Road Light E-13.

55-73

Open circuit 237 (PU) or 638 (PU) between Low Beam Relay K-05 (pin 5) and Left-hand Road Light E-13 connector X164 (pin B). Open in circuit 642 (BK) between Left-hand Road Light E-13 connector X164 (pin C) and ground.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 U - RIGHT-HAND ROAD LIGHT TEST (LOW BEAM BULB) 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Road Light Switch S-26 in headlights position (second twist position on stalk). Place the stalk in low beams position (pull to rear).

12 volts

Perform Low Beam Relay Test.

Measure for 12 volts at Low Beam Relay K-05 (pin 5). 2

If good reading, go to next test point.

Measure the for 12 volts at Right-hand Road Light E-14 connector X169 (pin B).

12 volts

Disconnect the Right-hand Road Light E-14.

Less than 1 ohm.

Measure the resistance on circuit 643 (BK) between Right-hand Road Light E-14 connector X169 (pin C) and ground.

If good reading, replace the low beam bulb of the Right-hand Road Light E-14.

If good reading, go to next test point.

Open circuit 237 (PU) or 639 (PU) between Low Beam Relay K-05 (pin 5) and Right-hand Road Light E-14 connector X169 (pin B). Open in circuit 643 (BK) between Right-hand Road Light E-14 connector X169 (pin C) and ground.

V - LEFT-HAND ROAD LIGHT TEST (HIGH BEAM BULB) 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Road Light Switch S-26 in headlights position (second twist position on stalk). Place the stalk in high beams position (push to front).

12 volts

Perform High Beam Relay Test.

If good reading, go to next test point.

Measure for 12 volts at High Beam Relay K-04 (pin 5). 2

Measure the voltage at Left-hand Road Light E-13 connector X164 (pin A).

12 volts

Disconnect the Left-hand Road Light E-13.

Less than 1 ohm.

Measure the resistance on circuit 642 (BK) between Left-hand Road Light E-13 connector X164 (pin C) and ground.

If good reading, replace the High beam bulb of the Left-hand Road Light E-13.

If good reading, go to next test point.

55-74

Open circuit 186 (PU) or 640 (PU) between High Beam Relay K-04 (pin 5) and Left-hand Road Light E-13 connector X164 (pin A). Open in circuit 642 (BK) between Left-hand Road Light E-13 connector X164 (pin C) and ground.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 X - RIGHT-HAND ROAD LIGHT TEST (HIGH BEAM BULB) 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Road Light Switch S-26 in headlights position (second twist position on stalk). Place the stalk in high beams position (push to front).

12 volts

Perform High Beam Relay Test.

Measure for 12 volts at High Beam Relay K-04 (pin 5). Measure the voltage at Right-hand Road Light E-14 connector X169 (pin A).

If good reading, go to next test point.

12 volts If good reading, go to next test point.

Disconnect the Right-hand Road Light E-14.

Less than 1 ohm.

Measure the resistance on circuit 643 (BK) between Right-hand Road Light E-14 connector X169 (pin C) and ground.

If good reading, replace the High beam bulb of the Right-hand Road Light E-14.

Open circuit 186 (PU) or 641 (PU) between High Beam Relay K-04 (pin 5) and Right-hand Road Light E-14 connector X169 (pin “A). Open in circuit 643 (BK) between Right-hand Road Light E-14 connector X169 (pin C) and ground.

Y - BRAKE LIGHTS RELAY TEST 1

Test Point

Good Reading

Possible Cause of Bad Reading

Depress brake pedal. Measure for 12 volts at Brake Lights Relay K-33 (pin 5). Depress brake pedal.

12 volts If good reading, the relay is OK.

Brake Lights Relay K-33. Adjacent circuits. Go to next test point.

12 volts

Measure for 12 volts at Brake Lights Relay K-33 (pin 1).

If good reading, go to next test point.

Open or short to ground in circuit 183 (WH) between Brake Lights Relay K-33 (pin 1) and CCM2 connector X015 (pin J1-18). Fault in CCM2.

Measure for 12 volts at Brake Lights Relay K-33 (pin 3).

12 volts If good reading, go to next test point.

Disconnect the Brake Lights Relay K-33.

Less than 1 ohm.

Measure resistance on circuit 159 (BK) between Brake Lights Relay K-33 (pin 2) and ground.

If good reading, go to next test point.

55-75

Open circuit 56 (RD) between Brake Lights Relay K-33 (pin 3) and Fuse #52. Short to ground on circuit 78 (PU) between Brake Lights Relay K-33 (pin 5) and Brake Lamps. A short will cause Fuse #52 to blow. Open circuit 159 (BK) between Brake Lights Relay K-33 (pin 2) and ground.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 Z - REAR WORK LIGHTS RELAY TEST 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Rear Work Light Switch S-44. Measure for 12 volts at Rear Work Lights Relay K-31 (pin 5).

12 volts

Rear Work Lights Relay K-31.

If good reading, the relay is operating properly.

Go to next test point.

Measure for 12 volts at Rear Work Lights Relay K-31 (pin 1).

12 volts

Open or short circuit 184 (WH) between Rear Work Lights Relay K-31 (pin 1) and CCM1 connector X018 (pin J1-18). Fault in CCM1.

Adjacent circuits.

If good reading, go to next test point. 3

Measure for 12 volts at Rear Work Lights Relay K-31 (pin 3).

12 volts

Disconnect the Rear Work Lights Relay K-31.

Less than 1 ohm.

Measure resistance on circuit 158 (BK) between Rear Work Lights Relay K-31 (pin 2) and ground.

If good reading, go to next test point.

Open in circuit 66 (RD) between Rear Work Lights Relay K-31 (pin 3) and Fuse #55. Short to ground on circuit 67 (PU) between Rear Work Lights Relay K-31 (pin 5) and Rear Work Lights E-27 and E-28 connector X106 and X110 (pin A). A short to ground will blow the Fuse #55. Open circuit 158 (BK) between Rear Work Lights Relay K-31 (pin 2) and ground.

AA - LEFT-HAND REAR WORK LIGHT TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Rear Work Light Switch S-43. Measure for 12 volts at Rear Work Lights Relay K-31 (pin 5).

12 volts

Perform Rear Work Lights Relay Test.

Measure the voltage at Left-hand Rear Work Light E-27 connector X106 (pin A).

12 volts If good reading, go to next test point.

Open circuit 652 (PU) or 67 (PU) between Rear Work Lights Relay K-31 (pin 5) and Left-hand Rear Work Light E-27 connector X106 (pin A).

Disconnect the Left-hand Rear Work Light E-27.

Less than 1 ohm.

Measure the resistance of circuit 661 (BK) between Left-hand Rear Work Light E-27 connector X106 (pin B) and ground.

Open in circuit 661 (BK) between Left-hand Rear Work Light E-27 connector X106 (pin B) and ground.

If good reading, replace the Rear Work Lights bulb of the Left-hand Rear Work Light E-27.

If good reading, go to next test point.

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 BB - RIGHT-HAND REAR WORK LIGHT TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Rear Work Light Switch S-44. Measure for 12 volts at Rear Work Lights Relay K-31 (pin 5).

12 volts

Perform Rear Work Lights Relay Test.

Measure the voltage at Right-hand Rear Work Light E-28 connector X110 (pin A).

12 volts If good reading, go to next test point.

Open circuit 653 (PU) or 67 (PU) between Rear Work Lights Relay K-31 (pin 5) and Right-hand Rear Work Light E-28 connector X110 (pin A).

Disconnect the Right-hand Rear Work Light E-28.

Less than 1 ohm.

Measure the resistance of circuit 662 (BK) between Right-hand Rear Work Light E-28 connector X110 (pin B) and ground.

Open in circuit 662 (BK) between Right-hand Rear Work Light E-28 connector X110 (pin B) and ground.

If good reading, replace the Rear Work Lights bulb of the Right-hand Rear Work Light E-28.

If good reading, go to next test point.

CC - BEACON LIGHT RELAY TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position.

12 volts

Beacon Light Relay K-29.

Close Beacon Light Switch S-41. Measure for 12 volts at Beacon Light Relay K-29 (pin 5).

If good reading, the relay is operating properly.

Adjacent circuits.

Measure for 12 volts at Beacon Light Relay K-29 (pin 1).

12 volts If good reading, go to next test point.

Open or short to ground in circuit between Beacon Light Relay K-29 (pin 1) and CCM2 connector X015 (pin J1-24). Fault in CCM2.

Measure for 12 volts at Beacon Light Relay K-29 (pin 3).

12 volts If good reading, go to next test point.

Open in circuit 069 (RD) between Beacon Light Relay K-29 (pin 3) and Fuse #53. Short to ground on circuit 578 (PU) between Beacon Light Relay K-29 (pin 5) and Rear Beacon Light E-33 connector X247 (pin A). A short will cause Fuse #53 to blow.

Disconnect the Beacon Light Relay K-29. Measure resistance on circuit 160 (BK) between Beacon Light Relay K-29 (pin 2) and ground.

Less than 1 ohm. If good reading, go to next test point.

Open circuit 160 (BK) between Beacon Light Relay K-29 (pin 2) and ground.

Go to next test point.

55-77

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 DD - REAR BEACON TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Beacon Light Switch S-41. Measure for 12 volts at Beacon Light Relay K-29 (pin 5).

12 volts

Perform Beacon Light Relay Test.

Measure the voltage at Rear Beacon Light E-33 connector X247 (pin A).

12 volts If good reading, go to next test point.

Open circuit 578 (PU) between Beacon Light Relay K-29 (pin 5) and Rear Beacon Light E-33 connector X247 (pin A).

Disconnect the Rear Beacon. Measure the resistance on circuit 623 (BK) between Rear Beacon Light E-33 connector X247 (pin B) and ground.

Less than 1 ohm.

Open circuit 623 (BK) between Rear Beacon Light E-33 connector X247 (pin B) and ground.

If good reading, go to next test point.

If good reading, replace the Beacon Light bulb of the Rear Beacon E-33.

EE - LEFT-HAND FRONT BEACON TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Beacon Light Switch S-41. Measure for 12 volts at Beacon Light Relay K-29 (pin 5).

12 volts

Perform Beacon Light Relay Test.

Measure for 12 volts at Left-hand Front Beacon Light E-31 connector X113 (pin A).

12 volts If good reading, go to next test point.

Open in circuit 579 (PU) or 663 (PU) between Beacon Light Relay K-29 (pin 5) and Left-hand Front Beacon Light E-31 connector X113 (pin A).

Disconnect the Left-hand Front Beacon E-31. Measure the resistance on circuit 666 (BK) between Left-hand Front Beacon Light E-31 connector X113 (pin B) and ground.

Less than 1 ohm.

Open in circuit 666 (BK) between Left-hand Front Beacon Light E-31 connector X113 (pin B) and ground.

If good reading, go to next test point.

If good reading, replace the Beacon Light bulb of the Left-hand Front Beacon E-31.

55-78

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 FF - RIGHT-HAND FRONT BEACON TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Beacon Light Switch S-41. Measure for 12 volts at Beacon Light Relay K-29 (pin 5).

12 volts

Perform Beacon Light Relay Test.

Measure for 12 volts at Right-hand Front Beacon Light E-32 connector X119 (pin A).

12 volts If good reading, go to next test point.

Open in circuit 579 (PU) or 664 (PU) between Beacon Light Relay K-29 (pin 5) and Right-hand Front Beacon Light E-32 connector X119 (pin A).

Disconnect the Right-hand Front Beacon E-32. Measure the resistance on circuit 667 (BK) between Right-hand Front Beacon Light E-32 connector X119 (pin B) and ground.

Less than 1 ohm.

Open in circuit 667 (BK) between Right-hand Front Beacon Light E-32 connector X119 (pin B) and ground.

If good reading, go to next test point.

If good reading, replace the Beacon Light bulb of the Right-hand Front Beacon E-32.

GG - SIEVE LIGHT SWITCH TEST Test Point

Good Reading

Possible Cause of Bad Reading

Measure the voltage at Sieve Light Switch S-54 connector X237 (pin 2).

12 volts If good reading, go to next test point.

Blown Fuse #14 Open circuit 604 (OR) between Sieve Light Switch S-54 connector X237 (pin 2) and Fuse #14. Short to ground on circuit 604 (OR) between Sieve Light Switch S-54 connector X237 (pin 2) and Fuse #14. A short to ground will blow the Fuse #14.

Close Sieve Light Switch S-54. Measure for 12 volts at Sieve Light Switch S-54 connector X237 (pin 3).

12 volts

Sieve Light Switch S-54 Short to ground in circuit 610 (PU) between Sieve Light Switch S-54 connector X237 (pin 3) and Sieve Light E-37 connector X234 (pin A). A short to ground will blow the Fuse #14.

If good reading, switch is working properly.

55-79

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 HH - SIEVE LIGHT TEST Test Point

Good Reading

Possible Cause of Bad Reading

Close Sieve Light Switch S-54. Measure for 12 volts at Sieve Light Switch S-54 connector X237 pin 3).

12 volts.

Perform Sieve Light Switch Test.

Measure for 12 volts at Sieve Light E-37 connector X234 (pin A).

12 volts If good reading, go to next test point.

Open circuit 610 (PU) between Sieve Light Switch S-54 connector X237 (pin 3) and Sieve Light E-37 connector X234 (pin A).

Disconnect the Sieve Light E-37. Measure the resistance on circuit 611 (BK) between Sieve Light E-37 connector X234 (pin B) and ground.

Less than 1 ohm.

Open circuit 611 (BK) between Sieve Light E-37 connector X234 (pin B) and ground.

If good reading, go to next test point.

If good reading, replace the Sieve Light bulb.

NOTE: Key switch must be turned OFF to perform this test.

II - TIMED SIDE WORK LIGHT RELAY TEST Test Point

Good Reading

Possible Cause of Bad Reading

Key switch off. Cycle Left-hand Door Switch. Measure for 12 volts at Timed Side Work Light Relay K-34 (pin 5).

12 volts If good reading, the relay is operating properly.

Timed Side Work Light Relay K-34. Adjacent circuits. Go to next test point.

Cycle Left-hand Door Switch. Measure for 12 volts at Timed Side Work Light Relay K-34 (pin 1).

12 volts If good reading, go to next test point.

Open or short to ground in circuit 969 (PU) between Time Delay Module K-20 (pin 87) and Timed Side Work Light Relay K-34 (pin 1). Time Delay Module K-20. Perform Time Delay Module test.

Measure for 12 volts at Left-hand Side Work Light Relay (pin 3).

12 volts If good reading, go to next test point.

Open in circuit 73 (RD) between Timed Side Work Light Relay K-34 (pin 3) and Fuse #50.

Disconnect the Timed Side Work Light Relay K-34. Measure the resistance on circuit 161 (BK) between Timed Side Work Light Relay K-34 (pin 2) and ground.

Less than 1 ohm.

Short to ground on circuit 76 (PU) 165 (PU) or 72 (PU) between Timed Side Work Light Relay K-34 (pin 5) and Side Work Lights E-25 and E-26 connector X297 and X298 (pin A). A short will cause Fuse #50 to blow.

55-80

Open in circuit 161 (BK) between Timed Side Work Light Relay K-34 (pin 2) and ground.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 NOTE: Key switch must be turned OFF to perform this test.

III - TIME DELAY MODULE TEST Test Point

Good Reading

Possible Cause of Bad Reading

Key switch off. Left-hand door closed. Measure voltage at Time Delay Module K-20 (pin 87). Open left-hand door while watching meter.

Voltage on pin 87 goes from 0 to +12 volts. If good reading, module has turned on correctly. Go to Step 4.

Time Delay Module K-20 bad. Defective Left-hand Door Switch S-40 or associated circuitry. Go to next test point.

Quick check of Door Switch S-40: Left-hand door closed. Place Dome Light E-34 switch in center position. Open left-hand door.

Dome light turns on. Door switch OK. Go to next test point.

Dome Light bulb bad. Defective left-hand Door Switch S-40. Open wire 865 (YE) between Door Switch S-40 and Dome Light E-34 connector X296 (pin 2). Open circuit 956 (RD) and 075 (RD) between Dome Light E-34 connector X296 (pin 2) and brake relay K-33 (pin 3).

Left-hand door closed. Measure voltage at Time Delay Module K-20 (pin 86). While watching meter, open left-hand door.

Reading goes from +12 volts to 0 volts when door is opened. If good reading, replace K-20.

Open circuit 967 (YE) or 865 (YE) between Time Delay Module K-20 (pin 86) and Dome Light E-34 connector X296 (pin 2).

Left-hand door closed. Measure voltage at Time Delay Module K-20 (pin 87). Cycle door switch.

Voltage goes from 0 to +12 volts. Remains at +12 volts for about 60 seconds, then returns to 0 volts.

Time Delay Module K-20 bad.

55-81

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 JJ - SIDE WORK LIGHT RELAY TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Work Light Switch S-43. Measure for 12 volts at Side Work Light Relay K-35 (pin 5).

12 volts.

Side Work Light Relay K-35.

If good reading, the relay is operating properly.

Adjacent circuits.

Partially remove Side Work Light Relay K-35. Measure for 12 volts at Side Work Light Relay K-35 (pin 1).

12 volts If good reading, go to next test point.

Open or short to ground in circuit 180 (WH) between Side Work Light Relay K-35 (pin 1) and CCM1 connector X018 (pin J1-24). Fault in CCM1.

Measure for 12 volts at Side Work Light Relay K-35 (pin 3).

12 volts If good reading, go to next test point.

Open circuit 071 (RD) or 073 (RD) between Side Work Light Relay K-35 (pin 3) and Fuse #50.

Go to next test point.

Short to ground on circuit 072 (PU), 165 (PU) or 076 (PU) between Side Work Light Relay K-35 (pin 5) and Side Work Lights E-25 and E-26 connectors X297 and X298 (pin A). A short will cause Fuse 0#50 to blow. 4

Disconnect the Side Work Light Relay K-35. Measure the resistance on circuit 162 (BK) between Side Work Light Relay K-35 (pin 2) and ground.

Less than 1 ohm. If good reading, replace Side Work Light Relay K-35.

Open in circuit 161 (BK) between Side Work Light Relay K-35 (pin 2) and ground.

KK - UNLOAD TUBE LIGHT RELAY TEST 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Unload tube must be swung out from its cradle to activate Unload Tube Light Relay K-32. Measure for 12 volts at Unload Tube Light Relay K-32 (pin 5).

12 volts.

Unload Tube Light Relay K-32.

If good reading, the relay is operating properly.

Adjacent circuits.

Measure for 12 volts at Unload Tube Light Relay K-32 (pin 1).

12 volts If good reading, go to test point 4.

Go to next test point.

55-82

Open or short to ground in circuit between Unload Tube Light Relay K-32 (pin 1) and CCM1 (J1-12). Go to next test point.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 Test Point

Good Reading

Possible Cause of Bad Reading

Ground CCM1 pin J3-36. Measure for 12 volts at Unload Tube Light Relay K-03 (pin 1).

12 volts If good reading, go to next test point.

Unload cradle sensor B-38. Open in circuit 485 (YE) between CCM1 (J3-36) and Unload Cradle Sensor B-38 or between B-38 and ground. Fault in CCM1.

Measure for 12 volts at Unload Tube Light Relay K-32 (pin 3).

12 volts

Open in circuit 074 (RD) between Unload Tube Light Relay K-32 (pin 3) and Fuse #50. Short to ground on circuit 077 (PU) between Unload Tube Light Relay K-32 (pin 5) and Unload Tube Light E-29 connector X322 (pin 1). A short will cause Fuse #50 to blow.

If good reading, go to next test point.

Disconnect the Unload Tube Light Relay K-32. Measure the resistance on circuit 163 (BK) between Unload Tube Light Relay K-32 (pin 2) and ground.

Less than 1 ohm. If good reading, replace Unload Tube Light Relay K-32.

Open in circuit 163 (BK) between Unload Tube Light Relay K-32 (pin 2) and ground.

LL - TIMED SIDE WORK LIGHT TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Work Light Switch S-43. Measure for 12 volts at Side Work Light Relay K-34 (pin 5).

12 volts.

Perform Timed Side Work Light Relay K-34 Test.

Measure for 12 volts at Timed Side Work Light E-25 connector X297 (pin A).

12 volts If good reading, go to next test point.

Open circuit 076 (PU) between Timed Side Work Lights Relay K-34 (pin 5) and Timed Side Work Light E-25 connector X297 (pin A).

Disconnect the Timed Side Work Light E-25. Measure the resistance on circuit 671 (BK) between Timed Side Work Light E-25 connector X297 (pin B) and ground.

Less Than 1 ohm.

Open circuit 671 (BK) between Side Work Light E-25 connector X297 (pin B) and ground.

If good reading, go to next test point.

If good reading, replace the Timed Side Work Light bulb.

55-83

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 MM - SIDE WORK LIGHT TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Work Light Switch S-43. Measure for 12 volts at Side Work Light Relay K-35 (pin 5).

12 volts.

Perform Side Work Light Relay K-35 Test.

Measure for 12 volts at Right-hand Side Work Light E-26 connector X298 (pin A).

12 volts If good reading, go to next test point.

Open circuit 072 (PU) between Side Work Lights Relay K-35 (pin 5) and Right-hand Side Work Light E-26 connector X298 (pin A).

Disconnect the Right-hand Side Work Light E-26. Measure the resistance on circuit 670 (BK) between Right-hand Side Work Light E-26 connector X298 (pin B) and ground.

Less Than 1 ohm.

Open circuit 670 (BK) between Right-hand Side Work Light E-26 connector X299 (pin B) and ground.

If good reading, go to next test point.

If good reading, replace the Right-hand Side Work Light bulb.

NN - UNLOAD TUBE LIGHT TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Unload tube must be swung out of its cradle to activate Unload Tube Light Relay K-32. Measure for 12 volts at Unload Tube Relay K-32 (pin 5).

12 volts.

Perform Unload Tube Light Relay Test.

Measure for 12 volts at Unload Tube Light E-29 connector X322 (pin A).

12 volts If good reading, go to next test point.

Open circuit 077 (PU) between Unload Tube Relay K-32 (pin 5) and Unload Tube Light E-29 connector X322 (pin A).

Disconnect the Unload Tube Light E-29. Measure the resistance on circuit 669 (BK) between Unload Tube Light E-29 connector X322 (pin B) and ground.

Less than 1 ohm.

Open in circuit 669 (BK) between Unload Tube Light E-29 connector X322 (pin B) and ground.

If good reading, go to next test point.

If good reading, replace the Unload Tube Light bulb.

55-84

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 OO - LOWER WORK LIGHTS RELAY TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Work Light Switch S-43. Measure for 12 volts at Lower Work Lights Relay K-30 (pin 5).

12 volts.

Lower Work Lights Relay.

If good reading, the relay is operating properly.

Adjacent circuits.

Measure for 12 volts at Lower Work Lights Relay K-30 (pin 1).

12 volts If good reading, go to next test point.

Open or short to ground in circuit 187 (WH), 188 (WH), 189 (WH) or 117 (WH) between Lower Work Lights Relay K-30 (pin 1) and CCM1 (J1-5). Fault in CCM1.

Measure for 12 volts at Lower Work Lights Relay K-30 (pin 3).

12 volts

Open in circuit 64 (RD) between Lower Work Lights Relay K-30 (pin 3) and Fuse #54. Short to ground in circuit 65 (PU), 645 (PU), 644 (PU) or 646 (PU) between Lower Work Lights Relay K-30 (pin 3) and Lower Work Lights E-23 and E-24 or Grain Tank Light E-30. A short will cause the Fuse #54 to blow.

Go to next test point.

If good reading, go to next test point.

Disconnect the Lower Work Lights Relay K-30. Measure resistance on circuit 157 (BK) to Lower Work Lights Relay K-30 (pin 2) and ground.

Less than 1 ohm.

Open in circuit 157 (BK) to Lower Work Lights Relay K-30 (pin 2) and ground.

If good reading, replace Lower Work Lights Relay K-30.

PP - GRAIN TANK LIGHT TEST 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Work Light Switch S-43. Measure for 12 volts at Grain Tank Light E-30 connector X108 (pin 1).

12 volts

Open circuit 065 (PU) or 646 (PU) between Lower Work Lights Relay K-30 (pin 5) and Grain Tank Light E-30 connector X108 (pin A).

Disconnect the Grain Tank Light E-30. Measure the resistance on circuit 681 (BK) between Grain Tank Light E-30 connector X108 (pin 2) and ground.

Less than 1 ohm.

If good reading, go to next test point.

If good reading, replace the Grain Tank Light E-30 bulb.

55-85

Open in circuit 681 (BK) or 688 (BK) between Grain Tank Light E-30 connector X108 (pin 2) and ground.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 QQ - LEFT-HAND LOWER WORK LIGHT TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Work Light Switch S-43. Measure for 12 volts at Lower Work Light Relay K-30 (pin 5).

12 volts.

Perform Lower Work Lights Relay Test.

Measure for 12 volts at Left-hand Lower Work Light E-23 connector X163 (pin A).

12 volts If good reading, go to next test point.

Open circuit 65 (PU) or 644 (PU) between Lower Work Lights Relay K-30 (pin 5) and Left-hand Lower Work Light E-23 connector X163 (pin A).

Disconnect the Left-hand Lower Work Light E-23. Measure the resistance on circuit 654 (BK) between Left-hand Lower Work Light E-23 connector X163 (pin B) and ground.

Less than 1 ohm.

Open in circuit 654 (BK) or 676 (BK) between Left-hand Lower Work Light E-23 connector X163 (pin B) and ground.

If good reading, go to next test point.

If good reading, replace the Left-hand Lower Work Light bulb.

RR - RIGHT-HAND LOWER WORK LIGHT TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Work Light Switch S-43. Measure for 12 volts at Right-hand Lower Work Light Relay K-30 (pin 5).

12 volts.

Perform Lower Work Lights Relay Test.

Measure for 12 volts at Lower Work Light E-24 connector X168 (pin A).

12 volts If good reading, go to next test point.

Open circuit 065 (PU) or 645 (PU) between Lower Work Lights Relay K-30 (pin 5) and Right-hand Lower Work Light E-24 connector X168 (pin A).

Disconnect the Right-hand Lower Work Light E-24. Measure the resistance on circuit 655 (BK) between Right-hand Lower Work Light E-24 connector X168 (pin B) and ground.

Less than 1 ohm.

Open in circuit 655 (BK) or 677 (BK) between Right-hand Lower Work Light E-24 connector X168 (pin B) and ground.

If good reading, go to next test point.

If good reading, replace the Right-hand Lower Work Light bulb.

55-86

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 SS - HEADER WORK LIGHTS RELAY TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Work Light Switch S-43. Measure for 12 volts at Header Work Lights Relay K-22 (pin 5).

12 volts.

Header Work Lights Relay Test.

If good reading, the relay is operating properly.

Adjacent circuits.

Measure for 12 volts at Header Work Lights Relay K-22 (pin 1).

12 volts If good reading, go to next test point.

Open or short on circuit 188 (WT) or 117 (WH) between Header Work Lights Relay K-22 (pin 1) and CCM1 (pin J1-5). Fault in CCM1.

Measure for 12 volts at Header Work Lights Relay K-22 (pin 3).

12 volts If good reading, go to next test point.

Open in circuit 062 (RD) between Header Work Lights Relay K-22 (pin 3) and Fuse #30. Short to ground in circuit 063 (PU), 258 (PU) or 257 (PU) between Header Work Lights Relay K-22 (pin 5) and Header Lights E-21 and E-22 connectors X167 and X162 (pin A). A short will cause Fuse #30 to blow.

Disconnect the Header Work Lights Relay K-22. Measure resistance on circuit 238 (BK) between Header Work Lights Relay K-22 (pin 2) and ground.

Less than 1 ohm.

Open circuit 238 (BK) between Header Work Lights Relay K-22 (pin 2) and ground.

Go to next test point.

If good reading, replace Header Work Lights Relay.

TT - LEFT-HAND HEADER LIGHT TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Work light Switch S-43. Measure for 12 volts at Header Work Lights Relay K-22 (pin 5).

12 volts.

Perform Header Work Lights Relay Test.

Measure for 12 volts at Left-hand Header Light E-21 connector X162 (pin A).

12 volts If good reading, go to next test point.

Open circuit 63 (PU) or 257 (PU) between Header Work Lights Relay K-22 (pin 5) and Left-hand Header Light E-21 connector X162 (pin A).

Disconnect the Left-hand Header Light E-21. Measure the resistance on circuit 267 (BK) between Left-hand Header Light E-21 connector X162 (pin B) and ground.

Less than 1 ohm.

Open circuit 267 (BK) between Left-hand Header Light E-21 connector X162 (pin B) and ground.

If good reading, go to next test point.

If good reading, replace the Left-hand Header Light bulb.

55-87

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 UU - RIGHT-HAND HEADER LIGHT TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Work light Switch S-43. Measure for 12 volts at Header Work Lights Relay K-22 (pin 5).

12 volts.

Perform Header Work Lights Relay Test.

Measure for 12 volts at Right-hand Header Light E-22 connector X167 (pin A).

12 volts If good reading, go to next test point.

Open circuit 063 (PU) or 258 (PU) between Header Work Lights Relay K-22 (pin 5) and Right-hand Header Light E-22 connector X167 (pin A).

Disconnect the Right-hand Header Light E-22. Measure the resistance on circuit 268 (BK) between Right-hand Header Light E-22 connector X167 (pin B) and ground.

Less than 1 ohm.

Open circuit 268 (BK) between Right-hand Header Light E-22 connector X167 (pin B) and ground.

If good reading, go to next test point.

If good reading, replace the Right-hand Header Light bulb.

VV - CAB ROOF WORK LIGHTS RELAY TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Work Light Switch S-43. Measure for 12 volts at Cab Roof Work Lights Relay K-01 (pin 87).

12 volts.

Cab Work Lights Relay K-01.

If good reading, the relay is operating properly.

Adjacent circuits.

Measure for 12 volts at Cab Roof Work Lights Relay K-01 (pin 86).

12 volts If good reading, go to next test point.

Open or short circuit 190 (WH) between Cab Roof Work Lights Relay K-01 (pin 86) and CCM1 (pin J1-11). Fault in CCM1.

Measure for 12 volts at Cab Roof Work Lights Relay K-01 (pin 30).

12 volts If good reading, go to next test point.

Open circuit 22 (RD) between Cab Roof Work Lights Relay K-01 (pin 30) and Fuse #31. Short to ground in circuit 023 (OR) or 088 (OR) between Cab Roof Work Lights Relay K-01 (pin 87) and Mid/Outer Work Lights E-15, E-16, E-19 and E-20. A short will cause Fuse #31 to blow.

Disconnect the Cab Roof Work Lights Relay K-01. Measure resistance on circuit 154 (BK) between Cab Roof Work Lights Relay K-01 (pin 85) and ground.

Less than 1 ohm.

Open circuit 154 (BK) between Cab Roof Work Lights Relay K-01 (pin 85) and ground.

If good reading, replace Cab Roof Work Lights Relay K-01.

55-88

Go to next test point.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 XX - LEFT-HAND CAB OUTER WORK LIGHT TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Work Light Switch S-43. Measure for 12 volts at Cab Roof Work Lights Relay K-01 (pin 87).

12 volts.

Perform Cab Roof Work Lights Relay Test.

Measure for 12 volts at Fuse #6, circuit 023 (OR).

12 volts If good reading, go to next test point.

Open circuit 023 (OR) between Fuse #6 and Cab Roof Work Lights Relay K-01 (pin 87).

Measure for 12 volts at Left-hand Cab Outer Work Light E-15 connector X112 (pin A).

12 volts If good reading, go to next test point.

Fuse #6 Open circuit 058 (PU) or 251 (PU) between Fuse #6 and Left-hand Cab Outer Work Light E-15 connector X112 (pin A).

Disconnect the Left-hand Cab Outer Work Light E-15. Measure the resistance on circuit 259 (BK) between Left-hand Cab Outer Work Light E-15 connector X112 (pin B) and ground.

Less than 1 ohm.

Open circuit 259 (BK) between Left-hand Cab Outer Work Light E-15 connector X112 (pin B) and ground.

If good reading, go to next test point.

If good reading, replace the Left-hand Cab Outer Work Light bulb.

YY - LEFT-HAND CAB MID WORK LIGHT TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Work Light Switch S-43. Measure for 12 volts at Cab Roof Work Lights Relay K-01 (pin 87).

12 volts.

Perform Cab Roof Work Lights Relay Test.

Measure for 12 volts at Fuse #6, circuit 023 (OR).

12 volts If good reading, go to next test point.

Open circuit 023 (OR) between Fuse #6 and Cab Roof Work Lights Relay K-01 (pin 87).

Measure for 12 volts at Left-hand Cab Mid Work Light E-19 connector X114 (pin A).

12 volts If good reading, go to next test point.

Fuse #6 Open circuit 058 (PU) or 252 (PU) between Fuse #6 and Left-hand Cab Mid Work Light E-19 connector X114 (pin A).

Disconnect the Left-hand Cab Mid Work Light E-19. Measure the resistance on circuit 260 (BK) between Left-hand Cab Mid Work Light E-19 connector X114 (pin B) and ground.

Less than 1 ohm.

Open circuit 260 (BK) between Left-hand Cab Mid Work Light E-19 connector X114 (pin B) and ground.

If good reading, go to next test point.

If good reading, replace the Left-hand Cab Mid Work Light E-19 bulb.

55-89

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 ZZ - RIGHT-HAND CAB OUTER WORK LIGHT TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Work Light Switch S-43. Measure for 12 volts at Cab Roof Work Lights Relay K-01 (pin 87).

12 volts.

Perform Cab Roof Work Lights Relay Test.

Measure for 12 volts at Fuse #7, circuit 088 (OR).

12 volts If good reading, go to next test point.

Open circuit 088 (OR) between Fuse #7 and Cab Roof Work Lights Relay K-01 (pin 87).

Measure for 12 volts at Right-hand Cab Outer Work Light E-16 connector X120 (pin A).

12 volts If good reading, go to next test point.

Fuse #7 Open circuit 059 (PU) or 254 (PU) between Fuse #7 and Right-hand Cab Outer Work Light E-16 connector X120 (pin A).

Disconnect the Right-hand Cab Outer Work Light E-16. Measure the resistance on circuit 264 (BK) between Right-hand Cab Outer Work Light E-16 connector X120 (pin B) and ground.

Less than 1 ohm.

Open circuit 264 (BK) between Right-hand Cab Outer Work Light E-16 connector X120 (pin B) and ground.

If good reading, go to next test point.

If good reading, replace the Right-hand Cab Outer Work Light E-16 bulb.

AAA - RIGHT-HAND CAB MID WORK LIGHT TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Work Light Switch S-43. Measure for 12 volts at Cab Roof Work Lights Relay K-01 (pin 87).

12 volts.

Perform Cab Roof Work Lights Relay Test.

Measure for 12 volts at Fuse #7, circuit 088 (OR).

12 volts If good reading, go to next test point.

Open circuit 088 (OR) between Fuse #7 and Cab Roof Work Lights Relay K-01 (pin 87).

Measure for 12 volts at Right-hand Cab Mid Work Light E-20 connector X118 (pin A).

12 volts If good reading, go to next test point.

Fuse #7 Open circuit 059 (PU) or 253 (PU) between Fuse #7 and Right-hand Cab Mid Work Light E-20 connector X118 (pin A).

Disconnect the Right-hand Cab Mid Work Light E-20. Measure the resistance on circuit 263 (BK) between Right-hand Cab Mid Work Light E-20 connector X118 (pin B) and ground.

Less than 1 ohm.

Open circuit 263 (BK) between Right-hand Cab Mid Work Light E-20 connector X118 (pin B) and ground.

If good reading, go to next test point.

If good reading, replace the Right-hand Cab Mid Work Light bulb.

55-90

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 BBB - DISTANCE WORK LIGHTS RELAY TEST Test Point 1

Good Reading

Place Key Switch S-02 in 12 volts “ON” position.

Possible Cause of Bad Reading Distance Work Lights Relay K-21.

Adjacent circuits. Close Work Light Switch If good reading, the relay is Go to next test point. operating properly. S-43. Measure for 12 volts at Distance Work Light Relay K-21 (pin 5). 2

Measure the voltage at 12 volts Open or short circuit 189 (WH) or 190 (WH) Distance Work Lights Relay between Distance Work Lights Relay K-21 K-21 (pin 1). (pin 1) and CCM1 (pin J1-11). If good reading, go to next test point. Fault in CCM1.

Measure for 12 volts at 12 volts Open circuit 60 (RD) between Distance Distance Work Lights Relay Work Lights Relay K-21 (pin 3) and Fuse If good reading, go to next #29. K-21 (pin 3). test point.

Disconnect the Distance Less than 1 ohm. Work Lights Relay K-21. Measure the resistance on If good reading, replace circuit 155 (BK) between Distance Work Lights Relay Distance Work Lights Relay K-21. K-21 (pin 2) and ground.

55-91

Open circuit 155 (BK) between Distance Work Lights Relay K-21 (pin 2) and ground.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 CCC - ROAD LIGHTS RELAY TEST Test Point 1

Good Reading

Place Key Switch S-02 in 12 volts “ON” position.

Possible Cause of Bad Reading Road lights Relay K-27.

Adjacent circuits. Road/Field Mode Switch If good reading, the relay is Go to next test point. S-12 in “Field” position. operating properly. Hazard Lights Switch in “OFF” position. Close Work Light Switch S-43. Measure for 12 volts at Road Lights Relay K-27 (pin 5). 2

Measure the voltage at Road 12 volts Lights Relay K-27 (pin 1).

Open or short circuit 117 between Road Lights Relay K-27 (pin 1) and CCM1 (pin J1-5).

If good reading, go to next Fault in CCM1. test point. 3

Measure for 12 volts at Road 12 volts Distance Work Lights Relay K-21. Perform Lights Relay K-27 (pin 3). Distance Work Lights Relay Test. If good reading, go to next test point. Open circuit 060 (RD) between Distance Work Lights Relay K-21 (pin 3) and Fuse #29. Open circuit on short to ground on circuit 021 (PU) between Distance Work Lights Relay K-21 (pin 5) and Road Lights Relay K-27 (pin 3). A short will cause Fuse #29 to blow.

Disconnect the Road Lights Less than 1 ohm. Relay K-27. Measure the resistance in circuit 518 (BK) between Road Lights Relay K-27 (pin 2) and ground.

55-92

Open circuit 518 (BK) between Road Lights Relay K-27 (pin 2) and ground.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 DDD - LEFT-HAND CAB INNER WORK LIGHT TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Close Work Light Switch S-43. Measure for 12 volts at Distance Work Lights Relay K-21 (pin 5).

12 volts.

Perform Distance Work Lights Relay Test.

Measure for 12 volts at Left-hand Cab Inner Work Lights E-17 (pin A).

12 volts If good reading, go to next test point.

Open circuit 061 (PU) or 255 (PU) between Work Light Relay K-21 (pin 5) and Left-hand Cab Inner Work Light E-17 connector X115 (pin A).

Disconnect the Left-hand Cab Inner Work Light E-17. Measure the resistance on circuit 261 (BK) between Left-hand Cab Inner Work Light E-17 connector X115 (pin B) and ground.

Less than 1 ohm.

Open circuit 261 (BK) or 245 (BK) between Left-hand Cab Inner Work Light E-17 connector X115 (pin B) and work light switch S-43 (pin 5). Open circuit 925 (BK) between S-43 (pin 6) and ground. Perform Work Light Switch Test.

If good reading, go to next test point.

If good reading, replace the Left-hand Cab Inner Work Light bulb.

DDD-A – LEFT-HAND CAB INNER WORK LIGHT TEST 1

Place Key Switch S-02 in 12 volts “ON” position. Road/Field Mode Switch S-12 in “Field” position. Hazard Lights switch S-25 in “OFF” position.

Road Lights Relay K-27.

If good reading, Road Lights Perform Road Lights Relay Test. Relay K-27 and Distance Work Lights Relay K-21 are operating properly.

Close Work Light Switch Go to test point 3. S-43.

Distance Work Lights Relay K-21.

Measure for 12 volts at Road Lights Relay K-27 (pin 5).

Go to next test point.

Measure for 12 volts at 12 volts Distance Work Lights Relay K-21. Perform Distance Road Lights Relay If good reading, Distance Distance Work Lights Relay Test. K-21 (pin 5). Work Lights Relay K-21 is operating properly. Go to next test point.

Measure for 12 volts at Left- 12 volts Open circuit 061 (PU) or 255 (PU) between hand Cab Inner Work Light If good reading, go to next Road Lights Relay K-27 (pin 5) and LeftE-17 (pin A) hand test point. Cab Inner Work Light E-17 connector X115 (pin A).

Disconnect the Left-hand Less than 1 ohm. Cab Inner Work Light E-17. Measure the resistance on circuit 261 (BK) between Lefthand Cab Inner Work Light E-17 X115 (pin B) and ground.

55-93

Open circuit 261 (BK) or 245 (BK) between Left-hand Cab Inner Work Light E-17 connector X115 (pin B) and Work Light Switch S-43 (pin 5). Open circuit 925 (BK) between S-43 (pin 6) and ground. Perform Work Light Switch Test

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 EEE - RIGHT-HAND CAB INNER WORK LIGHT TEST 1

Place Key Switch S-02 in “ON” position. Road/Field Mode Switch S-12 in “Field” position. Hazard Lights switch S-25 in “OFF” position. Close Work Light Switch S-43. Measure for 12 volts at Road Lights Relay K-27 (pin 5).

12 volts If good reading, Road Lights Relay K-27 and Distance Work Lights Relay K-21 are operating properly. Go to test point 3.

Road Lights Relay K-27. Perform Road Lights Relay Test. Distance Work Lights Relay K-21. Go to next test point.

Measure for 12 volts at Dis- 12 volts Distance Work Lights Relay K-21. Perform tance Road Lights Relay If good reading, Distance Distance Work Lights Relay Test. K-21 (pin 5). Work Lights Relay K-21 is operating properly. Go to next test point.

Measure for 12 volts at Right- 12 volts Open circuit 061 (PU) or 256 (PU) between hand Cab Inner Work Light If good reading, go to next Road Lights Relay K-27 (pin 5) and RightE-18 (pin A) hand Cab Inner Work Light E-18 connector test point. X117 (pin A).

Disconnect the Right-hand Less than 1 ohm. Cab Inner Work Light E-18. Measure the resistance on circuit 265 (BK) between Right-hand Cab Inner Work Light E-18 connector X117 (pin B) and ground.

Open circuit 265 (BK) or 245 (BK) between Left-hand Cab Inner Work Light E-18 connector X117 (pin B) and Work Light Switch S-43 (pin 5). Open circuit 925 (BK) between S-43 (pin 6) and ground. Perform Work Light Switch Test

FFF - WORK LIGHT SWITCH TEST Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Measure for 12 volts at Work Light Switch S-43 connector X132 (pin 2).

12 volts.

Open or short circuit 240 (OR) or 045 (OR) between Work Light Switch S-43 connector X132 (pin 2) and Fuse #49.

Close Work Light Switch. Use INFO Diagnostic Screen to check for voltage at CCM1 (pin J1-3).

12 volts. If good reading, go to next test point.

Work Light Switch S-43. Short to ground on circuit 171(YE) between Work Light Switch S-43 connector X132 (pin 3) and CCM1 (pin J1-3) A short will cause Fuse #49 to blow.

Turn Key Switch S-02 off. Using an ohmmeter, measure between Work Light Switch S-43 connector X132 (pin 5) and ground.

Less than 1 ohm. If good reading, go to next test point.

Work Light Switch S-43.

Measure for continuity at Work Light Switch S-43 connector X132 (pin 6) and cab roof ground.

Less than 1 ohm.

Open circuit 925 (PU) between Work Light Switch S-43 connector X132 (pin 6) and cab roof ground.

If good reading, go to next test point.

55-94

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 GGG - REAR WORK LIGHT SWITCH TEST 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Measure for 12 volts at Rear Work Light Switch S-44 connector X131 (pin 2).

12 volts.

Open circuit 239 (OR) or 045 (OR) between Rear Work Light Switch S-44 connector X131 (pin 2) and Fuse #49.

Close Rear Work Light Switch. Measure for 12 volts at Rear Work Light Switch S-44 connector X131 (pin 3).

12 volts

If good reading, go to next test point.

If good reading, system OK.

Rear Work Light Switch S-44. Short to ground on circuit 170 (YE) between Rear Work Light Switch S-44 connector X131 (pin 3) and CCM1 (pin J1-15) A short to ground will blow Fuse #49.

HHH - BEACON LIGHT SWITCH TEST 1

Test Point

Good Reading

Possible Cause of Bad Reading

Place Key Switch S-02 in “ON” position. Measure for 12 volts at Beacon Light Switch S-41 connector X130 (pin 2). Close Beacon Light Switch S-41. Measure for 12 volts at Beacon Light Switch S-41 connector X130 (pin 3).

12 volts.

Open circuit 172 (OR) or 045 (OR) between Beacon Light Switch S-41 connector X130 (pin 2) and Fuse #49.

If good reading, go to next test point. 12 volts

Beacon Light Switch.

If good reading, system OK.

Short to ground on circuit 166 (YE) between Beacon Light Switch S-41 connector X130 (pin 3) and CCM2 (pin J1-2) A short to ground will blow Fuse #49.

III - LEFT-HAND UNDERSHIELD LIGHT SWITCH TEST Test Point 1

Good Reading

Possible Cause of Bad Reading

Place Left-hand Undershield 12 volts Open circuit 1214 (RD) between Left-hand Light Switch S-63 in “ON” Undershield Light Switch S-63 connector position. X339 (pin 2) and Fuse #34. If good reading, the wiring Measure for 12 volts at has good continuity, go to Left-hand Undershield Light next test point. Switch S-63 connector X339 (pin 2). Close Left-hand Undershield 12 volts Left-hand Undershield Light Switch S-63. Light Switch S-63. Measure for 12 volts at If good reading, system OK. Left-hand Undershield Light Switch S-63. connector X339 (pin 3) and ground.

Short to ground on circuit 2004 (PU), 2005 (PU) or 2006 (PU) between Left-hand Undershield Light Switch S-63 connector X339 (pin 3) and ground. A short to ground will blow Fuse #34.

55-95

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6 JJJ - RIGHT-HAND UNDERSHIELD LIGHT SWITCH TEST 1

Test Point Good Reading Possible Cause of Bad Reading Place Right-hand Under- 12 volts Open circuit 1215 (RD) or 2008 (RD) shield Light Switch S-65 in between Right-hand Undershield Light “ON” position. Switch S-65 connector X341 (pin 2) and If good reading, the wiring Fuse #34. Measure for 12 volts at has good continuity, go to Right-hand Undershield next test point. Light Switch S-65 connector X341 (pin 2). Close Right-hand Under- 12 volts Right-hand Undershield Light Switch S-65. shield Light Switch S-65. Measure for 12 volts at If good reading, system OK. Right-hand Undershield Light Switch S-65 connector X341 (pin 3) and ground.

Short to ground on circuit 2010 (PU), 2011 (PU) or 2012 (PU) between Right-hand Undershield Light Switch S-65 connector X341 (pin 3) and ground. A short to ground will blow Fuse #34.

55-96

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7

SECTION 55 - ELECTRICAL SYSTEMS Chapter 7 - Cab Systems CONTENTS Section

Description

Page

Description and Operation of Cab Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Power Seat System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Seat Height Adjustment System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Power Seat Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Power Seat System Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Seat Suspension System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Wiper Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cab Roof Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Wiper Motor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Washer Motor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Wiper/Washer System Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Wiper/Washer System Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Wiper System Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Wiper System Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Wiper System Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Windscreen Washer System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Power Mirror System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Cab Roof Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Power Mirror Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Power Mirror Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Heated Mirror Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Power Mirror Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Mirror Fuse -- Power and Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Mirror Adjust Switch S-27 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Mirror Select Switch S-57 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Left Hand Mirror Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Right Hand Mirror Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Additional Mirror Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Mirror Heat Switch S-19 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Mirror Heat Circuits Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Horn System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Horn System Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Horn System Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Horn System Circuit Diagnostic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Audio System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Audio System Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Audio System Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Audio System Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

55-1

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 DESCRIPTION AND OPERATION OF CAB SYSTEMS This section describes the following electrical systems: • • • • •

Power Seat System Wiper Washer System Power Mirror System Horn System Audio System

These electrical systems are located in or near the combine cab. This section describes the components, current flow, and proper testing for each of the cab electrical systems.

55-2

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 POWER SEAT SYSTEM SEAT HEIGHT ADJUSTMENT SYSTEM The seat system has a power seat adjustment that uses air pressure to raise and lower the seat. A switch controls the air pressure. An unswitched battery circuit allows height adjustment at all times. Cab Main Harness to Seat Pump Connector X074 – Seat Pump, 1.

1 10010921

1 1. Fuse Panel 2. Main Cab Harness

3. Connector X074

2 50020059

POWER SEAT CIRCUIT Current travels across the fuse panel system buss bar to fuse F16. Current passes through fuse F16 and connector X074 pin A to connector X312 pin 1 of the seat adjustment switch S45. When the seat adjustment switch is moved to the “ON” position, current is sent from pin 2 of connector X312 to connector X313 pin A of the seat pump motor M26. The ground path to the motor is completed through connector X074 pin B to reach the cab floor ground location #3. This causes the motor to energize and pump air into the seat reservoir (raising the seat). Releasing a check valve, which is controlled mechanically, lowers the seat assembly.

55-3

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7

ACCESSORY FRAME--46

A-04 = RADIO F-02 = ACCESSORY 2 FUSE F-11 = RADIO FUSE F-13 = TRANSCEIVER FUSE

F-16 = SEAT PUMP FUSE F-35 = RADIO KAPWR FUSE H-04 = REAR LEFT SPEAKER H-05 = FRONT LEFT SPEAKER

55-4

H-06 = REAR RIGHT SPEAKER H-07 = FRONT RIGHT SPEAKER J-07 = TRANSCEIVER OUTLET K-03 = ACCESSORY 2 RELAY

M-26 = SEAT PUMP MOTOR S-45 = SEAT ADJUST SWITCH

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 POWER SEAT SYSTEM CIRCUIT TROUBLESHOOTING Before troubleshooting the seat system make sure that the following operating conditions are met: A. The batteries are fully charged and all connections are clean and tight. B. Transmission in neutral or park. C. Check all connectors for full installation, loose, corroded, pushed out, or bent terminals. D. Check fuse F16. NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.

Possible Cause Power and ground supply

Reference/Test Seat Suspension System Test

Seat Pump Motor Seat Solenoid Air system leaking

55-5

Check air lines for leakage

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 SEAT SUSPENSION SYSTEM TEST

No.

Test Point

Expected Result

Other Result (Possible Cause)

Press Seat Adjust Switch S-45 to the “UP” position.

Seat Pump Motor M-26 runs and seat raises. If compressor runs but seat does not adjust, check for air leakage. Go to test 2

If the seat pump motor does not run, there is a fault with the electrical circuit. Go to test 3

Press Seat Adjust Switch S-45 to “Down” position.

Air is released and seat lowers. System is OK.

If air is not released, there is a fault with the mechanical linkage to the release valve. Inspect the linkage and repair.

Unplug connector X312 from the seat adjust switch S-45. Check for 12 volts at the Seat Adjust switch S-45 connector X312 pin 1.

12 volts If good reading, wiring has continuity. Go to test 4

If no voltage, there is an open circuit in wire 80 (OR) between fuse F-16 and Seat Adjust switch S-45 connector X312 pin 1. Locate the open circuit and repair.

Unplug connector X312 from the seat adjust switch S-45, and connector X313 from the seat pump motor M-26. Use a multimeter to check for continuity between Seat Pump Motor M-26 connector X313 pin A and Seat Adjust Switch S-45 connector X312 pin 2.

Less than 1 ohms. If good reading, wiring has continuity. Go to test 5

If high or infinite resistance, there is an open circuit between Seat Pump Motor M-26 connector X313 pin A and Seat Adjust Switch S-45 connector X312 pin 2. Locate the open circuit and repair.

Unplug connector X312 from the seat adjust switch S-45. Use a multimeter to check for continuity between Seat Adjust Switch S-45 terminals 1 & 2. Operate the switch in the “UP” position while checking continuity.

Less than 1 ohms with switch in “UP” position. If good reading, switch has continuity. Go to test 6

If there is no continuity with the switch in the “UP” position, the switch has failed. Replace the switch.

55-6

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 No.

Test Point

Expected Result

Other Result (Possible Cause)

Unplug connector X313 from the seat pump motor M-26. Use a multimeter to check the resistance between connector X313 and a known good ground.

Less than 1 ohms. If good reading, the circuit has continuity to ground. Go to test 7

If the resistance to ground is greater than 1 ohms, there is excessive resistance or an open circuit in wire 164 BK to cab ground 3. Locate the excessive resistance or open circuit and repair.

Unplug connector X313 from the seat pump motor M-26. Use a multimeter to check the continuity of the seat pump motor M-26.

Less than 5 ohms resistance. Seat pump motor is good.

If the resistance is greater than 5 ohms, the motor has failed internally. Replace the motor.

55-7

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 WIPER WASHER SYSTEM The wiper washer system consists of a two--stage motor and a separate washer motor and reservoir. The system is energized by switched power and will operate in a continuous or fixed interval speeds.

CAB ROOF CONTROLS 2

3 1.

Windscreen wiper rocker switch

• • •

Wiper ON (continuous)

Windscreen washer rocker switch

• •

Wiper ON (intermittent) Wiper OFF

55-8

ON OFF

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 1. Fuse Panel 2. Connector X002 to Cab Roof harness 3. Connector X003 to Cab Roof harness 4. Cab Roof Ground

5. Connector X018, CCM1 -- J1

6. Connector X015, CCM2 -- J1 7. Connector X012, CCM3 -- J1 8. To Start Panel

50020059

4 1. Connector X002 to Cab Roof harness

2. Connector X003 to Cab Roof harness

3. Cab Roof Ground

2 1

4. Connector X135 Wiper Switch 5. Connector X134 Washer Switch

6. Connector X036 Outer Roof harness

50010891

55-9

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 WIPER MOTOR CIRCUIT

WASHER MOTOR CIRCUIT

Current travels across the fuse panel buss bar and passes through fuse F38 to pin 1 of the key switch S-02. When the key switch is in the ACC/Run position, current travels from pin 4 of the key switch to pin 1 of the wiper relay K-06. The relay energizes and latches pins 3 and 5.

Current travels across the fuse panel and buss bar and passes through fuse F38 to pin 1 of the key switch S-02. When the key switch is in the ACC/Run position, current travels from pin 4 of the key switch to pin 1 of the Accessory 1 relay K-08. The relay energizes and latches pins 3 and 5.

Current travels from the fuse panel buss bar and passes through fuse F04 to pin 3 of the wiper relay K-06. When the wiper relay is energized, power crosses to pin 5. Current exits pin 5 and passes through connector X002 pin 14 to the wiper switch S-20. The wiper switch controls current flow to the wiper motor.

Current travels from the fuse panel buss bar and passes through fuse F03 to pin 3 of the Accessory 1 relay K-08. When the relay is energized, power crosses to pin 5, and supplies fuses F08, F09 and F10 for accessory functions. Power from fuse F09 travels to the washer switch S-38 connector X134 pin 2, as well as to the mirror heat switch S-19 and mirror adjust switch S-27.

When the windshield wiper switch S-20 is in the OFF position, power flows through the switch from pin 2 to pin 1 only. This power flows through wire 276 WH to the wiper motor M-25 connector X116 pin 5 to activate the “Park” function of the wiper motor. Note: The wiper switch is shown in the middle “Intermittent” position in the schematic Frame 45. In the OFF position, the switch contacts would be positioned to the right. When the wiper switch S-20 is in the INTERMITTENT position, power flows through the switch from pin 2 to pins 1 and 6. This power flows through wires 276 WH and 277 WH to the wiper motor M-25 connector X116 pins 4 and 5 to activate the “Intermittent” function of the wiper motor. When the wiper switch S-20 is in the CONTINUOUS position, power flows through the switch from pin 2 to pins 3 and 6. This power flows through wires 275 WH and 277 WH to the wiper motor M-25 connector X116 pins 3 and 4 to activate the “Continuous” function of the wiper motor. The wiper motor M-25 is grounded at the cab roof grounding point #4 at the top of the left rear cab post.

55-10

When the washer switch S-38 is in the ON position, power passes through the switch from pin 2 to pin 3, and through connectors X002 and X005 on wire 278 WH to the washer motor M-24, located under the cab. The washer motor M-24 is grounded at the main frame ground #2, behind the left rear cab mount.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-11

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7

F-03 = ACCESSORY 1 FUSE F-04 = WIPER FUSE F-05 = CIGAR LIGHTER FUSE F-08 = ACCESSORY OUTLET FUSE

F-09 = WASHER/MIRROR FUSE F-10 = NOT USED J-06 = ACCESSORY SOCKET J-08 = ACCESSORY OUTLET

K-06 = WIPER RELAY K-08 = ACCESSORY 1 RELAY M-24 = WIPER WASHER MOTOR M-25 = WIPER MOTOR

55-12

R-08 = CIGAR LIGHTER S-20 = WIPER SWITCH S-38 = WASHER SWITCH

ACCESSORY FRAME--45

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 WIPER/WASHER SYSTEM CIRCUIT TROUBLESHOOTING Before troubleshooting the Wiper/Washer system make sure that the following operating conditions are met: A. The batteries are fully charged and all connections are clean and tight. B. Check all connectors for full installation, loose, corroded or pushed out terminals. C. Check Fuses F03, F04 and F09.

WIPER/WASHER SYSTEM SYMPTOM CHART NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.

Symptom

Possible Cause

Reference/Test

Wiper Relay

Wiper Relay Test

Wiper Switch

Wiper Switch Test

Wiper Motor

Wiper Motor Test

Wiper p Motor works in intermittent speed only

Wiper Switch

Wiper Switch Test

Wiper Motor

Wiper Motor Test

Wiper Motor works in high speed only

Wiper Switch

Wiper Switch Test

Wiper Motor

Wiper Motor Test

Wiper Motor does not park, stops when switch is turned OFF

Wiper Switch

Wiper Switch Test

Wiper Motor

Wiper Motor Test

Washer circuit inoperative

Washer Fluid Supply

Check reservoir and fluid lines.

Washer Switch

Windscreen Washer System Test

Wiper p Motor is inoperative p

55-13

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 WIPER SYSTEM RELAY TEST

No.

Test Point

Expected Result

Other Result (Possible Cause)

Remove wiper relay K-06. Key Switch S-02 in the “ON” position. Check for 12 volts at wiper relay K-06 pin 1.

12 volts Go to test 2

Open circuit in wire 123 OR between key switch S-02 connector X068 pin 4 and wiper relay K-06 pin 1. Locate the open circuit and repair.

Remove wiper relay K-06. Key Switch S-02 in the “OFF” position. Check for 12 volts at wiper relay K-06 pin 3.

12 volts Go to test 3

Open circuit in wire 70 RD between fuse F-04 and wiper relay K-06 pin 3, or fuse F-04 has failed. Inspect fuse F-04, and replace if necessary. Locate the open circuit and repair.

Remove wiper relay K-06. Key Switch S-02 in the “OFF” position. Check for continuity to ground at wiper relay K-06 pin 2.

Less than 1 ohms Go to test 4

Open circuit in wire 242 BK between wiper relay K-06 pin 2 and Cab ground #3. Locate the open circuit and repair.

Remove wiper relay K-06. Install a jumper wire between pins 3 & 5 on the fuse panel. Remove wiper switch S-20. Check for 12 volts at wiper switch S-20 connector X135 pin 2.

12 volts Go to test 5

Open or short circuit in wire 272 OR from wiper relay K-06 pin 5 through connector X002 pin 14 to wiper switch S-20 connector X135 pin 2. A short circuit will cause fuse F-04 to blow, opening the circuit. Inspect fuse F-04, and replace if necessary. Locate the open or short circuit and repair.

Remove jumper wire between 12 volts pins 3 & 5 on the fuse panel, Testing indicates relay is okay. and install wiper relay K-06. Remove wiper switch S-20. Key switch S-02 in the “ON” position. Check for 12 volts at wiper switch S-20 connector X135 pin 2.

55-14

If there is no voltage, wiper relay K-06 has failed. Replace relay.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 WIPER SYSTEM SWITCH TEST No.

Test Point

Expected Result

Key switch S-02 in “ON” position. Wiper switch S-20 in “OFF” position. Check for 12 volts at wiper switch S-20 connector X135 pin 2.

Key switch S-02 in “ON” posi12 volts at both pins tion. Go to test 3 Wiper switch S-20 in “OFF” position. Back probe connector to check for 12 volts at wiper switch S-20 connector X135 pins 1 and 4.

If there is no voltage, switch has failed internally. Replace switch.

Key switch S-02 in “ON” posi12 volts at both pins tion. Go to test 4 Wiper switch S-20 in “INTERMITTENT” position. Back probe connector to check for 12 volts at wiper switch S-20 connector X135 pins 1 and 6.

If there is no voltage, switch has failed internally. Replace switch.

Key Switch S-02 in “ON” 12 volts at both pins position. Testing indicates switch is okay. Wiper switch S-20 in “CONTINUOUS” position. Back probe connector to check for 12 volts at wiper switch S-20 connector X135 pins 3 and 6.

If there is no voltage, switch has failed internally. Replace switch.

12 volts Go to test 2

55-15

Other Result (Possible Cause) Open or short circuit in wire 272 OR from wiper relay K-06 pin 5 through connector X002 pin 14 to wiper switch S-20 connector X135 pin 2. A short circuit will cause fuse F-04 to blow, opening the circuit. Inspect fuse F-04, and replace if necessary. Locate the open or short circuit and repair.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 WIPER SYSTEM MOTOR TEST

Expected Result

Other Result (Possible Cause)

No.

Test Point

Unplug connector X116 at the wiper motor M-25. Key switch S-02 in the “ON” position. Wiper switch S-20 in the “OFF” position. Check for 12 volts at wiper motor M-25 connector X116 pin 5.

12 volts Go to test 2

Open circuit in wire 276 white between wiper switch S-20 connector X135 pin 5 through X036 pin 16 to wiper motor M-25 connector X116 pin 5. Locate the open circuit and repair.

Key switch S-02 in the “ON” position. Wiper switch S-20 in the “INTERMITTENT” position. Check for 12 volts at wiper motor M-25 connector X116 pins 4 and 5.

12 volts at both pins Go to test 3

Open circuit in wires 276 white and 277 white between wiper switch S-20 connector X135 pins 1 and 6 through X036 pins 16 and 17 to wiper motor M-25 connector X116 pins 4 and 5. Locate the open circuit and repair.

Key switch S-02 in the “ON” position. Wiper switch S-20 in the “CONTINUOUS” position. Check for 12 volts at wiper motor M-25 connector X116 pins 3 and 4.

12 volts at both pins Go to test 4

Open circuit in wires 275 white and 277 white between wiper switch S-20 connector X135 pins 3 and 6 through X036 pins 15 and 17 to wiper motor M-25 connector X116 pins 3 and 4. Locate the open circuit and repair.

Key switch in the “OFF” position. Wiper switch S-20 in “OFF” position. Check for continuity to ground at wiper motor M-25 connector X116 pin 1.

Continuity found. If good reading, circuit wiring is good, indicating a fault with the wiper motor. Replace the wiper motor.

Open circuit in wire 280 black between wiper motor M-25 connector X116 pin 1 through X036 pin 14 to Cab Roof ground #4. Locate the open circuit and repair.

55-16

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 WINDSCREEN WASHER SYSTEM TEST

Expected Result

Other Result (Possible Cause)

No.

Test Point

Key Switch S-02 in “ON” position. Check for 12 volts at fuse F-09.

12 volts Go to test 6

If there is no voltage, Go to test 2

Remove accessory 1 relay K-08. Key switch S-02 in the “ON” position. Check for 12 volts at accessory 1 relay K-08 pin 1.

12 volts Go to test 3

Open circuit in wire 123 orange or 241 orange between key switch S-02 connector X068 pin 4 and accessory 1 relay K-08 pin 1. Locate the open circuit and repair.

Remove accessory 1 relay K-08. Key switch S-02 in the “OFF” position. Check for 12 volts at accessory 1 relay K-08 pin 3.

12 volts Go to test 4

Open circuit in wire 020 red between fuse F-03 and accessory 1 relay K-08 pin 3, or fuse F-03 has failed. Inspect fuse F-03, and replace if necessary. Locate the open circuit and repair.

Remove accessory 1 relay K-08. Key switch S-02 in the “OFF” position. Check for continuity to ground at accessory 1 relay K-08 pin 2.

Less than 1 ohms Go to test 5

Open circuit in wire 150 BK between accessory 1 relay K-08 pin 2 and Cab ground #3. Locate the open circuit and repair.

Remove accessory 1 relay K-08, and install a jumper wire between pins 3 & 5 on the fuse panel. Check for 12 volts at fuse F-09.

12 volts If there is voltage, accessory 1 relay K-08 has failed. Replace the relay.

Open or short circuit in wire 009 orange from accessory 1 relay K-08 pin 5 to fuse F-09. A short to ground will cause fuse F-03 to blow, opening the circuit. Inspect fuse F-03, and replace if necessary. Locate the open or short circuit and repair.

Key Switch S-02 in “ON” position. Check for 12 volts at washer switch S-38 connector X134 pin 2.

12 volts Go to test 7

Open or short to ground in wires 279 orange or 079 orange between washer switch S-38 connector X134 pin 2 through connector X002 pin 8 to fuse F-09. A short to ground will cause fuse F-09 to fail. Locate the open or short circuit and repair. Replace fuse F-09 as necessary.

55-17

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7

No.

Test Point

Expected Result

Other Result (Possible Cause)

Key switch S-02 in “ON” position. Washer switch S-38 in “ON” position. Check for 12 volts at washer switch S-38 connector X134 pin 3.

12 volts Go to test 8

If there is no voltage, the switch has failed. Replace the switch.

Key switch S-02 in “ON” position. Washer switch S-38 in “ON” position. Check for 12 volts at washer motor M-24 connector X171 pin 2.

12 volts Go to test 9

Open or short to ground in wire 278 white between washer switch S-38 connector X134 pin 3 through connector X002 pin 17 and X005 pin 14 to washer motor M-24 connector X171 pin 2. A short to ground will cause fuse F-09 to fail. Locate the open or short circuit and repair. Replace fuse F-09 as necessary.

Key switch S-02 in “OFF” position. Check for continuity to ground at washer motor M-24 connector X171 pin 1.

Continuity found. If continuity to ground is found, and the washer system still does not function, the washer motor M-24 has failed. Replace washer motor M-24.

Open circuit in wire 449 black or 246 black between washer motor M-24 connector X171 pin 1 and main frame ground #2. Locate the open circuit and repair.

55-18

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 POWER MIRROR SYSTEM There are three types of mirrors found on the Combine: The LH, RH and German mirror (If Equipped).

CAB ROOF CONTROLS 1

6 Power Mirror Circuit Operation 1.

Mirror Adjustment Switch

• •

Arrow to the left: left-hand mirror Arrow to the right: right-hand mirror

Only one mirror can be operated at a time. There are two motors in each mirror assembly. Power and ground are supplied to the motors through three wires for each mirror assembly, one wire for each motor and one wire in common. Only

55-19

Mirror select rocker switch (if installed)

• •

Main mirror adjustment Additional mirror adjustment (Germany)

one motor can be operated at a time; up and down only, or in and out only. A change in mirror motor direction is accomplished by reversing current flow through the motors.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 POWER MIRROR CIRCUIT Current travels across the fuse panel buss bar and through fuse F38 to pin 1 of the key switch S-02. When the key switch is in the ACC/Run position, current travels from pin 4 of the key switch to pin 1 of the Accessory 1 relay K-08. The Accessory 1 Relay energizes and latches pins 3 and 5. Current sent from pin 5 of the Accessory 1 relay passes through fuse F09 and connector X002 pin 8 to the mirror adjust switch S-27. Depending on the switch position, current is sent to the motors within the mirror assemblies. The mirror to be adjusted is selected by rotating the stem of the mirror adjust switch S-27. When the stem is rotated to the left, the common wire 961 GY (pin C) Switch Position UP

•

LEFT

• •

RIGHT

The mirror adjust switch uses the power supply from fuse F09 at pin H and a ground path at pin A to control mirror movement. Moving the stem in one direction will cause a set of contacts in the switch to close, connecting the common wire from the selected mirror assembly to either power or ground, and connecting the other wire of the selected mirror motor to the opposite source. Refer to the chart for specific pin information at the mirror adjust switch for any given mirror adjust operation.

Mirror Adjust stem rotated left

•

DOWN

from the left mirror assembly is connected to additional contacts in the mirror adjust switch S-27. When the stem is rotated to the right, the common wire 954 GY (pin F) from the right mirror assembly is connected to additional contacts in the mirror adjust switch S-27.

•

Mirror Adjust stem rotated right

power at pin H flows to pin C for common wire 961 GY to left mirror assembly LH mirror up/down motor M-21 is grounded on wire 958 WH to pin D through switch to pin A to cab roof ground #4.

•

power at pin H flows to pin D for wire 958 WH to LH mirror up/down motor M-21 LH mirror up/down motor M-21 is grounded on common wire 961 GY to pin C through switch to pin A to cab roof ground #4.

•

power at pin H flows to pin B for wire 959 WH to LH mirror in/out motor M-22 LH mirror in/out motor M-22 is grounded on common wire 961 GY to pin C through switch to pin A to cab roof ground #4.

•

power at pin H flows to pin C for common wire 961 GY to left mirror assembly LH mirror in/out motor M-22 is grounded on wire 959 WH to pin B through switch to pin A to cab roof ground #4.

•

55-20

•

power at pin H flows to pin F for common wire 954 GY to right mirror assembly RH mirror up/down motor M-19 is grounded on wire 955 WH and 957 WH to pin E through switch to pin A to cab roof ground #4. power at pin H flows to pin E for wire 957 WH and 955 WH to RH mirror up/down motor M-19 RH mirror up/down motor M-19 is grounded on common wire 954 GY to pin F through switch to pin A to cab roof ground #4. power at pin H flows to pin G for wire 960 WH and 962 WH to RH mirror in/out motor M-20 RH mirror in/out motor M-20 is grounded on common wire 954 GY to pin F through switch to pin A to cab roof ground #4. power at pin H flows to pin F for common wire 954 GY to right mirror assembly RH mirror in/out motor M-20 is grounded on wire 962 WH and 960 WH to pin G through switch to pin A to cab roof ground #4.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 HEATED MIRROR CIRCUIT OPERATION 1

7 1.

Mirror heating rocker switch (if equipped)

• •

OFF

Switched power is supplied to the mirror heat switch through fuse F09 from the Accessory 1 relay.

the operator to determine the length of the heating cycle required to defrost the power mirrors.

Chassis ground is supplied to the LH, RH, and German Mirror heaters through connectors X111, X121, and X287.

When the ignition switch is in the RUN position and the mirror heat switch is in the closed position, current flows through the heating elements, in each mirror, to chassis ground.

The mirror heat switch controls the LH, RH, and German Mirror Heaters simultaneously and allows

55-21

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-22

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7

E-25 = LH SIDE WORK LIGHT E-26 = RH SIDE WORK LIGHT E-37 = SIEVE LIGHT F-14 = SERVICE LTS FUSE

K-34 = TIMED SIDE WORK LIGHT RELAY K-35 = SIDE WORK LIGHT RELAY S-54 = SIEVE LIGHT SWITCH

55-23

LIGHTING FRAME--43

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7

ACCESSORY FRAME--44

F-64 = SWITCH BYPASS FUSES M-19 = RH MIRROR UP/DOWN M-20 = RH MIRROR IN/OUT M-21 = LH MIRROR UP/DOWN

M-22 = LH MIRROR IN/OUT M-30 = GERMAN MIRROR UP/DOWN M-31 = GERMAN MIRROR IN/OUT R-10 = RH MIRROR HEAT

55-24

R-11 = LH MIRROR HEAT R-14 = RH GERMAN MIRROR HEAT S-19 = MIRROR HEAT SWITCH S-27 = MIRROR ADJUST SWITCH

S-57 = MIRROR SELECT SWITCH (D)

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7

F-03 = ACCESSORY 1 FUSE F-04 = WIPER FUSE F-05 = CIGAR LIGHTER FUSE F-08 = ACCESSORY OUTLET FUSE

F-09 = WASHER/MIRROR FUSE F-10 = NOT USED J-06 = ACCESSORY SOCKET J-08 = ACCESSORY OUTLET

K-06 = WIPER RELAY K-08 = ACCESSORY 1 RELAY M-24 = WIPER WASHER MOTOR M-25 = WIPER MOTOR

55-25

R-08 = CIGAR LIGHTER S-20 = WIPER SWITCH S-38 = WASHER SWITCH

ACCESSORY FRAME--45

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 POWER MIRROR CIRCUIT TROUBLESHOOTING

56061448

8 Before troubleshooting the power mirror system make sure that the following operating conditions are met: 1. Check Fuses F-03 and F-09. 2. Check operation of the Accessory 1 Relay K-08. 3. Check all connectors for complete installation, loose, corroded, pushed out, or bent terminals. NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter for these tests. For battery testing and service, see the battery section in the service manual.

55-26

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered light can cause damage to components in this system.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 Problem All Power Mirrors inoperable

Possible Cause

Correction

No power or ground to Mirror Adjust Switch S-27.

Refer to Mirror Fuse -- Testing Power and Ground

Mirror Adjust Switch S-27 failed.

Refer to Mirror Adjust Switch S-27 -- Testing.

Mirror Adjust Switch S-27 failed.

Refer to Mirror Adjust Switch S-27 -- Testing.

Harness or Left Mirror Assembly failure.

Refer to Left Hand Mirror -Testing.

Mirror Adjust Switch S-27 failed.

Refer to Mirror Adjust Switch S-27 -- Testing.

Bypass Fuses F-64/Mirror Select Switch S-57 failed.

Refer to Mirror Select Switch S-57 -- Testing.

Harness or Right Mirror Assembly failure.

Refer to Right Hand Mirror -Testing.

Mirror Adjust Switch S-27 failed.

Perform Mirror Adjust Switch S-27 -- Testing.

Mirror Select Switch S-57 failed.

Refer to Mirror Select Switch S-57 -- Testing.

Mirror Adjust Switch S-27 failed.

Refer to Mirror Adjust Switch S-27 -- Testing.

Bypass Fuses F-64/Mirror Select Switch S-57 failed.

Refer to Mirror Select Switch S-57 -- Testing.

Harness or German Mirror Assembly failure.

Refer to Additional Mirror -Testing .

No power or ground supply to Mirror Heat Switch S-19.

Refer to Mirror Fuse -- Testing Power and Ground.

Mirror Heat Switch S-19 failed.

Perform Mirror Heat Switch S-19 -- Testing.

Only LH Heated Mirror inoperable

Harness or LH Mirror Heating element failure.

Refer to Mirror Heat Circuits -Testing, steps 1 to 3.

Only RH Heated Mirror inoperable

Harness or RH Mirror Heating element failure.

Refer to Mirror Heat Circuits -Testing, steps 4 to 6.

Only German Heated Mirror inoperable

Harness or German Mirror Heating element failure.

Refer to Mirror Heat Circuits -Testing, steps 7 to 9.

Only Left Power Mirror inoperable

Only Right Power Mirror inoperable

Both RH and German Power Mirrors inoperable

Only German Power Mirror inoperable

All Heated Mirrors inoperable

55-27

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 Mirror Fuse -- Power and Ground Test

No.

Test Point

Expected Result

Other Result (Possible Cause)

Key switch OFF. Check condition of fuse F-03.

If fuse is good, Go to test 2

If fuse has failed, replace the fuse. If the fuse immediately fails, there is a short to ground in wire 020 red from fuse F-03 to the accessory 1 relay K-08. Locate the short and repair.

Key switch OFF. Remove the accessory 1 relay K-08. Use a multimeter to check for voltage at pin 3.

If there is 12 volts, Go to test 3

If there is no voltage, there is an open circuit in wire 020 red between fuse F-03 and the accessory 1 relay K-08. Locate the open and repair.

Turn key switch ON. If there is 12 volts, Go to test 4 With the accessory 1 relay K-08 removed, use a multimeter to check for voltage at pin 1.

If there is no voltage, there is an open circuit in the cab main (CM) harness between the key switch “Acc” terminal and the accessory 1 relay K-08 wires 123 orange or 241 orange. Locate the open and repair.

Install the accessory 1 relay K-08. Turn key switch ON. Use a multimeter to check for voltage at fuse F-09.

If there is 12 volts, Go to test 5

If there is no voltage, recheck the condition of fuse F-03. If fuse F-03 has failed, there is a short to ground in wire 009 orange between the accessory 1 relay K-08 and fuse F-09. If fuse F-03 has not failed, there is an open circuit in wire 009 orange between the accessory 1 relay K-08 and fuse F-09. Locate the short or open and repair.

Key switch OFF. Check condition of fuse F-09.

If fuse is good, Go to test 6

If fuse has failed, replace the fuse, and turn the key switch ON. If the fuse immediately fails, there is a short to ground in the cab main (CM) or cab roof (CR) harnesses wires 079 orange, 274 orange or 953 orange from fuse F-09 to the mirror adjust switch S-27 and mirror heat switch S-19. Locate the short and repair.

55-28

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7

No.

Test Point

Expected Result

Other Result (Possible Cause)

Carefully remove the mirror adjust switch S-27 from the upper left console. Turn key switch ON. Use a multimeter to check for voltage at connector X126 pin H.

If there is 12 volts, Go to test 7

If there is no voltage, there is an open circuit in the cab main (CM) or cab roof (CR) harnesses wires 079 orange or 274 orange. Locate the open and repair.

Carefully remove the mirror If there is 12 volts, Go to test 8 heat switch S-19 from the upper left console. Turn key switch ON. Use a multimeter to check for voltage at connector X127 pin 2.

If there is no voltage, there is an open circuit in the cab roof (CR) harness wire 953 orange. Locate the open and repair.

Turn key switch OFF. Carefully remove the mirror adjust switch S-27 from the upper left console. Use a multimeter to check for continuity between connector X126 pin A and ground.

If there is no continuity, there is an open circuit in the cab roof (CR) harness between connector X126 pin A and cab roof ground 4. Locate the open and repair.

If there is continuity to ground, the mirror power supply and ground circuits are functioning properly.

55-29

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 Mirror Adjust Switch S-27 Test

Expected Result

Other Result (Possible Cause)

No.

Test Point

Carefully remove the mirror adjust switch S-27 from the upper left console, but leave it connected to the cab roof (CR) harness. Turn key switch ON. Set Mirror Adjust Switch selector to Left mirror. Hold Mirror Adjust Switch in RIGHT position. Check the voltage at Mirror Adjust Switch connector X126 pin C.

12 volts. If good reading, Go to test 2

If there is no voltage, there is an open circuit inside the Mirror Adjust Switch. Replace the mirror adjust switch S-27.

Hold Mirror Adjust Switch in LEFT position. Check the voltage at Mirror Adjust Switch connector X126 pin B and pin G.

12 volts. If good reading, Go to test 3

If there is no voltage, there is an open circuit inside the Mirror Adjust Switch. Replace the mirror adjust switch S-27.

Hold Mirror Adjust Switch in DOWN position. Check the voltage at Mirror Adjust Switch connector X126 pin D and pin E.

12 volts. If good reading, Go to test 4

If there is no voltage, there is an open circuit inside the Mirror Adjust Switch. Replace the mirror adjust switch S-27.

Hold Mirror Adjust Switch in UP position. Check the voltage at Mirror Adjust Switch connector X126 pin C.

12 volts. If good reading, Go to test 5

If there is no voltage, there is an open circuit inside the Mirror Adjust Switch. Replace the mirror adjust switch S-27.

Set mirror selector to Right mirror. Hold Mirror Adjust Switch in RIGHT position. Check the voltage at Mirror Adjust Switch connector X126 pin F.

If there is 12 volts, all voltage paths in the switch test okay. Go to test 6

If there is no voltage, there is an open circuit inside the Mirror Adjust Switch. Replace the mirror adjust switch S-27.

Turn key switch OFF. Set Mirror Adjust Switch selector to Left mirror. Hold Mirror Adjust Switch in RIGHT position. Check resistance between Mirror Adjust Switch connector X126 pin B and ground, and then pin G and ground.

Less than 1 ohm. If good reading, Go to test 7

If there is no continuity, there is an open circuit inside the Mirror Adjust Switch. Replace the mirror adjust switch S-27.

55-30

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7

No.

Test Point

Expected Result

Other Result (Possible Cause)

Hold Mirror Adjust Switch in LEFT position. Check resistance between Mirror Adjust Switch connector X126 pin C and ground.

Less than 1 ohm. If good reading, Go to test 8

If there is no continuity, there is an open circuit inside the Mirror Adjust Switch. Replace the mirror adjust switch S-27.

Hold Mirror Adjust Switch in DOWN position. Check resistance between Mirror Adjust Switch connector X126 pin C and ground.

Less than 1 ohm. If good reading, Go to test 9

If there is no continuity, there is an open circuit inside the Mirror Adjust Switch. Replace the mirror adjust switch S-27.

Hold Mirror Adjust Switch in UP position. Check resistance between Mirror Adjust Switch connector X126 pin D and ground, and then pin E and ground.

Less than 1 ohm. If good reading, Go to test 10

If there is no continuity, there is an open circuit inside the Mirror Adjust Switch. Replace the mirror adjust switch S-27.

Hold Mirror Adjust Switch in LEFT position. Check resistance between Mirror Adjust Switch connector X126 pin F and ground.

Less than 1 ohm. If good reading, the mirror adjust switch is functioning properly.

If there is no continuity, there is an open circuit inside the Mirror Adjust Switch. Replace the mirror adjust switch S-27.

55-31

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 Mirror Select Switch S-57 Test NOTE: Combines sold in certain markets may be equipped with a third electrically adjusted mirror, and will have a Mirror Select switch S-57 plugged into connector X178 in the upper left console in the cab. No.

Test Point

All other markets will have two electrically adjusted mirrors, and will have two 10 amps fuses plugged into connector X178 between pins 2 and 3, and pins 5 and 6 in order to bypass this connector.

Expected Result

Other Result (Possible Cause)

Inspect the combine to determine if it has two or three electrically adjusted mirrors.

If there are two electrically adjusted mirrors, Go to test 2

If there are three electrically adjusted mirrors and a mirror select switch, Go to test 3

Carefully remove the HVAC controller from the upper left console to gain access to connector X178. Remove and inspect the two mini fuses that are installed in the connector.

If the fuses are good, Go to test 5

If one or both of the fuses have failed, replace the fuses. Turn the key switch ON, and operate the right mirror in all directions. If one or both fuses immediately fail, there is a short to ground in the cab roof (CR) or outer roof (OR) harnesses. Refer to Right Hand Mirror -Testing to locate the fault.

Carefully remove the mirror If there is continuity between select switch S-57 from the both sets of pins, Go to test 4 upper left console, and unplug it from the cab roof (CR) harness. Set the switch to the right mirror position (position 1). Use a multimeter to check the continuity between the switch pins 2 and 3, and then between pins 5 and 6.

If there is no continuity between one or both sets of pins, the switch has failed open. Replace the mirror select switch S-57.

Set the mirror select switch to the additional mirror position (position 2). Use a multimeter to check the continuity between the switch pins 1 and 2, and then between pins 4 and 5.

If there is no continuity between one or both sets of pins, the switch has failed open. Replace the mirror select switch S-57.

Carefully remove the mirror If there is continuity, Go to test adjust switch S-27 from the 6 upper left console, and unplug it from the cab roof (CR) harness. Use a multimeter to check from continuity between the mirror adjust switch connector X126 pin E and connector X178 pin 2.

If there is no continuity, there is an open circuit in the cab roof (CR) harness between connector X126 and connector X178 wire 957 white. Locate the open and repair.

Use a multimeter to check from continuity between the mirror adjust switch connector X126 pin G and connector X178 pin 5.

If there is no continuity, there is an open circuit in the cab roof (CR) harness between connector X126 and connector X178 wire 960 white. Locate the open and repair.

If there is continuity between both sets of pins, Go to test 5

If there is continuity, the mirror select/bypass fuses circuit is functioning properly.

55-32

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 Left Hand Mirror Test NOTE: A long [2 m (6 ft)] test lead will be required for one person to be able to complete this test. Construct the test lead using a Deutsch Size 16 Series 30 pin

(Deutsch part #0460-215-16141) on one end, and a suitable socket on the other that can connect to the multimeter test probe. Other Result (Possible Cause)

No.

Test Point

Expected Result

Unplug the small connector at the base of the mirror support bracket. Insert the pin of the test lead into socket 2 of this connector. Turn key switch ON. Set Mirror Adjust Switch to Left mirror. Hold Mirror Adjust Switch in RIGHT, and then UP positions. Use a multimeter to check for voltage at LH Mirror connector pin 2.

If there is 12 volts in each position, Go to test 2

If there is no voltage, check the condition of fuse F-09. If fuse F-09 has failed, there is a short to ground in this circuit. If fuse F-09 has not failed, there is an open circuit. This circuit is in the cab roof (CR) or outer roof (OR) harnesses between Mirror Adjust Switch connector X126 pin C, through connector X036 pin 25 and connector X111 pin 2 to the mirror connector wire 961 gray. Locate the short or open and repair.

Move the test lead pin to socket 4 of the mirror support bracket connector. Hold Mirror Adjust Switch in DOWN position. Use a multimeter to check for voltage at LH Mirror connector pin 4.

If there is 12 volts, Go to test 3

If there is no voltage, check the condition of fuse F-09. If fuse F-09 has failed, there is a short to ground in the circuit. If fuse F-09 has not failed, there is an open circuit. This circuit is in the cab roof (CR) or outer roof (OR) harnesses between Mirror Adjust Switch connector X126 pin D, through connector X036 pin 22 and connector X111 pin 4 to the mirror connector wire 958 white. Locate the short or open and repair.

Move the test lead pin to socket 1 of the mirror support bracket connector. Hold Mirror Adjust Switch in LEFT position. Use a multimeter to check for voltage at LH Mirror connector pin 1.

If there is 12 volts, the circuits to the left mirror are functioning properly. Test the left mirror assembly. Go to test 4

If there is no voltage, check the condition of fuse F-09. If fuse F-09 has failed, there is a short to ground in the circuit. If fuse F-09 has not failed, there is an open circuit. This circuit is in the cab roof (CR) or outer roof (OR) harnesses between Mirror Adjust Switch connector X126 pin B, through connector X036 pin 23 and connector X111 pin 1 to the mirror connector wire 959 white. Locate the short or open and repair.

55-33

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7

Expected Result

Other Result (Possible Cause)

No.

Test Point

Key switch OFF. Use a multimeter to check resistance through the mirror at the small connector pins 1 and 2.

If there is 10 -- 40 ohms resistance, Go to test 5

If there is zero or infinite resistance, the LH mirror in/out motor M-22 has failed. Repair or replace the mirror assembly.

Key switch OFF. Use a multimeter to check resistance through the mirror at the small connector pins 2 and 4.

If there is 10 -- 40 ohms resistance, the mirror adjust motors should be functioning properly.

If there is zero or infinite resistance, the LH mirror up/down motor M-21 has failed. Repair or replace the mirror assembly.

55-34

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 Right Hand Mirror Test NOTE: A long [2 m (6 ft)] test lead will be required for one person to be able to complete this test. Construct the test lead using a Deutsch Size 16 Series 30 pin

(Deutsch part #0460-215-16141) on one end, and a suitable socket on the other that can connect to the multimeter test probe. Other Result (Possible Cause)

No.

Test Point

Expected Result

Unplug the small connector at the base of the mirror support bracket. Insert the pin of the test lead into socket 2 of this connector. Turn key switch ON. Set Mirror Adjust Switch to Right mirror. Set the mirror select switch S-57 to position 1, if equipped. Hold Mirror Adjust Switch in RIGHT, and then UP positions. Use a multimeter to check for voltage at RH Mirror connector pin 2.

If there is 12 volts in each position, Go to test 2

If there is no voltage, check the condition of fuse F-09. If fuse F-09 has failed, there is a short to ground in this circuit. If fuse F-09 has not failed, there is an open circuit. This circuit is in the cab roof (CR) or outer roof (OR) harnesses between Mirror Adjust Switch connector X126 pin F, through connector X036 pin 26 and connector X121 pin 2 to the mirror connector wire 954 gray or 956 gray. Locate the short or open and repair.

Move the test lead pin to socket 4 of the mirror support bracket connector. Hold Mirror Adjust Switch in DOWN position. Use a multimeter to check for voltage at RH Mirror connector pin 4.

If there is 12 volts, Go to test 3

If there is no voltage, check the condition of fuse F-09. If fuse F-09 has failed, there is a short to ground in the circuit. If fuse F-09 has not failed, there is an open circuit. This circuit is in the cab roof (CR) or outer roof (OR) harnesses between connector X178 pin 3, through connector X036 pin 19 and connector X121 pin 4 to the mirror connector wire 955 white. Locate the short or open and repair.

Move the test lead pin to socket 1 of the mirror support bracket connector. Hold Mirror Adjust Switch in LEFT position. Use a multimeter to check for voltage at RH Mirror connector pin 1.

If there is 12 volts, the circuits to the left mirror are functioning properly. Test the right mirror assembly. Go to test 4

If there is no voltage, check the condition of fuse F-09. If fuse F-09 has failed, there is a short to ground in the circuit. If fuse F-09 has not failed, there is an open circuit. This circuit is in the cab roof (CR) or outer roof (OR) harnesses between connector X178 pin 6, through connector X036 pin 21 and connector X121 pin 1 to the mirror connector wire 962 white. Locate the short or open and repair.

55-35

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7

No.

Test Point

Expected Result

Other Result (Possible Cause)

Key switch OFF. Use a multimeter to check resistance through the mirror at the small connector pins 1 and 2.

If there is 10 -- 40 ohms resistance, Go to test 5

If there is zero or infinite resistance, the RH mirror in/out motor M-20 has failed. Repair or replace the mirror assembly.

Key switch OFF. Use a multimeter to check resistance through the mirror at the small connector pins 2 and 4.

If there is 10 -- 40 ohms resistance, the mirror adjust motors should be functioning properly.

If there is zero or infinite resistance, the RH mirror up/down motor M-19 has failed. Repair or replace the mirror assembly.

55-36

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 Additional Mirror Test NOTE: A long [2 m (6 ft)] test lead will be required for one person to be able to complete this test. Construct the test lead using a Deutsch Size 16 Series 30 pin No.

Test Point

(Deutsch part #0460-215-16141) on one end, and a suitable socket on the other that can connect to the multimeter test probe.

Expected Result

Other Result (Possible Cause)

Unplug the small connector at the base of the mirror support bracket. Insert the pin of the test lead into socket 2 of this connector. Turn key switch ON. Set Mirror Adjust Switch to Right mirror. Set the Mirror Select switch S-57 to position 2. Hold Mirror Adjust Switch in RIGHT, and then UP positions. Use a multimeter to check for voltage at German Mirror connector pin 2.

If there is 12 volts in each position, Go to test 2

If there is no voltage, check the condition of fuse F-09. If fuse F-09 has failed, there is a short to ground in this circuit. If fuse F-09 has not failed, there is an open circuit. This circuit is in the cab roof (CR) or outer roof (OR) harnesses between Mirror Adjust Switch connector X126 pin F, through connector X036 pin 26 and connector X287 pin 2 to the mirror connector wire 954 gray or 966 gray. Locate the short or open and repair.

Move the test lead pin to socket 4 of the mirror support bracket connector. Hold Mirror Adjust Switch in DOWN position. Use a multimeter to check for voltage at German Mirror connector pin 4.

If there is 12 volts, Go to test 3

If there is no voltage, check the condition of fuse F-09. If fuse F-09 has failed, there is a short to ground in the circuit. If fuse F-09 has not failed, there is an open circuit. This circuit is in the cab roof (CR) or outer roof (OR) harnesses between connector X178 pin 1, through connector X036 pin 20 and connector X287 pin 4 to the mirror connector wire 963 white. Locate the short or open and repair.

Move the test lead pin to socket 1 of the mirror support bracket connector. Hold Mirror Adjust Switch in LEFT position. Use a multimeter to check for voltage at German Mirror connector pin 1.

If there is 12 volts, the circuits to the left mirror are functioning properly. Test the German mirror assembly. Go to test 4

If there is no voltage, check the condition of fuse F-09. If fuse F-09 has failed, there is a short to ground in the circuit. If fuse F-09 has not failed, there is an open circuit. This circuit is in the cab roof (CR) or outer roof (OR) harnesses between connector X178 pin 4, through connector X036 pin 24 and connector X287 pin 1 to the mirror connector wire 964 white. Locate the short or open and repair.

55-37

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7

No.

Test Point

Expected Result

Other Result (Possible Cause)

Key switch OFF. Use a multimeter to check resistance through the mirror at the small connector pins 1 and 2.

If there is 10 -- 40 ohms resistance, Go to test 5

If there is zero or infinite resistance, the German mirror in/out motor M-31 has failed. Repair or replace the mirror assembly.

Key switch OFF. Use a multimeter to check resistance through the mirror at the small connector pins 2 and 4.

If there is 10 -- 40 ohms resistance, the mirror adjust motors should be functioning properly.

If there is zero or infinite resistance, the German mirror up/ down motor M-30 has failed. Repair or replace the mirror assembly.

55-38

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 Mirror Heat Switch S-19 Test No.

Test Point

Expected Result

Other Result (Possible Cause)

Carefully remove the mirror If there is no continuity, Go to heat switch S-19 from the upper test 2 left console, and unplug it from the cab roof (CR) harness. Set the switch in the OFF position. Use a multimeter to check for continuity between the Mirror Heat Switch terminals 2 and 3.

If there is continuity, the mirror heat switch is shorted internally. Replace the mirror heat switch S-19.

Set the Mirror Heat Switch in the ON position. Use a multimeter to check for continuity between Mirror Heat Switch terminals 2 and 3.

If there is continuity, the mirror heat switch is functioning properly. Go to test 3

If there is no continuity, the switch has failed open. Replace the mirror heat switch S-19.

Use a multimeter to check resistance between connector X127 pin 3 and ground.

If there is approximately 1 ohms If there is approximately 3 ohms resistance, there is an open cirresistance, the circuit is funccuit to one of the mirror heat tioning properly. elements. Continue the testing at Mirror Heat Circuits -- Testing. If there is infinite resistance, there is an open circuit in the cab roof (CR) or outer roof (OR) harnesses between X127 pin 3 and the wire splice in the outer roof (OR) harness wire 931 orange, or between the wire splice in the outer roof (OR) harness and cab roof ground 4 wire 295 black. Locate the open and repair.

55-39

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 Mirror Heat Circuits Test NOTE: Before starting any of these tests, the testing procedures at Mirror Fuse -- Testing Power and Ground and Mirror Heat Switch S-19 -- Testing should be completed first. If the left mirror heat circuit is not functioning, start at test 1.

No.

Test Point

If the right mirror heat circuit is not functioning, start at test 4. If the German mirror heat circuit is not functioning, start at test 7.

Expected Result

Other Result (Possible Cause)

Turn key switch ON. Activate the Mirror Heat circuit. Unplug the small connector at the left mirror support bracket. Use a multimeter to check for voltage at LH Mirror small connector pin 3.

If there is 12 volts, Go to test 2

If there is no voltage, there is an open circuit in the outer roof (OR) harness between the harness splice and LH mirror connector wire 935 orange. Locate the open and repair.

Key switch OFF. Use a multimeter to check the resistance between LH Mirror small connector pin 6 and ground.

If there is less than 1 ohm, Go to test 3

If there is infinite resistance, there is an open circuit in the outer roof (OR) harness between the LH mirror small connector and the harness splice wire 671 black. Locate the open and repair.

Use a multimeter to test the resistance through the mirror at connector pins 3 and 6.

If there is approximately 3 ohms resistance, the LH mirror heat circuit is functioning properly. Go to test 4

If there is infinite resistance, the LH mirror heat coil R-11 has failed. Repair or replace the mirror assembly.

Turn key switch ON. Activate the Mirror Heat circuit. Unplug the small connector at the right mirror support bracket. Use a multimeter to check for voltage at RH Mirror small connector pin 3.

If there is 12 volts, Go to test 5

If there is no voltage, there is an open circuit in the outer roof (OR) harness between the harness splice and RH mirror connector wire 932 orange. Locate the open and repair.

Key switch OFF. Use a multimeter to check the resistance between RH Mirror small connector pin 6 and ground.

If there is less than 1 ohm, Go to test 6

If there is infinite resistance, there is an open circuit in the outer roof (OR) harness between the RH mirror small connector and the harness splice wire 670 black. Locate the open and repair.

Use a multimeter to test the resistance through the mirror at connector pins 3 and 6.

If there is approximately 3 ohms resistance, the RH mirror heat circuit is functioning properly. Go to test 7

If there is infinite resistance, the RH mirror heat coil R-10 has failed. Repair or replace the mirror assembly.

55-40

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7

Expected Result

Other Result (Possible Cause)

Test Point

Turn key switch ON. Activate the Mirror Heat circuit. Unplug the small connector at the German mirror support bracket. Use a multimeter to check for voltage at German Mirror small connector pin 3.

If there is 12 volts, Go to test 8

If there is no voltage, there is an open circuit in the outer roof (OR) harness between the harness splice and German mirror connector wire 862 orange. Locate the open and repair.

Key switch OFF. Use a multimeter to check the resistance between German Mirror small connector pin 6 and ground.

If there is less than 1 ohm, Go to test 9

If there is infinite resistance, there is an open circuit in the outer roof (OR) harness between the German mirror small connector and the harness splice wire 863 black. Locate the open and repair.

Use a multimeter to test the resistance through the mirror at connector pins 3 and 6.

If there is approximately 3 ohms resistance, the German mirror heat circuit is functioning properly. All mirror heat circuits and components should be functioning properly.

If there is infinite resistance, the German mirror heat coil R-14 has failed. Repair or replace the mirror assembly.

55-41

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 HORN SYSTEM Power is supplied to the Horn Switch at all times. The Horn Switch is integrated into the Road Light Switch. When the operator closes the Horn Switch contact, current flows through the Horn Switch to operate the horn.

55-42

Current travels across the fuse panel buss bar through fuse F51 to connector X256 pin 8. When the horn portion of the road light switch S-26 is pushed inward to the “ON” position, current crosses from pin 8 to pin 9. Current passes through connector X004 pin 18 to connector X172. The ground path for the horn travels from connector X172 to the front frame ground location #2.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 HORN SYSTEM CIRCUIT

LIGHTING FRAME--36

A-05 = FLASHER MODULE E-13 = LH ROAD LIGHT E-14 = RH ROAD LIGHT F-32 = HIGH BEAM FUSE

F-33 = LOW BEAM FUSE F-51 = HORN, MARKER LTS FUSE H-02 = HORN K-02 = LIGHT CONTROL RELAY

55-43

K-04 = HIGH BEAM RELAY K-05 = LOW BEAM RELAY S-26 = ROAD LIGHT SWITCH

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 HORN SYSTEM DIAGNOSTIC TESTS NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.

HORN SYSTEM CIRCUIT DIAGNOSTIC TEST Test Point

Good Reading

Possible Cause of Bad Reading

Close Horn Switch located in the Road Light Switch. Check for 12 volts at horn connector X172 (pin 1).

12 volts If good reading, go to test point 5.

Open in B+ circuit 193 (WH) between Road Light Switch connector X256 (pin 9) and Horn connector X172 (pin 1). Go to next test point.

Close Horn Switch located in the Road Light Switch. Check for 12 volts at Road Light Switch connector X256 (pin 9).

12 volts If good reading, repair open in circuit 193 (WH). Check in-line connector X004 (pin 18) for connection.

Horn Switch. Go to next test point.

Check for 12 volts at Road Light Switch connector X256 (pin 8).

12 volts If good reading, replace Road Light Switch.

Open B+ circuit 214 (RD) between Road Light Switch connector X256 (pin 8) and Fuse F51. Go to next test point.

Check for 12 volts at Fuse F51.

12 volts If good reading, repair open in circuit 214 (RD).

Blown Fuse F51. Open in B+ circuit. See Power Distribution for testing.

Check resistance of circuit 631 (BK) between horn connector X172 (pin 2) and ground.

Less than 1 ohm If good reading, horn power and ground circuits okay. If horn does not work, replace horn.

Open circuit 631 (BK) between horn and ground.

55-44

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 AUDIO SYSTEM The audio system is energized by switched power and has a Transceiver Power Outlet connector so that the operator may add additional audio equipment. Radio, 1, Location with: •

12 Volts DC connection

•

Loudspeaker connections

•

Antenna connection: AM/FM Universal Motorola 3/4″ NMO mount (cable pre installed).

9 Connectors Connector X314 and connector X315, 1, To AM/FM Radio.

50020061

55-45

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 AUDIO SYSTEM CIRCUIT

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-46

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7

F-03 = ACCESSORY 1 FUSE F-04 = WIPER FUSE F-05 = CIGAR LIGHTER FUSE F-08 = ACCESSORY OUTLET FUSE

F-09 = WASHER/MIRROR FUSE F-10 = NOT USED J-06 = ACCESSORY SOCKET J-08 = ACCESSORY OUTLET

K-06 = WIPER RELAY K-08 = ACCESSORY 1 RELAY M-24 = WIPER WASHER MOTOR M-25 = WIPER MOTOR

55-47

R-08 = CIGAR LIGHTER S-20 = WIPER SWITCH S-38 = WASHER SWITCH

ACCESSORY FRAME--45

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7

ACCESSORY FRAME--46

A-04 = RADIO F-02 = ACCESSORY 2 FUSE F-11 = RADIO FUSE F-13 = TRANSCEIVER FUSE

F-16 = SEAT PUMP FUSE F-35 = RADIO KAPWR FUSE H-04 = REAR LEFT SPEAKER H-05 = FRONT LEFT SPEAKER

55-48

H-06 = REAR RIGHT SPEAKER H-07 = FRONT RIGHT SPEAKER J-07 = TRANSCEIVER OUTLET K-03 = ACCESSORY 2 RELAY

M-26 = SEAT PUMP MOTOR S-45 = SEAT ADJUST SWITCH

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 AUDIO SYSTEM CIRCUIT TROUBLESHOOTING Before troubleshooting the Audio system make sure that the following operating conditions are met: A. The batteries are fully charged and all connections are clean and tight. B. Transmission in neutral or park. C. Check all connectors for full installation, loose, corroded, pushed out, or bent terminals. D. Check Fuses F02, F11, F13, F35. NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.

Symptom Audio unit or Transceiver Power Outlet is inoperative

Noisy reception

Noisy reception, FM only

Possible Cause

Reference/Test

Fuse/Power Supply

A - Audio System Power and Ground Supply Test

Audio Unit

If A - Audio System Power and Ground Supply Test results are good, Audio unit is bad.

Antenna

F - Antenna Test

Audio Unit

If F - Antenna Test is good, audio unit is bad.

Antenna

F - Antenna Test

Audio unit

If F - Antenna Test is good, audio unit is bad.

Poor reception area

55-49

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 Symptom Poor quality/distorted sound-One or more speakers

No sound from speakers

Transceiver Power Outlet not operating

Possible Cause

Reference/Test

Audio speaker

B, C, D, E - Speaker Resistance Test Substitute known good speaker(s).

Circuit

Perform relevant speaker circuit test(s).

Audio unit

If speaker(s) and circuit(s) are good, audio unit is bad.

Speakers

B, C, D, E - Speaker Resistance Test Substitute known good speaker(s).

Circuit

Perform relevant speaker circuit test(s).

Audio unit

If speaker(s) and circuit(s) are good, audio unit is bad.

Circuit

A - Audio system power and ground supply test.

55-50

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 AUDIO SYSTEM DIAGNOSTIC TESTS NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.

WARNING Before performing any of the electrical tests, be sure all operating controls are in neutral or park lock position. This will eliminate accidental movement of the machine or start-up of power driven equipment. NOTE: Refer to Radio Owner’s Manual for operation and removal instructions. A -- Audio System Power and Ground Supply Test Test Point 1

Good Reading

Possible Cause of Bad Reading

Key Switch S02, in Less than 1ohm “OFF” position.

Open circuit 973 (BK) between Radio connector X314 (pin 8) and ground.

Measure resistance If good reading, go to next test Continue to next test point. between Radio con- point 2. nector X314 (Pin 8) and ground. 2

Key Switch S02, in 12 volts “OFF” position.

Blown Fuse F35

Measure 12 volts at If good reading, go to test point 5. Radio connector X314 (pin 4, KAPWR).

Open circuit 048 (RD) between Radio connector X314 (pin 4), connector X002 (pin 6) and fuse F35. Continue to next test point.

Measure for 12 volts 12 volts Open circuit 048(RD) between connector at connector X002 X002 (Pin 6) and Fuse F35. If good reading, repair open circuit (pin 6). in 830 (RD) or 048 (RD). Go to test point 5.

Measure for 12 volts 12 volts at Fuse F35.

Open circuit between Fuse F35 and unswitched power.

If good reading, repair open circuit 048 (RD).

See Power Distribution for testing.

Continue to next test point. 5

Key Switch S02 in 12 volts Open circuit 081 (OR) between Radio “IGN” or “ACC” posiconnector X314 (pin 7) and Fuse F11. tion. If good reading, power and Check for connection at connector X002 Measure 12 volts at grounds to Audio System are (Pin 9). Radio connector X314 operating properly. Continue to next test point. (pin7).

55-51

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 Test Point

Good Reading

Possible Cause of Bad Reading

6 Measure for 12 volts at 12 volts Fuse F11.

Open circuit 008 (OR) between Fuse F11 and Accessory 2 Relay K03.

If good reading, repair open circuit Blown fuse F11 or Accessory 2 Relay K03. 081 (OR) between Radio connecRefer to Power Distribution for Accessory 2 tor X314 (Pin 7) and Fuse F11. Relay K03 testing. 7 Key Ignition Switch S02 12 volts in “IGN” position. Measure for 12 volts at Transceiver Outlet con- If good reading, go to test point 9. nector X141 (pin 2).

Open 083 (RD) circuit between Transceiver Outlet connector X141 (pin 2) and Fuse F13. Check for connection at connector X002 (pin11). Continue to next test point.

8 Measure 12 volts at 12 volts Fuse F13. If good reading, repair open circuit 083 (OR) between Transceiver Outlet connector X141 (pin 2) and Fuse F13.

Blown Fuse F13. Open circuit 008 (OR) between Accessory 2 Relay K03 (pin 5) and Fuse F13. Refer to Power Distribution for Accessory 2 Relay K03 testing.

9 Measure resistance be- Less than 1 ohm Open circuit 281 (BK) between Transceiver tween Transceiver OutOutlet connector X141 (pin 1) and ground. If good reading, power and ground let connector X141 to Transceiver Outlet connector (pin 1). X141 (pin 1) are working properly. B -- Left Front Speaker Circuit Test Test Point 1 Disconnect connector X315 from Radio A04.

Good Reading

Possible Cause of Bad Reading

Approximately 4 ohms.

Open/short to ground in circuit 977 (WH) between Left Front Speaker H05 connector X136 (pin B) and Radio A04 connector X315 (pin 5).

Measure resistance be- If good reading, Left Front tween Radio A04 connector Speaker H05 and wiring are X315 (pin 6) and Radio A04 okay. connector X315 (pin 5). 2 Disconnect connector X136 Approximately 4 ohms. from Left Front Speaker H05.

Open/short to ground in circuit 983 (BL) between Left Front Speaker H05 connector X136 (pin A) and Radio A04 connector X315 (pin 6). Broken wire from Speaker H05 to connector X136, either to Pin A or to Pin B.

Measure resistance be- If good reading, continue with Broken solder connection at Speaker H05. tween Pin A and Pin B on the next step. Bad Speaker H05. lead from the Speaker H05.

55-52

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 Test Point

Good Reading

Possible Cause of Bad Reading

3 Disconnect connector X136 Less than 1 ohm from Left Front Speaker H05. Measure resistance be- If good reading, continue with tween Radio A04 connector next step. X315 (pin 6) and Left Front Speaker H05 connector X136 (pin A). 4 Measure resistance be- Less than 1 ohm tween Left front Speaker H05 connector X136 (pin If good reading, Left Front A) and Radio A04 connec- Speaker H05 wiring is okay. tor X315 (pin 6).

Open/short to ground in circuit 977 (WH) between Left Front Speaker H05 connector X136 (pin B) and Radio A04 connector X315 (pin 5).

Open/short to ground in circuit 983 (BL) between Left Front Speaker H05 connector X136 (pin A) and Radio A04 connector X315 (pin 6).

C -- Right Front Speaker Circuit Test Test Point

Good Reading

Possible Cause of Bad Reading

1 Disconnect connector X315 Approximately 4 ohms. from Radio A04.

Measure resistance be- If good reading, Right Front tween Radio A04 connector Speaker H07 and wiring are X315 (pin 3) and Radio okay. A04connector X315 (pin 4). 2 Disconnect connector X319 Approximately 4 ohms. from Right Front Speaker H07.

Open/short to ground in circuit 976 (WH) between Right Front Speaker H07 connector X139 (pin B) and Radio A04 connector X315 (pin 3). Open/short to ground in circuit 980 (BL) between Right Front Speaker H07 connector X139 (pin A) and Radio A04 connector X315 (pin 4). Broken wire from Speaker H07 to connector X139, either to Pin A or to Pin B.

Measure resistance be- If good reading, continue with Broken solder connection at Speaker H07. tween Pin A and Pin B on next step. Bad Speaker H07. the lead from Speaker H07. 3 Disconnect connector X139 Less than 1 ohm from Right Front Speaker H07. Measure resistance be- If good reading, continue with tween Radio A04 connector next step. X315 (pin 3) and Right Front Speaker H07 connector X139 (pin B). 4 Measure resistance be- Less than 1 ohm tween Right front Speaker H07 connector X139 (pin A) If good reading, Right Front and Radio A04 connector Speaker H07 wiring is okay. X315 (pin 4).

55-53

Open/short to ground in circuit 976 (WH) between Right Front Speaker H07 connector X139 (pin B) and Radio A04 connector X315 (pin 3).

Open/short to ground in circuit 980 (BL) between Right Front Speaker H07 connector X139 (pin A) and Radio A04 connector X315 (pin 4).

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 D -- Right Rear Speaker Circuit Test Test Point

Good Reading

Possible Cause of Bad Reading

1 Disconnect connector X315 Approximately 8 ohms. from Radio A04.

Measure resistance be- If good reading, Right Rear tween Radio A04 connector Speaker H06 and wiring are X315 (pin 1) and Radio okay. A04connector X315 (pin 2). 2 Disconnect connector X122 Approximately 8 ohms. from Right Rear Speaker H06.

Open/short to ground in circuit 974 (WH) between Right Rear Speaker H06 connector X122 (pin B) and Radio A04 connector X315 (pin 1). Open/short to ground in circuit 979 (BL) between Right Rear Speaker H06 connector X122 (pin A) and Radio A04 connector X315 (pin 2). Broken wire from Speaker H06 to connector X122, either to Pin A or to Pin B.

Measure resistance be- If good reading, continue with Broken solder connection at Speaker H06. tween Pin A and Pin B on next step. Bad Speaker H06. the lead from Speaker H06. 3 Disconnect connector X122 Less than 1 ohm from Right Rear Speaker H06. Measure resistance be- If good reading, continue with tween Radio A04 connector next step. X315 (pin 1) and Right Rear Speaker H06 connector X122 (pin B). 4 Measure resistance be- Less than 1 ohm tween Right Rear Speaker H06 connector X122 (pin A) If good reading, Right Rear and Radio A04 connector Speaker H06 wiring is okay. X315 (pin 2).

55-54

Open/short to ground in circuit 974 (WH) between Right Rear Speaker H06 connector X122 (pin B) and Radio A04 connector X315 (pin 1).

Open/short to ground in circuit 979 (BL) between Right Rear Speaker H06 connector X122 (pin A) and Radio A04 connector X315 (pin 2).

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 E -- Left Rear Speaker Circuit Test Test Point 1

Good Reading

Possible Cause of Bad Reading

Disconnect connector X315 Approximately 8 ohms. from Radio A04.

Open/short to ground in circuit 975 (WH) between Left Rear Speaker H04 connector X123 (pin B) and Radio A04 connector X315 (pin 7).

Measure resistance be- If good reading, Left Rear tween Radio A04 connector Speaker H04 and wiring are X315 (pin 8) and Radio okay. A04connector X315 (pin 7).

Open/short to ground in circuit 982 (BL) between Left Rear Speaker H04 connector X123 (pin A) and Radio A04 connector X315 (pin 8).

2 Disconnect connector X123 Approximately 8 ohms. from Left Rear Speaker H04.

Broken wire from Speaker H04 to connector X123, either to Pin A or to Pin B.

Measure resistance be- If good reading, continue with Broken solder connection at Speaker H04. tween Pin A and Pin B on next step. Bad Speaker H04. the lead from Speaker H04. 3

Disconnect connector X123 Less than 1 ohm from Left Rear Speaker H04. Measure resistance be- If good reading, continue with tween Radio A04 connector next step. X315 (pin 7) and Left Rear Speaker H04 connector X123 (pin B).

Measure resistance be- Less than 1 ohm tween Left Rear Speaker H04 connector X123 (pin If good reading, Left Rear A) and Radio A04 connec- Speaker H04 wiring is okay. tor X315 (pin 8).

55-55

Open/short to ground in circuit 975 (WH) between Left Rear Speaker H04 connector X123 (pin B) and Radio A04 connector X315 (pin 7).

Open/short to ground in circuit 979 (BL) between Left Rear Speaker H04 connector X123 (pin A) and Radio A04 connector X315 (pin 8).

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 7 F -- Antenna Test Test Point

Good Reading

Possible Cause of Bad Reading

1 Disconnect Antenna from Less than 1 ohm Radio A04.

Antenna.

Measure resistance be- If good reading, go to next test tween center terminal of point. Antenna (radio end) and Antenna Mast. 2 Measure resistance from Less than 1 ohm Antenna ground wire to Antenna is good. chassis ground.

Open circuit between Antenna and chassis ground.

55-56

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 8

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 8 -- Hydraulic Systems CONTENTS Section

Description

Page

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 55 000

55-1

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 8 DESCRIPTION OF OPERATION The hydraulic system on the CR combine has several sensors that monitor the state of the system. When an abnormal condition is detected by these sensors an alarm and/or error message will be displayed on the display monitor.

GEARBOX TEMPERATURE SENSOR The gearbox temperature sensor monitors the temperature of the oil in the engine gearbox. The gearbox temperature sensor, 1, is located on the front lower left section of the gearbox above the gearbox drain line.

1 40025222

1 Alarm Code for Gearbox Temperature Sensor. The combine will continue to operate when this alarm code is active. Alarm Code A0006

Description Gearbox Temp HIGH

Priority High

Check Condition Engine Running

Error Codes for Gearbox Temperature Sensor. Error Codes

Description

E0025--03

Gearbox Temperature sensor Shorted to high source

E0025--04

Gearbox Temperature sensor Shorted to low source

E0025--05

Gearbox Temperature sensor Line Disconnected

NOTE: Refer to the appropriate section of the repair manual for troubleshooting.

55-2

Activation

Resetting

2 sec> 90°C (194° F)

2 sec< 90°C (194° F)

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 8 HYDRAULIC RESERVOIR TEMPERATURE SENSOR The hydraulic reservoir temperature sensor monitors the temperature of the oil in the hydraulic reservoir. The hydraulic reservoir temperature sensor, 1, is located on the front of the hydraulic reservoir.

50014693

2 Alarm Code for Hydraulic Reservoir Temperature Sensor. The combine will continue to operate when this alarm code is active. Alarm Code A0007

Description Hydraulic Reservoir Temp HIGH

Priority

Check Condition

High

Activation

10 sec> 90°C (194° F) 3 sec< 85°C (185° F)

Error Codes for Hydraulic Reservoir Temperature Sensor. Error Codes

Description

E0024--03

Hyd. Oil Reservoir Temperature Sensor Shorted to high source

E0024--04

Hyd. Oil Reservoir Temperature Sensor Shorted to low source

E0024--05

Hyd. Oil Reservoir Temperature Sensor Line Disconnected

NOTE: Refer to the appropriate section of the repair manual for troubleshooting.

55-3

Resetting

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 8 HYDRAULIC RESERVOIR LEVEL LOW SENSOR The Hydraulic Reservoir Level Low Sensor detects when the hydraulic oil in the reservoir falls below a specific level. The Hydraulic Reservoir Level Low Sensor, 1, is located on the top of the Hydraulic Reservoir.

50014693

3 Alarm Code for Hydraulic Reservoir Level Low Sensor. The combine will continue to operate when this alarm code is active. Alarm Code A0011

Description Hydraulic Reservoir Level LOW

Priority

Check Condition

High

Activation 4 sec level low

Error Code for Hydraulic Reservoir Level Low Sensor. Error Codes E0133--03

Description Hydraulic Reservoir Level Sensor Shorted to high source

NOTE: Refer to the appropriate section of the repair manual for troubleshooting.

55-4

Resetting 0.5 sec level high

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 8 GEARBOX FILTER BYPASS SWITCH The Gearbox Filter Bypass Switch will be activated when the gearbox filter becomes blocked from contamination, and oil starts to bypass the filter. The Gearbox Filter Bypass Switch, 1, is located on the back side of the filter head.

The Gearbox Filter Bypass Switch is normally closed; when the filter becomes blocked, the switch opens, removing the circuit ground. 10020028

4 Alarm Code for Gearbox Filter Bypass Switch. The combine will continue to operate when this alarm code is active. Alarm Code A0010

Description Gearbox Filter Blocked

Priority

Check Condition

Activation

Resetting

10 sec > 0.69 Volts

2 sec < 0.69 Volts

Low

If the alarm code is displayed after replacing the filter, the circuit is shorted to ground.

Troubleshooting Step

Test Point

Good Reading

Possible Cause of Bad Reading

Disconnect harness from switch

If alarm is active; Go to step 2 No alarm; Bad switch. Replace switch

Key Switch in ”OFF” position. Unplug If you have continuity, inspect No continuity; Inspect for short to connector X024. Check continuity to for short to ground in Main ground in straw hood front harness, ground on Main Frame end of Frame harness, wire 448 (YE) wire 448 (YE) connector X024 (pin 8)

Error Code for Gearbox Filter Bypass Switch. Error Codes E0007--03

Description Gearbox Filter Bypass Switch Shorted to high source

NOTE: Refer to the appropriate section of the repair manual for troubleshooting.

55-5

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 8 RETURN FILTER BYPASS SWITCH The Return Filter Bypass Switch will be activated when the return filter becomes blocked from contamination and oil starts to bypass the filter. The Return Filter Bypass Switch, 1, is located on the back side of the filter head.

The Return Filter Bypass Switch is normally closed; when the filter becomes blocked, the switch opens, removing the circuit ground. 10020028

5 Alarm Code for Return Filter Bypass Switch. The combine will continue to operate when this alarm code is active. Alarm Code A0009

Description Return Filter Blocked

Priority

Check Condition

Low

Activation

Resetting

10 sec > 0.69 Volts 2 sec < 0.69 Volts

If the alarm code is displayed after replacing the filter, the circuit is shorted to ground.

Troubleshooting Step

Test Point

Good Reading

Possible Cause of Bad Reading

Disconnect harness from switch

If alarm is active; Go to step 2 No alarm; Bad switch. Replace switch

Error Code for Return Filter Bypass Switch. Error Codes E0006--03

Description Return Filter Bypass Switch Shorted to high source

NOTE: Refer to the appropriate section of the repair manual for troubleshooting.

55-6

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 8 CONTROL PRESSURE LOW SENSOR The Control Pressure Low Sensor monitors the pressure of the Low--pressure hydraulic system. The Control Pressure Low Sensor, 1, is located on the rear of the low pressure valve block for the clutches and park brake.

50020057

6 Alarm Code for Control Pressure Low Sensor. The combine engine will shut down when this alarm code is active. Alarm Code A0012

Description

Priority

Control Pressure LOW High

Check Condition

Resetting

Engine running for 3 sec 4 sec < 20 bar (290 psi) 0.5 sec > 20 bar or engine shut down (290 psi)

Error Code for Control Pressure Low Sensor. Error Codes

Activation

Description

E0162--01

Control Pressure sensor Valid below normal

E0162--03

Control Pressure sensor Shorted to high source

E0162--05

Control Pressure sensor Line Disconnected

NOTE: Refer to the appropriate section of the repair manual for troubleshooting.

55-7

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 8

55-8

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 9 -- Driveline Systems CONTENTS Section

Description

Page

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydrostatic Ground Drive Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Temperature Control System (TCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydrostat Ground Drive Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydrostat Ground Drive Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Check Calibration of the Multifunction Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Troubleshooting Multifunction Handle (MFH) Components . . . . . . . . . . . . . . . . . . . . . 5 Ground Speed Potentiometer (R04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Audio Alarm (H01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Park Brake Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Park Brake Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Park Brake Electrical Component Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Park Brake Switch S09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Service Brake Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Service Brake Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Gearshifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Special Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Gearshift Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Gearshift Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Gear Select Switch S24 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Ground Speed RPM Sensor B17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Ground Speed RPM Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Rear Wheel Assist (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Special Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Rear Wheel Assist Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Rear Wheel Assist Switch S10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

55-1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 DESCRIPTION OF OPERATION HYDROSTATIC GROUND DRIVE ELECTRICAL

Overview The hydrostatic ground drive system on the CR combine uses several electrical components, electronic controllers, and the CAN Bus to provide control of the hydrostatic pump. In order to move the combine in either forward or reverse, the operator must release the park brake, shift the mechanical transmission into the desired gear, and move the multifunction handle (MFH), 1, in the desired direction of travel.

ZDA2288A

NOTE: Depress the switch, 2, on the back of the MFH to activate the neutral unlock solenoid.

Two electrical components are mounted to the MFH assembly that are used for ground drive operation. The neutral switch, 1, serves two functions; when the MFH is in neutral, power from fuse F-48 flows through the neutral switch S-22 normally closed contacts (pins 1 and 2) to energize the neutral start relay K-23, allowing the engine to be started. When the MFH is moved out of the neutral position, power from fuse F-48 flows through the neutral switch S-22 normally open contacts (pins 1 and 3) to CCM2 connector X015 pin J1-17. This power is used by CCM2 to power the output to the ground drive hydrostat L-23 EDC valve solenoids. This provides a margin of safety by immediately disconnecting the power supply to the EDC valve when the MFH is returned to the neutral position.

1 2

40025230

The second component on the MFH assembly is the ground speed potentiometer R-04, 2, which monitors the position of the MFH. When the MFH moves out of neutral, the ground speed potentiometer R-04 signal to the RHM module changes. The RHM processes the signal against stored calibration information, and sends this information across CAN to CCM2. CCM2 processes this information against its stored calibration data for the EDC valve solenoids, and activates the output to the ground drive hydrostat L-23, 1, in proportion to the MFH movement.

10010872

55-2

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 CCM1 monitors the temperature of the case drain oil at 10-second intervals. If the temperature climbs to 100°C (212°F), CCM2 begins to de-stroke the hydrostatic pump. The hydrostatic pump will be de-stroked at increments of 5 to 10 %, depending on the level of cooling required, to reach the 95°C (203°F) and remain there for a minimum of 10 seconds.

Temperature Control System (TCS) The hydrostatic system also includes a high temperature control. Hydrostat Motor Temperature Sender B46, which senses case drain oil temperature, sends a signal to CCM1. CCM1 relays the reading to CCM2 via CAN. CCM2 software regulates the EDC valve L23 to lower the temperature of the oil when it reaches or exceeds the set point defined by the software.

The original setting of the MFH is restored by CCM2 after the temperature has stabilized. CCM2 will not de-stroke the hydrostatic pump more than 50% of the original MFH setting.

If the temperature exceeds 100°C (212°F), CCM2 will automatically reduce the current to the EDC Valve L23, reducing the swash plate angle independent of the MFH position. In addition, an alarm message (A0083) will be displayed.

Hydrostat Ground Drive Alarms Alarm Code

Description

Priority

Check Condition

Activation

Resetting

A0008

Hydrostatic Motor Temp HIGH

High

____________

10 sec> 105°C (221°F)

3 sec< 100°C (212°F)

A0033

Parking Brake On

Med

Park Brake On & Engine running

Multifunction Handle not in neutral (output to EDC is disabled)

Multifunction Handle in neutral and Release Park Brake (output to EDC is enabled)

A0081

Hydrostat Charge Pressure Low

High

Engine running for 1 sec

1 sec switch low Engine will shut down after 4 sec.

0.5 sec switch high

A0083

Hydro Speed Limitation (Motor Temp)

Low

____________

10 sec>100°C (212°F)

3 sec< 95°C (203°F)

55-3

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 Hydrostat Ground Drive Fault Codes The following fault codes must be resolved before proceeding to troubleshooting. In many cases, the fault codes will direct you to the proper component for repair and resolution. Fault Code

Description

E0023-03

Hydrostat Motor Temperature Sensor Shorted to high source

E0023-04

Hydrostat Motor Temperature Sensor Shorted to low source

E0023-05

Hydrostat Motor Temperature Sensor Line Disconnected

E0065-11

Ground Drive Back-Up Alarm Unidentified Failure Code

E0135-01

Charge pressure switch Valid below normal (Engine Shutdown)

E0135-03

Charge pressure switch Shorted to high source

E0135-05

Charge pressure switch Line Disconnected (Can only check when engine is not running or cranking)

E0164-03

Ground Speed Hydro Voltage Supply Shorted to high source

E0164-04

Ground Speed Hydro Voltage Supply Shorted to low source

E0179-03

Current Isense Grnd Speed Hydro Shorted to high source

E0179-04

Current Isense Grnd Speed Hydro Shorted to low source

E0179-05

Current Isense Grnd Speed Hydro Line Disconnected

E0202-11

Ground Drive Hydrostat Unidentified Failure Code

E0643-03

Multi Function Handle Position Shorted to high source

E0643-04

Multi Function Handle Position Shorted to low source

E0643-13

Multi Function Handle Position Needs Calibration

NOTE: Refer to the appropriate section of the repair manual for troubleshooting fault codes.

55-4

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 Check Calibration of the Multifunction Handle •

Move the MFH fully front, the reading should be on the “D” and have +100% for the percentage reading. Return the MFH to neutral lock. Move the MFH fully aft. The reading should be on the “A” and the percentage at 100%. If the Multi-Function Handle is not within the specifications, refer to the Operator’s Manual for Calibration procedure.

20072394

4 Troubleshooting Multifunction Handle (MFH) Components NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.

55-5

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 Right Hand Console - Hydrostat Control

1. Connector X059 - Neutral Switch 2. Neutral Switch - S22

3. Neutral Lock Solenoid - L01

4. Connector X041 - Neutral Lock 5. Audio Alarm - H01

4 40025230

5 Right Hand Console - Hydrostat Control 6. Connector X058 - Audio Alarm 7. Connector X057 - Ground Speed

8. Ground Speed Potentiometer - R04 9. Connector X028 - MFH

8 7

40025230

9 6

55-6

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 IMPORTANT: The MFH switches use a matrix-wiring configuration. Diodes are in the circuitry and high resistance readings are present. To test, use the Negative (--) test probe on the common pin and the Positive (+) on the variable. Neutral Unlock Switch The Neutral Unlock Switch controls the Neutral Lock Solenoid L01. Test Point 1

Good Reading

Possible Cause For Bad Reading

Disconnect connector X028 from Continuity present. Switch and Faulty switch. Replace MFH. RHM, check continuity between pin 1 circuit are OK. (common) and pin 2. Manually operate switch.

Neutral Unlock Solenoid (L01) The Neutral Unlock/Lock Solenoid L01, locks the MFH in the neutral position to facilitate starting of the engine and shifting of the transmission. Test Point

Good Reading

Possible Cause For Bad Reading

1 Key Switch S02, in “OFF” position. Continuity present. Coil is OK. Faulty coil. Replace assembly. Disconnect connector X041 at coil Proceed to next test point. (L01). Check for continuity between pin1 and pin 2 on coil connector. 2 Key Switch S02, in “OFF” position. Less than 1ohm Open circuit 317 (BK) between Measure resistance between conconnector X041 (pin B) and ground. nector X041 (pin B) and ground If good reading, proceed to next test point. circuit 317 (BK). 3 Key Switch S02, in “OFF” position. Less than 1ohm Open circuit between connector Measure resistance between conX041 (pin A) and connector X027 nector X041 (pin A) and connector If good reading, proceed to (pin 13) circuit 305 (WH). next test point. X027 (pin 13) circuit 305 (WH). 4 Key Switch S02, in “OFF” position. Less than 1ohm Open circuit between connector Measure resistance between conX041 (pin A) and connector X027 nector X041 (pin A) and connector If good reading, proceed to (pin 12) circuit 301 (WH), or failed next test point. X027 (pin 12) circuit 301 (WH). RHM.

55-7

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 Neutral Switch (S22) Neutral Start Switch S22, Normally Closed (NC) position, pin 1 and 2 supplies power to the neutral start relay K23, and cuts off the power supply of the Hydrostatic logic in CCM-2, when the MFH is in the neutral position. Test Point 1

Good Reading

Possible Cause For Bad Reading

Ignition switch in “IGN” position. 12 volts Open circuit 300 (OR) or 108 (OR) Measure 12 volts at Neutral Switch between Fuse F48 and Neutral If good reading, proceed to Switch S22 connector X059 (pin 1). S22 connector X059 (pin 1) next test point. Check in-line connector X001 (pin 3) for connection. Blown Fuse F48 (refer to Power Distribution section for testing).

Place Neutral Switch S22 in closed 12 volts Neutral Switch S22. position. Measure 12 volts at Neutral Switch S22 connector X059 (pin 2). If good reading, proceed to next test point.

Disconnect connector X059 and remove relay K-23. Measure the resistance between pin 1 on K-23 relay socket and pin 2 on the RH Console (RC) harness side of X059.

Less than 1 ohm If good reading, proceed to next test point.

Open circuit 093 (WH) between Neutral Switch S-22 and Neutral Start Relay K-23. Check in--line connector X001 (pin 18) for connection.

Place Neutral Switch S22 in open 12 volts Neutral Switch S22. position. Measure 12 volts at Neutral Switch S22 connector X059 (pin 3). If good reading, proceed to next test point.

Disconnect connectors X059 and X015. Measure the resistance between pin 3 on the RH Console (RC) harness side of X059 and pin J1-17 on the Cab Main (CM) harness side of X015.

Less than 1 ohm

Reload CCM-2 software and retest circuit operation.

Circuit functions

If good reading, Neutral Switch S-22 and switch circuits are good.

55-8

Open circuit 113 (YE) between Neutral Switch S-22 and CCM-2 module. Check in--line connector X001 (pin 17) for connection.

CCM-2 is faulted. Replace CCM-2.

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 GROUND SPEED POTENTIOMETER (R04)

•

The Ground Speed Potentiometer R04, on the rotation point of the MFH controls:

•

• •

The signal to the forward or rearward solenoid on the Hydrostat Pump L23. The Transmission Shift Motor M02 and the Pressure Release Valve L05. Gearshifting and power to the Pressure Release Valve L05 is not possible when the MFH is not in Neutral. Test Point

Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed. To monitor the MF-handle position, move the MFH fully front, the reading should be on the “D” and have +100% for the percentage reading. Return the MFH to neutral lock. Move the MFH fully aft. The reading should be on the “A” and the percentage at --100%.

A signal to the Back-up Alarm H08 is sent when the MFH is moved rearward. The Neutral Lock Solenoid L01 will be disengaged when the MFH is moved forward or rearward 7°(degrees) from the neutral lock position. This is to prevent overheating of the solenoid. The MFH will not be able to shift from forward to reverse and reverse to forward without locking in neutral.

Good Reading

Possible Cause For Bad Reading

The Ground Speed Potentiom- Faulty Potentiometer eter circuit. R04 and circuit are OK.

open

Proceed to next test point.

Testing complete.

Disconnect connectors X057 and Less than 1ohm. X027. Measure resistance between Proceed to next test point. pin C on X057 and pin 1 on X027

Open circuit 381 (YE).

Disconnect connectors X057 and Less than 1ohm. X026. Measure resistance between pin A on X057 and pin 16 on X027 Proceed to next test point.

Open circuit 316 (PK).

Disconnect connectors X057 and Less than 1ohm. X026. Measure resistance between pin B on X057 and pin 6 on X027. Proceed to next test point.

Open circuit 320 (BL).

Disconnect X027. Measure voltage Voltage is present. from pin 1 on X027 and ground. Proceed to next test point.

Groundspeed POT R-04 is faulted.

Reload RHM software and retest Circuit functions circuit operation.

RHM is faulted.

55-9

Replace R-04.

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 AUDIO ALARM (H01) The Audio Alarm H01 sounds every time an Alarm or Error message is displayed on the display. Test Point

Good Reading

Possible Cause for Bad Reading

1 Disconnect X057. Measure resist- Measurement of approximately Failure of the speaker. ance between pin A and pin B. 7 ohms. 2 Disconnect connector X026. Mea- Less than 1ohm. sure resistance between pin 18 Proceed to next test point. (388 BK) and pin B on X058.

Open circuit 388 (BK)

3 Disconnect connector X026. Less than 1ohm. Measure resistance between pin 19 Speaker circuit OK. (376 WH) and pin A on X058.

Open circuit 376 (WH)

PARK BRAKE The Park Brake is controlled manually with a switch (S09) 1, on the Right Hand Console (RHC). The Park Brake Switch S09 sends a signal to the RHM. The RHM sends a signal to CCM2. CCM2 sends a signal to the Park Brake Disengage Solenoid L10. When switch S09 is “ON” the Hydrostatic Pump L23 is disabled. The combine must be at a complete stop and the MFH in Neutral for the Park Brake to engage. CCM2 will engage the Park Brake automatically when shifting gears. An indicator will appear on the display and a light on the park brake switch S-09 will illuminate when Park Brake is engaged. The indicator will flash when conditions are not met for the brake to engage. The Park Brake is spring-applied, pressure release.

NOTE: An audible alarm will sound if the Park Brake is not set when the operator gets out of the seat with the engine running and the MFH in neutral. Park Brake Alarms Alarm Code

Description

Priority Check Condition

A0020

Set Parking Brake

High

Engine ON, MFH 2 sec after Operator 0.5 sec after Operator in Neutral, Park out of seat. seated Brake OFF

A0033

Parking Brake ON

Med

Park Brake ON, MFH not in Neutral Engine running

MFH in Neutral

High

Park Brake Switch MFH not in Neutral in Error, Engine Running and Park Brake Engaged

MFH in Neutral

55-10

Activation

Resetting

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 Park Brake Fault Codes The following fault code must be resolved before proceeding to troubleshooting. In many cases, the fault code will direct you to the proper component for repair and resolution. Description

Fault Code E0181-11

Park Brake Disengage Valve Unidentified Failure Code

E0668-04

Park Brake On Switch Shorted to Low Source

E0669-04

Park Brake Off Switch Shorted to Low Source

NOTE: Refer to the appropriate section of the repair manual for troubleshooting fault codes. Park Brake Electrical Component Troubleshooting NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.

WARNING Before performing any of the electrical tests, be sure all operating controls are in neutral or park lock position. This will eliminate accidental movement of the machine or start-up of power driven equipment. Park Brake Switch S09 Park Brake Switch S09 is a rocker switch that applies and releases the Park Brake.

55-11

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 Lamp in Park Brake Switch S09 Test Point

Good Reading

Possible Cause for Bad Reading

Measure resistance between Less than 1 ohm. connector X052 pin 9 (393 BK) and cab ground #3. Proceed to next test point.

Open circuit (393 BK) or failed Park Brake Switch S09.

Measure resistance between Less than 1 ohm. connector X052 pin 10 (355 PU) and pin 8 on connector Proceed to next test point X027.

Open circuit on circuit (355 PU) or failed Park Brake Switch S09.

Reload RHM software and Lamp is functioning properly. retest circuit operation.

RHM has failed. Replace RHM.

Park Brake Switch Test Point

Good Reading

Possible Cause for Bad Reading

1 Using the display monitor diag- OFF, approximately 4.9 volts. nostic capability to view “item” status, reference Section 55 ON, approximately 1.5 volts. Chapter 2, if needed. “Cycle Proceed to next test point. Park Brake off” switch.

Open circuit or short to high source.

2 Using the display monitor diag- ON, approximately 4.9 volts. nostic capability to view “item” status, reference Section 55 OFF, approximately 1.5 volts. Chapter 2, if needed. “Cycle Proceed to next test point. Park Brake on” switch.

Open circuit or short to high source.

3 Measure resistance between Less than 1 ohm. connector X052 pin 1 (335 YE) and pin 1 on connector X029. Proceed to next test point.

Open circuit or short to high source in circuit 335 (YE)

4 Measure resistance between Less than 1 ohm. connector X052 pin 3 (334 YE) and pin 9 on connector X029. Proceed to next test point.

Open circuit or short to high source in circuit 334 (YE)

5 Measure resistance between Less than 1 ohm. connector X052 pin 2 (365 OR) and pin C on connector X054. Proceed to next test point.

Open circuit or short to high source in circuit 365 (OR).

6 Measure resistance between Less than 1 ohm. connector X054 pin M (287 OR) Proceed to next test point. and pin 1 on connector X001.

Open circuit or short to high source in circuit 287 (OR).

Failed Park Brake Switch S09.

7 Reload RHM software and Park Brake Switch S09 and circuits RHM has failed. retest circuit operation. are OK. Replace RHM.

55-12

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 SERVICE BRAKES Service Brake line pressure is sensed by Brake Pressure Switch S39, 1. The signal is sent to CCM2 that activates the Brake Lights Relay K33, which sends power to activate the brake lights.

1 10010876

8 The Service Brake pads monitor wear by using a wire, 1, embedded in the pads that has voltage applied to them. As the pads wear down, the wire becomes exposed, and shorts to ground on the brake rotor, activating an alarm on the display.

Because of the embedded wire in the upper Service Brake pads, the pads are switches with the designation of Left Hand Brake Wear Switch S55 and the Right Hand Brake Wear Switch S56. NOTE: Only the upper brake caliper pads have electrical connectors. 9 Service Brake Alarm Codes Alarm Code

Description

Priority

Check Condition

Activation

A0047

Check Brakes

Med

___________

Input voltage <0.69V Input voltage >0.69V for for 5 seconds due to 10 seconds (circuit not brake pad wear or grounded) brake fluid low

Service Brake Fault Codes The following fault codes must be resolved before proceeding to troubleshooting. In many cases, the fault codes will direct you to the proper component for repair and resolution. Description

Fault Code E0134-03

Brake Pressure sensor Shorted to high source

E0199-11

Brake Lights relay Unidentified Failure Code

NOTE: Refer to the appropriate section of the repair manual for troubleshooting fault codes.

55-13

Resetting

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 GEARSHIFTING The operator rotates the Gear Select Switch S24, 1, on the RHC to the desired transmission gear, either 1- 2- N- 3- 4. This can be done at anytime whether in motion or parked. The actual gear shifting will not start until the MFH is locked in the neutral position, which automatically disables the Hydrostatic Driveline, and the combine stops forward or rearward travel.

1 10 The sequence of the transmission gear shift after the combine travel stops: •

•

• •

The Park Brake starts to be applied. The Park Brake indicator on the display will flash until the Park Brake is applied. The Park Brake indicator on the display will remain lit for the duration of the shift sequence. The Pressure Release Solenoid L05, in the Hydrostat Motor, is activated to equalize the hydraulic pressure to allow the gears to shift. The Transmission Shift Motor M02 begins to turn in the appropriate direction. When the selected gear is engaged, as sensed by Transmission Shift Position Sensor B37, the Transmission Shift Motor M02 stops turning and the Pressure Release Solenoid L05 is deactivated. The Park Brake starts to release. The Hydrostatic Driveline is enabled and driving can resume. The Park Brake indicator going out indicates this.

NOTE: When the Park Brake is engaged with the Park Brake Switch S09 before shifting, the Park Brake will remain on after shifting is completed. The Park Brake is released with Park Brake Switch S09 manually. The gear indicated on the display, in the upper left-hand corner, represents the currently engaged gear. This is detected by Transmission Shift Position Sensor B37, 1. When the gear can not be engaged because of either mechanical reason or failure of the Transmission Shift Position Sensor B37, the software in CCM2 will allow another gear to be selected.

NOTE: Refer to the Operator’s Manual for manual gear shifting procedure. 10004664

55-14

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 Special Conditions CCM2 limits the reverse speed of the Hydrostatic Pump L23 when Transmission Shift Position Sensor B37 indicates 3rd or 4th gear. Gearshift Alarms Description

Alarm Code A0080

Priority

Gearshift Not Suc- Low cessful

Check Condition ___________

Activation

Not able to get to Selected Gear found shift to selected Gear

Gearshift Fault Codes The following fault codes must be resolved before proceeding to troubleshooting. In many cases, the fault codes will direct you to the proper component for repair and resolution. Fault Code

Description

E0128-03

Trans Shift Position N sensor Shorted to high source

E0128-04

Trans Shift Position N sensor Shorted to low source

E0128-05

Trans Shift Position N sensor Line Disconnected

E0129-03

Trans Shift Position 3 sensor Shorted to high source

E0129-04

Trans Shift Position 3 sensor Shorted to low source

E0129-05

Trans Shift Position 3 sensor Line Disconnected

E0130-03

Trans Shift Position 2 sensor Shorted to high source

E0130-04

Trans Shift Position 2 sensor Shorted to low source

E0130-05

Trans Shift Position 2 sensor Line Disconnected

E0131-03

Trans Shift Position 1 sensor Shorted to high source

E0131-04

Trans Shift Position 1 sensor Shorted to low source

E0131-05

Trans Shift Position 1 sensor Line Disconnected

E0132-03

Trans Shift Position 4 sensor Shorted to high source

E0132-04

Trans Shift Position 4 sensor Shorted to low source

E0132-05

Trans Shift Position 4 sensor Line Disconnected

E0171-06

Transmission Shift Current Sense Short Circuit

E0195-11

Pressure Release valve Unidentified Failure Code

E0203-05

Transmission Shift Motor Line Disconnected

E0645-03

Gear Select or Rotary Switch Shorted to High Source

E0645-05

Gear Select or Rotary Switch Line Disconnected

E0645-07

Gear Select or Rotary Switch Mechanical Out of Range

NOTE: Refer to the appropriate section of the repair manual for troubleshooting fault codes.

55-15

Resetting

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 Gear Select Switch S24 Troubleshooting Test Point

Good Reading

Possible Cause for Bad Reading

1 Using the display monitor diag- Approximately 0.5 volts nostic capability to view “item” status, reference Section 55 Proceed to next test point. Chapter 2, if needed. Rotate Gear Select Switch S24 to gear 1.

Short to ground.

2 Using the display monitor diag- Approximately 1.5 volts nostic capability to view “item” status, reference Section 55 Chapter 2, if needed. Rotate Gear Select Switch S24 to gear Proceed to next test point. 2.

Short to ground.

3 Using the display monitor diag- Approximately 2.5 volts nostic capability to view “item” status, reference Section 55 Chapter 2, if needed. Rotate Proceed to next test point. Gear Select Switch S24 to N.

Short to ground.

4 Using the display monitor diag- Approximately 3.4 volts nostic capability to view “item” status, reference Section 55 Chapter 2, if needed. Rotate Gear Select Switch S24 to gear Proceed to next test point. 3.

Short to ground.

5 Using the display monitor diag- Approximately 4.5 volts nostic capability to view “item” status, reference Section 55 Chapter 2, if needed. Rotate Gear Select Switch S24 to gear Proceed to next test point. 4.

Short to ground.

6 Measure resistance between Less than 1 ohm. connectors X048 pin 3 (319 PK) and pin 17 on connector X026 Proceed to next test point. and chassis ground.

Short to ground in circuit 319 (PK).

7 Measure resistance between Less than 1 ohm. connectors X048 pin 2 (391 YE) and pin 11 on connector X027 Proceed to next test point. and chassis ground.

Short to ground in circuit 391 (YE)

8 Reload RHM software and Gear Select Switch S24 OK retest circuit operation.

RHM has failed.

55-16

Failed Gear Select Switch S24.

Replace RHM.

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 GROUND SPEED RPM SENSOR B17 The Ground Speed RPM Sensor B17, 1, is located on the top cover of the transmission and gives input for the read out of the ground speed on the display. The Ground Speed RPM Sensor B17 prevents the activation of the Transmission Shift Motor M02 when value from the sensor is above the threshold value. This avoids gear shifting when the gearbox has components that are in motion. 10004641

1 12

Ground Speed RPM Fault Codes The following fault codes must be resolved before proceeding to troubleshooting. In many cases, the fault codes will direct you to the proper component for repair and resolution. Fault Code

Description

E0142-03

Ground speed sensor Shorted to high source

E0142-04

Ground speed sensor Shorted to low source

E0142-05

Ground speed sensor Line Disconnected

NOTE: Refer to the appropriate section of the repair manual for troubleshooting fault codes.

REAR WHEEL ASSIST (IF EQUIPPED) Rear Wheel Assist (RWA) is the hydro-mechanical system that applies power to the rear wheels providing more traction for the combine. The motors are an extension of the combine’s hydrostatic system. When the operator engages the rear axle, the Equa-Trac II valve, which is mounted on the rear axle beam, allows hydraulic fluid to flow from the hydrostatic pump to the motors on the rear axle. The hydraulic fluid, in turn, powers the motors to rotate the rear wheels. The second valve assists the E-T II valve in draining hydraulic fluid from the motors. 10021843

55-17

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 Using the rear axle provides several advantages: •

Allows the combine hydrostatic system to operate at a lower pressure, thus helping to extend the life of the hydrostatic transmission and geartrain.

•

Reduces the hydraulic fluid temperature because of lower hydrostatic system pressure.

•

Powering the rear wheels provides improved steering response.

•

Additional traction when operating in adverse/ rough field conditions.

Rear Wheel Assist (RWA) is activated with the rocker switch, 1, on the RHC.

1 14 Special Conditions •

•

The Rear Wheel Assist (RWA) Solenoid L26 is disabled when the Transmission Shift Position Sensor B37 detects the transmission is in 4th gear. The Road Mode Switch S12 disables the Rear Wheel Assist Solenoid L26 in all transmission gears to prevent the use of the RWA in Road Mode.

15 S S

55-18

Rear Wheel Assist Switch S10 (If Equipped) ON OFF

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 Rear Wheel Assist Fault Codes The following fault code must be resolved before proceeding to troubleshooting. In many cases, the fault code will direct you to the proper component for repair and resolution. Fault Code

Description

E0066-11

Rear Axle On/Off valve Unidentified Failure Code

NOTE: Refer to the appropriate section of the repair manual for troubleshooting fault codes. NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.

55-19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 Rear Wheel Assist Switch S10 Troubleshooting Test Point

Good Reading

1 Using the display monitor diag- OFF, approximately 1.4 volts. nostic capability to view “item” status, reference Section 55 ON, approximately 5 volts. Chapter 2, if needed. Cycle Switch is OK. switch.

Possible Cause for Bad Reading Open circuit or short to ground. Failed Rear Wheel Assist Switch (SW 4WD On/Off) S10.

2 Disconnect Rear Wheel Assist Switch turned OFF, no reading. (OL) Failed Rear Wheel Assist Switch Switch S10 from connector S10. X051. Measure resistance be- Switch turned ON, Less then 1 ohm. tween pin 2 and pin 3 of switch. Switch is OK. Replace switch. 3 Measure resistance between Less then 1 ohm. connector X051 pin 9 (384 BK) Proceed to next test point. and Cab Ground #3.

Open in circuit 384 (BK).

4 Measure resistance between Less then 1 ohm. connector X051 pin 2 (366 OR) Proceed to next test point. and connector X054 pin D

Open or short to ground in circuit 366 (OR).

5 Measure resistance between Less then 1 ohm. connector X051 pin 3 (336 YE) Proceed to next test point. and connector X029 pin 17.

Open or short to ground in circuit 336 (YE).

6 Reload RHM software and Rear Wheel Assist (SW 4WD On/Off) RHM has failed. retest circuit operation. switch S-10 circuit OK Replace RHM.

55-20

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9 ELECTRICAL SCHEMATICS

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

55-21

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0 L

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

L-01 = NEUTRAL LOCK SOLENOID R-04 = GROUND SPEED POT S-09 = PARK BRAKE S-10 = REAR WHEEL ASSIST

S-11 = DUAL RANGE S-12 = ON THE ROAD SWITCH S-24 = GEAR SELECT

DRIVES FRAME--7

55-22

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

DRIVES FRAME--8

B-46 = HYDROSTAT MOTOR TEMP H-08 = BACK UP ALARM L-05 = PRESSURE RELEASE L-26 = REAR WHEEL ASSIST

L-27 = DUAL RANGE S-49 = BRAKE FLUID LEVEL SWITCH S-55 = LH BRAKE WEAR SWITCH S-56 = RH BRAKE WEAR SWITCH

55-23

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

55-24

S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME--9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-25

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 9

F-48 = RH CONSOLE FUSE H-01 = AUDIO ALARM W-01 = SPLICE BLOCK A W-02 = SPLICE BLOCK B

W-05 = SPLICE BLOCK E W-06 = SPLICE BLOCK F

DISTRIBUTION FRAME--25

55-26

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 10 -- Header Systems CONTENTS Section

Description

Page

55-1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 The combine electronics provide the operator with complete control over all header systems in order to maximize field performance. The header systems can be broken down into three control groups; reel speed, reel position (raise/lower and fore/aft), and header height control.

REEL SPEED The combine is capable of controlling reel speed on headers with two different types of reel drives, either mechanical (vari-speed sheaves) or hydraulic. On headers with mechanical reel drive, the combine controls an actuator that moves a variable sheave on a belt drive to control reel speed. On headers with hydraulic reel drive, the combine is equipped with a hydraulic valve in the feeder stack that provides oil flow to the header reel drive motor; the oil flow may be regulated through the valve to control reel speed. Operator Controls There are several controls and settings that may be made to control the operation of the header reel speed. The reel speed may be controlled manually by using the reel speed control switches on the multifunction handle (MFH). In manual mode, the operator adjusts the reel speed by depressing the reel speed increase, 2, or decrease, 1, switches, and CCM2 adjusts the output to the reel speed valve (hydraulic) or motor (mechanical). The reel may also be controlled automatically by engaging the reel speed synchronization switch, 3, on the console. In this operating mode, the reel speed is synchronized with the ground speed, so that the reel speed changes automatically as the operator changes the operating ground speed of the combine.

NOTE: The reel synchronization switch, 3, has a third, momentary contact position, however, this position has no function at this time. The operator can adjust the amount of ‘offset’ between the reel speed and the ground speed using the reel speed control switches, 1 & 2, on the multifunction handle while in the synchronization mode. Generally, the reel speed would be set to run slightly faster than ground speed in order to pull crop into the header, but it may be desired to run the reel speed significantly faster than ground speed if operating in lodged crop conditions, or about the same speed as ground speed in delicate or over-ripe crop conditions.

55-2

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 Configuration Settings The proper settings must be made in the Configuration screen in order for the reel speed synchronization mode to work properly. Select the Header Setup 2 screen, reference Section 55, Chapter 2 if needed, and adjust the following parameters: Reel Speed Min: a minimum reel speed may be set for the reel speed, so that the reel is turning at a certain speed even when the combine is stopped, or moving very slowly. This may be desired when working in lodged crop conditions. The value may be set between 0 – 10 km/h (0--6 mph) in 0.1 increments.

20072411

Auto Reel Speed Slope: is the relationship between the reel speed and the ground speed, and must be set to match the type of header installed. Select “hydraulic reel” for headers with hydraulic reel drive, “mechanical reel” for headers with mechanical vari-speed drives, and “pick-up reel” for windrow pick-up headers. Reel Speed Offset: is the offset between the reel speed and ground speed. This offset may be preset during header configuration, but will change to match the settings made by the operator using the reel speed increase and decrease switches during operation in synchronization mode. Reel Drive: the proper entry must be made in the Configuration screen to specify which type of reel drive is being used. Select Hydraulic or Mechanical to indicate which type of reel drive is in use on the combine and header. Reel Speed Sensor: must be set as “Installed” if a header with mechanical reel drive is installed, since these headers are equipped with a reel speed sensor for feedback. If a hydraulic reel drive header is being used, set this value to “Not Installed”. 20072412

55-3

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 Fault Codes If the reel drive system is not functioning properly, check for the following fault codes and correct the problem prior to beginning any other troubleshooting. For units with mechanical vari-speed for reel drive only. Auto reel speed synchronization will be disabled. E0141-03 E0141-04 E0141-05

Header Reel RPM sensor Shorted to high source Header Reel RPM sensor Shorted to low source Header Reel RPM sensor Line Disconnected

If these faults appear, auto reel speed synchronization will be disabled. E0142-03 E0142-04 E0142-05

Groundspeed RPM sensor Shorted to high source Groundspeed RPM sensor Shorted to low source Groundspeed RPM sensor Line Disconnected

For units with hydraulic reel drive only. Reel drive will not function. E0186-11

Header Reel Drive valve Unidentified Failure Code

For units with mechanical vari-speed for reel drive only. Reel drive speed cannot be changed. E0169-06 E0204-05

Current Sense Reel Speed Short circuit Header Reel Speed motor Unidentified Failure Code

55-4

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 REEL SPEED TROUBLESHOOTING Symptom: Reel speed cannot be changed in manual mode, or reel speed offset cannot be adjusted. Cause: No signal from reel speed increase or decrease switches on MFH. Possible Failure Modes: 1. Switch failed. 2. Open circuit on switch wiring in MFH. 3. RHM module failure. Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the reel speed increase switch. The “switch” screen should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 2. B.

If the voltage reading is within the proper limits, continue the troubleshooting at step 5.

NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 2 and pin 7, with the black (common) probe of the multimeter on pin 7. Depress the reel speed increase switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 3. 3. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the reel speed decrease switch. The “switch” screen should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 4. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 4. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 10 and pin 7, with the black (common) probe of the multimeter on pin 7. Depress the reel speed decrease switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 5. 5. Use the electronic service tool (EST) to reload the software in the RHM module, and retest the system. If the problem still exists, the RHM has failed. Replace the RHM.

55-5

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-6

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 Symptom: Reel speed synchronization cannot be engaged, or will not disengage. Cause: Constant or no signal from reel speed synchronization switch on the right hand console. Possible Failure Modes: 1. Switch failed. 2. Open circuit on switch wiring in console. 3. Short to high voltage on switch signal wire. 4. RHM module failure. Solution: The reel speed mode switch S08 is a three position switch that connects power to the RHM when in the manual or automatic position, and opens the signal wire when in the center position. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the reel speed synchronization switch. The “switch” screen should show “off” when the switch is in the synchronization position, and “on” when the switch is in the manual position. If the “Voltage” screen is selected, there should be approximately 5.0 volts with the switch in the manual position, and 1.7 volts when the switch is in the automatic position. A. If the voltage is low (1.7 volts) and does not change, continue with Step 2. B. If the voltage is high (5.0 volts) and does not change, continue with Step 9. C. If the voltage reading is within the proper limits, continue the troubleshooting at step 10. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low (1.7 volts) and does not change. Inspect fuse F48. A. If the fuse is okay, continue with Step 3. B. If the fuse has failed, replace the fuse and repeat Step 1. If the fuse immediately fails, there is a short to ground somewhere in the right console switch power circuit. Locate the short and repair. 3. The voltage reading on the display monitor is low (1.7 volts) and does not change. Disconnect connector X040 from the reel speed mode switch S08. Use a multimeter to check for voltage at connector X040 pin 2 wire 362 orange. There should be 12 volts. A. If there is no voltage, continue with Step 4. B. If there is 12 volts, continue with Step 7. 4. The voltage reading on the display monitor is low (1.7 volts) and does not change. Locate the splice block B, W02 in the right hand console. Use a multimeter to check for voltage at splice block B, W02 pin A. There should be 12 volts. A. If there is voltage, there is an open circuit in the right console (RC) harness between connector X040 pin 2 and splice block B, W02 pin A wire 321 orange or 362 orange. Locate the open and repair. B. If there is no voltage, continue with Step 5.

55-7

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 5. The voltage reading on the display monitor is low (1.7 volts) and does not change. Locate the splice block B, W02 in the right hand console. Use a multimeter to check for voltage at splice block B, W02 pin M. There should be 12 volts. A. If there is voltage, there is an open circuit in the splice block B, W02. Locate the open and repair. B. If there is no voltage, continue with Step 6. 6. The voltage reading on the display monitor is low (1.7 volts) and does not change. Disconnect connector X001. Use a multimeter to check for voltage at connector X001 pin 3. There should be 12 volts. A. If there is voltage, there is an open circuit in the right console (RC) harness between splice block B, W02 pin M and connector X001 pin 3 wire 287 orange or 108 orange. Locate the open and repair. B. If there is no voltage, there is an open circuit in the cab main (CM) harness between fuse F48 and connector X001 pin 3 wire 108 orange. Locate the open and repair. 7. The voltage reading on the display monitor is low (1.7 volts) and does not change. Position the reel speed mode switch S08 in the “Off” or “Manual” position. Disconnect connector X029 from the RHM module. Use a multimeter to check for voltage at connector X029 pin 10 wire 333 yellow. There should be 12 volts. A. If there is no voltage, continue with Step 8. B. If there is 12 volts, continue with Step 10. 8. The voltage reading on the display monitor is low (1.7 volts) and does not change. Disconnect connector X040 from the reel speed mode switch S08 and connector X029 from the RHM module. Use a multimeter to check for continuity between connector X040 pin 1 and connector X029 pin 10 wire 333 yellow. There should be continuity. A. If there is no continuity, there is an open circuit in the right console (RC) harness between connector X040 pin 1 and connector X029 pin 10 wire 333 yellow. Locate the open and repair. B. If there is continuity, the reel speed mode switch S08 is not functioning. Replace the switch. 9. The voltage reading on the display monitor is high (5.0 volts) and does not change. Key on. Disconnect connector X040 from the reel speed mode switch S08. Use a multimeter to check for voltage on connector X040 pin 1 wire 333 yellow. There should be approximately 1.7 volts. A. If the voltage is high (>5.0 volts), there is an short circuit in the right console (RC) harness between connector X040 pin 1 and connector X029 pin 10 wire 333 yellow. Locate the short and repair. B. If there is approximately 1.7 volts, the circuit is functioning properly. Continue with Step 10. 10. Use the electronic service tool (EST) to reload the software in the RHM module, and retest the system. If the problem still exists, the RHM has failed. Replace the RHM.

55-8

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

F-48 = RH CONSOLE FUSE H-01 = AUDIO ALARM W-01 = SPLICE BLOCK A W-02 = SPLICE BLOCK B

W-05 = SPLICE BLOCK E W-06 = SPLICE BLOCK F

DISTRIBUTION FRAME--25

55-10

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 REEL POSITION The combine is equipped with control circuits to control the reel height and fore/aft positioning on headers equipped with reels, or to control the deck plate opening on corn headers with hydraulic deck plate adjustment. Operator Controls The operator may control the reel position using the four way rocker pad, 1, on the multifunction handle (MFH) that activates four different switches. The top of the pad controls reel raise, the bottom controls reel lower, the left controls reel fore, and the right controls reel aft positioning.

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When the operator depresses one of these switches, a signal is transmitted to the RHM module in the right hand console. The RHM module transmits this information on the CAN network to the CCM2 module, which activates the appropriate solenoid on the feeder valve stack. Some headers may also be equipped with sensors that monitor the vertical and horizontal positioning of the reel. These sensors allow the CCM2 module to directly control the reel positioning under some circumstances without the direct involvement of the operator. These sensors allow the CCM2 module to automatically lower the reel, and move it rearward to sweep the cutter bar clean of crop when the header is raised at the headland of the field (header is raised above the maximum stubble height defined in calibration). In addition, these sensors allow the operator to set the reel positioning as part of the Automatic Crop Settings function on the combine. Configuration Settings Reel Fore-Aft; must be set as “Installed” if header installed on the combine is equipped with reel fore and aft cylinders, or if it is a corn head with hydraulic adjustable deck plates.

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55-11

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 Fault Codes If the reel positioning system is not functioning properly, check for the following fault codes and correct the problem prior to beginning any other troubleshooting. E0185-11 E0189-11

Reel Fore Valve Unidentified Failure Code Reel Aft Valve Unidentified Failure Code

E0187-11 E0188-11

Reel Raise Valve Unidentified Failure Code Reel Lower Valve Unidentified Failure Code

E0688-04 E0688-07

Reel Fore Switch – Shorted to Low Source Reel Fore Switch – Mechanical Out of Range

E0689-04 E0689-07

Reel Lower Switch – Shorted to Low Source Reel Lower Switch – Mechanical Out of Range

E0690-04 E0690-07

Reel Raise Switch – Shorted to Low Source Reel Raise Switch – Mechanical Out of Range

E0692-04 E0692-07

Reel Aft Switch – Shorted to Low Source Reel Aft Switch – Mechanical Out of Range

55-12

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 REEL POSITIONING TROUBLESHOOTING Symptom: Reel will not raise or lower. Cause: No signal from reel raise or lower switches on MFH. Possible Failure Modes: 1. Switch failed. 2. Open circuit on switch wiring in MFH. 3. RHM module failure. Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the reel raise switch. The “switch” screen should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 4 and pin 7, with the black (common) probe of the multimeter on pin 7. Depress the reel raise switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 3. 3. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the reel lower switch. The “switch” screen should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 4. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 4. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 11 and pin 7, with the black (common) probe of the multimeter on pin 7. Depress the reel lower switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 5. 5. Use the electronic service tool (EST) to reload the software in the RHM module, and retest the system. If the problem still exists, the RHM has failed. Replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-14

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 Symptom: Reel will not move fore or aft. Cause: No signal from reel fore or aft switches on MFH. Possible Failure Modes: 1. Switch failed. 2. Open circuit on switch wiring in MFH. 3. RHM module failure. Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the reel fore switch. The “switch” screen should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 5 and pin 7, with the black (common) probe of the multimeter on pin 7. Depress the reel fore switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 3. 3. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the reel aft switch. The “switch” screen should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 4. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 4. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 9 and pin 7, with the black (common) probe of the multimeter on pin 7. Depress the reel aft switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 5. 5. Use the electronic service tool (EST) to reload the software in the RHM module, and retest the system. If the problem still exists, the RHM has failed. Replace the RHM.

55-15

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-16

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 HEADER HEIGHT CONTROL The combine is equipped with control circuits to control the header height and lateral tilt positioning. Operator Controls The operator may control the header position using the four way rocker pad, 1, on the multifunction handle (MFH) that activates four different switches. The top of the pad controls head raise, the bottom controls head lower, the left controls head tilt CCW, and the right controls head tilt CW positioning. The header raise and lower switches are two position switches, which offers two speeds of raise and lower. When the switch is depressed to the first position, the head will raise or lower slowly, and when depressed further to the second position, the head will raise or lower quickly.

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NOTE: The slow raise rate and the fast lower rate may be adjusted in the “Header” configuration screen. When the operator depresses one of these switches, a signal is transmitted to the RHM module in the right hand console. The RHM module transmits this information on the CAN network to the HHC module, which activates the appropriate solenoid on the main valve stack (header lift) or feeder valve stack (header tilt). The Resume switch, 1, on the MFH is used by the operator for enabling the automatic header height modes. The automatic mode that is enabled must first be set using the Head Height Mode switch, 2, which is a three position switch. Positions 1 and 2 may be programmed for Stubble Height or Autofloat operation, while the third position is intended to be programmed for Pressure Compensation operation.

NOTE: The threshing and feeder systems must be engaged in order for the automatic header height systems to be engaged. The operator engages the selected mode by pressing the Resume switch on the MFH once; the head will then lower to the pre-selected position based on the setting of the Head Height Mode switch. While in the automatic mode, the operator may switch between the different modes simply by switching the Head Height Mode switch. The automatic modes are disengaged whenever the operator manually raises the header above the maximum stubble height that has been calibrated, or when the operator double-presses the Resume switch, which causes the header to automatically raise to the maximum stubble height.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 Header Height Sensors Several sensors on the combine and header provide information to the HHC module to provide for automatic header height control functions, as follows: •

Feeder Angle sensor, 1, is a potentiometer which provides information to the HHC module regarding the precise position of the feeder housing relative to the combine frame. This information is used for determining minimum and maximum stubble height.

40025215

8 •

Header Lift Pressure sensor, 1, is mounted in the main valve stack, and monitors the pressure in the lift cylinder supply line. This information is used for the header compensation system.

10020031

9 •

Stubble Height (Autofloat) sensors, 1, are mounted on the header, and are connected to the sense bars on the flexible header, or to the protection plates on rigid headers. These sensors provide precise feedback about the header clearance to the ground within a specific operating range.

50023023

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 In addition, signals are used from other components on the combine in order to control the header height system. Feeder Engage Switch must be engaged, and provide voltage to CCM1 before any of the automatic header height modes may be engaged. Note that the Threshing Engage switch must be engaged first to provide voltage to the Feeder Engage switch. Ground Speed sensor is mounted in the combine transmission, and provides a signal to CCM2 for ground speed calculations. The ground speed information is used when operating in a header height mode in order to adjust the amount of header height corrections, preventing overcorrecting and “hunting”. If the combine is equipped with lateral tilt, the combine will be equipped with a Lateral Tilt sensor to monitor the movement of the feeder faceplate. This sensor provides a signal which is used for lateral tilt position display on the display monitor only; this signal is not used by the header height control system for header control. Calibration There are several calibrations that must be completed each time a head is installed on the combine in order to ensure proper operation of the header height control systems. NOTE: To perform calibrations, follow the procedure specified in the Operator’s manuals. Header: The ‘Header’ calibration needs to be completed whenever a header is changed on the combine, to ensure that the correct settings are stored for the following values: • Ground position: This calibration stores the Feeder Angle sensor signal at this position. If the head is equipped with stubble height sensors, then the signals from these sensors are recorded also. • Pressure signal above soil: This calibration is essentially recording the “weight” of the head so that the system can recognize when the head makes contact with the ground. • Maximum lift height: This records the maximum possible lift height, and helps establish the operating range of the Feeder Angle sensor. Maximum Work Height: This setting would typically be the height the header would be raised to when turning on the headland. The signal from the Feeder Angle sensor, and the Stubble Height sensors (if equipped) is recorded for this setting.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 Configuration Settings There are a number of settings that need to be made in the “Header” configuration menu to ensure proper operation of the header height systems. HHC Raise Rate: the manual slow raise speed may be set to the speed desired by the operator. HHC Lower Rate: the manual fast lower speed may be set to the speed desired by the operator. HHC Threshold Level: this setting determines when the header height control system should switch into the compensation mode if the header contacts the ground. In general, this setting is best left at the factory setting.

20072414

Autofloat: must be set as “Installed” if Autofloat sensors are installed on the header. Maximum Work Height: displays a relative value to indicate the maximum stubble height that has been currently calibrated. Auto Header Lift: must be set as “Installed” if using a header at low cutting heights or in Compensation mode. When installed, the header will raise off the ground automatically if the combine is driven in reverse to protect header components. Header Lateral Tilt: must be set as “Installed” if header height control is installed on the combine.

20072415

13 Head Accumulator Operation The combine is equipped with an accumulator, 1, which is connected to the header lift cylinders through an accumulator control valve. This valve is used to ‘connect’ or ‘disconnect’ the accumulator from the header lift circuit as required for proper operation.

40025225

55-20

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 In most cases, the accumulator valve will be positioned to connect the accumulator to the cylinders, however, the accumulator is disconnected in the following conditions: •

Head Raise switch depressed; the accumulator is switched off for 2 seconds

•

Head Lower switch depressed; the accumulator is switched off for 2.5 seconds

•

Stubbleheight mode engaged; the accumulator is switched off for 2 seconds

•

Autofloat mode engaged; the accumulator is switched off for 4 seconds

Header Operating Modes – Dynamic Ride Control Dynamic Ride Control is automatically engaged and disengaged by the HHC module whenever necessary, and is not controlled by the operator. In this mode, the HHC module evaluates the signals from the header lift pressure sensor, and makes slight adjustments to header raise and lower as necessary to dampen any oscillations in header movement, such as when travelling over rough ground. By actively damping header oscillations, bouncing oscillations are reduced, steering safety is improved, operator comfort is improved, and stress loads on the combine and header frames are reduced.

•

Pressure Compensation mode engaged; the accumulator is switched off for 2 seconds

In order for Dynamic Ride Control to be engaged, several conditions must be met:

NOTE: During engagement of an automatic header height mode, if the header reaches a position close to the ground, or contacts the ground, the accumulator is switched on immediately.

•

Accumulator must be switched on

•

Feeder Angle sensor must be functioning (no errors)

If an automatic mode is not selected, and the header lift pressure signal drops below half of the recorded pressure signal (header weight), the accumulator stays switched off as long as the pressure is reduced. This would typically occur when a header is removed from the combine.

•

Header Lift Pressure sensor must be functioning (no errors)

•

If feeder is disengaged, Dynamic Ride Control is active irregardless of header position.

•

If feeder is engaged, Dynamic Ride Control is active only when header is above Maximum Stubble Height (defined by operator in Calibration screen)

•

If an automatic mode is not selected, and the header lift pressure signal increases above 180 bar (2646 psi), the accumulator stays switched off until the pressure drops below this level. This would typically occur when the header is raised to the maximum lift height.

55-21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 Header Operating Modes -- Transport The Transport mode is the default operating header height control mode, and allows the operator to make manual adjustments to the header position using the control switches, 1. This mode is automatically selected whenever the feeder drive is disengaged, and remains active with the feeder drive engaged until one of the automatic header height modes is engaged. The accumulator is turned on in this mode. The header position selected by the operator will be maintained by the HHC module. If necessary, the header raise valve will activate to make up for any leakage in the header lift circuit, as monitored by the feeder angle sensor.

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Dynamic Ride Control is active in the Transport mode in all header positions if the feeder drive is not engaged, but if the feeder is engaged, it is active above Maximum Stubble Height position only. When the Road-Field mode switch on the RH console is moved to the ‘Road’ position, and the header raise switch is pressed, the header will automatically raise to an appropriate height for road transport. The header control switches are then disabled until the ‘Field’ mode is selected. Header Operating Modes – Stubble Height NOTE: The feeder drive must be engaged in order for Stubble Height operating mode to be selected. The stubble height mode allows an operator to set a specific operating height for the head, and return to that height repeatedly. To engage the stubble height mode, the operator positions the Header Height Mode switch, 1, to the forward or mid position, and presses the ‘Resume’ switch, 2, on the MFH once. The header will automatically lower to the previously set operating height. If the operator depresses the ‘Resume’ switch twice quickly, the header will raise from the set operating height to just above the Maximum Stubble Height position for turning on the headland. Depressing the Resume switch once will reposition the head back to the set operating height. The operator may change the set height at any time by depressing the head raise slow or head lower slow switches, 3, to position the head at the desired operating height, and then depress the Resume switch for 2 seconds to ‘memorize’ the new operating height. NOTE: The effective operating range of the Stubble Height mode is from 2% below the operator-specified maximum stubble height to 2% below the calibrated ground level.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 If the header contacts the ground while in the Stubble Height mode (determined based on a drop of header pressure signal), the combine will automatically raise the head as required to maintain minimum ground pressure to avoid bulldozing and to prevent damage to the head. Dynamic Ride Control is not active when the Stubble Height mode is engaged. However, pressing the “Up” or “Down” push-button will override the Automatic Mode causing the damping–control--loop to go active and the lateral-control--loop to go off as long as Override is in effect. Override stays in effect until the Resume switch on the MFH is depressed. Header Operating Modes -- Autofloat NOTE: The feeder drive must be engaged in order for the Autofloat operating mode to be selected. If the header being used on the combine is equipped with Autofloat sensors, the header height control system on the combine may be operated in the Autofloat mode. The Autofloat mode allows an operator to set a specific operating height for the head, and return to that height repeatedly. In addition, the combine will automatically adjust the header height based on feedback from the header Autofloat sensors to maintain that specific operating height relative to the ground surface. To engage the Autofloat mode, the operator positions the Header Height Mode switch, 1, to the forward or mid position, and presses the ‘Resume’ switch, 2, on the MFH once. The header will automatically lower until the header sensors contact the ground, and the previously set operating height is reached. If the operator depresses the ‘Resume’ switch twice quickly, the header will raise from the set operating height to just above the Maximum Stubble Height position for turning on the headland. Depressing the Resume switch once will reposition the head back to the set operating height. The operator may change the set height at any time by depressing the head raise slow or head lower slow switches, 3, to position the head at the desired operating height, and then depress the Resume switch for 2 seconds to ‘memorize’ the new operating height. If the combine is equipped with lateral tilt, the header tilt will also be controlled automatically by adjusting the header tilt to get the same distance to the ground from both Autofloat sensors on the head. The automatic lateral tilt control remains active during changes in the operating height made by the operator. The operator may also temporarily override the automatic lateral tilt by depressing the head tilt left or right switches, 3; the automatic lateral tilt control will resume after the operator releases the switch. NOTE: The operating height range in the Autofloat mode is limited to the operational range of the header sensors.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 If the header contacts the ground while in the Autofloat mode (determined based on a drop of header pressure signal), the combine will automatically raise the head as required to maintain minimum ground pressure to avoid bulldozing and to prevent damage to the head. Dynamic Ride Control is not active when the Autofloat mode is engaged. However, pressing the “Up” or “Down” push-button will override the Automatic Mode causing the damping–control--loop to go active and the lateral-control--loop to go off as long as Override is in effect. Override stays in effect until the Resume switch on the MFH is depressed. Header Operating Modes – Pressure Compensation NOTE: The feeder drive must be engaged in order for the Pressure Compensation operating mode to be selected. The pressure compensation mode allows an operator to operate a head in contact with the ground surface at a specific surface pressure. As the combine and head move through the field, the combine monitors the hydraulic pressure in the header lift cylinders, and raises or lowers the head as required to maintain the pressure set by the operator. To engage the pressure compensation mode, the operator positions the Header Height Mode switch, 1, to the rearward position, and presses the ‘Resume’ switch, 2, on the MFH once. The header will automatically lower to the ground until the desired ground pressure is reached. If the operator depresses the ‘Resume’ switch twice quickly, the header will raise from the ground to just above the Maximum Stubble Height position for turning on the headland. Depressing the Resume switch once will reposition the head back to the ground at the set ground pressure. The operator may change the ground pressure at any time by depressing the head raise slow or head lower slow switches, 3, to position the head at the desired ground pressure, and then depress the Resume switch for 2 seconds to ‘memorize’ the new pressure value. The operating range for the pressure compensation is based on a percentage range of the calibrated pressure signal above the soil for that head. The range is set at 6% greater than to 25% less than the calibrated pressure signal for that head. It is important to understand that the friction in the feeder pivot and lift cylinders must be overcome in order for a pressure change to be detected in the header lift circuit and the system to provide an adjustment – the sensitivity of the Pressure Compensation system is limited by this amount of friction.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 If the combine is equipped with lateral tilt, and the head is equipped with Autofloat sensors, the header tilt will also be controlled automatically by adjusting the header tilt to get the same distance to the ground from both Autofloat sensors on the head. The automatic lateral tilt control remains active during changes in the head ground pressure made by the operator. The operator may also temporarily override the automatic lateral tilt by depressing the head tilt left or right switches, 3; the automatic lateral tilt control will resume after the operator releases the switch. If the header loses contacts with the ground while in the Pressure Compensation mode (determined based on a rise of header height above the ground position as measured by the head Autofloat sensors), the combine will automatically lower the head as required to maintain the desired ground. This will occur only if the head is equipped with Autofloat sensors. Dynamic Ride Control is not active when the Pressure Compensation mode is engaged. However, pressing the “Up” or “Down” push-button will override the Automatic Mode causing the damping–control--loop to go active and the lateral-control--loop to go off as long as Override is in effect. Override stays in effect until the Resume switch on the MFH is depressed.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 Fault Codes If the header height control system is not functioning properly, check for the following fault codes and correct the problem prior to beginning any other troubleshooting. E0029-03 E0029-04

Header Lateral Tilt Sensor -- Shorted to High Source Header Lateral Tilt Sensor -- Shorted to Low Source

E0047-03 E0047-04

Voltage Supply Feeder Clutch -- Shorted to High Source Voltage Supply Feeder Clutch -- Shorted to Low Source

E0080-12

HHC Module Bad Intelligent Device

E0142-03 E0142-04 E0142-05

Ground Speed Sensor -- Shorted to High Source Ground Speed Sensor -- Shorted to Low Source Ground Speed Sensor – Line Disconnected

E0512-05

Feeder Angle Sensor Line Disconnected

E0513-05

Header Lift Pressure Sens Line Disconnected

E0514-05 E0515-05

R Stubble Height / Flex R Line Disconnected L Stubble Height / Flex L Line Disconnected

E0516-11 E0517-11

Lateral Float CCW Valve Unidentified Failure Code Lateral Float CW Valve Unidentified Failure Code

E0518-11 E0519-11

Header Up valve Unidentified Failure Code Header Down valve Unidentified Failure Code

E0649-04

Switch Hhc Auto Height Mode 1 and 2 – Shorted to Low Source

E0653-04

Switch Compensation Mode – Shorted to Low Source

E0695-04 E0695-07

Header Tilt Counter Clockwise Switch -- Shorted to Low Source Header Tilt Counter Clockwise Switch -- Mechanical Out of Range

E0696-04 E0696-07

Header Lower Fast Switch -- Shorted to Low Source Header Lower Fast Switch -- Mechanical Out of Range

E0697-04 E0697-07

Header Raise Slow Switch -- Shorted to Low Source Header Raise Slow Switch -- Mechanical Out of Range

E0698-04 E0698-07

Header Raise Fast Switch -- Shorted to Low Source Header Raise Fast Switch -- Mechanical Out of Range

E0699-04 E0699-07

Hhc Resume Switch -- Shorted to Low Source Hhc Resume Switch -- Mechanical Out of Range

E0700-04 E0700-07

Header Tilt CW Switch -- Shorted to Low Source Header Tilt CW Switch -- Mechanical Out of Range

E0701-04 E0701-07

Header Lower Slow Switch -- Shorted to Low Source Header Lower Slow Switch -- Mechanical Out of Range

55-26

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 HEADER HEIGHT CONTROL TROUBLESHOOTING Symptom: Header will not raise or lower manually. NOTE: Check for all active alarms and errors and correct before following this troubleshooting procedure. Cause: No signal from head raise or lower switches on MFH. Possible Failure Modes: 1. Switch failed. 2. Open circuit on switch wiring in MFH. 3. RHM module failure. Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the header raise slow switch. The “switch” screen should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 3. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 4 and pin 6, with the black (common) probe of the multimeter on pin 6. Depress the header raise slow switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 3. 3. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the header raise fast switch to the second position. The “switch” screen should show “on” when the switch is fully depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 4. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 4. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 10 and pin 6, with the black (common) probe of the multimeter on pin 6. Fully depress the header raise fast switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 5.

55-27

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 5. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the header lower slow switch. The “switch” screen should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 6. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 7. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 6. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 8 and pin 6, with the black (common) probe of the multimeter on pin 6. Depress the header lower slow switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 7. 7. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, and monitor the display while cycling the header lower fast switch to the second position. The “switch” screen should show “on” when the switch is fully depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 8. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 9. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 8. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 11 and pin 6, with the black (common) probe of the multimeter on pin 6. Fully depress the header lower fast switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 9. 9. Use the electronic service tool (EST) to reload the software in the RHM module, and retest the system. If the problem still exists, the RHM has failed. Replace the RHM.

55-28

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-29

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 Symptom: Head will not tilt left or right. NOTE: Check for all active alarms and errors and correct before following this troubleshooting procedure. Cause: No signal from head tilt left or tilt right switches on MFH. Possible Failure Modes: 1. Switch failed. 2. Open circuit on switch wiring in MFH. 3. RHM module failure. Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the head tilt counter clockwise switch. The “switch” screen should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 5 and pin 6, with the black (common) probe of the multimeter on pin 6. Depress the head tilt counter clockwise switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 3. 3. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the head tilt CW switch. The “switch” screen should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 4. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 4. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 2 and pin 6, with the black (common) probe of the multimeter on pin 6. Depress the head tilt CW switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 5. 5. Use the electronic service tool (EST) to reload the software in the RHM module, and retest the system. If the problem still exists, the RHM has failed. Replace the RHM.

55-30

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-31

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 Symptom: One or more of the header height operating modes cannot be engaged or disengaged. NOTE: Check for all active alarms and errors and correct before following this troubleshooting procedure. Cause: Constant or no signal from header height mode switch on the right hand console. Possible Failure Modes: 1. Switch failed. 2. Open circuit on switch wiring in console. 3. Short to high voltage on switch signal wires. 4. RHM module failure. Solution: The header height mode switch S04 is a three position switch that momentarily connects power to the RHM connector X029 pin 3 when in Stubble Height/Autofloat position 1, opens both signal wires when in Stubble Height/Autofloat position 2, or connects power to the RHM connector X029 pin 11 when in Pressure Compensation position. If the switch, signal or supply wiring fails open, the unit will operate in Stubble Height/Autofloat position 2 mode continuously. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, and monitor the display while cycling the header height mode switch. The “switch” screen should show “off” when the switch is in Stubble Height/Autofloat position 2 (mid position), and “on” when the switch is in Stubble Height/Autofloat position 1 (forward position). If the “Voltage” screen is selected, there should be approximately 5.0 volts with the switch in Stubble Height/Autofloat position 1 (forward), and 1.7 volts when the switch is in Stubble Height/Autofloat position 2 (mid). A. If the voltage is low (1.7 volts) and does not change, continue with Step 2. B. If the voltage is high (5.0 volts) and does not change, continue with Step 12. C. If the voltage reading is within the proper limits, continue the troubleshooting at step 2. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the header height mode switch. The “switch” screen should show “off” when the switch is in Stubble Height/Autofloat position 2 (mid position), and “on” when the switch is in Pressure Compensation (rearward position). If the “Voltage” screen is selected, there should be approximately 5.0 volts with the switch in Pressure Compensation (rearward position), and 1.7 volts when the switch is in Stubble Height/Autofloat position 2 (mid). A. If the voltage is low (1.7 volts) and does not change for either or both signal wires, continue with Step 3. B. If the voltage is high (5.0 volts) and does not change, continue with Step 13. C. If the voltage readings for both signal wires are within the proper limits, continue the troubleshooting at step 14. 3. The voltage reading on the display monitor is low (1.7 volts) and does not change. Inspect fuse F48. A. If the fuse is okay, continue with Step 4. B. If the fuse has failed, replace the fuse and repeat Steps 1 & 2. If the fuse immediately fails, there is a short to ground somewhere in the right console switch power circuit. Locate the short and repair.

55-32

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 4. The voltage reading on the display monitor is low (1.7 volts) and does not change. Disconnect connector X061 from the header height mode switch S04. Use a multimeter to check for voltage at connector X061 pin 2 wire 361 orange. There should be 12 volts. A. If there is no voltage, continue with Step 5. B. If there is 12 volts, continue with Step 8. 5. The voltage reading on the display monitor is low (1.7 volts) and does not change. Locate the splice block B, W02 in the right hand console. Use a multimeter to check for voltage at splice block B, W02 pin H. There should be 12 volts. A. If there is voltage, there is an open circuit in the right console (RC) harness between connector X061 pin 2 and splice block B, W02 pin H wire 361 orange. Locate the open and repair. B. If there is no voltage, continue with Step 6. 6. The voltage reading on the display monitor is low (1.7 volts) and does not change. Locate the splice block B, W02 in the right hand console. Use a multimeter to check for voltage at splice block B, W02 pin M. There should be 12 volts. A. If there is voltage, there is an open circuit in the splice block B, W02. Locate the open and repair. B. If there is no voltage, continue with Step 7. 7. The voltage reading on the display monitor is low (1.7 volts) and does not change. Disconnect connector X001. Use a multimeter to check for voltage at connector X001 pin 3. There should be 12 volts. A. If there is voltage, there is an open circuit in the right console (RC) harness between splice block B, W02 pin M and connector X001 pin 3 wire 287 orange or 108 orange. Locate the open and repair. B. If there is no voltage, there is an open circuit in the cab main (CM) harness between fuse F48 and connector X001 pin 3 wire 108 orange. Locate the open and repair. 8. The voltage reading on the display monitor is low (1.7 volts) and does not change. Position the header height mode switch S04 in Stubble Height/Autofloat position 1. Disconnect connector X029 from the RHM module. Use a multimeter to check for voltage at connector X029 pin 3 wire 330 yellow. There should be 12 volts. A. If there is no voltage, continue with Step 9. B. If there is 12 volts, continue with Step 10. 9. The voltage reading on the display monitor is low (1.7 volts) and does not change. Disconnect connector X061 from the header height mode switch S04 and connector X029 from the RHM module. Use a multimeter to check for continuity between connector X061 pin 3 and connector X029 pin 3 wire 330 yellow. There should be continuity. A. If there is no continuity, there is an open circuit in the right console (RC) harness between connector X061 pin 3 and connector X029 pin 3 wire 330 yellow. Locate the open and repair. B. If there is continuity, the header height mode switch S04 is not functioning. Replace the switch. 10. The voltage reading on the display monitor is low (1.7 volts) and does not change. Position the header height mode switch S04 in the Pressure Compensation position. Disconnect connector X029 from the RHM module. Use a multimeter to check for voltage at connector X029 pin 11 wire 331 yellow. There should be 12 volts. A. If there is no voltage, continue with Step 11. B. If there is 12 volts, continue with Step 14. 11. The voltage reading on the display monitor is low (1.7 volts) and does not change. Disconnect connector X061 from the header height mode switch S04 and connector X029 from the RHM module. Use a multimeter to check for continuity between connector X061 pin 1 and connector X029 pin 11 wire 331 yellow. There should be continuity. A. If there is no continuity, there is an open circuit in the right console (RC) harness between connector X061 pin 1 and connector X029 pin 11 wire 331 yellow. Locate the open and repair. B. If there is continuity, the header height mode switch S04 is not functioning. Replace the switch.

55-33

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10 12. The voltage reading on the display monitor is high (5.0 volts) when the header mode switch S04 is in Stubble Height/Autofloat position 1, and does not change. Key on. Disconnect connector X061 from the header height mode switch S04. Use a multimeter to check for voltage on connector X061 pin 3 wire 330 yellow. There should be approximately 1.7 volts. A. If the voltage is high (>5.0 volts), there is an short circuit in the right console (RC) harness between connector X061 pin 3 and connector X029 pin 3 wire 330 yellow. Locate the short and repair. B. If there is approximately 1.7 volts, the circuit is functioning properly. Continue with Step 10. 13. The voltage reading on the display monitor is high (5.0 volts) when the header mode switch S04 is in the Pressure Compensation position, and does not change. Key on. Disconnect connector X061 from the header height mode switch S04. Use a multimeter to check for voltage on connector X061 pin 1 wire 331 yellow. There should be approximately 1.7 volts. A. If the voltage is high (>5.0 volts), there is an short circuit in the right console (RC) harness between connector X061 pin 1 and connector X029 pin 11 wire 331 yellow. Locate the short and repair. B. If there is approximately 1.7 volts, the circuit is functioning properly. Continue with Step 14. 14. Use the electronic service tool (EST) to reload the software in the RHM module, and retest the system. If the problem still exists, the RHM has failed. Replace the RHM.

55-34

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-35

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 10

F-48 = RH CONSOLE FUSE H-01 = AUDIO ALARM W-01 = SPLICE BLOCK A W-02 = SPLICE BLOCK B

W-05 = SPLICE BLOCK E W-06 = SPLICE BLOCK F

DISTRIBUTION FRAME--25

55-36

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 11 -- Feeder Systems CONTENTS Section

Description

Page

55-1

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 DESCRIPTION OF OPERATION The Feeder System consist of the following systems: Feeder Engage Feeder Variable Speed Feeder Reverser ASP (Advanced Stone Protection) System

FEEDER ENGAGE The feeder uses logic to prevent damage to the mechanical components of the system. Operation of the feeder system is quite simple. With the thresher engaged, the operator simply raises the Feeder Engage Switch, 1, to activate the Feeder.

5 3

To deactivate the feeder, the operator can depress the Engage switch, 1, or hold in the Emergency stop button, 2. When the emergency stop button, 2, on MFH is depressed for a few seconds the feeder will stop and the stone door will kick open. Raise the feeder to close the stone door. Once the sensor senses that the door is closed, the cylinder will release, latching the stone door.

1 2

Feeder Engagement Requirements Although Feeder engagement is simple, there are many conditions that must be met in order to activate the feeder. These conditions are monitored by the electrical system on the combine. It is important to understand all of these conditions to troubleshoot concerns with the Feeder System. •

The Thresher Switch, 3, must be in the “on” position.

•

The Reverser switch, 4, must be in the “off” position. If the operator tries to engage the feeder when the Reverser is engaged, an Alarm message is generated.

•

The Road/Field Mode switch, 5, must be in the “FIELD” position.

•

The Feeder Engage Switch, 1, must be in the “on” position. Power through the feeder engage switch, 1, on the right console to CCM is also used for output to the feeder engage solenoid (just like thresher system). In the event that power through the switch is lost, the output is also immediately lost and power stops traveling to the feeder.

•

The feeder drive ties into the Operator Presence switch in the seat – if the operator gets out of the seat for a brief period, the feeder drive is disengaged. This generates an alarm message within the display monitor.

20030010

55-2

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 Conditions that Prevent Feeder Engagement • Thresher not activated before attempting to engage Feeder. • Reverser switch in the “On” position. • Field Switch in “Road” Mode. • Feeder Engage Switch in the “On” position during engine startup. Feeder Engage Switch must be cycled to “Off” and then “On” for activation. • Seat Switch “Open” (no operator in seat) for 5 Seconds or more. • Emergency stop switch on MFH activated. • Stone Trap Door Open Feeder Engage – Alarms Description

Error A0014

Feeder Reverser Engaged

A0015

Seat Switch Open

Feeder Engage – Error Codes Error Code

Description

Result

E0000-03

Stone trap door sensor – Shorted to high source

Feeder will not engage

E0000-04

Stone trap door sensor – Shorted to low source

Feeder will not engage

E0000-05

Stone trap door sensor – Line Disconnected

Feeder will not engage

E0004-03

Feeder Reverser Disengage Sensor Shorted to high source Will not affect operation

E0004-04

Feeder Reverser Disengage Sensor Shorted to low source

Will not affect operation

E0004-05

Feeder Reverser Disengage Sensor Line Disconnected

Will not affect operation

E0047-03

Voltage Supply Feeder Clutch Shorted to high source

Feeder will not engage

E0047-04

Voltage Supply Feeder Clutch Shorted to low source

Feeder will not engage

E0050-03

Current Sense Feeder Clutch Shorted to high source

Feeder will not engage

E0052-11

Feeder Clutch valve Unidentified Failure Code

Feeder will not engage

E0140-04

Operator seat switch – Shorted to low source

Feeder will not engage

E0175-03

Voltage supply thresher clutch -- Shorted to high source

Will not affect operation

E0175-04

Voltage supply thresher clutch -- Shorted to low source

Feeder will not engage

E0646-04

Feeder reverser switch -- Shorted to low source

Will not affect operation

E0654-04

Road mode switch -- Shorted to low source

Will not affect operation

E0654-07

Road mode switch – Mechanical out of range

E0694-04

Emergency stop switch -- Shorted to low source

E0694-07

Emergency stop switch -- Mechanical out of range

55-3

Will not affect operation

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 Feeder Engage Circuit Power to the feeder engage switch S-31 is supplied from pin 5 of the Thresher switch S-30 whenever the combine engine is running and the Thresher is Engaged. Current flows to pin 6 of the Feeder engage switch. When the Feeder engage switch S-31 is moved to the “On” position, current flows from pin 5, through connector X001 to reach pin 15 to reach pin J1-7 of CCM-1. When the power from the feeder engage switch reaches pin J1-7 of CCM-1, current is sent from pin J2-30 to reach the Feeder Clutch (pin 1). The solenoid within the Feeder Clutch L-24 begins to engage. CCM-1 monitors current flowing from pin 2 of the feeder clutch to pin J2-40. Refer to chapter 18 CCM1 “Fault Codes” for more information on the feeder clutch.

55-4

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11

FEEDER FRAME--16

B-09 = REVERSER DISENGAGE B-14 = FEEDER RPM B-24 = STONE DOOR CLOSED F-24 = FAN, REVERSER FUSE

K-17 = FAN/REVERSER RELAY K-19 = NOT USED L-20 = FEEDER JOG FORWARD L-21 = FEEDER JOG REVERSE

55-5

L-24 = FEEDER CLUTCH M-05 = CLEANING FAN ADJUST MOTOR (EU) M-10 = FEEDER REVERSER ACTUATOR S-31 = FEEDER ENGAGE

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11

THRESHER FRAME--18

B-01 = ROTOR RPM K-28 = THRESHER LATCHING L-22 = GEARBOX CLUTCH L-29 = ROTOR INCREASE

L-30 = ROTOR DECREASE S-30 = THRESHER ENGAGE

55-6

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 Feeder Engage – Troubleshooting Symptom:

Feeder will not engage.

NOTE: Check for all active alarms and errors, and correct before following this troubleshooting procedure. Solution: 1. Ensure the “Feeder Reverser” switch S-07 is in the “Off” position. A. If the switch is in the “On” position, move it to the “Off” position and retest for feeder engage. Continue with step 2, if necessary. B. If the switch is in the “Off” position, continue with step 2. 2. Using the display monitor diagnostic capability to view “Item” status, reference Section 55 Chapter 2, if needed. Cycle the Feeder Reverser switch S-07 to check voltage range. The normal operating range for the feeder reverser switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the feeder reverser switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading is correct (0.5 – 3.5 volts = Off, 3.5 – 5.0 volts = On), continue with step 4. B. If the voltage reading remains high (> 5.0 volts), continue with step 3. 3. Key off and Feeder Reverser switch off, disconnect connector X039. Use a multi-meter to check for continuity on the switch between pin 2 and pin 3. There should not be continuity. A. If there is continuity, the Feeder Reverser switch is shorted. Replace the switch. B. If there is no continuity there is a short circuit to high voltage in the RH Console (RC) harness between the Feeder Reverser switch S-07 connector X039 pin 3 and the RHM connector X029 pin 5 wire 326 yellow. Locate the short and repair. 4. Ensure the “On The Road Switch” S-12 is in the “Field” position. A. If the switch is in the “Road” position, move it to the “Field” position and retest for feeder engage. Continue with step 5, if necessary. B. If the switch is in the “Field” position, continue with step 5. 5. Using the display monitor diagnostic capability to view “Item” status, reference Section 55 Chapter 2, if needed. Cycle the On The Road Switch S-12 to check voltage range. The normal operating range for the on the road switch in the “Field” position is 0.5 – 3.5 volts. The normal operating range for the on the road switch in the “Road” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading is correct (0.5 – 3.5 volts = Field, 3.5 – 5.0 volts = Road), continue with step 7. B. If the voltage reading remains high (> 5.0 volts), continue with step 6. 6. Key off and On The Road Switch in the “Field” position, disconnect connector X049. Use a multi-meter to check for continuity on the switch between pin 2 and pin 3. There should not be continuity. A. If there is continuity, the On The Road Switch is shorted. Replace the switch. B. If there is no continuity there is a short circuit to high voltage in the RH Console (RC) harness between the On The Road Switch S-12 connector X049 pin 3 and the RHM connector X029 pin 16 wire 339 yellow. Locate the short and repair.

55-7

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 7. Using the display monitor diagnostic capability to view “Item” status, reference Section 55 Chapter 2, if needed. Cycle the Operator Seat Switch S-05 to check voltage range. The normal operating range for the seat switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the seat switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading is correct (0.5 – 3.5 volts = Off, 3.5 – 5.0 volts = On), continue with step 13. B. If the voltage reading remains low (0.5 – 3.5 volts), there is an open circuit in the seat switch S-05 or the seat switch circuit, continue with step 8. 8. Key on, disconnect connector X317. Use a multi-meter to check for voltage on the jumper harness side of connector X317 pin A and chassis ground. There should be 12 volts. A. If there is voltage, continue with step 10. B. If there is no voltage, continue with step 9. 9. Key on, disconnect connector X073. Use a multi-meter to check for voltage on the Cab Main (CM) harness side of connector X073 pin A and chassis ground. There should be 12 volts. A. If there is voltage, there is an open in the jumper harness between connector X073 pin A and the seat switch connector X317 pin A. Locate the open and repair. B. If there is no voltage, there is an open in the Cab Main (CM) harness between connector X073 pin A and the splice wire 046 orange. Locate the open and repair. 10. Key off and seat switch actuated, disconnect connector X073. Use a multi-meter to check for continuity on the jumper harness side of connector X073 between pin A and pin B. There should be continuity. A. If there is continuity, continue with step 12. B. If there is no continuity, continue with step 11. 11. Key off and seat switch actuated, disconnect connector X317. Use a multi-meter to check for continuity on the switch between pin A and pin B. There should be continuity. A. If there is continuity, there is an open in the jumper harness between connector X073 pin B and the seat switch connector X317 pin B. Locate the open and repair. B. If there is no continuity, there is an open in the Operator Seat Switch S-05. Replace the switch. 12. Key off, disconnect connector X073 from the Cab Main (CM) harness and carefully disconnect connector X015 from the CCM-2 module. Place a jumper wire between connector X073 pin B on the Cab Main (CM) harness side and chassis ground. Use a multi-meter to check for continuity on the Cab Main (CM) harness side of connector X015 pin J1-9 and chassis ground. A. If there is continuity, the CCM has failed. Try reloading the CCM-2 software and retest for feeder engage. Replace the module if necessary. B. If there is no continuity, there is an open in the Cab Main (CM) harness between connector X073 pin B and connector X015 pin J1-9 wire 168 yellow. Locate the open and repair.

55-8

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 13. Ensure the “Thresher Engage” switch S-30 is “Engaged”. A. If the switch is not engaged, engage the switch and retest for feeder engage. Continue with step 14, if necessary. B. If the switch is “Engaged”, continue with step 14. 14. Using the display monitor diagnostic capability to view “Item” status, reference Section 55 Chapter 2, if needed. Cycle the Thresher Engage switch S-30 to check voltage range. The normal operating range for the thresher engage switch when it is not engaged is 0.5 – 3.5 volts. The normal operating range for the thresher engage switch when it is engaged is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading is correct (0.5 – 3.5 volts = Off, 3.5 – 5.0 volts = On), continue with step 15. B. If the voltage reading remains low (< 0.5 -- 3.5 volts), reference Section 55 Chapter 12 – Threshing Systems, to correct the problem of thresher not engaging. 15. Ensure the “Feeder Engage” switch S-31 is “Engaged”. A. If the switch is not engaged, engage the switch and retest for feeder engage. Continue with step 16, if necessary. B. If the switch is “Engaged” continue with step 16. 16. Using the display monitor diagnostic capability to view “Item” status, reference Section 55 Chapter 2, if needed. Cycle the Feeder Engage switch S-31 to check voltage range. The normal operating range for the feeder engage switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the feeder engage switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading is correct (0.5 – 3.5 volts = Off, 3.5 – 5.0 volts = On), continue with step 21. B. If the voltage reading remains low (0.5 – 3.5 volts), there is an open circuit in the feeder engage switch S-31 or the feeder engage switch circuit, continue with step 17. 17. Key on, disconnect connector X056. Use a multi-meter to check for voltage on the RH Console (RC) harness side of connector X056 pin 6 and chassis ground. There should be 12 volts. A. If there is voltage, continue with step 18. B. If there is no voltage, there is an open in the RH Console (RC) harness between connector X056 pin 6 and the splice wire 861 yellow. Locate the open and repair. 18. Key off and feeder engage switch engaged, disconnect connector X056. Use a multi-meter to check for continuity on the switch between pin 5 and pin 6. There should be continuity. A. If there is continuity, continue with step 19. B. If there is no continuity, there is an open in the Feeder Engage Switch S-31. Replace the switch. 19. Key off, disconnect connector X056 and connector X001. Use a multi-meter to check for continuity between connector X056 pin 5 and connector X001 pin 15. A. If there is continuity, continue with step 20. B. If there is no continuity, there is an open in the RH Console (RC) harness between connector X056 pin 5 and connector X001 pin15 wire 112 yellow. Locate the open and repair.

55-9

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 20. Key off, disconnect connector X001 from the RH Console (RC) harness and carefully disconnect connector X018 from the CCM-1 module. Place a jumper wire between connector X001 pin 15 on the Cab Main (CM) harness side and chassis ground. Use a multi-meter to check for continuity on the Cab Main (CM) harness side of connector X018 pin J1-7 and chassis ground. A. If there is continuity, the CCM has failed. Try reloading the CCM-1 software and retest for feeder engage. Replace the module if necessary. B. If there is no continuity, there is an open in the Cab Main (CM) harness between connector X001 pin 15 and connector X018 pin J1-7 wire 112 yellow. Locate the open and repair. 21. The electrical portion of the feeder engage system is functioning properly. Inspect the following areas of the combine: •

Damaged or restricted line from the low pressure valve block to the feeder clutch.

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 THIS PAGE LEFT BLANK

55-11

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 FEEDER SPEED (OPTIONAL) Feeder speed is adjusted from the cab by the operator using a switch on the right console, and the Feeder RPM may be monitored using the display monitor. The Feeder speed is adjusted using electrical control of a hydraulic valve assembly that controls a hydraulic piston in the Feeder drive variable sheave. Feeder Speed Adjust When the operator moves the Feeder speed switch S18 on the right console, a 12 volt signal is sent to the right hand module (RHM). To increase Feeder speed, a 12v signal is sent to connector X030 pin 12 wire 351 yellow; to decrease Feeder speed, a 12v signal is sent to connector X030 pin 5 wire 350 yellow. When the RHM receives a Feeder speed increase or decrease signal, it broadcasts a message over CAN which is picked up by CCM1. CCM1 will then activate the appropriate output to change the Feeder speed. Power is sent to the Feeder increase solenoid L11 to increase Feeder speed, while the Feeder decrease solenoid L12 is powered to decrease Feeder speed. These solenoids are simply turned ‘on’ or ‘off’, so do not need to be grounded back through CCM1 like a PWM solenoid. Both solenoids are grounded at the main frame ground #2, located behind the left rear corner of the cab on the main frame. The actual Feeder rpm is measured at the left end of the top feeder shaft using the Feeder rpm sensor B14.

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Feeder Speed Errors The combine electronic system monitors the Feeder speed sensor B14 and the outputs to the Feeder increase and decrease solenoids L11/L12. In the event of any problems with these circuits, the appropriate fault code will be displayed to indicate the specific fault with these components and the circuits containing them. The following fault codes relate to the Feeder speed sensor B14: E0014-03

Feeder RPM sensor Shorted to High Source

E0014-04

Feeder RPM sensor Shorted to Low Source

E0014-05

Feeder RPM sensor Line Disconnected

The following fault code relates to the Feeder increase solenoid L11: E0082-11

Feeder Speed Incr (1) Unidentified Failure Code

The following fault code related to the Feeder decrease solenoid L12: E0083-11

Feeder Speed Decr (1) Unidentified Failure Code

The following fault code related to the Feeder Speed switch S-18: E0666-04

Feeder Speed (Increase) – Shorted to low source

E0666-07

Feeder Speed (Increase) – Mechanical out of range

E0667-04

Feeder Speed (Decrease) – Shorted to low source

E0667-07

Feeder Speed (Decrease) – Mechanical out of range

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11

HYDRAULIC FRAME--10

B-18 = HYD OIL RESERVOIR TEMP B-32 = GEARBOX TEMPERATURE B-35 = LOW CONTROL PRESSURE S-17 = ROTOR SPEED

S-18 = FEEDER SPEED S-32 = RETURNS FILTER BYPASS S-33 = HYDRAULIC RESERVOIR LEVEL S-34 = GEARBOX FILTER BYPASS

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11

HEADER FRAME--14

A-07 = HHC MODULE B-29 = HEADER LIFT PRESSURE L-06 = HEADER HEIGHT ACCUMULATOR L-18 = LATERAL FLOAT CW

L-19 = LATERAL FLOAT CCW R-02 = LATERAL FLOAT POT R-03 = FEEDER ANGLE R-12 = LEFT STUBBLE HEIGHT

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R-13 = RIGHT STUBBLE HEIGHT

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11

A-08 = ASP AMPLIFIER B-48 = RH BOTTOM ASP SENSOR B-49 = LH BOTTOM ASP SENSOR F-46 = ASP POWER FUSE

L-11 = FEEDER INCREASE L-12 = FEEDER DECREASE L-31 = STONE DOOR OPEN S-07 = FEEDER REVERSER

FEEDER FRAME--15

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11

FEEDER FRAME--16

B-09 = REVERSER DISENGAGE B-14 = FEEDER RPM B-24 = STONE DOOR CLOSED F-24 = FAN, REVERSER FUSE

K-17 = FAN/REVERSER RELAY K-19 = NOT USED L-20 = FEEDER JOG FORWARD L-21 = FEEDER JOG REVERSE

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L-24 = FEEDER CLUTCH M-05 = CLEANING FAN ADJUST MOTOR (EU) M-10 = FEEDER REVERSER ACTUATOR S-31 = FEEDER ENGAGE

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 Feeder Speed -- Troubleshooting Symptom:

Feeder speed will not increase or decrease.

NOTE: Check for all active alarms and errors, and correct before following this troubleshooting procedure. Solution: 1. Using the display monitor diagnostic capability to view “Item” status, reference Section 55 Chapter 2, if needed. Cycle the Feeder Speed (Increase) switch S-18 to check voltage range. The normal operating range for the feeder speed switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the feeder speed switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading is correct (0.5 – 3.5 volts = Off, 3.5 – 5.0 volts = On), continue with step 4. B. If the voltage reading remains low (< 0.5 volts), continue with step 2. 2. Key off and feeder speed (Increase) switch actuated, disconnect connector X047. Use a multi-meter to check for continuity on the switch between pin 2 and pin 3. There should be continuity. A. If there is continuity, continue with step 3. B. If there is no continuity, there is an open in the Feeder Speed switch S-18. Replace the switch. 3. Key off, disconnect connector X047 and connector X030 from the RH Console (RC) harness. Use a multi-meter to check for continuity on the RH Console (RC) harness side of both connectors between connector X030 pin 12 and connector X047 pin 3. There should be continuity. A. If there is continuity, the RHM has failed. Try reloading the RHM software and retest for feeder speed (Increase). Replace the module if necessary. B. If there is no continuity, there is an open in the RH Console (RC) harness between connector X030 pin 12 and connector X047 pin 3 wire 351 yellow. Locate the open and repair. 4. Using the display monitor diagnostic capability to view “Item” status, reference Section 55 Chapter 2, if needed. Cycle the Feeder Speed (Decrease) switch S-18 to check voltage range. The normal operating range for the feeder speed switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the feeder speed switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading is correct (0.5 – 3.5 volts = Off, 3.5 – 5.0 volts = On), continue with step 4. B. If the voltage reading remains low (< 0.5 volts), continue with step 5. 5. Key off and feeder speed (Decrease) switch actuated, disconnect connector X047. Use a multi-meter to check for continuity on the switch between pin 2 and pin 1. There should be continuity. A. If there is continuity, continue with step 6. B. If there is no continuity, there is an open in the Feeder Speed switch S-18. Replace the switch. 6. Key off, disconnect connector X047 and connector X030 from the RH Console (RC) harness. Use a multi-meter to check for continuity on the RH Console (RC) harness side of both connectors between connector X030 pin 5 and connector X047 pin 1. There should be continuity. A. If there is continuity, the RHM has failed. Try reloading the RHM software and retest for feeder speed (Increase). Replace the module if necessary. B. If there is no continuity, there is an open in the RH Console (RC) harness between connector X030 pin 5 and connector X047 pin 1 wire 350 yellow. Locate the open and repair.

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11

HYDRAULIC FRAME--10

B-18 = HYD OIL RESERVOIR TEMP B-32 = GEARBOX TEMPERATURE B-35 = LOW CONTROL PRESSURE S-17 = ROTOR SPEED

S-18 = FEEDER SPEED S-32 = RETURNS FILTER BYPASS S-33 = HYDRAULIC RESERVOIR LEVEL S-34 = GEARBOX FILTER BYPASS

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 FEEDER REVERSER Description The combine is equipped with a system to reverse the gathering chains (in case of a corn header), the auger, and the feeder should a blockage occur. The feeder reverser switch, 1, is located on the right hand console. Use the reel speed buttons, 2, and 3, to rotate the feeder forward or reverse.

3 2

20030010

2 1. Feeder Reverser Actuator 2. Feeder Reverser Disengage Sensor The following conditions must be met to engage the Feeder Reverser: •

Engine running

•

Thresher switch in the “Off” position for a minimum of one second.

•

The Road/Field Mode switch must be in the “field” position.

When the reverser switch is activated, the reverser actuator moves the clutch pawl to engage the drive gear. After approximately two seconds, the reverser actuator is fully engaged, allowing the operator to use the reel speed buttons to rotate the feeder forward or backward. The Feeder Reverser Disengage Sensor, 2, monitors the position of the Feeder Reverser Clutch Pawl. The purpose of this sensor is to prevent the Feeder from being engaged while the Reverser is activated.

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10020041

1 3

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 Feeder Reverser – Alarms Description

Alarm A0014

Feeder Reverser Engaged

Feeder Reverser – Fault Codes Error Code

Description

Result

E0004-03

Feeder Reverser Disengage Sensor Shorted to high source Will not prevent engagement

E0004-04

Feeder Reverser Disengage Sensor Shorted to low source

Will not prevent engagement

E0004-05

Feeder Reverser Disengage Sensor Line Disconnected

Will not prevent engagement

E0042-06

Reverser Engage Motor Current Sense Short Circuit

Reverser will not engage

E0061-11

Feeder Jog Forward valve Unidentified Failure Code

Reverser will not engage

E0067-11

Feeder Jog Reverse valve Unidentified Failure Code

Reverser will not engage

E0077-11

Reverser Engage Motor Unidentified Failure Code

Reverser will not engage

E0175-03

Voltage supply thresher clutch -- Shorted to high source

Reverser will not engage

E0175-04

Voltage supply thresher clutch -- Shorted to low source

Will not affect operation

E0646-04

Feeder reverser switch -- Shorted to low source

Reverser will not engage

E0654-04

Road mode switch -- Shorted to low source

Will not affect operation

E0654-07

Road mode switch – Mechanical out of range

E0691-04

Reel speed decrease switch – Shorted to low source

E0691-07

Reel speed decrease switch – Mechanical out of range

E0693-04

Reel speed increase switch – Shorted to low source

E0693-07

Reel speed increase switch – Mechanical out of range

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Feeder will not reverse

Feeder will not forward

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 Feeder Reverser -- Troubleshooting Symptom: Feeder reverser will not engage, or will not disengage. NOTE: Check for all active alarms and errors and correct before following this troubleshooting procedure. Solution: The feeder reverser mode switch S07 is a two position switch that opens the signal wire when in the ‘Off’ position, and connects power to the RHM when in the ‘On’ position. If the switch, signal or supply wiring fails open, the feeder reverser can not be engaged. If the signal wire is shorted to high voltage, the feeder reverser will be engaged continuously. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the feeder reverser mode switch. The “switch” screen should show “off” when the switch is in the off position, and “on” when the switch is in the on position. If the “Voltage” screen is selected, there should be approximately 1.5 volts with the switch in the off position, and 5.0 volts when the switch is in the on position. A. If the voltage is low (1.5 volts) and does not change, continue with Step 2. B. If the voltage is high (4.9 volts) and does not change, continue with Step 9. C. If the voltage reading is within the proper limits, continue the troubleshooting at step 10. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low (1.5 volts) and does not change. Inspect fuse F48. A. If the fuse is okay, continue with Step 3. B. If the fuse has failed, replace the fuse and repeat Step 1. If the fuse immediately fails, there is a short to ground somewhere in the right console switch power circuit. Locate the short and repair. 3. The voltage reading on the display monitor is low (1.5 volts) and does not change. Disconnect connector X039 from the feeder reverser mode switch S07. Use a multimeter to check for voltage at connector X039 pin 2 wire 358 orange. There should be 12 volts. A. If there is no voltage, continue with Step 4. B. If there is 12 volts, continue with Step 7. 4. The voltage reading on the display monitor is low (1.5 volts) and does not change. Locate the splice block B, W02 in the right hand console. Use a multimeter to check for voltage at splice block B, W02 pin B. There should be 12 volts. A. If there is voltage, there is an open circuit in the right console (RC) harness between connector X039 pin 2 and splice block B, W02 pin B wire 321 orange or 358 orange. Locate the open and repair. B. If there is no voltage, continue with Step 5.

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 5. The voltage reading on the display monitor is low (1.5 volts) and does not change. Locate the splice block B, W02 in the right hand console. Use a multimeter to check for voltage at splice block B, W02 pin M. There should be 12 volts. A. If there is voltage, there is an open circuit in splice block B, W02 pin B. Locate the open and repair. B. If there is no voltage, continue with Step 6. 6. The voltage reading on the display monitor is low (1.5 volts) and does not change. Disconnect connector X001. Use a multimeter to check for voltage at connector X001 pin 3. There should be 12 volts. A. If there is voltage, there is an open circuit in the right console (RC) harness between splice block B, W02 pin M and connector X001 pin 3 wire 287 orange or 108 orange. Locate the open and repair. B. If there is no voltage, there is an open circuit in the cab main (CM) harness between fuse F48 and connector X001 pin 3 wire 108 orange. Locate the open and repair. 7. The voltage reading on the display monitor is low (1.5 volts) and does not change. Position the feeder reverser mode switch S07 in the “On” position. Disconnect connector X029 from the RHM module. Use a multimeter to check for voltage at connector X029 pin 5 wire 326 yellow. There should be 12 volts. A. If there is no voltage, continue with Step 8. B. If there is 12 volts, continue with Step 10. 8. The voltage reading on the display monitor is low (1.5 volts) and does not change. Disconnect connector X039 from the feeder reverser mode switch S07 and connector X029 from the RHM module. Use a multimeter to check for continuity between connector X039 pin 1 and connector X029 pin 5 wire 326 yellow. There should be continuity. A. If there is no continuity, there is an open circuit in the right console (RC) harness between connector X039 pin 1 and connector X029 pin 5 wire 326 yellow. Locate the open and repair. B. If there is continuity, the feeder reverser mode switch S07 is not functioning. Replace the switch. 9. The voltage reading on the display monitor is high (5.0 volts) and does not change. Key on. Disconnect connector X039 from the feeder reverser mode switch S07. Use a multimeter to check for voltage on connector X039 pin 1 wire 326 yellow. There should be approximately 1.5 volts. A. If the voltage is high (>5.0 volts), there is an short circuit in the right console (RC) harness between connector X039 pin 1 and connector X029 pin 5 wire 326 yellow. Locate the short and repair. B. If there is approximately 1.5 volts, the circuit is functioning properly. Continue with Step 10. 10. Use the electronic service tool (EST) to reload the software in the RHM module, and retest the system. If the problem still exists, the RHM has failed. Replace the RHM.

55-22

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 Symptom: Feeder reverser will engage, but will not move forward or backward. NOTE: Check for all active alarms and errors and correct before following this troubleshooting procedure. Solution: NOTE: The reel speed increase and decrease switches on the MFH are also used to move the feeder reverser forward and backwards when the reverser is engaged. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the reel speed increase switch. The “switch” screen should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 2 and pin 7, with the black (common) probe of the multimeter on pin 7. Depress the reel speed increase switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 3. 3. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the reel speed decrease switch. The “switch” screen should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 4. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 4. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 10 and pin 7, with the black (common) probe of the multimeter on pin 7. Depress the reel speed decrease switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 5. 5. Use the electronic service tool (EST) to reload the software in the RHM module, and retest the system. If the problem still exists, the RHM has failed. Replace the RHM.

55-23

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 ADVANCED STONE PROTECTION (ASP) SYSTEM

4 6

2 1 50021832

4 Stone Ejection System The advanced stone protection (ASP) system guards against stone intrusion by a) detecting when a stone enters the feeder and b) ejecting the stone from the combine. Stone detection is achieved through the use of piezo-electric sensors and electronic circuitry which distinguishes the acoustic signatures of stones or other hard objects impacting on a metal plate. When an impact is detected, the system then ejects the stone from the feeder. The first step, detection, is accomplished by having all the material entering the feeder pass over a metal plate, 1, mounted just below the infeed roller. The plate is mounted with rubber pads to reduce the pickup of acoustic hits from elsewhere in the combine. An automotive knock sensor is mounted on each end of the plate. These sensors are piezo-electric microphones (hardened for heavyduty applications) which relay acoustical information in the form of electrical signals to the ASP controller, 3, mounted on the left-hand side of the feeder. The ASP controller electronically analyzes the signals from the sensors and determines if stone

55-24

impact has occurred. Upon detection, the ASP controller activates a solenoid-controlled hydraulic valve, located in the feeder valve stack. This valve directs oil to the hydraulic cylinder, 4, which unlatches the bottom to swing down, deflecting the stone out the open door. After stone detection and ejection, the feeder bottom door is re-latched by a two-step process: a) reversing the feeder to clear the door opening and b) raising the feeder to its highest position. (This procedure is spelled out in detail in the feeder operating instructions). Proximity sensor, 7, senses when the door is in the closed position, at which time the stone trap solenoid valve is deactivated and the hydraulic cylinder, 4, releases the door latch mechanism. The stone trap door can also be opened by direct action by the operator if he or she observes foreign material entering the feeder. This is accomplished by pressing the emergency stop button and holding it down for 3 seconds.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 Schematic Frame 15 shows the wiring of the sensing and control components. The sensor set has its own wire harness, FB for bottom sensors B-48 and B-49. FB harness connects to the feeder harness (FE) at X261. Both branches then connect to the ASP controller A-08 through connector X086. Hydraulic control valve solenoid L-31 connects to the ASP controller at X082. A description of the hydraulic control valve can be found in Section 35 Hydraulic Systems -- Chapter 3. Schematic Frame 16 shows the wiring of the stone trap door sensor B-24. A branch of feeder (FE) harness connects to the sensor at X083. The sensor signal is routed to combine controller module CCM1 through connector X007, pin 11, and through the front frame (FF) harness to CCM1 connector X020, pin J3-28. The ASP controller communicates with controller CCM1 via the CAN bus. Schematic Frame 31 shows the CAN bus connection through A-08 connector X082, pins 6 and 7, through FE harness to connector X007, pins 8 and 9. The ASP controller a) signals the CCM1 regarding detection and activation status and b) receives operating parameters from CCM1. CCM1 directs display information to the display monitor.

55-25

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11

A-08 = ASP AMPLIFIER B-48 = RH BOTTOM ASP SENSOR B-49 = LH BOTTOM ASP SENSOR F-46 = ASP POWER FUSE

L-11 = FEEDER INCREASE L-12 = FEEDER DECREASE L-31 = STONE DOOR OPEN S-07 = FEEDER REVERSER

FEEDER FRAME--15

55-26

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11

FEEDER FRAME--16

B-09 = REVERSER DISENGAGE B-14 = FEEDER RPM B-24 = STONE DOOR CLOSED F-24 = FAN, REVERSER FUSE

K-17 = FAN/REVERSER RELAY K-19 = NOT USED L-20 = FEEDER JOG FORWARD L-21 = FEEDER JOG REVERSE

55-27

L-24 = FEEDER CLUTCH M-05 = CLEANING FAN ADJUST MOTOR (EU) M-10 = FEEDER REVERSER ACTUATOR S-31 = FEEDER ENGAGE

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11

A-01 = ENGINE CONTROL UNIT A-07 = HHC MODULE A-08 = ASP AMPLIFIER A-16 = CUMMINS ECU

F-45 = HHC MODULE FUSE R-16 = ENG CAN TERMINATION (9.0 L)

55-28

IVECO 10 L

CUMMINS 9.0 L

CAN NETWORK FRAME--31

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11 ASP System – Alarms Alarm

Description

A0031

Stonetrap Open

A0069

Stone Detected on Bottom Sensor

A0070

Electronic Stone Trap Disabled

A0071

Attempt Stone Door Re-Latch

A0072

Stone Door Failed to Open

A0073

Reverse Feeder Five Seconds

ASP System – Error Codes Description

Error Code E0000-03

Stone Trap Door Sensor Shorted to high source

E0000-04

Stone Trap Door Sensor Shorted to low source

E0000-05

Stone Trap Door Sensor Line Disconnected

E1281-05

ASP Bottom Sensor Line Disconnected

E1283-03

ASP Bottom Sensors Shorted to high source

E1283-05

ASP Bottom Sensors Line Disconnected

E1284-11

ASP Stonedoor Output Unidentified Failure Code

ASP System – Troubleshooting The ASP system goes through a self-diagnostic process during certain periods of operation. The ASP does these checks at the following times: •

Directly following engine startup.

•

Shortly after the feeder is disengaged

•

Once a minute during times when the feeder is NOT engaged.

The ASP self-diagnostics process measures voltage to assess the condition of the system. When a component is damaged or offline, the amount of voltage will fall out of the desired parameters. This allows the system to detect a failure.

55-29

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 11

55-30

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 12 -- Threshing Systems CONTENTS Section

Description

Page

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 55 000

55-1

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 DESCRIPTION OF OPERATION THRESHER SYSTEM 1

The threshing system operation is quite simple from an operator’s perspective; he simply raises the thresher engage switch S30, 1, to engage the threshing system, and depresses it to shut the threshing system off. However, there are many conditions that have to be met in order for the threshing system to operate that are controlled and monitored by the electronic system on the combine. It is important to understand all of these conditions in order to troubleshoot concerns with the threshing system.

50031473

Thresher Engage Power to the thresher engage switch S30 pin 3 is supplied from fuse F48 whenever the key is in the “On” position. When the top part of the thresher switch is depressed to unlock the switch, momentary contact is made between pins 3 and 2. Power then flows to terminals 5 and 1 of the thresher latching relay K28, causing the relay to become energized. Once the relay latches, power coming from fuse F48 to terminal 3 of the relay will ensure that the relay remains latched, even after the top part of the thresher switch is released.

As the thresher switch S30 is pulled upward, contact is made between pins 5 and 6. Since the thresher latching relay is energized, power flows from fuse F48 through the thresher latching relay K28 back to the switch, and flows through the switch where it is supplied to all three CCM’s 2 and 3, and to the feeder engage switch S31. NOTE: Power is supplied to all three CCM’s 2 and 3 to allow for optional features and different machine configurations. On the CR combine, the threshing system is engaged through CCM2. When the power from the thresher engage switch S30 reaches CCM2 pin J1-7, the CCM may begin to activate the output to the gearbox clutch solenoid L22 to begin the threshing engage process. The CCM2 uses the actual power supply coming from the thresher engage switch to power the gearbox clutch solenoid, so that if power supply through the switch is ever interrupted, power to the L22 solenoid will automatically be disconnected for safety reasons.

55-2

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12

THRESHER FRAME--18

B-01 = ROTOR RPM K-28 = THRESHER LATCHING L-22 = GEARBOX CLUTCH L-29 = ROTOR INCREASE

L-30 = ROTOR DECREASE S-30 = THRESHER ENGAGE

55-3

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12

20032194

55-4

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 Before CCM2 actually directs the power from the thresher switch S30 to the gearbox clutch solenoid L22, several things happen in software, as follows: •

• • •

•

Once the appropriate parameters are met, CCM2 will set the engine RPM, and begin engaging the gearbox clutch using the appropriate engagement curve. There are two different engagement curves that may be selected; normal and aggressive. The aggressive curve engages the clutch much quicker, putting more stress on driveline components, but preventing heat build-up and wear in the gearbox clutch itself, while the normal curve allows for less stress on the driveline components, but generates more heat and wear in the gearbox clutch due to the increased amount of slippage required for a smooth start-up. The curve that is selected depends on several factors, as follows:

Road/Field mode switch must be in the ‘Field’ position – thresher will not be engaged if in “Road” position Engine must be running – must be engine rpm sensor information Rear ladder is in the ‘raised’ position – thresher will not engage if ladder is down Status of engine throttle switch is determined (depressed v. not depressed) – affects clutch engagement of normal v. aggressive Status of gearbox clutch temperature sensor is determined (OK v. error) – affects clutch engagement of normal v. aggressive

Gearbox clutch temperature sensor status

Engine RPM

Not depressed

1500

Normal

Not depressed

Error

1500

Aggressive

Depressed

2100

Aggressive

Depressed

Error

1500

Aggressive

Throttle switch status

Gearbox clutch engagement curve

NOTE: The combination of the first two items in the table determine the settings that the CCM2 will make (the last two items in the table). Once the appropriate engagement curve is selected, the CCM2 starts modulating the gearbox clutch solenoid L22, 1, to engage the threshing system. While engaging the clutch, CCM2 monitors the rotor RPM sensor B01 to confirm that the rotors are beginning to rotate, OR the left returns sensor B06 for returns movement. If there is no rotor RPM increase (or returns rotation) during the start of gearbox clutch engagement, CCM2 will disengage the gearbox clutch fully. If rotor RPM is sensed (or returns rotation) during engagement, CCM2 will maintain clutch engagement.

1 2

BSC1322

NOTE: Left returns sensor B06 is used as a back-up RPM source, so that the threshing system may be engaged with the rotor gearboxes in neutral, to allow for rotor RPM changes for better belt tension when unplugging the machine.

If, during gearbox clutch engagement, the gearbox clutch temperature increases by more than 60°C (140°F) from the temperature measured at the start of clutch engagement, the gearbox clutch will be fully disengaged.

55-5

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 Thresher Disengage The thresher system may be disengaged by the operator, or could be disengaged by CCM2, depending on a number of different conditions. If necessary, CCM2 will disengage the threshing system to prevent damage to machine components and to ensure operator safety. The operator may disengage the threshing system by pushing the thresher engagement switch S30 downwards; this will disconnect the contact between pins 5 and 6 of the thresher engage switch S30, and power will no longer flow to CCM2 pin J1-7. Since this is the power supply that is used to power the gearbox clutch solenoid L22, the solenoid will de-energize, and the threshing system will be disengaged. CCM2 will disengage the threshing system if any of the following conditions are met: • •

Rear ladder is lowered Gearbox clutch temperature sensor B45, 2, indicates temperature >130 degrees C (266 degrees F) for more than 0.1 seconds.

Thresher Alarms The following alarms may be observed with the resulting actions while operating with the threshing system engaged: A0006

Gearbox Temp High – Alert operator, no other action taken.

A0010

Gearbox Filter Blocked – Alert operator, no other action taken.

A0012

Control Pressure Low – Alert operator, engine will shut-down.

A0013

Gearbox Clutch Temp HIGH – gearbox clutch will be disengaged.

A0016

Engine Speed Low – Alert operator, no other action taken.

A0021

Rear Ladder Down – gearbox clutch will be disengaged.

A0039

Beater Speed Low – Alert operator, no other action taken.

A0051

Road mode selected – gearbox clutch cannot be engaged.

55-6

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 Thresher Errors The following error messages are related to the threshing system, and should be corrected immediately when they occur, to allow for proper threshing system operation. E0015-03

Left Returns Speed sensor Shorted to High Source

E0015-04

Left Returns Speed sensor Shorted to Low Source

E0015-05

Left Returns Speed sensor Line Disconnected

NOTE: The error E0015 will not cause the threshing system to be disengaged, but will prevent startup of the threshing system if the rotor gearboxes are in neutral, or if the rotor RPM sensor is also failed. E0026-03

Rear Ladder sensor Shorted to High Source

E0026-04

Rear Ladder sensor Shorted to Low Source

E0026-05

Rear Ladder sensor Line Disconnected

NOTE: If the rear ladder sensor is disabled, the threshing system will continue to operate if the ladder is lowered. E0146-03

Drum/Rotor Speed sensor Shorted to High Source

E0146-04

Drum/Rotor Speed sensor Shorted to Low Source

E0146-05

Drum/Rotor Speed sensor Line Disconnected

NOTE: Thresher engagement will not occur if the rotor RPM sensor B01 and Left returns sensor B06 are both failed.

55-7

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 E0151-03

Thresher Clutch Temperature Shorted to High Source

E0151-04

Thresher Clutch Temperature Shorted to Low Source

E0151-05

Thresher Clutch Temperature Line Disconnected

NOTE: The threshing system can be engaged, but will engage only with aggressive engagement at 1500 engine RPM. E0175-03

Voltage Supply Thresher Clutch Shorted to High Source

E0175-04

Voltage Supply Thresher Clutch Shorted to Low Source

E0178-03

Current Sense Thresher Clutch Shorted to High Source

E0180-11

Thresher Clutch valve Unidentified Failure Code

NOTE: A fault exists on the output circuit from CCM2 to the gearbox clutch solenoid L22, preventing the threshing system from being engaged. E0654-04

Road Mode Switch Shorted to Low Source

E0654-07

Road Mode Switch Mechanical Out of Range

NOTE: The Road Mode Switch must be in the ‘Field’ position to allow the threshing system to be engaged.

55-8

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 Troubleshooting Thresher System Symptom:

Thresher will not engage.

NOTE: Check for all active alarms and errors, and correct before following this troubleshooting procedure. Solution: 1. Ensure that the “On-the-Road” switch S12 is in the ‘Field’ position. A. If switch is in the ‘Road’ position, move it to the ‘Field’ position and retest for thresher engage. Continue with step 2 if necessary. B. If switch is in the ‘Field’ position, continue with step 2. 2. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, cycle the On the Road switch S12 to check voltage range. The voltage should be 1.5 volts when the switch is in the “Road” position, and 5 volts when in the “Field” position. A. If the voltage reading is correct (1.5v = Road, 5v = Field), continue with Step 2. B. If the voltage reading remains at 1.5 volts, there is an open circuit in the right console (RC) harness between the On-the-Road switch S12 and the RHM connector X029 pin 16 wire 339 yellow. Locate the open and repair. C. If the voltage reading remains at 5 volts, there is a short circuit to high voltage in the right console (RC) harness between the On-the-Road switch S12 and the RHM connector X029 pin 16 wire 339 yellow. Locate the short and repair. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 3. Move the thresher engage switch S30 to the ‘engaged’ position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check the voltage range. The voltage should be 0 when the switch is in the “Off” position, and 12 volts when in the “engaged” position. A. If the voltage reading is correct (0v = ‘Off’, 12v = ‘engaged’), continue with Step19. B. If the voltage reading remains at 0 volts, continue with step 4. 4. Key switch in “On” position. Check fuse F48. A. If fuse F48 is okay, continue with step 6. B. If the fuse is blown, go to step 5. 5. Replace the failed fuse F48. A. If the fuse is okay, continue with step 6. B. If the fuse immediately fails again, a short to ground exists in one of the following wires: wire 109 orange, fuse F48 to thresher latching relay K28, terminal 3 wire 108 orange, fuse F48 to connector X001, pin 3 wire 110 orange, RC harness splice to thresher engage switch S30 pin 3 wire 300 orange, RC harness splice to neutral switch S22 pin 1 wire 1258 orange, RC harness splice to DA harness splice wire 1747 orange, RC harness splice to auto guidance switch S-78 pin 2 switch power wires from splice block B, W02 in the RH console (refer to frame 25 of electrical schematic for more information) Locate the short to ground and repair.

55-9

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 6. Depress the top cap of the thresher engage switch S30 without lifting the switch, and observe the fuse F48. A. If the fuse is okay, continue with step 7. B. If the fuse immediately fails, a short to ground exists in one of the following wires: wire 858 yellow, thresher engage switch S30 pin 2 to RC harness splice wire 857 yellow, RC harness splice to thresher engage switch S30 pin 6 wire 118 yellow, RC harness splice through connector X001 pin 14 to thresher latching relay K28 pin 5 wire 115 yellow, thresher latching relay K28 pin 5 to relay pin 1 Locate the short and repair. 7. Lift the thresher engage switch S30 upwards, and observe the fuse F48. A. If the fuse is okay, continue with step 8. B. If the fuse immediately fails, a short to ground exists in one of the following wires: wire 302 yellow, thresher engage switch S30 pin 5 to RC harness splice wire 861 yellow, RC harness splice to feeder engage switch S31 pin 6 wire 147 yellow, RC harness splice through connector X001 pin 13 to CM harness splice wire 111 yellow, CM harness splice to CCM2 connector X015 pin J1-7 wire 1061 yellow, CM harness splice to CCM3 connector X012 pin J1-7 Locate the short and repair. 8. Key on, thresher engage switch S30 engaged. Use a multi-meter to carefully back-probe connector X015 pin J1-7 and measure the voltage; the voltage should be 12 volts. A. Multimeter indicates 12 volts. Continue with step 19. B. There is no voltage present. Continue with step 9. 9. Key off. Disconnect connector X001. Use a multi-meter to check for continuity between connector X001 pin 13 and connector X015 pin J1-7. There should be continuity. A. If there is continuity, continue with step 10. B. If there is no continuity, there is an open circuit in the cab main (CM) harness between connector X001 pin 13 and connector X015 pin J1-7 wire 147 yellow or wire 111 yellow. Locate the open and repair. 10. Key off, thresher engage switch S30 engaged. Disconnect connector X001, and use a multimeter to check for continuity between connector X001 pins 13 and 14 on the RC harness end of the connector. A. If there is continuity, continue with step 12. B. If there is no continuity, continue with step 11. 11. Key off, thresher engage switch S30 engaged. Remove the top portion of the RH console, and unplug connector X055 at the thresher engage switch S30. Use a multi-meter to test for continuity between the switch end of connector X055 pins 5 & 6. A. If there is no continuity, the thresher engage switch S30 is defective. Replace the switch. B. If there is continuity, there is an open circuit in the right console (RC) harness between connector X001 pins 13 and 14 on one of the following wires: wire 118 yellow, connector X001 pin 14 to RC harness splice wire 857 yellow, RC harness splice to thresher engage switch S30 pin 6 wire 302 yellow, thresher engage switch S30 pin 5 to RC harness splice wire 147 yellow, RC harness splice to connector X001 pin 13 Locate the open and repair. 12. Key on. Disconnect connector X001, and use a multi-meter to check for voltage at the cab main (CM) harness end of connector X001 pin 3. There should be 12 volts present. A. If there is 12 volts, continue with step 13. B. If there is no voltage, there is an open circuit in the cab main (CM) harness between connector X001 pin 3 and fuse F48 in wire 108 orange. Locate the open and repair.

55-10

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 13. Key on, connector X001 connected. Remove the top portion of the RH console, and unplug connector X055 at the thresher engage switch S30. Use a multi-meter to test for voltage at the RC harness end of connector X055 pin 3. A. If there is 12 volts, continue with step 14. B. If there is no voltage, there is an open circuit in the right console (RC) harness between connector X001 pin 3 and connector X055 pin 3 wire 108 orange or wire 110 orange. Locate open and repair. 14. Key off, RH console opened. Disconnect connector X001. Use a multi-meter to test for continuity between the right console (RC) harness end of connector X001 pins 3 and 14 while depressing the top cap of the thresher engage switch S30. There should be continuity. A. If there is continuity, continue with step 16. B. If there is no continuity, continue with step 15. 15. Key off, RH console opened. Disconnect connector X055 at the thresher engage switch S30. Use a multi-meter to test for continuity between the switch end of connector X055 pins 2 and 3 while depressing the top cap of the switch. There should be continuity. A. If there is no continuity, the thresher engage switch S30 is defective. Replace the switch. B. If there is continuity, there is an open circuit in the right console (RC) harness between connector X055 and the RC harness splice in wire 858 yellow. Locate the open and repair. 16. Key on, all harness connectors should be connected. Remove the thresher latching relay K28 from the fuse panel. Use a multi-meter to test for voltage at pin 3 of the relay base in the fuse panel. There should be 12 volts. A. If there is voltage, continue with step 17. B. If there is no voltage, there is an open circuit in the cab main (CM) harness between fuse F48 and the K28 relay base wire 109 orange. Locate the open and repair. 17. Key on, thresher latching relay K28 removed. Use a multi-meter to test for voltage at pins 5 and 1 of the K28 relay base in the fuse panel while depressing the top cap of the thresher engage switch S30. There should be 12 volts at both pins. A. If there is 12 volts at both pins, continue with step 18. B. If there is 12 volts at pin 5 but not at pin 1, there is an open circuit in the cab main (CM) harness between K28 relay base pins 1 and 5 wire 115 yellow. Locate open and repair. C. If there is no voltage at both pins, there is an open circuit in the cab main (CM) harness between connector X001 pin 14 and K28 relay base pin 5 wire 118 yellow. Locate the open and repair. 18. Key off, thresher latching relay K28 removed. Use a multi-meter to test for continuity between the K28 relay base pin 2 and chassis ground. There should be continuity. A. If there is continuity, the thresher latching relay K28 is defective. Replace relay. B. If there is no continuity, there is an open circuit in the cab main (CM) harness between K28 relay base pin 2 and cab ground #3 wire 120 black. Locate open and repair. 19. The electrical portion of the thresher engage system is functioning properly. Inspect the following areas of the combine: ----

loose main drive belt is slipping at start-up, so that the minimum rotor or left returns speeds are not met. Physical blockage of thresher drive components, causing excessive heat-build-up in gearbox clutch at start-up and/or minimum rotor or left returns speeds are not met. Low control pressure [< 24 bar (350 psi)] at 1500 engine RPM, resulting in excessive clutch slippage, causing excessive heat-build-up in gearbox clutch at start-up and/or minimum rotor or left returns speeds are not met. Refer to Section 35 – Hydraulics in this manual for more information.

55-11

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 Symptom: Thresher disengages during operation. NOTE: Check for all active alarms and errors, and correct before following this troubleshooting procedure. Solution: During operation, there are limited conditions that may result in the thresher system being disengaged. --

If the rear ladder is lowered for more than 4 seconds while the thresher system is engaged, the thresher system will be disengaged, and the alarm message “A0021 Rear Ladder Down” will be displayed.

If the gearbox clutch temperature is greater than 130 degrees C (266 degrees F) for more than 0.1 seconds during operation, the gearbox clutch will be disengaged, and the alarm message “A0013 Gearbox Clutch Temperature HIGH” will be displayed.

If either of these alarms is displayed when the threshing system disengages, the cause of the alarm must be corrected in order for the threshing system to be re-engaged. The remaining possibilities include excessive resistance on the gearbox clutch solenoid L22 circuit or the thresher input voltage circuit through the thresher engage switch S30, or intermittent loss of voltage from the thresher input voltage circuit through the thresher engage switch S30. 1. Key off. Unplug connector X035 at the low pressure manifold on the engine gearbox. Use a multi-meter to check the resistance between connector X035 pins 7 and 8. The proper resistance range is 7.2 to 11.2 ohms. A. If out of specification, replace the solenoid. Continue with step 4. B. If the coil is within specification, continue with Step 2. 2. Disconnect inline connector X011. Use a multimeter to check the resistance of the gearbox clutch solenoid circuit between connector X011 pins N & O. The resistance should be the same as, or slightly higher than the resistance of the solenoid as measured in step 1. A. If the resistance is significantly higher than the previously measured resistance, there is excessive resistance in the harness or connections between connector X035 and connector X011 wires 878 white and 877 blue. Locate the source of the resistance and repair. Continue with step 4. B. If the resistance is the same as previously measured, continue with step 3. 3. Disconnect connector X016 on the bottom of CCM2 module. Use a multimeter to check the resistance of the gearbox clutch solenoid circuit between connector X016 pins J2-30 & J2-40. A. If the resistance is significantly higher than the previously measured resistance, there is excessive resistance in the harness or connections between connector X011 and connector X016 wires 878 white and 877 blue. Locate the source of the resistance and repair. Continue with step 4. B. If the resistance is the same as previously measured, continue with step 4. 4. Key on. Use a multi-meter to measure the voltage at the battery cable connection to the fuse panel, and record the voltage. Engage the thresher engage switch S30, and use the multi-meter to carefully back-probe connector X015 pin J1-7. Measure the voltage; the voltage should be within 1/2 volt of the voltage measured at the fuse panel. A. Voltage is within 1/2 volt of fuse panel voltage. Continue with step 9. B. Voltage is more than 1/2 volt below fuse panel voltage. Continue with step 5. 5. Key off. Disconnect connector X001 from the right console. Use a multi-meter to check the resistance between the cab main (CM) harness end of connector X001 pin 13 and connector X015 pin J1-7. The resistance should be less than 1 ohm. A. The resistance is less than 1 ohm. Continue with step 6. B. The resistance is greater than 1 ohm. There is excessive resistance in the cab main (CM) harness between connector X001 pin 13 and connector X015 pin J1-7 wire 147 yellow and wire 111 yellow. Locate the source of resistance and repair.

55-12

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 6. Key off. Disconnect connector X001 from the right console. Engage the thresher engage switch S30. Use a multi-meter to check the resistance between the right console end of connector X001 pins 13 and 14. The resistance should be less than 1 ohm. A. The resistance is less than 1 ohm. Continue with step 7. B. The resistance is greater than 1 ohm. There is excessive resistance in the right console (RC) harness between connector X001 pins 13 and 14 in one of the following wires or components: wire 147 yellow, connector X001 pin 13 to RC harness splice wire 302 yellow, RC harness splice to thresher engage switch S30 pin 5 wire 857 yellow, thresher engage switch S30 pin 6 to RC harness splice wire 118 yellow, RC harness splice to connector X001 pin 14 Thresher engage switch S30 assembly Locate the source of resistance and repair. 7. Key on. Remove the thresher latching relay K28 from the fuse panel. Use a multi-meter to measure the voltage at the K28 relay base pin 3. The voltage should be within 1/2 volt of the voltage recorded at the fuse panel in step 4. A. Voltage is within 1/2 volt of fuse panel voltage. Continue with step 8. B. Voltage is more than 1/2 volt below fuse panel voltage. There is excessive resistance in the fuse panel wiring through the cab power relay K26 to fuse F48 to the K28 relay base pin 3. Locate the source of the resistance and repair. 8. Install a jumper wire in the K28 relay base between pin 3 and pin 5. Unbolt the top half of the right console to gain access to the thresher engage switch S30 connector X055. Turn the key switch to the “On” position, and engage the thresher engage switch S30. Unplug connector X055, and use a multi-meter to measure the voltage at right console (RC) harness end of connector X055 pin 6. The voltage should be within 1/2 volt of the voltage recorded at the fuse panel in step 4. A. Voltage is within 1/2 volt of fuse panel voltage. The thresher latching relay K28 is defective. Replace the relay. B. Voltage is more than 1/2 volt below fuse panel voltage. There is excessive resistance in the cab main (CM) harness between the K28 relay base pin 5 and connector X001 pin 14. Locate the source of the resistance and repair. 9. Excessive resistance has been eliminated as a source of concern; intermittent supply voltage is suspected. Key on. Engage the thresher engage switch S30, and use a multi-meter to carefully back-probe connector X015 pin J1-7 to monitor the voltage. Carefully check the following areas while monitoring the voltage supply at CCM2: ---

---

Flex the cab main harness between the fuse panel, CCM2, and connector X001. If the voltage drops to zero at any time, there is a intermittent connection in the harness wiring at that point that must be repaired. Carefully wiggle the thresher latching relay K28 in its base in the fuse panel. If the voltage drops to zero at any time, there is an intermittent connection in the fuse panel in the area of the thresher latching relay K28. Wiggle the thresher engage switch S30 firmly; if the voltage drops to zero at any time, there is a fault in the switch. Replace the switch. Unbolt the top half of the right console. Flex the right console (RC) harness between the thresher engage switch S30 and connector X001. If the voltage drops to zero at any time, there is an intermittent connection in the harness wiring at that point that must be repaired.

55-13

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 THRESHER TROUBLESHOOTING

50020070

1 8

2 7

10004669

40025230

10020076

1. GEARBOX CLUTCH SOLENOID L22

2. CONNECTOR X035

40020077

3. CONNECTOR X011 4. CONNECTOR X016 5. CONNECTOR X015 6. CONNECTOR X055

10004693

7. THRESHER, LATCHING RELAY K28 8. FUSE F48

20031004

55-14

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12

B-22 = REAR LADDER F-23 = SCREEN BRUSH FUSE F-28 = FUEL PUMP FUSE K-07 = FUEL PUMP RELAY

M-23 = FUEL PUMP M-27 = ROTARY SCREEN BRUSH R-01 = FUEL LEVEL S-36 = ENGINE THROTTLE

S-61 = AIR FILTER SWITCH S-67 = COOLANT LEVEL

STARTING FRAME--3

55-15

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12

L-01 = NEUTRAL LOCK SOLENOID R-04 = GROUND SPEED POT S-09 = PARK BRAKE S-10 = REAR WHEEL ASSIST

S-11 = DUAL RANGE S-12 = ON THE ROAD SWITCH S-24 = GEAR SELECT

DRIVES FRAME--7

55-16

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12

THRESHER FRAME--18

B-01 = ROTOR RPM K-28 = THRESHER LATCHING L-22 = GEARBOX CLUTCH L-29 = ROTOR INCREASE

L-30 = ROTOR DECREASE S-30 = THRESHER ENGAGE

55-17

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12

F-48 = RH CONSOLE FUSE H-01 = AUDIO ALARM W-01 = SPLICE BLOCK A W-02 = SPLICE BLOCK B

W-05 = SPLICE BLOCK E W-06 = SPLICE BLOCK F

DISTRIBUTION FRAME--25

55-18

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 THIS PAGE LEFT BLANK

55-19

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 ROTOR SPEED Rotor speed is adjusted from the cab by the operator using a switch on the right console, and the rotor RPM may be monitored using the display monitor. The rotor speed is adjusted using electrical control of a hydraulic valve assembly that controls a hydraulic piston in the rotor drive variable sheave. Rotor Speed Adjust When the operator moves the rotor speed switch S17 on the right console, a 12 volt signal is sent to the right hand module (RHM). To increase rotor speed, a 12v signal is sent to connector X030 pin 11 wire 349 yellow; to decrease rotor speed, a 12v signal is sent to connector X030 pin 4 wire 348 yellow. When the RHM receives a rotor speed increase or decrease signal, it broadcasts a message over CAN which is picked up by CCM2. CCM2 will then activate the appropriate output to change the rotor speed. Power is sent to the rotor increase solenoid L29 to increase rotor speed, while the rotor decreases solenoid L30 is powered to decrease rotor speed. These solenoids are simply turned ‘on’ or ‘off’, so do not need to be grounded back through CCM2 like a PWM solenoid. Both solenoids are grounded at the main frame ground #2, located behind the left rear corner of the cab on the main frame. The actual rotor rpm is measured at the front of the left rotor using the rotor rpm sensor B01. Rotor Speed Alarms A0037 Rotor Speed Low – this alarm occurs if the threshing system is engaged, no manual changes are being made, and the rotor RPM is less than 200 rpm for more than 1 second. A typical cause of this alarm would be if the threshing system is engaged, but the engine is not throttled up to high idle immediately. The alarm will reset after the rotor rpm increases above 200 rpm for more than 3 seconds. If this alarm occurs while harvesting, the typical causes would be a slipping or damaged rotor drive belt, or some other problem with the physical rotor drive components.

55-20

Rotor Speed Errors The combine electronic system monitors the rotor speed sensor B01 and the outputs to the rotor increase and decrease solenoids L29/L30. In the event of any problems with these circuits, the appropriate fault code will be displayed to indicate the specific fault with these components and the circuits containing them. The following fault codes relate to the rotor speed sensor B01: E0146-03

Drum/Rotor Speed sensor Shorted to High Source

E0146-04

Drum/Rotor Speed sensor Shorted to Low Source

E0146-05

Drum/Rotor Speed sensor Line Disconnected

The following fault code relates to the rotor increase solenoid L29: E0191-11

Drum/Rotor Speed Increase Valve Unidentified Failure Code

The following fault code related to the rotor decrease solenoid L30: E0192-11

Drum/Rotor Speed Decrease Valve Unidentified Failure Code

The following fault codes relate to the rotor speed switch S-17: E0664-04

Rotor Speed Increase Switch Shorted to Low Source

E0664-07

Rotor Speed Increase Switch Mechanical Out of Range

E0665-04

Rotor Speed Decrease Switch Shorted to Low Source

E0665-07

Rotor Speed Decrease Switch Mechanical Out of Range

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12

HYDRAULIC FRAME--10

B-18 = HYD OIL RESERVOIR TEMP B-32 = GEARBOX TEMPERATURE B-35 = LOW CONTROL PRESSURE S-17 = ROTOR SPEED

S-18 = FEEDER SPEED S-32 = RETURNS FILTER BYPASS S-33 = HYDRAULIC RESERVOIR LEVEL S-34 = GEARBOX FILTER BYPASS

55-21

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12

THRESHER FRAME--18

B-01 = ROTOR RPM K-28 = THRESHER LATCHING L-22 = GEARBOX CLUTCH L-29 = ROTOR INCREASE

L-30 = ROTOR DECREASE S-30 = THRESHER ENGAGE

55-22

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 Rotor Speed Troubleshooting Symptom:

Rotor speed will not increase or decrease.

NOTE: Check for all active alarms and errors, and correct before following this troubleshooting procedure. Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, cycle the rotor speed switch S17 in both directions to check voltage range. The voltage should be 1.5 when the switch is in the “middle” position, and 5 volts when in the “Increase” or “Decrease” positions. A. If the voltage readings are correct, continue with Step 9. B. If there is no 5 volt reading in any switch position, continue with step 2. C. If the voltage reading indicates 5 volts for “CSW Thresher Speed Incr” but 1.5 volts for “CSW Thresher Speed Decr”, there is an open circuit in the right console (RC) harness between the rotor speed switch S17 pin 1 and the RHM connector X030 pin 4 wire 348 yellow. Locate the open and repair. D. If the voltage reading indicates 5 volts for “CSW Thresher Speed Decr” but 1.5 volts for “CSW Thresher Speed Incr”, there is an open circuit in the right console (RC) harness between the rotor speed switch S17 pin 3 and the RHM connector X030 pin 11 wire 349 yellow. Locate the open and repair. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Key switch in “On” position. Check fuse F48. A. If fuse F48 is okay, continue with step 4. B. If the fuse is blown, go to step 3. 3. Replace the failed fuse F48. A. If the fuse is okay, continue with step 4. B. If the fuse immediately fails again, a short to ground exists in one of the following wires: wire 109 orange, fuse F48 to thresher latching relay K28, terminal 3 wire 108 orange, fuse F48 to connector X001, pin 3 wire 110 orange, RC harness splice to thresher engage switch S30 pin 3 wire 300 orange, RC harness splice to neutral switch S22 pin 1 wire 1258 orange, RC harness splice to DA harness splice wire 1747 orange, RC harness splice to auto guidance switch S-78 pin 2 switch power wires from splice block B, W02 in the RH console (refer to frame 25 of electrical schematic for more information) Locate the short to ground and repair. 4. Toggle the rotor speed switch S17 in both directions, and observe the fuse F48. A. If the fuse is okay, continue with step 5. B. If the fuse immediately fails in the ‘decrease’ direction, there is a short to ground in the right console (RC) harness between the rotor speed switch connector X046 pin 1 and connector X030 pin 4 wire 348 yellow. Locate the short and repair. C. If the fuse immediately fails in the ‘increase’ direction, there is a short to ground in the right console (RC) harness between the rotor speed switch connector X046 pin 3 and connector X030 pin 11 wire 349 yellow. Locate the short and repair. 5. Unbolt the top half of the right console to gain access to the rotor speed switch S17 connector X046. Turn the key switch to the “On” position. Unplug connector X046, and use a multi-meter to measure the voltage at right console (RC) harness end of connector X046 pin 2. There should be 12 volts. A. If there is 12 volts, the rotor speed switch S17 is defective. Replace the switch. B. If there is no voltage, continue with step 6.

55-23

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 6. Key on. Use a multi-meter to measure the voltage at splice block B, W02, pin B. There should be 12 volts. A. If there is no voltage, continue with step 7. B. If there is 12 volts, there is an open circuit in the right console (RC) harness between splice block B, W02, pin B and connector X046 pin 2 wire 327 orange or 374 orange. Locate the open and repair. 7. Key on. Use a multi-meter to measure the voltage at splice block A, W02, pin M. There should be 12 volts. A. If there is no voltage, continue with step 8. B. If there is 12 volts, there is an open circuit internally in the splice block due to loose wire connections, or a corroded or damaged splice bar. Repair or replace the splice block as required to repair the open. 8. Key on. Disconnect connector X001. Use a multi-meter to measure the voltage at connector X001 pin 3. There should be 12 volts. A. If there is no voltage, there is an open circuit in the cab main (CM) harness between connector X001 pin 3 and fuse F48 wire 108 orange. Locate the open and repair. B. If there is voltage, there is an open circuit in the right console (RC) harness between splice block B, W02, pin M and connector X001 pin 3 wire 287 orange or 108 orange. Locate the open and repair. 9. Verify that the RHM and CCM2 modules are on-line on the network. Use the display monitor, reference Section 55 Chapter 2, if needed. If either of the modules is off-line and is not capable of transmitting on the network. Refer to Section 55 Electrical, Chapter 4 – ‘CAN Network’ in this manual for more information in troubleshooting this concern.

55-24

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 ROTOR TROUBLESHOOTING

2 50020070

10010917

10010918

1. CONNECTOR X046 2. CONNECTOR X030 3. CONNECTOR X001 4. FUSE F48

50031004

55-25

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12

HYDRAULIC FRAME--10

B-18 = HYD OIL RESERVOIR TEMP B-32 = GEARBOX TEMPERATURE B-35 = LOW CONTROL PRESSURE S-17 = ROTOR SPEED

S-18 = FEEDER SPEED S-32 = RETURNS FILTER BYPASS S-33 = HYDRAULIC RESERVOIR LEVEL S-34 = GEARBOX FILTER BYPASS

55-26

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12

THRESHER FRAME--18

B-01 = ROTOR RPM K-28 = THRESHER LATCHING L-22 = GEARBOX CLUTCH L-29 = ROTOR INCREASE

L-30 = ROTOR DECREASE S-30 = THRESHER ENGAGE

55-27

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12

F-48 = RH CONSOLE FUSE H-01 = AUDIO ALARM W-01 = SPLICE BLOCK A W-02 = SPLICE BLOCK B

W-05 = SPLICE BLOCK E W-06 = SPLICE BLOCK F

DISTRIBUTION FRAME--25

55-28

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 THIS PAGE LEFT BLANK

55-29

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 CONCAVE CLEARANCE Concave clearance is adjusted from the cab by the operator using a switch on the right console, and the relative concave clearance may be monitored using the display monitor. The concave clearance is adjusted using an electrical actuator working a mechanical linkage to raise and lower the center plate that carries the inner ends of the concaves. Concave Clearance Adjust When the operator moves the concave clearance switch S16 on the right console, a 12 volt signal is sent to the right hand module (RHM). To increase concave clearance, a 12v signal is sent to connector X030 pin 3 wire 347 yellow; to decrease concave clearance, a 12v signal is sent to connector X030 pin 8 wire 346 yellow. When the RHM receives a concave clearance increase or decrease signal, it broadcasts a message over CAN which is picked up by CCM1. CCM1 will then activate the appropriate output to change the concave clearance. Power is sent to activate the concave/covers relay K16, so that the appropriate output signal is directed to the concave clearance motor M04. The concave clearance motor is powered by an “H-bridge” circuit in CCM1; H-bridge circuits have two connector pins associated with them to control both sides of the circuit, and function by connecting one pin to ground when the opposite pin is connected to power. To reverse direction of the output, the power and ground connections are switched. This type of output control allows the module to operate motors and actuators in both directions. The H-bridge circuit holds both sides of the circuit to ground when the circuit is not active to “lock” the motor and prevent it from rotating. The relative concave clearance is measured at the rear of the linkage using the concave clearance potentiometer R06. Concave Clearance Alarms A0076 Concave Shearbolt Broken – If the relative concave clearance exceeds a certain value, this alarm will be displayed, indicating that the shear bolt in the concave clearance linkage has failed. Concave Clearance Errors The combine electronic system monitors the concave clearance potentiometer R06 and the H-bridge outputs to the concave clearance motor

55-30

M04. In the event of any problems with these circuits, the appropriate fault code will be displayed to indicate the specific fault with these components and the circuits containing them. The following fault codes relate to the concave clearance potentiometer R06: E0034-03

Concave Position sensor Shorted To Low Source

E0034-05

Concave Position sensor Line Disconnected

The following fault code relates to the output to the concave / covers relay K16: E0069-11

Covers / Concave Select Relay Unidentified Failure Code

The following fault codes relate to the concave clearance motor M04: E0044-06

Concave Adjustment Motor Current Sense Short Circuit

E0045-06

Grain Tank Covers Motor Current Sense Short Circuit

E0078-05

Concave Adjusting Motor Line Disconnected

E0079-05

Grain Tank Covers Motor Line Disconnected

The following fault codes relate to the concave clearance switch S-16: E0670-04

Concave Opening Decrease Switch Shorted to Low Source

E0670-07

Concave Opening Decrease Switch Mechanical Out of Range

E0671-04

Concave Opening Increase Switch Shorted to Low Source

E0671-07

Concave Opening Increase Switch Mechanical Out of Range

NOTE: The concave clearance is controlled using an H-bridge-controlled circuit. The concave clearance motor (M04) circuit is paired with the grainbin covers motor (M12) circuit, and the module switches between these two circuits using the Concave / Covers relay K-16. Because these circuits are connected and driven from the same module outputs, the troubleshooting procedure must consider both circuits at the same time. Refer to the ‘CCM1 Fault Codes’ chapter in this manual for more information.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12

B-45 = GEARBOX CLUTCH TEMP K-16 = CONCAVE/COVERS RELAY M-04 = CONCAVE CLEARANCE MOTOR M-12 = COVERS MOTOR

R-06 = CONCAVE POSITION S-16 = CONCAVE CLEARANCE

THRESHER FRAME--17

55-31

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12

F-48 = RH CONSOLE FUSE H-01 = AUDIO ALARM W-01 = SPLICE BLOCK A W-02 = SPLICE BLOCK B

W-05 = SPLICE BLOCK E W-06 = SPLICE BLOCK F

DISTRIBUTION FRAME--25

55-32

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 Concave Clearance Troubleshooting Symptom:

Concave clearance will not increase or decrease.

NOTE: Check for all active alarms and errors, and correct before following this troubleshooting procedure. Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, cycle the concave clearance switch S16 in both directions to check voltage range. The voltage should be 1.5 when the switch is in the “middle” position, and 5 volts when in the “Increase” or “Decrease” positions. A. If the voltage readings are correct, continue with Step 9. B. If there is no 5 volt reading in any switch position, continue with step 2. C. If the voltage reading indicates 5 volts for “CSW Concave Clear Incr” but 1.5 volts for “CSW Concave Clear Decr”, there is an open circuit in the right console (RC) harness between the concave clearance switch S16 pin 1 and the RHM connector X030 pin 8 wire 346 yellow. Locate the open and repair. D. If the voltage reading indicates 5 volts for “CSW Concave Clear Decr” but 1.5 volts for “CSW Concave Clear Incr”, there is an open circuit in the right console (RC) harness between the concave clearance switch S16 pin 3 and the RHM connector X030 pin 3 wire 347 yellow. Locate the open and repair. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Key switch in “On” position. Check fuse F48. A. If fuse F48 is okay, continue with step 4. B. If the fuse is blown, go to step 3. 3. Replace the failed fuse F48. A. If the fuse is okay, continue with step 4. B. If the fuse immediately fails again, a short to ground exists in one of the following wires: wire 109 orange, fuse F48 to thresher latching relay K28, terminal 3 wire 108 orange, fuse F48 to connector X001, pin 3 wire 110 orange, RC harness splice to thresher engage switch S30 pin 3 wire 300 orange, RC harness splice to neutral switch S22 pin 1 wire 1258 orange, RC harness splice to DA harness splice wire 1747 orange, RC harness splice to auto guidance switch S-78 pin 2 switch power wires from splice block B, W02 in the RH console (refer to frame 25 of electrical schematic for more information) Locate the short to ground and repair. 4. Toggle the concave clearance switch S16 in both directions, and observe the fuse F48. A. If the fuse is okay, continue with step 5. B. If the fuse immediately fails in the ‘decrease’ direction, there is a short to ground in the right console (RC) harness between the concave clearance switch connector X044 pin 1 and connector X030 pin 8 wire 346 yellow. Locate the short and repair. C. If the fuse immediately fails in the ‘increase’ direction, there is a short to ground in the right console (RC) harness between the concave clearance switch connector X044 pin 3 and connector X030 pin 3 wire 347 yellow. Locate the short and repair.

55-33

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 5. Unbolt the top half of the right console to gain access to the concave clearance switch S16 connector X044. Turn the key switch to the “On” position. Unplug connector X044, and use a multi-meter to measure the voltage at right console (RC) harness end of connector X044 pin 2. There should be 12 volts. A. If there is 12 volts, the concave clearance switch S16 is defective. Replace the switch. B. If there is no voltage, continue with step 6. 6. Key on. Use a multi-meter to measure the voltage at splice block B, W02, pin B. There should be 12 volts. A. If there is no voltage, continue with step 7. B. If there is 12 volts, there is an open circuit in the right console (RC) harness between splice block B, W02, pin B and connector X044 pin 2 wire 327 orange or 373 orange. Locate the open and repair. 7. Key on. Use a multi-meter to measure the voltage at splice block B, W02, pin M. There should be 12 volts. A. If there is no voltage, continue with step 8. B. If there is 12 volts, there is an open circuit internally in the splice block due to loose wire connections, or a corroded or damaged splice bar. Repair or replace the splice block as required to repair the open. 8. Key on. Disconnect connector X001. Use a multi-meter to measure the voltage at connector X001 pin 3. There should be 12 volts. A. If there is no voltage, there is an open circuit in the cab main (CM) harness between connector X001 pin 3 and fuse F48 wire 108 orange. Locate the open and repair. B. If there is voltage, there is an open circuit in the right console (RC) harness between splice block B, W02, pin M and connector X001 pin 3 wire 287 orange or 108 orange. Locate the open and repair. 9. Verify that the RHM and CCM1 modules are on-line on the network. Use the display monitor, reference Section 55 Chapter 2, if needed. If either of the modules is off-line and is not capable of transmitting on the network. Refer to Section 55 Electrical, Chapter 4 -- ‘CAN Network’ in this manual for more information in troubleshooting this concern.

55-34

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12 CONCAVE TROUBLESHOOTING

2 50020070

10010917

10010918

1. CONNECTOR X044 2. CONNECTOR X030 3. CONNECTOR X001 4. FUSE F48

50031004

55-35

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12

B-45 = GEARBOX CLUTCH TEMP K-16 = CONCAVE/COVERS RELAY M-04 = CONCAVE CLEARANCE MOTOR M-12 = COVERS MOTOR

R-06 = CONCAVE POSITION S-16 = CONCAVE CLEARANCE

THRESHER FRAME--17

55-36

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12

F-48 = RH CONSOLE FUSE H-01 = AUDIO ALARM W-01 = SPLICE BLOCK A W-02 = SPLICE BLOCK B

W-05 = SPLICE BLOCK E W-06 = SPLICE BLOCK F

DISTRIBUTION FRAME--25

55-37

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 12

55-38

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 13 -- Cleaning Systems CONTENTS Section

Description

Page

55-1

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 DESCRIPTION AND OPERATION SELF-LEVELING CLEANING SHOE The function of the self-leveling cleaning shoe is quite simple. The lateral inclination sensor B-02, 1, monitors the tilt of the combine and sends the information to pin J2-33 of CCM1. CCM1 uses this information to determine how far the cleaning shoe must be tilted to be level.

1 10004686

1 CCM1 uses two pairs of pins to send current to the shoe leveling actuator. This allows CCM1 to reverse the polarity and change the direction of the actuator. The first pair of pins, J-39 and J-40, send current through to a wire splice and through connector X023 pin 2 to connector X088 pin D of the actuator (M-03). The second pair of pins, J3-19 and J3-20, send current through a wire splice to Pin E of the shoe leveling actuator (M-03). The Shoe Leveling Actuator M-03 at the front right of cleaning shoe (behind the transmission) is also used to monitor the angle in which the cleaning shoe is tilted. Voltage is applied to pin A of the actuator. The ground path travels from pin B. As the actuator moves through its travel, the resistance through the actuator changes. A signal is sent from pin C of the actuator to connector X020 pin J3-32 of CCM1. CCM1 receives the signal and uses the changes in resistance to monitor the position of the actuator.

10004665

1 2

CCM1’s software detects when the self-leveling cleaning shoe makes contact with the frame (by detecting that the actuator motor is stalled) and establishes the limit of travel. These limits are NOT stored in non-volatile memory so they are established at least once per key-on cycle (each direction) when threshing is engaged.

55-2

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 Alarms Alarm Code A0077

Description Leveling Sieve Not level

Priority Med

Check Condition Threshing Engaged

Low

This is the (feedback) sensor in the linear actuator M-03. Sieve position sensor Shorted to high source

E0032-05

Sieve position sensor Line disconnected

E0043-06

Sieve Leveling Motor Current Sense Short Circuit

E0075-05

Leveling Sieve Motor Line Disconnected

Sieve actuator running in one direction for 15 seconds

Resetting Sieve position stable

Sieve position sensor Sieve position sensor faulty or lateral inOK and lateral inclination sensor faulty clination sensor OK

Fault Codes The self-leveling cleaning shoe operation is completely monitored by fault codes. If the self-leveling shoe does not operate correctly, check the fault history for any of the following fault codes, and correct. Recalibrate the cleaning system if necessary.

E0032-03

Activation

55-3

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 CLEANING FAN MOTOR (HYDRAULIC) The hydraulic cleaning fan motor, 1, replaces the belt drive and electric speed adjusting motor used in pre-model year 2006 combines. The hydraulic system is provided in all 2006 models and may be installed in some earlier models.

1 10051783

3 A hydraulic pump, 1, mounted on and driven by the hydrostatic propulsion drive pump, 2, drives the cleaning fan motor, 3. A proportional valve, 4, driven by a pulse width-modulated (PWM) signal from the system electronics modulates oil flow to the motor to regulate the motor speed.

1 2

3 66060051

55-4

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 A switch on the right hand console, 1, may be activated by the operator to manually adjust the cleaning fan RPM. In addition, the Automatic Crop Settings (ACS) system will automatically adjust the fan speed to a predefined RPM setting when activated, using feedback from the cleaning fan RPM sensor B16.

20030010

5 When the operator activates the cleaning fan speed switch in the cab, the right-hand module (RHM) sends a message via the CAN bus to controller CCM1, which sends a PWM signal to solenoid L-44, 1, on the cleaning fan control valve, 2. The solenoid valve works together with a proportional valve to regulate the flow of oil to the cleaning fan motor in accordance with the speed setting. An RPM sensor on the cleaning fan shaft sends speed information to CCM1. CCM1 relays the information to RHM, which provides the operator with a visual indication of the speed on the display monitor.

In Automatic Crop Settings (ACS) mode, the speed sensor provides feedback to the system, which in turn delivers the correct amount of PWM signal to the solenoid valve to maintain a constant speed. Fault Code E0054-11

66060560

Cleaning Fan Drive Valve Unidentified Failure Code

55-5

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 CLEANING SYSTEM SENSORS The cleaning system sensors monitor the shaft speeds of the mechanical components of the cleaning system. The sensors report this information to CCM1. CCM1 activates an audible alarm when a sensor reports that a cleaning system component speed has dropped below 80%. This number is relative to the engine speed. This means that if the engine rpm is lowered and the cleaning system components slow to 80% of their original speed, the audible alarm will not be activated. Lateral Inclination Sensor B02 The lateral inclination sensor, 1, is mounted under the cab near the right front cab mount. The lateral inclination sensor provides information to CCM1 regarding the lateral positioning of the combine chassis relative to level. Fault Codes E0033-03 E0033-05

Combine Lateral Tilt sensor Shorted to high source

Combine Lateral Tilt sensor Line disconnected

10004686

7 Fan Speed Switch S15 The fan speed switch, 1, is located on the right hand console, and is used by the operator to adjust the cleaning fan speed. Fault Codes E0662-04

Fan Speed Increase Switch Shorted to low source

E0662-07

Fan Speed Increase Switch Mechanical out of range

E0663-04

Fan Speed Decrease Switch Shorted to low source

E0663-07

20030010

Fan Speed Decrease Switch Mechanical out of range

55-6

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 Cleaning Fan RPM Sensor B16 The hydraulic cleaning fan RPM sensor, 1, monitors the speed of the cleaning fan and reports the information back to CCM1.

10051858

9 Alarms Alarm Code A0041

Fault Code E0013-03

Description Fan Speed Low

Priority

Activation

Resetting

High

1 sec < 130 RPM

3 sec > 130 RPM

Med

1 sec < 80% of threshold RPM

3 sec > 80% of threshold RPM

Fan Speed sensor Shorted to high source

E0013-04

Fan Speed sensor Shorted to low source

E0013-05

Fan Speed sensor Line disconnected

55-7

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 Left Returns RPM Sensor B06 The left returns sensor, 1, provides RPM information to warn in case of blockage. The left returns sensor also provides information to the operator display regarding returns volume; one fixed paddle and one hinged paddle are mounted on the end of the returns auger. The sensor monitors the time difference between the two paddles, as well as ‘counting’ RPM. As returns volume increases, the hinged paddle is deflected more, resulting in a longer time between the fixed paddle and hinged paddle, and a shorter time between the hinged paddle and the fixed paddle. CCM1 processes this time delay, and converts it into a representation of the volume of returns flowing through the system – this is displayed to operator on display monitor.

10004638

Alarms Alarm Code A0043

Description Returns Left Speed Low

Priority

Activation

Resetting

High

1 sec < 195 RPM

3 sec > 195 RPM

Med

1 sec < 80% of threshold RPM

3 sec > 80% of threshold RPM

Fault Codes E0015-03

Left Returns Speed sensor Shorted to high source

E0015-04

Left Returns Speed sensor Shorted to low source

E0015-05

Left Returns Speed sensor Line Disconnected

55-8

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 Clean Grain Elevator RPM Sensor B08 The clean grain elevator sensor, 1, monitors the RPM of the clean grain cross auger and elevator to guard against drive failure or blockage.

10004651

11 Alarms Alarm Code A0040

Description Grain Elevator Speed Low

Priority

Activation

Resetting

High

1 sec < 100 RPM

3 sec > 100 RPM

Med

1 sec < 80% of threshold RPM

3 sec > 80% of threshold RPM

Fault Codes E0016-03

Grain Elevator Speed Sensor Shorted to high source

E0016-04

Grain Elevator Speed Sensor Shorted to low source

E0016-05

Grain Elevator Speed Sensor Line disconnected

55-9

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 Right Returns RPM Sensor B39 The right returns RPM sensor, 1, monitors the RPM of the right returns auger to guard against drive failure or blockage.

10004668

12 Alarms Alarm Code A0044

Description Returns Right Speed Low

Priority

Activation

Resetting

High

1 sec < 195 RPM

3 sec > 195 RPM

Med

1 sec < 80% of threshold RPM

3 sec > 80% of threshold RPM

Fault Codes E0018-03

Right Returns Speed sensor Shorted to high source

E0018-04

Right Returns Speed sensor Shorted to low source

E0018-05

Right Returns Speed sensor Line disconnected

Loss Sensors Several loss sensors are used on the combine to monitor the performance of the separating and cleaning systems. Two rotor loss sensors are mounted on either side of the rotors to monitor the amount of grain being separated from the straw at the rear of the rotor, prior to the straw being discharged from the combine.

55-10

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 Rotor Loss Sensors B-19 and B-20 The rotor loss sensors, 1, are located on either side of the rotor.

40025223

13 Sieves Loss Sensor B-21 A single, full-width sensor, 1, is positioned behind the chaffer sieve to monitor the volume of grain that is discharged off the rear of the cleaning shoe.

1 10010864

55-11

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 REMOTE SIEVE ADJUST The combine may be equipped with optional remote adjust sieves, which uses linear actuators to adjust the chaffer and clean grain sieve clearance, either remotely from the cab using switches S-13 and S-14,1 and 2, on the right hand console,

15 or using remote mounted switches S-35 and S-46, 3 and 4, at the rear of the cleaning shoe. The sieve clearance may also be set automatically using the “Automatic Crop Settings” feature in the combine.

Sensors in the linear actuators provide a signal back to CCM3 on the relative opening of the sieve, so that information may be displayed to the operator on the display monitor. The remote sieve adjust is powered from an H-bridge circuit off of CCM3, and this circuit is switched by a relay, since both sieve actuators are powered from the same set of module outputs.

40024710

55-12

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 Alarms Alarm Code

Description

Priority

Activation

Resetting

A0120

Upper Sieve Not In Commanded Position

Med

Actual upper sieve position is not within 1 mm of position set point for 4 seconds

Actual upper sieve position is within 1 mm of position set point

A0124

Lower Sieve Not In Commanded Position

Med

Actual lower sieve position is not within 1 mm of position set point for 4 seconds

Actual lower sieve position is within 1 mm of position set point

A0125

Upper Sieve Calibration Required

Low

Upper sieve has never been calibrated

Calibrate upper sieve

A0126

Lower Sieve Calibration Required

Low

Lower sieve has never been calibrated

Calibrate lower sieve

Fault Codes E0261-03

Lower Sieve Close – Rear Switch Shorted to high source

E0334-05

Lower Sieve Adjust motor Line Disconnected

E0261-04

Lower Sieve Close – Rear Switch Shorted to low source

E0335-05

Upper Sieve Adjust motor Line Disconnected

E0262-03

Upper Sieve Close – Rear Switch Shorted to high source

E0672-04

Upper Sieve Decrease Switch Shorted to low source

E0262-04

Upper Sieve Close – Rear Switch Shorted to low source

E0672-07

Upper Sieve Decrease Switch Mechanical out of range

E0263-03

Lower Sieve Open – Rear Switch Shorted to high source

E0673-04

Upper Sieve Increase Switch Shorted to low source

E0263-04

Lower Sieve Open – Rear Switch Shorted to low source

E0673-07

Upper Sieve Increase Switch Mechanical out of range

E0282-03

Upper Sieve Open – Rear Switch Shorted to high source

E0674-04

Lower Sieve Decrease Switch Shorted to low source

E0282-04

Upper Sieve Open – Rear Switch Shorted to low source

E0674-07

Lower Sieve Decrease Switch Mechanical out of range

E0300-06

Lower Sieve Current Sense Short Circuit

E0675-04

Lower Sieve Increase Switch Shorted to low source

E0301-06

Upper Sieve Current Sense Short Circuit

E0675-07

Lower Sieve Increase Switch Mechanical out of range

E0325-11

Upper / Lower Sieve Select Relay Unidentified Failure Code

55-13

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 ELECTRICAL SCHEMATICS

B-16 = CLEANING FAN RPM B-21 = SIEVES LOSS F-22 = SHOE LEVELING MOTOR FUSE L-44 = FAN DRIVE SOLENOID

M-03 = SHOE LEVELING ACTUATOR S-13 = UPPER SIEVE S-14 = LOWER SIEVE S-15 = FAN SPEED

55-14

CLEANING FRAME--19

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13

CLEANING FRAME--20

B-02 = LATERAL INCLINATION B-06 = LEFT RETURNS RPM B-08 = CLEAN GRAIN ELEVATOR RPM B-19 = LEFT ROTOR LOSS

B-20 = RIGHT ROTOR LOSS B-39 = RIGHT RETURNS RPM

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13

F-27 = SIEVE/SPREADER FUSE K-18 = UPPER/LOWER SIEVE RELAY M-06 = UPPER SIEVE ACTUATOR M-07 = LOWER SIEVE ACTUATOR

S-35 = UPPER SIEVE REAR ADJUST S-46 = LOWER SIEVE REAR ADJUST

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CLEANING FRAME--21

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13

F-48 = RH CONSOLE FUSE H-01 = AUDIO ALARM W-01 = SPLICE BLOCK A W-02 = SPLICE BLOCK B

W-05 = SPLICE BLOCK E W-06 = SPLICE BLOCK F

DISTRIBUTION FRAME--25

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 TROUBLESHOOTING CLEANING FAN MOTOR M05 Symptom:

Fan speed will not increase or decrease.

NOTE: Check for all active alarms and errors, and correct before following this troubleshooting procedure. Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, cycle the fan speed switch S15 in both directions to check voltage range. The voltage should be 0 when the switch is in the “middle” position, and 12 volts when in the “Increase” or “Decrease” positions. The normal operating range for the fan speed switch in the “Off” position is 0.5 -- 3.5 volts. The normal operating range for the fan speed switch in the “On” position is 3.5 -- 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage readings are correct, continue with Step 9. B. If there is no 12 volt reading in any switch position, continue with step 2. C. If the voltage reading indicates 12 volts for “CSW Fan Speed Fan Increase” but 0 volts for “CSW Fan Speed Decrease”, there is an open circuit in the right console (RC) harness between the fan speed switch S15 pin 1 and the RHM connector X030 pin 9 wire 344 yellow. Locate the open and repair. D. If the voltage reading indicates 12 volts for “CSW Fan Speed Decrease” but 0 volts for “CSW Fan Speed Increase”, there is an open circuit in the right console (RC) harness between the fan speed switch S15 pin 3 and the RHM connector X030 pin 10 wire 345 yellow. Locate the open and repair. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Key switch in “On” position. Check fuse F48. A. If fuse F48 is okay, continue with step 4. B. If the fuse is blown, go to step 3. 3. Replace the failed fuse F48. A. If the fuse is okay, continue with step 4. B. If the fuse immediately fails again, a short to ground exists in one of the following wires: wire 109 orange, fuse F48 to thresher latching relay K28, terminal 3 wire 108 orange, fuse F48 to connector X001, pin 3 wire 110 orange, RC harness splice to thresher engage switch S30 pin 3 wire 300 orange, RC harness splice to neutral switch S22 pin 1 wire 1258 orange, RC harness splice to DA harness splice wire 1747 orange, RC harness splice to Autoguidance switch S-78 pin 2 switch power wires from splice block B, W02 in the RH console (refer to frame 25 of electrical schematic for more information) Locate the short to ground and repair. 4. Toggle the fan speed switch S15 in both directions, and observe the fuse F48. A. If the fuse is okay, continue with step 5. B. If the fuse immediately fails in the ‘decrease’ direction, there is a short to ground in the right console (RC) harness between the fan speed switch connector X045 pin 1 and connector X030 pin 9 wire 344 yellow. Locate the short and repair. C. If the fuse immediately fails in the ‘increase’ direction, there is a short to ground in the right console (RC) harness between the fan speed switch connector X045 pin 3 and connector X030 pin 10 wire 345 yellow. Locate the short and repair.

55-18

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 5. Unbolt the top half of the right console to gain access to the fan speed switch S15 connector X045. Turn the key switch to the “On” position. Unplug connector X045, and use a multi-meter to measure the voltage at right console (RC) harness end of connector X045 pin 2. There should be 12 volts. A. If there is 12 volts, the fan speed switch S15 is defective. Replace the switch. B. If there is no voltage, continue with step 6. 6. Key on. Use a multi-meter to measure the voltage at splice block B, W02, pin A. There should be 12 volts. A. If there is no voltage, continue with step 7. B. If there is 12 volts, there is an open circuit in the right console (RC) harness between splice block B, W02, pin A and connector X045 pin 2 wire 372 orange or 374 orange. Locate the open and repair. 7. Key on. Use a multi-meter to measure the voltage at splice block B, W02, pin M. There should be 12 volts. A. If there is no voltage, continue with step 8. B. If there is 12 volts, there is an open circuit internally in the splice block due to loose wire connections, or a corroded or damaged splice bar. Repair or replace the splice block as required to repair the open. 8. Key on. Disconnect connector X001. Use a multi-meter to measure the voltage at connector X001 pin 3. There should be 12 volts. A. If there is no voltage, there is an open circuit in the cab main (CM) harness between connector X001 pin 3 and fuse F48 wire 108 orange. Locate the open and repair. B. If there is voltage, there is an open circuit in the right console (RC) harness between splice block A, W02, pin M and connector X001 pin 3 wire 287 orange or 108 orange. Locate the open and repair. 9. Verify that the RHM and CCM1 modules are on-line on the network. Use the display monitor, reference Section 55 Chapter 2, if needed. Scroll through the screen as necessary to locate the RHM and CCM1 modules. If either of the modules is off-line and is not capable of transmitting on the network. Refer to Section 55 Electrical, Chapter 4 -- ‘CAN Network’ in this manual for more information in troubleshooting this concern.

55-19

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 LOSS SENSORS There are no fault codes to indicate a problem with the loss sensors. To troubleshoot a problem with the loss sensors, check for continuity between CCM1 and each sensor. IMPORTANT: Disconnect the batteries while troubleshooting the Rotor Loss Sensors to avoid damaging the electrical system. Left Rotor Loss Sensor B-19 1. Check the input side of the left rotor loss sensor by unplugging connector X016 from CCM2 and jumping wire MF-465-BL, connector X016 pin J2-14, of the harness to ground. Unplug connector X241 from the left rotor sensor and check for continuity between pin 1 and ground. If continuity exists, proceed to step 2. If continuity does not exist, check wire MF-457-Blue for damage. 2. Unplug connector X241 from the left rotor loss sensor and jump wire MF-410 Yellow to ground. Unplug connector X016 from CCM2 and check for continuity between wire MF-410 Yellow, connector X016 pin J2-25, and ground. If continuity exists proceed to Step 3. If continuity does not exist, check wire MF-410 Yellow for damage.

40025223

3. The left rotor loss sensor is defective and requires replacement. Right Rotor Loss Sensor B-20 1. Check the input side of the right rotor loss sensor by unplugging connector X017 from CCM2 and jumping wire MF-766-BL, connector X017 pin J3-18, of the harness to ground. Unplug connector X250 from the right rotor sensor and check for continuity between pin 1 and ground. If continuity exists, proceed to step 2. If continuity does not exist, check wire MF-458-Blue for damage. 2. Unplug connector X250 from the right rotor loss sensor and jump wire MF-402 Yellow to ground. Unplug connector X016 from CCM2 and check for continuity between wire MF-402 Yellow connector X016 pin J2-26 and ground. If continuity exists proceed to Step 3. If continuity does not exist, check wire MF-402 Yellow for damage. 3. The right rotor loss sensor is defective and requires replacement.

55-20

40025224

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 Sieves Loss Sensor B-21 Symptom: Sieves Loss Sensor is not functioning properly. Solution: Use a multimeter to test the Sieves Loss Sensor circuit. Make sure the key switch is in the “Run” position while testing the sieve loss sensor. 1. Unplug connector X232 and test for continuity to ground on pin 1. A. If continuity exists, go to step 6. B. If continuity to ground does not exist, go to the next step. 2. Unplug connector X072 and test wire SW-494-BL on the strawhood front (SW) harness side for continuity to ground on pin C. A. If continuity exists, wire LR-494-BL is broken or damaged. Replace as necessary. B. If continuity does not exist, go to the next step. 3. Unplug connector X024 and test wire MF-461-BL on the main frame (MF) harness side for continuity to ground on pin 11. A. If continuity exists, wire MF-461-BL is broken or damaged. Replace as necessary. B. If continuity does not exist, go to the next step. 4. Unplug connector X008 and test wire FF-401-BL on the front frame (FF) harness side for continuity to ground on pin 7. A. If continuity exists, wire FF-401-BL is broken or damaged. Replace as necessary. B. If continuity does not exist, go to the next step. 5. Unplug connector X020 and test pin J3-18 of CCM1 on the module for continuity to ground. A. If continuity exists, wire FF-501-BL is broken or damaged. Replace as necessary. B. If continuity does not exist, CCM1 is damaged and requires repair or replacement. 6. Unplug connector X232 and test pin 2 on the lower frame rear (LR) harness side for voltage. A. If voltage exists, the sieve loss sensor is defective and requires replacement. B. If voltage does not exist, go to the next step. 7. Unplug connector X072 and test pin D on the straw hood front (SW) harness side for voltage. A. If voltage exists, wire LR-431-YE is broken or damaged and requires replacement. B. If voltage does not exist, go to the next step. 8. Unplug connector X024 and test pin 5 on the main frame (MF) harness side for voltage. A. If voltage exists, wire SW-431-YE is broken or damaged and requires replacement. B. If voltage does not exist, go to the next step. 9. Unplug connector X019 and test pin J2-25 on the module for voltage. A. If voltage exists, wire MF-431-YE is broken or damaged and requires replacement. B. If voltage does not exist, CCM1 is damaged and requires repair or replacement.

55-21

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 REMOTE SIEVE ADJUST When activated, the remote sieve switches cause power to be sent from the CCM3, and activate the circuit by connecting the circuit to ground -- when the CCM3 sees a particular remote switch circuit shorted to ground, it then activates the appropriate output). As an example, if one of the remote switch circuits was shorted to ground, CCM3 would think the switch was being depressed, and would try to adjust the sieve -- ultimately fully opening or closing it, depending on which wire was grounded.

55-22

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 Upper Remote Sieve Adjust Switch Symptom:

Upper sieve will not raise or lower.

NOTE: Check for all active alarms and errors, and correct before following this troubleshooting procedure. Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, cycle the upper sieve switch S13 in both directions to check voltage range. The voltage should be 0 when the switch is in the “middle” position, and 12 volts when in the “Raise” or “Lower” positions. The normal operating range for the upper sieve switch in the “Off” position is 0.5 -- 3.5 volts. The normal operating range for the upper sieve switch in the “On” position is 3.5 -- 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage readings are correct, continue with Step 9. B. If there is no 12 volt reading in any switch position, continue with step 2. C. If the voltage reading indicates 12 volts for “upper sieve raise” but 0 volts for “upper sieve lower”, there is an open circuit in the right console (RC) harness between the upper sieve switch S13 pin 1 and the RHM connector X030 pin 7 wire 340 yellow. Locate the open and repair. D. If the voltage reading indicates 12 volts for “upper sieve lower” but 0 volts for “upper sieve raise”, there is an open circuit in the right console (RC) harness between the upper sieve switch S13 pin 3 and the RHM connector X030 pin 2 wire 341 yellow. Locate the open and repair. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Key switch in “On” position. Check fuse F48. A. If fuse F48 is okay, continue with step 4. B. If the fuse is blown, go to step 3. 3. Replace the failed fuse F48. A. If the fuse is okay, continue with step 4. B. If the fuse immediately fails again, a short to ground exists in one of the following wires: wire 109 orange, fuse F48 to thresher latching relay K28, terminal 3 wire 108 orange, fuse F48 to connector X001, pin 3 wire 110 orange, RC harness splice to thresher engage switch S30 pin 3 wire 300 orange, RC harness splice to neutral switch S22 pin 1 wire 1258 orange, RC harness splice to DA harness splice wire 1747 orange, RC harness splice to Autoguidance switch S-78 pin 2 switch power wires from splice block B, W02 in the RH console (refer to frame 25 of electrical schematic for more information) Locate the short to ground and repair. 4. Toggle the upper sieve switch S13 in both directions, and observe the fuse F48. A. If the fuse is okay, continue with step 5. B. If the fuse immediately fails in the ‘lower’ direction, there is a short to ground in the right console (RC) harness between the upper sieve switch connector X043 pin 1 and connector X030 pin 7 wire 340 yellow. Locate the short and repair. C. If the fuse immediately fails in the ‘raise’ direction, there is a short to ground in the right console (RC) harness between the upper sieve switch connector X043 pin 3 and connector X030 pin 2 wire 341 yellow. Locate the short and repair.

55-23

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 5. Unbolt the top half of the right console to gain access to the upper sieve switch S13 connector X043. Turn the key switch to the “On” position. Unplug connector X043, and use a multi-meter to measure the voltage at right console (RC) harness end of connector X043 pin 2. There should be 12 volts. A. If there is 12 volts, the upper sieve switch S13 is defective. Replace the switch. B. If there is no voltage, continue with step 6. 6. Key on. Use a multi-meter to measure the voltage at splice block B, W02, pin B. There should be 12 volts. A. If there is no voltage, continue with step 7. B. If there is 12 volts, there is an open circuit in the right console (RC) harness between splice block B, W02, pin B and connector X043 pin 2 wire 370 orange or 327 orange. Locate the open and repair. 7. Key on. Use a multi-meter to measure the voltage at splice block A, W02, pin M. There should be 12 volts. A. If there is no voltage, continue with step 8. B. If there is 12 volts, there is an open circuit internally in the splice block due to loose wire connections, or a corroded or damaged splice bar. Repair or replace the splice block as required to repair the open. 8. Key on. Disconnect connector X001. Use a multi-meter to measure the voltage at connector X001 pin 3 on the cab main (CM) harness side. There should be 12 volts. A. If there is no voltage, there is an open circuit in the cab main (CM) harness between connector X001 pin 3 and fuse F48 wire 108 orange. Locate the open and repair. B. If there is voltage, there is an open circuit in the right console (RC) harness between splice block B, W02, pin M and connector X001 pin 3 wire 287 orange or 108 orange. Locate the open and repair. 9. Verify that the RHM and CCM3 modules are on-line on the network. Use the display monitor, reference Section 55 Chapter 2, if needed. Scroll through the screen as necessary to locate the RHM and CCM3 modules. If either of the modules is off-line and is not capable of transmitting on the network. Refer to Section 55 Electrical, Chapter 4 -- ‘CAN Network’ in this manual for more information in troubleshooting this concern.

55-24

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 Lower Remote Sieve Adjust Switch Symptom:

Lower sieve will not raise or lower.

NOTE: Check for all active alarms and errors, and correct before following this troubleshooting procedure. Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, cycle the lower sieve switch S14 in both directions to check voltage range. The voltage should be 0 when the switch is in the “middle” position, and 12 volts when in the “Raise” or “Lower” positions. The normal operating range for the lower sieve switch in the “Off” position is 0.5 -- 3.5 volts. The normal operating range for the lower sieve switch in the “On” position is 3.5 -- 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage readings are correct, continue with Step 9. B. If there is no 12 volt reading in any switch position, continue with step 2. C. If the voltage reading indicates 12 volts for “lower sieve raise” but 0 volts for “lower sieve lower”, there is an open circuit in the right console (RC) harness between the lower sieve switch S14 pin 1 and the RHM connector X030 pin 1 wire 342 yellow. Locate the open and repair. D. If the voltage reading indicates 12 volts for “lower sieve lower” but 0 volts for “lower sieve raise”, there is an open circuit in the right console (RC) harness between the lower sieve switch S14 pin 3 and the RHM connector X030 pin 6 wire 343 yellow. Locate the open and repair. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Key switch in “On” position. Check fuse F48. A. If fuse F48 is okay, continue with step 4. B. If the fuse is blown, go to step 3. 3. Replace the failed fuse F48. A. If the fuse is okay, continue with step 4. B. If the fuse immediately fails again, a short to ground exists in one of the following wires: wire 109 orange, fuse F48 to thresher latching relay K28, terminal 3 wire 108 orange, fuse F48 to connector X001, pin 3 wire 110 orange, RC harness splice to thresher engage switch S30 pin 3 wire 300 orange, RC harness splice to neutral switch S22 pin 1 wire 1258 orange, RC harness splice to DA harness splice wire 1747 orange, RC harness splice to Autoguidance switch S-78 pin 2 switch power wires from splice block B, W02 in the RH console (refer to frame 25 of electrical schematic for more information) Locate the short to ground and repair. 4. Toggle the lower sieve switch S14 in both directions, and observe the fuse F48. A. If the fuse is okay, continue with step 5. B. If the fuse immediately fails in the ‘lower’ direction, there is a short to ground in the right console (RC) harness between the lower sieve switch connector X042 pin 1 and connector X030 pin 1 wire 342 yellow. Locate the short and repair. C. If the fuse immediately fails in the ‘raise’ direction, there is a short to ground in the right console (RC) harness between the lower sieve switch connector X042 pin 3 and connector X030 pin 6 wire 343 yellow. Locate the short and repair.

55-25

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 5. Unbolt the top half of the right console to gain access to the lower sieve switch S14 connector X042. Turn the key switch to the “On” position. Unplug connector X042, and use a multi-meter to measure the voltage at right console (RC) harness end of connector X042 pin 2. There should be 12 volts. A. If there is 12 volts, the lower sieve switch S14 is defective. Replace the switch. B. If there is no voltage, continue with step 6. 6. Key on. Use a multi-meter to measure the voltage at splice block B, W02, pin B. There should be 12 volts. A. If there is no voltage, continue with step 7. B. If there is 12 volts, there is an open circuit in the right console (RC) harness between splice block B, W02, pin B and connector X042 pin 2 wire 327 orange or 371 orange. Locate the open and repair. 7. Key on. Use a multi-meter to measure the voltage at splice block B, W02, pin M. There should be 12 volts. A. If there is no voltage, continue with step 8. B. If there is 12 volts, there is an open circuit internally in the splice block due to loose wire connections, or a corroded or damaged splice bar. Repair or replace the splice block as required to repair the open. 8. Key on. Disconnect connector X001. Use a multi-meter to measure the voltage at connector X001 pin 3 on the cab main (CM) harness side. There should be 12 volts. A. If there is no voltage, there is an open circuit in the cab main (CM) harness between connector X001 pin 3 and fuse F48 wire 108 orange. Locate the open and repair. B. If there is voltage, there is an open circuit in the right console (RC) harness between splice block B, W02, pin M and connector X001 pin 3 wire 287 orange or 108 orange. Locate the open and repair. 9. Verify that the RHM and CCM3 modules are on-line on the network. Use the display monitor, reference Section 55 Chapter 2, if needed. Scroll through the screen as necessary to locate the RHM and CCM3 modules. If either of the modules is off-line and is not capable of transmitting on the network. Refer to Section 55 Electrical, Chapter 4 -- ‘CAN Network’ in this manual for more information in troubleshooting this concern.

55-26

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 Upper Sieve Rear Adjust Switch S-35 The Upper Sieve Rear Adjust Switch, 1, is a two-position momentary rocker switch. When the switch is activated in either direction, the corresponding ground path is completed. CCM3 establishes a ground path is completed, and activates the upper sieve actuator in the proper direction. If the rocker switch is pushed in the opposite position, CCM3 reverses the current flow to send the upper actuator in the opposite direction. Resolve any issues with Fault codes before troubleshooting the upper sieve rear adjust circuit.

40024710

Refer to the chart below to troubleshoot the Upper Sieve Rear Adjust Switch Circuit.

Symptom

Probable Causes

Upper Sieve Actuator Raises Short to ground on circuit 540 Without Switch Activation

Troubleshooting 1. Unplug connectors X025 and X013. Test for continuity to ground on pin 7 on wire EX-540YE-0.8. If continuity exists, wire EX-540-YE-0.8 is damaged and requires repair. If continuity does not exist, proceed to the next step. 2. With connector X025 still unplugged, unplug connector X225 and test for continuity to ground on wire SW-540-YE-0.8. If continuity exists, wire SW-540-YE-0.8 is damaged and requires repair. If no continuity exists, proceed to the next step. 3. With the upper sieve rear adjust switch in the middle (off) position, test the pins for continuity. If continuity exists between any of the pins in the off position, the switch is defective and requires replacement. 4. If it is determined that the switch or wire harness is not defective, CCM3 is defective and requires repair or replacement.

55-27

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 Symptom

Probable Causes

Upper Sieve Actuator Lowers Short to ground on circuit 539 Without Switch Activation

Troubleshooting 1. Unplug connectors X025 and X013. Test for continuity to ground on pin 6 on wire EX-539YE-0.8. If continuity exists, wire EX-539-YE-0.8 is damaged and requires repair. If continuity does not exist, proceed to the next step. 2. With connector X025 still unplugged, unplug connector X225 and test for continuity to ground on wire SW-539-YE-0.8. If continuity exists, wire SW-539-YE-0.8 is damaged and requires repair. If no continuity exists, proceed to the next step. 3. With the lower sieve rear adjust switch in the middle (off) position, test the pins for continuity. If continuity exists between any of the pins in the off position, the switch is defective and requires replacement. 4. If it is determined that the switch or wire harness is not defective, CCM3 is defective and requires repair or replacement.

Upper Sieve Actuator Will Not Open circuit 550 Raise or Lower

1. Check for loose or corroded connectors on circuit 539. If no loose or corroded connectors are found, proceed to the next step. 2. Unplug connector X025 and test for continuity to ground on circuit EX-550-Bk-0.8. If continuity does not exist, circuit EX-550-Bk-0.8 is damaged and requires repair. If continuity exists, proceed to the next step. 3. With connector X025 still disconnected, unplug connector X225 and jump pin 2 on the straw hood front (SW) harness side to ground. Test pin 19 of connector X025 on the straw hood front (SW) harness side for continuity to ground. If continuity does not exist, Circuit SW-550 is damaged and requires repair. If continuity exists, the upper sieve rear adjust switch is defective and requires replacement.

55-28

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 Symptom

Probable Causes

Upper Sieve Actuator Will Not Open circuit 540 Raise

Troubleshooting 1. Unplug connector X225 and press the upper sieve rear adjust switch into the “raise” position. Continuity should exist between pins 2 and 3. If continuity does not exist, the switch is defective and requires replacement. If continuity exists between terminals 2 and 3 when the switch is in the “raise” position, proceed to the next step. 2. Disconnect connector X025 and turn to the key to the “RUN” position. Using a voltmeter, check for voltage at pin 7 of connector X025 of circuit EX-540YE-0.8. If voltage exist, circuit SW-540-YE is damaged and requires replacement. If voltage does not exist, unplug connector X013 and check voltage at pin J2-17 of CCM3. If voltage exists, circuit EX-540 is damaged and requires replacement. If voltage does not exist at pin J2-17, CCM3 is defective and requires replacement.

Upper Sieve Actuator Will Not Open circuit 539 Lower

1. Unplug connector X225 and press the upper sieve rear adjust switch into the “lower” position. Continuity should exist between pins 2 and 1. If continuity does not exist, the switch is defective and requires replacement. If continuity exists between terminals 2 and 1 when the switch is in the “lower” position, proceed to the next step. 2. Disconnect connector X025 and turn to the key to the “RUN” position. Using a voltmeter, check for voltage at pin 6 of connector X025 of circuit EX-539YE-0.8. If voltage exist, circuit SW-539-YE is damaged and requires replacement. If voltage does not exist, unplug connector X013 and check voltage at pin J2-34 of CCM3. If voltage exists, circuit SW-539 is damaged and requires replacement. If voltage does not exist at pin J2-34, CCM3 is defective and requires replacement.

55-29

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 Lower Sieve Rear Adjust Switch S-46 The Lower Sieve Rear Adjust Switch, 2, is a two-position momentary rocker switch. When the switch is activated in either direction, the corresponding ground path is completed. CCM3 establishes a ground path is completed, and activates the lower sieve actuator in the proper direction. If the rocker switch is pushed in the opposite position, CCM3 reverses the current flow to send the lower actuator in the opposite direction. Resolve any issues with alarm codes before troubleshooting the lower sieve rear adjust circuit.

40024710

Refer to the chart below to troubleshoot the Lower Sieve Rear Adjust Switch Circuit.

Symptom

Probable Causes

Lower Sieve Actuator Raises Short to ground on circuit 542 Without Switch Activation

Troubleshooting 1. Unplug connectors X025 and X013. Test for continuity to ground on pin 11 on wire EX-542YE-0.8. If continuity exists, wire EX-542-YE-0.8 is damaged and requires repair. If continuity does not exist, proceed to the next step. 2. With connector X025 still unplugged, unplug connector X226 and test for continuity to ground on wire SW-542-YE-0.8. If continuity exists, wire SW-542-YE-0.8 is damaged and requires repair. If no continuity exists, proceed to the next step. 3. With the lower sieve rear adjust switch in the middle (off) position, test the pins for continuity. If continuity exists between any of the pins in the off position, the switch is defective and requires replacement. 4. If it is determined that the switch or wire harness is not defective, CCM3 is defective and requires repair or replacement.

55-30

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 Symptom

Probable Causes

Lower Sieve Actuator Lowers Short to ground on circuit 541 Without Switch Activation

Troubleshooting 1. Unplug connectors X025 and X013. Test for continuity to ground on pin 9 on wire EX-541YE-0.8. If continuity exists, wire EX-541-YE-0.8 is damaged and requires repair. If continuity does not exist, proceed to the next step. 2. With connector X025 still unplugged, unplug connector X226 and test for continuity to ground on wire SW-541-YE-0.8. If continuity exists, wire SW-541-YE-0.8 is damaged and requires repair. If no continuity exists, proceed to the next step. 3. With the lower sieve rear adjust switch in the middle (off) position, test the pins for continuity. If continuity exists between any of the pins in the off position, the switch is defective and requires replacement. 4. If it is determined that the switch or wire harness is not defective, CCM3 is defective and requires repair or replacement.

Lower Sieve Actuator Will Not Open circuit 551 Raise or Lower

1. Check for loose or corroded connectors on circuit 551. If no loose or corroded connectors are found, proceed to the next step. 2. Unplug connector X025 and test for continuity to ground on circuit EX-551-Bk-0.8. If continuity does not exist, circuit EX-551-Bk-0.8 is damaged and requires repair. If continuity exists, proceed to the next step. 3. With connector X025 still disconnected, unplug connector X226 and jump pin 2 on the straw hood front (SW) harness side to ground. Test pin 13 of connector X025 on the straw hood front (SW) harness side for continuity to ground. If continuity does not exist, Circuit SW-551 is damaged and requires repair. If continuity exists, the lower sieve rear adjust switch is defective and requires replacement.

55-31

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 13 Symptom

Probable Causes

Lower Sieve Actuator Will Not Open circuit 542 Raise

Troubleshooting 1. Unplug connector X226 and press the lower sieve rear adjust switch into the “raise” position. Continuity should exist between pins 2 and 3. If continuity does not exist, the switch is defective and requires replacement. If continuity exists between terminals 2 and 3 when the switch is in the “raise” position, proceed to the next step. 2. Disconnect connector X025 and turn to the key to the “RUN” position. Using a voltmeter, check for voltage at pin 11 of connector X025 of circuit EX-542YE-0.8. If voltage exist, circuit SW-542-YE is damaged and requires replacement. If voltage does not exist, unplug connector X013 and check voltage at pin J2-35 of CCM3. If voltage exists, circuit EX-542 is damaged and requires replacement. If voltage does not exist at pin J2-35, CCM3 is defective and requires replacement.

Lower Sieve Actuator Will Not Open circuit 541 Lower

1. Unplug connector X226 and press the lower sieve rear adjust switch into the “lower” position. Continuity should exist between pins 2 and 1. If continuity does not exist, the switch is defective and requires replacement. If continuity exists between terminals 2 and 1 when the switch is in the “lower” position, proceed to the next step. 2. Disconnect connector X025 and turn to the key to the “RUN” position. Using a voltmeter, check for voltage at pin 9 of connector X025 of circuit EX-541 YE-0.8. If voltage exist, circuit SW-541-YE is damaged and requires replacement. If voltage does not exist, unplug connector X013 and check voltage at pin J2-39 of CCM3. If voltage exists, circuit SW-541 is damaged and requires replacement. If voltage does not exist at pin J2-39, CCM3 is defective and requires replacement.

55-32

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 14

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 14 -- Clean Grain Systems CONTENTS Section

Description

Page

55-1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 14 This section explains the following clean Grain system components: •

Unload system engage

•

Grain bin sensors

•

Grain Tank covers

•

Unload Tube Swing

UNLOAD ENGAGE The Unload engage is triggered from a switch, 1, in the Multi-Function Handle (MFH); press once to engage the unloading system, press again to disengage unloading. The MFH switch sends a signal to the Right-hand Control Module (RHM). The RHM transmits messages via CAN to CCM2, CCM2 sends a PWM signal to a solenoid on the engine gearbox valve to engage the clutch L-08 in the engine gearbox.

The Unload engage will not engage if: •

The Road/Field switch is in “Road” mode or the Emergency stop button on the MFH is depressed.

•

The Unload tube is in, or is moved into the “Home” Position.

20030010

Unload Engage – Alarms A0022 Unload Engaged – will occur any time the unloading system is engaged. Unload Engage – Fault Codes E0177-03 Current sense Unload Clutch Shorted to high source E0184-11

Unloading Clutch valve Unidentified Failure Code

55-2

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 14 Unload Engage – Troubleshooting NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned.

The unload system will not engage. Cause: No signal from the unload engage switch on MFH. Possible Failure Modes: 1. Switch failed.

2. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 4 and pin 1, with the black (common) probe of the multimeter on pin 1. Depress the unload auger engage switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance.

2. Open circuit on switch wiring in MFH. 3. RHM module failure. Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the Unload Engage switch. The “switch” screen should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed.

A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 3.

A. If the voltage does not change, continue with Step 2.

3. Use the electronic service tool (EST) to reload the software in the RHM module, and retest the system. If the problem still exists, the RHM has failed. Replace the RHM.

B. If the voltage reading is within the proper limits, continue the troubleshooting at step 3.

55-3

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 14

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-4

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 14

UNLOAD FRAME--22

B-38 = UNLOAD CRADLE B-47 = COVERS CLOSED L-03 = UNLOAD TUBE IN L-04 = UNLOAD TUBE OUT

L-08 = UNLOAD TUBE CLUTCH S-28 = GRAIN BIN 3/4 FULL S-29 = GRAIN BIN FULL S-42 = TANK COVERS SWITCH

55-5

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 14 GRAIN BIN SENSORS S-28 AND S-29 There are two grain bin sensors that work together to monitor the amount of grain in the grain bin. The two sensors are wired in series. The system monitors change in resistance controlled by the two grain bin sensors. •

Grain Bin Becoming Full – The combine is equipped with a lower (3/4), 1, and upper (bin full), 2, grain tank level sensor. These sensors monitor the level of material in the grain bin. When the thresher is engaged and the material in the grain bin reaches the lower sensor, the rotating beacons will flash*. The flashing beacons inform a grain truck operator to prepare for unloading the grain bin.

56063222

*If the work lights are activated, the rotating beacons will only flash for approximately 10 seconds. The rotating beacons flash again for another 10 seconds when the upper sensor detects material. If the work lights are not activated, the beacons will remain illuminated until the grain bin is emptied. Grain Bin Sensors – Alarms A0030 Grainbin FULL Grain Bin Sensors – Fault Codes E0159-03 Grain Tank Full sensor Shorted to high source E0159-05

Grain Tank Full sensor Line Disconnected

55-6

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 14 Grain Bin Sensors -- Troubleshooting 3. Disconnect connector X109 from the Grain Bin Full switch S-29. Use a multi-meter to check for continuity between connector X109 pin B on the Grain Tank (GT) harness side and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the Grain Tank (GT) harness between connector X109 pin B and connector X107 pin B wire 445 yellow. Locate and repair the short to ground.

The grain bin becoming full and / or full does not occur. Cause: No signal from the sensor(s) in the grain tank. Possible Failure Modes: 1. Sensor(s) or circuit wiring shorted to ground. 2. Controller internal failure (Internal regulator failure).

B. If no continuity is found, there is a short to ground in the Grain Tank Full switch S-29. Replace the switch.

Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage.

4. Disconnect connector X107 from the Grain Tank ¾ Full switch S-28. Use a multi-meter to check for continuity between connector X107 pin C on the Grain Tank (GT) harness side and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 5.

The proper voltage with neither switch actuated is approximately 2.5 volts. The proper voltage with the 3/4 full switch actuated is approximately 3.3 volts.

B. If no continuity is found, there is a short to ground in the Grain Tank ¾ Full switch S-28. Replace the switch.

The proper voltage with both switches actuated is approximately 3.7 volts. A. If the voltage reading is low (< 2.5 volts) out of range, continue with step 2.

5. Disconnect connector X009 from the Main Frame (MF) harness. Use a multi-meter to check for continuity between connector X009 pin E on the Main Frame (MF) harness side and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 6.

B. If the voltage reading is within the proper limits, continue the troubleshooting with step 6. NOTE: visually inspect the wiring harness and connectors. Verify that the connectors are fully installed. Inspect the terminals and wires at the connectors for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned.

B. If no continuity is found, there is a short to ground in the Grain Tank (GT harness between connector X009 pin E and connector X107 pin C wire 400 yellow. Locate and repair the short to ground.

2. The voltage reading on the display monitor remains low. Disconnect connector X009 from the Main Frame (MF) harness and connector X107 from the Grain Bin 3/4 Full switch S-28. Use a multi-meter to check for continuity between connector X107 pin B on the Grain Tank (GT) harness side and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3.

6. Disconnect connector X016 from the CCM-2. Use a multi-meter to check for continuity between connector X016 pin J2-22 on the Main Frame (MF) harness side and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the Main Frame (MF) harness between connector X009 pin E and connector X016 pin J2-22 wire 400 yellow. Locate and repair the short to ground.

B. If no continuity is found, continue with step 4.

B. If no continuity is found, continue with step 7. 7. Use the electronic service tool (EST) to reload CCM-2 software, and retest the system. If the problem still exists, the CCM has failed. Replace the CCM-2.

55-7

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 14

UNLOAD FRAME--22

B-38 = UNLOAD CRADLE B-47 = COVERS CLOSED L-03 = UNLOAD TUBE IN L-04 = UNLOAD TUBE OUT

L-08 = UNLOAD TUBE CLUTCH S-28 = GRAIN BIN 3/4 FULL S-29 = GRAIN BIN FULL S-42 = TANK COVERS SWITCH

55-8

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 14 UNLOAD TUBE SWING Activated by two position switches, 1, and 2, on multifunction handle (MFH). RHM sends signal via CAN to CCM2 to activate the extend or retract the unload tube. Unload tube swing is disabled by road mode switch on console. There are two swing modes – one manual (first switch position), and one automatic (second switch position) – see Operator’s manual pg. 2-13 for details.

2 1

Unload swing open is disabled when in ‘Road’ mode. 20030010

Unload Tube Swing -- Alarms A0029 Unloading Tube Open – will occur if ‘Road’ mode is selected while unload tube is out of the cradle. A0051

Road Mode selected – will occur if attempt to swing unload tube out while ’Road’ mode is selected.

Unload Tube Swing -- Fault Codes E0193-11

Unload Tube In valve Unidentified Failure Code

E0194-11

Unload Tube Out valve Unidentified Failure Code

55-9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 14 Unload Tube Swing Control Troubleshooting Unload tube will not swing in or out. Cause: No signal from unload swing in or swing out switches on MFH. Possible Failure Modes: 1. Switch failed. 2. Open circuit on switch wiring in MFH. 3. RHM module failure. Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the unload tube out switch. The “switch” screen should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 3. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 5 and pin 1, with the black (common) probe of the multimeter on pin 1. Depress the unload tube out switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 3.

55-10

3. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the unload tube out switch to the second position. The “switch” screen should show “on” when the switch is fully depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 4. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 4. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 11 and pin 1, with the black (common) probe of the multimeter on pin 1. Fully depress the unload tube out switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 5.

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 14 5. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the unload tube in switch. The “switch” screen should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 6. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 7. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 6. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 10 and pin 1, with the black (common) probe of the multimeter on pin 1. Depress the unload tube in switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 7.

7. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, monitor the display while cycling the unload tube in switch to the second position. The “switch” screen should show “on” when the switch is fully depressed. If the “Voltage” screen is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed. A. If the voltage does not change, continue with Step 8. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 9. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 8. The voltage reading on the display monitor does not change. Disconnect connector X028 from the RHM module. Use a multimeter to check resistance between the harness end of connector X028 pin 9 and pin 1, with the black (common) probe of the multimeter on pin 1. Fully depress the unload tube in switch; the resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance. A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH. B. If the resistance reading is correct, continue with Step 7. 9. Use the electronic service tool (EST) to reload the software in the RHM module, and retest the system. If the problem still exists, the RHM has failed. Replace the RHM.

55-11

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 14 GRAIN BIN COVERS The grain bin covers are activated by a switch S-42, 1. This is a two position switch – it will either be in the ‘open’ or ‘closed’ position – the operator does not have to hold it. The switch is located on the upper left console in the headliner.

4 The switch sends a signal to CCM2 module, which is relayed via CAN to CCM1. CCM1 then activates the output to the covers motor M12 to open or close the grain bin covers. A linear actuator, 2, is used to move linkage that opens and closes the grain bin covers, as well as fold the bubble-up auger up or down. The covers closed sensor B47 on the bubble-up auger is used to determine if the covers are open or not. For Grain Tank Covers control on CX/CR combines the following will stop or prevent the covers from opening or closing:

2 10004684

•

Emergency switch actuation

•

Grain Tank Covers switch error

•

Threshing engaged

•

If the actuator current is greater than 18 amps for 0.1 seconds (i.e. actuator stalled)

Additionally, if Road Mode is engaged it will stop or prevent the covers from opening (generates alarm A0051). You can close covers in road mode.

55-12

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 14 Grain Bin Covers -- Alarms A0028 Grain tank Covers Open – will occur if ‘Road’ mode is selected or ground speed exceeds 15 kph (10 mph) and covers are open.

Grain Bin Covers -- Fault Codes E0001-03 Grain Tank Covers Open sensor Shorted to high source

A0051

Road mode selected – will occur if ‘Road” mode is selected, and attempt to open covers.

A0079

Grain tank Covers Closed – will occur if covers are closed and threshing is engaged.

55-13

E0001-04

Grain Tank Covers Open sensor Shorted to low source

E0001-05

Grain Tank Covers Open sensor Line Disconnected

E0045-06

Grain Tank Covers Motor Current Sense Short Circuit

E0069-11

Covers / Concave Select Relay Unidentified Failure Code

E0079-05

Grain Tank Covers motor Line Disconnected

E0137-04

Grain Tank Covers switch Shorted to low source (disabled)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 14 Grain Bin Covers -- Troubleshooting The grain bin covers will not open or will not close. Cause: No signal or continuous signal from the Grain Tank Covers switch.

between connector X002 pin 13 and chassis ground. There should not be voltage. A. If voltage is found, continue with step 4.

Possible Failure Modes: 1. Switch or switch circuit wiring shorted to high source or open.

B. If no voltage is found, there is a short to high source in the Cab Roof (CR) harness between connector X002 pin 13 and connector X125 pin 3 wire 167 yellow. Locate and repair the short to high source.

2. Controller internal failure (Internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while cycling the Grain Tank Covers switch S-42. The normal operating range for the grain tank covers switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the grain tank covers switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading is high (> 5.0 volts) out of range, continue with step 2. B. If the voltage reading is low (<0.5 volts) out of range, continue with step 5. C. If the voltage reading is within the proper limits, continue the troubleshooting with step 7. NOTE: visually inspect the wiring harness and connectors. Verify that the connectors are fully installed. Inspect the terminals and wires at the connectors for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor remains high. Disconnect connector X125 from the Tank Covers Switch S-42. With the grain tank covers switch in the “Off” position, use a multimeter to check for voltage on the switch from pin 3 to chassis ground. There should not be voltage. A. If voltage is found, the switch has failed. Replace the switch. B. If no voltage is found, continue with step 3. 3. Disconnect connector X002 from the Cab Roof (CR) harness. Use a multi-meter to check for voltage on the Cab Main (CM) harness side

55-14

4. Disconnect connector X015 from the CCM-2. Use a multi-meter to check for voltage on the module between connector X015 pin J1-3 and chassis ground. There should not be voltage A. If voltage is found, continue with step 7. B. If no voltage is found, there is a short to high source in the Cab Main (CM) harness between connector X002 pin 13 and connector X015 pin J1-3 wire 167 yellow. Locate and repair the short to high source. 5. Disconnect connector X002 from the Cab Main (CM) harness and connector X125 from the Grain Tank Covers Switch S-42. Install a jumper wire on the Cab Roof (CR) harness side between connector X125 pin 3 and chassis ground. Use a multi-meter to check for continuity between connector X002 pin 13 on the Cab Roof (CR) harness side and chassis ground. There should be continuity to ground. A. If continuity is found, continue with step 6. B. If no continuity is found, there is an open between the Grain Tank Covers Switch S-42 connector X125 pin 3 connector X002 pin 13 wire 167 yellow. Locate and repair the open. 6. Disconnect connector X002 from the Cab Roof (CR) harness and connector X015 from CCM-2. Install a jumper wire on the Cab Main (CM) harness side between connector X002 pin 13 and chassis ground. Use a multi-meter to check for continuity between connector X015 pin J1-3 on the Cab Main (CM) harness side and chassis ground. There should be continuity to ground. A. If continuity is found, continue with step 7. B. If no continuity is found, there is an open between connector X015 pin J1-3 and connector X002 pin 13. wire 167 yellow. Locate and repair the open. 7. Use the electronic service tool (EST) to reload CCM-2 software, and retest the system. If the problem still exists, the CCM has failed. Replace the CCM-2.

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 14

UNLOAD FRAME--22

B-38 = UNLOAD CRADLE B-47 = COVERS CLOSED L-03 = UNLOAD TUBE IN L-04 = UNLOAD TUBE OUT

L-08 = UNLOAD TUBE CLUTCH S-28 = GRAIN BIN 3/4 FULL S-29 = GRAIN BIN FULL S-42 = TANK COVERS SWITCH

55-15

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 14

55-16

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 15

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 15 -- Crop Residue CONTENTS Section

Description

Page

55-1

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 15 INTRODUCTION The Crop Residue System in located at the rear end of the combine. This system chops and/or disperses the residue of the crops processed by the combine. The electrical portion of the Crop Residue System controls and monitors the various components of this system.

55-2

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 15 STRAW CHOPPER Chopper RPM Sensor B10 The Chopper RPM Sensor B10 is located at the right rear of the combine.

40011023

2 The Chopper RPM Sensor B10, 1, is a proximity sensor that sends a signal to CCM2 every time the sensor plate, 2, passes over the face of the switch. CCM2 monitors the pulsed signals and determines if the rotor shaft is rotating. NOTE: In order for CCM2 to recognize and report chopper RPM, it must be configured as “Installed”. Refer to the Configuration and Calibration Section of the Operators Manual for more information.

40011026

55-3

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 15 Alarm Code Chopper RPM Sensor B10 Description

Alarm Code A0042

Priority

Chopper Speed LOW High

Check Condition Threshing and no manual RPM changes

Activation

Resetting

1 sec< 100 RPM -- OR -1 sec < 80% of threshold RPM

3 sec> 100 RPM -- OR -3 sec > 80% of threshold RPM

Fault Codes for Chopper RPM Sensor B10 Error Code

Description

E0143-03

Chopper Speed Sensor Shorted to High Source

E0143-04

Chopper Speed Sensor Shorted to Low Source

E0143-05

Chopper Speed Sensor Line Disconnected

NOTE: Refer to the CCM2 Fault Codes section of the repair manual for troubleshooting.

CHAFF SPREADER

Chaff Spreader Valve Solenoid L28 The Chaff Spreader Valve Solenoid L28, 1, is located at the left rear of the combine. The Chaff Spreader is activated by CCM1 module when Threshing is engaged. NOTE: Chaff Spreader must be configured as ”Installed”. Refer to the Configuration and Calibration Section of the Operators Manual for more information.

2 10020028

When the Chaff Spreader Valve Solenoid L28 is activated, low-pressure oil is directed to the adjustable flow control valve, 2. Oil that can flow through the flow control valve travels through a quick coupler to the two chaff spreader motors that are connected in series.

Fault Code for Chaff Spreader Valve Solenoid L28 Error Code E0053-11

Description Chaff Spreader Valve Unidentified Failure Code

NOTE: Refer to the CCM1 Fault Codes section of the repair manual for troubleshooting.

55-4

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 15 POSITIVE STRAW DISCHARGE (PSD) In combines equipped with the positive straw discharge (PSD) system, the PSD works in conjunction with the chaff spreader system to provide a more positive delivery of straw to the spreaders. An additional hydraulic motor is place in series with the spreader motors, thus operating simultaneously with them. Also, a different valve block, 1, is used, since additional outputs must be provided for the PSD motor.

Electrically, the system works the same as in combines equipped with chaff spreader but not the PSD. Chaff Spreader Valve Solenoid L28, 2, controls the flow of oil to the spreader motors and the PSD motor as described above. Alarm and error codes valid for the L28 apply here as well.

66060557

1 5

55-5

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 15 STRAW CHOPPER SPREADER PLATE

20030010

6 When the Spreader Plate Switch S23 is toggled, a signal is sent to the RHM. The RHM relays the signal to CCM3. CCM3 applies current to the Spreader Plate Motor M11 energizing it to extend or retract to move the Spreader Plates.

Spreader Plate Switch S23 The Spreader Plate Switch S23, 1, is located on the RHC. The Spreader Plate Switch S23 controls the Spreader Plate Motor M11 to adjust the direction of the divider plates. The adjustment of the divider plates allows the operator to choose the direction of the residue exiting the rear of the combine.

NOTE: Spreader Plate Switch must be configured as “Installed”. Refer to the Configuration and Calibration Section of the Operators Manual for more information.

55-6

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 15 1

Right Hand Discharge

Neutral

Left Hand Discharge

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual.

2 3

7 Fault Codes for Spreader Plate Switch S23 E0648-04

Switch Spread Plates to the Right Shorted to Low Source

E0648-07

Switch Spread Plates to the Right Mechanical Out of Range

E0655-04

Switch Spread Plates to the Left Shorted to Low Source

E0655-07

Switch Spread Plates to the Left Mechanical Out of Range

Spreader Plate Motor M11 The Spreader Plate Motor M11, 1, is located on the rear of the combine on the top of the spreader plate. The Spreader Plate Motor M11 is controlled by Spreader Plate Switch S23 on the RHC. When the Spreader Plate Switch S23 is cycled, either for left hand discharge or right hand discharge, a signal is sent to the RHM. From the RHM a signal is sent to CCM3 which energizes the motor causing it to move the plunger in (left) or out (right) in turn moving the Spreader Plate Fins. The position of the motor and the Spreader Plate Fins are monitored by an integral potentiometer on the motor.

50032239

The potentiometer sends a signal to CCM3 which relays it to be displayed on the display monitor while the Spreader Plate Switch S23 is activated. Fault Codes for Spreader Plate Motor M11 Error Code

Description

E0289-03

Spread Plate Position Sensor Shorted to High Source

E0289-05

Spread Plate Position Sensor Line Disconnected

E0297-06

Current Sense Spreader Plates Short Circuit

E0332-05

Spread Position Adjustment Motor Line Disconnected

NOTE: Refer to the CCM3 Fault Codes Section of the repair manual for troubleshooting.

55-7

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 15 ELECTRICAL SCHEMATICS

F-27 = SIEVE/SPREADER FUSE K-18 = UPPER/LOWER SIEVE RELAY M-06 = UPPER SIEVE ACTUATOR M-07 = LOWER SIEVE ACTUATOR

S-35 = UPPER SIEVE REAR ADJUST S-46 = LOWER SIEVE REAR ADJUST

CLEANING FRAME--21

55-8

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 15

B-10 = CHOPPER RPM L-28 = CHAFF SPREADER M-11 = SPREADER PLATE MOTOR S-23 = SPREADER PLATE

B-74 = PSD RPM

TRASH FRAME--23

55-9

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 15

F-48 = RH CONSOLE FUSE H-01 = AUDIO ALARM W-01 = SPLICE BLOCK A W-02 = SPLICE BLOCK B

W-05 = SPLICE BLOCK E W-06 = SPLICE BLOCK F

DISTRIBUTION FRAME--25

55-10

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 15

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-11

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 15

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME--27

55-12

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 15 SPREADER PLATE SWITCH S23 TROUBLESHOOTING

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.

Test Point

Good Reading

Possible Cause of Bad Reading

Using the display monitor diagnostic ON is displayed when switch Blown fuse F48, open circuit, capability to view “item” status, is cycled to ON position. Failed switch. reference Section 55 Chapter 2, if Proceed to next test point. needed. Cycle switch for right-hand discharge.

Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed.

Approximately 1.3 volts with Blown fuse F48, open circuit, switch in neutral, Approxi- Failed switch. mately 4.9 volts with switch depressed for right-hand discharge. Proceed to next test Cycle switch for right-hand discharge. point.

Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed. Cycle switch for left-hand discharge.

Approximately 1.3 volts with Blown fuse F48, open circuit, switch in neutral, Approxi- Failed switch. mately 4.9 volts with switch depressed for left-hand discharge. Proceed to next test point.

Disconnect connector X037 and re- Less than 1 ohm. move Spreader Plate Switch S23 from RHC. Test continuity between pin 2 and 3 while depressing switch for Proceed to next test point. right-hand spreading.

Switch failure.

Test continuity between pin 2 and 1 Less than 1 ohm. while depressing switch for left-hand Proceed to next test point. spreading.

Switch failure.

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 15 Step

Test Point

Good Reading

Possible Cause of Bad Reading

Test continuity of circuit 324 (YE) Less than 1 ohm. between connector X037 pin 3 and Proceed to next test point. connector X029 pin 18.

Open circuit in 324 (YE).

Test continuity of circuit 325 (YE) Less than 1 ohm. between connector X037 pin 1 and Proceed to next test point. connector X029 pin 14.

Open circuit in 325 (YE).

Test continuity of circuit 357 (OR) Less than 1 ohm. between connector X037 pin 2 and connector X054 pin A.

Open circuit in 357 (OR).

55-14

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 15 SPREADER PLATE MOTOR M11 TROUBLESHOOTING NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for these tests. For battery testing and service, see the battery section in the service manual.

CAUTION DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause damage to components in this system.

Test Point

Test continuity between pin A and pin B. Approximately 10 ohms This will test position potentiometer.

Failed potentiometer.

Proceed to next test point.

Test continuity between pin B and pin C. Approximately 10 ohms This will test position potentiometer.

Possible Cause of Bad Reading

Proceed to next test point.

Test continuity between pin A and pin C. >10 ohms This will test position potentiometer.

Good Reading

Failed potentiometer.

Proceed to next test point.

Test continuity between connector Less than 1 ohm. X224 pin A and connector X071 pin 1. Proceed to next test point. This circuit is 473 (PK).

Open circuit in circuit 473 (PK).

Test continuity between connector Less than 1 ohm. X071 pin 1 and connector X025 pin 1. Proceed to next test point. This circuit is 473 (PK).

Open circuit in circuit 473 (PK).

Test continuity between connector Less than 1 ohm. X025 pin 1 and connector X013 pin Proceed to next test point. J2-31. This circuit is 473 (PK).

Open circuit in circuit 473 (PK).

Test continuity between connector Less than 1 ohm. X224 pin B and connector X071 pin 2. Proceed to next test point. This circuit is 471 (BL).

Open circuit in circuit 471 (BL).

55-15

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 15 Step

Test Point

Good Reading

Possible Cause of Bad Reading

Test continuity between connector Less than 1 ohm. X071 pin 2 and connector X025 pin 2. Proceed to next test point. This circuit is 471 (BL) and 439 (BL)

Open circuit in circuit 471 (BL) and 439 (BL)

Test continuity between connector Less than 1 ohm. X224 pin C and connector X071 pin 10. Proceed to next test point. This circuit is 477 (YE).

Open circuit in circuit 477 (YE)

Test continuity between connector Less than 1 ohm. X071 pin 10 and connector X025 pin 5. Proceed to next test point. This circuit is 477 (YE).

Open circuit in circuit 477 (YE)

Test continuity between connector Less than 1 ohm. X025 pin 5 and connector X013 pin J2-33. This circuit is 477 (YE).

Open circuit in circuit 477 (YE)

55-16

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 16 -- Precision Farming CONTENTS Section

Description

Page

55-1

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 The CR Series combine may be equipped with several different precision farming packages to allow the operator to monitor and/or record different harvesting parameters for analysis. The basic precision farming component is the moisture sensor, which is mounted in the clean grain elevator. This component measures the moisture level of the grain being harvested, and displays this information on the Infoview monitor.

40024715

1 The next precision farming component that may be added is the grain yield sensor, which mounts in the top of the clean grain elevator, and provides information to the operator on instantaneous or average yield of the crop being harvested. In addition, the operator may view reports with average and total values for the field that was harvested.

10004680

2 The optional CCM3 module, 1, must be installed for both the moisture sensor and grain yield sensor. Addition of a data logger unit and GPS antenna and receiver allows the moisture and yield information to be ‘mapped’ to specific locations in the field, and further allows the operator to create maps following the harvest showing detailed moisture and yield information at specific locations throughout the field.

PRECISION FARMING ACCURACY The following items all affect precision farming accuracy, and must be adjusted or calibrated accurately in order for the precision farming system to provide accurate information. •

Grain Yield sensor calibration

•

Moisture sensor calibration

•

Tire Radius calibration (ground speed)

•

Maximum Stubble Height calibration

•

GPS configuration

•

Header width & Header Usage settings

•

Row Distance & Rows in Use settings

10004693

55-2

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 MOISTURE SENSOR The moisture sensor is mounted in a bypass housing that is located on the clean grain elevator housing. The moisture sensor provides a measurement of both grain moisture and temperature.

40024715

4 A portion of the grain being transported up the clean grain elevator falls into the opening, 1, of the bypass housing, and fills up the cavity around the moisture sensor, 2, so that it remains completely surrounded by grain all the time. When the cavity is completely full, as monitored by an optical sensor, 3, CCM3 turns on a small transfer auger, 4, which augers the grain out of the cavity and back into the return side of the clean grain elevator. This ensures a constant flow of harvested grain past the moisture sensor. By positioning the moisture sensor in the bypass housing, the potential for plugging or build-up occurring in weedy or muddy crop conditions is reduced.

1 2

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4 5

CCM3 will run the transfer auger for 30 seconds after the threshing system is disengaged in order to clean all material from the bypass housing. The optical sensor may be adjusted for sensitivity; refer to Section 80 Grain Storage, Chapter 1 Clean Grain Transport for more information.

55-3

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 GRAIN YIELD SENSOR A mass-flow type sensor is used to monitor the flow of grain into the grain bin, representing the volume of grain harvested. The sensor is mounted at the top of the clean grain elevator. Grain flowing out of the elevator is concentrated and guided to the sensor plate. The sensor plate is connected via a lever beam over a rotation point to a load cell and counter weight. The counter weight keeps the sensor unit in balance when driving uphill or downhill to maintain accuracy. The design of the sensor results in a near-linear relationship with crop flow, so that the sensor typically only requires a single calibration to ensure proper accuracy. In addition, if the sensor detects “zero flow” for at least 5 seconds (would typically occur during headland turns), the system will reset the “zero flow” value. This compensates for temperature changes, build-up, and wear and tear of the sensing plate to insure maximum accuracy.

10004680

There are several critical adjustments that affect the accuracy and performance of the sensor, as follows: Grain elevator upper shaft adjustment; controls paddle tip clearance to top of elevator housing. This clearance is increasingly critical in light or small seed crops. Refer to Section 80 Grain Storage Chapter 1 Clean Grain Transport for more information. Grain yield sensor plate adjustment; controls positioning of the sensor plate to the elevator housing. This adjustment is critical to the overall accuracy of the grain yield sensor. Refer to Section 80 Grain Storage Chapter 1 Clean Grain Transport for more information. Grain yield sensor offset adjustment; may be required if alarm “A0052 Yield Sensor Out of Range” occurs frequently, and sensor plate is clean and adjusted properly. Grain Yield Sensor Offset Adjustment If the alarm message “A0052 Yield Sensor Out of Range” occurs frequently while harvesting high capacity crops, and the sensor plate is clean (no residue build-up) and adjusted properly, the grain yield sensor offset may need to be adjusted. Navigate to the “Diagnostic”, “Settings”, “Group”, “PFS”, “Item” screen, and select “Grain yield sensor”.

20065546

55-4

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 The voltage level for the Grain Yield sensor should be between 0.5 to 1.2 volts. If the voltage is above the range, it needs to be adjusted.

20065547

8 Remove the cover, 1, in the grain tank to expose the grain yield sensor.

9 Remove the four bolts, 1, and slide the shield, 2, off of the grain yield sensor.

1 1

55-5

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 Remove the protective cover, 1, from the connector on the yield sensor control box to expose the connector pins.

50031024

11 Use a small screwdriver or other metal object to carefully short between the offset control pin, 1, and the ground pin, 2. Move the screwdriver as required to provide short pulses between these two pins. By giving short pulses shorter than one second, the offset will move in one direction. Halting the pulses longer than one second, and then restarting the pulses will change the direction of the offset movement. Provide pulses to the pins as required while monitoring the offset voltage value on the Infoview monitor until the offset is within 0.5 to 1.2 volts. To memorize the new offset position, apply nine pulses (offset will move in one direction), pause for a period longer than 2 seconds, and then apply an additional nine pulses (offset should return to desired value).

20031025

55-6

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 Install the protective cap over the connector. Slide the shield, 1, onto the grain yield sensor, using caution to install the wire harness grommet, 2, in the slot. Secure the shield using the four bolts, 3. Install the cover in the grain tank.

3 3

AUTOGUIDANCE Autoguidance, as the name suggests, provides a means for hands-off automatic steering of a combine in the field. This capability has been developed to improve harvest efficiency and yield quality. It provides two main benefits: a) Since it provides a means of automatically steering the combine, the operator can devote more of his attention to monitoring the crop yield parameters and making the necessary adjustments to assure a quality harvest. b) It reduces waste and makes better use of time by lining up the header precisely along the edge of the last pass, thus using the full width of the header and eliminating the need to overlap onto the previous swath. Overlap of as little as 25 cm can add up to a lot of wasted header use over, for example, a 500-hectare parcel. Autoguidance, therefore, means the harvest can be accomplished in less time than by manual steering. Two techniques have been developed to provide autoguidance. These are Edge Guidance and GPS Guidance.

55-7

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 EDGE GUIDANCE Edge guidance is a technique used to precisely and automatically guide the path of a harvester along the edge of a standing crop, that is, along the separation point between the yet-uncut plants and bare ground or the stubble left from the prior cutting pass.

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55-8

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 Description of Operation Figure 14 is a concept drawing of a SMARTSTEERTM-equipped CR combine harvesting a grain crop. An infrared laser scanner, 1, located under the left-hand roof extension of the combine (Figure 15) emits two beams, which are aimed ahead of the header. One of the beams reflects off the standing crop, the other, off the bare ground or stubble. Because of the difference in the beams’ travel distance, their reflections return to the scanner at different times. By analyzing these time differences, the combine’s onboard computer can accurately determine the location of the crop edge.

1 56065524

15 Figure 16 shows the scanner drive portion of the edge guidance system. The mechanical components are mounted on the combine’s mirror support bracket 1. The laser scanner 2, known as the Harvest Guide Sensor (HGS), is fastened to spindle 3, which is suspended through turntable 4. A computer-controlled electrical actuator 5 drives pivot arm 6, which turns the spindle. The HGS swings in a wide arc and can detect the crop edge on either the left or right side of the header.

The HGS locates the crop edge during an automated calibration procedure initiated by the operator before beginning the first harvest pass. Once the HGS has locked onto the crop edge, it remains fixed on it and the onboard computer directs the steering to keep the HGS aimed on the edge, thereby holding the combine on a defined path.

3 4

2 56065526

The computer controls the steering by sending commands to the hydraulic steering valve, which controls the movements of the steering cylinder at the rear axle. The operator can override the automatic steering by moving the steering wheel slightly. The combine then reverts to manual steering. The system is activated via the SMARTSTEER engage switch 1 in the right-hand control console (Figure 17).

1 56065528

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16

CCM3

CAN

10 56065536

55-10

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 Figure 18 is a functional diagram of the SMARTSTEER system. Engage switch 1 turns the system on. Combine Control Module 3 (CCM3) 2 serves as system controller. At the beginning of the first harvest pass, the operator initiates HGS calibration through prompts on the display 3. CCM3 instructs the HGS actuator 4 to swing the HGS 5. The HGS is initially facing in a forward direction, but the actuator swings it in an arc, right to left, until the scanner detects the edge of the crop. A sensor 6 in the HGS actuator provides position information to CCM3, completing the HGS control loop. CCM3 monitors the scanner data via the combine’s Controller Area Network (CAN) bus. When CCM3 determines that the scanner has detected the crop edge, it stops the actuator, and the scanner is locked onto the edge. The operator can now proceed with the first pass, but will not need to steer the vehicle. CCM3 seeks to keep the HGS scanner locked onto the crop edge during the combine’s travel and compensates for any detected drift by directing the steering valve to correct the course. The steering valve 8 routes hydraulic oil flow to the steering cylinder 9 at the rear axle in accordance with CCM3’s directions. A sensor 10 in the steering cylinder reports back the rear wheel angle to CCM3 to complete the autosteering loop. Eventually the operator will need to take over manual steering as, for example, when reaching the end of a row. When the operator moves the steering wheel slightly, the manual override sensor 11 detects the movement and reports it to CCM3, which cancels the automatic steering process. When the operator turns the combine into position to begin the next pass, the system initiates a new search for the crop edge by the HGS. Once the edge is located, the combine is once again in automatic steering and the edge guidance system aligns the combine correctly for the pass.

55-11

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 GPS AUTOGUIDANCE The Global Positioning System (GPS) provides a means of determining a precise position anywhere on the planet to a high degree of accuracy. As such, this capability can be harnessed to provide a means for automatically steering a vehicle. GPS provides the guidance data for the INTELLISTEERTM automatic steering function of the CR combine. GPS Definition GPS is a worldwide radionavigation system comprising 24 satellites in precise orbits. Each satellite transmits a radio signal containing highly accurate timing and location information. A groundbased receiver that can receive signals from a minimum of three GPS satellites can use this information to triangulate its position (Figure 19). Each satellite contains a precision atomic clock to assure time accuracy. By comparing the time of transmission of the signal with its own internal clock, thus telling how long it took the signal to reach its location, the ground receiver can calculate the distance to the satellite. (The ground receiver’s clock is satellite-corrected to assure its accuracy). Upon recovering distance information from three satellites, the receiver now has a part of what it needs to triangulate its position. For the distance data to be useful, the receiver also needs to know the locations of the satellites. The GPS receiver contains an almanac which tells each satellite’s location with respect to the earth at any given time. Although the satellites have been placed in highly precise orbits, the accuracy of each satellite’s location data is constantly monitored by precision radar at ground stations around the world. Correction data is then sent to the satellite, if necessary. Equipped with distance and location information from a minimum of three satellites, the receiver can apply triangulation calculations to determine its position. Note that three satellites are the “minimum” requirement for triangulation. For greater accuracy and to obtain effective receiver clock correction, four or more satellites should be acquired. Four satellites are also required to determine elevation.

55-12

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 When the vehicle’s position has been determined, it is possible to get the vehicle to self-steer along a course and have it arrive at another location at the end of the course. In simple terms, this is done by having the vehicle’s onboard navigation controller monitor the position data as fed to it by the GPS receiver and apply correction signals to the vehicle’s steering hydraulics to keep it on course. The operator “teaches” the system the desired course by driving one swath and entering the beginning and end points. The autoguidance system uses this input to create and store a swath pattern, which it then uses to auto-steer the combine in subsequent passes over the field. The system is also able to memorize a curved course and hold it for all passes. Turning the combine at the end of a pass must be done manually and the system alerts the operator with an audible signal when the end of the row is approaching. A slight turn of the steering wheel disengages the autoguidance and returns the combine to manual control. Once the operator has turned onto the new pass the system is able to reacquire the course and calculate a smooth transition, to avoid sudden turns or “searching” maneuvers. To achieve this level of performance, the GPS position accuracy must be within 2.5 to 25 cm (1 to 10 in). This degree of precision is not achievable using the GPS satellite network alone to calculate position. This is because the satellite signals can be delayed passing through the earth’s ionosphere and troposphere, causing timing errors, resulting in inaccurate position calculations. Signals may also be subject to reflection off local obstructions, causing additional delays. Pass-to-pass accuracy under these conditions is about 2 to 3 m (6.6 to 10 ft). The accuracy of position acquisition can be greatly improved through the use of Differential GPS (DGPS).

55-13

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 Differential GPS Differential GPS (DGPS) makes use of a second, fixed GPS receiver (Figure 20). This receiver 1 is placed at a spot that has been accurately surveyed, so its position is known and never changes. It receives the same GPS satellite signals as the mobile receiver 2 in the combine. If these triangulate to a position other than the fixed receiver’s known position, the receiver determines the amount of error and sends this error information to the mobile receiver via a radio link 3. The mobile receiver then makes the necessary corrections, resulting in highly accurate position measurements.

2 1 3 56065531

There are currently many DGPS fixed receiver stations throughout the world, providing GPS corrections free to users who are able to pick up their signals. For example, the U.S. Coast Guard has some 200 such stations throughout the United States. These stations transmit on the 300 kHz radio beacon band and the user would need a receiver capable of working on this band, as well as the proper data interface to the GPS receiver. This DGPS system can provide accuracy to less than 1 m (3.3 ft), but accuracy decreases with distance from the station.

There are also space-based DGPS beacons that send correction signals: WAAS – The Federal Aviation Administration (FAA) has created the Wide Area Augmentation System (WAAS) to provide differential correction information to mobile GPS receivers (Figure 21). Ground stations 1 in the WAAS network receive signals from the GPS satellites 2. The ground stations send their data via terrestrial communications links 3 to a master control station 4, which transmits position correction information to geostationary satellites 5. These satellites then broadcast the information to WAAS-equipped mobile GPS receivers 6, which then apply the corrections. This WAAS service is free, although coverage is only available in the United States and parts of Canada. WAAS provides accuracy to within 25 cm (10 inches). A similar service over Europe is the EGNOS (European Geostationary Overlay Service) network. OmniSTARt* System -- This system continuously monitors GPS satellite signals at ground stations around the globe. The stations compute corrections and make them available to users via geostationary satellites around the world. This is a worldwide subscription service and requires OmniSTAR–ready receivers. There are three levels of performance available: *OmniSTAR is the trademark of OmniSTAR, Inc., of the Fugro Companies group.

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3 6

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4 21

OmniSTAR VBS (Virtual Base Station) – Accurate to within 25 cm (10 in). OmniSTAR XP (eXtra Performance) – Accurate to within 12 cm (5 in). OmniSTAR HP (High Performance) – Accurate to within 10 cm (4 in). It will be noted that the DGPS methods described above provide accuracies ranging from 10 cm -- 1 m (4 in – 3.3 ft). But the greatest precision – + 2.5 cm (1 in) – requires the use of Real Time Kinematic (RTK) methods.

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 REAL TIME KINEMATIC (RTK) DGPS In the RTK DGPS system (Figure 22), a local base station 1 sends position correction information to the mobile station 2, just as in conventional DGPS. However, the RTK receiver is capable of receiving not only standard GPS signals on the L1 GPS radio band, which contains the coding by which conventional GPS receivers calculate position, but also signals on the L2 band, which is primarily meant for military use. Through complex processing, the receiver is able to compare key parameters of both signals, yielding much greater position accuracy than conventional receivers. Accuracy to 2.5 cm (1 in) is achievable with RTK. The receiver’s coded output is coupled to a radio link 3 for transmission to the mobile unit in the field. The NH RTK Base Station (Figure 23) is a portable, tripod-mounted system 1. The system shown is self-contained and self-powered. The compact receiver unit 2 contains the GPS receiver, a rechargeable battery power supply and the radio transmitter needed to send correction data. The correction data radio link operates in the 900 MHz radio band and uses spread-spectrum technology. No license is required for this service in the U.S., Canada, Australia or New Zealand. Frequently operator-owned, the system can be set up only when needed and at a spot convenient for the field operations (although the spot must be precisely surveyed and must have a clear view of the sky and operational area). Such systems are capable of operating over a range of 10 km (6 miles). Subscription RTK, in which an operator sets up a fixed base station and makes correction transmissions available to users for a fee, is also becoming available in many areas. This saves the subscriber the expense of buying and maintaining his own RTK base station, and the time involved in setting it up.

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2 1

3 56065533

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 Description of Operation

1 2

3 4

9 5

CCM3

CAN-2

CAN-1 6

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8 24

55-16

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 Standard GPS Autoguidance Figure 24 is a functional diagram of the INTELLISTEER system. The system is activated via the INTELLISTEER engage switch 1 on the right-hand console. The GPS receiver 2, communicating via the combine’s secondary Controller Area Network (CAN-2) bus 3, sends position data to the NH NAV II navigation controller 4. The navigation controller, in turn, generates steering commands as determined by the current position, the predetermined target position, and the rear wheel angle. The navigation controller communicates with Combine Control Module 3 (CCM3) 5 via the CAN-2 bus. CCM3 directly controls the steering by sending the appropriate signals to the hydraulic steering valve 6. These are pulse width-modulated (PWM) signals and provide proportional movement of the steering valve to provide to the steering cylinder 7 the oil flow necessary for course correction. A position sensor in the steering cylinder sends rear wheel angle 8 information to CCM3, which provides this information to the navigation controller via thevehicle CAN-2 bus, completing the autosteer control loop. CCM3 also monitors the steering wheel sensor 9. This sensor responds to a slight manual movement of the steering wheel, by which the operator indicates that he or she wishes to take over manual control, as, for example, when it is necessary to turn the combine to start a new pass. CCM3 then disengages automatic control. The display 10, in addition to its many control and monitoring functions for the combine, provides the operator with the means to set up and calibrate the autoguidance system and provides a continuous visual indication of its status. It also provides information on the status of the GPS satellite network.

55-17

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 Differential GPS Autoguidance Differential GPS (DGPS) systems work on the principal that a precisely located receiver that continuously monitors the same GPS satellites as a moving vehicle can detect errors in the GPS positioning data and relay this information to the moving vehicle, enabling it to continuously correct its position calculations. Figure 25 is a functional block diagram of a Real-Time Kinematic (RTK) DGPS system.

5 1

CCM3

56065538

55-18

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 The receiver 1 in the fixed RTK base station 2 generates a correction code when it detects position errors. It sends this code to the vehicle via a 900-MHz radio link (transmitter 3 and receiver 4). The RTK-enabled GPS receiver 5 uses the correction data to correct its own GPS calculations. The resulting position information it provides to the NH NAV II navigation controller 6 is much more accurate than that of standard GPS. The remainder of the system works as described in the description of Standard GPS Guidance, above.

THE GPS-EQUIPPED CR COMBINE

Figure 26 shows the NH252 GPS receiver 1 mounted on the front grain tank extension of a CR combine. This unit is self-contained, housing both the GPS receiver and antenna. The unit receives GPS signals on both the L1 and L2 radio bands for RTK corrections. The receiver is also equipped to work with the OmniSTAR and WAAS/EGNOS satellite correction systems.

56065522

26 The NH252 GPS receiver 1 communicates with external devices via the CAN-2 bus and/or an RS-232 serial data interface. It can couple to an outside device to receive position correction data. Figure 27 shows the NH252 coupled to a companion NH900 radio set 2 which receives correction data via a 900 MHz radio link to a fixed RTK base station. The radio has a separate stick antenna 3.

1 3

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27 The NH252 receiver connects to the NH NAV II navigation controller 1 in the cab via wire harness 2 (Figure 28). The harness not only completes the communications links between the devices, but also provides a DC power path for the receiver. The navigation controller generates steering correction signals based on current position compared to the end points and swath pattern stored in memory from the initial setup and calibration. The navigation controller also contains three gyrometers and three accelerometers to assure true course tracking even on uneven terrain. The controller communicates with CCM3, which manages the actual steering control and sensing functions.

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 The INTELLISTEER steering valve (Figure 29, 1), located under the cab floor, is plumbed in parallel with the manual steering system. PWM steering signals from CCM3 are applied to proportional solenoids 2, which drive a bidirectional valve 3, directing hydraulic oil flow to the steering cylinder as necessary to correct the steering.

2 2

Detailed instructions on operating the system are in the INTELLISTEER Auto Steering System Operator’s Manual.

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29 Configurations There is a “Precision Farming” configuration screen, with the following user settings available: Crop -- may change the crop type being harvested. Crop delay -- is the time needed (in seconds) to transport the crop from the cutter bar through the combine to the grain yield sensor. This adjustment is necessary for use with GPS, to synchronize the grain yield sensor data with a specific location in the field as determined by GPS. In general, this value should be left at the factory default setting. Calibrations There are several different calibration procedures required to ensure accurate information is provided by the precision farming sensors. Grain yield sensor -- must be calibrated in order to provide accurate yield data. This calibration is generally only required to be done once per season, and does not have to be done in each crop harvested. Refer to the CR Combine Operator’s manual for more information. Moisture sensor -- must be done for each crop type that is harvested, unlike the grain flow sensor, in order to ensure accurate moisture readings during harvest. Refer to the CR Combine Operator’s manual for more information.

55-20

SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 Precision Farming Alarms Alarm

Module

Description

A0052 Yield Sensor Out of Range

CCM3

Yield sensor out of range (> 5.2 volts). Clean and adjust sensor plate. Adjust sensor offset.

A0054 Moisture bypass auger not activating

CCM3

Will occur if auger is not activated within 2 minutes after threshing and feeder engaged, and combine moving forward. Relay is open, fuse is blown; or motor is not functioning.

A0055 Moisture bypass not cycling

CCM3

Will occur if CCM3 is activating motor and bypass unit full sensor does not change within 30 seconds. Mud buildup on sensor, sensor too sensitive, housing plugged, or motor damaged.

A1000 PLD (fpga)

DLU

Module can’t be programmed. Reset the module (power off & on), and try a different data card. Replace module if necessary.

A1001 eeprom

DLU

Reset DLU module (power off & on). Replace module if necessary.

A1002 Log error

DLU

Will occur due to corrupt files on data card. Format data card.

A1003 Message set error

DLU

Use Service Info/Network screen to check functioning of CCM modules.

A1004 Object file error

DLU

Corrupt ‘objects.def’ file on data card; erase file.

A1005 Marker error

DLU

Corrupt ‘markers.def’ file on data card; erase file.

A1006 Datacard space

DLU

Data card is 95% full. Remove files from data card.

Precision Farming Fault Codes E0142-03 E0142-04 E0142-05

Groundspeed RPM sensor Shorted to high source Groundspeed RPM sensor Shorted to low source Groundspeed sensor Line Disconnected

E0277-03 E0277-05

Bypass Unit Full sensor Shorted to high source Bypass Unit Full sensor Line Disconnected

E0283-03 E0283-05

Moisture Temp sensor Shorted to high source Moisture Temp sensor Line Disconnected

E0284-03 E0284-05

Moisture Sensor - Shorted to high source Moisture Sensor - Line Disconnected

E0285-03 E0285-05

Moisture Sensor + Shorted to high source Moisture Sensor + Line Disconnected

E0288-03 E0288-05

Grain Yield Sensor Shorted to high source Grain Yield Sensor Line Disconnected

E0310-11

Bypass Unit Engage output Unidentified Failure Code

E0512-05

Feeder Angle sensor Line Disconnected

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SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 16 Precision Farming Troubleshooting Component Grain Yield sensor

Concern

Solution

Alarm message “A0052 Yield sen- Adjust sensor offset via diagnostic sor out of range” connector. Refer to “Grain Yield Sensor Offset Adjustment” procedure listed above. Flow read out at zero when Engage threshing and feeder, and threshing is engaged. run engine at high idle. Wait until flow read out is zero (unit is self-calibrating). Errors consistently out of range in Check and adjust grain yield sensor both directions. plate. Refer to Section 80 Grain Storage Chapter 1 Clean Grain Transport for more information. Errors consistently out of range in Recalibrate the grain yield sensor. one direction

Moisture sensor

Moisture read out not varying

Optical switch not sensitive enough. Adjust switch sensitivity. Refer to Section 80 Grain Storage Chapter 1 Clean Grain Transport for more information. In line fuse failed. Replace fuse. Fuse F47 failed. Replace fuse.

Moisture read out is vibrating.

Optical switch set too sensitive. Adjust switch sensitivity. Refer to Section 80 Grain Storage Chapter 1 Clean Grain Transport for more information.

Acre Counting

Acre counting is not accurate.

Recalibrate maximum stubble height. Refer to the CR Combine Operator’s manual for more information.

DGPS

GPS icon flashing (no differential Set the receiver up for differential signal). correction.

55-22

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17

SECTION 55 - ELECTRICAL SYSTEMS Chapter 17 - Electrical Connectors CONTENTS Section

Description

Page

Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 X001

Cab Main/Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

X002

Cab Main/Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

X003

Cab Main/Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

X004

Main Frame/Cab Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

X005

Main Frame/Cab Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

X006

Cab Main/HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

X007

Front Frame/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

X008

Main Frame/Front Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

X009

Main Frame/Grain Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

X010

Main Frame/Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

X011

Main Frame/Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

X012

CCM-3 J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

X013

CCM-3 J2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

X014

CCM-3 J3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

X015

CCM-2 J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

X016

CCM-2 J2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

X017

CCM-2 J3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

X018

CCM-1 J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

X019

CCM-1 J2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

X020

CCM-1 J3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

X021

Front Frame/Feeder Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

X023

Front Frame/Lower Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

X024

Main Frame/Straw Walker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

X025

Straw Walker/Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

X026

RHM J6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

X027

RHM J7A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

X028

RHM J7B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

X029

RHM J8A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

X030

RHM J8B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

55-1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 Section

Description

Page

X031

Front Frame/Cab Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

X032

Header/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

X033

Cab Main/Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

X034

Expansion/Main Frame A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

X035

Gearbox Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

X036

Cab Roof/Outer Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

X037

Spreader Plate S23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

X038

Alternate Settings S21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

X039

Feeder Reverser S07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

X040

Reel Speed Mode S08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

X041

Neutral Lock S22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

X042

Lower Sieves S14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

X043

Upper Sieves S13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

X044

Concave Clearance S16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

X045

Fan Speed S15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

X046

Rotor Speed S17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

X047

Feeder Speed S18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

X048

Gear Select S24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

X049

On the Road S12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

X050

Dual Range S11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

X051

Rear Wheel Assist 210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

X052

Park Brake S09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

X053

Splice Block A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

X054

Splice Block B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

X055

Thresher Engage S30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

X056

Feeder Engage S31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

X057

Ground Speed R04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

X058

Audio Alarm H01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

X059

Neutral Switch S22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

X059

Neutral Switch S22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

X059

Neutral Switch S22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

X060

Throttle S36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

X061

Header Height S04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

X062

Header Width Adjust S06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

X063

Vertical Knives S51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

55-2

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 Section

Description

Page

X065

Diagnostics and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

X067

Acc. Socket J06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

X068

Key Switch S02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

X069

Lighter R08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

X070

Lighter Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

X071

Straw Hood/Straw Walker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

X072

Lower Frame Rear/Straw Walker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

X073

Seat Switch S05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

X074

Seat Pump M26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

X075

Accessory Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

X076

Accessory Outlet J08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

X077

Ground, 3, CM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

X079

Reverser Disengage B09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

X080

Feeder Reverser M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

X081

Lat Float Pot R02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

X082

ASP Amplifier KN2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

X083

ASP Door Position B-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

X084

LH Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

X085

RH Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

X086

ASP Amplifier KN2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

X087

Ground Speed RPM B17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

X088

Shoe Motor M03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

X089

Cleaning Fan RPM B16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

X090

Cleaning Fan Motor M05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

X091

Hydrostat Motor Temp B46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

X092

Foot and Inch L05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

X093

Trans Shift Position B37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

X094

Transmission Shift Motor M02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

X095

Ground, 2, FF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

X097

Gearbox Temperature B32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

X098

Control Pressure B35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

X099

Clutch Temperature B45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

X100

Ground Speed Hydrostat L23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

X101

Charge Pressure S37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

X102

Ground, 1, GB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

55-3

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 Section

Description

Page

X103

Reservoir Temperature B18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

X104

Reservoir Level S33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

X105

Unload Tube Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

X106

Left Rear Work Light E27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

X107

3/4 Full Bin Sensor S28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

X108

Grain Tank Light E30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

X109

Full Bin Sensor S29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

X110

Right Rear Work Light E28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

X111

Left Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

X112

Left Outer Work Light E15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

X113

Left Beacon Light E31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

X114

Left Middle Work Light E19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

X115

Left Inner Work Light E17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

X116

Wiper Motor M25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

X117

Right Inner Work Light E18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

X118

Right Middle Work Light E20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

X119

Right Beacon Light 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

X120

Right Outer Work Light E16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

X121

Right Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

X122

Right Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

X123

Left Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

X126

Mirror Adjust Switch S27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

X127

Mirror Heat Switch S19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

X128

HVAC Control Panel A09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

X129

Dome Light E34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

X130

Beacon Light Switch S41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

X131

Rear Work Light Switch S44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

X132

Front Work Lights Switch S43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

X133

Splice Block C, Backlighting, CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

X134

Washer Switch S38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

X135

Wiper Switch S20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

X136

Front Left Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

X137

Door Switch S40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

X138

Right Console Light E35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

X139

Front Right Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

55-4

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 Section

Description

Page

X141

Transceiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

X142

G.P.S. Unit A11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

X143

Separator Blower M18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

X144

Separator Blower M18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

X145

Ground, 3, AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

X147

Cold Box Door M15 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

X148

Outlet Temp Sensor B27 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

X149

Cab Temperature Sensor B26 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . 80

X150

Evaporator Probe B28 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

X151

Water Valve M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

X152

Blower Speed Control A-14 (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

X160

Left Front Hazard Light E03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

X161

Left Front Service Socket J02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

X162

Left Header Light E21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

X163

Left Lower Work Light E23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

X164

Left Road Light E13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

X165

Right Front Hazard Light E04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

X167

Right Header Light E22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

X168

Right Lower Work Light E24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

X169

Right Road Light E14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

X170

Lateral Inclination Sensor B02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

X171

Wiper Washer Motor M24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

X172

Horn H02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

X172

Horn H02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

X173

Brake Pressure S39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

X173

Brake Pressure S39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

X174

Feeder Angle R03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

X175

Ground, 2, MF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

X177

Rotor RPM B01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

X178

Mirror Select Switch S-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

X180

Spice Block E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

X181

Left Returns RPM B06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

X182

Clean Grain RPM B08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

X183

Fuel Pump M23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

X184

Fuel Level R01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

55-5

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 Section

Description

Page

X186

Right Returns RPM B39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

X188

RH Rotor Loss B20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

X189

Concave Position R06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

X190

Concave Motor M04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

X193

ECU Connector B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

X194

Service Socket J05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

X195

Covers Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

X198

Splice Block F, Backlighting, RC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

X202

Air Filter S61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

X206

Rotary Screen Brush M27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

X211

Grid Heater Relay K37/K39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

X215

A/C Clutch L07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

X216

A/C High Pressure S47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

X217

A/C Low Pressure S48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

X218

Flip-Up Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

X219

Expansion B/Main Frame B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

X221

Moisture Sensor B12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

X222

Sample Motor M28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

X223

Yield Sensor R05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

X224

Spreader Plate Motor M11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

X225

Upper Sieve Adjust S35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

X226

Lower Sieve Adjust S46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

X227

Upper Sieve Motor M06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

X228

Lower Sieve Motor M07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

X232

Sieves Loss B21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

X233

RWA Solenoid L26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

X234

Sieve Light E37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

X235

Chaff Spreader Solenoid L28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

X237

Sieve Light Switch S54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

X238

Gearbox Filter Bypass S34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

X239

Returns Filter Bypass S32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

X243

Left Tail Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

X244

Unload Cradle B38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

X246

Right Tail Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

X247

Rear Beacon Light E-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

55-6

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 Section

Description

Page

X248

Back Up Alarm H-08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

X248

Back Up Alarm H-08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

X251

Rear Ladder B22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

X252

Right Service Socket J03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

X253

Chopper RPM B10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

X255

Flasher Module A05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

X256

Road Lights Switch S26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

X257

Turn Indicator E09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

X258

High Beam/Trailer E10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

X259

Hazard Switch S25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

X261

ASP Bottom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

X262

LH Bottom ASP Sensor B49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

X263

RH Bottom ASP Sensor B48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

X266

Feeder Reverse L21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

X267

Lateral Float CW L18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

X268

Reel AFT L15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

X269

Reel Down L13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

X270

Feeder Forward L20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

X271

Lateral Float CCW L19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

X272

Reel Fore L16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

X273

Reel Up L14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

X274

Reel Drive L17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

X275

Rotor Increase L29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

X276

Unload Tube In L03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

X277

Unload Tube Out L04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

X278

Rotor Decrease L30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

X279

HDR Height Pressure B29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

X280

Accumulator L06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

X281

HHC Module A07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

X282

Feeder Decrease L12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

X283

Feeder Increase L11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

X284

Feeder RPM B14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

X285

Trailer Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

X287

German Third Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

X288

Covers Position B-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

55-7

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 Section

Description

Page

X289

Covers Actuator M-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

X292

Stone Door Open L31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

X293

Dual Range Solenoid L27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

X294

LH Brake Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

X295

RH Brake Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

X296

Dome Light Power E-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

X314

FM Radio “B” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

X315

FM Radio “C” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

X316

Center Work LT E38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

X321

DGPS Module Antenna A-11 (252 Receiver) . . . . . . . . . . . . . . . . . . . . . . 115

X322

Unload Tube Work LT E29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

X323

Unload Tube Marker LT E39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

X326

HID Distance LT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

X327

Brake Fluid Level S49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

X329

Brake Limiting Valve L-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

X330

Air Filter Resistor R15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

X339

Left Light Switch S-63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

X340

Engine Light Switch S-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

X341

Right Light Switch S-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

X342

LH Shield LTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

X343

RH Shield LTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

X344

Right Shield Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

X345

Left Front Light E-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

X346

Left Rear LIght E-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

X347

Right Front Light E-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

X348

Right Rear Light E-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

X349

Engine Light E-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

X350

RH Position Light E-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

X351

LH Position Light E-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

X352

RH Flashing Light E-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

X353

LH Flashing Light E-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

X354

RH Front Austria Light E-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

X355

LH Front Austria Light E-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

X356

RH Front Turn/Position Light E-04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

X357

LH Front Turn/Position Light E-03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

55-8

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 Section

Description

Page

X358

RH Marker Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

X359

LH Marker Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

X360

RH Rear Marker Light E-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

X361

LH Rear Marker Light E-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

X368

Park Brake Pressure B53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

X371

IVECO Harness to Boost Temperature/Pressure Sensor B-23 . . . . . . . 124

X372

IVECO Harness to Fuel Temperature B-36 . . . . . . . . . . . . . . . . . . . . . . . . 125

X373

IVECO Harness to Coolant Temperature B-44 . . . . . . . . . . . . . . . . . . . . . 126

X376

IVECO Harness to Fuel Actuator 1, L-34 (Cyl 1) . . . . . . . . . . . . . . . . . . . 127

X377

IVECO Harness to Fuel Actuator 1, L-34 (Cyl 4) . . . . . . . . . . . . . . . . . . . 128

X378

IVECO Harness to Fuel Actuator 3, L-36 (Cyl 2) . . . . . . . . . . . . . . . . . . . 129

X379

IVECO Harness to Fuel Actuator 4, L-37 (Cyl 6) . . . . . . . . . . . . . . . . . . . 129

X380

IVECO Harness to Fuel Actuator 5, L-38 (Cyl 3) . . . . . . . . . . . . . . . . . . . 130

X381

IVECO Harness to Fuel Actuator 6, L-39 (Cyl 5) . . . . . . . . . . . . . . . . . . . 130

X382

Chopper RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

X389

Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

X396

Blower Speed Control A-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

X397

ATC Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

X414

ECU Connector B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

X415

ECU -- Power (Cummins ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

X419

WIF Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

X422

Terminator at ECU (Cummins Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

X424

Water in Fuel Sensor B-59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

X439

Coolant Level S-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

X444

Fan Drive Solenoid L-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

X446

CAN 1 Terminator R-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

X462

Rear Axle Angle B-70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

X464

Steering Sensor B-69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

X469

Straw Walker/Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

X471

IVECO Harness to Injector Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

X472

Washer Motor M-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

X474

Grid Heater Relay K-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

X476

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

X483

Alternator G-01 +12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

X484

Auto Guidance Switch S-78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

X485

RCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

55-9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 Section

Description

Page

X487

Expansion C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

X498

DGPS Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

X500

CAN 2 Terminator R-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

X502

Display A-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

X503

Rotary Encoder S-79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

X504

Display Home Switch S-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

X505

Display Escape Switch S-81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

X506

Display Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

X509

USB Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

X513

PSD RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

X515

IVECO Harness; ECU to Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

X516

IVECO Harness; ECU to Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

X517

IVECO Harness to Engine Oil Temperature/Pressure Sensor B-75 . . . 147

X518

IVECO Harness to Engine Camshaft RPM B-07 . . . . . . . . . . . . . . . . . . . 148

X519

IVECO Harness to Engine Flywheel RPM B-05 . . . . . . . . . . . . . . . . . . . . 149

55-10

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 ELECTRICAL CONNECTORS CONNECTOR X001 CAB MAIN/CONSOLE CAV

WIRE NUMBER

1212 (YE)

051 (RD)

X012-CCM-3 J1-17, NOT USED FUSE #39, BATTERY POWER TO MODULE MEMORY

108 (OR)

FUSE #48, RH CONSOLE POWER FROM RELAY K-26

4 5 6 7 8 9

1225 (YE) 1224 (GN) 127 (YE) 128 (GN) 129 (YE) 130 (GN)

135 (RD)

CAN 2 HI CAN 2 LO CAN HI CAN LO CAN HI CAN LO DAM-CONN X065 PIN F, RHM X026 PIN 12 (TX)

136 (BK)

DAM-CONN X065 PIN G, RHM X026 PIN 3 (RX)

12 13

122 (BK) 147 (YE)

118 (YE)

15 16

112 (YE)

GROUND THRESHER ENGAGE SWITCH S30 K-28, THRESHER LATCHING RELAY TO S-30, THRESHER ENGAGE SWITCH FEEDER ENGAGE SWITCH S-31

113 (YE)

X015-CCM-2 J1-17, NEUTRAL SWITCH S22

093 (WH)

POWER TO K-23, NEUTRAL START RELAY

19 20

225 (YE) 1211 (YE)

1744 (YE)

X018-CCM-IJI-17, NOT USED K-19 COIL, NOT USED AUTO GUIDANCE SWITCH S-78, X012-CCM-3 J1-21

1745 (YE)

AUTO GUIDANCE SWITCH S-78, X012-CCM-3 J1-9

23 24

082

CIRCUIT REFERENCE

AMP_206838--1

X001 CONSOLE

AMP_206837--1

X001 CAB MAIN

+12V F-12 (K-03 SWITCHED)

10010921

1 1.

55-11

CONNECTOR X001 - CAB MAIN (CM) HARNESS TO RH CONSOLE (RC) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X002 CAB MAIN/ROOF CAV

WIRE NUMBER

045 (OR)

CAB POWER FUSE #49 (K-26 SWITCHED)

058 (PU)

LH CAB WORK LIGHTS FUSE #6 (K-01 SWITCHED)

072 (PU)

SIDE WORK LIGHT RELAY, K-35 TO RH SIDE WORK LIGHT E-26

059 (PU)

RH CAB MID/OUTER WORK LIGHTS E-20/16 FUSE #7 (K-01 SWITCHED)

048 (RD)

FUSE #35, BATTERY POWER TO RADIO MEMORY

063 (PU)

POWER FROM RELAY K-22 TO LH, RH, AND CENTER HEADER LIGHTS

079 (OR)

FUSE #9, POWER TO SWITCHES S-19, S-27, AND S-38

081 (OR)

FUSE #11, POWER TO RADIO

083 (OR)

FUSE #13, POWER TO AUX. RADIO OUTLET

166 (YE)

X015-CCM-2 J1-2, BEACON LIGHTS SWITCH S41

167 (YE)

X015-CCM-2 J1-3, OPEN COVERS SWITCH S42

272 (OR)

POWER TO WIPER SWITCH S-20 FROM RELAY K-6

170 (YE)

X018-CCM-1 J1-15, REAR WORK LIGHTS SWITCH S44

171 (YE)

X018-CCM-1 J1-3, FRONT WORK LIGHTS SWITCH S43

278 (WH)

WASHER SWITCH S-38 TO X-005 PIN 14, WASHER MOTOR M24

232 (PU)

X015-CCM-2 J1-11, BACKLIGHTING FROM SPLICE BLOCK C W-03

965 (RD)

POWER FROM TIME DELAY MODULE, K-20 TO DOME LIGHT E-34

076 (PU)

LH SIDE WORK LIGHT E-25 FROM K-34

579 (PU)

POWER FROM BEACON LIGHT RELAY, K-29 TO LH/RH BEACON LIGHTS E-31/32

210 (PU)

POWER FORM HEADER WORK LTS RELAY K-22 TO CENTER WORK LIGHT E38

CIRCUIT REFERENCE

AMP_206838--1

X002 CAB MAIN

AMP_206837--1

X002 ROOF

10010915

2 1.

55-12

CONNECTOR X002 - CAB MAIN (CM) HARNESS TO CAB ROOF (CR) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X003 CAB MAIN/ ROOF CAV

WIRE NUMBER

CIRCUIT REFERENCE

131 (YE)

CAN HI

132 (GN)

CAN LOW

900 (WH)

A/C CLUTCH RELAY, K-10

137 (YE)

CAN HI

902 (WH)

SEPARATOR BLOWER RELAY, K-9

138 (GN)

CAN LOW

904 (WH)

NOT USED

905 (WH)

NOT USED

906 (WH)

MAIN BLOWER RELAY HIGH, K-13

907 (BL)

HVAC CONTROL MODULE A-09 POWER TO ATC MODULE A-15, COLD BOX DOOR M-15, WATER VALVE M-16(ATC)

908 (YE)

HVAC CONTROL MODULE A-09 GROUND FOR ATC MODULE A-15, COLD BOX DOOR M-15, WATER VALVE M-16, CAB/OUTLET/EVAPORATOR TEMPERATURE SENSORS B-26/27/28 (ATC)

909 (BL)

HIGH PRESSURE TO ATC MODULE A-15

910 (YE)

HIGH/LOW PRESSURE COMMON TO ATC MODULE A-15

911 (BL)

A/C CLUTCH FROM ATC MODULE, A-15

912 (YE)

BLOWER SPEED TO ATC MODULE, A-15

913 (BL)

BLOWER SPEED/TEMP SELECTION GROUND

914 (YE)

TEMP SELECTION TO ATC MODULE, A-15

939 (YE)

NOT USED

934 (BL)

X005 -PIN 28 A/C HIGH PRESSURE SWITCH S-47 GROUND

917 (YE)

X005 -PIN 29 A/C HIGH PRES SWITCH S47

918 (BK)

AUTO SWITCH TO ATC MODULE, A-15

919 (YE)

NOT USED

920 (OR)

DEMIST SWITCH SIGNAL TO AC MODULE, A-15

978 (PU)

ROAD LIGHTS RELAY, K-27

922 (BK)

NOT USED

923 (YE)

ATC MODULE A-15 DATA TO HVAC CONTROL MODULE A-09

924 (OR)

NOT USED

981 (PU)

ROAD LIGHTS RELAY, K-27

967 (YE)

TIME DELAY RELAY, K-20

1702 (GY)

TURNTABLE ACTUATOR, M-35

1703 (PK)

TURNTABLE ACTUATOR, M-35

1704 (BL)

TURNTABLE ACTUATOR, M-35

1705 (YE)

TURNTABLE ACTUATOR, M-35

1706 (WH)

TURNTABLE ACTUATOR, M-35

AMP_206151

X003 CAB MAIN

AMP_206150--1

X003 ROOF

10010915

3 1.

55-13

CONNECTOR X003 - CAB MAIN (CM) HARNESS TO CAB ROOF (CR) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X004 MAIN FRAME/CAB MAIN CAV

WIRE NUMBER

032 (OR)

X019 CCM-1, J2-2FUSE 43 (K-24 SWITCHED)

033 (OR)

X019 CCM-1, J2-9 FUSE 43 (K-24 SWITCHED)

035 (OR)

MOISTURE/YIELD SENSOR B-12/R-05 AND SAMPLE MOTOR M-28, FUSE 47 (K-26 SWITCHED)

036 (OR)

X013 CCM-3, J2-2/9 FUSE 47 (K-26 SWITCHED)

037 (OR)

X017 CCM-2, J2-2 FUSE 36 (K-25 SWITCHED)

1214 (RD)

B+ FUSE F34, TO LEFT SHIELD LT SW S-63

039 (OR)

X016 CCM-2 J2-9, FUSE 37 (K-25 SWITCHED)

065 (PU)

LOWER WORK LIGHTS E-23/24 FROM RELAY, K-30

067 (PU)

REAR WORK LIGHTS E-27/28 FROM RELAY, K-31

068 (RD)

SERVICE SOCKETS J-02/03/05 FROM FUSE, F-15 (B+)

578 (PU)

REAR BEACON LIGHT E-33 FROM RELAY, K-29

875 (BL)

NOT USED

1210 (BL)

NOT USED

077 (PU)

UNLOAD TUBE LIGHT E-29 FROM RELAY, K-32

078 (PU)

LH/RH TAIL/BRAKE LIGHTS E-11/12 FROM RELAY, K-33

827 (YE)

DAM CONNECTOR J-10 X065 PIN E FROM ECU A-01 X193 PIN 89

193 (WH)

ROAD LIGHT SWITCH S-26 TO HORN H-02

856 (WH)

FUEL PUMP M-23 FROM RELAY, K-07

604 (OR)

FUSE, F-14 (K-03 SWITCHED) TO SIEVE LIGHT SWITCH S-54

243 (PU)

LH FLASHING LAMP E07 FROM FLASHER MOD. A-05 X255 PIN 10

244 (PU)

RH FLASHING LAMP E08 FROM FLASHER MOD. A-05 X255 PIN 11

CIRCUIT REFERENCE

3 DEUTSCH_HDP26--24--31S_PLUG

X004 MAIN FRAME

DEUTSCH_HDP24--24--31P_RECEPTACLE

X004 CAB MAIN

1 10010899

4 1.

24 809 (WH)

B+ F-01 POWER TO ECU A-01, X193 PIN 2/3/8/9 OR A-16, X415 PIN 3/4

523 (WH)

CONCAVE/COVERS RELAY, K-16 FROM X019 CCM-1 J2-21

695 (WH)

CONCAVE/COVERS RELAY, K-16 TO CONCAVE CLEARANCE MOTOR M-04

696 (WH)

CONCAVE/COVERS RELAY, K-16 TO COVERS MOTOR M-12

25 26 27 28

55-14

CONNECTOR X004, MAIN FRAME (MF) HARNESS TO CAB MAIN (CM) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X005 MAIN FRAME/CAB MAIN CAV

WIRE NUMBER

025 (RD)

B+ F-23 TO X016 CCM-2 J2-11

026 (RD)

B+ F-24 TO X019 CCM-1 JE-11

030 (RD)

B+ F-26 TO X014 CCM-3 J3-29/30

031 (RD)

B+ F-27 TO X013 CCM-3 J2-11, X014 CCM-3 J3-7

013 (OR)

F-45 (K-24 SWITCHED) TO HHC MODULE A-07 X281 PIN 2, WATER IN FUEL SENSOR B-59

092 (WH)

24V START RELAY, K-38 FROM STARTING RELAY K-15

176 (PU)

RH MARKER LIGHTS FUSE, F-21

177 (PU)

LH MARKER LIGHTS FUSE, F-20

178 (WH)

A/C CLUTCH RELAY, K-10 TO A/CLCLUTCH L-07

186 (PU)

HIGH BEAM RELAY, K-4 TO ROAD LIGHTS E-13/14

CIRCUIT REFERENCE

196 (PU)

X033 PIN 7, RS FLASHING LIGHTS

200 (PU)

X033 PIN 9, LS FLASHING LIGHTS

237 (PU)

LOW BEAM RELAY, K-5 TO ROAD LIGHTS E-13/14

278 (WH)

X002 PIN 17, WASHER MOTOR M24 FROM WASHER SWITCH S-38

786 (WH)

UPPER/LOWER SIEVE RELAY, K-18 FROM X013 CCM-3 J2-21

790 (WH)

UPPER/LOWER SIEVE RELAY, K-18 TO LOWER SEIVE ACTUATOR M-07

792 (WH)

UPPER/LOWER SIEVE RELAY, K-18 TO UPPER SIEVE ACUTATOR M-06

1702 (GY)

X014 CCM-3 J3-39 TO TURNTABLE ACTUATOR M-35

1215 (RD)

B+ FUSE F34, TO ENGINE/RIGHT SHIELD LIGHT SWITCHES S-64/65

1739 (YE)

X014 - CCM-3 J2-36 TO STEERING WHEEL POSITION B-69

1703 (PK)

X014 CCM-3 J3-26 TO TURNTABLE ACTUATOR M-35

1718 (BL)

X013 CCM-3 J2-14 TO TURNTABLE ACTUATOR M-35

1705 (YE)

X013 CCM-3 J2-29 TO TURNTABLE ACTUATOR M-35

1706 (WH)

X014 CCM-3 J3-19 TO TURNTABLE ACTUATOR M-35

859 (OR)

DEUTSCH_HDP26--24--29S_PLUG

X005 MAIN FRAME

DEUTSCH_HDP24--24--29P_RECEPTACLE

X005 CAB MAIN

10010899

5 1.

KEY SWITCH S-02 TO ECU A-01 X193 PIN 40

915 (YE)

NOT USED

916 (BL)

X003 PIN 19, A/C HIGH PRES SWITCH S-47

917 (YE)

X003 PIN 20, A/C HIGH PRES SWITCH S47

55-15

CONNECTOR X005, MAIN FRAME (MF) HARNESS TO CAB MAIN (CM) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X006 CAB MAIN/HVAC CAV

WIRE NUMBER

CIRCUIT REFERENCE

907 (BL)

HVAC CONTROL MODULE A-09 POWER TO ATC MODULE A-15, COLD BOX DOOR M-15 AND WATER VALVE M-16 (ATC)

926 (WH)

SEPARATOR BLOWER RELAY, K-09

908 (YE)

HVAC CONTROL MODULE A-09 GROUND FOR ATC MODULE A-15, COLD BOX DOOR M-15, WATER VALVE M-16, CAB/OUTLET/ EVAPORATOR TEMPERATURE SENSORS B-26/27/28 (ATC)

928 (WH)

NOT USED

929 (WH)

NOT USED

909 (BL)

HIGH PRESSURE TO ATC MODULE A-15

946 (WH)

BLOWER SPEED CONTROL A-14 (ATC)

910 (YE)

HIGH/LOW PRESSURE COMMON TO ATC MODULE A-15

911 (BL)

A/C CLUTCH FROM ATC MODULE A-15

912 (YE)

BLOWER SPEED TO ATC MODULE A-15

913 (BL)

BLOWER SPEED/TEMP SELECTION GROUND

914 (YE)

TEMP SELCTION TO ATC MODULE A-15

918 (BK)

AUTO SWITCH SIGNAL TO ATC MODULE A-15

919 (YE)

NOT USED

920 (OR)

DEMIST SWITCH SIGNAL TO ATC MODULE A-15

922 (BK)

NOT USED

923 (YE)

ATC MODULE A-15 DATA TO HVAC CONTROL MODULE A-09

924 (OR)

NOT USED

1584 (YE)

NOT USED

1583 (BL)

NOT USED

DEUTSCH_HDP26--24--21S_PLUG

X006 HVAC

DEUTSCH_HDP24--24--21P_RECEPTACLE

X006 CAB MAIN

10010899

6 1.

55-16

CONNECTOR X006, A/C HARNESS TO CAB MAIN (CM) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X007 FRONT FRAME/FEEDER CAV

WIRE NUMBER

719 (WH)

FAN REVERSER RELAY K-17 TO FEEDER REVERSER ACTUATOR M-10

770 (GY)

FEEDER REVERSER DECREASING ACTUATION X020 CCM-1 J3-6 TO FEEDER REVERSER ACTUATOR M-10

712 (WH)

X017 - CCM-2 J3-8, TO REEL SPEED MOTOR M09

613 (PU)

L SIDE FLASHING LIGHTS

618 (PU)

R SIDE FLASHING LIGHTS

580 (WH)

POWER TO ASP AMPLIFIER FROM F-46 (K-25 SWITCHED)

729 (YE)

CAN HI

730 (GN)

CAN LO

733 (YE)

REVERSER DISENGAGE B-09 SIGNAL TO X020 CCM-1 J3-27

743 (YE)

STONE DOOR CLOSED B-24 TO X020 CCM-1 J3-28

749 (BL)

REFERENCE GROUND FOR SENSORS, X020 CCM-1 J3-18

750 (BL)

REFERENCE GROUND FOR SENSORS, X017 CCM-2 J3-18

737 (YE)

X032 PIN 7, REEL RPM SENSOR B15 TO X017 CM-2 J3-13

738 (YE)

L STUBBLE HEIGHT SENSOR R12 TO X281 HHC MOD.A-07 PIN 15

739 (YE)

R STUBBLE HEIGHT SENSOR R13 TO X281 HHC MOD.A-07 PIN 16

741 (YE)

LATERAL FLOAT SENSOR R02 TO X020 CCM-1 J3-17

752 (PU)

HEADER MARKER LIGHTS E40, E41 FROM F-21 (EU)

711 (GY)

X017 -CCM2 J3-6 TO REEL SPEED MOTOR M09

1223 (PK)

+5V FOR HEADER TYPE MODULE/ REEL HORIZONTAL/VERTICAL POSOTION R-20/24/25 AND X017 CCM-2 J3-26

776 (BK)

GROUND

757 (PK)

+5V FOR LAT FLOAT SENSOR R02

779 (YE)

REEL HORIZONTAL POSITION R-24 TO X017 CCM-2 J3-25

780 (YE)

REEL VERTICAL POSITION R-25 TO X017 CCM-2 J3-32

767 (BK)

GROUND

758 (PK)

POWER TO STUBBLE HEIGHT SENSORS R12, R13 FROM HHC MODULE A-07 X281 PIN 5

1116 (YE)

HEADER TYPE MODULE R-20 SIGNAL TO X017 CCM-2 J3-24

748 (BL)

REFERENCE GROUND FOR STUBBLE HEIGHT SENSORS R12, R13 FROM HHC MODULE A-07 X281 PIN 4

CIRCUIT REFERENCE

DEUTSCH_HDP26--24--29S_PLUG

X007 FRONT FRAME

DEUTSCH_HDP24--24--29P_RECEPTACLE

X007 FEEDER

40024707

7 1.

55-17

CONNECTOR X007 - FEEDER (FE) HARNESS TO FRONT FRAME (FF) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X008 MAIN FRAME/FRONT FRAME CA V

WIRE NUMBER

1 2 3 4

674 (YE) 675 (GN) 744 (YE) 746 (GN)

1503 (YE)

1017 (YE)

401 (BL)

485 (YE)

9 10

872 (GY) 873 (WH)

879 (GY)

X024 - PIN 14, UNLOAD TUBE CRADLED SENSOR B38 TO X020 CCM-1 J3-36 X011 - PIN J, NOT USED X011 - PIN K, NOT USED X011 - PIN P, HYDROSTAT EDC VALVE L23 FROM X017 CCM-2 J3-21

880 (WH)

X011 - PIN Q, HYDROSTAT EDC VALVE L23 FROM X017 CCM-2 J3-31

555 (BL)

X021 - PIN HK, REF. GROUND FOR LAT. FLOAT SOLENOIDS L18, L19

425 (BL)

REF. GROUND FOR SENSORS, X017 CCM-2 J3-18

15 16

613 (PU) 618 (PU)

682 (YE)

758 (PK)

748 (BL)

874 (BL)

881 (BL)

738 (YE)

739 (YE)

548 (WH)

549 (WH)

435 (YE)

776 (BK)

30 31

CIRCUIT REFERENCE

CAN HI CAN LO CAN HI CAN LO X019 - CCM-1 J2-26, BRAKE PAD WEAR SWITCHES S55, S56 AND BRAKE FLUID LEVEL S-49 FUTURE OPTION X020 - CCM-1 J3-18, REF. GROUND FOR SENSORS

DEUTSCH_HDP24--24--31P_RECEPTACLE

X008 MAIN FRAME

DEUTSCH_HDP26--24--31S_PLUG

LH FLASHING LAMPS RH FLASHING LAMPS X011 - PIN U, GEARBOX CLUTCH TEMP SENSOR B45 TO X017 CCM-2 J3-33 LEFT/RIGHT STUBBLE HEIGHT SENSOR, R-12/13, HHC MODULE A-07 X281 PIN 5

X008 FRONT FRAME

LEFT/RIGHT STUBBLE HEIGHT SENSOR, R-12/13, HHC MODULE A-07 X281 PIN 4 X011 - PIN F, NOT USED X011 - PIN G, REF. GROUND FOR HYDRO EDC VALVE L23, X017 CCM-2 J3-35 X032 - PIN 1, L STUBBLE HEIGHT SENSOR R12, HHC MODULE A-07 X281 PIN 15 X032 - PIN 2, R STUBBLE HEIGHT SENSOR R13, HHC MODULE A-07 X281 PIN 16 X021 - PIN J, LAT. FLOAT CCW SOLENOID L19, HHC MODULE A-07 X281 PIN 7 X021 - PIN G, LAT. FLOAT CW SOLENOID L18, HHC MODULE A-07 X281 PIN 8 COVERS CLOSED SENSOR B47 TO X020 CCM-1 J3-38

10020075

8 1.

HEADER FLASHING E-01/02, GROUND

55-18

CONNECTOR X008, MAIN FRAME (MF) HARNESS TO FRONT FRAME (FF) HARNESS (BEHIND CAB)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X009 MAIN FRAME/GRAIN TANK CAV

WIRE NUMBER

A B C

077 (PU)

X004 - PIN 15, UNLOAD TUBE LIGHT E29

400 (YE)

X016 - CCM-2 J2-22, GRAIN BIN SENSORS S28, S29

440 (PK)

X016 - CCM-2 J2-31, 5V REF. VOLTAGE

443 (BL)

X015 - CCM-2 J2-14, REF. GROUND FOR SENSORS

646 (PU)

668 (BK)

GRAIN TANK LIGHT E30 GROUND, UNLOAD & GRAIN TANK LIGHTS

L M N P

530 (PU)

UNLOAD TUBE MARKER LIGHT E39

CIRCUIT REFERENCE

DEUTSCH_HDP26--18--14S_PLUG

X009 MAIN FRAME

DEUTSCH_HDP24--18--14P_RECEPTACLE

X009 GRAIN TANK

10010900

9 1.

55-19

CONNECTOR X009, GRAIN TANK (GT) HARNESS TO MAIN FRAME (MF) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X010 MAIN FRAME/ENGINE CAV

WIRE NUMBER

CIRCUIT REFERENCE

524 (GY)

X016 -CCM-2 J2-1, ROT SCR BRUSH MOTOR M27

821 (WH)

ROT SCR BRUSH MOTOR M27, X016 CCM-2 J2-21

3 4

092 (WH)

6 7

864 (YE)

504 (YE)

X016 -CCM-2 J2-27, COOLANT LEVEL S-67

178 (WH)

X005 - PIN 9, A/C CLUTCH L07 FROM A/C CLUTCH RELAY K-10

12 13

650 (RD) -

468 (BL)

15 16

915 (YE) -

827 (YE)

18 19

819 (YE)

1131 (YE)

820 (GN)

916 (BL)

CAN HI WATER IN FUEL SENSOR B-59 TO IVECO ECU A-01 PIN 42 OR CUMMINS ECU A-16 PIN 14 CAN LO X005 - PIN 28, A/C HIGH PRES SWITCH S-47 GROUND

859 (OR)

X005 - PIN 25, KEY SWITCH S-02 TO ECU A-01 PIN 40

917 (YE)

26 27

809 (WH)

X005 - PIN 6, STARTING RELAY K15 TO 24V START RELAY K-38

DEUTSCH_HDP26--24--29S_PLUG

X010 MAIN FRAME

X016 -CCM-2 J2-24, AIR FILT SWITCH S61

ENG SERVICE SOCKET, J-05 REF. GROUND FOR COOLANT LEVEL S-67, AIR FILTER S-16 NOT USED

DEUTSCH_HDP24--24--29P_RECEPTACLE

X004 - PIN 17, DAM CONNECTOR X065 FROM ECU A-01 X193 PIN 89

X010 ENGINE

X005 - PIN 29, A/C HIGH PRES SWITCH S47

X004 - PIN 25, ECU POWER FROM F-01 (B+)

10020076

10 1.

55-20

CONNECTOR X010 - ENGINE (EN) HARNESS TO MAIN FRAME (MF) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X011 MAIN FRAME/GEARBOX CAV

WIRE NUMBER

422 (YE)

X019 - CCM-1 J2-27, GEARBOX TEMP SENSOR B32

423 (YE)

X016 - CCM-2 J2-19, CONTROL PRES SENSOR B35

424 (YE)

X016 - CCM-2 J2-39, HYD. RESERVOIR LEVEL S33

486 (PK)

X016 - CCM-2 J2-31, 5V REF. VOLTAGE

446 (YE)

X019 - CCM-1 J2-24, HYD. RESERVOIR TEMP B18

874 (BL)

881 (BL)

X020 - CCM-1 J3-35, NOT USED X017 - CCM-2 J3-35, REF. GROUND FOR HYDRO EDC VALVE L23

488 (BL)

REF. GROUND FOR SENSORS, X020 CCM-1 J3-18

J K

872 (GY) 873 (WH)

875 (BL)

X020 - CCM-1 J3-21, NOT USED X020 - CCM-1 J3-31, NOT USED X019 - CCM-1 J2-40, FEEDER CLUTCH L24

876 (WH)

X019 - CCM-1 J2-30, FEEDER CLUTCH L24

877 (BL)

X016 - CCM-2 J2-40, GEARBOX CLUTCH L22

878 (WH)

X016 - CCM-2 J2-30, GEARBOX CLUTCH L22

879 (GY)

X017 - CCM-2 J3-21, HYDROSTAT EDC VALVE L23

880 (WH)

X017 - CCM-2 J3-31, HYDROSTAT EDC VALVE L23

572 (WH)

X016 - CCM-2 J2-15, PARK BRAKE DISENGAGE VALVE L10

568 (WH)

X016 - CCM-2 J2-4, UNLOAD TUBE CLUTCH L08

601 (BL)

X016 - CCM-2 J2-20, UNLOAD TUBE CLUTCH L08

682 (YE)

X017 - CCM-2 J3-33, GEARBOX CLUTCH TEMP B45

683 (BL)

X016 - CCM-2 J2-14, REF. GROUND FOR SENSORS

684 (YE)

X016 - CCM-2 J2-35, CHARGE PRES SWITCH S37

CIRCUIT REFERENCE

DEUTSCH_HDP26--24--23S_PLUG

X011 MAIN FRAME

DEUTSCH_HDP24--24--23P_RECEPTACLE

X011 GEARBOX

10020076

11 1.

55-21

IN-LINE CONNECTOR X011 - GEARBOX (GB) HARNESS TO MAIN FRAME (MF) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X012 CCM-3 J1 CAV

WIRE NUMBER

1 2 3 4 5

049 (RD) 101 (OR) -

787 (WH)

1061 (YE)

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

217 (BK) 1745 (YE) 134 (GN) 133 (YE) 1212 (YE) 1744 (YE) -

CIRCUIT REFERENCE

FUSE F-39, KEEP ALIVE POWER

KEYSWITCH POWER UPPER/LOWER SIEVE RELAY, K-18 FROM X012 CCM-3 J1-6 X001 - PIN 13, THRESHER ENGAGE SWITCH S30 TO X015 CCM-2 J1-17 GROUND, X012 CCM-3 J1-8 AUTOGUIDANCE SWITCH S-78

DEUTSCH_DRC16--24S_PLUG

X012 CCM-3 J1

CAN LO CAN HI

X001 - PIN 1, NOT USED

AUTOGUIDANCE SWITCH S-78 10004693

1 12

55-22

CONNECTOR X012 - CCM3-J1 FROM CAB MAIN (CM) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X013 CCM-3 J2 CAV

WIRE NUMBER

785 (GY)

UPPER/LOWER SIEVE MOTOR M06/M07

505 (OR)

FUSE 47 (K-26 SWITCHED)

520 (BK)

GROUND

CIRCUIT REFERENCE

771 (WH)

LH VERTICAL KNIFE RELAY K43

772 (WH)

RH VERTICAL KNIFE RELAY K42

506 (OR)

FUSE 47 (K-26 SWITCHED)

511 (RD)

FUSE 27 (B+)

690 (BK)

GROUND

837 (WH)

SAMPLE MOTOR M28

1723 (BL)

540 (YE)

UPPER SIEVE ADJUST SW S35 INCR

691 (BK)

GROUND

476 (YE)

LOWER SIEVE MOTOR M07

1730 (BL)

786 (WH)

UPPER/LOWER SIEVE RELAY K-18

475 (YE)

UPPER SIEVE MOTOR M06

838 (YE)

DEUTSCH_DRC16--40S_PLUG

X013 CCM-3 J2

REF. GROUND FOR SENSORS

STEER RIGHT/LEFT SOLENOID L-57/58 40020077

1 13

SAMPLE MOTOR M28

1705 (YE)

683 (PK)

477 (YE)

SPREADER PLATE MOTOR M11

539 (YE)

UPPER SIEVE ADJUST SW S35 DEC

542 (YE)

LOWER SIEVE ADJUST SW S46 INCR

1739 (YE)

541 (YE)

TURNTABLE ACTUATOR M-35 5V REF. VOLTAGE

STEERING WHEEL POSITION B-69

LOWER SIEVE ADJUST SW S46 DEC

55-23

CONNECTOR X013 - CCM-3 J2 FROM EXPANSION (EX) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X014 CCM-3 J3 CAV

WIRE NUMBER

1727 (GY)

STEERING LEFT SOLENOID L-58

1726 (WH)

STEERING RIGHT SOLENOID L-57

1758 (WH)

STEERING ENABLE SOLENOID L-59

6 7 8 9 10

509 (GY) 512 (RD) 510 (WH) 536 (BK) 537 (BK)

1733 (OR)

3 4

12 13 14 15 16 17 18 19 20 21 22 23

521 (BK) 593 (YE) 563 (BL) 1706 (WH) 1754 (YE)

CIRCUIT REFERENCE

SPREADER PLATE MOTOR M11 FUSE 27 (B+) SPREADER PLATE MOTOR M11 GROUND GROUND REAR AXLE ANGLE B-70 TO X013 CCM-3 J2-2/9 AND F-47 (K-26 SWITCHED)

TURNTABLE ACTUATOR M-35

X485 PIN 2 (NOT USED)

24 25

1732 (YE)

REAR AXLE ANGLE B-70

1715 (PK)

TURNTABLE ACTUATOR M-35

534 (RD) 535 (RD) 552 (YE) 595 (YE) 1702 (GY)

X014 CCM-3 J3

GROUND MOISTURE SENSOR B12 YIELD SENSOR R05

594 (YE) 1753 (YE)

27 28 29 30 31 32 33 34 35 36 37 38

DEUTSCH_DRC16--40S_PLUG

40020077

MOISTURE SENSOR B12

1 14

X485 PIN 1 (NOT USED)

B(+) FUSE 26 B(+) FUSE 26 YIELD SENSOR SIGNAL R05 MOISTURE SENSOR SIGNAL B12

TURNTABLE ACTUATOR M-35

55-24

CONNECTOR X014 - CCM-3 J3 FROM EXPANSION (EX) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X015 CCM-2 J1 CAV

WIRE NUMBER

050 (RD)

166 (YE)

FUSE F39, KEEP ALIVE POWER X002 - PIN 12, BEACON LIGHTS SWITCH S41

167 (YE)

X002 - PIN 13, TANK COVERS SWITCH S42

100 (OR)

204 (YE)

KEYSWITCH POWER X033 - PIN 10, FLASHER MODULE A05 PIN 9

111 (YE)

X001 - PIN 13, THRESHER ENGAGE SWITCH S30

8 9 10

216 (BK) 168 (YE) -

231 (PU)

12 13 14 15 16

970 (WH) 132 (GN) 131 (YE) 1209 (PU) -

113 (YE)

18 19 20 21 22 23 24

183 (WH) 134 (GN) 133 (YE) 090 (OR) 182 (WH)

CIRCUIT REFERENCE

DEUTSCH_DRC16--24S_PLUG

X015 CCM-2 J1

GROUND SEAT SWITCH S05 SPICE BLOCK C, W-03, BACKLIGHTING FUEL PUMP RELAY K-07 CAN LO CAN HI X033 - PIN 2, HAZARD SWITCH S25 X001 - PIN 17, NEUTRAL SWITCH S22 BRAKE LIGHTS RELAY, K-33 CAN LO CAN HI NEUTRAL START RELAY, K-23

10004693

1 15

BEACON LIGHTS RELAY, K-29

55-25

CONNECTOR X015 - CCM2-J1 FROM CAB MAIN (CM) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X016 CCM-2 J2 CAV

WIRE NUMBER

524 (GY)

2 3

037 (OR) 514 (BK)

568 (WH)

5 6 7 8 9 10 11 12 13 14

1504 (WH) 574 (WH) 567 (WH) 566 (WH) 039 (OR) 025 (RD) 688 (BK) 465 (BL)

572 (WH)

16 17 18

573 (WH) 427 (YE) 689 (BK)

423 (YE)

UNLOAD TUBE OUT L04 FUEL LEVEL SIGNAL R01 GROUND X011 - PIN B, LOW CONTROL PRES SENSOR B35

601 (BL)

X011 - PIN T, UNLOAD TUBE CLUTCH L08

821 (WH)

400 (YE)

746 (GN)

864 (YE)

25 26

410 (YE) 402 (YE)

504 (YE)

28 29

532 (YE) -

878 (WH)

X011 - PIN 0, GEARBOX CLUTCH L22

31 32 33 34

459 (PK) 744 (YE)

5V REF VOLTAGE CAN HI

418 (YE)

684 (YE)

BRAKE PRESSURE SWITCH S39 X011 - PIN W, CHARGE PRES. SWITCH S37

36 37 38

416 (YE) 413 (YE)

424 (YE)

ROTOR RPM B01 CHOPPER RPM B10 X011 - PIN C, HYD. RESERVOIR LEVEL S33

877 (BL)

X011 - PIN N, GEARBOX CLUTCH L22

CIRCUIT REFERENCE

X010 - PIN 1, ROT SCR BRUSH MOTOR M27 FUSE 36 (K-25 SWITCHED) GROUND X011 - PIN S, UNLOAD TUBE CLUTCH L08 BRAKE LIMITING L-32 UNLOAD TUBE IN L03 ROTOR INCREASE L29 ROTOR DECREASE L30 FUSE 37 (K-25 SWITCHED)

DEUTSCH_DRC16--40S_PLUG

X016 CCM-2 J2

FUSE 23 (B+) GROUND REF. GROUND FOR SENSORS X011 - PIN R, PARK BRAKE DISENGAGE L10

ROTARY SCREEN BRUSH M-27 X009 - PIN E, GRAIN BIN 3/4 FULL SENSORS S28, S29

40020077

CAN LO X010 - PIN 18, AIR FILTER SWITCH S-61

16 1.

LEFT ROTOR LOSS B19 RIGHT ROTOR LOSS B20 X010 - PIN 10, COOLANT LEVEL S-67 PSD RPM B-74

55-26

CONNECTOR X016 - CCM-2 J2 FROM MAIN FRAME (MF) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X017 CCM-2 J3 CAV

WIRE NUMBER

1 2 3 4 5

560 (WH) 556 (WH) 558 (WH) 557 (WH) 559 (WH)

711 (GY)

028 (RD)

712 (WH)

9 10 11 12

516 (BK) 517 (BK) 038 (OR) -

737 (YE)

X032 - PIN 7, REEL RPM SENSOR B15

403 (YE)

X023 - PIN 6, GROUND SPEED RPM B17

575 (WH)

X023 - PIN 13, PRESSURE RELEASE L05

16 17 18

515 (BK) 766 (BL)

526 (GY)

REF. GROUND FOR SENSORS X023 - PIN 3, TRANS SHIFT MOTOR M02

527 (GY)

X023 - PIN 3, TRANS SHIFT MOTOR M02

879 (GY)

X011 - PIN P, HYDROSTAT EDC VALVE L23

22 23 24 25 26

1116 (YE) 779 (YE) 1557 (PK)

409 (YE)

HEADER TYPE MODULE R-20 REEL HORIZONTAL POSITION R-24 5V REF. VOLTAGE X023 - PIN 12, SHIFT POSITION SENSOR B37 (4TH)

407 (YE)

X023 - PIN 10, SHIFT POSITION B37 (N)

29 30

507 (RD) 508 (RD)

880 (WH)

780 (YE)

682 (YE)

1536 (YE)

881 (BL)

PARK BRAKE PRESSURE B53 X008 - PIN 22, REF. GROUND FOR HYDRO EDC VALVE L23

405 (YE)

X023 - PIN 8, SHIFT POSITION SENSOR B37 (1ST)

406 (YE)

X023 - PIN 9, SHIFT POSITION SENSOR B37 (2ND)

408 (YE)

X023 - PIN 11, SHIFT POSITION SENSOR B37 (3RD)

528 (WH)

X023 - PIN 4, TRANS SHIFT MOTOR M02

529 (WH)

X023 - PIN 4, TRANS SHIFT MOTOR M02

CIRCUIT REFERENCE

X021 - PIN P, REEL FORWARD L16 X021 - PIN E, REEL DRIVE L17 X021 - PIN L, REEL UP L14 X021 - PIN N, REEL DOWN L13 X021 - PIN R, REEL AFT L15 X032 - PIN 26, REEL SPEED MOTOR M09 FUSE 23 (B+) X032 - PIN 20, REEL SPEED MOTOR M09

DEUTSCH_DRC16--40S_PLUG

GROUND GROUND FUSE 36 (K-25 SWITCHED)

X017 CCM-2 J3

GROUND

1 40020077

17 1.

FUSE 25 (B+) FUSE 25 (B+) X011 - PIN Q, HYDROSTAT EDC VALVE L23 REEL VERTICAL POSITION R-25 X011 - PIN U, THRESHER CLUTCH TEMP B45

55-27

CONNECTOR X017 - CCM-2 J3 FROM FRONT FRAME (FF) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X018 CCM-1 J1 CAV

WIRE NUMBER

1 2

052 (RD) 198 (PU)

171 (YE)

4 5 6 7 8 9 10

099 (OR) 117 (WH) 692 (WH) 112 (YE) 215 (BK) 194 (PU) -

190 (WH)

12 13 14

181 (WH) 138 (GN) 137 (YE)

170 (YE)

16 17 18 19 20 21 22 23 24

225 (YE) 184 (WH) 130 (GN) 129 (YE) 212 (OR) 107 (BK) 180 (WH)

CIRCUIT REFERENCE

FUSE F39, KEEP ALIVE POWER LEFT TURN SIGNAL S26 X002 - PIN 16, FRONT WORK LIGHTS SWITCH S43 KEYSWITCH POWER ROAD LIGHTS RELAY, K-27 CONCAVE/COVERS RELAY, K-16 FEEDER ENGAGE S-31 GROUND RIGHT TURN SIGNAL S26

DEUTSCH_DRC16--24S_PLUG

X018 CCM-1 J1

CAB ROOF WORK LIGHTS RELAY, K-1 UNLOAD TUBE LIGHT RELAY, K-32 CAN LO CAN HI X002 - PIN 15, REAR WORK LIGHTS SWITCH S44 X001 - PIN 19, (NOT USED) REAR WORK LIGHTS RELAY, K-31 CAN LO CAN HI LIGHT CONTROL RELAY, K-02

CCM-3/CAB POWER RELAY, K-26 SIDE WORK LIGHT RELAY, K-35

10004693

18 1.

55-28

CONNECTOR X018 - CCM1-J1 FROM CAB MAIN (CM) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X019 CCM-1 J2 CAV

WIRE NUMBER

522 (GY)

2 3 4 5 6 7 8 9 10 11 12

FUSE 43 (K-24 SWITCHED) GROUND

032 (OR) 513 (BK) 452 (WH) 582 (WH) 581 (WH) 033 (OR) 026 (RD) 686 (BK) 1161 (WH)

460 (BL)

576 (WH)

REF. GROUND FOR SENSORS X024 - PIN 17, CHAFF SPREADER L28

569 (WH)

570 (YE)

18 19 20 21 22 23

687 (BK) 411 (YE) 523 (WH) -

446 (YE)

431 (YE)

CIRCUIT REFERENCE

CONCAVE CLEARANCE MOTOR M04/COVERS MOTOR M12

X024 - PIN 13, BACKUP ALARM H08 FEEDER INCREASE L11 FEEDER DECREASE L12 FUSE 43 (K-24 SWITCHED)

DEUTSCH_DRC16--40S_PLUG

FUSE 24 (B+) GROUND

X019 CCM-1 J2

FAN DRIVE SOLENOID L-44

X024 - PIN 15, RWA SOLENOID L26 X024 - PIN 16, REAR LADDER SENSOR B22 GROUND CONCAVE POSITION R06

CONCAVE/COVERS RELAY K-16

X011 - PIN E, HYD. OIL RESERVOIR TEMP. SENSOR B18

40020077

X024 - PIN 5, SIEVES LOSS B21 X008 - PIN 5, BRAKE PAD WEAR SWITCHES S55, S56, BRAKE FLUID LEVEL S-49 X011 - PIN A, GEARBOX TEMP SENSOR B32

1503 (YE)

422 (YE)

28 29 30 31 32

450 (YE) 876 (WH) 453 (PK) -

430 (YE)

LATERAL INCLINATION SENSOR B02

447 (YE)

X024 - PIN 7, RETURNS FILTER BYPASS S32

448 (YE)

X024 - PIN 8, GEARBOX FILTER BYPASS S34

36 37 38 39 40

441 (YE) 433 (YE) 432 (YE) 875 (BL)

RIGHT RETURNS RPM B39 LEFT RETURNS RPM B06 NOT USED X011 - PIN L, FEEDER CLUTCH L24

19 1.

CLEAN GRAIN ELEVATOR RPM B08 X011 - PIN M, FEEDER CLUTCH L24 5V REF VOLTAGE

55-29

CONNECTOR X019 - CCM-1 J2 FROM MAIN FRAME (MF) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X020 CCM-1 J3 CAV

WIRE NUMBER

1 2

762 (WH)

561 (WH)

X021 - PIN A, FEEDER JOG FORWARD L20

713 (GY)

CLEANING FAN MOTOR M05/REVERSER ACTUATOR M10

027 (RD)

714 (WH)

9 10 11 12

702 (BK) 703 (BK) 034 (OR) 768 (WH)

404 (YE)

489 (YE)

562 (WH)

704 (BK)

741 (YE)

501 (BL)

705 (GY)

REF. GROUND FOR SENSORS X023 - PIN 1, SHOE LEVELING ACTUATOR M03

706 (GY)

X023 - PIN 1, SHOE LEVELING ACTUATOR M03

21 22 23 24 25 26

872 (GY) 726 (PK)

733 (YE)

5V REF. VOLTAGE X007 - PIN 10, REVERSER POSITION B09

743 (YE)

X007 - PIN 11, ASP DOOR POSITION B24

29 30 31

700 (RD) 701 (RD) 873 (WH)

721 (YE)

FUSE 22 FUSE 22 NOT USED X023 - PIN 15, SHOE LEVELING ACTUATOR M03

773 (YE)

X023 - PIN 26, HYDROSTAT TEMP. SENSOR B46

34 35 36 37 38

874 (BL) 485 (YE) 435 (YE)

708 (WH)

COVERS CLOSED SENSOR B47 X023 - PIN 2, SHOE LEVELING ACTUATOR M03

709 (WH)

X023 - PIN 2, SHOE LEVELING ACTUATOR M03

CIRCUIT REFERENCE

X023 - PIN 21, DUAL RANGE SOLENOID L27

FUSE 24 CLEANING FAN MOTOR M05/REVERSER ACTUATOR M10

DEUTSCH_DRC16--40S_PLUG

X020 CCM-1 J3

GROUND GROUND FUSE 44 FAN/REVERSER RELAY K-17 X023 - PIN 7, CLEANING FAN RPM B16

FEEDER RPM B14 X021 - PIN C, FEEDER JOG REVERSE L21 GROUND X007 - PIN 17, LATERAL FLOAT POT R02

40020077

NOT USED

20 1.

NOT USED UNLOAD CRADLE SENSOR B38

55-30

CONNECTOR X020 - CCM-1 J3 FROM FRONT FRAME (FF) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X021 FRONT FRAME/FEEDER VALVE CAV

WIRE NUMBER

A B C D E F G

561 (WH) 590 (BK) 562 (WH) 591 (BK) 556 (WH) 585 (BK) 549 (WH)

554 (BL)

548 (WH)

553 (BL)

L M N O P Q R S T U V W X

558 (WH) 587 (BK) 557 (WH) 586 (BK) 560 (WH) 589 (BK) 559 (WH) 588 (BK) -

CIRCUIT REFERENCE

FEEDER FORWARD ACTUATION FEEDER FORWARD GROUND FEEDER REVERSE ACTUATION FEEDER REVERSE GROUND REEL DRIVE ACTUATION REEL DRIVE GROUND LATERAL FLOAT CW ACTUATION LATERAL FLOAT CW PRINTED CIRCUIT GROUND

DEUTSCH_HDP26--24--23S_PLUG

X021 FRONT FRAME

LATERAL FLOAT CCW ACTUATION LATERAL FLOAT CCW PRINTED CIRCUIT GROUND REEL UP ACTUATION REEL UP GROUND REEL DOWN ACTUATION REEL DOWN GROUND REEL FORE ACTUATION REEL FORE GROUND REEL AFT ACTUATION REEL AFT GROUND

DEUTSCH_HDP24--24--23P_RECEPTACLE

X021 FEEDER VALVE

40024707

21 1.

55-31

CONNECTOR X021 - FEEDER VALVES (FV) HARNESS TO FRONT FRAME (FF) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X023 FRONT FRAME/LOWER FRAME CAV

WIRE NUMBER

CIRCUIT REFERENCE

707 (GY)

X020 CCM1 J3-19, 20, SHOE LEVELING ACTUATOR M03

710 (WH)

X020 CCM1 J3-39, 40, SHOE LEVELING ACTUATOR M03

715 (GY)

X017 CCM2 J3-19, 20, TRANS SHIFT MOTOR M02

716 (WH)

X017 CCM2 J3-39, 40, TRANS SHIFT MOTOR M02

042 (BL)

403 (YE)

REF. GROUND FOR SENSORS X017 CCM2 J3-14, GROUND SPEED RPM B17

404 (YE)

X020 CCM1 J3-13, CLEANING FAN RPM B16

405 (YE)

X017 CCM2 J3-36, SHIFT POSITION SENSOR B37 (1ST)

406 (YE)

X017 CCM2 J3-37, SHIFT POSITION SENSOR B37 (2ND)

407 (YE)

X017 CCM2 J3-28, SHIFT POSITION SENSOR B37 (N)

408 (YE)

X017 CCM2 J3-38, SHIFT POSITION SENSOR B37 (3RD)

409 (YE)

X017 CCM2 J3-27, SHIFT POSITION SENSOR B37 (4TH)

575 (WH)

X017 CCM2 J3-15, FOOT AND INCH VALVE L05

434 (YE)

X019 CCM1 J2-26, BRAKE PAD WEAR SWITCHES S55, S56

721 (YE)

X020 CCM1 J3-32, SHOE LEVELING ACTUATOR M03

16 17 18

723 (BL) 727 (PK) -

761 (GY)

762 (WH)

X020 CCM1 J3-3, DUAL RANGE SOLENOID L27

763 (WH)

CLEANING FAN ADJUST MOTOR M05

23 24 25

765 (BK)

773 (YE)

27 28 29

836 (BK)

DEUTSCH_HDP24--24--29P_RECEPTACLE

X023 FRONT FRAME

DEUTSCH_HDP26--24--29S_PLUG

X023 LOWER FRAME

REF. GROUND FOR SENSORS 5V REF. VOLTAGE CLEANING FAN ADJUST MOTOR M05

GROUND X020 CCM1 J3-33, HYDROSTAT TEMP SENSOR B46

10010898

22 1.

GROUND

55-32

CONNECTOR X023, FRONT FRAME (FF) HARNESS TO LOWER FRAME (LF) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X024 MAIN FRAME/STRAW HOOD FRONT CAV

WIRE NUMBER

078 (PU)

3 4

431 (YE)

432 (YE)

447 (YE)

NOT USED X019 CCM1 J2-34, RETURNS FILTER BYPASS SWITCH S32

448 (YE)

X019 CCM1 J2-35, GEARBOX FILTER BYPASS SWITCH S34

9 10

243 (PU) 244 (PU)

461 (BL)

463 (PK)

452 (WH)

FUTURE OPTION X019 CCM1 J2-6, BACKUP ALARM H08

485 (YE)

X020 CCM1 J3-36, UNLOAD CRADLE B38

569 (WH)

X019 CCM1 J2-16, REAR WHEEL ASSIST L26

570 (YE)

X019 CCM1 J2-17, REAR LADDER SENSOR B22

576 (WH)

X019 CCM1 J2-15, CHAFF SPREADER L28

1017 (YE)

19 20 21 22

CIRCUIT REFERENCE

BRAKE LIGHTS RELAY K-33 TO BRAKE LIGHTS E-11/12, TRAILER OUTLET J-09

X019 CCM1 J2-25, SIEVES LOSS B21

DEUTSCH_HDP24--24--31P_RECEPTACLE

X024 STRAW HOODFRONT

FUTURE OPTION REAR BEACON LIGHT E33 LH REAR FLASHING LAMP E05 RH REAR FLASHING LAMP E06 X016 CCM-2 J2-28, PSD RPM B-74

REAR WORK LIGHTS RELAY K-31

067 (PU) 1161 (WH)

28 29

625 (PU)

24 25 26

X024 MAIN FRAME

LEFT FLASHING LAMP E07 RIGHT FLASHING LAMP E08 X020 CCM1 J3-18, REF. GROUND FOR SENSORS

578 (PU) 614 (PU) 617 (PU) 532 (YE) 1021 (BL)

DEUTSCH_HDP26--24--31S_PLUG

PSD RPM B-74 REF.GND.

X019 CCM-1 J2-13 , FAN DRIVE SOLENOID L-44

626 (PU)

FUSE 20 TO LEFT MARKER LIGHTS FUSE 21 TO RIGHT MARKER LIGHTS

678 (RD)

B(+) FUSE 15 TO RH SERVICE SOCKET J03

10020076

23 1.

55-33

CONNECTOR X024 - STRAW HOODFRONT (SW) HARNESS TO MAIN FRAME (MF) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X025 STRAW HOOD FRONT/EXPANSION CAV

WIRE NUMBER

1 2

683 (PK) 439 (BL)

475 (YE)

5V REF. VOLTAGE REF. GROUND FOR SENSORS X013 CCM3 J2-22, UPPER SIEVE MOTOR M06

476 (YE)

X013 CCM3 J2-19, LOWER SIEVE MOTOR M07

477 (YE)

X013 CCM3 J2-33, SPREADER PLATE MOTOR M11

539 (YE)

X013 CCM3 J2-34, UPPER SIEVE ADJUST SW S35 - DEC

540 (YE)

X013 CCM3 J2-17, UPPER SIEVE ADJUST SW S35 - INCR

509 (GY)

X014 CCM3 J3-6, SPREADER PLATE MOTOR M11

541 (YE)

X013 CCM3 J2-39, LOWER SIEVE ADJUST SW S46 - DEC

510 (WH)

X014 CCM3 J3-8, SPREADER PLATE MOTOR M11

542 (YE)

X013 CCM3 J2-35, LOWER SIEVE ADJUST SW S46 - INCR

12 13

551 (BK)

785 (GY)

15 16 17 18 19

790 (WH) 792 (WH) 550 (BK)

CIRCUIT REFERENCE

DEUTSCH_HDP24--24--19P_RECEPTACLE

X025 STRAW HOOD FRONT

GROUND SIEVE MOTORS M06, M07, X013 CCM-3 J2-1

DEUTSCH_HDP26--24--19S_PLUG

X025 EXPANSION

LOWER SIEVE MOTOR M07 UPPER SIEVE MOTOR M06 GROUND

10020076

24 1.

55-34

CONNECTOR X025, STRAW WALKER (SW) HARNESS TO EXPANSION (EX) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X026 RHM J6 CAV

1 2 3 4 5 6 7 8 9

WIRE NUMBER

CIRCUIT REFERENCE

130 (GN) 129 (YE) 136 (BK) 098 (OR) 089 (OR) 320 (BL) 323 (BL) 1298 (GN)

CAN 1 LO CAN 1 HI RX TO DIAGNOSTIC OUTLET J-10 SPLICE BLOCK B W-02 SPLICE BLOCK B W-02 GROUND SPEED POT R-04 GEAR SELECT

1299 (YE)

12 13 14 15 16 17 18

135 (RD) 307 (RD) 389 (BK) 316 (PK) 319 (PK) 388 (BK)

376 (WH)

GROUND SPLICE BLOCK A W-01 GROUND SPEED POT R-04 GEAR SELECT GROUND FOR AUDIO ALARM H-01 ACTUATION FOR AUDIO ALARM H-01

352 (BK)

GROUND FOR SPLICE BLOCK A W-01

CAN 1 LO

AMP_O--174952--1

CAN 1 HI

X026 RHM J6

TX TO DIAGNOSTIC OUTLET J-10 F-39 (B+)

10010917

25 1.

55-35

CONNECTOR X026, RHMJ6 FROM RIGHT CONSOLE (RC) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X027 RHM J7A CAV

WIRE NUMBER

CIRCUIT REFERENCE

381 (YE)

GROUND SPEED POT R-04

2 3

364 (BK)

GROUND FOR SPLICE BLOCK A

356 (BK)

GROUND FOR SPLICE BLOCK A

304 (YE)

SIGNAL FOR HHC FINE ADJUST S-06

303 (YE)

SIGNAL FOR HHC FINE ADJUST S-06

355 (PU)

LIGHTING FOR PARK BRAKE

9 10

391 (YE)

GEAR SELECT SIGNAL

301 (WH)

ACTUATION FOR NEUTRAL LOCK SOL. S-01

305 (WH)

ACTUATION FOR NEUTRAL LOCK SOL. S-01

228 (PU)

LIGHTING FOR VERTICAL KNIVES SW. S-51

354 (PU)

LIGHTING FOR REEL SPEED SW. S-08

353 (PU)

LIGHTING FOR HEADER HEIGHT SW. S-04

338 (YE)

ENGINE THROTTLE SWITCH S-36

329 (PU)

SPLICE BLOCK F LIGHTING FEED W-06

AMP_173853

X027 RHM J7A

10010917

26 1.

55-36

CONNECTOR X027, RHMJ7A FROM RIGHT CONSOLE (RC) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X028 RHM J7B CAV

WIRE NUMBER

1 2

PU PK

3 4

OPEN GN

UNLOAD TUBE OUT/HEADER TILT LEFT/REEL FORWARD

6 7

BK RD

HEADER CIRCUITS – COMMON REEL CIRCUITS, EMERGENCY STOP – COMMON

HEADER DOWN SLOW/EMERGENCY STOP

UNLOAD TUBE IN LOCK/HEADER RESUME/REEL AFT

UNLOAD TUBE IN/HEADER UP SLOW/REEL SPEED DECREASE

UNLOAD TUBE OUT LOCK/HEADER DOWN FAST/REEL DOWN

OPEN

CIRCUIT REFERENCE

UNLOAD CIRCUITS – COMMON HEADER TILT RIGHT/REEL SPEED INCREASE/HANDLE UNLOCK UNLOAD AUGER ENGAGE/HEADER UP FAST/REEL UP

AMP_O--173851--1

X028 RHM J7B

NOTE: Use the following table to determine the correct pin combinations for each switch on the propulsion handle. The MFH circuits contain diodes, so the multimeter test leads must be connected to the proper pins as indicated in the table. The active switch reading will be approximately 1.7M ohms. SWITCH NAME

+ PIN

-PIN

2 PK

1 PU

UNLOAD AUGER ENGAGE

4 GN

1 PU

UNLOAD TUBE OUT

5 WH

1 PU

UNLOAD TUBE IN LOCK

9 GY

1 PU

UNLOAD TUBE IN

10 YE

1 PU

UNLOAD TUBE OUT LOCK

11 BN

1 PU

HEADER TILT RIGHT/CW

2 PK

6 BK

HEADER UP SLOW

4 GN

6 BK

HEADER TILT LEFT/CCW

5 WH

6 BK

HEADER DOWN SLOW

8 BL

6 BK

HEADER RESUME

9 GY

6 BK

HEADER UP FAST

10 YE

6 BK

HEADER DOWN FAST

11 BN

6 BK

REEL SPEED INCREASE

2 PK

7 RD

REEL UP

4 GN

7 RD

REEL FORE

5 WH

7 RD

EMERGENCY STOP

8 BL

7 RD

REEL AFT

9 GY

7 RD

REEL SPEED DECREASE

10 YE

7 RD

REEL DOWN

11 BN

7 RD

HANDLE UNLOCK

55-37

10010917

27 1.

CONNECTOR X028, FROM MULTI-FUNCTION HANDLE (MFH)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X029 RHM J8A CAV

WIRE NUMBER

335 (YE)

PARK BRAKE SIGNAL S-09

2 3

332 (YE) 330 (YE)

REEL SPEED SIGNAL S-08 HEADER HEIGHT SIGNAL S-04

322 (YE)

THROTTLE SIGNAL S-36

326 (YE)

FEEDER DIRECTION SIGNAL S-07

6 7

337 (YE) 230 (YE)

DUAL RANGE SIGNAL S-11 VERTICAL KNIVES SIGNAL S-51

CIRCUIT REFERENCE

9 10

334 (YE) 333 (YE)

PARK BRAKE SIGNAL S-09 REEL SPEED SIGNAL S-08

331 (YE)

HEADER HEIGHT SIGNAL S-04

328 (YE)

ALTERNATE SETTING SIGNAL S-21

13 14

318 (YE) 325 (YE)

THROTTLE SIGNAL S-36 SPREADER PLATE SIGNAL S-23

229 (YE)

VERTICAL KNIVES SIGNAL S-51

16 17

339 (YE) 336 (YE)

ON THE ROAD SIGNAL S-12 REAR WHEEL ASSIST SIGNAL S-10

324 (YE)

SPREADER PLATE SIGNAL S-23

AMP_173853

X029 RHM J8A

10010917

1 28

55-38

CONNECTOR X029, RHMJ8A FROM RIGHT CONSOLE (RC) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X030 RHM J8B CAV

WIRE NUMBER

1 2

342 (YE) 341 (YE)

347 (YE)

LOWER SIEVE SIGNAL DEC. S-14 UPPER SIEVE SIGNAL INC. S-13 CONCAVE CLEARANCE SIGNAL INC. S-16

348 (YE)

ROTOR/DRUM SPEED SIGNAL DEC. S-17

5 6 7

350 (YE) 343 (YE) 340 (YE)

346 (YE)

9 10

344 (YE) 345 (YE)

349 (YE)

FAN SPEED SIGNAL DEC. S-15 FAN SPEED SIGNAL INC. S-15 ROTOR/DRUM SPEED SIGNAL INC. S-17

351 (YE)

FEEDER SPEED SIGNAL INC. S-18

CIRCUIT REFERENCE

FEEDER SPEED SIGNAL DEC. S-18 LOWER SIEVE SIGNAL INC. S-14 UPPER SIEVE SIGNAL DEC. S-13 CONCAVE CLEARANCE SIGNAL DEC. S-16

AMP_O--173851--1

X030 RHM J8B

10010917

29 1.

55-39

CONNECTOR X030, RHMJ8B FROM RIGHT CONSOLE (RC) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X031 FRONT FRAME/CAB MAIN CAV

WIRE NUMBER

034 (OR)

CCM-1B FUSE, F-44 (K-24 SWITCHED)

038 (OR)

CCM-2A FUSE, F-36 (K-25 SWITCHED)

3 4 5

027 (RD) 028 (RD) 1501 (YE)

752 (PU)

HEADER MARKER LIGHTS E-40/41 (EU)

580 (OR)

ASP POWER FUSE, F-46 (K-25 SWITCHED)

8 9

714 (WH) 768 (WH)

719 (WH)

763 (WH)

029 (RD)

15 16 17 18 19

024 (RD) -

CIRCUIT REFERENCE

FAN/REVERSER FUSE, F-24 (B+) THROTTLE/BRUSH FUSE, F-23 (B+) DEUTSCH_HDP26--24--19S_PLUG

BRAKE FLUID LEVEL SWITCH S-49

X031 FRONT FRAME

FAN/REVERSER RELAY, K-17 FAN/REVERSER RELAY, K-17 FAN/REVERSER RELAY, K-17 TO FEEDER REVERSER ACTUATOR M-10 (EU) FAN/REVERSER RELAY, K-17 TOP CLEANING FAN ADJUST MOTOR M-05 DEUTSCH_HDP24--24--19P_RECEPTACLE

X017 CCM-2 J3-29/30 FUSE, F-25 (B+)

X031 CAB MAIN

X020 CCM-1 J3-29/30 FUSE, F-22 (B+)

10010899

30 1.

55-40

CONNECTOR X031, FRONT FRAME (FF) HARNESS TO CAB MAIN (CM) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X032 HEADER/FEEDER CAV

WIRE NUMBER

738 (YE)

X281 HHC PIN 15, LEFT STUBBLE HEIGHT R12

739 (YE)

X281 HHC PIN 16, LEFT STUBBLE HEIGHT R13

3 4

848 (PK)

LEFT STUBBLE HEIGHT R12 - 5V REF.

847 (BL)

LEFT STUBBLE HEIGHT R12 - REF. GROUND

737 (YE)

779 (YE)

X017 CCM2 J3-13, REEL RPM B15 REEL HORIZONTAL POSITION R-24 TO X017 CCM-2 J3-25

780 (YE)

REEL VERTICAL POSITION R-25 TO X017 CCM-2 J3-32

10 11

1223 (PK)

750 (BL)

14 15 16 17 18 19

712 (WH)

X017 CCM2 J3-8, REEL SPEED MOTOR M09

776 (BK)

GROUND FOR FLIP-UP HEAD LIGHT KIT

613 (PU)

LH HEADER FLASHING LAMP E01/03/52(EU)

849 (PK)

RIGHT STUBBLE HEIGHT R13 - 5V REF.

752 (PU)

HEADER MARKER LIGHTS E40, E41(EU)

846 (BL)

RIGHT STUBBLE HEIGHT R13 - REF. GROUND

711 (GY)

X017 CCM2 J3-6, REEL SPEED MOTOR M09

1116 (YE)

HEADER TYPE MODULE R-20 TO X017 CCM-2 J3-24

618 (PU)

RH HEADER FLASHING LAMP E02/04/51(EU)

775 (BK)

CIRCUIT REFERENCE

DEUTSCH_HDP24--24--31P_RECEPTACLE

X032 HEADER

+5V TO HEADER TYPE MODULE/ REEL HROIZONTAL/VERTICAL POSITION R-20/24/25 REEL RPM B15, HEADER TYPE MODULE R-20, REEL HORIZONTAL/ VERTICAL POSITION R-25/25 - REF. GROUND

DEUTSCH_HDP26--24--31S_PLUG

X032 FEEDER

1 10020040

31 1.

GROUND, FRONT FRAME 2 FOR HEADER FLASHING LIGHTS E-01/02 AND E-40/41(EU)

55-41

CONNECTOR X032, FEEDER (FE) HARNESS TO HEADER (HH) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X033 CAB MAIN/STEERING COLUMN CAV

WIRE NUMBER

054 (RD)

1209 (PU)

3 4 5 6 7 8 9

043 (PU) 201 (PU) 196 (PU) 197 (PU) 200 (PU)

204 (PU)

11 12 13 14 15 16

219 (BK) 243 (PU) 244 (PU) -

CIRCUIT REFERENCE

HAZARD LIGHTS FUSE, F-56 X015 - CCM-2 J1-15, HAZARD SWITCH S25 HIGH BEAM INDICATOR E-10 RH TURN SIGNAL RH FLASHING LIGHTS LH TURN SIGNAL LH FLASHING LIGHTS X015 - CCM-2 J1-5, ISO/NASO SELECT

AMP_206037--1

X033 CAB MAIN

GROUND LH NASO FLASHING LAMP E07 RH NASO FLASHING LAMP E08

AMP_206036--1

X033 STEERING COLUMN

10010914

32 1.

55-42

CONNECTOR X033, STEERING COLUMN (SC) HARNESS TO CAB MAIN (CM) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X034 EXPANSION/MAIN FRAME A CAV

WIRE NUMBER

1 2 3 4 5 6

030 (RD) 031 (RD) 035 (OR) 036 (OR) 771 (WH) 772 (WH)

CIRCUIT REFERENCE

FUSE F26 (B+) FUSE F27 (B+) FUSE F47 (K-26 SWITCHED) FUSE F47 (K-26 SWITCHED) LH VERTICAL KNIFE RELAY K-43 RH VERTICAL KNIFE RELAY K-42

DEUTSCH_DT06--6S_PLUG

X034 EXPANSION A

DEUTSCH_DT04--6P_RECEPTACLE

X034 MAIN FRAME A

40025228

33 1.

55-43

CONNECTOR X034, MAIN FRAME (MF) HARNESS TO EXPANSION (EX) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X035 GEARBOX VALVE CAV

WIRE NUMBER

1 2

876 (WH) 875 (BL)

572 (WH)

605 (BK)

568 (WH)

PARK BRAKE DISENGAGE GROUND UNLOAD TUBE CLUTCH ACTUATION

6 7 8

601 (BL) 878 (WH) 877 (BL)

UNLOAD TUBE CLUTCH GROUND GEARBOX CLUTCH ACTUATION GEARBOX CLUTCH GROUND

CIRCUIT REFERENCE

FEEDER CLUTCH ACTUATION FEEDER CLUTCH GROUND PARK BRAKE DISENGAGE ACTUATION DEUTSCH_DT06--8S_PLUG

X035 GEARBOX VALVE

10004669

34 1.

55-44

GB W/H, CONNECTOR X035 - GEARBOX VALVE

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X036 CAB ROOF/OUTER ROOF CAV

WIRE NUMBER

058 (PU)

059 (PU)

3 4 5

063 (PU) 072 (PU)

076 (PU)

579 (PU)

245 (BK)

246 (BK)

262 (BK)

HEADER LIGHTS E21, E22 RH SIDE WORK LIGHT E26 LH SIDE WORK LIGHT E25 FROM TIMED SIDEWORK LIGHT RELAY K-34 BEACON LIGHTS E31, E32 LH/RH CAB INNER WORK LIGHT E-17/18 GROUND THROUGH WORK LIGHT SWITCH S43 GROUND, LH/RH HEADER & CENTER WORK LIGHTS E-21/22/38 AND WIPER WASHER MOTOR M-24 GROUND, LH CAB OUTER & MID WORK LIGHTS E-15/19

266 (BK)

GROUND, RH CAB OUTER & MID WORK LIGHTS E-16/20

295 (BK)

GROUND, SIDE LIGHTS & MIRROR HEAT E-25/26 & R-10/11, R-14 (EU)

665 (BK)

GROUND, BEACON LIGHTS E31, E32

14 15 16

280 (BK) 275 (WH) 276 (WH)

277 (WH)

18 19 20 21 22 23 24 25 26 27

931 (OR) 955 (WH) 963 (WH) 962 (WH) 958 (WH) 959 (WH) 964 (WH) 961 (GY) 954 (GY) 978 (PU)

981 (PU)

29 30 31

210 (PU) -

CIRCUIT REFERENCE

LH CAB OUTER & MID WORK LIGHTS E-15/19 FROM F-06 (K-01 SWITCHED) RH CAB OUTER & MID WORK LIGHTS E-16/20 FROM F-07 (K-01 SWITCHED) DEUTSCH_HDP24--24--31P_RECEPTACLE

X036 CAB ROOF

DEUTSCH_HDP26--24--31S_PLUG

X036 OUTER ROOF

GROUND, WIPER MOTOR M25 WIPER MOTOR M25 - PARK WIPER MOTOR M25 - ON WIPER MOTOR M25 INTERMITTENT

MIRROR HEAT SWITCH S19 RH MIRROR M19 - DOWN RH GERMAN MIRROR M30 - DOWN RH MIRROR M20 - IN LH MIRROR M21 - DOWN LH MIRROR M22 - OUT RH GERMAN MIRROR M31 - IN LH MIRROR ADJUST RH MIRROR ADJUST (EU) NOT USED LH/RH CAB INNER WORK LIGHT E-17/18

10010916

35 1.

CENTER WORK LIGHT E38

55-45

CONNECTOR X036, CAB ROOF (CR) HARNESS TO OUTER ROOF (OR) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X037 SPREADER PLATE S23 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

325 (YE) 357 (OR) 324 (YE) 398 (PU) 386 (BK) -

CIRCUIT REFERENCE

SPREADER PLATE SIGNAL SPREADER PLATE IGNITION B+ SPREADER PLATE SIGNAL EATON_25--13936

X037 SPREADER PLATE

BACKLIGHTING SPREADER PLATE GROUND

CONNECTOR X038 ALTERNATE SETTINGS S21 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

359 (OR) 328 (YE) 249 (PU) 377 (BK) -

CIRCUIT REFERENCE

ALTERNATE SETTING IGNITION B+ ALTERNATE SETTING SIGNAL EATON_25--13936

X038 ALTERNATE SETTINGS

BACKLIGHTING ALTERNATE SETTING GROUND

CONNECTOR X039 FEEDER REVERSER S07 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8

358 (OR) 326 (YE) 293 (PU) -

387 (BK)

CIRCUIT REFERENCE

FEEDER REVERSER B+ FEEDER REVERSER SIGNAL EATON_25--13936

X039 FEEDER REVERSER

BACKLIGHTING FEEDER REVERSER CHASSIS GROUND

55-46

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X040 REEL SPEED MODE S08 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

333 (YE) 362 (OR) 332 (YE) 396 (PU) 380 (BK) 354 (PU)

CIRCUIT REFERENCE

REEL SPEED MODE SIGNAL REEL SPEED MODE IGNITION B+ REEL SPEED MODE SIGNAL EATON_25--13936

X040 REED SPEED MODE

BACKLIGHTING REEL SPEED MODE GROUND REEL SPEED MODE “ON” LIGHT

CONNECTOR X041 NEUTRAL LOCK S22 CAV

WIRE NUMBER

301, 305 (WH)

NEUTRAL LOCK SOLENOID FEED

317 (BK)

NEUTRAL LOCK SOLENOID GROUND

CIRCUIT REFERENCE

AMP_926474--1

X041 NEUTRAL LOCK

CONNECTOR X042 LOWER SIEVES S14 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

342 (YE) 371 (OR) 343 (YE) -

CIRCUIT REFERENCE

LOWER SIEVES SIGNAL LOWER SIEVES IGNITION B+ LOWER SIEVES SIGNAL EATON_25--13936

X042 LOWER SIEVES

55-47

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X043 UPPER SIEVES S13 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

340 (YE) 370 (OR) 341 (YE) -

CIRCUIT REFERENCE

UPPER SIEVES SIGNAL UPPER SIEVES IGNITION B+ UPPER SIEVES SIGNAL EATON_25--13936

X043 UPPER SIEVES

CONNECTOR X044 CONCAVE CLEARANCE S16 CAV

WIRE NUMBER

346 (YE)

373 (OR)

3 4 5 6 7 8 9 10

347 (YE) -

CIRCUIT REFERENCE

CONCAVE CLEARANCE SIGNAL CONCAVE CLEARANCE IGNITION B+ CONCAVE CLEARANCE SIGNAL

EATON_25--13936

X044 CONCAVE CLEARANCE

CONNECTOR X045 FAN SPEED S15 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

344 (YE) 372 (OR) 345 (YE) -

CIRCUIT REFERENCE

FAN SPEED SIGNAL FAN SPEED IGNITION B+ FAN SPEED SIGNAL EATON_25--13936

X045 FAN SPEED

55-48

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X046 ROTOR SPEED S17 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

348 (YE) 374 (OR) 349 (YE) -

CIRCUIT REFERENCE

ROTOR/DRUM SPEED SIGNAL ROTOR/DRUM SPEED IGNITION B+ ROTOR/DRUM SPEED SIGNAL EATON_25--13936

X046 ROTOR/DRUM SPEED

CONNECTOR X047 FEEDER SPEED S18 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

350 (YE) 375 (OR) 351 (YE) -

CIRCUIT REFERENCE

FEEDER SPEED SIGNAL FEEDER SPEED IGNITION B+ FEED SPEED SIGNAL EATON_25--13936

X047 FEEDER SPEED

CONNECTOR X048 GEAR SELECT S24 CAV

WIRE NUMBER

319 (PK)

GEAR SELECT REFERENCE VOLTAGE

323 (BL)

GEAR SELECT GROUND

391 (YE)

GEAR SELECT SIGNAL

CIRCUIT REFERENCE

PAC_12064758

X048 GEAR SELECT

55-49

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X049 ON THE ROAD S12 CAV

WIRE NUMBER

368 (OR)

ON THE ROAD SWITCH B+ IGNITION

339 (YE)

ON THE ROAD SWITCH SIGNAL

291 (PU)

392 (BK)

CIRCUIT REFERENCE

EATON_25--13936

X049 ON THE ROAD BACKLIGHTING ON THE ROAD SWITCH GROUND

CONNECTOR X050 DUAL RANGE S11 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

367 (OR) 337 (YE) 290 (PU) 385 (BK) -

CIRCUIT REFERENCE

DUAL RANGE B+ IGNITION DUAL RANGE SIGNAL EATON_25--13936

X050 DUAL RANGE

BACKLIGHTING DUAL RANGE GROUND

CONNECTOR X051 REAR WHEEL ASSIST S10 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

366 (OR) 336 (YE) 289 (PU) 384 (BK) -

CIRCUIT REFERENCE

REAR WHEEL ASSIST B+ IGNITION REAR WHEEL ASSIST SIGNAL EATON_25--13936

X051 REAR WHEEL ASSIST

BACKLIGHTING REAR WHEEL ASSIST GROUND

55-50

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X052 PARK BRAKE S09 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

335 (YE) 365 (OR) 334 (YE) 397 (PU) 393 (BK) 355 (PU)

CIRCUIT REFERENCE

PARK BRAKE SIGNAL PARK BRAKE B+ IGNITION PARK BRAKE SIGNAL EATON_25--13936

X052 PARK BRAKE

BACKLIGHTING PARK BRAKE GROUND PARK BRAKE “ON” LIGHT

CONNECTOR X053 SPLICE BLOCK A CAV

WIRE NUMBER

122 (BK)

1277 (BK)

C D E F

352 (BK) 356 (BK) 364 (BK) 389 (BK)

378 (BK)

CHASSIS GROUND GROUND FOR DISPLAY MODULE A-02, DGPS MODULE A-11, NAVIGATION MODULE A-24, ROTARY ENCODER SWITCH S-79, DISPLAY HOME SWITCH S-80 & DISPLAY ESCAPE SWITCH S-81 GROUND FOR RPM GROUND FOR RHM GROUND FOR RHM GROUND FOR RHM GROUND FOR HHC FINE ADJUST S-06

379 (BK)

GROUND FOR HEADER HEIGHT MODE S-04

390 (BK)

GROUND FOR ENGINE THROTTLE S-36

K L

399 (BK)

CIRCUIT REFERENCE

PAC_15305291

X053 SPLICE BLOCK A

GROUND FOR X180 SPLICE BLOCK W-05

55-51

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X054 SPLICE BLOCK B CAV

WIRE NUMBER

321 (OR)

327 (OR)

C D E F G H J K L M

365 (OR) 366 (OR) 367 (OR) 368 (OR) 360 (OR) 361 (OR) 098 (OR) 369 (OR) 089 (OR) 287 (OR)

CIRCUIT REFERENCE

B+ FOR LOWER SIEVE, UPPER SERVE, CONCAVE CLEARANCE FAN SPEED, ROTOR DRUM SPEED, AND FEEDER REVERSER, REEL SPEED MODE B+ FOR FEEDER REVERSER, REEL SPEED MODE, VERTICAL KNIVES, ALTERNATE SETTING AND SPREADER PLATE B+ FOR PARK BRAKE B+ FOR REAR WHEEL ASSIST B+ FOR DUAL RANGE B+ FOR ON THE ROAD SWITCH B+ FOR HHC FINE ADJUST B+ FOR HEADER HEIGHT MODE B+ FOR RHM B+ FOR ENGINE THROTTLE B+ FOR RHM B+ FOR THRESHER ENGAGE

PAC_15305291

X054 SPLICE BLOCK B

CONNECTOR X055 THRESHER ENGAGE S30 CAV

WIRE NUMBER

1 2 3 4 5 6

858 (YE) 110 (OR) 302 (YE) 857 (YE)

CIRCUIT REFERENCE

THRESHER ENGAGE SIGNAL THRESHER ENGAGE B+ IGNITION

AMP_344266--1

X055 THRESHER ENGAGE

THRESHER ENGAGE SIGNAL THRESHER ENGAGE SIGNAL

CONNECTOR X056 FEEDER ENGAGE S31 CAV

WIRE NUMBER

1 2 3 4 5 6

860 (YE) 861 (YE) 112 (YE) 859 (YE)

CIRCUIT REFERENCE

FEEDER ENGAGE SIGNAL FEEDER ENGAGE SIGNAL

AMP_344266--1

X056 FEEDER ENGAGE

FEEDER ENGAGE SIGNAL FEEDER ENGAGE SIGNAL

55-52

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X057 GROUND SPEED R04 CAV

WIRE NUMBER

316 (PK)

5V REF. VOLTAGE, X026 PIN 16, RHM

B C

320 (BL) 381 (YE)

GROUND, X026 PIN 6, RHM X027 PIN 1, RHM

CIRCUIT REFERENCE

DEUTSCH_DT06--3S_PLUG

X057 GROUND SPEED

CONNECTOR X058 AUDIO ALARM H01 CAV

WIRE NUMBER

1 2

376 (WH) 388 (BK)

CIRCUIT REFERENCE

X026 PIN 19, RHM X026 PIN 18, RHM

AMP_280543--0

X058 AUDIO ALARM

CONNECTOR X059 NEUTRAL SWITCH S22 CAV

WIRE NUMBER

300

CIRCUIT REFERENCE

+12V FROM F-48 (K-26 SWITCHED) AMP_154719

X059 NEUTRAL SWITCH

CONNECTOR X059 NEUTRAL SWITCH S22 CAV

WIRE NUMBER

093

CIRCUIT REFERENCE

NEUTRAL START RELAY K-23 AMP_154719

X059 NEUTRAL SWITCH

55-53

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X059 NEUTRAL SWITCH S22 CAV

WIRE NUMBER

113

CIRCUIT REFERENCE

X015 CCM-2 J1-17 SIGNAL AMP_154719

X059 NEUTRAL SWITCH

CONNECTOR X060 THROTTLE S36 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

322 (YE) 369 (OR) 318 (YE) 394 (PU) 390 (BK) 338 (PU)

CIRCUIT REFERENCE

THROTTLE SIGNAL THROTTLE B+ IGNITION THROTTLE SIGNAL EATON_25--13936

X060 THROTTLE

BACKLIGHTING THROTTLE GROUND THROTTLE LIGHTING

55-54

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X061 HEADER HEIGHT S04 CAV

WIRE NUMBER

331 (YE)

361 (OR)

3 4 5 6 7 8 9 10

330 (YE) 395 (PU) 379 (BK) 353 (PU)

CIRCUIT REFERENCE

HEADER HEIGHT MODE SIGNAL HEADER HEIGHT MODE B+ IGNITION HEADER HEIGHT MODE SIGNAL

EATON_25--13936

X061 HEADER HEIGHT

BACKLIGHTING HEADER HEIGHT MODE GROUND HEADER HEIGHT MODE LIGHTING

CONNECTOR X062 HEADER WIDTH ADJUST S06 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

303 (YE) 360 (OR) 304 (YE) 382 (PU) 378 (BK) -

CIRCUIT REFERENCE

HDR WIDTH ADJUST SIGNAL HDR WIDTH ADJUST B+ IGNITION HDR WIDTH ADJUST SIGNAL EATON_25--13936

X062 HEADER WIDTH ADJUST

BACKLIGHTING GROUND

CONNECTOR X063 VERTICAL KNIVES S51 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9

230 (YE) 248 (OR) 229 (YE) 292 (PU) 226 (BK)

228 (PU)

CIRCUIT REFERENCE

VERTICAL KNIVES SWITCH SIGNAL SWITCHED B+ VERTICAL KNIVES SWITCH SIGNAL EATON_25--13936

X063 VERTICAL KNIVES

CCM ILLUMINATION CONTEST GROUND VERTICAL KNIVES SWITCH INDICATOR CONTROL

55-55

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X065 DIAGNOSTICS AND MAINTENANCE CAV

WIRE NUMBER

A B C D

146 (BK) 142 (RD) 271 (YE) 270 (GN)

827 (YE)

F G H

135 (RD) 136 (BK) 1221 (YE) 1222 (GN)

CIRCUIT REFERENCE

GROUND FUSE F39, KEEP ALIVE POWER (B+) CAN HI CAN LO ISO-K, ECU CONNECTOR X193 PIN 89

DEUTSCH_HD10--9--1939PE

RS-232 RX RS-232 TX CAN 2 HI

X065 DIAGNOSTICS AND MAINTENANCE

CAN 2 LO

55-56

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X067 ACC. SOCKET J06 CAV

WIRE NUMBER

1 2

151 (BK) 084 (OR)

CIRCUIT REFERENCE

GROUND ACCESSORY OUTLET FUSE, F-8

AMP_926522

X067 ACC. SOCKET

CONNECTOR X068 KEY SWITCH S02 CAV

WIRE NUMBER

1 2 3 4 5 6

053 (RD) 091 (OR) 123 (OR) 859 (OR) 096 (OR)

CIRCUIT REFERENCE

KEY SWITCH FUSE, F-38 NEUTRAL START RELAY, K-23 ACCESSORY POWER POWER TO ECU POWER, IGNITION

PAC_02984017

X068 KEY SW

CONNECTOR X069 LIGHTER R08 CAV

WIRE NUMBER

1 2

152 (BK) 085 (OR)

CIRCUIT REFERENCE

GROUND CIGAR LIGHTER FUSE, F-5

AMP_926522

X069 LIGHTER

CONNECTOR X070 LIGHTER BACKLIGHT CAV

WIRE NUMBER

206 (PU)

CIRCUIT REFERENCE

BACKLIGHTING AMP_154719

X070 LIGHTER BACKLIGHT

55-57

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X071 STRAW HOOD/STRAW HOOD FRONT CAV

WIRE NUMBER

473 (PK)

5V REF. VOLTAGE FOR M-11 SPREADER PLATE MOTOR

471 (BL)

REF. GROUND FOR M-11 SPREADER PLATE MOTOR

481 (BL)

REF. GROUND FOR SENSOR B-22 REAR LADDER

4 5 6 7 8 9

477 (YE)

X013 CCM3 J2-33, SPREADER PLATE MOTOR M11

570 (YE)

X019 CCM1 J2-17, REAR LADDER SENSOR B22

1576 (BK)

678 (RD)

452 (WH)

RH SERVICE SOCKET J03 X019 CCM1 J2-6, BACKUP ALARM H08

510 (WH)

X014 CCM3 J3-8, SPREADER PLATE MOTOR M11

509 (GY)

X014 CCM3 J3-6, SPREADER PLATE MOTOR M11

17 18 19 20 21 22 23 24 25 26 27 28 29 30

243 (PU) 412 (PU) 619 (PU) 629 (PU) 421 (PU) 578 (PU) 244 (PU) 622 (PU) 630 (PU) 478 (BK) 628 (BK) 067 (PU) 672 (BK) 444 (BL)

485 (YE)

CIRCUIT REFERENCE

DEUTSCH_HDP24--24--31P_RECEPTACLE

X071 STRAW HOOD FRONT

RH/LH AUSTRIA MARKER LT E-55/56

DEUTSCH_HDP26--24--31S_PLUG

X071 STRAW HOOD

LEFT FLASHING LAMP E07 LH TAIL LIGHT E11 LH REAR FLASHING LAMP E05 LH BRAKE LIGHT E11 RH TAIL LIGHT E12 REAR BEACON LIGHT E33 RIGHT FLASHING LAMP E08 RH REAR FLASHING LAMP E06 RH BRAKE LIGHT E12 GROUND GROUND REAR WORK LIGHTS E27, E28 GROUND REF. GROUND FOR SENSOR B38 X020 CCM1 J3-36, UNLOAD CRADLE B38

50026220

36 1.

55-58

CONNECTOR X071, STRAW WALKER (SW) HARNESS TO STRAW HOOD (SH) HARNESS

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X072 LOWER FRAME REAR/STRAW HOOD FRONT CAV

WIRE NUMBER

569 (WH)

B C D

602 (BK) 494 (BL) 431 (YE)

793 (PK)

GROUND REF. GROUND FOR SENSORS X019 CCM1 J2-25, SIEVE LOSS B21 5V REF. VOLTAGE, UPPER SIEVE MOTOR

795 (BL)

REF. GROUND FOR UPPER SIEVE MOTOR M06

475 (YE)

X013 CCM3 J2-22, UPPER SIEVE MOTOR M06

H J

792 (WH) 791 (GY)

794 (PK)

UPPER SIEVE MOTOR M06 UPPER SIEVE MOTOR M06 5V REF. VOLTAGE LOWER SIEVE MOTOR

796 (BL)

REF. GROUND FOR LOWER SIEVE MOTOR M07

476 (YE)

X013 CCM3 J2-19, LOWER SIEVE MOTOR M07

N P

790 (WH) 789 (GY)

LOWER SIEVE MOTOR M07 LOWER SIEVE MOTOR M07

CIRCUIT REFERENCE

X019 CCM1 J2-16, REAR WHEEL ASSIST L26

DEUTSCH_HDP26--18--14S_PLUG

X072 LOWER FRAME REAR

DEUTSCH_HDP24--18--14P_RECEPTACLE

X072 STRAW HOOD FRONT

40020080

37 1.

CONNECTOR X072, STRAW WALKER (SW) HARNESS TO LOWER FRAME REAR (LR) HARNESS

CONNECTOR X073 SEAT SWITCH S05 CAV

WIRE NUMBER

A B

046 (OR) 168 (YE)

CIRCUIT REFERENCE

CAB FUSE, F-49 X015-CCM-2 J1-9 PAC_12052641

X073 SEAT SWITCH

55-59

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X074 SEAT PUMP M26 CAV

WIRE NUMBER

A B

080 (OR) 164 (BK)

CIRCUIT REFERENCE

MAIN BLOWER FUSE, F-18 GROUND PAC_12015792

X074 SEAT PUMP

CONNECTOR X075 ACCESSORY BACKLIGHT CAV

WIRE NUMBER

247 (PU)

CIRCUIT REFERENCE

ACCESSORY LIGHTING AMP_154719

X075 ACCESSORY BACKLIGHT

CONNECTOR X076 ACCESSORY OUTLET J08 CAV

WIRE NUMBER

1 2

153 (BK) 086 (OR)

CIRCUIT REFERENCE

GROUND ACCESSORY OUTLET FUSE, F-8

AMP_926522

X076 ACCESSORY OUTLET

CONNECTOR X077 GROUND, 3, CM CAV

WIRE NUMBER

116 (BK) 156 (BK) 160 (BK) 161 (BK) 945 (BK) 152 (BK) 151 (BK) 153 (BK) 164 (BK) 788 (BK)

CIRCUIT REFERENCE

CCM-1, 2, AND 3 LOW BEAM RELAY, K-5 BEACON LIGHTS RELAY, K-29 SIDE WORK LIGHT RELAY, K-35 A/C CLUTCH RELAY, K-10 CIGAR LIGHTER, R-08 ACCESSORY SOCKET, J-06 ACCESSORY OUTLET, J-08 SEAT PUMP MOTOR, M-26

X077 GROUND

UPPER/LOWER SIEVE RELAY, K-18

55-60

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X079 REVERSER DISENGAGE B09 CAV

WIRE NUMBER

777 (BL)

REF. GROUND FOR REVERSER DISENGAGE B09

733 (YE)

X020 CCM1 J3-27, REVERSER DISENGAGE B09

CIRCUIT REFERENCE

DEUTSCH_DT06--2S_PLUG

X079 REVERSER DISENGAGE

CONNECTOR X080 FEEDER REVERSER M10 CAV

WIRE NUMBER

A B

719 (WH) 770 (GY)

CIRCUIT REFERENCE

FEEDER REVERSER M10 FEEDER REVERSER M10

PAC_15300027

X080 FEEDER REVERSER

CONNECTOR X081 LAT FLOAT POT R02 CAV

WIRE NUMBER

CIRCUIT REFERENCE

757 (PK)

5V REF. VOLTAGE, LATERAL FLOAT POT R02

745 (BL)

REF. GROUND, LATERAL FLOAT POT R02

741 (YE)

X020 CCM1 J3-17, LATERAL FLOAT POT R02

PAC_12065287

X081 LAT FLOAT POT

55-61

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X082 ASP AMPLIFIER KN2 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8

720 (BK) 731 (WH) 580 (WH) 729 (YE) 730 (GN) 732 (BK)

CIRCUIT REFERENCE

GROUND STONE DOOR OPEN L31 FUSE F46 DEUTSCH_DT06--8S_PLUG

CAN HI CAN LO STONE DOOR OPEN L31

X082 ASP AMPLIFIER KN2

1 10020074

38 1.

CONNECTOR X082 -ASP AMPLIFIER KN2

CONNECTOR X083 ASP DOOR POSITION B-24 CAV

WIRE NUMBER

754 (BL)

REFERENCE GROUND B TO CCM1 J3-18

743 (YE)

SIGNAL TO CCM1 J3-28

CIRCUIT REFERENCE

DEUTSCH_DT06--2S_PLUG

X083 ASP DOOR POSITION B-24

CONNECTOR X084 LH BRAKE PADS CAV

WIRE NUMBER

1 2 3

607 (YE) 843 (YE)

CIRCUIT REFERENCE

X019-CCM-1 J2-26 X019-CCM-1 J2-26 AMP_794412--1

X084 LH BRAKE PADS

55-62

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X085 RH BRAKE PADS CAV

WIRE NUMBER

1 2 3

835 (YE) 844 (YE)

CIRCUIT REFERENCE

X019-CCM-1 J2-26 X019-CCM-1 J2-26 AMP_794412--1

X085 RH BRAKE PADS

CONNECTOR X086 ASP AMPLIFIER KN2 CAV

WIRE NUMBER

1 2 3 4

990 (YE) 988 (YE) 986 (YE) 984 (YE)

985 (BL)

LH ASP TOP SENSOR B51 RH ASP TOP SENSOR B50 LH ASP BOTTOM SENSOR B49 RH ASP BOTTOM SENSOR B48 REF. GROUND, RH ASP BOTTOM SENSOR B48

987 (BL)

REF. GROUND, LH ASP BOTTOM SENSOR B49

989 (BL)

REF. GROUND, RH ASP TOP SENSOR B50

991 (BL)

REF. GROUND, LH ASP TOP SENSOR B51

CIRCUIT REFERENCE

DEUTSCH_DT06--8S_PLUG

X086 ASP AMPLIFIER KN2

10020074

39 1.

55-63

CONNECTOR X086 -ASP AMPLIFIER KN1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X087 GROUND SPEED RPM B17 CAV

WIRE NUMBER

717 (BL)

REF. GROUND, GROUND SPEED RPM B17

403 (YE)

X017 CCM2 J3-14, GROUND SPEED RPM B17

CIRCUIT REFERENCE

DEUTSCH_DT06--2S_PLUG

X087 GROUND RPM

CONNECTOR X088 SHOE MOTOR M03 CAV

WIRE NUMBER

CIRCUIT REFERENCE

727 (PK)

5V REF. VOLTAGE, SHOE LEVELING ACTUATOR M03

724 (BL)

REF. GROUND, SHOE LEVELING ACTUATOR M03

721 (YE)

X020 CCM1 J3-32, SHOE LEVELING ACTUATOR M03

D E

710 (WH) 707 (GY)

SHOE LEVELING ACTUATOR M03 SHOE LEVELING ACTUATOR M03 PAC_12084891

X088 SHOE MOTOR

CONNECTOR X089 CLEANING FAN RPM B16 CAV

WIRE NUMBER

CIRCUIT REFERENCE

718 (BL)

REF. GROUND, CLEANING FAN RPM B16

404 (YE)

X020 CCM1 J3-13, CLEANING FAN RPM B16

DEUTSCH_DT06--2S_PLUG

X089 CLEANING FAN RPM

CONNECTOR X090 CLEANING FAN MOTOR M05 (EU) CAV

WIRE NUMBER

763 (WH)

CLEANING FAN ADJUST MOTOR M05

761 (GY)

CLEANING FAN ADJUST MOTOR M05

CIRCUIT REFERENCE

PAC_15300027

X090 CLEANING FAN MOTOR

55-64

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X091 HYDROSTAT MOTOR TEMP B46 CAV

WIRE NUMBER

774 (BL)

REF. GROUND, HYDROSTAT MOTOR TEMP B46

773 (YE)

X020 CCM1 J3-33, HYDROSTAT MOTOR TEMP B46

CIRCUIT REFERENCE

PAC_12162193

X091 HYDROSTAT TEMP

CONNECTOR X092 FOOT AND INCH L05 CAV

WIRE NUMBER

575 (WH)

X017 CCM2 J3-15, FOOT AND INCH VALVE L05

606 (BK)

GROUND

CIRCUIT REFERENCE

PAC_12015792

X092 FOOT AND INCH

CONNECTOR X093 TRANS SHIFT POSITION B37 CAV

WIRE NUMBER

407 (YE)

X017 CCM2 J3-28, TRANS SHIFT POSITION B37 - NEUTRAL

405 (YE)

X017 CCM2 J3-36, TRANS SHIFT POSITION B37 - 1ST GEAR

406 (YE)

X017 CCM2 J3-37, TRANS SHIFT POSITION B37 - 2ND GEAR

408 (YE)

X017 CCM2 J3-38, TRANS SHIFT POSITION B37 - 3RD GEAR

409 (YE)

X017 CCM2 J3-27, TRANS SHIFT POSITION B37 - 4TH GEAR

426 (BL)

REF. GROUND, TRANS SHIFT POSITION B37

CIRCUIT REFERENCE

DEUTSCH_DT06--6S_PLUG

X093 TRANS SHIFT POSITION

CONNECTOR X094 TRANSMISSION SHIFT MOTOR M02 CAV

WIRE NUMBER

CIRCUIT REFERENCE

A B

716 (WH) 715 (GY)

TRANSMISSION SHIFT MOTOR M02 TRANSMISSION SHIFT MOTOR M02

PAC_15300027

X094 TRANSMISSION SHIFT MOTOR

55-65

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X095 GROUND, 2, FF CAV

WIRE NUMBER

585 (BK) 767 (BK)

CIRCUIT REFERENCE

765 (BK)

REEL DRIVE SOLENOID L17 HEADER LIGHTING, ASP MODULE X020 CCM1 J3-9, 10 -SHOE LEVELING MOTOR M03, X020 CCM1 J3-16 -CLEANING FAN MOTOR M05, FEEDER REVERSER MOTOR M10 X017 CCM2 J3-9, 10 -TRANS SHIFT MOTOR M02, X017 CCM2 J3-16 -REEL SPEED MOTOR M09 REEL UP/DOWN, FORE/AFT L13-16 FOOT AND INCH L05, DUAL RANGE L27

836 (BK)

BRAKE PAD WEAR SENSORS

778 (BK)

538 (BK) 592 (BK)

X095 GROUND

CONNECTOR X097 GEARBOX TEMPERATURE B32 CAV

WIRE NUMBER

466 (BL)

REF. GROUND, GEARBOX TEMPERATURE B32

422 (YE)

X019 CCM1 J2-27, GEARBOX TEMPERATURE B32

CIRCUIT REFERENCE

PAC_12162193

X097 GEARBOX TEMPERATURE

CONNECTOR X098 CONTROL PRESSURE B35 CAV

WIRE NUMBER

434 (BL)

REF. GROUND, LOW CONTROL PRESSURE B35

486 (PK)

5V REF. VOLTAGE, LOW CONTROL PRESSURE B35

423 (YE)

X016 CCM2 J2-19, LOW CONTROL PRESSURE B35

CIRCUIT REFERENCE

PAC_12065287

X098 CONTROL PRESSURE

CONNECTOR X099 CLUTCH TEMPERATURE B45 CAV

WIRE NUMBER

685 (BL)

REF. GROUND, GEARBOX CLUTCH TEMP B45

682 (YE)

X017 CCM2 J3-33, GEARBOX CLUTCH TEMP B45

CIRCUIT REFERENCE

PAC_12052641

X099 CLUTCH TEMPERATURE

55-66

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X100 GROUND SPEED HYDROSTAT L23 CAV

WIRE NUMBER

A B C D

879 (GY) 886 (BL) 887 (BL) 880 (WH)

CIRCUIT REFERENCE

GROUND SPEED HYDROSTAT L23 GROUND SPEED HYDROSTAT L23 GROUND SPEED HYDROSTAT L23 GROUND SPEED HYDROSTAT L23 PAC_12015797

X100 GROUND SPEED HYDROSTAT

CONNECTOR X101 CHARGE PRESSURE S37 CAV

WIRE NUMBER

CIRCUIT REFERENCE

684 (YE)

X016 CCM2 J2-35, CHARGE PRESSURE

X101 CHARGE PRESSURE

CONNECTOR X102 GROUND, 1, GB CAV

WIRE NUMBER

487 (BK) 605 (BK)

CIRCUIT REFERENCE

HYD. RESERVOIR LEVEL S33 PARK BRAKE DISENGAGE L10

X102 GROUND

CONNECTOR X103 RESERVOIR TEMPERATURE B18 CAV

WIRE NUMBER

480 (BL)

REF. GROUND, HYD OIL RESERVOIR TEMP B18

446 (YE)

X019 CCM1 J2-24, HYD OIL RESERVOIR TEMP B18

CIRCUIT REFERENCE

PAC_12162193

X103 RESERVOIR TEMPERATURE

55-67

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X104 RESERVOIR LEVEL S33 CAV

WIRE NUMBER

487 (BK)

424 (YE)

CIRCUIT REFERENCE

GROUND X016 CCM2 J2-39, RESERVOIR LEVEL S33 PAC_12015792

X104 RESERVOIR LEVEL

CONNECTOR X105 UNLOAD TUBE LIGHT CAV

WIRE NUMBER

1 2 3 4

077 (PU) 669 (BK) 530 (PU) 531 (BK)

CIRCUIT REFERENCE

WORK LIGHT POWER WORK LIGHT GROUND MARKER LIGHT POWER MARKER LIGHT GROUND

DEUTSCH_DT06--4S_PLUG

DEUTSCH_DT04--4P_RECEPTACLE

X105 UNLOAD TUBE LIGHT

CONNECTOR X106 LEFT REAR WORK LIGHT E27 CAV

WIRE NUMBER

A B

652 (PU) 661 (BK)

CIRCUIT REFERENCE

LEFT REAR WORK LIGHT POWER GROUND

PAC_12124819

X106 LEFT REAR WORK LIGHT

CONNECTOR X107 3/4 FULL BIN SENSOR S28 CAV

WIRE NUMBER

CIRCUIT REFERENCE

440 (PK)

5V REF. VOLTAGE, 3/4 FULL SENSOR S28

445 (YE)

400 (YE)

FULL BIN SENSOR S29 X016 CCM2 J2-22, BIN SENSOR SIGNAL

PAC_12015793

X107 3/4 FULL BIN SENSOR

55-68

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X108 GRAIN TANK LIGHT E30 CAV

WIRE NUMBER

1 2

646 (PU) 681 (BK)

CIRCUIT REFERENCE

GRAIN TANK LIGHT POWER GROUND DEUTSCH_DT06--2S_PLUG

X108 GRAIN TANK LIGHT

CONNECTOR X109 FULL BIN SENSOR S29 CAV

WIRE NUMBER

A B C

443 (BL) 445 (YE) -

CIRCUIT REFERENCE

REF. GROUND, FULL BIN SENSOR 3/4 FULL BIN SENSOR S28 PAC_12015793

X109 FULL BIN SENSOR

CONNECTOR X110 RIGHT REAR WORK LIGHT E28 CAV

WIRE NUMBER

CIRCUIT REFERENCE

A B

653 (PU) 662 (BK)

RIGHT REAR WORK LIGHT POWER GROUND

PAC_12124819

X110 RIGHT REAR WORK LIGHT

CONNECTOR X111 LEFT MIRROR CAV

WIRE NUMBER

959 (WH)

961 (GY)

935 (OR)

958 (WH)

HEATED MIRROR SWITCH OUTPUT LEFT MIRROR UP/DOWN ACTUATION

5 6

076 (PU) 671 (BK)

RELAY K-34 GROUND

CIRCUIT REFERENCE

LEFT MIRROR IN/OUT ACTUATION LEFT MIRROR DECREASING ACTUATION DEUTSCH_DT06--6S_PLUG

X111 LEFT MIRROR

55-69

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X112 LEFT OUTER WORK LIGHT E15 CAV

WIRE NUMBER

CIRCUIT REFERENCE

A B

251 (PU) 259 (BK)

LEFT OUTER WORK LIGHT POWER GROUND PAC_12059183

X112 LEFT OUTER WORK LIGHT

CONNECTOR X113 LEFT BEACON LIGHT E31 CAV

WIRE NUMBER

1 2

663 (PU) 666 (BK)

CIRCUIT REFERENCE

LEFT BEACON LIGHT POWER GROUND DEUTSCH_DT06--2S_PLUG

X113 LEFT BEACON LIGHT

CONNECTOR X114 LEFT MIDDLE WORK LIGHT E19 CAV

WIRE NUMBER

CIRCUIT REFERENCE

A B

252 (PU) 260 (BK)

LEFT MIDDLE WORK LIGHT POWER GROUND PAC_12059183

X114 LEFT MIDDLE WORK LIGHT

CONNECTOR X115 LEFT INNER WORK LIGHT E17 CAV

WIRE NUMBER

A B

255 (PU) 261 (BK)

CIRCUIT REFERENCE

LEFT INNER WORK LIGHT POWER GROUND PAC_12059183

X115 LEFT INNER WORK LIGHT

55-70

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X116 WIPER MOTOR M25 CAV

WIRE NUMBER

1 2 3 4 5

280 (BK) 275 (WH) 277 (WH) 276 (WH)

CIRCUIT REFERENCE

GROUND WIPER LOW SPEED WIPER HIGH SPEED WIPER PARK POSITION

FRAM_FFH05102BKT

X116 WIPER MOTOR

CONNECTOR X117 RIGHT INNER WORK LIGHT E18 CAV

WIRE NUMBER

CIRCUIT REFERENCE

A B

256 (PU) 265 (BK)

RIGHT INNER WORK LIGHT POWER GROUND PAC_12059183

X117 RIGHT INNER WORK LIGHT

CONNECTOR X118 RIGHT MIDDLE WORK LIGHT E20 CAV

WIRE NUMBER

253 (PU)

RIGHT MIDDLE WORK LIGHT POWER

263 (BK)

GROUND

CIRCUIT REFERENCE

PAC_12059183

X118 RIGHT MIDDLE WORK LIGHT

CONNECTOR X119 RIGHT BEACON LIGHT E32 CAV

WIRE NUMBER

664 (PU)

RIGHT BEACON LIGHT POWER

667 (BK)

GROUND

CIRCUIT REFERENCE

DEUTSCH_DT06--2S_PLUG

X119 RIGHT BEACON LIGHT

55-71

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X120 RIGHT OUTER WORK LIGHT E16 CAV

WIRE NUMBER

254 (PU)

RIGHT OUTER WORK LIGHT POWER

264 (BK)

GROUND

CIRCUIT REFERENCE

PAC_12059183

X120 RIGHT OUTER WORK LIGHT

CONNECTOR X121 RIGHT MIRROR CAV

WIRE NUMBER

962 (WH)

956 (GY)

932 (OR)

955 (WH)

HEATED MIRROR SWITCH OUTPUT RIGHT MIRROR UP/DOWN ACTUATION

5 6

072 (PU) 670 (BK)

RELAY K-35 GROUND

CIRCUIT REFERENCE

RIGHT MIRROR IN/OUT ACTUATION RIGHT MIRROR DECREASING ACTUATION DEUTSCH_DT06--6S_PLUG

X121 RIGHT MIRROR

CONNECTOR X122 RIGHT REAR SPEAKER H-06 CAV

WIRE NUMBER

A B

979 (BL) 974 (WH)

CIRCUIT REFERENCE

RIGHT REAR SPEAKER (-) RIGHT REAR SPEAKER (+) PAC_12052832

X122 RIGHT REAR SPEAKER

CONNECTOR X123 LEFT REAR SPEAKER H-04 CAV

WIRE NUMBER

A B

982 (BL) 975 (WH)

CIRCUIT REFERENCE

LEFT REAR SPEAKER (-) LEFT REAR SPEAKER (+) PAC_12052832

X123 LEFT REAR SPEAKER

55-72

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X125 GRAIN TANK EXTENSIONS SWITCH S42 CAV

WIRE NUMBER

1 2

124 (OR)

167 (YE)

4 5 6 7 8 9 10

284 (PU) 298 (BK) -

CIRCUIT REFERENCE

SWITCHED B+ TANK EXTENSIONS SWITCH SIGNAL

EATON_25--13936

X125 GRAIN TANK EXTENSIONS SWITCH

BACKLIGHTING GROUND

CONNECTOR X126 MIRROR ADJUST SWITCH S27 CAV

WIRE NUMBER

A B

949 (BK) 959 (WH)

961 (GY)

GROUND LEFT MIRROR IN/OUT ACTUATION LEFT MIRROR DECREASING ACTUATION

958 (WH)

LEFT MIRROR UP/DOWN ACTUATION

957 (WH)

RIGHT MIRROR UP/DOWN ACTUATION

954 (GY)

RIGHT MIRROR DECREASING ACTUATION

G H

960 (WH) 274 (OR)

RIGHT MIRROR IN/OUT ACTUATION SWITCHED B+

CIRCUIT REFERENCE

PAC_12046688

X126 MIRROR ADJUST SWITCH

CONNECTOR X127 MIRROR HEAT SWITCH S19 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

953 (OR) 931 (OR) 285 (PU) 950 (BK) -

CIRCUIT REFERENCE

IGNITION B(+) IGNITION B(+) EATON_25--13936

X127 MIRROR HEAT SWITCH

BACKLIGHTING GROUND

55-73

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X128 HVAC CONTROL PANEL A09 CAV

WIRE NUMBER

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10

972 (PU) 901 (OR) 900 (WH) 902 (WH) 904 (WH) 905 (WH) 906 (WH) 907 (BL)

C11

908 (YE)

C12

909 (BL)

C13

910 (YE)

C14

911 (BL)

HIGH/LOW PRESSURE COMMON TO ATC MODULE A-15 AND A/C LOW PRESSURE SWITCH S-48 A/C CLUTCH FROM ATC MODULE A-15

C15

912 (YE)

BLOWER SPEED TO ATC MODULE A-15

CIRCUIT REFERENCE

BACKLIGHTING SWITCHED B+ A/C CLUTCH RELAY K10 SEPARATOR BLOWER RELAY K09

NOT USED NOT USED MAIN BLOWER RELAY HIGH K13 POWER TO ATC MODULE A-15 GROUND FOR ATC MODULE A-15, COLD BOX DOOR M-15, WATER VALVE M-16, CAB/OUTLET/ EVAPORATOR TEMPERATURE SENSORS B-26/27/28 HIGH PRESSURE TO ATC MODULE A-15

913 (BL)

914 (YE)

939 (YE)

934 (BL)

NOT USED A/C HIGH PRESSURE SENSOR S-47 GROUND

917 (YE)

A/C HIGH PRESSURE SWITCH S-47 SIGNAL

918 (BK)

AUTO SWITCH SIGNAL TO ATC MODULE A-15

919 (YE)

920 (OR)

922 (BK)

D10

923 (YE)

D11

924 (OR)

D12 D13 D14 D15 D16

921 (BK) -

X128 HVAC CONTROL PANEL

GROUND FOR ATC MODULE A-15, COLD BOX DOOR M-15, WATER VALVE M-16, CAB/OUTLET/ EVAPORATOR TEMPERATURE SENSORS B-26/27/28 TEMP SELECTION TO ATC MODULE A-15

C16

PAC_12110207

A/C LOW PRESSURE S-48 SIGNAL DEMIST SWITCH SIGNAL TO ATC MODULE A-15 GROUND FOR ATC MODULE A-15, COLD BOX DOOR M-15, WATER VALVE M-16, CAB/OUTLET/ EVAPORATOR TEMPERATURE SENSORS B-26/27/28 ATC MODULE A-15 DATA POWER TO ATC MODULE A-15, COLD BOX DOOR M-15 AND WATER VALVE M-16.

GROUND

55-74

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X129 DOME LIGHT E34 CAV

WIRE NUMBER

1 2 2

971 (BK) 865 (YE) 967 (YE)

CIRCUIT REFERENCE

GROUND DOME LIGHT CONTROL (TIME DELAY K20, LH DOOR SW S40) AMP_926522

X129 DOME LIGHT

CONNECTOR X130 BEACON LIGHT SWITCH S41 CAV

WIRE NUMBER

172 (OR)

3 4 5 6 7 8 9 10

166 (YE) 283 (PU) 297 (BK) -

CIRCUIT REFERENCE

BEACON LIGHT SWITCH IGNITION B+ BEACON LIGHT SWITCH SIGNAL

EATON_25--13936

X130 BEACON LIGHT SWITCH

BACKLIGHTING BEACON LIGHT SWITCH GROUND

CONNECTOR X131 REAR WORK LIGHT SWITCH S44 CAV

WIRE NUMBER

239 (OR)

REAR WORK LIGHT SWITCH IGNITION FEED

170 (YE)

REAR WORK LIGHT SWITCH SIGNAL

4 5 6 7 8

233 (PU) -

223 (BK)

CIRCUIT REFERENCE

EATON_25--13936

X131 REAR WORK LIGHT SWITCH

BACKLIGHTING REAR WORK LIGHT SWITCH GROUND

55-75

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X132 FRONT WORK LIGHTS SWITCH S43 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

240 (OR) 171 (YE) 245 (BK) 925 (BK) 235 (PU) 224 (BK) -

CIRCUIT REFERENCE

IGNITION B(+) X018 CCM1 J1-3 EATON_25--13936

INNER WORK LIGHTS E17, E18 WORK LTS GROUND BACKLIGHTING

X132 FRONT WORK LIGHTS SWITCH

GROUND

CONNECTOR X133 SPLICE BLOCK C, BACKLIGHTING, CR CAV

WIRE NUMBER

A B C D E F G H J K L M

175 (PU) 232 (PU) 233 (PU) 235 (PU) 273 (PU) 283 (PU) 284 (PU) 285 (PU) 286 (PU) 972 (PU)

CIRCUIT REFERENCE

CONSOLE LIGHT E35 X015 CCM2 J1-11 REAR WORK LIGHT SWITCH S44 WORK LIGHT SWITCH S43 WIPER SWITCH S20 BEACON LIGHT SWITCH S41 TANK EXTENSIONS SWITCH S42 MIRROR HEAT SWITCH S19 WASHER SWITCH S38

PAC_15305291

X133 SPLICE BLOCK C

HVAC MODULE A09

CONNECTOR X134 WASHER SWITCH S38 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

279 (OR) 278 (WH) 286 (PU) 951 (BK) -

CIRCUIT REFERENCE

WASHER SWITCH IGNITION B(+) WASHER SWITCH ACTUATION EATON_25--13936

X134 WASHER SWITCH

BACKLIGHTING GROUND

55-76

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X135 WIPER SWITCH S20 CAV

WIRE NUMBER

1 2 3 4 5

276 (WH) 272 (OR) 275 (WH) -

277 (WH)

7 8 9 10

273 (PU) 296 (BK) -

CIRCUIT REFERENCE

WIPER SWITCH ACTUATION, ON WIPER SWITCH IGNITION B(+) WIPER SWITCH ACTUATION, PARK EATON_25--13936 WIPER SWITCH ACTUATION, INTERMITTENT

X135 WIPER SWITCH

BACKLIGHTING GROUND

CONNECTOR X136 FRONT LEFT SPEAKER H-05 CAV

WIRE NUMBER

A B

983 (BL) 977 (WH)

CIRCUIT REFERENCE

FRONT LEFT SPEAKER (-) FRONT LEFT SPEAKER (+) PAC_12052832

X136 FRONT LEFT SPEAKER

CONNECTOR X137 DOOR SWITCH S40 CAV

WIRE NUMBER

865 (YE)

CIRCUIT REFERENCE

DOOR SWITCH SIGNAL AMP_154719

X137 DOOR SWITCH

CONNECTOR X138 RIGHT CONSOLE LIGHT E35 CAV

1 2

WIRE NUMBER

175 (PU) 269, 973 (BK)

CIRCUIT REFERENCE

BACKLIGHTING GROUND

AMP_926522

X138 RIGHT CONSOLE LIGHT

55-77

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X139 FRONT RIGHT SPEAKER H-07 CAV

WIRE NUMBER

A B

980 (BL) 976 (WH)

CIRCUIT REFERENCE

FRONT RIGHT SPEAKER (-) FRONT RIGHT SPEAKER (+) PAC_12052832

X139 FRONT RIGHT SPEAKER

CONNECTOR X141 TRANSCEIVER CAV

WIRE NUMBER

1 2

281 (BK) 083 (OR)

CIRCUIT REFERENCE

GROUND IGNITION B+

AMP_926522

X141 TRANSCEIVER

CONNECTOR X142 G.P.S. UNIT A11 CAV

WIRE NUMBER

1 2 3 4

903 (OR) 999 (YE) 282 (BK) 996 (GN)

CIRCUIT REFERENCE

B+ IGNITION CAN HI GROUND CAN LO

DEUTSCH_DT06--4S_PLUG

X142 G.P.S. UNIT

CONNECTOR X143 SEPARATOR BLOWER M18 CAV

WIRE NUMBER

926 (WH)

CIRCUIT REFERENCE

SEPARATOR BLOWER ACTUATION

X143 SEPARATOR BLOWER

CONNECTOR X144 SEPARATOR BLOWER M18 CAV

WIRE NUMBER

933 (BK)

CIRCUIT REFERENCE

SEPARATOR BLOWER GROUND

X144 SEPARATOR BLOWER

55-78

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X145 GROUND, 3, AC CAV

WIRE NUMBER

CIRCUIT REFERENCE

933 (BK) 948 (BK)

SEPARATOR BLOWER M18 MAIN BLOWER M17

X145 GROUND

CONNECTOR X147 COLD BOX DOOR M15 (ATC ONLY) CAV

WIRE NUMBER

A B C

924 (OR) 954 (BK)

959 (WH)

E F

CIRCUIT REFERENCE

B+ GROUND COLD BOX DOOR SIGNAL FROM ATC MODULE A-15 CONNECTOR X397 PIN 11

PAC_12052848

X147 COLD BOX DOOR (ATC ONLY)

CONNECTOR X148 OUTLET TEMP SENSOR B27 (ATC ONLY) CAV

WIRE NUMBER

958 (WH)

954 (BK)

CIRCUIT REFERENCE

OUTLET TEMP SENSOR SIGNAL TO ATC MODULE A-15 CONNECTOR X397 PIN 22 OUTLET TEMP SENSOR GROUND DEUTSCH_DT06--2S_PLUG

X148 OUTLET TEMP SENSOR (ATC ONLY)

55-79

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X149 CAB TEMPERATURE SENSOR B26 (ATC ONLY) CAV

WIRE NUMBER

952 (BL)

954 (BK)

CIRCUIT REFERENCE

CAB TEMPERATURE SENSOR SIGNAL, TO ATC MODULE A-15 CONNECTOR X397 PIN 21 CAB TEMPERATURE SENSOR GROUND

DEUTSCH_DT06--2S_PLUG

X149 CAB TEMPERATURE SENSOR (ATC ONLY)

CONNECTOR X150 EVAPORATOR PROBE B28 (ATC ONLY) CAV

WIRE NUMBER

951 (BL)

954 (BK)

CIRCUIT REFERENCE

EVAPORATOR PROBE SIGNAL TO ATC MODULE A-15 CONNECTOR X397 PIN 23 EVAPORATOR PROBE GROUND

DEUTSCH_DT04--2P_RECEPTACLE

X150 AMBIENT TEMP SENSOR (ATC ONLY)

CONNECTOR X151 WATER VALVE M16 CAV

WIRE NUMBER

A B C

924 (OR) 954 (BK)

955 (YE)

E F

CIRCUIT REFERENCE

SWITCHED (B+) GROUND WATER VALVE SIGNAL FROM ATC MODULE A-15 CONNECTOR Z397 PIN 3

PAC_12052848

X151 WATER VALVE

55-80

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X152 BLOWER SPEED CONTROL A-14 (ATC) CAV

WIRE NUMBER

1 2

946 (RD) 948 (BK)

953 (YE)

CIRCUIT REFERENCE

MAIN BLOWER FEED, HIGH (K13) GROUND BLOWER SPEED SIGNAL FROM ATC MODULE A-15 DEUTSCH_DTP06--4S_PLUG

NOT USED

DEUTSCH_DTP04--4P_RECEPTACLE

X152 MAIN BLOWER

CONNECTOR X160 LEFT FRONT HAZARD LIGHT E03 CAV

WIRE NUMBER

A B C

624 (PU) 615 (PU) 620 (BK)

CIRCUIT REFERENCE

MARKER LIGHT HAZARD LIGHT GROUND DEUTSCH_DT06--3S_PLUG

DEUTSCH_DT04--3P_RECEPTACLE

X160 LEFT FRONT HAZARD LIGHT

55-81

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X161 LEFT FRONT SERVICE SOCKET J02 CAV

WIRE NUMBER

A B

647 (RD) 656 (BK)

CIRCUIT REFERENCE

UNSWITCHED (B+) GROUND

PAC_2973781

X161 LEFT FRONT SERVICE SOCKET

CONNECTOR X162 LEFT HEADER LIGHT E21 CAV

WIRE NUMBER

CIRCUIT REFERENCE

A B

257 (PU) 267 (BK)

HEADER WORK LIGHTS RELAY K22 GROUND

PAC_12124819

X162 LEFT HEADER LIGHT

55-82

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X163 LEFT LOWER WORK LIGHT E23 CAV

WIRE NUMBER

A B

644 (PU) 654 (BK)

CIRCUIT REFERENCE

LOWER WORK LIGHTS RELAY K30 GROUND

PAC_12124819

X163 LEFT LOWER WORK LIGHT

CONNECTOR X164 LEFT ROAD LIGHT E13 CAV

WIRE NUMBER

C B A

640 (PU) 638 (PU) 642 (BK)

CIRCUIT REFERENCE

HIGH BEAM RELAY K04 LOW BEAM RELAY K05 GROUND

PAC_08917857

X164 LEFT ROAD LIGHT

CONNECTOR X165 RIGHT FRONT HAZARD LIGHT E04 CAV

WIRE NUMBER

A B C

627 (PU) 616 (PU) 621 (BK)

CIRCUIT REFERENCE

MARKER LIGHT HAZARD LIGHT GROUND DEUTSCH_DT06--3S_PLUG

DEUTSCH_DT04--3P_RECEPTACLE

X165 RIGHT FRONT HAZARD LIGHT

55-83

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X167 RIGHT HEADER LIGHT E22 CAV

WIRE NUMBER

A B

258 (PU) 268 (BK)

CIRCUIT REFERENCE

HEADER WORK LIGHT RELAY K22 GROUND PAC_12124819

X167 RIGHT HEADER LIGHT

CONNECTOR X168 RIGHT LOWER WORK LIGHT E24 CAV

WIRE NUMBER

A B

645 (PU) 655 (BK)

CIRCUIT REFERENCE

LOWER WORK LIGHT RELAY K30 GROUND PAC_12124819

X168 RIGHT LOWER WORK LIGHT

CONNECTOR X169 RIGHT ROAD LIGHT E14 CAV

WIRE NUMBER

C B A

641 (PU) 639 (PU) 643 (BK)

CIRCUIT REFERENCE

HIGH BEAM RELAY K04 LOW BEAM RELAY K05 GROUND

PAC_08917857

X169 RIGHT ROAD LIGHT

55-84

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X170 LATERAL INCLINATION SENSOR B02 CAV

WIRE NUMBER

A B C

451 (PK) 462 (BL) 430 (YE)

CIRCUIT REFERENCE

5V REF. VOLTAGE REF. GROUND X019 CCM-1 J2-33 DEUTSCH_DT06--3S_PLUG

X170 LATERAL INCLINATION SENSOR

CONNECTOR X171 WIPER WASHER MOTOR M24 CAV

WIRE NUMBER

1 2

449 (BK) 278 (WH)

CIRCUIT REFERENCE

GROUND WASHER SWITCH S38

AMP_926522

X171 WIPER WASHER MOTOR

CONNECTOR X172 HORN H02 CAV

WIRE NUMBER

CIRCUIT REFERENCE

193 (WH)

ROAD LIGHTS SWITCH S26

CONNECTOR X172 HORN H02 CAV

WIRE NUMBER

631 (BK)

CIRCUIT REFERENCE

AMP_154719

GROUND

X172 HORN

CONNECTOR X173 BRAKE PRESSURE S39 CAV

WIRE NUMBER

497 (BK)

CIRCUIT REFERENCE

GROUND

CONNECTOR X173 BRAKE PRESSURE S39 CAV

WIRE NUMBER

418 (YE)

CIRCUIT REFERENCE

AMP_154719

X016 CCM-2 J2-34

X173 BRAKE PRESSURE

55-85

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X174 FEEDER ANGLE R03 CAV

WIRE NUMBER

1 2 3

756 (BL) 740 (YE) 751 (PK)

CIRCUIT REFERENCE

REF. GROUND, X281 PIN 4 HHC MODULE A07, X281 PIN 14 5V REF. VOLTAGE, X281 PIN 5

AMP_282191--1

X174 FEEDER ANGLE

CONNECTOR X175 GROUND, 2, MF CAV

WIRE NUMBER

CIRCUIT REFERENCE

LH/RH HEADER & CENTER WORK LIGHTS E-21/22/38 & WIPER WASHER MOTOR M24 GRAIN TANK, UNLOAD TUBE LIGHTING

246 (BK) 668 (BK) 676 (BK) 677 (BK)

LS ROAD/HAZARD LIGHTING RS ROAD/HAZARD LIGHTING, HORN H02

483 (BK)

MAIN VALVE STACK, HHC MODULE A07, FUEL PUMP M23

583 (BK)

584 (BK) 2014 (BK) 2015 (BK)

X019 CCM1 J2-12, 18, MODULE GROUND; X019 CCM1 J2-3, CONCAVE CLEARANCE M04, BIN COVERS M12 X016 CCM 2 J2-12, 18, MODULE GROUND; X016 CCM2 J2-3, THROTTLE M13, ROT SCR BRUSH M27 LS UNDERSHIELD LIGHTING RS UNDERSHIELD LIGHTING

X175 FRONT GROUND

CONNECTOR X177 ROTOR RPM B01 CAV

WIRE NUMBER

1 2

495 (BL) 416 (YE)

CIRCUIT REFERENCE

REF. GROUND X016 CCM-2 J2-37 DEUTSCH_DT06--2S_PLUG

X177 DRUM RPM

55-86

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X178 MIRROR SELECT SWITCH S-57 CAV

WIRE NUMBER

963 (WH)

TO GERMAN MIRROR UP/DOWN MOTOR M-30

957 (WH)

FROM MIRROR ADJUST SWITCH S--27

2009 (PU)

TO RH MIRROR UP/DOWN MOTOR M-19

964 (WH)

TO GERMAN MIRROR IN/OUT MOTOR M-31

960 (WH)

FROM MIRROR ADJUST SWITCH S-27

6 7 8 9 10

962 (WH) -----

TO RH MIRROR IN/OUT MOTOR M-20

CIRCUIT REFERENCE

EATON_25--13936

X178 MIRROR SELECT SWITCH

CONNECTOR X180 SPLICE BLOCK E CAV

WIRE NUMBER

317

GROUND FOR NEUTRAL LOCK SOLENOID L-01

380

GROUND FOR REEL SPEED MODE S-08

226

GROUND FOR VERTICAL KNIVES S-51

387

GROUND FOR FEEDER REVERSER S-07

1746

GROUND FOR AUTO PILOT SWITCH S-78

377

GROUND FOR ALTERNATE SETTINGS S-21

386

GROUND FOR SPREADER PLATE S-23

H J

393 384

GROUND FOR PARK BRAKE S-09 GROUND FOR REAR WHEEL ASSIST S-10

385

GROUND FOR REAR WHEEL ASSIST S-10

392

GROUND FOR ON THE ROAD SWITCH S-12

399

FRAME GROUND FROM X053 PIN M

CIRCUIT REFERENCE

PAC_15305291

X180 SPLICE BLOCK E

CONNECTOR X181 LEFT RETURNS RPM B06 CAV

WIRE NUMBER

1 2

500 (BL) 433 (YE)

CIRCUIT REFERENCE

REF. GROUND X019 CCM-1 J2-38 DEUTSCH_DT06--2S_PLUG

X181 LEFT RETURNS RPM

55-87

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X182 CLEAN GRAIN RPM B08 CAV

WIRE NUMBER

1 2

491 (BL) 450 (YE)

CIRCUIT REFERENCE

REF. GROUND X019 CCM1 J2-28 DEUTSCH_DT06--2S_PLUG

X182 CLEAN GRAIN RPM

CONNECTOR X183 FUEL PUMP M23 CAV

WIRE NUMBER

A B

856 (WH) 845 (BK)

CIRCUIT REFERENCE

FUEL PUMP RELAY K07 GROUND

PAC_15300027

X183 FUEL PUMP

55-88

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X184 FUEL LEVEL R01 CAV

WIRE NUMBER

1 2

467 (BL) 427 (YE)

CIRCUIT REFERENCE

REF. GROUND X016 CCM2 J2-17 DEUTSCH_DT06--2S_PLUG

X184 FUEL LEVEL

CONNECTOR X186 RIGHT RETURNS RPM B39 CAV

WIRE NUMBER

1 2

442 (BL) 441 (YE)

CIRCUIT REFERENCE

REF. GROUND X019 CCM1 J2-37 DEUTSCH_DT06--2S_PLUG

X186 RIGHT RETURNS RPM

CONNECTOR X188 RH ROTOR LOSS B20 CAV

WIRE NUMBER

CIRCUIT REFERENCE

458 (BL)

REF. GROUND

402 (YE)

X016 CCM2 J2-26 DEUTSCH_DT06--2S_PLUG

X188 RH ROTOR LOSS

CONNECTOR X189 CONCAVE POSITION R06 CAV

WIRE NUMBER

498 (PK)

5V REF. VOLTAGE

456 (BL)

REF. GROUND

411 (YE)

X019 CCM1 J2-19

CIRCUIT REFERENCE

PAC_12065287

X189 CONCAVE POSITION

55-89

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X190 CONCAVE MOTOR M04 CAV

WIRE NUMBER

695 (WH)

CONCAVE MOTOR INCREASE

694 (GY)

CONCAVE MOTOR DECREASE

CIRCUIT REFERENCE

PAC_15300027

X190 CONCAVE MOTOR

55-90

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X193 ECU CONNECTOR B CAV

1 2 3 4 5 6 7

WIRE NUMBER

CIRCUIT REFERENCE

810 (WH) 811 (WH) 815 (BK) 816 (BK) 1625 (WH)

1626 (WH)

F-01 (B+)

1627 (BK)

TO FRAME GROUND

1628 (BK)

TO FRAME GROUND

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

822 (BK) 820 (GN) 819 (YE)

GRID HEATER RELAY K-39

859 (OR)

KEYSWITCH S-02

1131 (YE)

818 (WH)

GRID HEATER RELAY K-39

827 (YE)

DIAGNOSTIC OUTLET J-10 X065 PIN E

F-01 (B+) F01 (B+) TO FRAME GROUND TO FRAME GROUND F-01 (B+)

BOSCH 1928401982

X193 ECU CONNECTOR B

1 50014698

40 CAN 1 LO CAN 1 HI

WATER IN FUEL SENSOR B-59

10010906

NOTE: CAN 1 termination (ECU) located within IVECO ECU.

55-91

41 1. 2.

CONNECTOR X193 -ECU CONNECTOR B (7.5L) CONNECTOR X193 -ECU CONNECTOR B (IVECO)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X194 SERVICE SOCKET J05 CAV

WIRE NUMBER

A B

659 (BK) 650 (RD)

CIRCUIT REFERENCE

GROUND B+

PAC_2973781

X194 SERVICE SOCKET

CONNECTOR X195 COVERS CLOSED CAV

WIRE NUMBER

CIRCUIT REFERENCE

435 (YE)

X020 CCM1 J3-38, COVERS CLOSED B47

454 (BL)

REF. GROUND, COVERS CLOSED B47

3 4

693 (GY) 696 (WH)

COVERS MOTOR M12 COVERS MOTOR M12

DEUTSCH_DT04--4P_RECEPTACLE

DEUTSCH_DT06--4S_PLUG

X195 COVERS CLOSED

55-92

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X198 SPLICE BLOCK F, BACKLIGHTING, RC CAV

WIRE NUMBER

288 (PU)

B C D E F G H J K L

289 (PU) 290 (PU) 291 (PU) 292 (PU) 293 (PU) 249 (PU) 329 (PU) 396 (PU) 397 (PU) 398 (PU) 1752 (PU)

CIRCUIT REFERENCE

HHC FINE ADJUST S06 HEADER HEIGHT S-04, ENGINE THROTTLE S-36 REAR WHEEL ASSIST S10 DUAL RANGE S11 ON THE ROAD SWITCH S12 VERTICAL KNIVES S51 FEEDER REVERSER S07 ALTERNATE SETTINGS S21 X027 PIN 18, RHM REEL SPEED MODE S08 PARK BRAKE S09 SPREADER PLATE S23

PAC_15305291

X198 SPLICE BLOCK F

AUTOGUIDANCE SWITCH S-78

CONNECTOR X202 AIR FILTER S61 CAV

WIRE NUMBER

851 (BL)

864 (YE)

CIRCUIT REFERENCE

REF. GROUND X016 CCM2 J2-24; AIR FILTER SWITCH S-61 AMP_282189--1

X202 AIR FILTER

CONNECTOR X206 ROTARY SCREEN BRUSH M27 CAV

WIRE NUMBER

A B

821 (WH) 524 (GY)

CIRCUIT REFERENCE

THROTTLE/BRUSH RELAY K15 X016 CCM2 J2-1

PAC_15300027

X206 ROTARY SCREEN BRUSH

55-93

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X211 GRID HEATER RELAY K37/K39 CAV

WIRE NUMBER

818 (WH)

IVECO ECU A-01 X193 PIN 75 OR CUMMINS ECU A-16 X423 PIN 40

822 (BK)

GROUND X193 PIN 12, ECU (IVECO) OR X423 PIN 42 (CUMMINS)

CIRCUIT REFERENCE

BOSCH 1928403112

X211 GRID HEATER RELAY

CONNECTOR X215 A/C CLUTCH L07 CAV

WIRE NUMBER

178 (WH)

CIRCUIT REFERENCE

A/C CLUTCH RELAY K10

PAC_12015791

X215 A/C CLUTCH

CONNECTOR X216 A/C HIGH PRESSURE S47 CAV

WIRE NUMBER

910 (YE)

916 (YE)

CIRCUIT REFERENCE

X128 PIN D-4, HVAC MODULE A09 GROUND, X128 PIN D-3, HVAC MODULE A09 PAC_12065863

X216 A/C HIGH PRESSURE

55-94

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X217 A/C LOW PRESSURE S48 CAV

WIRE NUMBER

910 (YE)

950 (BL)

CIRCUIT REFERENCE

X128 PIN C-13, HVAC MODULE A09 GROUND, X128 PIN D-6, HVAC MODULE A09 PAC_12015792

X217 A/C LOW PRESSURE

CONNECTOR X218 FLIP-UP KIT CAV

WIRE NUMBER

637 (PU)

776 (BK)

CIRCUIT REFERENCE

RH MARKER LIGHTS FUSE F21 GROUND (THROUGH X032 HEADER CONNECTOR) DEUTSCH_DT06--2S_PLUG

X218 FLIP-UP KIT

55-95

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X219 EXPANSION B/MAIN FRAME B CAV

WIRE NUMBER

786 (WH)

790 (WH)

UPPER/LOWER SIEVE RELAY B+ UPPER/LOWER SIEVE RELAY N/O OUTPUT

792 (WH)

UPPER/LOWER SIEVE RELAY N/C OUTPUT

4 5 6

CIRCUIT REFERENCE

DEUTSCH_DT04--6P_RECEPTACLE

X219 EXPANSION B

DEUTSCH_DT06--6S_PLUG

X219 MAIN FRAME B

CONNECTOR X221 MOISTURE SENSOR B12 CAV

WIRE NUMBER

1 2 3 4 5 6

699 (OR) 565 (BK) 593 (YE) 594 (YE) 595 (YE) -

CIRCUIT REFERENCE

SWITCHED B+, FUSE F47 GROUND X014 CCM3 J3-17 X014 CCM3 J3-23 X014 CCM3 J3-34

DEUTSCH_DT06--6S_PLUG

X221 MOISTURE SENSOR

55-96

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X222 SAMPLE MOTOR M28 CAV

WIRE NUMBER

1 2 3 4

682 (OR) 564 (BK) 838 (YE) 837 (WH)

CIRCUIT REFERENCE

SWITCHED B+, FUSE 47 GROUND X013 CCM3 J2-25 X013 CCM3 J2-13

DEUTSCH_DT06--4S_PLUG

X222 SAMPLE MOTOR

CONNECTOR X223 YIELD SENSOR R05 CAV

WIRE NUMBER

A B C

698 (OR) 563 (BL) 552 (YE)

CIRCUIT REFERENCE

SWITCHED B+, FUSE 47 REF. GROUND, X014 CCM3 J3-18 X014 CCM3 J3-32 DEUTSCH_DT06--3S_PLUG

X223 YIELD SENSOR

CONNECTOR X224 SPREADER PLATE MOTOR M11 CAV

WIRE NUMBER

A B C D E

473 (PK) 471 (BL) 477 (YE) 510 (WH) 509 (GY)

CIRCUIT REFERENCE

5V REF. VOLTAGE REF. GROUND X013 CCM3 J2-33 X014 CCM3 J3-8 X014 CCM3 J3-6

PAC_12084891

X224 SPREADER PLATE MOTOR

CONNECTOR X225 UPPER SIEVE ADJUST S35 CAV

WIRE NUMBER

1 2 3

540 (YE) 550 (BK) 539 (YE)

CIRCUIT REFERENCE

X013 CCM3 J2-34; DECR GROUND X013 CCM3 J2-17; INCR

DEUTSCH_DTM04--3P_RECEPTACLE

X225 UPPER SIEVE ADJUST

55-97

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X226 LOWER SIEVE ADJUST S46 CAV

WIRE NUMBER

1 2 3

542 (YE) 551 (BK) 541 (YE)

CIRCUIT REFERENCE

X013 CCM3 J2-39; DECR GROUND X013 CCM3 J2-35; INCR

DEUTSCH_DTM04--3P_RECEPTACLE

X226 LOWER SIEVE ADJUST

CONNECTOR X227 UPPER SIEVE MOTOR M06 CAV

WIRE NUMBER

A B C D E

793 (PK) 795 (BL) 475 (YE) 792 (WH) 791 (GY)

CIRCUIT REFERENCE

5V REF. VOLTAGE REF. GROUND X013 CCM3 J2-2 UPPER/LOWER SIEVE RELAY K18 X013 CCM3 J2-1

PAC_12146045

X227 UPPER SIEVE MOTOR

CONNECTOR X228 LOWER SIEVE MOTOR M07 CAV

WIRE NUMBER

A B C D E

794 (PK) 796 (BL) 476 (YE) 790 (WH) 789 (GY)

CIRCUIT REFERENCE

5V REF. VOLTAGE REF. GROUND X013 CCM3 J2-19 UPPER/LOWER SIEVE RELAY K18 X013 CCM3 J2-1

PAC_12146045

X228 LOWER SIEVE MOTOR

55-98

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X232 SIEVES LOSS B21 CAV

WIRE NUMBER

1 2

494 (BL) 431 (YE)

CIRCUIT REFERENCE

REF. GROUND X019 CCM1 J2-25 DEUTSCH_DT06--2S_PLUG

X232 SIEVES LOSS

CONNECTOR X233 RWA SOLENOID L26 CAV

WIRE NUMBER

A B

569 (WH) 602 (BK)

CIRCUIT REFERENCE

X019 CCM1 J2-16 GROUND PAC_12015792

X233 RWA SOLENOID

CONNECTOR X234 SIEVE LIGHT E37 CAV

WIRE NUMBER

A B

610 (PU) 611 (BK)

CIRCUIT REFERENCE

SIEVE LIGHT SWITCH S54 GROUND

PAC_12124819

X234 SIEVE LIGHT

CONNECTOR X235 CHAFF SPREADER SOLENOID L28 CAV

WIRE NUMBER

A B

576 (WH) 577 (BK)

CIRCUIT REFERENCE

X019 CCM1 J2-15 GROUND DEUTSCH_DT06--2S_PLUG

X235 CHAFF SPREADER SOLENOID

55-99

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X237 SIEVE LIGHT SWITCH S54 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

604 (OR) 610 (PU) -

CIRCUIT REFERENCE

B+ (K-03 SWITCHED) SIEVE LIGHT E37 EATON_25--13936

X237 SIEVE LIGHT SWITCH

CONNECTOR X238 GEARBOX FILTER BYPASS S34 CAV

WIRE NUMBER

A B

484 (BK) 448 (YE)

CIRCUIT REFERENCE

GROUND X019 CCM1 J2-35 PAC_12015792

X238 GEARBOX FILTER BYPASS

CONNECTOR X239 RETURNS FILTER BYPASS S32 CAV

WIRE NUMBER

A B

603 (BK) 447 (YE)

CIRCUIT REFERENCE

GROUND X019 CCM1 J2-34 PAC_12015792

X239 RETURNS FILTER BYPASS

55-100

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X243 LEFT TAIL LIGHT CAV

WIRE NUMBER

CIRCUIT REFERENCE

BRAKE LIGHTS RELAY K33

629 (PU) 1570 (PU)

3 4 5 6

619 (PU) 634 (BK) 243 (PU) 679 (BK)

LH HAZARD LIGHTS GROUND LH NASO FLASHING LAMP E07 GROUND

LH BRAKE/TAIL LIGHT E-11 DEUTSCH_DT06--6S_PLUG

X243 LEFT TAIL LIGHT

CONNECTOR X244 UNLOAD CRADLE B38 CAV

WIRE NUMBER

1 2

444 (BL) 485 (YE)

CIRCUIT REFERENCE

REF. GROUND X020 CCM1 J3-36 DEUTSCH_DT06--2S_PLUG

X244 UNLOAD CRADLE

CONNECTOR X246 RIGHT TAIL LIGHT CAV

WIRE NUMBER

CIRCUIT REFERENCE

BRAKE LIGHTS RELAY K33

630 (PU) 1572 (PU)

3 4 5 6

622 (PU) 635 (BK) 244 (PU) 680 (BK)

RH HAZARD LIGHTS GROUND RH NASO FLASHING LAMP E08 GROUND

RH BRAKE/TAIL LIGHT E-12 DEUTSCH_DT06--6S_PLUG

X246 RIGHT TAIL LIGHT

55-101

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X247 REAR BEACON LIGHT E-33 CAV

WIRE NUMBER

578 (PU)

POWER FROM BEACON LIGHT RELAY K-29

623 (BK)

TO REAR FRAME GROUND 1

CIRCUIT REFERENCE

DEUTSCH_DT06--2S_PLUG

X247 BEACON LT

CONNECTOR X248 BACK UP ALARM H-08 CAV

WIRE NUMBER

CIRCUIT REFERENCE

452 (WH)

SIGNAL FROM CCM-1 J2-6

CONNECTOR X248 BACK UP ALARM H-08 CAV

WIRE NUMBER

SPRING_SPADE

CIRCUIT REFERENCE

455 (BK)

X248 BACK-UP ALARM

TO REAR FRAME GROUND 1

CONNECTOR X251 REAR LADDER B22 CAV

WIRE NUMBER

1 2

481 (BL) 570 (YE)

CIRCUIT REFERENCE

REF. GROUND X019 CCM1 J2-17 DEUTSCH_DT06--2S_PLUG

X251 REAR LADDER

CONNECTOR X252 RIGHT SERVICE SOCKET J03 CAV

WIRE NUMBER

A B

658 (BK) 678 (RD)

CIRCUIT REFERENCE

GROUND B+

PAC_2973781

X252 RIGHT SERVICE SOCKET

55-102

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X253 CHOPPER RPM B10 CAV

WIRE NUMBER

1 2

632 (BL) 413 (YE)

CIRCUIT REFERENCE

REF. GROUND X016 CCM2 J2-38 DEUTSCH_DT06--2S_PLUG

X253 CHOPPER RPM

CONNECTOR X255 FLASHER MODULE A05 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10 11 12

102 (RD) 179 (PU) 199 (PU) 195 (PU) 208 (PU) 141 (BK) 201 (PU) 197 (PU) 204 (PU) 243 (PU) 244 (PU) -

CIRCUIT REFERENCE

B(+) HAZARD SWITCH S25 LH FLASHING LIGHTS RH FLASHING LIGHTS INDICATOR LIGHT E10 GROUND ROAD LIGHT SW. S26; RIGHT TURN ROAD LIGHT SW. S26; LEFT TURN ISO/NASO SELECTION LH NASO FLASHING LIGHT E07 RH NASO FLASHING LIGHT E08

DEUTSCH_DT06--12S_PLUG

X255 FLASHER MODULE

CONNECTOR X256 ROAD LIGHTS SWITCH S26 CAV

WIRE NUMBER

173 (OR)

LIGHT CONTROL RELAY, K02, MARKER LIGHTS

2 3 4 5 6 7 8 9

203 (PU) 202 (PU) 218 (YE) 213 (OR) 055 (OR) 169 (YE) 214 (RD) 193 (WH)

RIGHT TURN LEFT TURN HIGH BEAM RELAY K04 FUSE, F-49 KEY SWITCH S02, IGNITION LOW BEAM RELAY, K05 FUSE, F51 HORN, H02

CIRCUIT REFERENCE

AMP_1--480706--O

X256 ROAD LIGHTS SWITCH

55-103

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X257 TURN INDICATOR E09 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

140 (PU) 209 (BK) 139 (PU)

CIRCUIT REFERENCE

EATON_25--13936

X257 TURN INDICATOR

LH FLASHING LIGHTS GROUND RH FLASHING LIGHTS

CONNECTOR X258 HIGH BEAM/TRAILER E10 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

208 (PU) 221 (BK) 043 (PU)

CIRCUIT REFERENCE

EATON_25--13936

X258 HIGH BEAM/TRAILER

FLASHER MODULE A05, X255 PIN 5 GROUND ROAD LIGHTS SW. S26; HIGH BEAM

CONNECTOR X259 HAZARD SWITCH S25 CAV

WIRE NUMBER

1 2

040 (RD)

207 (PU)

4 5 6 7 8 9 10

220 (BK) -

CIRCUIT REFERENCE

FUSE F56 X015 CCM2 J1-15; FLASHER MODULE A05, X255 PIN 2

EATON_25--13936

X259 HAZARD SWITCH GROUND

55-104

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X261 ASP BOTTOM SENSORS CAV

WIRE NUMBER

1 2 3 4

984 (YE) 985 (BL) 986 (YE) 987 (BL)

CIRCUIT REFERENCE

RH BOTTOM ASP SENSOR B48 RH BOTTOM ASP SENSOR B48 LH BOTTOM ASP SENSOR B49 LH BOTTOM ASP SENSOR B49

DEUTSCH_DT04--4P_RECEPTACLE

X261 ASP BOTTOM SENSORS

CONNECTOR X262 LH BOTTOM ASP SENSOR B49 CAV

WIRE NUMBER

1 2 3

986 (YE) 987 (BL) -

CIRCUIT REFERENCE

X086 PIN 3 X086 PIN 6 AMP_282191--1

X262 LH BOTTOM ASP SENSOR

CONNECTOR X263 RH BOTTOM ASP SENSOR B48 CAV

WIRE NUMBER

1 2 3

984 (YE) 985 (BL) -

CIRCUIT REFERENCE

X086 PIN 4 X086 PIN 5 AMP_282191--1

X263 RH BOTTOM ASP SENSOR

55-105

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X266 FEEDER REVERSE L21 CAV

WIRE NUMBER

1 2

562 (WH) 591 (BK)

CIRCUIT REFERENCE

X020 CCM1 J3-15 GROUND AMP_282189--1

X266 FEEDER REVERSE

CONNECTOR X267 LATERAL FLOAT CW L18 CAV

WIRE NUMBER

549 (WH)

X281 PIN 8, HHC MODULE A07

554 (BL)

REF. GROUND

CIRCUIT REFERENCE

AMP_282189--1

X267 LATERAL FLOAT CW

55-106

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X268 REEL AFT L15 CAV

WIRE NUMBER

1 2

559 (WH) 588 (BK)

CIRCUIT REFERENCE

X017 CCM2 J3-5 GROUND AMP_282189--1

X268 REEL AFT

CONNECTOR X269 REEL DOWN L13 CAV

WIRE NUMBER

1 2

557 (WH) 586 (BK)

CIRCUIT REFERENCE

X017 CCM2 J3-4 GROUND AMP_282189--1

X269 REEL DOWN

CONNECTOR X270 FEEDER FORWARD L20 CAV

WIRE NUMBER

1 2

561 (WH) 590 (BK)

CIRCUIT REFERENCE

X020 CCM1 J3-5 GROUND AMP_282189--1

X270 FEEDER FORWARD

CONNECTOR X271 LATERAL FLOAT CCW L19 CAV

WIRE NUMBER

1 2

548 (WH) 553 (BL)

CIRCUIT REFERENCE

X281 PIN 7, HHC MODULE A07 REF. GROUND AMP_282189--1

X271 LATERAL FLOAT CCW

55-107

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X272 REEL FORE L16 CAV

WIRE NUMBER

1 2

560 (WH) 589 (BK)

CIRCUIT REFERENCE

X017 CCM2 J3-1 GROUND AMP_282189--1

X272 REEL FORE

CONNECTOR X273 REEL UP L14 CAV

WIRE NUMBER

1 2

558 (WH) 587 (BK)

CIRCUIT REFERENCE

X017 CCM2 J3-3 GROUND AMP_282189--1

X273 REEL UP

CONNECTOR X274 REEL DRIVE L17 CAV

WIRE NUMBER

1 2

556 (WH) 585 (BK)

CIRCUIT REFERENCE

X017 CCM2 J3-2 GROUND AMP_282189--1

X274 REEL DRIVE

CONNECTOR X275 ROTOR INCREASE L29 CAV

WIRE NUMBER

1 2

566 (WH) 596 (BK)

CIRCUIT REFERENCE

X016 CCM2 J2-7 GROUND AMP_282189--1

X275 DRUM DECREASE

55-108

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X276 UNLOAD TUBE IN L03 CAV

WIRE NUMBER

1 2

574 (WH) 599 (BK)

CIRCUIT REFERENCE

X016 CCM2 J2-6 GROUND AMP_282189--1

X276 UNLOAD TUBE IN

CONNECTOR X277 UNLOAD TUBE OUT L04 CAV

WIRE NUMBER

1 2

573 (WH) 598 (BK)

CIRCUIT REFERENCE

X016 CCM2 J2-16 GROUND AMP_282189--1

X277 UNLOAD TUBE OUT

CONNECTOR X278 ROTOR DECREASE L30 CAV

WIRE NUMBER

1 2

567 (WH) 597 (BK)

CIRCUIT REFERENCE

X016 CCM2 J2-8 GROUND AMP_282189--1

X278 ROTOR INCREASE

CONNECTOR X279 HDR HEIGHT PRESSURE B29 CAV

WIRE NUMBER

1 2 3

725 (BL) 722 (YE) 728 (PK)

CIRCUIT REFERENCE

REF. GROUND X281 PIN 9, HHC MODULE A07 5V REF. VOLTAGE AMP_282189--1

X279 HDR HEIGHT

55-109

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X280 ACCUMULATOR L06 CAV

WIRE NUMBER

1 2

759 (WH) 760 (BK)

CIRCUIT REFERENCE

X281 PIN 1, HHC MODULE A07 GROUND AMP_282189--1

X280 ACCUMULATOR

CONNECTOR X281 HHC MODULE A07 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8

759 (WH) 781 (OR) 438 (BK) 472 (BL) 474 (PK) 545 (BK) 548 (WH) 549 (WH)

722 (YE)

10 11 12

544 (RD)

555 (BL)

CAN HI LATERAL FLOAT SOLENOID GROUND

14 15 16

740 (YE) 738 (YE) 739 (YE)

FEEDER ANGLE R03 LEFT STUBBLE HEIGHT R12 RIGHT STUBBLE HEIGHT R13

CIRCUIT REFERENCE

ACCUMULATOR SOLENOID L06 F-45 (K-24 SWITCHED) GROUND REF. GROUND FOR SENSORS 5V REF. VOLTAGE CAN LO LATERAL FLOAT CCW L19 LATERAL FLOAT CW L18 HDR HEIGHT PRESSURE SENSOR B29

BOSCH 1928404201

X281 HHC MODULE

CONNECTOR X282 FEEDER DECREASE L12 CAV

WIRE NUMBER

1 2

581 (WH) 608 (BK)

CIRCUIT REFERENCE

X019 CCM1 J2-8 GROUND AMP_282189--1

X282 FEEDER DECREASE

55-110

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X283 FEEDER INCREASE L11 CAV

WIRE NUMBER

1 2

582 (WH) 609 (BK)

CIRCUIT REFERENCE

X019 CCM1 J2-7 GROUND AMP_282189--1

X283 FEEDER INCREASE

CONNECTOR X284 FEEDER RPM B14 CAV

WIRE NUMBER

1 2

437 (BL) 489 (YE)

CIRCUIT REFERENCE

REF. GROUND X020 CCM1 J3-14 DEUTSCH_DT06--2S_PLUG

X284 FEEDER RPM

CONNECTOR X285 TRAILER HITCH CAV

WIRE NUMBER

1 2 3 4 5 6

997 (PU) 992 (PU) 993 (PU) 994 (PU) 995 (PU) 998 (BK)

CIRCUIT REFERENCE

BRAKE LAMPS LEFT TURN/HAZARD LAMPS RIGHT TURN/HAZARD LAMPS LEFT TAIL LAMPS RIGHT TAIL LAMPS GROUND

DEUTSCH_DT06--8S_PLUG

DEUTSCH_DT04--8P_RECEPTACLE

X285 TRAILER HITCH

55-111

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X287 GERMAN THIRD MIRROR CAV

WIRE NUMBER

1 2 3 4 5 6

964 (OR) 966 (GY) 862 (OR) 963 (WH) 863 (BK)

CIRCUIT REFERENCE

MIRROR SELECT SWITCH S57 MIRROR ADJUST SWITCH S27 MIRROR HEAT SWITCH S19 MIRROR SELECT SWITCH S57

DEUTSCH_DT04--6P_RECEPTACLE

X287 GERMAN THIRD MIRROR

GROUND

CONNECTOR X288 COVERS CLOSED B-47 CAV

WIRE NUMBER

454 (BL)

REFERENCE GROUND TO CCM1 J2-14

435 (YE)

SIGNAL TO CCM1 J3-38

CIRCUIT REFERENCE

DEUTSCH_DT06--2S_PLUG

X288 COVERS CLOSED

55-112

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X289 COVERS ACTUATOR M-12 CAV

WIRE NUMBER

696 (WH)

POWER FROM CCM1 J2-21 THROUGH CONCAVE/COVERS RELAY K-16

693 (GY)

POWER FROM CCM1 J2-1

CIRCUIT REFERENCE

PAC_15300027

X289 COVERS ACTUATOR

CONNECTOR X292 STONE DOOR OPEN L31 CAV

WIRE NUMBER

1 2

731 (WH) 732 (BK)

CIRCUIT REFERENCE

X082 PIN 2, ASD MODULE A08 X082 PIN 8, ASD MODULE A08 AMP_282189--1

X292 STONE DOOR OPEN

55-113

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X293 DUAL RANGE SOLENOID L27 CAV

WIRE NUMBER

762 (WH)

X020 CCM1 J3-3, DUAL RANGE SOLENOID L27

764 (BK)

DUAL RANGE SOLENOID GROUND

CIRCUIT REFERENCE

PAC_12010793

X293 DUAL RANGE SOLENOID

CONNECTOR X294 LH BRAKE GROUND CAV

WIRE NUMBER

866 (BK)

CIRCUIT REFERENCE

X294 LH BRAKE GROUND

LH BRAKE GROUND

CONNECTOR X295 RH BRAKE GROUND CAV

WIRE NUMBER

867 (BK)

CIRCUIT REFERENCE

X295 RH BRAKE GROUND

RH BRAKE GROUND

CONNECTOR X296 DOME LIGHT POWER E-34 CAV

WIRE NUMBER

965 (RD)

CIRCUIT REFERENCE

POWER FROM FUSE F-52 AMP_154719

X296 DOME LIGHT POWER

CONNECTOR X314 FM RADIO “B” CAV

WIRE NUMBER

1 2 3 4 5 6 7 8

048 RD 081 OR 973 BK

CIRCUIT REFERENCE

KEEP ALIVE POWER, B+, FUSE F35

RADIO POWER, B+, FUSE F11 RADIO GROUND TO CAB ROOF #4

AMP_962189--1

X314 FM RADIO “B”

55-114

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X315 FM RADIO “C” CAV

WIRE NUMBER

1 2 3 4 5 6 7 8

974 WH 979 BL 976 WH 980 BL 977 WH 983 BL 975 WH 982 BL

CIRCUIT REFERENCE

REAR RIGHT SPEAKER, SUPPLY REAR RIGHT SPEAKER, GROUND FRONT RIGHT SPEAKER, SUPPLY FRONT RIGHT SPEAKER, GROUND FRONT LEFT SPEAKER, SUPPLY FRONT LEFT SPEAKER, GROUND REAR LEFT SPEAKER, SUPPLY REAR LEFT SPEAKER, GROUND

AMP_962191--1

X315 FM RADIO “C”

CONNECTOR X316 CENTER WORK LT E38 CAV

WIRE NUMBER

1 2

210 (PU) 234 (BK)

CIRCUIT REFERENCE

HEADER WORK LIGHT RELAY K22 GROUND DEUTSCH_DT06--2S_PLUG

X316 CENTER WORK LT

CONNECTOR X321 DGPS MODULE A-11 (252 RECEIVER) CAV

WIRE NUMBER

1241 (YE)

CAN 2 HI, CAN 2 TERMINATION (DGPS) R-27

1219 (RD)

X496 PIN 2 CERES MODULE A-24

1220 (BL)

X496 PIN 31 CERES MODULE A-24

1234 (YE)

X496 PIN 21 CERES MODULE A-24

1246 (YE)

X496 PIN 12 CERES MODULE A-24

1238 (OR)

X496 PIN 11 CERES MODULE A-24 AND F-48 (K-26 SWITCHED)

1239 (BK)

X496 PIN 1 CERES MODULE A-24 AND GROUND

1240 (GN)

CAN 2 LOW, CAN 2 TERMINATION 9DGPS) R-27

CIRCUIT REFERENCE

DEUTSCH_DTM06--12S_PLUG

X321 DGPS MODULE A-11 (252 RECEIVER)

6 7 8 9

55-115

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X322 UNLOAD TUBE WORK LT E29 CAV

WIRE NUMBER

A B

077 (PU) 669 (BK)

CIRCUIT REFERENCE

UNLOAD TUBE LIGHT RELAY K32 GROUND

PAC_12124819

X322 UNLOAD TUBE WORK LT CONNECTOR X323 UNLOAD TUBE MARKER LT E39 CAV

WIRE NUMBER

1 2

530 (PU) 531 (BK)

CIRCUIT REFERENCE

MARKER LIGHTS, FUSE F20 GROUND AMP_282080--1

X323 UNLOAD TUBE MARKER LT

CONNECTOR X326 HID DISTANCE LT CAV

WIRE NUMBER

210 (WH)

POWER FROM ROAD LIGHTS RELAY K-27

234 (BK)

TO WORK LIGHT SWITCH S-43 TO CAB ROOF GROUND 4

CIRCUIT REFERENCE

PAC_12059181

X326 HID DISTANCE LT

CONNECTOR X327 BRAKE FLUID LEVEL S49 CAV

WIRE NUMBER

CIRCUIT REFERENCE

1502 (BK) 122 (BK)

GROUND

1501 (YE)

X019 CCM1 J2-26

AMP_154719

X327 BRAKE FLUID LEVEL

CONNECTOR X329 BRAKE LIMITING VALVE L-32 CAV

WIRE NUMBER

A B

1504 (WH) 1505 (BK)

CIRCUIT REFERENCE

POWER FROM CCM2 J2-7 TO FRONT FRAME GROUND 2 PAC_12015792

X329 BRAKE LIMITING VALVE

55-116

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X330 AIR FILTER RESISTOR R15 CAV

WIRE NUMBER

469 (PK)

860 (YE)

CIRCUIT REFERENCE

5V REF. VOLTAGE AIR FILTER SWITCH S61; X016 CCM2 J2-29 DEUTSCH_DT06--3S_PLUG

X330 AIR FILTER RESISTOR

CONNECTOR X339 LEFT LIGHT SWITCH S-63 CAV

WIRE NUMBER

1 2 3

1214 (RD) 2004 (PU)

4 5 6 7 8 9 10

CIRCUIT REFERENCE

POWER FROM FUSE F-34 (B+) POWER TO LEFT UNDER SHIELD LIGHTS E-42 & E-43

EATON_25--13936

X339 LEFT LIGHT SWITCH

CONNECTOR X340 ENGINE LIGHT SWITCH S-64 CAV

WIRE NUMBER

1 2 3 4 5 6 7 8 9 10

2007 (RD) 2009 (PU) -

CIRCUIT REFERENCE

POWER FROM FUSE F-34 (B+) POWER TO ENGINE LIGHT E-46 EATON_25--13936

X340 ENGINE LIGHT SWITCH

55-117

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X341 RIGHT LIGHT SWITCH S-65 CAV

WIRE NUMBER

1 2 3

2008 (RD) 2010 (PU)

4 5 6 7 8 9 10

CIRCUIT REFERENCE

POWER FROM FUSE F-34 POWER TO RIGHT UNDER SHIELD LIGHTS E-44 & E-45

EATON_25--13936

X341 RIGHT LIGHT SWITCH

CONNECTOR X342 LH SHIELD LTS CAV

WIRE NUMBER

A B

1214 (RD) 2014 (BK)

CIRCUIT REFERENCE

FUSE F34 GROUND PAC_12015792

X342 LH SHIELD LTS

CONNECTOR X343 RH SHIELD LTS CAV

WIRE NUMBER

A B

1215 (RD) 2015 (BK)

CIRCUIT REFERENCE

FUSE F34 GROUND PAC_12015792

X343 RH SHIELD LTS

CONNECTOR X344 RIGHT SHIELD LIGHTS CAV

WIRE NUMBER

A B

2009 (PU) 2013 (BK)

CIRCUIT REFERENCE

POWER TO ENGINE LIGHT E-46 GROUND FOR ENGINE LIGHT E-46 THROUGH X343 TO FRONT FRAME GROUND 2

PAC_12010973

PAC_12015792

X344 RIGHT SHIELD LIGHTS

55-118

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X345 LEFT FRONT LIGHT E-42 CAV

WIRE NUMBER

2005 (PU)

POWER FROM UNDER SHIELD LIGHT SWITCH S-63

2017 (BK)

TO FRONT FRAME GROUND 2

CIRCUIT REFERENCE

PAC_12124819

X345 LEFT FRONT LIGHT

CONNECTOR X346 LEFT REAR LIGHT E-43 CAV

WIRE NUMBER

2006 (PU)

POWER FROM UNDER SHIELD LIGHT SWITCH S-63

2016 (BK)

TO FRONT FRAME GROUND 2

CIRCUIT REFERENCE

PAC_12124819

X346 LEFT REAR LIGHT

CONNECTOR X347 RIGHT FRONT LIGHT E-44 CAV

WIRE NUMBER

2012 (PU)

POWER FROM UNDER SHIELD LIGHT SWITCH S-63

2018 (BK)

TO FRONT FRAME GROUND 2

CIRCUIT REFERENCE

PAC_12124819

X347 RIGHT FRONT LIGHT

CONNECTOR X348 RIGHT REAR LIGHT E-45 CAV

WIRE NUMBER

2011 (PU)

POWER FROM UNDER SHIELD LIGHT SWITCH S-63

2019 (BK)

TO FRONT FRAME GROUND 2

CIRCUIT REFERENCE

PAC_12124819

X348 RIGHT REAR LIGHT

55-119

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X349 ENGINE LIGHT E-46 CAV

WIRE NUMBER

2009 (PU)

POWER FROM ENGINE LIGHT SWITCH S-64

2013 (BK)

TO FRONT FRAME GROUND 2

CIRCUIT REFERENCE

PAC_12124819

X349 ENGINE LIGHT

CONNECTOR X350 RH POSITION LIGHT E-49 CAV

WIRE NUMBER

1 2

1553 (WH) 1554 (BK)

CIRCUIT REFERENCE

POWER FROM FUSE F-21 TO FRONT FRAME GROUND 2 DEUTSCH_DT06--2S_PLUG

X350 RH POSITION LIGHT

CONNECTOR X351 LH POSITION LIGHT E-50 CAV

WIRE NUMBER

1 2

1563 (WH) 1564 (BK)

CIRCUIT REFERENCE

POWER FROM FUSE F-20 TO FRONT FRAME GROUND 2 DEUTSCH_DT06--2S_PLUG

X351 LH POSITION LIGHT

CONNECTOR X352 RH FLASHING LIGHT E-51 CAV

WIRE NUMBER

1551 (YE)

POWER FROM FLASHER MODULE A-05

1552 (BK)

TO FRONT FRAME GROUND 2

CIRCUIT REFERENCE

DEUTSCH_DT06--2S_PLUG

X352 RH FLASHING LIGHT

55-120

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X353 LH FLASHING LIGHT E-52 CAV

WIRE NUMBER

1561 (YE)

POWER FROM FLASHER MODULE A-05

1562 (BK)

TO FRONT FRAME GROUND 2

CIRCUIT REFERENCE

DEUTSCH_DT06--2S_PLUG

X353 LH FLASHING LIGHT

CONNECTOR X354 RH FRONT AUSTRIA LIGHT E-53 CAV

WIRE NUMBER

A B

1555 (WH) 1556 (BK)

CIRCUIT REFERENCE

POWER FROM FUSE F-21 TO FRONT FRAME GROUND 2 AMP_282080--1

X354 RH FRONT AUSTRIA LIGHT

CONNECTOR X355 LH FRONT AUSTRIA LIGHT E-54 CAV

WIRE NUMBER

A B

1565 (WH) 1566 (BK)

CIRCUIT REFERENCE

POWER FROM FUSE F-20 TO FRONT FRAME GROUND 2 AMP_282080--1

X355 LH FRONT AUSTRIA LIGHT

CONNECTOR X356 RH FRONT TURN/POSITION LIGHT E-04 CAV

WIRE NUMBER

A B

1559 (WH) 1558 (YE)

POWER FROM FUSE F-21 POWER FROM FLASHER MODULE A-05

1550 (BK)

TO FRONT FRAME GROUND 2

CIRCUIT REFERENCE

DEUTSCH_DT06--3S_PLUG

X356 RH FRONT TURN/POSITION LIGHT

55-121

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X357 LH FRONT TURN/POSITION LIGHT E-03 CAV

WIRE NUMBER

A B

1549 (WH) 1548 (YE)

POWER FROM FUSE F-20 POWER FROM FLASHER MODULE A-05

1560 (BK)

TO FRONT FRAME GROUND 2

CIRCUIT REFERENCE

DEUTSCH_DT06--3S_PLUG

X357 LH FRONT TURN/POSITION LIGHT

CONNECTOR X358 RH MARKER LIGHT CAV

WIRE NUMBER

1 2

1573 (PU) 1575 (BK)

CIRCUIT REFERENCE

POWER FROM FUSE F-21 TO REAR FRAME GROUND 1 DEUTSCH_DT06--2S_PLUG

X358 RH MARKER LIGHT

CONNECTOR X359 LH MARKER LIGHT CAV

WIRE NUMBER

1 2

1571 (PU) 1574 (BK)

CIRCUIT REFERENCE

POWER FROM FUSE F-20 TO REAR FRAME GROUND 1 DEUTSCH_DT06--2S_PLUG

X359 LH MARKER LIGHT

CONNECTOR X360 RH REAR MARKER LIGHT E-55 CAV

WIRE NUMBER

1 2

(WH) (BK)

CIRCUIT REFERENCE

POWER FROM FUSE F-21 TO REAR FRAME GROUND 1 AMP_282080--1

X360 RH REAR MARKER LIGHT

55-122

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X361 LH REAR MARKER LIGHT E-56 CAV

WIRE NUMBER

1 2

(WH) (BK)

CIRCUIT REFERENCE

POWER FROM FUSE F-20 TO REAR FRAME GROUND 1 AMP_282080--1

X361 LH REAR MARKER LIGHT

CONNECTOR X368 PARK BRAKE PRESSURE B53 CAV

WIRE NUMBER

A B C

1538 (BL) 1537 (PK) 1536 (YE)

CIRCUIT REFERENCE

REF. GROUND 5V REF. VOLTAGE X017 CCM2 J3-34

PAC_12065287

X368 PARK BRAKE PRESSURE

55-123

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X371 IVECO HARNESS TO BOOST TEMPERATURE/PRESSURE SENSOR B-23 CAV

WIRE NUMBER

CIRCUIT REFERENCE

WHITE

ORANGE

RED

GREEN

TO ECU A-0 1 CONNECTOR X51 6 PIN 25 (COMMON) TO ECU A-0 1 CONNECTOR X516 PIN 36 (TEMPERATURE SIGNAL) FROM ECU A-0 1 CONNECTOR X51 6 PIN 33 (+ 5 VOLTS) TO ECU A-0 1 CONNECTOR X516 PIN 34 (PRESSURE SIGNAL)

NOTE: Wire colors are not generally visible due to harness sheathing. BSCH_1928403736

X371 IVECO HARNESS TO BOOST TEMPERATURE/ PRESSURE SENSOR B-23

1 2

83063848

42 Intake Manifold, Rear of Engine 1. 2.

55-124

Boost Temperature/Pressure Sensor B-23 Connector X371

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X372 IVECO HARNESS TO FUEL TEMPERATURE B-36 CAV

WIRE NUMBER

CIRCUIT REFERENCE

WHITE/ RED ORANGE/ BLACK

TO ECU A-01 CONNECTOR X516 PIN 35 TO ECU A-01 CONNECTOR X516 PIN 18

NOTE: Wire colors are not generally visible due to harness sheathing.

BSCH_1928403874

X372 IVECO HARNESS TO FUEL TEMPERATURE B-36

2 83063852

43 Fuel Filter, Rear of Engine 1. 2.

55-125

Fuel Temperature B-36 Connector X372

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X373 IVECO HARNESS TO COOLANT TEMPERATURE B-44 CAV

WIRE NUMBER

CIRCUIT REFERENCE

PINK

YELLOW

TO ECU A-01 CONNECTOR X516 PIN 15 TO ECU A-01 CONNECTOR X516 PIN 26

NOTE: Wire colors are not generally visible due to harness sheathing.

BSCH_1928403874

X373 IVECO HARNESS TO COOLANT TEMPERATURE B-44

2 83063851

44 Cylinder head, under valve cover 1. 2.

55-126

Coolant Temperature B-44 Connector X373

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X376 IVECO HARNESS TO FUEL ACTUATOR 1, L-34 (CYL 1) CAV

WIRE NUMBER

CIRCUIT REFERENCE

WHITE

RED

TO ECU A-01 CONNECTOR X516 PIN 4 TO ECU A-01 CONNECTOR X516 PIN 13

NOTE: Wire colors are not generally visible due to harness sheathing.

BSCH_1928403874

X376 IVECO HARNESS TO FUEL ACTUATOR 1, L-34 (CYL 1)

1 2

MIDO305A

45 Cylinder head, under valve cover 1. 2.

55-127

Connector to fuel actuator (ring terminals) Fuel actuator

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X377 IVECO HARNESS TO FUEL ACTUATOR 1, L-34 (CYL 4) CAV

WIRE NUMBER

CIRCUIT REFERENCE

BLUE

GRAY

TO ECU A-01 CONNECTOR X515 PIN 3 TO ECU A-01 CONNECTOR X515 PIN 14

NOTE: Wire colors are not generally visible due to harness sheathing.

BSCH_1928403874

X377 IVECO HARNESS TO FUEL ACTUATOR 1, L-34 (CYL 4)

1 2

MIDO305A

46 Cylinder head, under valve cover 1. 2.

55-128

Connector to fuel actuator (ring terminals) Fuel actuator

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 X378 IVECO HARNESS TO FUEL ACTUATOR 3, L-36 (CYL 4)

CONNECTOR X378 IVECO HARNESS TO FUEL ACTUATOR 3, L-36 (CYL 2) CAV

WIRE NUMBER

CIRCUIT REFERENCE

YELLOW

RED

TO ECU A-01 CONNECTOR X515 PIN 11 TO ECU A-01 CONNECTOR X515 PIN 6

1 2

MIDO305A

47 Cylinder head, under valve cover 1. 2.

X379 IVECO HARNESS TO FUEL ACTUATOR 4, L-37 (CYL 6)

CONNECTOR X379 IVECO HARNESS TO FUEL ACTUATOR 4, L-37 (CYL 6) CAV

WIRE NUMBER

CIRCUIT REFERENCE

BLACK

GRAY

TO ECU A-01 CONNECTOR X515 PIN 2 TO ECU A-01 CONNECTOR X515 PIN 15

Connector to fuel actuator (ring terminals) Fuel actuator

1 2

MIDO305A

48 Cylinder head, under valve cover 1. 2.

55-129

Connector to fuel actuator (ring terminals) Fuel actuator

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 X380 IVECO HARNESS TO FUEL ACTUATOR 5, L-38 (CYL 3)

CONNECTOR X380 IVECO HARNESS TO FUEL ACTUATOR 5, L-38 (CYL 3) CAV

WIRE NUMBER

CIRCUIT REFERENCE

GREEN

RED

TO ECU A-01 CONNECTOR X515 PIN 5 TO ECU A-01 CONNECTOR X515 PIN 12

1 2

MIDO305A

49 Cylinder head, under valve cover 1. 2.

X381 IVECO HARNESS TO FUEL ACTUATOR 6, L-39 (CYL 5)

CONNECTOR X381 IVECO HARNESS TO FUEL ACTUATOR 6, L-39 (CYL 5) CAV

WIRE NUMBER

CIRCUIT REFERENCE

PURPLE

GRAY

TO ECU A-01 CONNECTOR X515 PIN 1 TO ECU A-01 CONNECTOR X515 PIN 16

Connector to fuel actuator (ring terminals) Fuel actuator

1 2

MIDO305A

50 Cylinder head, under valve cover 1. 2.

55-130

Connector to fuel actuator (ring terminals) Fuel actuator

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X382 CHOPPER RPM CAV

WIRE NUMBER

1 2

632 (BL) 413 (YE)

CIRCUIT REFERENCE

CCM-2 REFERENCE GROUND B TO CCM-2 J2-38 DEUTSCH_DT06--2S_PLUG

X382 CHOPPER RPM

CONNECTOR X389 ENGINE HARNESS CAV

WIRE NUMBER

092 (WH)

CIRCUIT REFERENCE

12/24V RELAY PAC_12010996

X389 ENGINE HARNESS

CONNECTOR X396 BLOWER SPEED CONTROL A-14 CAV

WIRE NUMBER

1 2 3 4

X396 BLOWER SPEED CONTROL A-14

CIRCUIT REFERENCE

X397 PIN 5 ATC MODULE A-15 GROUND 3 MAIN BLOWER RELAY HIGH K-13

55-131

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17

PACKARD_12110487

X397 ATC CONTROL MODULE A-15

CONNECTOR X397 ATC CONTROL MODULE A-15 CAV

WIRE NUMBER

907 (BL)

959 (WH)

924 (OR)

911 (BL)

924 (OR)

19 20

X128 C-10 HVAC CONTROL MODULE A-09, COLD BOX DOOR (ATC) M-15, WATER VALVE M-16

WIRE NUMBER

952 (BL)

958 (WH)

951 (BL)

X147 PIN D COLD BOX DOOR (ATC) M-15

918 (YE) X128 D5 HVAC CONTROLMODULE A-09 AUTO SWITCH 960 (WH)

912 (YE) X128 C15 HVAC CONTROL MODULE A-09 BLOWER SELECT

914 (YE) Z128 D1 HVAC CONTROL MODULE A-09 TEMP SELECT -

X128 C-14 HVAC CONTROL MODULE A-09, SIGNAL (GND) FOR CLUTCH RELAY

55-132

GROUND FOR DEG. C

X128 C-10 HVAC CONTROL MODULE A-09, COLD BOX DOOR (ATC) M-15, WATER VALVE M-16

923 (YE) X128 D-10 HVAC CONTROL MODULE A-09 TX TO KEY PAD

X150 PIN 2 EVAPORATOR TEMP SENSOR (ATC) B28

X148 PIN 2 OUTLET TEMP SENSOR (ATC) B-27

954 (BK) GROUND 3

X149 PIN 2 CAB TEMP SENSOR (ATC) B-26

920 (BK) X128 D7 HVAC CONTROL MODULE A-09 DEMIST SWITCH

X128 D-11 HVAC CONTROL MODULE A-09, COLD BOX DOOR (ATC) M-15, WATER VALVE M-16

CIRCUIT REFERENCE

X151 PIN D WATER VALVE M-16

953 (YE) X396 PIN 2 BLOWER SPEED CONTROL A-14

CIRCUIT REFERENCE

CAV

909 (BL)

910 (YE) X128 C-13 HVAC CONTROL MODULE A-09 PRESSURE SWITCH COMMON TO UNIT, X217 PIN A (B) A/C LOW PRESSURE S-48

950 (BL)

910 (YE) X128 C-13 HVAC CONTROL MODULE A-09 PRESSURE SWITCH COMMON TO UNIT, X217 PIN A (B) A/C LOW PRESSURE S-48

X128 C12 HVAC CONTROL MODULE A-09 HIGH PRESSURE SWITCH TO UNIT

X217 PIN B (A) Z/C LOW PRESSURE S-48, X128 D6 HVAC CONTROL MODULE A-09 LOW PRESSURE SWITCH TO UNIT

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17

DEUTSCH_DRC26--50S_PLUG

X414 ECU CONNECTOR B

CONNECTOR X414 ECU CONNECTOR B

CAV

WIRE NUMBER

818

CIRCUIT REFERENCE

55-133

859

X068 PIN 5 KEY SWITCHS-02, X010 PIN 23 (X193 PIN 40 A-01)

822

X211 PIN 2 GRID HEATER RELAY K-39 (X193 PIN 12 A-01) X211 PIN 1 GRID HEATER RELAY K-39 (X193 PIN 75 A-01)

1145

NOT FOUND ON FRAMES

1146

NOT FOUND ON FRAMES

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X415 ECU -- POWER (CUMMINS ECU) CAV

WIRE NUMBER

1 2 3 4

815 816 810 811

CIRCUIT REFERENCE

FRAME GROUND 5 FRAME GROUND 5 B+ F-01 B+ F-01

DEUTSCH_DTP06--4S_PLUG

X415 ECU -POWER (CUMMINS ECU)

CONNECTOR X419 WIF CONNECTOR CAV

1 2

WIRE NUMBER

1131

CIRCUIT REFERENCE

WATER IN FUEL SENSOR DEUTSCH_DT04--2P_RECEPTACLE

X419 WIF CONNECTOR

CONNECTOR X422 CAN 1 TERMINATOR AT ECU (CUMMINS ONLY) CAV

WIRE NUMBER

CIRCUIT REFERENCE

A B C DEUTSCH_DT06--3S_PLUG

X422 CAN 1 TERMINATOR AT ECU (CUMMINS ONLY)

55-134

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X424 WATER IN FUEL SENSOR B-59 CAV

WIRE NUMBER

1131

X193 PIN 42 IVECO ECU A-01 OR X423 PIN 14 CUMMINS ECU A-16

2 3

1291 1290

FRAME GROUND 2 +12V FROM F-45 (K24 SWITCHED)

CIRCUIT REFERENCE

AMP_282191--1

X424 WATER IN FUEL SENSOR B-59

CONNECTOR X439 COOLANT LEVEL S-67 CAV

WIRE NUMBER

A B

850 504

CIRCUIT REFERENCE

X016 J2-14 CCM-2 SENSOR REF. X016 J2-27 CCM-2 SIGNAL PAC_12015792

X439 COOLANT LEVEL S-67

CONNECTOR X444 FAN DRIVE SOLENOID L-44 CAV

WIRE NUMBER

1 2

1161 1192

CIRCUIT REFERENCE

Z019 J2-13 CCM-1 FRAME GROUND 2 DEUTSCH_DT06--2S_PLUG

X444 FAN DRIVE SOLENOID L-44

55-135

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X446 CAN 1 TERMINATOR R-17 CAV

A B C

WIRE NUMBER

144 143

CIRCUIT REFERENCE

CAN 1 LO CAN 1 HI

DEUTSCH_DT04--3P_RECEPTACLE

DEUTSCH_DT06--3S_PLUG

X446 CAN 1 TERMINATOR R-17

CONNECTOR X462 REAR AXLE ANGLE B-70 CAV

WIRE NUMBER

A B C

1735 1719 1732

CIRCUIT REFERENCE

X013 J2-2/X014 J3-11 CCM-3 X013 J2-14 CCM-3 X014 J3-25 CCM-3 DEUTSCH_DT06--3S_PLUG

X462 REAR AXLE ANGLE B-70

CONNECTOR X464 STEERING SENSOR B-69 CAV

WIRE NUMBER

1 2

1720 1739

CIRCUIT REFERENCE

STEERING SENSOR B-69 SIGNAL STEERING SENSOR B-69 REF. DEUTSCH_DT06--2S_PLUG

X464 STEERING SENSOR B-69

55-136

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X469 STRAW WALKER/EXPANSION CAV

WIRE NUMBER

CIRCUIT REFERENCE

1702

X480 PIN E TURNTABLE ACTUATOR M35

2 3

1701 1700

1703

CAN 1 LO CAN 1 HI X480 PIN A TURNTABLE ACTUATOR M-35

1704

X480 PIN B TURNTABLE ACTUATOR M-35

1705

X480 PIN C TURNTABLE ACTUATOR M-35

1706

X480 PIN D TURNTABLE ACTUATOR M-35

1707

FRAME GROUND 4

1708

+12V FROM F-49 (K-26 SWITCHED)

8 9 10 11 12 13 14 15 16 17 18 19

DEUTSCH_HDP24--24--19P_RECEPTACLE

X469 STRAW WALKER/EXPANSION

55-137

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X471 IVECO HARNESS TO INJECTOR HARNESS CAV

WIRE NUMBER

CIRCUIT REFERENCE

WHITE

RED

YELLOW

RED

GREEN

RED

BLUE

GRAY

PURPLE

GRAY

BLACK

GRAY

ECU A-01 CONNECTOR X515 PIN 4 TO FUEL ACTUATOR 1, L-34 (CYL 1) ECU A-01 CONNECTOR X515 PIN 13 TO FUEL ACTUATOR 1, L-34 (CYL 1) ECU A-01 CONNECTOR X515 PIN 11 TO FUEL ACTUATOR 3, L-36 (CYL 2) ECU A-01 CONNECTOR X515 PIN 6 TO FUEL ACTUATOR 3, L-36 (CYL 2) ECU A-01 CONNECTOR X515 PIN 5 TO FUEL ACTUATOR 5, L-38 (CYL 3) ECU A-01 CONNECTOR X515 PIN 12 TO FUEL ACTUATOR 5, L-38 (CYL 3) ECU A-01 CONNECTOR X515 PIN 3 TO FUEL ACTUATOR 2, L-35 (CYL 4) ECU A-01 CONNECTOR X515 PIN 14 TO FUEL ACTUATOR 2, L-35 (CYL 4) ECU A-01 CONNECTOR X515 PIN 1 TO FUEL ACTUATOR 6, L-39 (CYL 5) ECU A-01 CONNECTOR X515 PIN 16 TO FUEL AC T UATOR 6, L-39 (CYL 5) ECU A-01 CONNECTOR X515 PIN 2 TO FUEL ACTUATOR 4, L-37 (CYL 6) ECU A-01 CONNECTOR X515 PIN 15 TO FUEL AC T UATOR 4, L-37 (CYL 6)

VEAM_08-16-12S

X471 IVECO HARNESS TO INJECTOR HARNESS

NOTE: Wire colors are not generally visible due to harness sheathing.

51 Front of cylinder head on engine

55-138

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17

CONNECTOR X472 WASHER MOTOR M-24 CAV

WIRE NUMBER

1 2

449 (BK) 278 (WH)

CIRCUIT REFERENCE

TO FRONT FRAME GROUND 2 POWER FROM WASHER SWITCH S-38 AMP_926522

X472 WASHER MOTOR

CONNECTOR X474 GRID HEATER RELAY K-39 CAV

WIRE NUMBER

840

CIRCUIT REFERENCE

X474 GRID HEATER RELAY K-39

ALTERNATOR G-01

CONNECTOR X476 VALVES CAV

WIRE NUMBER

1729

1728

1727

X013 J2-20 CCM-3, COMMON FOR STEER RIGHT/LEFT SOLENOIDS L57/L58 X013 J2-20 CCM-3, COMMON FOR STEER RIGHT/LEFT SOLENOIDS L57/58 X014 J3-1 CCM-3 SIGNAL STEER LEFT SOLENOID L58

1726

X014 J3-2 CCM-3 SIGNAL STEER RIGHT SOLENOID L57

1758

X014 J3-5 CCM-3 SIGNAL STEER ENABLE SOLENOID L59

1759

FRAME GROUND 2 STEER ENABLE SOLENOID L59

CIRCUIT REFERENCE

DEUTSCH_DT06--6S_PLUG

X476 VALVES

CONNECTOR X483 ALTERNATOR G-01 +12V CAV

WIRE NUMBER

840

CIRCUIT REFERENCE

X474 GRID HEATER RELAY K-39

X483 ALTERNATOR G-01 +12V

55-139

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X484 AUTO GUIDANCE SWITCH S-78 CAV

1 2 3 4 5 6 7 8 9 10

WIRE NUMBER

1745 1747 1744

CIRCUIT REFERENCE

X012 J1-9 CCM-3 SIGNAL +12V FROM F-48 (K-26 SWITCHED) X012 J1-21 CCM-3 SIGNAL EATON_25--13936

1752

X198 PIN M SPLICE BLOCK F W-06

1746

X053 PIN M SPLICE BLOCK A W-01

X484 AUTO GUIDANCE SWITCH S-78

CONNECTOR X485 RCS CAV

WIRE NUMBER

1 2 3 4

1753 1754 1756 1755

CIRCUIT REFERENCE

X014 J3-24 CCM-3 X014 J3-22 CCM-3 X014 J3-26 CCM-3 X013 J2-14 CCM-3

DEUTSCH_DT06--6S_PLUG

X485 VALVES CONNECTOR X487 EXPANSION C CAV

WIRE NUMBER

1705

1718

1703

TURNTABLE ACTUATOR M-35 AND STEERING WHEEL POSITION B-69 TO X013 J2-14 CCM-3 TURNTABLE ACTUATOR M-35 TO X014 J3-26 CCM-3

1739

STEERING WHEEL POSITION B-69 TO X013 J2-36 CCM-3

1702

TURNTABLE ACTUATOR M-35 TO X014 J3-39 CCM-3

1706

TURNTABLE ACTUATOR M-35 TO X014 J3-19 CCM-3

CIRCUIT REFERENCE

TURNTABLE ACTUATOR M-35 TO X013 J2-29 CCM-3

DEUTSCH_DT06--8S_PLUG

7 8

DEUTSCH_DT04--8P_RECEPTACLE

X487 EXPANSION C

55-140

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X498 DGPS HARNESS CAV

WIRE NUMBER

A B C D

1203 1206 1229 1228

1212

+12V FROM F-48 (K-26 SWITCHED) FRAME GROUND FROM X506 PIN B CAN 2 HI CAN 2 LO X496 PIN 33 CERES MOD. A-2 TX TO X502 PIN 10 DISPLAY A-02 RX

1211

X496 PIN 4 CERES MOD. A-24 RX TO X502 PIN 9 DISPLAY A-02 TX

G H J K

1217 1218

CIRCUIT REFERENCE

PACKARD_12064769

X498 DGPS HARNESS

CAN 1 HI CAN 1 LO

CONNECTOR X500 CAN 2 TERMINATOR R-26 CAV

A B C

WIRE NUMBER

1256 1257

CIRCUIT REFERENCE

CAN 1 LO CAN 1 HI

DEUTSCH_DT04--3P_RECEPTACLE

DEUTSCH_DT06--3S_PLUG

X500 CAN 2 TERMINATOR R-26

55-141

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X502 DISPLAY A-02 CAV

WIRE NUMBER

1 2

1171 1172

1287

CAN 1 HI CAN 1 LO X503 PIN 2 ROTARY ENCODER SWITCH S79

1289

X503 PIN 6 ROTARY ENCODER SWITCH S-79

5 6 7 8 9 10 11 12 13 14 15 16

1227 1226

CAN 2 HI CAN 2 LO

CIRCUIT REFERENCE

1211 1212

X496 PIN 4 CERES MOD. A-24 X496 PIN 33 CERES MOD. A-24

1276 1213 1209

B+ FROM F-39 FRAME GROUND FROM X506 PIN B +12V FROM F-48 (K-26 SWITCHED)

1281

DISPLAY HOME SWITCH S-80 SIGNAL

1282

DISPLAY ESCAPE SWITCH S-81 SIGNAL

1283

X503 PIN 4 ROTARY ENCODER SWITCH S-79

1288

X503 PIN 1 ROTARY ENCODER SWITCH S-79

21 22

USB 5V USB DATA +

USB DATA --

USB GND

AMP_2--1437285--3

X502 DISPLAY A-02

25 26

55-142

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X503 ROTARY ENCODER S-79 CAV

WIRE NUMBER

CIRCUIT REFERENCE

1 2 3 4 5 6

1288 1287 1295 1283 1294 1289

X502 PIN 20 DISPLAY A-02 X502 PIN 3 DISPLAY A-02 FRAME GROUND FROM X506 PIN B X502 PIN 19 DISPLAY A-02 FRAME GROUND FROM X506 PIN B X502 PIN 4 DISPLAY A-02

AMP_344266--1

X503 ROTARY ENCODER S-79

CONNECTOR X504 DISPLAY HOME SWITCH S-80 CAV

WIRE NUMBER

CIRCUIT REFERENCE

1 2

1281 1292

X502 PIN 17 DISPLAY A-02 FRAME GROUND FROM X506 PIN B

AMP_174057--2

X504 DISPLAY HOME SWITCH S-80

CONNECTOR X505 DISPLAY ESCAPE SWITCH S-81 CAV

WIRE NUMBER

CIRCUIT REFERENCE

1 2

1282 1293

X502 PIN 18 DISPLAY A-02 FRAME GROUND FROM X506 PIN B

AMP_174057--2

X505 DISPLAY ESCAPE SWITCH S-81

55-143

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X506 DISPLAY HARNESS CAV

A B C D E F G H

WIRE NUMBER

CIRCUIT REFERENCE

1258 1277 1225 1224 1297 1296 1276

+12V FROM F-48 (K-26 SWITCHED) FRAME GROUND FROM X053 PIN B CAN 2 HI CAN 2 LO CAN 1 HI CAN 1 LO B+ FROM F-39

PACKARD_12064767

X506 DISPLAY HARNESS

CONNECTOR X509 USB PORT CAV

WIRE NUMBER

1 2 3 4

CIRCUIT REFERENCE

USB 5V USB DATA -USB DATA + USB GND.

USB_Standard_A

X509 USB PORT

CONNECTOR X513 PSD RPM CAV

WIRE NUMBER

1 2

1021 532

CIRCUIT REFERENCE

(NOT ON FRAMES) X024 PIN 23 (NOT ON FRAMES) X024 PIN 22 DEUTSCH_DT06--2S_PLUG

X513 PSD RPM

55-144

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X515 IVECO HARNESS; ECU TO INJECTORS CAV

WIRE NUMBER

CIRCUIT REFERENCE

1 2 3 4 5 6 7 TO 10 11 12 13 14 15 16

PURPLE BLACK BLUE WHITE GREEN RED OPEN

TO FUEL ACTUATOR 6, L-39 (CYL 5) TO FUEL ACTUATOR 4, L-37 (CYL 6) TO FUEL ACTUATOR 2, L-35 (CYL 4) TO FUEL ACTUATOR 1, L-34 (CYL 1) TO FUEL ACTUATOR 5, L-38 (CYL 3) TO FUEL ACTUATOR 3, L-36 (CYL 2) NOTUSED

YELLOW RED RED GRAY GRAY GRAY

TO FUEL ACTUATOR 3, L-36 (CYL 2) TO FUEL ACTUATOR 5, L-38 (CYL 3) TO FUEL ACTUATOR 1, L-34 (CYL 1) TO FUEL ACTUATOR 2, L-35 (CYL 4) TO FUEL ACTUATOR 4, L-37 (CYL 6) TO FUEL ACTUATOR 6, L-39 (CYL 5)

BSCH_1928402400

X515 IVECO HARNESS; ECU TO INJECTORS

NOTE: Wire colors are not generally visible due to harness sheathing.

1 2

83063848

52 ECU, Rear of Engine

55-145

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X516 IVECO HARNESS; ECU TO SENSORS CAV

WIRE NUMBER

1 TO 8 9 10 11 TO 14 15

OPEN

NOT USED

WHITE RED OPEN

ENGINE CAMSHAF T RPM B-07 ENGINE CAMSHAF T RPM B-07 NOT USED

16 TO 17 18 19 20 TO 22 23 24

PINK OPEN

FUEL TEMPERATURE SENSOR B-36

WHITE BROWN

ENGINE FLYWHEEL RPM B-05 OIL TEMPERATURE/PRESSURE SENSOR B-75 (COMMON) BOOST TEMPERATURE/PRESSURE SENSOR B-41 (COMMON) COOLANT TEMPERATURE SENSOR B-44 (COMMON) OIL TEMPERATURE/PRESSURE SENSOR B-75 (PRESSURE SIGNAL) OIL TEMPERATURE/PRESSURE SENSOR B-75 (TEMPERATURE SIGNAL) NOT USED

WHITE

YELLOW

ORANGE/ BLACK BLUE

29 TO 31 32

ORANGE

RED

OPEN

GREEN

WHITE/ RED ORANGE

COOLANT TEMPERATURE SENSOR B-44 NOTUSED

ORANGE/ BLACK BLACK OPEN

CIRCUIT REFERENCE

BSCH_1928404202

X516 IVECO HARNESS; ECU TO SENSORS

ENGINE FLYWHEEL RPM B-05 NOT USED

1 2

83063848

OIL TEMPERATURE/PRESSURE SENSOR B-75 (+5 VOLTS) BOOST TEMPERATURE/PRESSURE SENSOR B-41 (+5 VOLTS) BOOST TEMPERATURE/PRESSURE SENSOR B-41 (PRESSURE SIGNAL) FUEL TEMPERATURE SENSOR B-36

53 ECU, Rear of Engine 1. 2. 3.

BOOST TEMPERATURE/PRESSURE SENSOR B-413 (TEMPERATURE SIGNAL)

NOTE: Wire colors are not generally visible due to harness sheathing.

55-146

Connector X516 Connector X515 Connector X193

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X517 IVECO HARNESS TO ENGINE OIL TEMPERATURE/PRESSURE SENSOR B-75 CAV

WIRE NUMBER

CIRCUIT REFERENCE

WHITE

ORANGE

RED

GREEN

TO ECU A-01 CONNECTOR X516 PIN 24 (COMMON) TO ECU A-01 CONNECTOR X516 PIN 28 (TEMPERATURE SIGNAL) FROM ECU A-01 CONNECTOR X516 PIN 32 (+5 VOLTS) TO ECU A-01 CONNECTOR X516 PIN 27 (PRESSURE SIGNAL)

NOTE: Wire colors are not generally visible due to harness sheathing. BSCH_1928403736

X517 IVECO HARNESS TO ENGINE OIL TEMPERATURE/PRESSURE SENSOR B-75

2 1

83063850

54 Front side of engine 1. 2.

55-147

Engine Oil Temperature/Pressure Sensor B-75 Connector X517

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X518 IVECO HARNESS TO ENGINE CAMSHAFT RPM B-07 CAV

WIRE NUMBER

CIRCUIT REFERENCE

RED

WHITE

TO ECU A-01 CONNECTOR X516 PIN 10 TO ECU A-01 CONNECTOR X516 PIN 9

NOTE: Wire colors are not generally visible due to harness sheathing.

BSCH_1928403874

X518 IVECO HARNESS TO ENGINE CAMSHAFT RPM B-07

1 2

83063853

55 Front of Engine 1. 2.

55-148

Engine Camshaft RPM B-07 Connector X518

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17 CONNECTOR X519 IVECO HARNESS TO ENGINE FLYWHEEL RPM B-05 CAV

WIRE NUMBER

CIRCUIT REFERENCE

WHITE

BLACK

TO ECU A-01 CONNECTOR X516 PIN 23 TO ECU A-01 CONNECTOR X516 PIN 19

NOTE: Wire colors are not generally visible due to harness sheathing.

BSCH_1928403874

X519 IVECO HARNESS TO ENGINE FLYWHEEL RPM B-05

83063854

56 Rear of Engine 1. 2.

55-149

Engine Flywheel RPM B-05 Connector X519

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 17

55-150

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 18 -- CCM1 Error Codes CONTENTS Section

Description

Page

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

55-1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 Section

Description

Page

55-2

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0000-03 Stone Trap Closed Sensor Shorted To High Source Cause: The stone trap closed sensor (B24) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage for sensor when blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage for sensor when not blocked by ferrous metal -- 0.5 to 5.6 volts. The proper voltage sensor when disconnected -- 7.3 to 9.0 volts. A. If the voltage reading is high out of range (9.0 to 10.0 volts), continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading is high. Disconnect the stone trap closed sensor connector X083. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains high, continue with Step 3. 3. The voltage reading is high. Disconnect the feeder (FE) harness and front frame (FF) harness at connector X007. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the feeder (FE) harness between connector X007 and connector X083 wire 743 yellow. Locate the short and repair. B. If the voltage remains high, the short circuit is in the front frame (FF) harness between connector X007 and connector X020 pin J3-28 wire 743 yellow. Locate the short and repair. 4. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state. Adjust the sensor clearance to 3 mm (1/8″). Erase the fault code and continue operation.

55-3

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0000-04 Stone Trap Closed Sensor Shorted To Low Source Cause: The stone trap closed sensor (B24) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts. The proper voltage sensor when disconnected -- 7.3 to 9.0 volts. A. If the voltage reading is low (0 to 0.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading is low. Disconnect the stone trap closed sensor connector X083. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low, continue with Step 3. 3. The voltage reading is low. Disconnect the feeder (FE) harness from the front frame (FF) harness at connector X007. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the feeder (FE) harness between connector X007 and connector X083 wire 743 yellow. Locate the short and repair. B. If the voltage remains low, the short circuit is in the front frame (FF) harness between connector X007 and connector X020 pin J3-28 wire 743 yellow. Locate the short and repair. 4. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state. Adjust the sensor clearance to 3 mm (1/8″). Erase the fault code and continue operation.

55-4

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0000-05 Stone Trap Closed Sensor Line Disconnected Cause: The stone trap closed sensor (B24) circuit has an open. Possible failure modes: 1. Sensor supply wiring has an open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts. The proper voltage sensor when disconnected -- 7.3 to 9.0 volts. A. If the voltage reading is high (7.3 to 9.0 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 6. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. 2. The voltage reading is 7.3 to 9.0 volts. Disconnect the stone trap closed sensor connector X083. Use a jumper wire to short pin 2 on the harness end of connector X083 to ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply side of the circuit. Continue with step 4. B. If the display monitor still displays 7.3 to 9.0 volts, continue with Step 3. 3. The voltage reading is 7.3 to 9.0 volts. Disconnect the feeder (FE) harness from the front frame (FF) harness at connector X007. Use a jumper wire to short pin 11 on connector X007 to ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the feeder (FE) harness between connector X007 and the connector X083 pin 2, wire 743 yellow. Locate the open and repair. B. If the display monitor still displays 7.3 to 9.0 volts, the open circuit is in the front frame (FF) harness between connector X007 and connector X020 pin J3-28 wire 743 yellow. Locate the open and repair. 4. Disconnect the stone trap closed sensor connector X083. Use a multimeter to check for continuity between the harness end of connector X083 pin A and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity, continue with Step 5. 5. Disconnect the feeder (FE) harness from the front frame (FF) harness at connector X007. Use a multimeter to check for continuity between the front frame (FF) harness end of connector X007 pin 12 and chassis ground. A. If there is continuity, the open circuit is in the feeder (FE) harness between connector X007 and the connector X083 pin 1, wire 754 blue or 749 blue. Locate the open and repair. B. If there is no continuity, the open circuit is in the front frame (FF) harness between connector X007 and connector X020 pin J3-18 wire 749 blue or 501 blue. Locate the open and repair. 6. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state. Adjust the sensor clearance to 3 mm (1/8″). Erase the fault code and continue operation.

55-5

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

3 1

40024707

50031009 50020085

1 1. STONE TRAP CLOSED SENSOR B24 2. CONNECTOR X083

3. CONNECTOR X007 4. CONNECTOR X020

55-6

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FEEDER FRAME--16

B-09 = REVERSER DISENGAGE B-14 = FEEDER RPM B-24 = STONE DOOR CLOSED F-24 = FAN, REVERSER FUSE

K-17 = FAN/REVERSER RELAY K-19 = NOT USED L-20 = FEEDER JOG FORWARD L-21 = FEEDER JOG REVERSE

55-7

L-24 = FEEDER CLUTCH M-05 = CLEANING FAN ADJUST MOTOR (EU) M-10 = FEEDER REVERSER ACTUATOR S-31 = FEEDER ENGAGE

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-8

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0001-03 Bin Covers Open Sensor Shorted To High Source Cause: The bin covers open sensor (B47) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage for covers open -- 5.6 to 7.3 volts. The proper voltage for covers closed -- 0.5 to 5.6 volts. A. If the voltage reading is high out of range, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 5. 2. The voltage reading is high. Disconnect the covers closed proximity sensor connector X288 in the grain bin. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains high, continue with Step 3. 3. The voltage reading is high. Disconnect the connector X195 behind the grain bin. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the jumper (JP) harness between connector X195 and connector X288 wire 435 yellow. Locate the short and repair. B. If the voltage remains high, continue with Step 4. 4. The voltage reading is high. Disconnect the main frame (MF) harness from the front frame (FF) harness at connector X008. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the main frame (MF) harness between connector X008 and connector X195 wire 435 yellow. Locate the short and repair. B. If the voltage remains high, the short circuit is in the front frame (FF) harness between connector X008 and connector X020 J3-38 on CCM1 wire 435 yellow. Locate the short and repair. 5. Operate the grain bin doors in both directions and monitor the voltage readings. A. If high voltage reading is viewed, continue with Step 2 while operating grain bin doors. B. If a high voltage reading cannot be generated, erase the fault code and continue operation.

55-9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0001-04 Bin Covers Open Sensor Shorted To low Source Cause: The bin covers open sensor (B47) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage for covers open -- 5.6 to 7.3 volts. The proper voltage for covers closed -- 0.5 to 5.6 volts. A. If the voltage reading is low (0 to 0.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 5. 2. The voltage reading is low. Disconnect the covers closed proximity sensor connector X288 in the grain bin. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low, continue with Step 3. 3. The voltage reading is low. Disconnect the connector X195. A. If the voltage increases to 7.3 to 9.0 volts, the short to ground is in the jumper (JP) harness between connector X195 and connector X288 wire 435 yellow. Locate the short and repair. B. If the voltage remains low, continue with Step 3. 4. The voltage reading is low. Disconnect the connector X008. A. If the voltage increases to 7.3 to 9.0 volts, the short to ground is in the main frame (MF) harness between connector X008 and connector X195 wire 435 yellow. Locate the short and repair. B. If the voltage remains low, the short to ground is in the front frame (FF) harness between connector X008 and connector X020 J3-38 on CCM1 wire 435 yellow. Locate the short and repair. 5. If a 0 to 0.5 voltage reading is not shown, erase the fault code and continue operation.

55-10

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0001-05 Bin Covers Open Sensor Line Disconnected Cause: The bin covers open sensor (B47) has an open circuit. Possible failure modes: 1. Sensor supply wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage for covers open -- 5.6 to 7.3 volts. The proper voltage for covers closed -- 0.5 to 5.6 volts. If there is an open in the supply, the voltage will read 7.3 to 9.0 volts. A. If the voltage reading is high indicating an open, continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 7. 2. The voltage reading is 7.3 to 9.0 volts. Disconnect the covers closed proximity sensor connector X288 in the grain bin. Install a jumper wire between pins 1 and 2 on connector X288. A. If the voltage drops to 0 to 0.5 volts, the open is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains at 7.3 to 9.0 volts, continue with Step 3. 3. The voltage reading is 7.3 to 9.0 volts. Check for continuity between pin 1 on the bin covers (BC) harness side of connector X288 and chassis ground. A. If no continuity is found, continue with Step 4. B. If continuity is found, continue with Step 5. 4. Disconnect connector X195. Check for continuity between pin 2 on the main frame (MF) harness side of connector X195 and chassis ground. A. If continuity is found, the open is between connector X195 and X288 wire 454 blue. Locate open and repair. B. If no continuity is found, the open is n the main frame (MF) harness between connector X195 and connector X019 pin J2-14 CCM1, wires 454, or 460 blue. Locate open and repair. 5. The voltage reading is 7.3 to 9.0 volts. Disconnect the connector X195. Install a jumper wire between pins 1 and 2 on connector X195. A. If the voltage drops to 0 to 0.5 volts, the open is between connector X195 and X288 on wire 435 yellow. Locate and repair the open. B. If the voltage remains at 7.3 to 9.0 volts, continue with Step 6. 6. The voltage reading is 7.3 to 9.0 volts. Disconnect the connector X008. Install a jumper wire between pin 27 on connector X008 and chassis ground. A. If the voltage drops to 0 to 0.5 volts, the open is in the main frame (MF) harness between connector X008 and X195 wire 435 yellow. Locate and repair the open. B. If the voltage remains at 7.3 to 9.0 volts, the open is in the front frame (FF) harness between connector X008 and connector X020 J3-38 wire 435 yellow. Locate and repair the open. 7. Visually inspect harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. If no damage is found, erase fault code and continue operation.

55-11

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

1 10004683

4 5

10020075

50020082

2 1. BIN COVERS SENSOR B47 2. CONNECTOR X195 3. CONNECTOR X008

4. CONNECTOR X019 5. CONNECTOR X020

55-12

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

UNLOAD FRAME--22

B-38 = UNLOAD CRADLE B-47 = COVERS CLOSED L-03 = UNLOAD TUBE IN L-04 = UNLOAD TUBE OUT

L-08 = UNLOAD TUBE CLUTCH S-28 = GRAIN BIN 3/4 FULL S-29 = GRAIN BIN FULL S-42 = TANK COVERS SWITCH

55-13

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-14

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0003-03 Unload Tube Cradled Shorted To High Source Cause: The unload tube cradled sensor (B38) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage for sensor when blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage for sensor when not blocked by ferrous metal -- 0.5 to 5.6 volts. The proper voltage sensor when disconnected -- 7.3 to 9.0 volts. A. If the voltage reading is high out of range (9.0 to 10.0 volts), continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at step 6. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading is high. Disconnect the unload tube cradled sensor connector X244. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains high, continue with Step 3. 3. The voltage reading is high. Disconnect the straw hood (SH) harness and straw hood front (SW) harness at connector X071. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the straw hood (SH) harness between connector X071 and connector X244 wire 485 yellow. Locate the short and repair. B. If the voltage remains high, continue with Step 4. 4. The voltage reading is high. Disconnect the straw hood front (SW) harness and main frame (MF) harness at connector X024. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the straw hood front (SW) harness between connector X071 and connector X024 wire 485 yellow. Locate the short and repair. B. If the voltage remains high, continue with Step 5. 5. The voltage reading is high. Disconnect the main frame (MF) harness and front frame (FF) harness at connector X008. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the main frame (MF) harness between connector X008 and connector X024 wire 485 yellow. Locate the short and repair. B. If the voltage remains high, the short circuit is in the front frame (FF) harness between connector X008 and connector X020 pin J3-36 wire 485 yellow. Locate the short and repair. 6. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state. Adjust the sensor clearance to 3 mm (1/8″). Erase the fault code and continue operation.

55-15

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0003-04 Unload Tube Cradled Shorted To Low Source Cause: The unload tube cradled sensor (B38) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts. The proper voltage sensor when disconnected -- 7.3 to 9.0 volts. A. If the voltage reading is low (0 to 0.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 6. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading is low. Disconnect the unload tube cradled sensor connector X244. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor B. If the voltage remains low, continue with Step 3. 3. The voltage reading is low. Disconnect the straw hood (SH) harness from the straw hood front (SW) harness at connector X071. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the straw hood (SH) harness between connector X071 and connector X244 wire 485 yellow. Locate the short and repair. B. If the voltage remains low, continue with Step 4. 4. The voltage reading is low. Disconnect the straw hood front (SW) harness from the main frame (MF) harness at connector X024. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the straw hood front (SW) harness between connector X071 and connector X024 wire 485 yellow. Locate the short and repair. B. If the voltage remains low, continue with Step 5. 5. The voltage reading is low. Disconnect the main frame (MF) harness from the front frame (FF) harness at connector X008. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the main frame (MF) harness between connector X024 and connector X008 wire 485 yellow. Locate the short and repair. B. If the voltage remains low, the short circuit is in the front frame (FF) harness between connector X008 and connector X020 pin J3-36 wire 485 yellow. Locate the short and repair. 6. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state. Adjust the sensor clearance to 3 mm (1/8″). Erase the fault code and continue operation.

55-16

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0003-05 Unload Tube Cradled Line Disconnected Cause: The unload tube cradled sensor (B38) circuit has an open. Possible failure modes: 1. Sensor supply wiring has an open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts. The proper voltage sensor when disconnected -- 7.3 to 9.0 volts. A. If the voltage reading is high (7.3 to 9.0 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 10. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. 2. The voltage reading is 7.3 to 9.0 volts. Disconnect the unload tube cradled sensor connector X244. Use a jumper wire to short pin B on the harness end of connector X244 to ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply side of the circuit. Continue with step 6. B. If the display monitor still displays 7.3 to 9.0 volts, continue with Step 3. 3. The voltage reading is 7.3 to 9.0 volts. Disconnect the straw hood (SH) harness from the straw hood front (SW) harness at connector X071. Use a jumper wire to short pin 31 on connector X071 to ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the straw hood (SH) harness between connector X071 and the connector X244 pin B, wire 485 yellow. Locate the open and repair. B. If the display monitor still displays 7.3 to 9.0 volts, continue with Step 4. 4. The voltage reading is 7.3 to 9.0 volts. Disconnect the straw hood front (SW) harness from the main frame (MF) harness at connector X024. Use a jumper wire to short pin 14 on connector X024 to ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the straw hood front (SW) harness between connector X071 and the connector X024 wire 485 yellow. Locate the open and repair. B. If the display monitor still displays 7.3 to 9.0 volts, continue with Step 5. 5. The voltage reading is 7.3 to 9.0 volts. Disconnect the main frame (MF) harness from the front frame (FF) harness at connector X008. Use a jumper wire to short pin 8 on connector X008 to ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the main frame (MF) harness between connector X008 and the connector X024 wire 485 yellow. Locate the open and repair. B. If the display monitor still displays 7.3 to 9.0 volts, the open circuit is in the front frame (FF) harness between connector X008 and connector X020 pin J3-36 wire 485 yellow. Locate the open and repair.

55-17

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 6. Disconnect the unload tube cradled sensor connector X244. Use a multimeter to check for continuity between the harness end of connector X244 pin 1 and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity, continue with Step 7. 7. Disconnect the straw hood (SH) harness from the straw hood front (SW) harness at connector X071. Use a multimeter to check for continuity between the straw hood front (SW) harness end of connector X071 pin 30 and chassis ground. A. If there is continuity, the open circuit is in the straw hood (SH) harness between connector X071 and the connector X244 pin 1, wire 444 blue. Locate the open and repair. B. If there is no continuity, continue with Step 8. 8. Disconnect the straw hood front (SW) harness from the main frame (MF) harness at connector X024. Use a multimeter to check for continuity between the main frame (MF) harness end of connector X024 pin 11 and chassis ground. A. If there is continuity, the open circuit is in the straw hood front (SW) harness between connector X071 and the connector X024 wire 444 blue or 461 blue. Locate the open and repair. B. If there is no continuity, continue with Step 9. 9. Disconnect the main frame (MF) harness from the front frame (FF) harness at connector X008. Use a multimeter to check for continuity between the front frame (FF) harness end of connector X008 pin 7 and chassis ground. A. If there is continuity, the open circuit is in the main frame (MF) harness between connector X008 and the connector X024 wire 461 blue or 401 blue. Locate the open and repair. B. If there is no continuity, the open circuit is in the front frame (FF) harness between connector X008 and connector X020 pin J3-18 wire 401 blue or 501 blue. Locate the open and repair. 10. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state. Adjust the sensor clearance to 3 mm (1/8″). Erase the fault code and continue operation.

55-18

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

40024709

50026220

10020075

10020076

50020084

3 1. UNLOAD TUBE CRADLED SENSOR B38 2. CONNECTOR X071 3. CONNECTOR X024

55-19

4. CONNECTOR X008 5. CONNECTOR X020

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

UNLOAD FRAME--22

B-38 = UNLOAD CRADLE B-47 = COVERS CLOSED L-03 = UNLOAD TUBE IN L-04 = UNLOAD TUBE OUT

L-08 = UNLOAD TUBE CLUTCH S-28 = GRAIN BIN 3/4 FULL S-29 = GRAIN BIN FULL S-42 = TANK COVERS SWITCH

55-20

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0004-03 Fdr Reverser Disengaged Shorted To High Source Cause: The feeder reverser disengaged sensor (B09) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage with feeder reverser disengaged -- 5.6 to 7.3 volts. The proper voltage with feeder reverser engaged -- 0.5 to 5.6 volts. A. If the voltage reading is high out of range, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. 2. The voltage reading is high. Disconnect the feeder reverser disengaged proximity sensor connector X079. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains high, continue with Step 3. 3. The voltage reading is high. Disconnect the feeder (FE) harness from the front frame (FF) harness at connector X007. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the feeder (FE) harness between connector X007 and connector X079 wire 733 yellow. Locate the short and repair. B. If the voltage remains high, the short circuit is in the front frame (FF) harness between connector X007 and connector X020 J3-27 on CCM1 wire 733 yellow. Locate the short and repair. 4. Operate the feeder reverser function and monitor the voltage readings. A. If high voltage reading is now viewed, go back to Step 2. B. If a high voltage reading cannot be generated, erase the fault code and continue operation.

55-22

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0004-04 Fdr Reverser Disengaged Shorted To Low Source Cause: The feeder reverser disengaged sensor (B09) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage with feeder reverser disengaged -- 5.6 to 7.3 volts. The proper voltage with feeder reverser engaged- 0.5 to 5.6 volts. A. If the voltage reading is low (0 to 0.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 4. 2. The voltage reading is low. Disconnect the feeder reverser disengaged proximity sensor connector X079. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low, continue with Step 3. 3. The voltage reading is low. Disconnect the feeder (FE) harness from the lower frame (LF) harness at connector X007. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the feeder (FE) harness between connector X007 and connector X079 wire 733 yellow. Locate the short and repair. B. If the voltage remains low, the short circuit is in the front frame (FF) harness between connector X007 and connector X020 J3-27 on CCM1 wire 733 yellow. Locate the short and repair. 4. Operate the feeder reverser function and monitor the voltage readings. A. If low voltage reading (0 to 0.5 volts) is now viewed, go back to Step 2. B. If a low voltage reading cannot be generated, erase the fault code and continue operation.

55-23

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0004-05 Fdr Reverser Disengaged Line Disconnected Cause: The feeder reverser disengaged sensor (B09) has an open circuit. Possible failure modes: 1. Sensor supply wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage with feeder reverser disengaged -- 5.6 to 7.3 volts. The proper voltage with feeder reverser engaged- 0.5 to 5.6 volts. If there is an open in the supply, the voltage will read 7.3 to 9.0 volts. A. If the voltage reading is high indicating an open, continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 6. 2. The voltage reading is 7.3 to 9.0 volts. Disconnect the feeder reverser disengaged sensor connector X079. Install a jumper wire between pins 1 and 2 on connector X079. A. If the voltage drops to 0 to 0.5 volts, the open is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains 7.3 to 9.0 volts, continue with Step 3. 3. The voltage reading is 7.3 to 9.0 volts. Remove the jumper wire from connector X079. Check for continuity between pin 1 on connector X079 and chassis ground. A. If no continuity is found, continue with Step 4. B. If continuity is found, continue with Step 5. 4. Use a multimeter to check for continuity between pin 12 on connector X007 and chassis ground. A. If no continuity is found, there is an open in the front frame (FF) harness between connectors X007 and connector X020 J3-18 wire 749 or 501 blue. Locate and repair the open circuit. B. If continuity is found, the open is in the feeder (FE) harness between connector X007 and X079 wire 749 or 777 blue. Locate open and repair. 5. The voltage reading is 7.3 to 9.0 volts. Disconnect the connector X007. Install a jumper wire between pin 10 and chassis ground. A. If the voltage drops to 0 to 0.5 volts, the open is in the feeder (FE) harness between connector X007 and X079 wire 733 yellow. Locate and repair the open. B. If the voltage remains at 7.3 to 9.0 volts, the open is in the front frame (FF) harness between connector X007 and connector X020 J3-27 wire 733 yellow. Locate and repair the open. 6. Visually inspect harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. If no damage is found, erase fault code and continue operation.

55-24

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

2 1

40024707

20021064

50020085

4 1. FEEDER REVERSER DISENGAGE SENSOR B09 2. CONNECTOR X007 3. CONNECTOR X020

55-25

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FEEDER FRAME--16

B-09 = REVERSER DISENGAGE B-14 = FEEDER RPM B-24 = STONE DOOR CLOSED F-24 = FAN, REVERSER FUSE

K-17 = FAN/REVERSER RELAY K-19 = NOT USED L-20 = FEEDER JOG FORWARD L-21 = FEEDER JOG REVERSE

55-26

L-24 = FEEDER CLUTCH M-05 = CLEANING FAN ADJUST MOTOR (EU) M-10 = FEEDER REVERSER ACTUATOR S-31 = FEEDER ENGAGE

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-27

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0006-03 Return Filter Bypass Shorted To High Source Cause: The return filter bypass pressure switch (S32) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The normal operating range for the return filter bypass is 1.8 to 10.0 volts. A. If the voltage reading is 10.0 volts or greater, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. 2. The voltage reading is above 10.0 volts. Disconnect the return filter bypass pressure switch connector X239. A. If the voltage drops below 10 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage is above 10.0 volts, continue with Step 3. 3. The voltage reading is above 10.0 volts. Disconnect the straw hood front (SW) harness from the main frame (MF) harness at connector X024. A. If the voltage drops back within range, the short is in the straw hood front (SW) harness between connector X024 and connector X239 wire 447 yellow. Locate the short circuit and repair. B. If the voltage remains above 10.0 volts, the short is in the main frame (MF) harness between connector X024 and connector X019 pin J2-34 wire 447 yellow. Locate the short and repair. 4. Erase fault code and continue operation.

55-28

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

3 1

40020080

10020076

50020086

5 1. RETURN FILTER BYPASS SWITCH S32 2. CONNECTOR X024 3. CONNECTOR X019

55-29

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

HYDRAULIC FRAME--10

B-18 = HYD OIL RESERVOIR TEMP B-32 = GEARBOX TEMPERATURE B-35 = LOW CONTROL PRESSURE S-17 = ROTOR SPEED

S-18 = FEEDER SPEED S-32 = RETURNS FILTER BYPASS S-33 = HYDRAULIC RESERVOIR LEVEL S-34 = GEARBOX FILTER BYPASS

55-30

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0007-03 Gearbox Filter Bypass Shorted To High Source Cause: The gearbox filter bypass switch (S34) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The normal operating range for the gearbox filter bypass is 1.8 to 10.0 volts. A. If the voltage reading is 10.0 volts or greater, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. 2. The voltage reading is above 10.0 volts. Disconnect the gearbox filter bypass pressure switch connector X238. A. If the voltage drops below 10.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage is above 10.0 volts, continue with Step 3. 3. The voltage reading is above 10 volts. Disconnect the straw hood front (SW) harness from the main frame (MF) harness at connector X024. A. If the voltage drops below 10.0 volts, the short is in the straw hood front (SW) harness between connector X024 and connector X238 wire 448 yellow. Locate the short circuit and repair. B. If the voltage remains above 10.0 volts, the short is in the main frame (MF) harness between connector X024 and connector X019 pin J2-35 wire 448 yellow. Locate the short and repair. 4. Erase fault code and continue operation.

55-31

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

40020080

10020076

50020086

6 1. GEARBOX FILTER BYPASS SWITCH S34 2. CONNECTOR X024

55-32

3. CONNECTOR X019

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

HYDRAULIC FRAME--10

B-18 = HYD OIL RESERVOIR TEMP B-32 = GEARBOX TEMPERATURE B-35 = LOW CONTROL PRESSURE S-17 = ROTOR SPEED

S-18 = FEEDER SPEED S-32 = RETURNS FILTER BYPASS S-33 = HYDRAULIC RESERVOIR LEVEL S-34 = GEARBOX FILTER BYPASS

55-33

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0008-04 Left Turn Signal Shorted To Low Source Cause: The left turn signal switch (S26) circuit is shorted to ground. Possible failure modes: 1. Switch or CCM1 supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The normal operating range for the left turn signal switch -- ON is 4.0 to 5.0 volts. The normal operating range for the left turn signal switch -- OFF is 0.25 to 4.0 volts. NOTE: Check fuse 38. If a short to ground occurred on this circuit the fuse will have blown. A. If the voltage reading is 0 to 0.25 volts in either switch position, continue with Step 2. B. If the voltage reading is 0.25 to 4.0 volts with the switch OFF and 0 to 0.25 with the switch ON, continue with Step 3. 2. The voltage reading remains near zero. The short to ground is somewhere between the switch and CCM1. Disconnect the cab main (CM) harness from the steering column (SC) harness at connector X033. A. If the voltage increases to 0.25 to 4.0 volts, the short is in the electronic flasher, or steering column (SC) harness wire 197 purple. Replace the electronic flasher before attempting to repair the steering column (SC) harness. Erase fault code and operate system. B. If the voltage remains low, the short is somewhere in the cab main (CM) harness between connector X033, connector X018 and the road light switch connector X256 wires 197,198 or 202 purple. Locate the short and repair. 3. The voltage reading is 0.25 to 4.0 volts with the switch OFF and 0 to 0.25 with the switch ON. The short to ground is between the fuse and switch. A. The short is in the cab main (CM) harness wire 055 orange. Visually inspect the cab main (CM) harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair.

55-34

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

1 2

5 4 3

10010914

10004693

50020087

7 1. ROAD LIGHT SWITCH S26 2. FLASHER MODULE A05 3. CONNECTOR X033

4. CONNECTOR X256 5. CONNECTOR X018

3. CONNECTOR X033

55-35

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-36

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

LIGHTING FRAME--36

A-05 = FLASHER MODULE E-13 = LH ROAD LIGHT E-14 = RH ROAD LIGHT F-32 = HIGH BEAM FUSE

F-33 = LOW BEAM FUSE F-51 = HORN, MARKER LTS FUSE H-02 = HORN K-02 = LIGHT CONTROL RELAY

55-37

K-04 = HIGH BEAM RELAY K-05 = LOW BEAM RELAY S-26 = ROAD LIGHT SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0009-04 Front Work Lights Switch Shorted To Low Source Cause: The front work lights switch (S43) circuit is shorted to ground. Possible failure modes: 1. Switch or CCM1 supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The normal operating range for the front work lights switch -- ON is 4.0 to 5.0 volts. The normal operating range for the front work lights switch -- OFF is 0.25 to 4.0 volts. NOTE: Check fuse 49. If a short to ground occurred on this circuit the fuse will have blown. A. If the voltage reading is 0 to 0.25 volts in either switch position, continue with Step 2. B. If the voltage reading is 0.25 to 4.0 volts with the switch OFF and 0 to 0.25 with the switch ON, continue with Step 3. 2. The voltage reading remains near zero. The short to ground is between the switch and CCM1. Disconnect the cab main (CM) harness from the cab roof (CR) harness at connector X002. A. If the voltage increases to 0.25 to 4.0 volts, the short is in the cab roof (CR) harness between connector X002 and the switch wire 171 yellow. Locate and repair the short. B. If the voltage remains low, the short is in the cab main (CM) harness between connector X002 and connector X018 J1-3, wire 171 yellow. Locate the short and repair. 3. The voltage reading is 0.25 to 4.0 volts with the switch OFF and 0 to 0.25 with the switch ON. The short to ground is between the fuse and switch. Disconnect the cab main (CM) harness from the cab roof (CR) harness at connector X002. A. Operate the switch again and observe the voltage reading. If the voltage reading is 0.25 to 4.0 volts with the switch OFF and 0 to 0.25 with the switch ON, the short is in the cab roof (CR) harness between connector X002 and the switch wire 240 or 045 orange. Locate and repair the short. B. If the voltage reading remains between 0.25 to 4.0 volts, the short is in the cab main (CM) harness between connector X002 and fuse 49 wire 045 orange. Locate the short and repair.

55-38

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

10010915

4 3 50020070

10004693 50020088

8 1. FRONT WORK LIGHTS SWITCH S43 2. CONNECTOR X002

3. CONNECTOR X018 4. FUSE F49

55-39

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME--27

55-40

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

LIGHTING FRAME--42

E-27 = LH REAR WORK LIGHT E-28 = RH REAR WORK LIGHT F-55 = REAR WORK LTS FUSE K-31 = REAR WORK LTS RELAY

S-43 = WORK LIGHT SWITCH S-44 = REAR WORK LIGHT SWITCH

55-41

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0010-04 Rear Work Lights Switch Shorted To Low Source Cause: The rear work lights switch (S44) circuit is shorted to ground. Possible failure modes: 1. Switch or CCM1 supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The normal operating range for the rear work lights switch -- ON is 4.0 to 5.0 volts. The normal operating range for the rear work lights switch -- OFF is 0.25 to 4.0 volts. NOTE: Check fuse 49. If a short to ground occurred on this circuit the fuse will have blown. A. If the voltage reading is 0 to 0.25 volts in either switch position, continue with Step 2. B. If the voltage reading is 0.25 to 4.0 volts with the switch OFF and 0 to 0.25 with the switch ON, continue with Step 3. 2. The voltage reading is 0 to 0.25 volts. The short to ground is between the switch and CCM1. Disconnect the cab main (CM) harness from the cab roof (CR) harness at connector X002. A. If the voltage increases to 0.25 to 4.0 volts, the short is in the cab roof (CR) harness between connector X002 and the switch wire 170 yellow. Locate and repair the short. B. If the voltage remains low, the short is in the cab main (CM) harness between connector X002 and connector X018 J1-15 wire 170 yellow. Locate the short and repair. 3. The voltage reading is 0.25 to 4.0 volts with the switch OFF and 0 to 0.25 with the switch ON. The short to ground is between the fuse and switch. Disconnect the cab main (CM) harness from the cab roof (CR) harness at connector X002. A. Operate the switch again and observe the voltage reading. If the voltage reading is 0.25 to 4.0 volts with the switch OFF and 0 to 0.25 with the switch ON, the short is in the cab roof (CR) harness between connector X002 and the switch wire 239 or 045 orange. Locate and repair the short. B. If the voltage reading remains between 0.25 to 4.0 volts, the short is in the cab main (CM) harness between connector X002 and fuse 49 wire 045 orange. Locate and repair the short.

55-42

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

10010915

4 3 50020070

10004693 50020088

9 1. REAR WORK LIGHTS SWITCH S44 2. CONNECTOR X002

3. CONNECTOR X018 4. FUSE F49

55-43

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME--27

55-44

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

LIGHTING FRAME--42

E-27 = LH REAR WORK LIGHT E-28 = RH REAR WORK LIGHT F-55 = REAR WORK LTS FUSE K-31 = REAR WORK LTS RELAY

S-43 = WORK LIGHT SWITCH S-44 = REAR WORK LIGHT SWITCH

55-45

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0011-04 Road Lights Signal Shorted To Low Source Cause: The road light switch (S26) circuit is shorted to ground. Possible failure modes: 1. Switch or CCM1 supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: The input to CCM1 for the road light signal is supplied by the “Park” lights output (Pin1) of the road light switch (S26). 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The normal operating range for the road lights signal switch -- ON is 4.0 to 5.0 volts. The normal operating range for the road lights signal switch -- OFF is 0.25 to 4.0 volts. If a short to ground is present, the voltage indicated will be less than 0.25V. 2. Check fuse F49. If a short to ground occurred, the fuse will have failed. A. If fuse F49 has failed, go to Step 3. B. If the fuse is okay, go to Step 8. 3. Replace fuse F49. A. If fuse F49 immediately fails, the short to ground is in the cab main (CM) harness wire 213 red to road light switch S26 pin 5 (lights). Locate the short and repair. B. If fuse F49 is okay, go to Step 4. 4. Turn the Road Light switch S26 to the “Park” lights position and inspect fuse F49. A. If fuse F49 immediately fails, the short to ground is in the cab main (CM) harness in one of the following wires: wire 173 orange, road light switch S26 pin 1 to light control relay K02 pin 5 wire 114 orange, light control relay K02 pin 5 to pin 1 wire 212 orange, light control relay K02 pin 1 to CCM1 connector X018 pin J1-21 B. If fuse F49 is okay, go to Step 5. 5. Turn the Road Light switch S26 to the “Road” lights, “Low Beam” position and inspect fuse F49. A. If fuse F49 immediately fails, the short to ground is in the cab main (CM) harness wire 169 yellow, from the road light switch S26 pin 7 to the Low Beam relay K05 pin 1. Locate the short and repair. B. If fuse F49 is okay, go to Step 6. 6. Turn the Road Light switch S26 to the “Road” lights, “High Beam” position and inspect fuse F49. A. If fuse F49 immediately fails, the short to ground is in the cab main (CM) harness in one of the following wires: wire 218 yellow, road light switch S26 pin 4 to CM harness splice wire 191 yellow, CM splice to High Beam relay K04 pin 1. wire 043 purple, CM splice to High Beam indicator lamp E10 Locate the short and repair. B. If fuse F49 is okay, go to Step 7.

55-46

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 7. Blow the horn by depressing the road light switch S26, and inspect fuse F49. A. If fuse F49 immediately fails, the short to ground is in the cab main (CM) harness wire 193 white, from the road light switch S26 pin 9 to horn H02. Locate the short and repair. B. If fuse F49 is okay, go to Step 8. 8. If fuse F49 is okay, and testing does not reveal any short to ground in the circuit, the fault is either intermittent or is no longer valid. Erase the error code and continue operation.

55-47

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

1 2 10010914

50020070 10004693 50020087

10 1. ROAD LIGHT SWITCH S26 2. CONNECTOR X256

3. FUSE F49 4. CONNECTOR X018

55-48

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME--27

55-49

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

LIGHTING FRAME--36

A-05 = FLASHER MODULE E-13 = LH ROAD LIGHT E-14 = RH ROAD LIGHT F-32 = HIGH BEAM FUSE

F-33 = LOW BEAM FUSE F-51 = HORN, MARKER LTS FUSE H-02 = HORN K-02 = LIGHT CONTROL RELAY

55-50

K-04 = HIGH BEAM RELAY K-05 = LOW BEAM RELAY S-26 = ROAD LIGHT SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0012-04 Right Turn Signal Shorted To Low Source Cause: The right turn signal switch (S26) circuit is shorted to ground. Possible failure modes: 1. Switch or CCM1 supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The normal operating range for the right turn signal switch -- ON is 4.0 to 5.0 volts. The normal operating range for the right turn signal switch -- OFF is 0.25 to 4.0 volts. NOTE: Check fuse 38. If a short to ground occurred on this circuit the fuse will have blown. A. If the voltage reading is 0 to 0.25 volts in either switch position, continue with Step 2. B. If the voltage reading is 0.25 to 4.0 volts with the switch OFF and 0 to 0.25 with the switch ON, continue with Step 3. 2. The voltage reading remains near zero. The short to ground is between the switch and CCM1. Disconnect the cab main (CM) harness from the steering column (SC) harness at connector X033. A. If the voltage increases to 0.25 to 4.0 volts, the short is in the electronic flasher, or steering column (SC) harness wire 201 purple. Replace the electronic flasher before attempting to repair the steering column (SC) harness. Erase fault code and operate system. B. If the voltage remains low, the short is in the cab main (CM) harness between connector X033, connector X018 and the road light switch connector X256 in wires 201,194 or 203 purple. Locate the short and repair. 3. The voltage reading is 0.25 to 4.0 volts with the switch OFF and 0 to 0.25 with the switch ON. The short to ground is between the fuse and switch. A. The short is in the cab main (CM) harness wire 055 orange. Visually inspect the cab main (CM) harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair.

55-51

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

1 2

5 4 3

10010914

10004693

50020087

11 1. ROAD LIGHT SWITCH S26 2. FLASHER MODULE A05 3. CONNECTOR X033

4. CONNECTOR X256 5. CONNECTOR X018

55-52

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-53

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

LIGHTING FRAME--36

A-05 = FLASHER MODULE E-13 = LH ROAD LIGHT E-14 = RH ROAD LIGHT F-32 = HIGH BEAM FUSE

F-33 = LOW BEAM FUSE F-51 = HORN, MARKER LTS FUSE H-02 = HORN K-02 = LIGHT CONTROL RELAY

55-54

K-04 = HIGH BEAM RELAY K-05 = LOW BEAM RELAY S-26 = ROAD LIGHT SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0013-03 Cleaning Fan RPM Sensor Shorted To High Source Cause: The cleaning fan RPM sensor (B16) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts. A. If the voltage reading is high out of range, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. 2. The voltage reading is high. Disconnect the cleaning fan RPM sensor connector X089. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains high, continue with Step 3. 3. The voltage reading is high. Disconnect the front frame (FF) harness from the lower frame (LF) harness at connector X023. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the lower frame (LF) harness between connector X023 and connector X089 wire 404 yellow. Locate the short and repair. B. If the voltage remains high, the short circuit is in the front frame (FF) harness between connector X023 and connector X020 pin J3-13 wire 404 yellow. Locate the short and repair. 4. Operate the cleaning fan and monitor the voltage readings. A. If high voltage reading is viewed, continue with Step 2 while operating grain bin doors. B. If a high voltage reading cannot be generated, erase the fault code and continue operation.

55-55

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0013-04 Cleaning Fan RPM Sensor Shorted To Low Source Cause: The cleaning fan RPM sensor (B16) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. Select “Cleaning” sub menu. Select “Cleaning Fan RPM sensor” and check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts. A. If the voltage reading is 0 to 0.5 volts, continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 4. 2. The voltage reading is low. Disconnect the cleaning fan RPM sensor connector X089. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low, continue with Step 3. 3. The voltage reading is low. Disconnect the lower frame (LF) harness from the front frame harness (FF) at connector X023. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the lower frame (LF) harness between connector X023 and connector X089 wire 404 yellow. Locate the short and repair. B. If the voltage remains low, the short circuit is in the front frame (FF) harness between connector X023 and connector X020 J3-13 wire 404 yellow. Locate the short and repair. 4. If a 0 to 0.5 voltage reading is not shown, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0013-05 Cleaning Fan RPM Sensor Line Disconnected Cause: The cleaning fan RPM sensor (B16) circuit is disconnected. Possible failure modes: 1. Sensor supply or ground wiring is disconnected. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts. If there is an open in the supply/ground wiring, the voltage will read 7.3 to 9.0 volts. A. If the voltage reading is high indicating an open, continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 6. 2. The voltage reading is 7.3 to 9.0 volts. Disconnect the cleaning fan RPM sensor connector X089. Install a jumper wire between pins 1 and 2 on connector X089. A. If the voltage drops to 0 to 0.5 volts, the open is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains out of range, continue with Step 3. 3. The voltage reading is 7.3 to 9.0 volts. Remove the jumper wire from connector X089. Use a multimeter to check for continuity between pin 1 on connector X089 and chassis ground. A. If no continuity is found, continue with Step 4. B. If continuity is found, continue with Step 5. 4. Use a multimeter to check for continuity between connector X023 pin 16 and chassis ground. A. If no continuity is found, there is an open in the front frame (FF) harness between connectors X023 and connector X020 J3-18 wire 723 or 501 blue. Locate and repair the open circuit. B. If continuity is found, the open is in the lower frame (LF) harness between connector X023 and connector X089 wire 723 or 718 blue. Locate the open and repair. 5. The voltage reading is 7.3 to 9.0 volts. Disconnect the connector X023. Install a jumper wire between pins 7 and 16 on connector X023. A. If the voltage drops to 0 to 0.5 volts, the open is in the lower frame (LF ) harness between connector X023 and connector X089 wire 404 yellow. Locate and repair the open. B. If the voltage remains at 7.3 to 9.0 volts, the open is in the front frame (FF) harness between connector X023 and connector X020 J3-13 wire 404 yellow. Locate and repair the open. 6. Visually inspect harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. If no damage is found, erase fault code and continue operation.

55-57

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

30998030

10010898 50020089

12 1. CLEANING FAN RPM SENSOR B16 2. CONNECTOR X023

3. CONNECTOR X020

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

B-16 = CLEANING FAN RPM B-21 = SIEVES LOSS F-22 = SHOE LEVELING MOTOR FUSE L-44 = FAN DRIVE SOLENOID

M-03 = SHOE LEVELING ACTUATOR S-13 = UPPER SIEVE S-14 = LOWER SIEVE S-15 = FAN SPEED

55-59

CLEANING FRAME--19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0014-03 Feeder RPM sensor Shorted To High Source Cause: The feeder RPM sensor (B14) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage for sensor when blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage for sensor when not blocked by ferrous metal -- 0.5 to 5.6 volts. The proper voltage sensor when disconnected -- 7.3 to 9.0 volts. A. If the voltage reading is high out of range (9.0 to 10.0 volts), continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at step 3. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading is high. Disconnect the feeder RPM sensor connector X284. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains high, the short circuit is in the front frame (FF) harness between connector X284 and connector X020 pin J3-14 wire 489 yellow. Locate the short and repair. 3. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state. Adjust the sensor clearance to 3 mm (1/8″). Erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0014-04 Feeder RPM sensor Shorted To Low Source Cause: The feeder RPM sensor (B14) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts. The proper voltage sensor when disconnected -- 7.3 to 9.0 volts. A. If the voltage reading is low (0 to 0.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 3. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading is low. Disconnect the feeder RPM sensor connector X284. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low, the short is in the front frame (FF) harness between connector X284 and connector X020 pin J3-14 wire 489 yellow. Locate the short and repair. 3. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state. Adjust the sensor clearance to 3 mm (1/8″). Erase the fault code and continue operation.

55-62

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0014-05 Feeder RPM Sensor Line Disconnected Cause: The feeder RPM sensor (B14) circuit has an open. Possible failure modes: 1. Sensor supply wiring has an open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts. The proper voltage sensor when disconnected -- 7.3 to 9.0 volts. A. If the voltage reading is high (7.3 to 9.0 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. 2. The voltage reading is 7.3 to 9.0 volts. Disconnect the feeder RPM sensor connector X284. Use a jumper wire to short pin 2 on the harness end of connector X284 to ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply side of the circuit. Continue with step 3. B. If the display monitor still displays 7.3 to 9.0 volts, the open circuit is in the front frame (FF) harness between connector X284 and connector X020 pin J3-14 wire 489 yellow. Locate the open and repair. 3. The voltage reading is 7.3 to 9.0 volts. Disconnect the feeder RPM sensor connector X284. Use a multimeter to check for continuity between the harness end of connector X284 pin 1 and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity to ground, there is an open circuit in the front frame (FF) harness between connector X284 and connector X020 pin J3-18 wire 437 blue or 501 blue. Locate the open and repair. 4. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state. Adjust the sensor clearance to 3 mm (1/8″). Erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

2 1 50031000

50020085

13 1. FEEDER RPM SENSOR B14 2. CONNECTOR X284

3. CONNECTOR X020

55-64

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FEEDER FRAME--16

B-09 = REVERSER DISENGAGE B-14 = FEEDER RPM B-24 = STONE DOOR CLOSED F-24 = FAN, REVERSER FUSE

K-17 = FAN/REVERSER RELAY K-19 = NOT USED L-20 = FEEDER JOG FORWARD L-21 = FEEDER JOG REVERSE

55-65

L-24 = FEEDER CLUTCH M-05 = CLEANING FAN ADJUST MOTOR (EU) M-10 = FEEDER REVERSER ACTUATOR S-31 = FEEDER ENGAGE

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0015-03 Left Returns RPM Sensor Shorted To High Source Cause: The left returns RPM sensor (B06) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts. A. If the voltage reading is high out of range, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 3. 2. The voltage reading is high. Disconnect the left hand returns RPM sensor connector X181. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains high, the short is in the main frame (MF) harness between connector X181 and connector X019 J2-38 wire 433 yellow. Locate the short and repair. 3. Operate the left hand returns auger and monitor the voltage readings. A. If high voltage reading is viewed, continue with Step 2. B. If a high voltage reading cannot be generated, erase the fault code and continue operation.

55-67

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0015-04 Left Returns RPM Sensor Shorted To Low Source Cause: The left returns RPM sensor (B06) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts. A. If the voltage reading is low (0 to 0.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 3. 2. The voltage reading is low. Disconnect the left returns RPM sensor connector X181. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low, the short is in the main frame (MF) harness between connector X181 and connector X019 J2-38 wire 433 yellow. Locate the short and repair. 3. If a 0 to 0.5 voltage reading is not shown, erase the fault code and continue operation.

55-68

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0015-05 Left Returns RPM Sensor Line Disconnected Cause: The left returns RPM sensor (B06) circuit is open. Possible failure modes: 1. Sensor supply wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage for sensor unblocked by ferrous metal is 0.5 to 5.6 volts. The proper voltage for sensor blocked by ferrous metal is 5.6 to 7.3 volts. The proper voltage with sensor disconnected is 7.3 to 9.0 volts. A. If the voltage reading is high (7.3 to 9.0 volts), continue with Step 2. B. If the voltage reading is within the proper limits, the open is not present at this time. Continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading is 7.3 to 9.0 volts. Disconnect the left returns RPM sensor connector X181. Use a jumper wire to short the harness end of connector X181 pin 2 to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply side of the circuit. Continue with step 3. B. If the display monitor still displays 7.3 to 9.0 volts, the open circuit is in the main frame (MF) harness between connector X181 pin 2 and connector X019 pin J2-38 wire 433 yellow. Locate the open and repair. 3. Disconnect the left returns RPM sensor connector X181. Use a multimeter to check for continuity between the harness end of connector X181 pin 1 and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity to ground, the ground path for the sensor is open. Continue with step 4. 4. Disconnect the main frame (MF) harness from the front frame (FF) harness at connector X008. Use a multimeter to check for continuity between the harness end of connector X008 pin 7 and chassis ground. A. If there is continuity, the open circuit is in the main frame (MF) harness between connector X181 pin 1 and connector X008 pin 7 wire 500 blue or 401 blue. Locate the open and repair. B. If there is no continuity to ground, the open circuit is in the front frame (FF) harness between connector X008 pin 7 and connector X020 pin J3-18 wire 401 blue or 501 blue. Locate the open and repair. 5. Erase the error code and, continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

4 3

2 1 10004638 10020075

50020090

14 1. LEFT RETURNS RPM SENSOR B06 2. CONNECTOR X008

3. CONNECTOR X019 4. CONNECTOR X020

55-70

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

CLEANING FRAME--20

B-02 = LATERAL INCLINATION B-06 = LEFT RETURNS RPM B-08 = CLEAN GRAIN ELEVATOR RPM B-19 = LEFT ROTOR LOSS

B-20 = RIGHT ROTOR LOSS B-39 = RIGHT RETURNS RPM

55-71

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-72

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0016-03 Clean Grain Elevator RPM Shorted To High Source Cause: The clean grain elevator RPM sensor (B08) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts. A. If the voltage reading is high out of range, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 3. 2. The voltage reading is high. Disconnect the clean grain elevator RPM sensor connector X182. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains high, the short circuit is in the main frame (MF) harness between connector X182 and connector X019 J2-28 wire 450 yellow. Locate the short and repair. 3. Operate the clean grain elevator and monitor the voltage readings. A. If high voltage reading is viewed, continue with Step 2. B. If a high voltage reading cannot be generated, erase the fault code and continue operation.

55-73

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0016-04 Clean Grain Elevator RPM Shorted To Low Source Cause: The clean grain elevator RPM sensor (B08) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts. A. If the voltage reading is low (0 to 0.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 3. 2. The voltage reading is low. Disconnect the clean grain RPM sensor connector X182. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low, the short circuit is in the main frame (MF) harness between connector X182 and connector X019 J2-28 wire 450 yellow. Locate the short and repair. 3. If a 0 to 0.5 voltage reading is not shown, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0016-05 Clean Grain Elevator RPM Line Disconnected Cause: The clean grain elevator RPM sensor (B08) circuit is open. Possible failure modes: 1. Sensor supply wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage for sensor unblocked by ferrous metal is 0.5 to 5.6 volts. The proper voltage for sensor blocked by ferrous metal is 5.6 to 7.3 volts. The proper voltage with sensor disconnected is 7.3 to 9.0 volts. A. If the voltage reading is high (7.3 to 9.0 volts), continue with Step 2. B. If the voltage reading is within the proper limits, the open is not present at this time. Continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading is 7.3 to 9.0 volts. Disconnect the clean grain elevator RPM sensor connector X182. Use a jumper wire to short the harness end of connector X182 pin 2 to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply side of the circuit. Continue with step 3. B. If the display monitor still displays 7.3 to 9.0 volts, the open circuit is in the main frame (MF) harness between connector X182 pin 2 and connector X019 pin J2-28 wire 450 yellow. Locate the open and repair. 3. Disconnect the clean grain elevator RPM sensor connector X182. Use a multimeter to check for continuity between the harness end of connector X182 pin 1 and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity to ground, the ground path for the sensor is open. Continue with step 4. 4. Disconnect the main frame (MF) harness from the front frame (FF) harness at connector X008. Use a multimeter to check for continuity between the harness end of connector X008 pin 7 and chassis ground. A. If there is continuity, the open circuit is in the main frame (MF) harness between connector X181 pin 1 and connector X008 pin 7 wire 491 blue or 401 blue. Locate the open and repair. B. If there is no continuity to ground, the open circuit is in the front frame (FF) harness between connector X008 pin 7 and connector X020 pin J3-18 wire 401 blue or 501 blue. Locate the open and repair. 5. Erase the error code and, continue operation.

55-75

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

4 3

10004651

10020075 50020090

15 1. CLEAN GRAIN RPM SENSOR B08 2. CONNECTOR X008

3. CONNECTOR X019 4. CONNECTOR X020

55-76

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

CLEANING FRAME--20

B-02 = LATERAL INCLINATION B-06 = LEFT RETURNS RPM B-08 = CLEAN GRAIN ELEVATOR RPM B-19 = LEFT ROTOR LOSS

B-20 = RIGHT ROTOR LOSS B-39 = RIGHT RETURNS RPM

55-77

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-78

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0018-03 Right Returns RPM Sensor Shorted To High Source Cause: The right returns RPM sensor (B39) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts. A. If the voltage reading is high out of range, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 3. 2. The voltage reading is high. Disconnect the right hand returns RPM sensor connector X186. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains high, the short circuit is in the main frame (MF) harness between connector X186 and connector X019 J2-37 wire 441 yellow. Locate the short and repair. 3. Operate the right returns auger and monitor the voltage readings. A. If high voltage reading is viewed, continue with Step 2. B. If a high voltage reading cannot be generated, erase the fault code and continue operation.

55-79

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0018-04 Right Returns RPM Sensor Shorted To Low Source Cause: The right returns RPM sensor (B39) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts. The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts. A. If the voltage reading is low out of range, continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 3. 2. The voltage reading is low. Disconnect the right returns RPM sensor connector X186. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low, the short is in the main frame (MF) harness between connector X186 and connector X019 J2-37 wire 441 yellow. Locate the short and repair. 3. If a 0 to 0.5 voltage reading is not shown, erase the fault code and continue operation.

55-80

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0018-05 Right Returns RPM Sensor Line Disconnected Cause: The right returns RPM sensor (B39) circuit is open. Possible failure modes: 1. Sensor supply wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage for sensor unblocked by ferrous metal is 0.5 to 5.6 volts. The proper voltage for sensor blocked by ferrous metal is 5.6 to 7.3 volts. The proper voltage with sensor disconnected is 7.3 to 9.0 volts. A. If the voltage reading is high (7.3 to 9.0 volts), continue with Step 2. B. If the voltage reading is within the proper limits, the open is not present at this time. Continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading is 7.3 to 9.0 volts. Disconnect the right returns RPM sensor connector X186. Use a jumper wire to short the harness end of connector X186 pin 2 to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply side of the circuit. Continue with step 3. B. If the display monitor still displays 7.3 to 9.0 volts, the open circuit is in the main frame (MF) harness between connector X186 pin 2 and connector X019 pin J2-37 wire 441 yellow. Locate the open and repair. 3. Disconnect the right returns RPM sensor connector X186. Use a multimeter to check for continuity between the harness end of connector X186 pin 1 and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity to ground, the ground path for the sensor is open. Continue with step 4. 4. Disconnect the main frame (MF) harness from the front frame (FF) harness at connector X008. Use a multimeter to check for continuity between the harness end of connector X008 pin 7 and chassis ground. A. If there is continuity, the open circuit is in the main frame (MF) harness between connector X186 pin 1 and connector X008 pin 7 wire 442 blue or 401 blue. Locate the open and repair. B. If there is no continuity to ground, the open circuit is in the front frame (FF) harness between connector X008 pin 7 and connector X020 pin J3-18 wire 401 blue or 501 blue. Locate the open and repair. 5. Erase the error code and, continue operation.

55-81

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

10004668

4 3

10020075 50020091

16 1. RIGHT RETURNS RPM SENSOR B39 2. CONNECTOR X008

3. CONNECTOR X019 4. CONNECTOR X020

55-82

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

CLEANING FRAME--20

B-02 = LATERAL INCLINATION B-06 = LEFT RETURNS RPM B-08 = CLEAN GRAIN ELEVATOR RPM B-19 = LEFT ROTOR LOSS

B-20 = RIGHT ROTOR LOSS B-39 = RIGHT RETURNS RPM

55-83

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-84

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0023-03 Hydrostat Motor Temp Shorted To High Source Cause: The hydrostat motor temperature (B46) is shorted to high source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The normal operating voltage range is -- 0.5 to 4.9 volts. A. If the voltage reading is above 5.2 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. 2. The voltage reading is high. Disconnect the hydrostatic motor temperature sensor connector X091. A. If the voltage drops to 4.9 to 5.2 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains high, continue with Step 3. 3. The voltage reading is high. Disconnect the lower frame (LF) harness from the front frame (FF) harness at connector X023. A. If the voltage drops to 4.9 to 5.2 volts, the short is in the lower frame (LF) harness between connector X023 and connector X091 wire 773 yellow. Locate the short and repair. B. If the voltage remains high, the short circuit is in the front frame (FF) harness between connector X023 and connector X020 J3-33 wire 773 yellow. Locate the short and repair. 4. Visually inspect harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. If no damage is found, erase fault code and continue operation.

55-85

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0023-04 Hydrostatic Motor Temp Shorted To Low Source Cause: The hydrostat motor temperature (B46) is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The normal operating voltage range is -- 0.5 to 4.9 volts. A. If the voltage reading is (0 to 0.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 4. 2. The voltage reading is low. Disconnect the hydrostatic motor temperature sensor connector X091. A. If the voltage increases to 4.9 to 5.2 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low, continue with Step 3. 3. The voltage reading is low. Disconnect the front frame (FF) harness from the lower frame (LF) harness at connector X023. A. If the voltage increases to 4.9 to 5.2 volts, the short is in the lower frame (LF) harness between connector X023 and connector X091 wire 773 yellow. Locate the short and repair. B. If the voltage remains low, the short circuit is in the front frame (FF) harness between connector X023 and connector X020 J3-33 wire 773 yellow. Locate the short and repair. 4. Visually inspect harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. If no damage is found, erase fault code and continue operation.

55-86

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0023-05 Hydrostatic Motor Temp Line Disconnected Cause: The hydrostatic motor temperature (B46) is disconnected. Possible failure modes: 1. Sensor supply wiring has an open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The normal operating voltage range is -- 0.5 to 4.9 volts. If there is an open in the supply/ground wiring the voltage will read 4.9 to 5.2 volts. A. If the voltage reading is 4.9 to 5.2 volts, continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 6. 2. The voltage reading is 4.9 to 5.2 volts. Disconnect the hydrostatic motor temperature sensor connector X091. Install a jumper wire between pins A and B on connector X091. A. If the voltage drops to 0 to 0.5 volts, the open is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains out of range, continue with Step 3. 3. The voltage reading is 4.9 to 5.2 volts. Remove the jumper wire from connector X091. Use a multimeter to check for continuity between pin A on connector X091 and chassis ground. A. If no continuity is found, continue with Step 4. B. If continuity is found, continue with Step 5. 4. Use a multimeter to check for continuity between pin 16 on connector X023 and chassis ground. A. If no continuity is found, there is an open in the front frame (FF) harness between connectors X023 and connector X020 J3-18 wire 723, or 501 blue. Locate and repair the open circuit. B. If continuity is found, the open is in the lower frame (LF) harness between connector X023 and X091 wire 723 or 774 blue. Locate the open and repair. 5. The voltage reading is 4.9 to 5.2 volts. Disconnect the connector X023. Install a jumper wire between pins 26 and 16 on connector X023. A. If the voltage drops to 0 to 0.5 volts, the open is in the lower frame (LF) harness between connector X023 and X091 wire 773 yellow. Locate and repair the open. B. If the voltage remains at 4.9 to 5.2 volts, the open is in the front frame (FF) harness between connector X023 and connector X020 J3-33 wire 773 yellow. Locate and repair the open. 6. Visually inspect harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. If no damage is found, erase fault code and continue operation.

55-87

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

1 2

10004663

10010898

50020089

17 1. HYDROSTATIC MOTOR TEMPERATURE SENSOR B46 2. CONNECTOR X023 3. CONNECTOR X020

55-88

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DRIVES FRAME--8

B-46 = HYDROSTAT MOTOR TEMP H-08 = BACK UP ALARM L-05 = PRESSURE RELEASE L-26 = REAR WHEEL ASSIST

L-27 = DUAL RANGE S-49 = BRAKE FLUID LEVEL SWITCH S-55 = LH BRAKE WEAR SWITCH S-56 = RH BRAKE WEAR SWITCH

55-89

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-90

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0024-03 Hydraulic Reservoir Temp Shorted To High Source Cause: The hydraulic reservoir temperature (B18) is shorted to high source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is -- 0.5 to 4.9 volts. A. If the voltage reading is above 5.2 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. 2. The voltage reading is high. Disconnect the hydraulic reservoir temperature sensor connector X103. A. If the voltage drops to 4.9 to 5.2 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains high, continue with Step 3. 3. The voltage reading is high. Disconnect the gearbox (GB) harness from the main frame (MF) harness at connector X011. A. If the voltage drops to 4.9 to 5.2 volts, the short is in the gearbox (GB) harness between connector X011 and connector X103 wire 446 yellow. Locate the short and repair. B. If the voltage remains high, the short circuit is in the main frame (MF) harness between connector X011 and connector X020 J2-24 wire 446 yellow. Locate the short and repair. 4. Visually inspect harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. If no damage is found, erase fault code and continue operation.

55-91

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0024-04 Hydraulic Reservoir Temp Shorted To Low Source Cause: The hydraulic reservoir temperature (B18) is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The normal operating voltage range is -- 0.5 to 4.9 volts. A. If the voltage reading is (0 to 0.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 4. 2. The voltage reading is low. Disconnect the hydraulic reservoir temperature sensor connector X103. A. If the voltage increases to 4.9 to 5.2 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low, continue with Step 3. 3. The voltage reading is low. Disconnect the gearbox (GB) harness from the main frame (MF) harness at connector X011. A. If the voltage increases to 4.9 to 5.2 volts, the short is in the gearbox (GB) harness between connector X011 and connector X103 wire 446 yellow. Locate the short and repair. B. If the voltage remains low, the short circuit is in the main frame (MF) harness between connector X011 and connector X020 J2-24 wire 446 yellow. Locate the short and repair. 4. Visually inspect harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. If no damage is found, erase fault code and continue operation.

55-92

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0024-05 Hydraulic Reservoir Temp Line Disconnected Cause: The hydraulic oil reservoir temperature sensor (B18) circuit is open. Possible failure modes: 1. Sensor supply wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The normal operating range for the sensor is 0.5 to 4.9 volts. If there is an open in the supply or ground wiring, the voltage will be 4.9 to 5.2 volts. A. If the voltage reading is high (4.9 to 5.2 volts), continue with Step 2. B. If the voltage reading is within the proper limits, the open is not present at this time. Continue the troubleshooting at step 7. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading is 4.9 to 5.2 volts. Disconnect the hydraulic oil reservoir temperature sensor connector X103. Use a jumper wire to short the harness end of connector X103 pin B to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply side of the circuit. Continue with step 4. B. If the display monitor still displays 4.9 to 5.2 volts, continue with Step 3. 3. The voltage reading is 4.9 to 5.2 volts. Disconnect the gearbox (GB) harness from the main frame (MF) harness at connector X011. Use a jumper wire to short connector X011 pin E to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the gearbox (GB) harness between connector X011 pin E and connector X103 pin B wire 446 yellow. Locate the open and repair. B. If the display monitor still displays 4.9 to 5.2 volts, the open circuit is in the main frame (MF) harness between connector X011 pin E and connector X019 pin J2-24 wire 446 yellow. Locate the open and repair. 4. Disconnect the hydraulic oil reservoir temperature sensor connector X103. Use a multimeter to check for continuity between the harness end of connector X103 pin A and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity to ground, the ground path for the sensor is open. Continue with step 5.

55-93

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 5. Disconnect the gearbox (GB) harness from the main frame (MF) harness at connector X011. Use a multimeter to check for continuity between the harness end of connector X011 pin H and chassis ground. A. If there is continuity, the open circuit is in the gearbox (GB) harness between connector X011 pin H and connector X103 pin A wire 480 blue or 488 blue. Locate the open and repair. B. If there is no continuity to ground, continue with step 6. 6. Disconnect the main frame (MF) harness from the front frame (FF) harness at connector X008. Use a multimeter to check for continuity between the harness end of connector X008 pin 7 and chassis ground. A. If there is continuity, the open circuit is in the main frame (MF) harness between connector X011 pin H and connector X008 pin 7 wire 488 blue or 401 blue. Locate the open and repair. B. If there is no continuity to ground, the open circuit is in the front frame (FF) harness between connector X008 pin 7 and connector X020 pin J3-18 wire 401 blue or 501 blue. Locate the open and repair. 7. Erase the error code and, continue operation.

55-94

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

1 50014693

5 4 2

3 10020076

10020075 50020093

18 1. HYDRAULIC OIL RESERVOIR TEMPERATURE B18 2. CONNECTOR X011 3. CONNECTOR X008

55-95

4. CONNECTOR X019 5. CONNECTOR X020

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

HYDRAULIC FRAME--10

B-18 = HYD OIL RESERVOIR TEMP B-32 = GEARBOX TEMPERATURE B-35 = LOW CONTROL PRESSURE S-17 = ROTOR SPEED

S-18 = FEEDER SPEED S-32 = RETURNS FILTER BYPASS S-33 = HYDRAULIC RESERVOIR LEVEL S-34 = GEARBOX FILTER BYPASS

55-96

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-97

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0025-03 Gearbox Temp Sensor Shorted To High Source Cause: The gearbox temperature (B32) is shorted to 12 volts. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is -- 0.5 to 4.9 volts. A. If the voltage reading is above 5.2 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. 2. The voltage reading is high. Disconnect the gearbox temperature sensor connector X097. A. If the voltage drops to 4.9 to 5.2 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains high, continue with Step 3. 3. The voltage reading is high. Disconnect the gearbox (GB) harness from the main frame (MF) harness at connector X011. A. If the voltage drops to 4.9 to 5.2 volts, the short is in the gearbox (GB) harness between connector X011 and connector X097 wire 422 yellow. Locate the short and repair. B. If the voltage remains high, the short circuit is in the main frame (MF) harness between connector X011 and connector X020 J2-27 wire 422 yellow. Locate the short and repair. 4. Visually inspect harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. If no damage is found, erase fault code and continue operation.

55-98

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0025-04 Gearbox Temp Sensor Shorted To Low Source Cause: The gearbox temperature (B32) is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The normal operating voltage range is -- 0.5 to 4.9 volts. A. If the voltage reading is low (0 to 0.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 4. 2. The voltage reading is low. Disconnect the gearbox temperature sensor connector X097. A. If the voltage increases to 4.9 to 5.2 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low, continue with Step 3. 3. The voltage reading is low. Disconnect the gearbox (GB) harness from the main frame (MF) harness at connector X011. A. If the voltage increases to 4.9 to 5.2 volts, the short is in the gearbox (GB) harness between connector X011 and connector X097 wire 422 yellow. Locate the short and repair. B. If the voltage remains low, the short circuit is in the main frame (MF) harness between connector X011 and connector X020 J2-27 wire 422 yellow. Locate the short and repair. 4. Visually inspect harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. If no damage is found, erase fault code and continue operation.

55-99

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0025-05 Gearbox Temp Sensor Line Disconnected Cause: The gearbox temperature sensor (B32) circuit is open. Possible failure modes: 1. Sensor supply wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The normal operating range for the sensor is 0.5 to 4.9 volts. If there is an open in the supply or ground wiring, the voltage will be 4.9 to 5.2 volts. A. If the voltage reading is high (4.9 to 5.2 volts), continue with Step 2. B. If the voltage reading is within the proper limits, the open is not present at this time. Continue the troubleshooting at step 7. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading is 4.9 to 5.2 volts. Disconnect the gearbox temperature sensor connector X097. Use a jumper wire to short the harness end of connector X097 pin B to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply side of the circuit. Continue with step 4. B. If the display monitor still displays 4.9 to 5.2 volts, continue with Step 3. 3. The voltage reading is 4.9 to 5.2 volts. Disconnect the gearbox (GB) harness from the main frame (MF) harness at connector X011. Use a jumper wire to short connector X011 pin A to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the gearbox (GB) harness between connector X011 pin A and connector X097 pin B wire 422 yellow. Locate the open and repair. B. If the display monitor still displays 4.9 to 5.2 volts, the open circuit is in the main frame (MF) harness between connector X011 pin A and connector X019 pin J2-27 wire 422 yellow. Locate the open and repair. 4. Disconnect the gearbox temperature sensor connector X097. Use a multimeter to check for continuity between the harness end of connector X097 pin A and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity to ground, the ground path for the sensor is open. Continue with step 5. 5. Disconnect the gearbox (GB) harness from the main frame (MF) harness at connector X011. Use a multimeter to check for continuity between the harness end of connector X011 pin H and chassis ground. A. If there is continuity, the open circuit is in the gearbox (GB) harness between connector X011 pin H and connector X097 pin A wire 466 blue or 488 blue. Locate the open and repair. B. If there is no continuity to ground, continue with step 6.

55-100

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 6. Disconnect the main frame (MF) harness from the front frame (FF) harness at connector X008. Use a multimeter to check for continuity between the harness end of connector X008 pin 7 and chassis ground. A. If there is continuity, the open circuit is in the main frame (MF) harness between connector X011 pin H and connector X008 pin 7 wire 488 blue or 401 blue. Locate the open and repair. B. If there is no continuity to ground, the open circuit is in the front frame (FF) harness between connector X008 pin 7 and connector X020 pin J3-18 wire 401 blue or 501 blue. Locate the open and repair. 7. Erase the error code and, continue operation.

55-101

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

5 1

40025222

2 3

10020076 10020075

50020093

19 1. GEARBOX TEMPERATURE SENSOR B32 2. CONNECTOR X011 3. CONNECTOR X008

55-102

4. CONNECTOR X019 5. CONNECTOR X020

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

HYDRAULIC FRAME--10

B-18 = HYD OIL RESERVOIR TEMP B-32 = GEARBOX TEMPERATURE B-35 = LOW CONTROL PRESSURE S-17 = ROTOR SPEED

S-18 = FEEDER SPEED S-32 = RETURNS FILTER BYPASS S-33 = HYDRAULIC RESERVOIR LEVEL S-34 = GEARBOX FILTER BYPASS

55-103

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-104

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0026-03 Rear Ladder Sensor Shorted To High Source Cause: The rear ladder sensor (B22) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage for sensor when rear ladder is up is 0.5 to 3.9 volts. The proper voltage for sensor when rear ladder is down is 3.9 to 4.9 volts. The proper voltage with sensor disconnected is 4.9 to 5.2 volts. A. If the voltage reading is high out of range (>5.2 volts), continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. 2. The voltage reading is high. Disconnect the rear ladder sensor connector X251. A. If the voltage drops to 4.9 to 5.2 volts, the short is in the sensor or sensor wiring. Replace the sensor. B. If the voltage remains high, continue with Step 3. 3. The voltage reading is high. Disconnect the straw hood (SH) harness from the straw hood front (SW) harness at connector X071. A. If the voltage drops to 4.9 to 5.2 volts, the short is in the straw hood (SH) harness between connector X071 pin 11 and connector X251 pin 2 wire 570 yellow. Locate the short and repair. B. If the voltage remains high, continue with Step 4. 4. The voltage reading is high. Disconnect the straw hood front (SW) harness from the main frame (MF) harness at connector X024. A. If the voltage drops to 4.9 to 5.2 volts, the short is in the straw hood front (SW) harness between connector X024 pin 16 and connector X071 pin 11 wire 570 yellow. Locate the short and repair. B. If the voltage remains high, the short circuit is in the main frame (MF) harness between connector X024 pin 16 and connector X019 pin J2-17 wire 570 yellow. Locate the short and repair. 5. Turn the key to ON position. Observing the LED on the harness end side of the sensor, raise and lower the ladder. The sensor is functioning if LED changes state. Erase the error code and, continue operation.

55-105

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0026-04 Rear Ladder Sensor Shorted To Low Source Cause: The rear ladder sensor (B22) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage for sensor when rear ladder is up is 0.5 to 3.9 volts. The proper voltage for sensor when rear ladder is down is 3.9 to 4.9 volts. The proper voltage with sensor disconnected is 4.9 to 5.2 volts. A. If the voltage reading is low (0 to 0.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. 2. The voltage reading is low. Disconnect the rear ladder sensor connector X251. A. If the voltage increases to 4.9 to 5.2 volts, the short to ground is in the sensor or sensor wiring. Replace the sensor. B. If the voltage remains low, continue with Step 3. 3. The voltage reading is low. Disconnect the straw hood (SH) harness from the straw hood front (SW) harness at connector X071. A. If the voltage increases to 4.9 to 5.2 volts, the short to ground is in the straw hood (SH) harness between connector X071 pin 11 and connector X251 pin 2 wire 570 yellow. Locate the short and repair. B. If the voltage remains low, continue with Step 4. 4. The voltage reading is low. Disconnect the straw hood front (SW) harness from the main frame (MF) harness at connector X024. A. If the voltage increases to 4.9 to 5.2 volts, the short is in the straw hood front (SW) harness between connector X024 pin 16 and connector X071 pin 11 wire 570 yellow. Locate the short and repair. B. If the voltage remains low, the short to ground is in the main frame (MF) harness between connector X024 pin 16 and connector X019 pin J2-17 wire 570 yellow. Locate the short and repair. 5. Turn the key to ON position. Observing the LED on the harness end side of the sensor, raise and lower the ladder. The sensor is functioning if LED changes state. Erase the error code and, continue operation.

55-106

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0026-05 Rear Ladder Sensor Line Disconnected Cause: The rear ladder sensor (B22) circuit is open. Possible failure modes: 1. Sensor supply wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage for sensor when rear ladder is up is 0.5 to 3.9 volts. The proper voltage for sensor when rear ladder is down is 3.9 to 4.9 volts. The proper voltage with sensor disconnected is 4.9 to 5.2 volts. A. If the voltage reading is high (4.9 to 5.2 volts), continue with Step 2. B. If the voltage reading is within the proper limits, the open is not present at this time. Continue the troubleshooting at step 9. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading is 4.9 to 5.2 volts. Disconnect the rear ladder sensor connector X251. Use a jumper wire to short the harness end of connector X251 pin 2 to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply side of the circuit. Continue with step 5. B. If the display monitor still displays 4.9 to 5.2 volts, continue with Step 3. 3. The voltage reading is 4.9 to 5.2 volts. Disconnect the straw hood (SH) harness from the straw hood front (SW) harness at connector X071. Use a jumper wire to short connector X071 pin 11 to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the straw hood (SH) harness between connector X071 pin 11 and connector X251 pin 2 wire 570 yellow. Locate the open and repair. B. If the display monitor still displays 4.9 to 5.2 volts, continue with Step 4. 4. The voltage reading is 4.9 to 5.2 volts. Disconnect the straw hood front (SW) harness from the main frame (MF) harness at connector X024. Use a jumper wire to short connector X024 pin 16 to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the straw hood front (SW) harness between connector X024 pin 16 and connector X071 pin 11 wire 570 yellow. Locate the open and repair. B. If the display monitor still displays 4.9 to 5.2 volts, the open circuit is in the main frame (MF) harness between connector X024 pin 16 and connector X019 pin J2-17 wire 570 yellow. Locate the open and repair.

55-107

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 5. Disconnect the rear ladder sensor connector X251. Use a multimeter to check for continuity between the harness end of connector X251 pin 1 and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity to ground, the ground path for the sensor is open. Continue with step 6. 6. Disconnect the straw hood (SH) harness from the straw hood front (SW) harness at connector X071. Use a multimeter to check for continuity between the harness end of connector X071 pin 3 and chassis ground. A. If there is continuity, the open circuit is in the straw hood (SH) harness between connector X071 pin 3 and connector X251 pin 1 wire 481 blue. Locate the open and repair. B. If there is no continuity to ground, continue with step 7. 7. Disconnect the straw hood front (SW) harness from the main frame (MF) harness at connector X024. Use a multimeter to check for continuity between the harness end of connector X024 pin 11 and chassis ground. A. If there is continuity, the open circuit is in the straw hood front (SW) harness between connector X024 pin 11 and connector X071 pin 3 wire 481 blue or 461 blue. Locate the open and repair. B. If there in no continuity to ground, continue with step 8. 8. Disconnect the main frame (MF) harness from the front frame (FF) harness at connector X008. Use a multimeter to check for continuity between the harness end of connector X008 pin 7 and chassis ground. A. If there is continuity, the open circuit is in the main frame (MF) harness between connector X024 pin 11 and connector X008 pin 7 wire 461 blue or 401 blue. Locate the open and repair. B. If there is no continuity to ground, the open circuit is in the front frame (FF) harness between connector X008 pin 7 and connector X020 pin J3-18 wire 401 blue or 501 blue. Locate the open and repair. 9. Turn the key to ON position. Observing the LED on the harness end side of the sensor, raise and lower the ladder. The sensor is functioning if LED changes state. Erase the error code and, continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 1

40025227

6 2

50026220

10020075

10020076

50020083

20 1. REAR LADDER SENSOR B22 2. CONNECTOR X071 3. CONNECTOR X024

4. CONNECTOR X008 5. CONNECTOR X019 6. CONNECTOR X020

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

B-22 = REAR LADDER F-23 = SCREEN BRUSH FUSE F-28 = FUEL PUMP FUSE K-07 = FUEL PUMP RELAY

M-23 = FUEL PUMP M-27 = ROTARY SCREEN BRUSH R-01 = FUEL LEVEL S-36 = ENGINE THROTTLE

S-61 = AIR FILTER SWITCH S-67 = COOLANT LEVEL

STARTING FRAME--3

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0029-03 Lateral Float Sensor Shorted To High Source Cause: The lateral float sensor (R02) circuit is shorted to high voltage, or the sensor ground is open. Possible failure modes: 1. Sensor supply or signal wiring is shorted to high voltage (12V). 2. Sensor ground wiring is open. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. Tilt the feeder cradle side to side several times while monitoring the voltage; the voltage should stay within range, and should change smoothly with feeder cradle movement. The proper voltage range for a properly adjusted sensor is 0.2 to 4.7 volts. A. If the voltage reading is high (>4.7 volts) out of range, continue with Step 2. B. If the voltage reading is within the proper limits, the circuit may not be shorted at this time. Continue the troubleshooting at step 11. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Key off. Disconnect connector X081, and use a multimeter to test for continuity to ground on connector X081 pin B. There should be low resistance (<1 ohm) to ground. A. If continuity is found (<1 ohm), continue with step 6. B. If no continuity is found, or there is high resistance (>1 ohm) to ground, continue with step 3. 3. Key off. Disconnect connector X007. Use a multimeter to test for continuity between connector X007 pin 12 and chassis ground. There should be low resistance (<1 ohm) to ground. A. If no continuity is found, or there is high resistance (>1 ohm) to ground, continue with step 4. B. If continuity is found, there is an open circuit in feeder (FE) harness between connector X081 pin B and connector X007 pin 12 wire 745 blue or 749 blue. Locate the open and repair. 4. Key off. Carefully remove connector X020 to the bottom of CCM1. Use a multimeter to test for continuity between connector X007 pin 12 and connector X020 pin J3-18. A. If continuity is found, continue with step 5. B. If no continuity is found, there is an open circuit in front frame (FF) harness between connector X007 pin 12 and connector X020 pin J3-18 wire 749 blue or 501 blue. Locate the open and repair. 5. Key off. Use a multimeter to test for continuity between connector X020 pin J3-18 on CCM1 and chassis ground. There should be low resistance (<1 ohm) to ground. A. If no continuity is found, or there is high resistance (>1 ohm) to ground, the CCM1 module is not supplying a ground path for the sensor due to an internal failure. Replace the CCM1 module. B. If continuity is found, the ground path for the sensor tests okay. Reconnect all connectors and retest for continuity to ground at step 2.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 6. Disconnect connector X081, and use a multimeter to test for voltage on connector X081 pin C. There should not be any voltage present. A. If no voltage is found, continue with step 8. B. If high (>4.7V) voltage is found, continue with step 7. 7. Disconnect connector X007, and use a multimeter to test for voltage on the front frame (FF) harness end of connector X007 pin 17. There should not be any voltage present. A. If high (>4.7V) voltage is found, there is a short to high voltage in the front frame (FF) harness between connector X007 pin 17 and connector X020 pin J3-17 wire 741 yellow. Locate the short and repair. B. If no voltage is found, there is a short to high voltage in the feeder (FE) harness between connector X081 pin C and connector X007 pin 17 wire 741 yellow. Locate the short and repair. 8. Disconnect connector X081, and use a multimeter to test for voltage on connector X081 pin A. There should be 5 volts present. A. If 5 volts is found, continue with step 11. B. If high (>5V) voltage is found, continue with step 9. NOTE: This supply circuit is also used to supply power to the shoe leveling sensor in the shoe leveling actuator M03, so a short to 12 volts anywhere on the supply circuit will activate this error code. 9. Disconnect connector X007, and use a multimeter to test for voltage on connector X007 pin 22. There should be 5 volts present. A. If 5 volts is found, there is a short to high voltage in the feeder (FE) harness between connector X081 pin A and connector X007 pin 22 wire 757 pink. Locate the short and repair. B. If high (>5V) voltage is found, continue with step 10. 10. Disconnect connector X023, and use a multimeter to test for voltage on the front frame (FF) harness end of connector X023 pin 17. A. If 5 volts is found, there is a short to high voltage in the lower frame (LF) harness between connector X088 pin A on the shoe leveling actuator M03 and connector X023 pin 17 wire 727 pink. Locate the short and repair. B. If high (>5V) voltage is found, there is a short to high voltage in the front frame (FF) harness between connector X023 pin 17, connector X007 pin 22 and connector X020 pin J3-26 on one of the following wires: wire 757 pink, connector X007 pin 22 to FF harness splice wire 727 pink, connector X023 pin 17 to FE harness splice wire 726 pink, FE harness splice to connector X020 pin J3-26 Locate the short and repair. 11. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation. If the fault code immediately resets, determine which 12 volt circuit (such as the shoe leveling actuator) was activated to cause the short.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0029-05 Lateral Float Sensor Line Disconnected Cause: The lateral float sensor (R02) circuit is open or shorted to ground. Possible failure modes: 1. Sensor signal wiring is open or shorted to ground. 2. Loss of power to the sensor. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. Tilt the feeder cradle side to side several times while monitoring the voltage; the voltage should stay within range, and should change smoothly with feeder cradle movement. The proper voltage range for a properly adjusted sensor is 0.2 to 4.7 volts. A. If the voltage reading is low (<0.2 volts) out of range, continue with Step 2. B. If the voltage reading is within the proper limits, the circuit may not be open or shorted to ground at this time. Continue the troubleshooting at step 8. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Disconnect connector X081, and use a multimeter to test for voltage on connector X081 pin A. There should be 5 volts present. A. If 5 volts is found, continue with step 4. B. If no voltage is found, continue with step 3. 3. Disconnect connector X007, and use a multimeter to test for voltage on connector X007 pin 22. There should be 5 volts present. A. If 5 volts is found, there is an open circuit in the feeder (FE) harness between connector X081 pin A and connector X007 pin 22 wire 757 pink. Locate the open and repair. B. If no voltage is found, there is an open circuit in the front frame (FF) harness between connector X007 pin 22 and connector X020 pin J3-26 wire 757 pink or 726 pink. Locate the open and repair. 4. Disconnect connector X081. Use a multimeter to check for continuity between connector X081 pin C and ground. A. If continuity is found, continue with step 5. B. If no continuity is found, continue with step 6. 5. Disconnect connector X007. Use a multimeter to check for continuity between connector X007 pin 17 and ground. A. If no continuity is found, there is a short to ground in the feeder (FE) harness between connector X081 pin C and connector X007 pin 17 wire 741 yellow. Locate the short and repair. B. If continuity is found, there is a short to ground in the front frame (FF) harness between connector X007 pin 17 and connector X020 pin J3-17 wire 741 yellow. Locate the short and repair.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 6. Disconnect connector X081 and connector X007. Use a multimeter to check for continuity between connector X081 pin C and connector X007 pin 17. A. If continuity is found, continue with step 7. B. If no continuity is found, there is an open circuit in the feeder (FE) harness between connector X081 pin C and connector X007 pin 17 wire 741 yellow. Locate the open and repair. 7. Carefully disconnect connector X020 to the bottom of CCM1 module. Use a multimeter to check for continuity between connector X007 pin 17 and connector X020 pin J3-17. A. If continuity is found, the open is in the sensor. Replace the sensor. B. If no continuity is found, there is an open circuit in the front frame (FF) harness between connector X007 pin 17 and connector X020 pin J3-17 wire 741 yellow. Locate the open and repair. 8. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

40024707

10020040 50020085

21 1. LATERAL FLOAT POTENTIOMETER R02 2. CONNECTOR X007

3. CONNECTOR X020

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

HEADER FRAME--14

A-07 = HHC MODULE B-29 = HEADER LIFT PRESSURE L-06 = HEADER HEIGHT ACCUMULATOR L-18 = LATERAL FLOAT CW

L-19 = LATERAL FLOAT CCW R-02 = LATERAL FLOAT POT R-03 = FEEDER ANGLE R-12 = LEFT STUBBLE HEIGHT

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R-13 = RIGHT STUBBLE HEIGHT

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0032-03 Shoe Position Sensor Shorted To High Source Cause: The shoe leveling actuator (M03) position sensor circuit is shorted to high voltage, or the sensor ground is open. Possible failure modes: 1. Sensor supply or signal wiring is shorted to high voltage (12V). 2. Sensor ground wiring is open. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.3 to 5.2 volts. A. If the voltage reading is high (>5.2 volts) out of range, continue with Step 2. B. If the voltage reading is within the proper limits, the circuit may not be shorted at this time. Continue the troubleshooting at step 11. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Key off. Disconnect connector X088, and use a multimeter to test for continuity to ground on connector X088 pin B. There should be low resistance (<1 ohm) to ground. A. If continuity is found (<1 ohm), continue with step 6. B. If no continuity is found, or there is high resistance (>1 ohm) to ground, continue with step 3. 3. Key off. Disconnect connector X023. Use a multimeter to test for continuity between connector X023 pin 16 and chassis ground. There should be low resistance (<1 ohm) to ground. A. If no continuity is found, or there is high resistance (>1 ohm) to ground, continue with step 4. B. If continuity is found, there is an open circuit in lower frame (LF) harness between connector X088 pin B and connector X023 pin 16 wire 724 blue or 723 blue. Locate the open and repair. 4. Key off. Carefully remove connector X020 to the bottom of CCM1. Use a multimeter to test for continuity between connector X023 pin 16 and connector X020 pin J3-18. A. If continuity is found, continue with step 5. B. If no continuity is found, there is an open circuit in front frame (FF) harness between connector X023 pin 16 and connector X020 pin J3-18 wire 723 blue or 501 blue. Locate the open and repair. 5. Key off. Use a multimeter to test for continuity between connector X020 pin J3-18 on CCM1 and chassis ground. There should be low resistance (<1 ohm) to ground. A. If no continuity is found, or there is high resistance (>1 ohm) to ground, the CCM1 module is not supplying a ground path for the sensor due to an internal failure. Replace the CCM1 module. B. If continuity is found, the ground path for the sensor tests okay. Reconnect all connectors and retest for continuity to ground at step 2.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 6. Disconnect connector X088, and use a multimeter to test for voltage on connector X088 pin C. There should not be any voltage present. A. If no voltage is found, continue with step 8. B. If high (>5.2V) voltage is found, continue with step 7. 7. Disconnect connector X023, and use a multimeter to test for voltage on the front frame (FF) harness end of connector X023 pin 15. There should not be any voltage present. A. If high (>5.2V) voltage is found, there is a short to high voltage in the front frame (FF) harness between connector X023 pin 15 and connector X020 pin J3-32 wire 721 yellow. Locate the short and repair. B. If no voltage is found, there is a short to high voltage in the lower frame (LF) harness between connector X088 pin C and connector X023 pin 15 wire 721 yellow. Locate the short and repair. 8. Disconnect connector X088, and use a multimeter to test for voltage on connector X088 pin A. There should be 5 volts present. A. If 5 volts is found, continue with step 11. B. If high (>5.2V) voltage is found, continue with step 9. NOTE: This supply circuit is also used to supply power to the lateral float sensor, so a short to 12 volts anywhere on the supply circuit will activate this error code. 9. Disconnect connector X023, and use a multimeter to test for voltage on connector X023 pin 17. There should be 5 volts present. A. If 5 volts is found, there is a short to high voltage in the lower frame (LF) harness between connector X088 pin A and connector X023 pin 17 wire 727 pink. Locate the short and repair. B. If high (>5.2V) voltage is found, continue with step 10. 10. Disconnect connector X007, and use a multimeter to test for voltage on the front frame (FF) harness end of connector X007 pin 22. A. If 5 volts is found, there is a short to high voltage in the feeder (FE) harness between connector X081 pin A on the lateral float sensor R02 and connector X007 pin 22 wire 757 pink. Locate the short and repair. B. If high (>5V) voltage is found, there is a short to high voltage in the front frame (FF) harness between connector X023 pin 17, connector X007 pin 22 and connector X020 pin J3-26 on one of the following wires: wire 757 pink, connector X007 pin 22 to FF harness splice wire 727 pink, connector X023 pin 17 to FF harness splice wire 726 pink, FF harness splice to connector X020 pin J3-26 Locate the short and repair. 11. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation. If the fault code immediately resets, determine which 12 volt circuit (such as the shoe leveling actuator) was activated to cause the short.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0032-05 Shoe Position Sensor Line Disconnected Cause: The shoe leveling actuator (M03) position sensor circuit is open or shorted to ground. Possible failure modes: 1. Sensor signal wiring is open or shorted to ground. 2. Loss of power to the sensor. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.3 to 5.2 volts. A. If the voltage reading is low (<0.3 volts) out of range, continue with Step 2. B. If the voltage reading is within the proper limits, the circuit may not be open or shorted to ground at this time. Continue the troubleshooting at step 8. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Disconnect connector X088, and use a multimeter to test for voltage on connector X088 pin A. There should be 5 volts present. A. If 5 volts is found, continue with step 4. B. If no voltage is found, continue with step 3. 3. Disconnect connector X023, and use a multimeter to test for voltage on connector X023 pin 17. There should be 5 volts present. A. If 5 volts is found, there is an open circuit in the lower frame (LF) harness between connector X088 pin A and connector X023 pin 17 wire 727 pink. Locate the open and repair. B. If no voltage is found, there is an open circuit in the front frame (FF) harness between connector X023 pin 17 and connector X020 pin J3-26 wire 727 pink or 726 pink. Locate the open and repair. 4. Disconnect connector X088. Use a multimeter to check for continuity between connector X088 pin C and ground. A. If continuity is found, continue with step 5. B. If no continuity is found, continue with step 6. 5. Disconnect connector X023. Use a multimeter to check for continuity between connector X023 pin 15 and ground. A. If no continuity is found, there is a short to ground in the lower frame (LF) harness between connector X088 pin C and connector X023 pin 15 wire 721 yellow. Locate the short and repair. B. If continuity is found, there is a short to ground in the front frame (FF) harness between connector X023 pin 15 and connector X020 pin J3-32 wire 721 yellow. Locate the short and repair.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 6. Disconnect connector X088 and connector X023. Use a multimeter to check for continuity between connector X088 pin C and connector X023 pin 15. A. If continuity is found, continue with step 7. B. If no continuity is found, there is an open circuit in the lower frame (LF) harness between connector X088 pin C and connector X023 pin 15 wire 721 yellow. Locate the open and repair. 7. Carefully disconnect connector X020 to the bottom of CCM1 module. Use a multimeter to check for continuity between connector X023 pin 15 and connector X020 pin J3-32. A. If continuity is found, the open is in the sensor. Replace the sensor. B. If no continuity is found, there is an open circuit in the front frame (FF) harness between connector X023 pin 15 and connector X020 pin J3-32 wire 721 yellow. Locate the open and repair. 8. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

10004665

10010898 50020089

22 1. SHOE LEVELING ACTUATOR M03 2. CONNECTOR X023 3. CONNECTOR X020

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

B-16 = CLEANING FAN RPM B-21 = SIEVES LOSS F-22 = SHOE LEVELING MOTOR FUSE L-44 = FAN DRIVE SOLENOID

M-03 = SHOE LEVELING ACTUATOR S-13 = UPPER SIEVE S-14 = LOWER SIEVE S-15 = FAN SPEED

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CLEANING FRAME--19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0033-03 Lateral Inclination Sens Shorted To High Source Cause: The lateral inclination sensor (B02) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range for the lateral inclination sensor is 0.3 to 5.2 volts. A. If the voltage reading is high out of range, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 3. 2. The voltage reading is high. Disconnect the lateral inclination sensor connector X170. A. If the voltage drops back to 0.3 to 5.2 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains high, then the short circuit is in the main frame (MF) harness between connector X170 and connector X019 J2-33 wire 430 yellow. Locate the short and repair. 3. Visually inspect harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. If no damage is found, erase fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0033-05 Lateral Inclination Sens Line Disconnected Cause: The lateral inclination sensor (B02) circuit is open or shorted to ground. Possible failure modes: 1. Sensor signal wiring is open or shorted to ground. 2. Loss of power to the sensor. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.3 to 5.2 volts. A. If the voltage reading is low (<0.3 volts) out of range, continue with Step 2. B. If the voltage reading is within the proper limits, the circuit may not be open or shorted to ground at this time. Continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Key on. Disconnect connector X170, and use a multimeter to test for voltage on connector X170 pin A. There should be 5 volts present. A. If 5 volts is found, continue with step 3. B. If no voltage is found, there is an open circuit in the main frame (MF) harness between connector X170 pin A and connector X019 pin J2-31 wire 451 pink or 453 pink. Locate the open and repair. 3. Key off. Disconnect connector X170. Use a multimeter to check for continuity between connector X170 pin C and ground. A. If no continuity is found, continue with step 4. B. If continuity is found, there is a short to ground in the main frame (MF) harness between connector X170 pin C and connector X019 pin J2-33 wire 430 yellow. Locate the short and repair. 4. Key off. Carefully disconnect connector X019 to the bottom of the CCM1 module. Use a multimeter to check for continuity between connector X170 pin C and connector X019 pin J2-33. A. If continuity is found, the open is in the sensor. Replace the sensor. B. If no continuity is found, there is an open circuit in the main frame (MF) harness between connector X170 pin C and connector X019 pin J2-33 wire 430 yellow. Locate the open and repair. 5. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation.

55-127

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

10004686

50020091

23 1. LATERAL INCLINATION SENSOR B02

55-128

2. CONNECTOR X019

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

CLEANING FRAME--20

B-02 = LATERAL INCLINATION B-06 = LEFT RETURNS RPM B-08 = CLEAN GRAIN ELEVATOR RPM B-19 = LEFT ROTOR LOSS

B-20 = RIGHT ROTOR LOSS B-39 = RIGHT RETURNS RPM

55-129

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0034-03 Concave Position Sensor Shorted To High Source Cause: The concave position sensor (R06) circuit is shorted to high voltage, or the sensor ground is open. Possible failure modes: 1. Sensor supply or signal wiring is shorted to high voltage (12V). 2. Sensor ground wiring is open. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.3 to 5.2 volts. A. If the voltage reading is high (>5.2 volts) out of range, continue with Step 2. B. If the voltage reading is within the proper limits, the circuit may not be shorted at this time. Continue the troubleshooting at step 7. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Key off. Disconnect connector X189, and use a multimeter to test for continuity to ground on connector X189 pin B. There should be low resistance (<1 ohm) to ground. A. If continuity is found (<1 ohm), continue with step 5. B. If no continuity is found, or there is high resistance (>1 ohm) to ground, continue with step 3. 3. Key off. Carefully remove connector X019 to the bottom of CCM1. Use a multimeter to test for continuity between connector X189 pin B and connector X019 pin J2-14. A. If continuity is found, continue with step 4. B. If no continuity is found, there is an open circuit in the main frame (MF) harness between connector X189 pin B and connector X019 pin J2-14 wire 456 blue or 460 blue. Locate the open and repair. 4. Key off. Use a multimeter to test for continuity between connector X019 pin J2-14 on CCM1 and chassis ground. There should be low resistance (<1 ohm) to ground. A. If no continuity is found, or there is high resistance (>1 ohm) to ground, the CCM1 module is not supplying a ground path for the sensor due to an internal failure. Replace the CCM1 module. B. If continuity is found, the ground path for the sensor tests okay. Reconnect all connectors and retest for continuity to ground at step 2. 5. Disconnect connector X189, and use a multimeter to test for voltage on connector X189 pin C. There should not be any voltage present. A. If no voltage is found, continue with step 6. B. If high (>5.2V) voltage is found, there is a short to high voltage in the main frame (MF) harness between connector X189 pin C and connector X019 pin J2-19 wire 411 yellow. Locate the short and repair.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 6. Disconnect connector X189, and use a multimeter to test for voltage on connector X189 pin A. There should be 5 volts present. NOTE: This supply circuit is also used to supply power to the lateral inclination sensor B02, so a short to 12 volts anywhere on the supply circuit will activate this error code. A. If 5 volts is found, continue with step 7. B. If high (>5.2V) voltage is found, there is a short to high voltage in the main frame (MF) harness between connector X189 pin A, connector X170 pin A and connector X019 pin J2-31 on one of the following wires: wire 498 pink, connector X189 pin A to MF harness splice wire 451 pink, connector X170 pin A to MF harness splice wire 453 pink, MF harness splice to connector X019 pin J2-31 Locate the short and repair. 7. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation. If the fault code immediately resets, determine which 12 volt circuit (such as the concave clearance motor) was activated to cause the short.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0034-05 Concave Position Sensor Line Disconnected Cause: The concave position sensor (R06) circuit is open or shorted to ground. Possible failure modes: 1. Sensor signal wiring is open or shorted to ground. 2. Loss of power to the sensor. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.3 to 5.2 volts. A. If the voltage reading is low (<0.3 volts) out of range, continue with Step 2. B. If the voltage reading is within the proper limits, the circuit may not be open or shorted to ground at this time. Continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Disconnect connector X189, and use a multimeter to test for voltage on connector X189 pin A. There should be 5 volts present. A. If 5 volts is found, continue with step 3. B. If no voltage is found, there is an open circuit in the main frame (MF) harness between connector X189 pin A and connector X019 pin J2-31 wire 498 pink or 453 pink. Locate the open and repair. 3. Disconnect connector X189. Use a multimeter to check for continuity between connector X189 pin C and ground. A. If no continuity is found, continue with step 4. B. If continuity is found, there is a short to ground in the front frame (FF) harness between connector X189 pin C and connector X019 pin J2-19 wire 411 yellow. Locate the short and repair. 4. Carefully disconnect connector X019 to the bottom of CCM1 module. Use a multimeter to check for continuity between connector X189 pin C and connector X019 pin J2-19. A. If continuity is found, the open is in the sensor. Replace the sensor. B. If no continuity is found, there is an open circuit in the main frame (MF) harness between connector X189 pin C and connector X019 pin J2-19 wire 411 yellow. Locate the open and repair. 5. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation.

55-133

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

40025229

50020091

24 1. CONCAVE POSITION SENSOR R06

2. CONNECTOR X019

55-134

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

B-45 = GEARBOX CLUTCH TEMP K-16 = CONCAVE/COVERS RELAY M-04 = CONCAVE CLEARANCE MOTOR M-12 = COVERS MOTOR

R-06 = CONCAVE POSITION S-16 = CONCAVE CLEARANCE

THRESHER FRAME--17

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0037-03 CCM1 5V Ref Voltage 3 Shorted To High Source Cause: The circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Circuit wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 4.5 to 5.5 volts. A. If the voltage reading is high out of range, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. 2. The voltage reading is high. Disconnect the concave position sensor connector X189. A. If the voltage drops back to the normal range, the short is in the concave position sensor, or sensor wiring. Replace the concave position sensor. B. If the voltage remains high, continue with Step 3. 3. The voltage reading is high. Disconnect the lateral inclination sensor connector X170. A. If the voltage drops back to the normal range, the short is in the lateral inclination sensor, or sensor wiring. Replace the sensor. B. If the voltage remains high, then the short circuit is in the main frame (MF) harness between connector X170, connector X189, and connector X019 J2-31 wires 498, 451 or 453 pink. Locate the short and repair. 4. Visually inspect harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. If no damage is found, erase fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0037-04 CCM1 5V Ref Voltage 3 Shorted To Low Source Cause: The circuit is shorted to ground. Possible failure modes: 1. Circuit wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 4.5 to 5.5 volts. A. If the voltage reading is low (less than 4.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 4. 2. The voltage reading is low. Disconnect the concave position sensor connector X189. A. If the voltage increases to 4.5 to 5.5 volts, the short is in the concave position sensor, or sensor wiring. Replace the concave position sensor. B. If the voltage remains low, continue with Step 3. 3. The voltage reading is low. Disconnect the lateral inclination sensor connector X170. A. If the voltage increases to 4.5 to 5.5 volts, the short is in the lateral inclination sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low, then the short circuit is in the main frame (MF) harness between connector X170, connector X189, and connector X019 J2-31 wires 498, 451 or 453 pink. Locate the short and repair. 4. Visually inspect harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. If no damage is found, erase fault code and continue operation.

55-138

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

40025229

10004686

50020091

25 1. CONCAVE POSITION SENSOR R06 2. LATERAL INCLINATION SENSOR B02

3. CONNECTOR X019

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

B-45 = GEARBOX CLUTCH TEMP K-16 = CONCAVE/COVERS RELAY M-04 = CONCAVE CLEARANCE MOTOR M-12 = COVERS MOTOR

R-06 = CONCAVE POSITION S-16 = CONCAVE CLEARANCE

THRESHER FRAME--17

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

CLEANING FRAME--20

B-02 = LATERAL INCLINATION B-06 = LEFT RETURNS RPM B-08 = CLEAN GRAIN ELEVATOR RPM B-19 = LEFT ROTOR LOSS

B-20 = RIGHT ROTOR LOSS B-39 = RIGHT RETURNS RPM

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0038-03 CCM1 8V Ref Voltage Shorted To High Source Cause: The CCM1 8V Ref Voltage circuit is shorted to a higher than normal source. Possible failure modes: 1. 12V short on 8V regulated power circuit. 2. Controller internal failure (internal regulator failure). Solution: The 8V regulated power supply is provided from the key switch power to the module, and is used to provide power to all the speed and position sensor circuits. In some cases, a 12V short on one of the sensor signal wires could result in backfeeding that upsets the 8V regulator, and may cause the short to high source fault. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage is 7.5 to 8.5 volts. A. If the reading is high out of range, continue with step 2. B. If the reading is within the proper range, reload the software in CCM1. Erase the fault code and continue operation. If the fault code persists, replace the module. 2. Turn off the key switch, and disconnect the battery key to remove all power from the module. Carefully remove connector X019 and connector X020 to the bottom of CCM1 module. Reconnect the battery key. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage is 7.5 to 8.5 volts. A. If the voltage reading is normal, there is a short to high source on one of the sensor wires. Continue with step 3. B. If the voltage reading is still high out of range, then CCM1 has an internal failure. Replace the controller. 3. Turn off the key switch, and disconnect the battery key to remove all power from the module. Carefully reconnect connector X019 and connector X020 to the bottom of CCM1 module. Reconnect the battery key and use the display monitor, reference Section 55 Chapter 2, if needed, check for any errors for sensor circuits short to high source on CCM1 module. A. If there are any sensor circuits on CCM1 that are shorted to high source, correct those circuits, and continue with step 1 of this troubleshooting to verify this concern is resolved. B. If there are no sensor circuits errors on CCM1, reload the software in CCM1. Erase the fault code and continue operation. If the fault code persists, replace the module.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0038-04 CCM1 8V Ref Voltage Shorted To Low Source Cause: The CCM1 8V Ref Voltage circuit is shorted to ground. Possible failure modes: 1. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage is 7.5 to 8.5 volts. A. If the voltage reading is low out of range, then CCM1 has an internal failure. Replace the controller. B. If the voltage reading is within proper limits, the failure may not be present at this time. Continue diagnosis with step 2. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation.

55-144

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0039-03 CCM1 5V Ref Voltage 1 Shorted To High Source Cause: The circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Circuit wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 4.5 to 5.5 volts. A. If the voltage reading is high out of range, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. 2. The voltage reading is high. Disconnect the lower frame (LF) harness from the front frame (FF) harness at connector X023. A. If the voltage drops back to the normal range, the short is in the lower frame (LF) harness between connector X023 and the shoe leveling actuator (M03) wire 727 pink. Locate the short and repair. B. If the voltage remains high, continue with Step 3. 3. The voltage reading is high. Disconnect the feeder (FE) harness from the front frame (FF) harness at connector X007. A. If the voltage drops back to the normal range, the short is in the feeder (FE) harness between connector X007 and the lateral float potentiometer (R02) wire 757 pink. Locate the short and repair. B. If the voltage remains high, the short circuit is in the front frame (FF) harness between connector X023, connector X007 and connector X020 J3-26 wires 726, 727 or 757 pink. Locate the short and repair. 4. Visually inspect harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. If no damage is found, erase fault code and continue operation.

55-145

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0039-04 CCM1 5V Ref Voltage 1 Shorted To Low Source Cause: The circuit is shorted to ground. Possible failure modes: 1. Circuit wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 4.5 to 5.5 volts. A. If the voltage reading is low (less than 4.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 4. 2. The voltage reading is low. Disconnect the lower frame (LF) harness from the front frame (FF) harness at connector X023. A. If the voltage increases to 4.5 to 5.5 volts, the short is in the lower frame (LF) harness between connector X023 and the shoe leveling actuator (M03) wire 727 pink. Locate the short and repair. B. If the voltage remains low, continue with Step 3. 3. The voltage reading is low. Disconnect the feeder (FE) harness from the front frame (FF) harness at connector X007. A. If the voltage increases to 4.5 to 5.5 volts, the short is in the feeder (FE) harness between connector X007 and the lateral float potentiometer (R02) wire 757 pink. Locate the short and repair. B. If the voltage remains low, the short circuit is in the front frame (FF) harness between connector X023, connector X007 and connector X020 J3-26 wires 726, 727 or 757 pink. Locate the short and repair. 4. Visually inspect harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. If no damage is found, erase fault code and continue operation.

55-146

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

1 10004665

10020040

3 4

10010898 50020094

40024707

26 1. LATERAL FLOAT POTENTIOMETER R02 2. SHOE LEVELING ACTUATOR M03 3. CONNECTOR X023

4. CONNECTOR X007 5. CONNECTOR X020

55-147

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

HEADER FRAME--14

A-07 = HHC MODULE B-29 = HEADER LIFT PRESSURE L-06 = HEADER HEIGHT ACCUMULATOR L-18 = LATERAL FLOAT CW

L-19 = LATERAL FLOAT CCW R-02 = LATERAL FLOAT POT R-03 = FEEDER ANGLE R-12 = LEFT STUBBLE HEIGHT

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R-13 = RIGHT STUBBLE HEIGHT

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

B-16 = CLEANING FAN RPM B-21 = SIEVES LOSS F-22 = SHOE LEVELING MOTOR FUSE L-44 = FAN DRIVE SOLENOID

M-03 = SHOE LEVELING ACTUATOR S-13 = UPPER SIEVE S-14 = LOWER SIEVE S-15 = FAN SPEED

55-149

CLEANING FRAME--19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-150

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0040-03 CCM1 Key Switch Voltage Shorted To High Source Cause: The circuit is shorted to a higher than normal source. Possible failure modes: 1. Circuit wiring shorted to high voltage source. 2. Faulty alternator/regulator. 3. Controller internal failure (internal regulator failure). Solution: Key switch voltage is used to initialize (wake-up) the module, and also supplies power to the 5V and 8V regulators for the regulated voltage circuits. The module will shutdown if the voltage is less than 9 volts, but there is no shutdown for excessive voltage. 1. Start the combine engine. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. Increase the engine RPM to high idle (maximum) and check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is greater than 18 volts, continue with Step 2. B. If the voltage reading is between 10 and 18 volts, go to Step 5. 2. Shut off the combine engine, and then turn the key switch on again. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, the alternator and/or regulator has failed, and is producing excessive voltage. Refer to “Charging Systems” in Chapter 5 -- Engine Systems in this section for additional alternator testing information. B. If the voltage reading is greater than 18 volts, continue with Step 3. 3. Turn the key switch off to power down the system. Check the voltage at fuse F38 using a multi-meter. A. If the voltage reading is greater than 18 volts, then the batteries have been mistakenly connected in series, or there is a fault in the wiring of the 24V starting system. Refer to “Starting Systems” in Chapter 5 -- Engine Systems in this section for additional information. B. If the voltage reading is between 10 and 18 volts, continue with Step 4.

55-151

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 4. Remove the buddy seat and storage bin to gain access to connector X018 on CCM1. Turn the key on. Check the voltage at connector X018 pin J1-4. A. If the voltage reading is greater than 18 volts, then a high voltage source has been connected to one of the following wires in the cab main (CM) harness. wire 053 red, fuse F38 to key switch S02 pin 1 wire 859 orange, key switch S02 pin 5 to ECU connector X193 pin 40 wire 096 orange, key switch S02 pin 6 to CM harness splice wire 055 orange, CM harness splice to Road Light switch S26 pin 6 wire 095 orange, CM harness splice to CCM1 Power relay K24 pin 1 wire 103 orange, CCM1 power relay K24 pin 1 to CCM2 Power relay K25 pin 1 wire 104 orange, CCM2 Power relay K25 pin 1 to Cab Power relay K26 pin 1 wire 222 orange, Cab Power relay pin 1 to Time Delay module K20 pin 30 wire 101 orange, CM harness splice to CCM3 connector X012 pin J1-4 wire 100 orange, CM harness splice to CCM2 connector X015 pin J1-4 wire 099 orange, CM harness splice to CCM1 connector X018 pin J1-4 Locate the source of high voltage and repair. B. If the voltage reading is 10 to 18 volts, and the diagnostic screen is still indicating voltage in excess of 18 volts, there is an internal fault in CCM1. Reload the software for CCM1. If that does not correct the concern, replace the module. 5. Erase the error code and, continue operation.

55-152

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0040-04 CCM1 Key Switch Voltage Shorted To Low Source Cause: Low battery voltage to CCM1, or the circuit is shorted to ground. Possible failure modes: 1. Loose or corroded connections, or damaged wires. 2. Batteries are discharged, and/or alternator/regulator failure. 3. CCM1 supply wiring from key switch shorted to ground. NOTE: Check fuse F38. If a short to ground occurred on this circuit the fuse will have blown. 4. Controller internal “failure (internal regulator failure). Solution: Key switch voltage is used to initialize (wake-up) the module, and also supplies power to the 5V and 8V regulators for the regulated voltage circuits. The module will shutdown if the voltage is less than 9 volts, but there is no shutdown for excessive voltage. 1. Key switch in “Off” position. Check fuse F38. A. If fuse F38 is okay, continue with Step 6. B. If the fuse is blown, go to Step 2. 2. Replace the failed fuse F38. A. If the fuse is okay, continue with Step 3. B. If the fuse immediately fails again, a short to ground exists in wire 053 red between the fuse and the key switch S02 in the cab main (CM) harness. Visually inspect the cab main (CM) harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair. 3. If the fuse does not fail when it is replaced, turn the key switch to the “Acc” position. A. If the fuse is okay, continue with Step 4. B. If the fuse immediately fails, there is a short to ground in one of the following wires: wire 123 orange, key switch to the Wiper relay K06 pin 1 wire 241 orange, Wiper relay K06 pin 1 to Accessory 1 relay K08 pin 1 wire 126 orange, Accessory 1 relay K08 pin 1 to Accessory 2 relay K03 pin 1 All three wires are in the cab main (CM) harness. Visually inspect the cab main (CM) harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair.

55-153

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 4. If the fuse does not fail with the key switch in the “Acc” position, turn the key switch to the “On” position. A. If the fuse is okay, continue with Step 5. B. If the fuse immediately fails, there is a short to ground in one of the following wires: wire 859 orange, key switch to ECU connector X193 pin 40 wire 096 orange, key switch to cab main (CM) harness splice wire 055 orange, CM harness splice to Road Light Switch S26 wire 095 orange, CM harness splice to CCM power relays K24, K25, K26 and Time delay module K20 wires 099, 100 & 101 orange to pins J1-4 on CCM’s 1, 2 & 3 All wires except wire 859 orange to ECU are in the cab main (CM) harness. Visually inspect the cab main (CM) harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair. 5. If the fuse does not fail with the key switch in the “On” position, turn the key switch briefly to the “Start” position. A. If the fuse is okay, continue with Step 6. B. If the fuse immediately fails, there is a short to ground in one of the following wires: wire 091 orange, key switch to Neutral start relay K23 pin 3 wire 090 orange, neutral start relay K23 pin 3 to CCM2, connector X015, pin 21 wire 502 white, neutral start relay K23 pin 5 to starting relay K15 pin 1 Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair. 6. Key switch in “Off” position. Check the voltage at fuse F38 using a multi-meter. A. If the voltage reading is between 10 and 18 volts, continue with Step 7. B. If the voltage reading is less than 10 volts, there is excessive resistance between the batteries and the cab fuse panel, due to loose or corroded connections, or the batteries have discharged excessively, and are not capable of supplying the minimum voltage requirement for CCM1. Inspect the wiring from the batteries to the engine compartment, and from there to the cab. Recharge or replace the batteries. 7. Key switch in “On” position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, continue with Step 8. B. If the voltage reading is less than 10 volts, there is excessive resistance between the fuse panel and CCM1. Inspect wire 053 red to the key switch, and wires 096 and 099 orange to CCM1 connector X018 pin J1-4 for loose or corroded connections, or damage to the wires. 8. Start the combine engine. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. With the engine RPM at low idle, engage road and work lights. Check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, continue with Step 9. B. If the voltage reading is less than 10 volts, the alternator and/or regulator may have failed, and the charging system is not producing sufficient voltage. Refer to “Charging Systems” in Chapter 7 -Electrical Systems, Schematics and Diagnostics for additional alternator testing information. 9. Erase the error code and, continue operation.

55-154

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

20013706

50020070 10004693 50020087

27 1. KEY SWITCH S02 2. CONNECTOR X018 3. FUSE F38

55-155

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

55-156

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0 L

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--28

F-36 = CCM-2A FUSE F-37 = CCM-2B FUSE F-40 = CCM-1 POWER FUSE F-41 = CCM-2 POWER FUSE

F-42 = CCM-3, CAB POWER FUSE K-24 = CCM-1 POWER RELAY K-25 = CCM-2 POWER RELAY K-26 = CCM-3, CAB POWER RELAY

55-157

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-158

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

LIGHTING FRAME--36

A-05 = FLASHER MODULE E-13 = LH ROAD LIGHT E-14 = RH ROAD LIGHT F-32 = HIGH BEAM FUSE

F-33 = LOW BEAM FUSE F-51 = HORN, MARKER LTS FUSE H-02 = HORN K-02 = LIGHT CONTROL RELAY

55-159

K-04 = HIGH BEAM RELAY K-05 = LOW BEAM RELAY S-26 = ROAD LIGHT SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

LIGHTING FRAME--38

E-34 = DOME LIGHT E-35 = CONSOLE LIGHT E-42 = LH FRONT SHIELD LT E-43 = LH REAR SHIELD LT

E-44 = RH FRONT SHIELD LT E-45 = RH REAR SHIELD LT E-46 = ENGINE LT F-34 = UNDERSHIELD LIGHTS

55-160

F-52 = DOME/BRAKE LT FUSE K-20 = TIME DELAY MODULE K-33 = BRAKE LIGHTS RELAY S-40 = LH DOOR SWITCH

S-63 = LEFT SHIELD LT SW S-64 = ENGINE LT SW S-65 = RIGHT SHIELD LT SW

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

F-03 = ACCESSORY 1 FUSE F-04 = WIPER FUSE F-05 = CIGAR LIGHTER FUSE F-08 = ACCESSORY OUTLET FUSE

F-09 = WASHER/MIRROR FUSE F-10 = NOT USED J-06 = ACCESSORY SOCKET J-08 = ACCESSORY OUTLET

K-06 = WIPER RELAY K-08 = ACCESSORY 1 RELAY M-24 = WIPER WASHER MOTOR M-25 = WIPER MOTOR

55-161

R-08 = CIGAR LIGHTER S-20 = WIPER SWITCH S-38 = WASHER SWITCH

ACCESSORY FRAME--45

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

ACCESSORY FRAME--46

A-04 = RADIO F-02 = ACCESSORY 2 FUSE F-11 = RADIO FUSE F-13 = TRANSCEIVER FUSE

F-16 = SEAT PUMP FUSE F-35 = RADIO KAPWR FUSE H-04 = REAR LEFT SPEAKER H-05 = FRONT LEFT SPEAKER

55-162

H-06 = REAR RIGHT SPEAKER H-07 = FRONT RIGHT SPEAKER J-07 = TRANSCEIVER OUTLET K-03 = ACCESSORY 2 RELAY

M-26 = SEAT PUMP MOTOR S-45 = SEAT ADJUST SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0042-06 Current Sense Reverser Short Circuit Cause: The reverser (M10) circuit indicates high current draw. Possible failure modes: 1. Circuit connection shorted. 2. Excessive mechanical load on motor. 3. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed. A. Start the combine. B. Engage the threshing mechanism and operate feeder reverser circuits in both directions. C. Does feeder reverser engage? D. Reload error history. E. Check for the following fault codes: E0042-06 and E0077-05. F. Use the following table to determine the location of the fault.

SYMPTOM

FAULT CODES E0042-06

Reverser operates in 1 direction only

Go to Step 2 (Mechanical failure)

Go to Step 3

Reverser does not operate in either direction Reverser does not operate in either direction

E0077-05

X NO FAULT CODE

Go to Step 8 Go to Step 17

2. The reverser motor actuator is bound up. See the appropriate service manual chapter for repair. 3. The reverser operates in one direction only. Fault codes indicate a short to ground. Disconnect the reverser motor connector X080. Measure the resistance on connector X080 between pin A and pin B. The proper resistance range for the coil is 4.0 to 8.0 ohms. A. If out of specification, replace reverser motor. B. If the motor coil resistance is within specification, continue with Step 4. 4. Measure the resistance on connector X080 between pin A and chassis ground. Flex the feeder and front frame (FF) harnesses while making this check. A. If no continuity to ground is found, continue with step 5. B. If there is continuity to ground, continue with Step 6.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 5. Disconnect connector X007. Use the multimeter to check for continuity between connector X007 pin 2 and chassis ground. A. If continuity is found, the short is between connector X080 and CCM1 connector X020 J3-6 wires 713, 761 or 770 gray in front frame (FF) harness. Locate the short and repair. B. If no continuity is found, the short to ground is in the feeder (FE) harness between connector X007 and connector X080 wire 770 gray. Locate the short and repair. 6. Disconnect connector X007. Use the multimeter to check for continuity between connector X007 pin 1 and chassis ground. A. If continuity is found, continue with Step 7. B. If no continuity is found, the short to ground is in the feeder (FE) harness between connector X007 and connector X080 wire 719 white. Locate the short and repair. 7. Disconnect connector X031. Use the multimeter to check for continuity between connector X031 pin 10 and chassis ground. A. If continuity is found, the short to ground is in the cab main (CM) harness between connector X031 and the relay base for relay K17 terminal 3 wire 719 white or connector X031 pin 8 to K17 terminal 3 wire 714 white. Locate the short and repair. B. If no continuity is found, the short to ground is in the front frame (FF) harness between connector X031 and connector X007 wire 719 white or connector X020 CCM1--J3--8 to connector X031 pin 8 wire 714 white. Locate the short and repair. 8. Reverser does not operate in either direction. Fault code indicates an open in circuit. Disconnect the reverser motor connector X080. Measure the resistance on connector X080 between pin A and pin B. The proper resistance range for the coil is 4.0 to 8.0 ohms. A. If out of specification, replace feeder reverser actuator. B. If the motor coil resistance is within specification, continue with Step 9. 9. Replace the fan/reverser relay K17 with a known good relay. Connect connector X080 and operate reverser. A. If the reverser is now working, troubleshooting is complete. B. If the reverser still does not work, continue with Step 10. 10. Disconnect reverser connector X080. Key switch on, engine running. Place straw elevator reverse tumbler switch in ON position. Activate reel speed increase to REVERSE. Use a multimeter to measure the voltage between connector X080 pin A and chassis ground. A. If 12 volts is read, continue with Step 11. B. If 12 volts is not read, continue with Step 13. 11. Key switch on engine running. Place straw elevator reverse tumbler switch in ON position. Activate reel speed decrease to ROCK. Use multimeter to measure the voltage between connector X080 pin B and chassis ground. A. If 12 volts is not read, continue with Step 12. B. If 12 volts is read, the open is in the feeder reverser actuator connector X080. 12. Disconnect connector X007. Key switch on, engine running. Activate reel speed decrease to ROCK. Use multimeter to measure the voltage between connector X007 pin 2 and chassis ground. A. If 12 volts is read, the open is in the feeder (FE) harness between connector X080 and connector X007 wire 770 gray. Locate the open and repair. B. If 12 volts is not read, the open is in the front frame (FF) harness between connector X007 and the next splice in wire 770 gray. Locate the open and repair. 13. Disconnect connector X007. Key switch on, engine running. Activate reel speed increase to REVERSE. Use a multimeter to measure the voltage between connector X007 pin 1 and chassis ground. A. If 12 volts is read, the open is in the feeder (FE) harness between connector X007 and connector X080 wire 719 white. Locate the open and repair. B. If 12 volts is not read, continue with Step 14.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 14. Disconnect connector X031. Key switch on, engine running. Activate reel speed increase to REVERSE. Use a multimeter to measure the voltage between connector X031 pin 10 and chassis ground. A. If 12 volts is read, the open is in the front frame (FF) harness between connector X031 and connector X007 wire 719 white. Locate the open and repair. B. If 12 volts is not read, the open is in the cab main (CM) harness between connector X031 and relay base terminal 3 on relay K17, wire 719 white. Locate the open and repair. 15. Remove the fan/reverser relay K17 from the relay base. Uses the display monitor, reference Section 55 Chapter 2, if needed, to operate the fan/reverser. Use a multimeter to measure the voltage between relay base K17 terminal 3 and chassis ground. A. If 12 volts is read, the open is in the cab main (CM) harness between connector X031 pin 10 and relay base K17 terminal 4 wire 719 white. Locate the open and repair. B. If 12 volts is not read, continue with Step 16. 16. Disconnect connector X031. Operate the fan/reverser through the display monitor diagnostics screen. Use a multimeter to measure the voltage between connector X031 pin 8 and chassis ground. A. If 12 volts is read, the open is in the cab main (CM) harness between connector X031 and relay base K17 terminal 3. Locate the open and repair. B. If 12 volts is not read, the open is in front frame (FF) harness between connector X031 and CCM1 connector X020 J3-8 wire 714 white. Locate the open and repair. 17. Reverser does not operate in either direction, and there are no error codes indicated, the supply power for the circuits may not be present. Remove fuse F24 and inspect. A. Fuse has failed. Go to step 18. B. Fuse is okay. Go to step 19. 18. If fuse has failed, replace the fuse. A. If fuse immediately fails, a short to ground exists in the cab main (CM) or front frame (FF) harnesses on wire 027 red from fuse F24 through connector X031 pin 3 to connector X020 pin J3-7 on CCM1 module. Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. B. Fuse is okay. Go to step 19. 19. Test for 12V power at connector X020 pin J3-7 on the CCM1 module under the cab. A. If there is no power, there is an open circuit in the cab main (CM) or front frame (FF) harnesses on wire 027 red from fuse F24 through connector X031 pin 3 to connector X020 pin J3-7 on CCM1 module. Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the open and repair. After repair, go to step 20. B. If there is power, go to step 20. 20. Test for continuity to ground at connector X020 pin J3-16 on the CCM1 module under the cab. A. If there is no continuity to ground, there is an open circuit in the front frame (FF) harness between connector X020 pin J3-16 and the front frame ground #2 wire 704 or 778 black. Locate the open and repair. After repair, go to step 21. B. If there is continuity to ground, go to step 21. 21. Once it has been verified that power is being supplied to the module, recheck the circuit operation as described in step 1. If the fuse fails during the testing, a short to ground on the circuit is causing the fuse to fail. Start the troubleshooting at step 3 to locate the short to ground.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 1

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2 50020070

10010899 40024707 50020085

28 1. FEEDER REVERSER ACTUATOR M10 2. CONNECTOR X007 3. CONNECTOR X031

4. FAN/REVERSER RELAY K17 5. CONNECTOR X020

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FEEDER FRAME--16

B-09 = REVERSER DISENGAGE B-14 = FEEDER RPM B-24 = STONE DOOR CLOSED F-24 = FAN, REVERSER FUSE

K-17 = FAN/REVERSER RELAY K-19 = NOT USED L-20 = FEEDER JOG FORWARD L-21 = FEEDER JOG REVERSE

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L-24 = FEEDER CLUTCH M-05 = CLEANING FAN ADJUST MOTOR (EU) M-10 = FEEDER REVERSER ACTUATOR S-31 = FEEDER ENGAGE

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0043-06 Current Sense Lev Shoe Short Circuit Cause: The Leveling shoe motor (M03) circuit indicates high current draw. Possible failure modes: 1. Circuit connection shorted to ground. 2. Excessive mechanical load on motor. 3. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed. A. Start the combine. B. Manually tilt the cleaning shoe in each direction. C. Record in which direction(s) the shoe leveling actuator operates. D. Reload error history. Check for fault codes E0043-06 and E0075-05. E. Use the following table to determine the location of the fault. Fault Code

Symptom

E0043-06 Leveling shoe motor operates in 1 direction only

Leveling g shoe motor does not operate in either direction

Fault Type

E0075-05 X X

Go to Step 2

Binding

Go to Step 3

Short to ground

Go to Step 2

Binding

Go to Step 8

Open circuit

Go to Step 13

No power supply

2. The self leveling shoe mechanism is mechanically bound up, resulting in high current draw. See the appropriate repair manual chapter for repair and adjustment of the self leveling shoe. 3. Fault codes indicate circuit fault due to short to ground. Disconnect shoe leveling motor connector X088. Use a multimeter to check for continuity between the actuator side of connector X088 pins D and E and a known good ground. There should not be continuity to ground. A. If there is continuity to ground, there is a short to ground in the motor. Replace the shoe leveling motor. B. If there is no continuity to ground, continue with step 4. 4. Disconnect the batteries using the battery key. Use the multimeter to check for continuity between connector X088 pin E and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position. Power must be removed from the module prior to testing for short to ground condition on the motor circuit to remove this ground path. A. If continuity is found, continue with step 5. B. If no continuity is found, continue with step 6.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 5. Disconnect connector X023. Use a multimeter to check for continuity between connector X023 pin 1 and chassis ground. A. If no continuity is found, the short to ground is in the lower frame (LF) harness between connector X023 pin 1 and connector X088 pin E wire 707 gray. Locate the short and repair. B. If continuity is found, the short to ground is in the front frame (FF) harness between connector X023 pin 1 and connector X020 pins J3-19 and 20 on one of the following wires: wire 707 gray, connector X023 pin 1 to harness splice wire 705 gray, harness splice to connector X020 pin J3-19 wire 706 gray, harness splice to connector X020 pin J3-20 Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. 6. Use a multimeter to check for continuity between connector X088 pin D and chassis ground. A. If continuity is found, continue with step 7. B. If no continuity is found, recheck the motor for continuity to ground at step 3. 7. Disconnect connector X023. Use a multimeter to check for continuity between connector X023 pin 2 and chassis ground. A. If no continuity is found, the short to ground is in the lower frame (LF) harness between connector X088 pin D and X023 pin 2 wire 710 white. Locate the short and repair. B. If continuity is found, the short to ground is in the front frame (FF) harness between connector X023 pin 2 and connector X020 pins J3-39 and 40 on one of the following wires: wire 710 white, connector X023 pin 2 to harness splice wire 708 white, harness splice to connector X020 pin J3-39 wire 709 white, harness splice to connector X020 pin J3-40 Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. 8. Fault codes indicate circuit fault due to open circuit condition. Disconnect shoe leveling motor connector X088. Measure the resistance of the motor between terminals D and E. The correct resistance is 1 to 5 ohms. A. The resistance is infinite, indicating an open condition in the motor. Replace the shoe leveling motor. B. The resistance is in specification. Continue with step 9. 9. Ensure that the batteries are connected using the battery key, and that fuse F22 is good. Use the multimeter to check for continuity between connector X088 pin E and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F22. This ground path may be used to test for an open circuit condition. A. If continuity is found, continue with step 11. B. If no continuity is found, continue with step 10.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 10. Disconnect connector X023. Use a multimeter to check for continuity between connector X023 pin 1 and chassis ground. A. If continuity is found, the open circuit is in the lower frame (LF) harness between connector X023 pin 1 and connector X088 pin E wire 707 gray. Locate the open and repair. B. If no continuity is found, the open circuit is in the front frame (FF) harness between connector X023 pin 1 and connector X020 pins J3-19 and 20 on one of the following wires: wire 707 gray, connector X023 pin 1 to harness splice wire 705 gray, harness splice to connector X020 pin J3-19 wire 706 gray, harness splice to connector X020 pin J3-20 Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the open circuit and repair. 11. Use a multimeter to check for continuity between connector X088 pin D and chassis ground. A. If no continuity is found, continue with step 12. B. If continuity is found, recheck the motor for continuity at step 8. 12. Disconnect connector X023. Use a multimeter to check for continuity between connector X023 pin 2 and chassis ground. A. If continuity is found, the open circuit is in the lower frame (LF) harness between connector X088 pin D and X023 pin 2 wire 710 white. Locate the open and repair. B. If no continuity is found, the open circuit is in the front frame (FF) harness between connector X023 pin 2 and connector X020 pins J3-39 and 40 on one of the following wires: wire 710 white, connector X023 pin 2 to harness splice wire 708 white, harness splice to connector X020 pin J3-39 wire 709 white, harness splice to connector X020 pin J3-40 Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the open circuit and repair. 13. If the shoe leveling motor does not operate in either direction, and there are no fault codes indicated, the supply power for the circuit may not be present. Remove and inspect fuse F22. A. Fuse has failed. Go to step 14. B. Fuse is okay. Go to step 15. 14. If fuse has failed, replace the fuse. A. If fuse immediately fails, a short to ground exists on one of the following wires: wire 024 red, from the fuse panel through connector X031 pin 16 to harness splice in front frame (FF) harness wire 700 red, harness splice to connector X020 pin J3-29 on CCM1 module wire 701 red, harness splice to connector X020 pin J3-30 on CCM1 module Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. B. Fuse is okay. Go to step 15.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 15. Test for 12V power at connector X020 pins J3-29 and 30 on the CCM1 module under the cab. A. If there is no power, there is an open circuit on one of the following wires: wire 024 red, from the fuse panel through connector X031 pin 16 to harness splice in front frame (FF) harness wire 700 red, harness splice to connector X020 pin J3-29 on CCM1 module wire 701 red, harness splice to connector X020 pin J3-30 on CCM1 module Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the open and repair. After repair, go to step 16. B. If there is power, go to step 16. 16. Test for continuity to ground at connector X020 pins J3-9 & 10 on the CCM1 module under the cab. A. If there is no continuity to ground, there is an open circuit on one of the following wires: wire 702 black, from connector X020 pin J3-9 to harness splice in front frame (FF) harness wire 703 black, from connector X020 pin J3-10 to harness splice in front frame (FF) harness wire 778 black, harness splice to front frame ground #2 Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the open and repair. After repair, go to step 17. B. If there is continuity to ground, go to step 17. 17. Once it has been verified that power is being supplied to the module, recheck the circuit operation as described in step 1. If the fuse fails during the testing, a short to ground on the circuit is causing the fuse to fail. Start the troubleshooting at step 3 to locate the short to ground.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

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10010898 50020089

29 1. SHOE LEVELING ACTUATOR M03 2. CONNECTOR X023 3. CONNECTOR X020

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

B-16 = CLEANING FAN RPM B-21 = SIEVES LOSS F-22 = SHOE LEVELING MOTOR FUSE L-44 = FAN DRIVE SOLENOID

M-03 = SHOE LEVELING ACTUATOR S-13 = UPPER SIEVE S-14 = LOWER SIEVE S-15 = FAN SPEED

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CLEANING FRAME--19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0044-06 Current Sense Concave CL Short Circuit Cause: The concave clearance motor (M04) circuit indicates high current draw. Possible failure modes: 1. Circuit connection shorted. 2. Excessive mechanical load on motor. 3. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed. A. Start the combine. B. Operate concave clearance and bin covers circuits in both directions. C. Record in which direction(s) the concave clearance increases or decreases. D. Reload error history. E. Check for the following fault codes: E0044-06, E0045-06, E0078-05 and E0079-05. F. Use the following table to determine the location of the fault. FAULT CODES

SYMPTOM E0044-06 Concave operates in 1 direction only

E0045-06

E0078-05

E0079-05 Go to Step 2

Go to Step 3

X X

Concave does not operate in either direction

Go to Step 9

Go to Step 14

Covers operates in 1 direction only

Go to Step 15

Covers do not operate in either direction Both concave and covers do not operate in either direction Both concave and covers do not operate in either direction

Go to Step 6

Concave and covers operate in 1 direction only

NO FAULT CODE

55-174

Go to Step 16

Go to Step 20

Go to Step 27

Go to Step 28

Go to Step 30

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 2. The concave clearance adjustment motor is bound up. See the appropriate service manual chapter for repair. 3. The concave clearance motor operates in one direction only. Fault codes indicate a short to ground. Disconnect the concave clearance motor connector X176. Measure the resistance on connector X176 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. A. If out of specification, replace concave motor. B. If the motor coil resistance is within specification, continue with Step 4. 4. Measure the resistance on connector X176 between pin A and chassis ground. Flex the main frame (MF) harness while making this check. A. If no continuity to ground is found, erase the fault code and continue operation. B. If there is continuity to ground, continue with Step 5. 5. Disconnect connector X004. Use the multimeter to check for continuity between connector X004 pin 30 and chassis ground. A. If continuity is found, the short to ground is in the cab (CM) frame harness between connector X004 and relay base K16 terminal 4 wire 695 white. Locate the short and repair. B. If no continuity is found, the short to ground is in the main frame (MF) harness between connector X004 and connector X176 wire 695 white. Locate the short and repair. 6. Concave and covers operate in one direction only. Fault codes indicate a short to ground. Disconnect both the concave motor connector X176 and covers motor connector X289. A. Measure the resistance on connector X176 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. If out of specification, replace concave motor. B. Measure the resistance on connector X289 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. If out of specification, replace covers motor. C. If the motor coil resistance is within specification, continue with Step 7. 7. Check for continuity on connector X176 between pin B and chassis ground. Flex the main frame (MF) harness while making this check. Next check for continuity on connector X289 between pin B and chassis ground. Flex the bin covers (BC) and main harnesses while making this check. A. If no continuity to ground is found, erase fault code and continue operation. B. If there is continuity to ground, continue with Step 8. 8. Disconnect connector X195. Use the multimeter to check for continuity between connector X195 pin 3 and chassis ground. A. If continuity is found, the short is in the main frame (MF) harness between connector X176, the splice, connector X195 and connector X019 J2-1, wires 694, 693 and 522 gray. Locate the short and repair. B. If no continuity is found, the short to ground is in the bin covers (BC) harness between connector X195 and connector X289 wire 693 gray. Locate the short and repair. 9. Concave does not operate in either direction. Fault code indicates an open in circuit. Disconnect the concave adjustment motor connector X176. Measure the resistance on connector X176 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. A. If out of specification, replace motor. B. If the motor coil resistance is within specification, continue with Step 10. 10. Replace the concave/covers relay K16 with a known good relay. Connect connector X176 and operate the concaves. A. If the concaves are now working troubleshooting is complete. B. If the concaves still do not work, continue with Step 11.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 11. Disconnect concave motor connector X176. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the concave motor. Use a multimeter to measure the voltage between connector X176 pin A and chassis ground. A. If 12 volts is read, continue with Step 12. B. If 12 volts is not read, continue with Step 13. 12. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the concave motor. Use a multimeter to measure the voltage between connector X176 pin B and chassis ground. A. If 12 volts is not read, the open is in main frame (MF) harness between connector X176 and connector X019 J2-1 wire 694 or 522 gray. Locate the open and repair. 13. Disconnect connector X004. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the concave motor. Use a multimeter to measure the voltage between connector X004 pin 30 and chassis ground. A. If 12 volts is read, the open is in the main frame (MF) harness between connector X004 and connector X176 wire 695 white. Locate the open and repair. B. If 12 volts is not read, the open is in the cab main (CM) harness between connector X004 and relay base terminal 4 on relay K16, wire 695 white. Locate the open and repair. 14. Disconnect connector X176 at the concave clearance motor. Use a multimeter to check for an internal short to ground between both pin A and B. If short to ground is found, replace motor. 15. The bin covers actuator is bound up. See the appropriate service manual chapter for repair. 16. The covers operates in one direction only. Fault codes indicate a short to ground. Disconnect the covers motor connector X289. Measure the resistance on connector X289 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. A. If out of specification, replace covers motor. B. If the motor coil resistance is within specification, continue with Step 17. 17. Measure the resistance on connector X289 between pin A and chassis ground. Flex the bin covers (BC) and main frame (MF) harnesses while making this check. A. If no continuity to ground is found, erase the fault code and continue operation. B. If there is continuity to ground, continue with Step 18. 18. Disconnect connector X195. Use the multimeter to check for continuity between connector X195 pin 4 and chassis ground. A. If continuity is found, continue with Step 19. B. If no continuity is found, the short to ground is in the bin covers (BC) harness between connector X195 and connector X289 wire 696 white. Locate the short and repair. 19. Disconnect connector X004. Use the multimeter to check for continuity between connector X004 pin 31 and chassis ground. A. If continuity is found, the short to ground is in the cab main (CM) harness between connector X004 and the relay base for relay K16 terminal 4 wire 695 white. Locate the short and repair. B. If no continuity is found, the short to ground is in the main frame (MF) harness between connector X004 and connector X195 wire 696 white. Locate the short and repair. 20. Covers do not operate in either direction. Fault code indicates an open in circuit. Disconnect the covers motor connector X289. Measure the resistance on connector X289 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. A. If out of specification, replace covers motor. B. If the motor coil resistance is within specification, continue with Step 21.

55-176

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 21. Replace the concave/covers relay K16 with a known good relay. Connect connector X289 and operate covers. A. If the covers are now working, troubleshooting is complete. B. If the covers still do not work, continue with Step 22. 22. Disconnect the covers connector X289. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the covers motor. Use a multimeter to measure the voltage between connector X289 pin A and chassis ground. A. If 12 volts is read, continue with Step 23. B. If 12 volts is not read, continue with Step 25. 23. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the covers motor. Use multimeter to measure the voltage between connector X289 pin B and chassis ground. A. If 12 volts is not read, continue with Step 24. B. If 12 volts is read, recheck the motor for continuity at Step 20. Erase the fault codes and, continue operation. 24. Disconnect connector X195. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the covers motor. Use multimeter to measure the voltage between connector X195 pin 3 and chassis ground. A. If 12 volts is read, the open is in the bin covers (BC) harness between connector X289 and connector X195 wire 693 gray. Locate the open and repair. B. If 12 volts is not read, the open is in the main frame (MF) harness between connector X195 and the next splice in wire 693 gray. Locate the open and repair. 25. Disconnect connector X195. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the covers motor. Use a multimeter to measure the voltage between connector X195 pin 4 and chassis ground. A. If 12 volts is read, the open is in the bin covers (BC) harness between connector X195 and connector X289 wire 696 white. Locate the open and repair. B. If 12 volts is not read, continue with Step 26. 26. Disconnect connector X004. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the covers motor. Use a multimeter to measure the voltage between connector X004 pin 31 and chassis ground. A. If 12 volts is read, the open is in the main frame (MF) harness between connector X004 and connector X195 wire 696 white. Locate the open and repair. B. If 12 volts is not read, the open is in the cab main (CM) harness between connector X004 and relay base terminal 3 on relay K16, wire 696 white. Locate the open and repair. 27. Disconnect connector X289 at the covers motor. Use a multimeter to check for an internal short to ground between both pin A and B. If short to ground is found, replace motor. 28. Both concave and covers do not operate in either direction. Fault code indicates an open circuit. Remove the concave/covers relay K16 from the relay base. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the concave/covers. Use a multimeter to measure the voltage between relay base K16 terminal 3 and chassis ground. A. If 12 volts is read, the open is in the main frame (MF) harness between CCM1 connector X019 J2-1 and splice with wire 522 gray. Locate the open and repair. B. If 12 volts is not read, continue with Step 29. 29. Disconnect connector X004. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the concave/covers. Use a multimeter to measure the voltage between connector X004 pin 29 and chassis ground. A. If 12 volts is read, the open is in the cab main (CM) harness between connector X004 and relay base K16 terminal 3. Locate the open and repair. B. If 12 volts is not read, the open is in main frame (MF) harness between connector X004 and CCM1 connector X019 J2-21 wire 523 white. Locate the open and repair.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 30. If neither the concave or bin covers do not operate in either direction, and there are no error codes indicated, the supply power for the circuits may not be present. Remove fuse F24 and inspect. A. Fuse has failed. Go to step 31. B. Fuse is okay. Go to step 32. 31. If fuse has failed, replace the fuse. A. If fuse immediately fails, a short to ground exists in the cab main (CM) or main frame (MF) harnesses on wire 026 red from fuse F24 through connector X005 pin 2 to connector X019 pin J2-11 on CCM1 module. Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. B. Fuse is okay. Go to step 32. 32. Test for 12V power at connector X019 pin J2-11 on the CCM1 module under the cab. A. If there is no power, there is an open circuit in the cab main (CM) or main frame (MF) harnesses on wire 026 red from fuse F24 through connector X005 pin 2 to connector X019 pin J2-11 on CCM1 module. Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the open and repair. After repair, go to step 33. B. If there is power, go to step 33. 33. Test for continuity to ground at connector X019 pin J2-3 on the CCM1 module under the cab. A. If there is no continuity to ground, there is an open circuit in the front frame (FF) harness between connector X019 pin J2-3 and the front frame ground #2 wire 513 black. Locate the open and repair. After repair, go to step 34. B. If there is continuity to ground, go to step 34. 34. Once it has been verified that power is being supplied to the module, recheck the circuit operation as described in step 1. If the fuse fails during the testing, a short to ground on the circuit is causing the fuse to fail. Start the troubleshooting at step 3 to locate the short to ground.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

40025229

2 3 50020070 10010899

50020091

30 1. CONCAVE CLEARANCE ACTUATOR M04 2. CONNECTOR X004

3. CONCAVE/COVERS RELAY K16 4. CONNECTOR X019

55-179

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

B-45 = GEARBOX CLUTCH TEMP K-16 = CONCAVE/COVERS RELAY M-04 = CONCAVE CLEARANCE MOTOR M-12 = COVERS MOTOR

R-06 = CONCAVE POSITION S-16 = CONCAVE CLEARANCE

THRESHER FRAME--17

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0045-06 Current Sense Bin Covers Short Circuit Cause: The bin covers motor (M12) circuit indicates high current draw. Possible failure modes: 1. Circuit connection shorted. 2. Excessive mechanical load on motor. 3. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed. A. Start the combine. B. Operate concave clearance and bin covers circuits in both directions. C. Record in which direction(s) the concave clearance increases or decreases. D. Reload error history. E. Check for the following fault codes: E0044-06, E0045-06, E0078-05 and E0079-05. F. Use the following table to determine the location of the fault. FAULT CODES

SYMPTOM E0044-06 Concave operates in 1 direction only

E0045-06

E0078-05

E0079-05 Go to Step 2

Go to Step 3

X X

Concave does not operate in either direction

Go to Step 9

Go to Step 14

Covers operates in 1 direction only

Go to Step 15

Covers do not operate in either direction Both concave and covers do not operate in either direction Both concave and covers do not operate in either direction

Go to Step 6

Concave and covers operate in 1 direction only

NO FAULT CODE

55-181

Go to Step 16

Go to Step 20

Go to Step 27

Go to Step 28

Go to Step 30

55-182

55-183

55-184

55-185

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

10004684

3 4 50020070 10010899

50020082

31 1. GRAIN BIN COVERS MOTOR M12 2. CONNECTOR X195 3. CONNECTOR X004

4. CONCAVE / COVERS RELAY K16 5. CONNECTOR X019

55-186

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

B-45 = GEARBOX CLUTCH TEMP K-16 = CONCAVE/COVERS RELAY M-04 = CONCAVE CLEARANCE MOTOR M-12 = COVERS MOTOR

R-06 = CONCAVE POSITION S-16 = CONCAVE CLEARANCE

THRESHER FRAME--17

55-187

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0046-03 CCM1 Battery Voltage Shorted To High Source Cause: The circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Circuit wiring shorted to high voltage source. 2. Faulty alternator/regulator. 3. Controller internal failure (internal regulator failure). Solution: 1. Start the Combine engine. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. Increase the engine RPM to high idle (maximum) and check voltage range. The proper voltage range is 10.0 to 18.0 volts. A. If the voltage reading is greater than 18 volts, continue with Step 2. B. If the voltage reading is between 10 and 18 volts, go to Step 5. 2. Shut off the combine engine, and then turn the key switch on again. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, the alternator and/or regulator has failed, and is producing excessive voltage. Refer to “Charging Systems” in Chapter 5 -- Engine Systems in this section for additional alternator testing information. B. If the voltage reading is greater than 18 volts, continue with Step 3. 3. Turn the key switch off to power down the system. Check the voltage at fuse F39 using a multi-meter. A. If the voltage reading is greater than 18 volts, then the batteries have been mistakenly connected in series, or there is a fault in the wiring of the 24V starting system. Refer to “Starting Systems” in Chapter 5 -- Engine Systems in this section for additional information. B. If the voltage reading is between 10 and 18 volts, continue with Step 4.

55-188

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 4. Remove the buddy seat and storage bin to gain access to connector X018 on CCM1. Check the voltage at connector X018 pin J1-1. A. If the voltage reading is greater than 18 volts, then a high voltage source has been connected to one of the following wires: wire 047 red, fuse F39 to splice in the cab main (CM) harness wire 052 red, harness splice to CCM1 connector X018, pin J1-1 wire 050 red, harness splice to CCM2 connector X015, pin J1-1 wire 049 red, harness splice to CCM3 connector X012, pin J1-1 wire 051 red, harness splice through connector X001, pin 2 to RHM connector X026, pin 13 wire 1276 red, harness splice to display monitor connector X502, pin 13 wire 142 red, harness splice to DAM connector X065, pin B Visually inspect the cab main (CM) harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short and repair. B. If the voltage reading is 10 to 18 volts, and the diagnostic screen is still indicating voltage in excess of 18 volts, there is an internal fault in CCM1. Reload the software for CCM1. If that does not correct the concern, replace the module. 5. Erase the error code and, continue operation.

55-189

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0046-04 CCM1 Battery Voltage Shorted To Low Source Cause: Low battery voltage to CCM1, or the circuit is shorted to ground. Possible failure modes: 1. Loose or corroded connections, or damaged wires. 2. Batteries are discharged, and/or alternator/regulator failure. 3. CCM1 supply wiring from fuse F39 shorted to ground. NOTE: Check fuse F39. If a short to ground occurred on this circuit the fuse will have blown. 4. Controller internal failure (internal regulator failure). Solution: 1. Key switch in “Off” position. Check fuse F39. A. If fuse F39 is okay, continue with Step 6. B. If the fuse is blown, go to Step 2. 2. Replace the failed fuse F39. A. If the fuse is okay, continue with Step 3. B. If the fuse immediately fails again, a short to ground exists in one of the following wires: wire 047 red, fuse F39 to splice in the cab main (CM) harness wire 052 red, harness splice to CCM1 connector X018, pin J1-1 wire 050 red, harness splice to CCM2 connector X015, pin J1-1 wire 049 red, harness splice to CCM3 connector X012, pin J1-1 wire 051 red, harness splice through connector X001, pin 2 to RHM connector X026, pin 13 wire 1276 red, harness splice to display monitor connector X502, pin 13 wire 142 red, harness splice to DAM connector X065, pin B Visually inspect the cab main (CM) harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair. 3. Key switch in “Off” position. Check the voltage at fuse F39 using a multi-meter. A. If the voltage reading is between 10 and 18 volts, continue with Step 4. B. If the voltage reading is less than 10 volts, there is excessive resistance between the batteries and the cab fuse panel, due to loose or corroded connections, or the batteries have discharged excessively, and are not capable of supplying the minimum voltage requirement for CCM1. Inspect the wiring from the batteries to the engine compartment, and from there to the cab. Recharge or replace the batteries. 4. Key switch in “On” position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, continue with Step 5. B. If the voltage reading is less than 10 volts, there is excessive resistance between the fuse panel and CCM1. Inspect wires 047 & 052 red to CCM1 connector X018 pin J1-1 for loose or corroded connections, or damage to the wires.

55-190

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 5. Start the combine engine. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. With the engine RPM at low idle, engage road and work lights. Check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, continue with Step 6. B. If the voltage reading is less than 10 volts, the alternator and/or regulator may have failed, and the charging system is not producing sufficient voltage. Refer to “Charging Systems” in Chapter 5 -- Engine Systems in this section for additional alternator testing information. 6. Erase the error code and, continue operation.

55-191

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

1 2

50020070 10004693 50020087

32 1. FUSE F39

2. CONNECTOR X018

55-192

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-193

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION/ AUTO GUIDANCE FRAME--32

A-02 = DISPLAY MODULE A-11 = DGPS MODULE A-24 = NAVIGATION MODULE L-57 = STEER LEFT SOLENOID

L-58 = STEER RIGHT SOLENOID L-59 = STEER ENABLE SOLENOID S-78 = AUTOGUIDANCE SWITCH S-79 = ROTARY ENCODER SWITCH

55-194

S-80 = DISPLAY HOME SWITCH S-81 = DISPLAY ESCAPE SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0047-03 V Supply Feeder Clutch Shorted To High Source Cause: The feeder clutch supply voltage circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Supply wiring shorted to greater than 18.0 volts. 2. Faulty alternator/regulator. 3. Controller internal failure (internal regulator failure). Solution: 1. Start the Combine engine. Engage the threshing and feeder engage switches. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper feeder clutch supply voltage is 10.0 to 18.0 volts (Feeder switch engaged). A. If the voltage reading is greater than 18 volts, continue with Step 2. B. If the voltage reading is between 10 and 18 volts, go to Step 5. 2. Shut off the combine engine, and then turn the key switch on again. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, the alternator and/or regulator has failed, and is producing excessive voltage. Refer to “Charging Systems” in Chapter 5 -- Engine Systems in this section for additional alternator testing information. B. If the voltage reading is greater than 18 volts, continue with Step 3. 3. Key switch in the “Off” position. Check the voltage at fuse F42 using a multi-meter. A. If the voltage reading is greater than 18 volts, then the batteries have been mistakenly connected in series, or there is a fault in the wiring of the 24V starting system. Refer to “Starting Systems” in Chapter 5 -- Engine Systems in this section for additional information. B. If the voltage reading is between 10 and 18 volts, continue with Step 4.

55-195

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 4. Key switch in the “On” position. Engage the thresher engage switch S30 and feeder engage switch S31. Remove the buddy seat and storage bin to gain access to connector X018 on CCM1. Check the voltage at connector X018 pin J1-7. A. If the voltage reading is greater than 18 volts, then a high voltage source has been connected to one of the following wires: wire 109 orange, fuse F48 to thresher latching relay K28, terminal 3 wire 108 orange, fuse F48 through connector X001, pin 3 to RC harness splice wire 110 orange, RC harness splice to thresher engage switch S30 pin 3 wire 300 orange, RC harness splice to neutral switch S22 wire 1258 orange, RC harness splice to display module A-02 wire 302 and 861 yellow, thresher engage switch S30 pin 5 to feeder engage switch S31 pin 6 wire 112 yellow, feeder engage sw to CCM1 connector X018 pin J1-7 wire 147 or 111 yellow, thresher engage sw to CCM2 connector X015 pin J1-7 wire 1061 yellow, thresher engage SW S-30 to connector X012 CCM-3 J1-7 switch power wires from splice block B, W02 in the RH console B. If the voltage reading is 10 to 18 volts, and the diagnostic screen is still indicating voltage in excess of 18 volts, there is an internal fault in CCM1. Reload the software for CCM1. If that does not correct the concern, replace the module. 5. Erase the error code and, continue operation.

55-196

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0047-04 V Supply Feeder Clutch Shorted To Low Source Cause: Low battery voltage to CCM1 through the feeder engage switch S31, or the circuit is shorted to ground. Possible failure modes: 1. Loose or corroded connections, or damaged wires. 2. Batteries are discharged, and/or alternator/regulator failure. 3. Feeder engage switch supply wiring shorted to ground. 4. Controller internal failure (internal regulator failure). Solution: 1. Key switch in “Off” position. Check fuse F42. A. If fuse F42 is okay, continue with Step 3. B. If the fuse is blown, go to Step 2. 2. Replace the failed fuse F42. A. If the fuse is okay, continue with Step 3. B. If the fuse immediately fails again, a short to ground exists in wire 010 red to Cab Power Relay K26 pin 3. Locate short and repair. 3. Key switch in “On” position. Check fuse F48. A. If fuse F48 is okay, continue with Step 5. B. If the fuse is blown, go to Step 4. 4. Replace the failed fuse F48. A. If the fuse is okay, continue with Step 5. B. If the fuse immediately fails again, a short to ground exists in one of the following wires: wire 109 orange, fuse F48 to thresher latching relay K28, terminal 3 wire 108 orange, fuse F48 through connector X001, pin 3 to RC harness splice wire 110 orange, RC harness splice to thresher engage switch S30 pin 3 wire 300 orange, RC harness splice to neutral switch S22 wire 1258 orange, RC harness splice to display module A-02 switch power wires from splice block B, W02 in the RH console 5. Engage the thresher engage switch S30, and observe the fuse F48. A. If the fuse is okay, continue with Step 6. B. If the fuse immediately fails, a short to ground exists in one of the following wires: wire 857, 858, or 118 yellow, thresher engage switch S30, pins 2 & 6 to thresher latching relay K28, terminal 5 wire 115 yellow, thresher latching relay K28, terminal 5 to terminal 1 wire 861 yellow, thresher engage switch S30, pin 5 to feeder engage switch S31, pin 6 wires 147, 111, 1061 yellow, thresher engage switch S30, pin 5 to CCM2 connector X015 pin J1-7 and CCM3 connector X012 pin J1-7 Locate short and repair.

55-197

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 6. Engage the feeder engage switch S31, and observe fuse F48. A. If the fuse is okay, continue with Step 7. B. If the fuse immediately fails, a short to ground exists in wire 112 or 1211 yellow from feeder engage switch S31, pin 5 to CCM1 connector X018, J1-7. Locate short and repair. 7. Key switch in “Off” position. Check the voltage at fuse F42 using a multi-meter. A. If the voltage reading is between 10 and 18 volts, continue with Step 8. B. If the voltage reading is less than 10 volts, there is excessive resistance between the batteries and the cab fuse panel due to loose or corroded connections, or the batteries have discharged excessively and are not capable of supplying the minimum voltage requirement for CCM1. Inspect the wiring from the batteries to the engine compartment, and from there to the cab. Recharge or replace the batteries. 8. Key switch in “On” position. Engage thresher (S30) and feeder (S31) switches. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The acceptable voltage range is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, continue with Step 9. B. If the voltage reading is less than 10 volts, there is excessive resistance between the fuse panel and CCM1. Inspect the following for loose or corroded connections, or damage to the wires. wire 010 red, fuse F42 to Cab Power relay K26, terminal 3 wire 007 orange, Cab Power relay K26, terminal 5 to buss strip wire 108 orange, fuse F48 through connector X001, pin 3, to right console (RC) harness splice wire 110 orange, RC harness splice to thresher engage switch S30, pin 3 wire 857, 858, or 118 yellow, thresher engage switch S30, pins 2 & 6 to thresher latching relay K28, terminal 5 wire 115 yellow, thresher latching relay K28, terminal 5 to terminal 1 wire 861 yellow, thresher engage switch S30, pin 5 to feeder engage switch S31, pin 6 wire 112 and 1211 yellow, feeder engage switch S31, pin 5 to CCM1 connector X018, J1-7 9. Start the combine engine. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. With the engine RPM at low idle, engage road and work lights. Check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, continue with Step 10. B. If the voltage reading is less than 10 volts, the alternator and/or regulator may have failed, and the charging system is not producing sufficient voltage. Refer to “Charging Systems” in Chapter 5 -- Engine Systems in this section for additional alternator testing information. 10. Erase the error code and, continue operation.

55-198

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

2 1 10010919 10010921

7 50020070

50020087

10004693

33 1. FEEDER ENGAGE SWITCH S31 2. CONNECTOR X001 3. CONNECTOR X018 4. FUSE F42 5. CAB POWER RELAY K26 6. FUSE F48 7. THRESHER LATCHING RELAY K28

55-199

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

55-200

S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME--9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FEEDER FRAME--16

B-09 = REVERSER DISENGAGE B-14 = FEEDER RPM B-24 = STONE DOOR CLOSED F-24 = FAN, REVERSER FUSE

K-17 = FAN/REVERSER RELAY K-19 = NOT USED L-20 = FEEDER JOG FORWARD L-21 = FEEDER JOG REVERSE

55-201

L-24 = FEEDER CLUTCH M-05 = CLEANING FAN ADJUST MOTOR (EU) M-10 = FEEDER REVERSER ACTUATOR S-31 = FEEDER ENGAGE

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

THRESHER FRAME--18

B-01 = ROTOR RPM K-28 = THRESHER LATCHING L-22 = GEARBOX CLUTCH L-29 = ROTOR INCREASE

L-30 = ROTOR DECREASE S-30 = THRESHER ENGAGE

55-202

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

F-48 = RH CONSOLE FUSE H-01 = AUDIO ALARM W-01 = SPLICE BLOCK A W-02 = SPLICE BLOCK B

W-05 = SPLICE BLOCK E W-06 = SPLICE BLOCK F

DISTRIBUTION FRAME--25

55-203

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DISTRIBUTION FRAME--28

F-36 = CCM-2A FUSE F-37 = CCM-2B FUSE F-40 = CCM-1 POWER FUSE F-41 = CCM-2 POWER FUSE

F-42 = CCM-3, CAB POWER FUSE K-24 = CCM-1 POWER RELAY K-25 = CCM-2 POWER RELAY K-26 = CCM-3, CAB POWER RELAY

55-204

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0050-03 Isense Feeder Clutch Shorted To High Source Cause: The Feeder clutch solenoid (L-24) circuit has excessive current draw, or is shorted to a high voltage source. Possible failure modes: 1. Bad solenoid. 2. Return side wiring shorted to 12 volts. 3. Controller internal failure (internal regulator failure). Solution: The Isense Feeder Clutch circuit is the ground path for the feeder clutch PWM solenoid. By monitoring current flow on the return path of the feeder clutch solenoid, the module can provide precise control of the solenoid engagement. When this error message is reported, this is an indication of excessive current draw on the circuit, or a result of a high voltage short on the return line. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper feeder clutch solenoid current should be approximately 1.0 to 1.5 amps. The fault code is triggered by current flow greater than 3.3 amps. NOTE: If the current reading is high, immediately shut off the circuit to prevent module damage. A. If the reading is greater than 3.3 amps, continue with step 2. B. If the reading is normal (1.0 to 1.5 amps), continue the troubleshooting at step 8. C. If there is no current reading, the module may have failed as a result of a 12V short on the Isense circuit. Continue with step 5. 2. The current reading is high. Turn the key switch to the OFF position and disconnect the feeder clutch solenoid connector X035. Use a multimeter to check the resistance of the feeder clutch solenoid L24 between connector X035 pins 1 & 2. The proper resistance range for the feeder clutch solenoid is 7.2 to 11.2 ohms. A. If out of specification, replace the solenoid. Continue with step 7. B. If the coil is within specification, continue with Step 3. 3. Disconnect connector X011. Use a multimeter to check the resistance of the feeder clutch solenoid circuit between connector X011 pins L & M. The resistance should be the same as, or slightly higher than the resistance of the solenoid as measured in step 2. A. If the resistance is lower than the previously measured resistance, there is a short in the harness between connector X035 and connector X011 wires 876 white and 875 blue. Locate the short and repair. Continue with step 7. B. If the resistance is the same as previously measured, continue with step 4. 4. Disconnect connector X019 on the bottom of CCM1 module. Use a multimeter to check the resistance of the feeder clutch solenoid circuit between connector X019 pins J2-30 & J2-40. A. If the resistance is lower than the previously measured resistance, there is a short in the harness between connector X011 and connector X019 wires 876 white and 875 blue. Locate the short and repair. Continue with step 7. B. If the resistance is the same as previously measured, continue with step 5.

55-205

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 5. Key on. Disconnect connector X035. Use a multimeter to check for voltage at connector X035 pin 2 (harness end). There should be no voltage on this wire. NOTE: The high voltage source may not be present as it may not be currently powered up. If the fault code typically appears when operating another circuit, activate that circuit while performing this check. A. There is no voltage present on the wire. Continue with step 7. B. There is voltage present on the wire. Continue with step 6. 6. Key on. Disconnect connector X011. Use a multimeter to check for voltage at connector X011 pin L (module side of connector). There should be no voltage on this wire. NOTE: The high voltage source may not be present as it may not be currently powered up. If the fault code typically appears when operating another circuit, activate that circuit while performing this check. A. There is no voltage on the wire. The short to voltage is between connector X035 and connector X011 wire 875 blue. Locate the short and repair. Continue with step 7. B. There is voltage on the wire. The short to voltage is between connector X011 and connector X019 wire 875 blue. Locate the short and repair. Continue with step 7. 7. The sense resistor in the module for the Isense Feeder Clutch circuit is easily damaged as a result of excessive current draw or a short to high voltage. After locating the source of the problem and correcting, the module must be checked for damage. Disconnect connector X011. Use a multimeter to check resistance between connector X011 pin L and chassis ground. There should be less than 1 ohm resistance. A. There is infinite resistance. The sense resistor in the CCM1 module has failed. Replace the module. B. The resistance is correct. The sense resistor in the CCM1 module is okay, and the circuit should function correctly. Continue with step 8. 8. Erase fault code and continue operation. If the fault immediately reoccurs, replace CCM1 with a known good controller.

55-206

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 .

2 10004669

10020076

50020093

34 1. FEEDER CLUTCH SOLENOID L24 2. CONNECTOR X035

3. CONNECTOR X011 4. CONNECTOR X019

55-207

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FEEDER FRAME--16

B-09 = REVERSER DISENGAGE B-14 = FEEDER RPM B-24 = STONE DOOR CLOSED F-24 = FAN, REVERSER FUSE

K-17 = FAN/REVERSER RELAY K-19 = NOT USED L-20 = FEEDER JOG FORWARD L-21 = FEEDER JOG REVERSE

55-208

L-24 = FEEDER CLUTCH M-05 = CLEANING FAN ADJUST MOTOR (EU) M-10 = FEEDER REVERSER ACTUATOR S-31 = FEEDER ENGAGE

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0052-11 Feeder Clutch Valve Unidentified Failure Code Cause: The Feeder Clutch Valve (L-24) circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad solenoid. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed. Engage the Feeder engage switch S31. The proper current is approximately 1.0 to 1.5 amps. A. If the current reading goes to maximum, and then back to zero, the circuit is shorted to ground and the software has shut off the output to protect the module and wiring. Continue with Step 2. B. If the reading is 0 amps, the circuit is open. Continue with step 5. C. If the reading is within the proper range, the circuit is working properly. Continue with step 11. 2. Disconnect connector X035. Use a multimeter to check between connector X035 pin 1 (valve side) and chassis ground. A. If there is continuity, the feeder clutch solenoid is shorted to ground. Replace the solenoid. B. If there is no continuity, continue with step 3. 3. Use a multimeter to check for continuity between connector X035 pin 1 (harness side) and chassis ground. Flex the gearbox (GB) harness between the clutch valve and connector X011 while making this check. A. If there is continuity to ground, continue with step 4. B. If there is no continuity to ground, erase the fault code and continue operation. 4. Disconnect connector X011. Use a multimeter to check for continuity between connector X011 pin M and chassis ground. Flex the main frame (MF) harness between the connector X011 and connector X019 while making this check. A. If there is no continuity to ground, the short to ground is in the gearbox (GB) harness between connector X011 and connector X035 wire 876 white. Locate the short and repair. B. If there is continuity to ground, the short to ground is in the main frame (MF) harness between connector X011 and connector X019 wire 876 white. Locate the short and repair. 5. Disconnect connector X035. Use a multimeter to check the resistance of the feeder clutch valve coil between connector X035 pins 1 & 2. The proper resistance range is 7.2 to 11.2 ohms. A. If there is no continuity, replace solenoid. B. If the coil is within specification, continue with step 6. 6. Use a multimeter to check for continuity between connector X035 pin 2 (harness side) and chassis ground. Flex the gearbox (GB) harness between the clutch valve and connector X011 while making this check. A. If there is no continuity to ground, continue with step 7. B. If there is continuity to ground, continue with step 9.

55-209

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 7. Disconnect connector X011. Use a multimeter to check for continuity between connector X011 pin L and chassis ground. Flex the main frame (MF) harness between the connector X011 and connector X019 while making this check. A. If there is continuity to ground, the open circuit is in the gearbox (GB) harness between connector X011 and connector X035 wire 875 blue. Locate the open and repair. B. If there is no continuity to ground, continue with step 8. 8. Disconnect connector X019 on the bottom of CCM1 module. Use a multimeter to check for continuity between connector X019 pin 40 on the module and chassis ground. NOTE: The sense resistor in the module for the Isense Feeder Clutch circuit is easily damaged as a result of excessive current draw or a short to high voltage. A. If there is infinite resistance, the sense resistor in the CCM1 module has failed. Replace the module. B. If there is less than 1 ohm resistance, the sense resistor in the CCM1 module is okay. The open circuit is in the main frame (MF) harness between connector X011 and connector X019 wire 875 blue. Locate the open and repair. 9. Turn the key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the feeder clutch valve. Use a multimeter to check for 12 volts between connector X035 pin 1 and chassis ground. NOTE: The Feeder engage switch S31 must be engaged to supply power to the circuit. A. If 12 volts is not present, continue with step 10. B. If 12 volts is found, continue with step 11. 10. Turn the key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the Feeder clutch valve. Use a multimeter to check for 12 volts between connector X011 pin M and chassis ground. NOTE: The Feeder engage switch S31 must be engaged to supply power to the circuit. A. If 12 volts is present, the open circuit is in the gearbox (GB) harness between connector X035 pin 1 and connector X011 pin M wire 876 white. Locate the open circuit and repair. B. If 12 volts is not present there is an open circuit in the main frame (MF) harness between connector X011 pin M and connector X019 pin J2-30 wire 876 white. Locate the open and repair. 11. Erase the fault code and continue operation.

55-210

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

2 10004669

10020076

50020093

35 1. FEEDER CLUTCH SOLENOID L24 2. CONNECTOR X035

3. CONNECTOR X011 4. CONNECTOR X019

55-211

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FEEDER FRAME--16

B-09 = REVERSER DISENGAGE B-14 = FEEDER RPM B-24 = STONE DOOR CLOSED F-24 = FAN, REVERSER FUSE

K-17 = FAN/REVERSER RELAY K-19 = NOT USED L-20 = FEEDER JOG FORWARD L-21 = FEEDER JOG REVERSE

55-212

L-24 = FEEDER CLUTCH M-05 = CLEANING FAN ADJUST MOTOR (EU) M-10 = FEEDER REVERSER ACTUATOR S-31 = FEEDER ENGAGE

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0053-11 Chaff Spreader Valve Unidentified Failure Code Cause: The chaff spreader control voltage to chaff spreader valve (L-28) circuit open, or short to ground. Possible failure modes: 1. Supply wiring damaged. 2. Controller internal failure (internal regulator failure). 3. Bad solenoid. Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with step 7. 2. Turn the key switch to the OFF position and disconnect the chaff spreader connector X235. A. Use a multimeter to check the resistance of the chaff spreader coil. The proper resistance range for the coil is 3.0 to 7.0 ohms. If out of specification, replace coil. B. If the coil is within specification, continue with Step 3. 3. Use a multimeter to check for continuity between connector X235 pin 1 and chassis ground. Flex the straw hood front (SW) harness while making this check. A. If no continuity to ground is found, continue with Step 4. B. If there is continuity to ground, continue with Step 6. 4. Turn the key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the chaff spreader. Use the multimeter to check for 12 volts between connector X235 pin 1 and chassis ground. A. If 12 volts is not present, continue with Step 5. B. If 12 volts is found, continue with Step 7. 5. Key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the chaff spreader. Use the multimeter to check for 12 volts between connector X024 pin 17 and chassis ground. A. If 12 volts is not present, the open is in the main frame (MF) harness between connector X024 and connector X019 J2-15 wire 576 white. Locate the open and repair. B. If 12 volts is read, the open is in the straw hood front (SW) harness between connector X024 and connector X235 wire 576 white. Locate the open and repair. 6. Disconnect connector X024. Use the multimeter to check for continuity between connector X024 pin 17 and chassis ground. A. If continuity is found, the short to ground is in the main frame (MF) harness between connector X024 and connector X019 J2-15 wire 576 white. Locate the short and repair. B. If no continuity is found, the short to ground is in the straw hood front (SW) harness between connector X024 and connector X235 wire 576 white. Locate the short and repair. 7. Erase the fault code and continue operation.

55-213

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

40020080

10020076

50020086

36 1. CHAFF SPREADER VALVE SOLENOID L28 2. CONNECTOR X024

55-214

3. CONNECTOR X019

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

B-10 = CHOPPER RPM L-28 = CHAFF SPREADER M-11 = SPREADER PLATE MOTOR S-23 = SPREADER PLATE

B-74 = PSD RPM

TRASH FRAME--23

55-215

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0054-11 Fan Drive Solenoid Unidentified Failure Code Cause: The fan drive solenoid (L-44) circuit open, or short to ground. Possible failure modes: 1. Supply wiring damaged. 2. Controller internal failure (internal regulator failure). 3. Bad solenoid. Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with step 7. 2. Turn the key switch to the OFF position and disconnect the fan drive solenoid connector X444. A. Use a multimeter to check the resistance of the fan drive solenoid coil. The proper resistance range for the coil is 3.0 to 7.0 ohms. If out of specification, replace coil. B. If the coil is within specification, continue with Step 3. 3. Use a multimeter to check for continuity between connector X444 pin 1 and chassis ground. Flex the straw hood front (SW) harness while making this check. A. If no continuity to ground is found, continue with Step 4. B. If there is continuity to ground, continue with Step 6. 4. Turn the key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the fan drive. Use the multimeter to check for 12 volts between connector X444 pin 1 and chassis ground. A. If 12 volts is not present, continue with Step 5. B. If 12 volts is found, continue with Step 7. 5. Key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the fan drive. Use the multimeter to check for 12 volts between connector X024 pin 27 and chassis ground. A. If 12 volts is not present, the open is in the main frame (MF) harness between connector X444 and connector X019 J2-13 wire 1161 white. Locate the open and repair. B. If 12 volts is read, the open is in the straw hood front (SW) harness between connector X024 and connector X444 wire 1161 white. Locate the open and repair. 6. Disconnect connector X024. Use the multimeter to check for continuity between connector X024 pin 27 and chassis ground. A. If continuity is found, the short to ground is in the main frame (MF) harness between connector X024 and connector X019 J2-13 wire 1161 white. Locate the short and repair. B. If no continuity is found, the short to ground is in the straw hood front (SW) harness between connector X024 and connector X444 wire 1161 white. Locate the short and repair. 7. Erase the fault code and continue operation.

55-216

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

10051856

10020076

56064137

37 1. FAN DRIVE SOLENOID L44 2. CONNECTOR X024

3. CONNECTOR X019

55-217

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

B-16 = CLEANING FAN RPM B-21 = SIEVES LOSS F-22 = SHOE LEVELING MOTOR FUSE L-44 = FAN DRIVE SOLENOID

M-03 = SHOE LEVELING ACTUATOR S-13 = UPPER SIEVE S-14 = LOWER SIEVE S-15 = FAN SPEED

55-218

CLEANING FRAME--19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0059-11 Dual Range Valve Unidentified Failure Code Cause: The dual range solenoid (L27) circuit open or is shorted to ground. Possible failure modes: 1. Supply wiring shorted to ground or open circuit. 2. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with step 7. 2. Turn the key switch to the OFF position and disconnect the dual range valve connector X293. Use a multimeter to check the resistance of the dual range valve coil. The proper resistance range for the coil is 1.0 to 8.0 ohms. A. If out of specification, replace coil. B. If the coil is within specification, continue with Step 3. 3. Use a multimeter to check for continuity between connector X293 pin A and chassis ground. Flex the front frame (FF) harness while making this check. A. If no continuity to ground is found, continue with Step 4. B. If there is continuity to ground, continue with Step 6. 4. Turn the key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the dual range solenoid. Use the multimeter to check for 12 volts between connector X293 pin A and chassis ground. A. If 12 volts is not present, continue with Step 5. B. If 12 volts is found, continue with Step 8. 5. Key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the dual range solenoid. Use the multimeter to check for 12 volts between connector X023 pin 21 and chassis ground. A. If 12 volts is not present the open is in the front frame (FF) harness between connector X023 and connector X020 J3-3 wire 762 white. Locate the open and repair. B. If 12 volts is read, the open is in the lower frame (LF) harness between connector X023 and connector X293 wire 762 white. Locate the open and repair. 6. Disconnect connector X023. Use the multimeter to check for continuity between connector X023 pin 21 and chassis ground. A. If continuity is found, the short to ground is in the front frame (FF) harness between connector X023 and connector X020 J3-3 wire 762 white. Locate the short and repair. B. If no continuity is found, the short to ground is in the lower frame (LF) harness between connector X023 and connector X293 wire 762 white. Locate the short and repair. 7. Erase the fault code and continue operation.

55-219

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

10004663

10010898 50020089

38 1. DUAL RANGE VALVE L27 2. CONNECTOR X023 3. CONNECTOR X020

55-220

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DRIVES FRAME--8

B-46 = HYDROSTAT MOTOR TEMP H-08 = BACK UP ALARM L-05 = PRESSURE RELEASE L-26 = REAR WHEEL ASSIST

L-27 = DUAL RANGE S-49 = BRAKE FLUID LEVEL SWITCH S-55 = LH BRAKE WEAR SWITCH S-56 = RH BRAKE WEAR SWITCH

55-221

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0061-11 Feeder Jog Forward Valve Unidentified Failure Code Cause: The feeder jog forward solenoid (L20) circuit open or is shorted to ground. Possible failure modes: 1. Supply wiring shorted to ground or open circuit. 2. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the circuit. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with step 9. 2. Turn the key switch to the OFF position and disconnect the feeder jog forward connector X270. Use a multimeter to check the resistance of the feeder jog forward valve coil. The proper resistance range for the coil is 2.0 to 6.0 ohms. A. If out of specification, replace coil. B. If the coil is within specification, continue with Step 3. 3. Use a multimeter to check for continuity between connector X270 pin 1 and chassis ground. Flex the front frame (FF) harness while making this check. A. If no continuity to ground is found, continue with Step 4. B. If there is continuity to ground, continue with Step 6. 4. Turn the key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the feeder jog forward solenoid. Use the multimeter to check for 12 volts between connector X270 pin 1 and chassis ground. A. If 12 volts is not present, continue with Step 5. B. If 12 volts is found, continue with Step 7. 5. Key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the feeder jog forward solenoid. Use the multimeter to check for 12 volts between connector X021 pin A and chassis ground. A. If 12 volts is not present, the open is in the front frame (FF) harness between connector X021 and connector X020 J3-5 wire 561 white. Locate the open and repair. B. If there is 12 volts, the open is in the feeder valves (FV) harness between connector X021 and connector X270 wire 561 white. Locate the open and repair. 6. Disconnect connector X021. Use the multimeter to check for continuity between connector X021 pin A and chassis ground. A. If continuity is found, the short to ground is in the front frame (FF) harness between connector X021 and connector X020 J3-5 wire 561 white. Locate the short and repair. B. If no continuity is found, the short to ground is in the feeder valves (FV) harness between connector X021 and connector X270 wire 561 white. Locate the short and repair.

55-222

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 7. Disconnect connector X270. Use a multimeter to check for continuity between connector X270 pin 2 and chassis ground. A. If there is continuity, the circuit should be functional. Continue with step 9. B. If there is no continuity, continue with step 8. 8. Disconnect connector X021. Use a multimeter to check for continuity between the front frame (FF) harness end of connector X021 pin B and chassis ground. A. If there is continuity, there is an open circuit in the feeder valves (FV) harness between connector X270 and connector X021 wire 590 black. Locate the open and repair. B. If there is no continuity, there is an open circuit in the front frame (FF) harness between connector X021 and front frame ground #2 wire 590 black or 592 black. Locate the open and repair. 9. Erase the fault code and continue operation.

55-223

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

2 1 40024707

10020032 50020095

39 1. FEEDER JOG FORWARD SOLENOID L20 2. CONNECTOR X021 3. CONNECTOR X020 4. FRONT FRAME GROUND #2

55-224

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FEEDER FRAME--16

B-09 = REVERSER DISENGAGE B-14 = FEEDER RPM B-24 = STONE DOOR CLOSED F-24 = FAN, REVERSER FUSE

K-17 = FAN/REVERSER RELAY K-19 = NOT USED L-20 = FEEDER JOG FORWARD L-21 = FEEDER JOG REVERSE

55-225

L-24 = FEEDER CLUTCH M-05 = CLEANING FAN ADJUST MOTOR (EU) M-10 = FEEDER REVERSER ACTUATOR S-31 = FEEDER ENGAGE

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0062-11 Fan / Reverser Select Unidentified Failure Code Cause: The fan/reverser relay (K-17) circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad relay. 3. Controller internal failure (internal regulator failure). Solution: The fan/reverser relay is used to switch an output circuit from CCM1 to the feeder reverser actuator M10. The relay is controlled by CCM1. If the control circuit to the relay fails, the reverser circuit should function. 1. Replace the fan/reverser relay with a known good relay. A. Fan/reverser function is restored. Troubleshooting completed. B. If function has not been restored, continue with step 2. 2. Turn the key switch to the OFF position and remove the fan/reverser relay K17. Use a multimeter to check the resistance of the fan/reverser relay coil. The proper resistance range for the fan/reverser relay coil is 74.3 to 78.3 ohms. A. If out of specification, replace relay. B. If the coil is within specification, continue with Step 3. 3. Use a multimeter to check for continuity between relay socket pin 1 and chassis ground. A. If no continuity to ground is found, continue with Step 5. B. If there is continuity to ground, continue with step 4. 4. Disconnect connector X031. Use a multimeter to check for continuity between the harness end of connector X031 pin 9 and chassis ground. A. If there is continuity to ground, there is a short to ground in the cab main (CM) harness between connector X031 pin 9 and the fan/reverser relay K17 pin 1 wire 768 white. Locate the short and repair. B. If no continuity to ground is found, there is a short to ground in the front frame (FF) harness between connector X031 pin 9 and connector X020 pin J3-12 wire 768 white. Locate the short and repair. 5. Use a multimeter to check for continuity between relay socket pin 2 and chassis ground. A. If continuity to ground is found, continue with Step 6. B. If there is no continuity to ground, there is an open circuit in the cab main (CM) harness between the fan/reverser relay K17 pin 2 and cab ground #2 wire 769 black. Locate the open and repair. 6. Turn the key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the fan/reverser relay. Use the multimeter to check for 12 volts between relay socket pin 1 and chassis ground. A. If 12 volts is not present, continue with Step 7. B. If 12 volts is found, continue with Step 9.

55-226

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 7. Turn the key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the fan/reverser relay. Disconnect connector X031, and use the multimeter to check for 12 volts between connector X031 pin 9 and chassis ground. A. If 12 volts is not present, continue with Step 8. B. If 12 volts is found, there is an open circuit in the cab main (CM) harness between connector X031 pin 9 and the fan/reverser relay K17 pin 1 wire 768 white. Locate the open and repair. 8. Key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the fan/reverser relay. Use the multimeter to check for 12 volts between connector X020 J3-12 and chassis ground. A. If 12 volts is not present, replace the CCM1 with a known good controller. B. If 12 volts is present, there is an open circuit in the front frame (FF) harness between connector X020 J3-12 and connector X031 pin 9 wire 768 white. Locate the open and repair. 9. Erase the fault code and continue operation.

55-227

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

3 50020070

10010899

50020089

40 1. CONNECTOR X020 2. CONNECTOR X031

3. FAN/REVERSER RELAY K17

55-228

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FEEDER FRAME--16

B-09 = REVERSER DISENGAGE B-14 = FEEDER RPM B-24 = STONE DOOR CLOSED F-24 = FAN, REVERSER FUSE

K-17 = FAN/REVERSER RELAY K-19 = NOT USED L-20 = FEEDER JOG FORWARD L-21 = FEEDER JOG REVERSE

55-229

L-24 = FEEDER CLUTCH M-05 = CLEANING FAN ADJUST MOTOR (EU) M-10 = FEEDER REVERSER ACTUATOR S-31 = FEEDER ENGAGE

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0065-11 Backup Alarm Unidentified Failure Code Cause: The backup alarm (H08) circuit open or shorted to ground. Possible failure modes: 1. Circuit connection/wiring damaged between CCM1 and backup alarm. 2. Controller internal failure (internal regulator failure). Solution: 1. Turn the key switch to the OFF position and disconnect the backup alarm connector X248. A. Use a multimeter to check the resistance of the backup alarm coil. The proper resistance range for the coil is 1.0 to 8.0 ohms. If out of specification, replace coil. B. If the coil is within specification, continue with Step 2. 2. Disconnect connector X248. Use a multimeter to check for continuity between connector X248 pin 1 (white wire) and chassis ground. Flex the harness while making this check. A. If no continuity to ground is found, continue with Step 3. B. If there is continuity to ground, continue with Step 6. 3. Disconnect connector X248. Turn the key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the backup alarm. Use the multimeter to check for 12 volts between connector X248 pin 1 and chassis ground. A. If 12 volts is not present, continue with Step 4. B. If 12 volts is found, continue with Step 8. 4. Disconnect connector X071. Key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the backup alarm. Use the multimeter to check for 12 volts between connector X071 pin 14 and chassis ground. A. If 12 volts is not present, continue with Step 5. B. If there is 12 volts, the open is in the straw hood (SH) harness between connector X071 and connector X248 wire 452 white. Locate the open and repair. 5. Disconnect connector X024. Key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the backup alarm. Use the multimeter to check for 12 volts between connector X024 pin 13 and chassis ground. A. If 12 volts is not present, the open is in the main frame (MF) harness between connector X024 and connector X019 J2-6 wire 452 white. Locate the open and repair. B. If there is 12 volts, the open is in the straw hood front (SW) harness between connector X024 and connector X071 wire 452 white. Locate the open and repair. 6. Disconnect connector X071. Use the multimeter to check for continuity between connector X071 pin 14 and chassis ground. A. If continuity is found, continue with Step 7. B. If no continuity is found, the short to ground is in the straw hood (SH) harness between connector X071 and connector X248 wire 452 white. Locate the short and repair. 7. Disconnect connector X024. Use the multimeter to check for continuity between connector X024 pin 13 and chassis ground. A. If continuity is found, the short to ground is in the main frame (MF) harness between connector X024 and connector X019 J2-6 wire 452 white. Locate the short and repair. B. If no continuity is found, the short to ground is in the straw hood front (SW) harness between connector X024 and connector X071 wire 452 white. Locate the short and repair.

55-230

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 8. Use a multimeter to check for continuity between connector X248 pin 1 (black wire) and chassis ground. Flex the harness while making this check. A. If no continuity to ground is found, continue with step 9. B. If there is continuity to ground, the circuit is functional. Continue with step 10. 9. Disconnect connector X071. Use a multimeter to check for continuity between the straw hood front (SW) harness end of connector X071 pin 26 and chassis ground. A. If there is continuity to ground, there is an open circuit in the straw hood (SH) harness between connector X248 and connector X071 wire 455 black or 478 black. Locate the open and repair. B. If there is no continuity to ground, there is an open circuit in the straw hood front (SW) harness between connector X071 and rear frame ground #1 wire 478 black. Locate the open and repair. 10. Erase the fault code and continue operation.

55-231

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

40024711

50026220

10020076 50020083

41 1. BACK UP ALARM H08 2. CONNECTOR X071 3. REAR FRAME GROUND #1

55-232

4. CONNECTOR X024 5. CONNECTOR X019

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DRIVES FRAME--8

B-46 = HYDROSTAT MOTOR TEMP H-08 = BACK UP ALARM L-05 = PRESSURE RELEASE L-26 = REAR WHEEL ASSIST

L-27 = DUAL RANGE S-49 = BRAKE FLUID LEVEL SWITCH S-55 = LH BRAKE WEAR SWITCH S-56 = RH BRAKE WEAR SWITCH

55-233

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0066-11 Rear Wheel Assist Valve Unidentified Failure Code Cause: The rear wheel assist (L26) circuit open, or is shorted to ground. Possible failure modes: 1. Circuit connection/wiring damaged between CCM1 and rear wheel assist solenoid. 2. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with step 11. 2. Turn the key switch to the OFF position and disconnect the rear wheel assist connector X233. Use a multimeter to check the resistance of the rear wheel assist coil. The proper resistance range for the coil is 1.0 to 8.0 ohms. A. If out of specification, replace coil. B. If the coil is within specification, continue with Step 3. 3. Use a multimeter to check for continuity between connector X233 pin A and chassis ground. Flex the harness while making this check. A. If no continuity to ground is found, continue with Step 4. B. If there is continuity to ground, continue with Step 7. 4. Disconnect connector X233. Turn the key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the rear wheel assist. Use the multimeter to check for 12 volts between connector X233 pin A and chassis ground. A. If 12 volts is not present, continue with Step 5. B. If 12 volts is found, continue with Step 9. 5. Disconnect connector X072. Key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the rear wheel assist. Use the multimeter to check for 12 volts between connector X072 pin A and chassis ground. A. If 12 volts is not present, continue with Step 6. B. If there is 12 volts, the open is in the lower frame rear (LR) harness between connector X072 and connector X233 wire 569 white. Locate the open and repair. 6. Disconnect connector X024. Key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the rear wheel assist. Use the multimeter to check for 12 volts between connector X024 pin 15 and chassis ground. A. If 12 volts is not present, the open is in the main frame (MF) harness between connector X024 and connector X019 J2-16 wire 569 white. Locate the open and repair. B. If there is 12 volts, the open is in the straw hood front (SW) harness between connector X024 and connector X072 wire 569 white. Locate the open and repair.

55-234

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 7. Disconnect connector X072. Use the multimeter to check for continuity between connector X072 pin A and chassis ground. A. If continuity is found, continue with Step 8. B. If no continuity is found, the short to ground is in the lower frame rear (LR) harness between connector X072 and connector X233 wire 569 white. Locate the short and repair. 8. Disconnect connector X024. Use the multimeter to check for continuity between connector X024 pin 15 and chassis ground. A. If continuity is found, the short to ground is in the main frame (MF) harness between connector X024 and connector X019 J2-16 wire 569 white. Locate the short and repair. B. If no continuity is found, the short to ground is in the straw hood front (SW) harness between connector X024 and connector X072 wire 569 white. Locate the short and repair. 9. Disconnect connector X233. Use a multimeter to check for continuity between connector X233 pin B and chassis ground. A. If there is continuity to ground, the circuit is functioning properly. Continue with step 11. B. If there is no continuity to ground, continue with step 10. 10. Disconnect connector X072. Use a multimeter to check for continuity between the straw hood front (SW) harness end of connector X072 pin B and chassis ground. A. If there is continuity to ground, there is an open circuit in the lower frame rear (LR) harness between connector X233 and connector X072 wire 602 black. Locate the open and repair. B. If there is no continuity to ground, there is an open circuit in the straw hood front (SW) harness between connector X072 and rear frame ground #1 wire 602 black or 479 black. Locate the open and repair. 11. Erase the fault code and continue operation.

55-235

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

40020080 10020076

10010896

50020092

42 1. REAR WHEEL ASSIST SOLENOID L26 2. CONNECTOR X072 3. REAR FRAME GROUND #1

55-236

4. CONNECTOR X024 5. CONNECTOR X019

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

DRIVES FRAME--8

B-46 = HYDROSTAT MOTOR TEMP H-08 = BACK UP ALARM L-05 = PRESSURE RELEASE L-26 = REAR WHEEL ASSIST

L-27 = DUAL RANGE S-49 = BRAKE FLUID LEVEL SWITCH S-55 = LH BRAKE WEAR SWITCH S-56 = RH BRAKE WEAR SWITCH

55-237

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0067-11 Feeder Jog Reverse Valve Unidentified Failure Code Cause: The feeder jog reverse solenoid (L21) circuit open, or is shorted to ground. Possible failure modes: 1. Supply wiring shorted to ground or open circuit. 2. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with step 9. 2. Turn the key switch to the OFF position and disconnect the feeder jog reverse connector X266. Use a multimeter to check the resistance of the feeder jog reverse valve coil. The proper resistance range for the coil is 2.0 to 6.0 ohms. A. If out of specification, replace coil. B. If the coil is within specification, continue with Step 3. 3. Disconnect connector X266. Use a multimeter to check for continuity between connector X266 pin 1 and chassis ground. Flex the front frame (FF) harness while making this check. A. If no continuity to ground is found, continue with Step 4. B. If there is continuity to ground, continue with Step 6. 4. Disconnect connector X266. Turn the key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the feeder jog reverse solenoid. Use the multimeter to check for 12 volts between connector X266 pin 1 and chassis ground. A. If 12 volts is not present, continue with Step 5. B. If 12 volts is found, continue with Step 7. 5. Disconnect connector X021. Key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the feeder jog reverse solenoid. Use the multimeter to check for 12 volts between connector X021 pin C and chassis ground. A. If 12 volts is not present, the open is in the front frame (FF) harness between connector X021 and connector X020 J3-15 wire 562 white. Locate the short and repair. B. If there is 12 volts, the open is in the feeder valves (FV) harness between connector X021 and connector X266 wire 562 white. Locate the open and repair. 6. Disconnect connector X021. Use the multimeter to check for continuity between connector X021 pin C and chassis ground. A. If continuity is found, the short to ground is in the front frame (FF) harness between connector X021 and connector X020 J3-15 wire 562 white. Locate the short and repair. B. If no continuity is found, the short to ground is in the feeder valves (FV) harness between connector X021 and connector X266 wire 562 white. Locate the short and repair.

55-238

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 7. Disconnect connector X266. Use a multimeter to check for continuity between connector X266 pin 2 and chassis ground. A. If there is continuity, the circuit should be functional. Continue with step 9. B. If there is no continuity, continue with step 8. 8. Disconnect connector X021. Use a multimeter to check for continuity between the front frame (FF) harness end of connector X021 pin D and chassis ground. A. If there is continuity, there is an open circuit in the feeder valves (FV) harness between connector X266 and connector X021 wire 591 black. Locate the open and repair. B. If there is no continuity, there is an open circuit in the front frame (FF) harness between connector X021 and front frame ground #2 wire 591 black or 592 black. Locate the open and repair. 9. Erase the fault code and continue operation.

55-239

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

2 1 40024707

10020032 50020095

43 1. FEEDER JOG REVERSE SOLENOID L21 2. CONNECTOR X021 3. FRONT FRAME GROUND #2 3. CONNECTOR X020

55-240

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FEEDER FRAME--16

B-09 = REVERSER DISENGAGE B-14 = FEEDER RPM B-24 = STONE DOOR CLOSED F-24 = FAN, REVERSER FUSE

K-17 = FAN/REVERSER RELAY K-19 = NOT USED L-20 = FEEDER JOG FORWARD L-21 = FEEDER JOG REVERSE

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L-24 = FEEDER CLUTCH M-05 = CLEANING FAN ADJUST MOTOR (EU) M-10 = FEEDER REVERSER ACTUATOR S-31 = FEEDER ENGAGE

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0068-11 Unload Tube Light Relay Unidentified Failure Code Cause: The unload tube light relay (K32) circuit open or shorted to ground. Possible failure modes: 1. Circuit connection/wiring damaged between CCM1 and relay. 2. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with step 5. 2. Turn the key switch to the OFF position and remove the unload tube light relay K32 from relay base in cab. Use a multimeter to check for continuity between relay base (K 32) pin 1 and chassis ground. Flex the cab main (CM) harness while making this check. A. If no continuity to ground is found, continue with Step 3. B. If there is continuity to ground, the short to ground is in the cab main (CM) harness between relay base and connector X018 J1-12 wire 181 white. Locate the short and repair. 3. Use a multimeter to check for continuity between relay base (K32) pin 2 and chassis ground. A. If there is continuity to ground, continue with Step 4. B. If no continuity to ground is found, there is an open circuit in the cab main (CM) harness between relay base pin 2 and cab ground #3 wire 163 black. Locate the open and repair. 4. Turn the key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the unload tube light relay K32. Use the multimeter to check for 12 volts between relay base (K 32) pin 1 and chassis ground. A. If 12 volts is not present, the open is between the relay base K32 and connector X018 J1-12 wire 181 white. B. If 12 volts is found, continue with Step 5. 5. Erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

2 50020070

10004693 50020087

44 1. CONNECTOR X018 2. UNLOAD TUBE LIGHT RELAY K32

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

LIGHTING FRAME--40

E-21 = LH HEADER LIGHT E-22 = RH HEADER LIGHT E-23 = LH LOWER WORK LIGHT E-24 = RH LOWER WORK LIGHT

E-29 = UNLOAD TUBE LIGHT E-30 = GRAIN TANK LIGHT E-38 = CENTER WORK LIGHT F-30 = HEADER WORK LTS FUSE

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F-50 = SIDE LTS FUSE F-54 = LOWER WORK LTS FUSE K-22 = HEADER WORK LTS RELAY K-30 = LOWER WORK LTS RELAY

K-32 = UNLOAD TUBE LIGHT RELAY

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0069-11 Covers / Concave Cl Sel Unidentified Failure Code Cause: The covers/concave clearance relay (K16) circuit open or shorted to ground. Possible failure modes: 1. Circuit connection/wiring damaged between CCM1 and relay. 2. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with step 5. 2. Turn the key switch to the OFF position and remove the covers/concave clearance relay K16 from relay base in cab. Use a multimeter to check for continuity between relay base K16 pin 1 and chassis ground. Flex the cab main (CM) harness while making this check. A. If no continuity to ground is found, continue with Step 3. B. If there is continuity to ground, the short to ground is in the cab main (CM) harness between relay base and connector X018 J1-6 wire 692 white. Locate the short and repair. 3. Use a multimeter to check for continuity between relay base K16 pin 2 and chassis ground. A. If there is continuity to ground, continue with Step 4. B. If no continuity to ground is found, there is an open circuit in the cab main (CM) harness between relay base pin 2 and cab ground #3 wire 697 black. Locate the open and repair. 4. Turn the key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the covers/concave clearance relay K16. Use the multimeter to check for 12 volts between relay base K16 pin 1 and chassis ground. A. If 12 volts is not present, the open is between the relay base K16 and connector X018 J1-6 wire 692 white. B. If 12 volts is found, continue with Step 5. 5. Erase the fault code and continue operation.

55-245

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

1 2 50020070 10004693 50020087

45 1. CONNECTOR X018 2. CONCAVE / COVERS RELAY K16

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

B-45 = GEARBOX CLUTCH TEMP K-16 = CONCAVE/COVERS RELAY M-04 = CONCAVE CLEARANCE MOTOR M-12 = COVERS MOTOR

R-06 = CONCAVE POSITION S-16 = CONCAVE CLEARANCE

THRESHER FRAME--17

55-247

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0070-11 Front Work Lights Relay Unidentified Failure Code Cause: The front work lights relay(s) (K01, K21) circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad relay(s). 3. Controller internal failure (internal regulator failure). Solution: Two relays are used to control the numerous work lights installed on the combine, but both relays are engaged using a single output signal from CCM1. Since the two relays are wired in parallel, it is possible to have a single relay fail, preventing certain lighting from coming on, without having a fault code indicated. This fault code will only occur if there is a short to ground anywhere on the supply wiring to the relays, or if there is an open circuit between the CCM1 module and the first relay (K01). An open circuit on one of the relay ground paths, or in the supply wiring to the K21 relay will not cause this error to be displayed. 1. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with step 4. 2. Key OFF. Remove the Cab Roof Work Lights relay K01, and use a multimeter to check between relay base pin 1 and chassis ground. A. If there is not continuity to ground, continue with step 3. B. If there is continuity to ground, there is a short to ground in the cab main (CM) harness between connector X018 pin J1-11 and the work lights relays on one of the following wires: wire 190 white, connector X018 pin J1-11 to relay K01 pin 1 wire 189 white, relay K01 pin 1 to relay K21 pin 1 Locate the short and repair. 3. Key OFF. Remove the Cab Roof Work Lights relay K01. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the front work lights relays. Use a multimeter to check for 12V power between relay base pin 1 and chassis ground. A. If 12V is not present, there is an open circuit in the cab main (CM) harness between connector X018 pin J1-11 and relay base (K01) pin 1 wire 190 white. Locate the open and repair. B. If 12V is present, continue with step 4. 4. Erase the fault code and continue operation.

55-248

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

1 50020070

10004693 50020087

46 1. CONNECTOR X018 2. CAB ROOF WORK LIGHTS RELAY K01 3. DISTANCE WORK LIGHTS RELAY K21

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

E-15 = LH CAB OUTER WORK LIGHT E-16 = RH CAB OUTER WORK LIGHT E-17 = LH CAB INNER WORK LIGHT E-18 = RH CAB INNER WORK LIGHT

E-19 = LH CAB MID WORK LIGHT E-20 = RH CAB MID WORK LIGHT F-06 = LH CAB WORK LTS FUSE F-07 = RH CAB WORK LTS FUSE

F-29 = DISTANCE WORK LTS FUSE F-31 = CAB ROOF WORK LTS FUSE K-01 = CAB ROOF WORK LTS RELAY K-21 = DISTANCE WORK LTS RELAY

55-250

K-27 = ROAD LIGHTS RELAY

LIGHTING FRAME--41

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0071-11 Rear Work Lights Relay Unidentified Failure Code Cause: The rear work lights relay (K31) circuit is open or shorted to ground. Possible failure modes: 1. Circuit connection/wiring damaged between CCM1 and relay. 2. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with step 5. 2. Turn the key switch to the OFF position and remove the rear work light relay K31 from relay base in cab. Use a multimeter to check for continuity between relay base (K 31) pin 1 and chassis ground. Flex the cab main (CM) harness while making this check. A. If no continuity to ground is found, continue with Step 3. B. If there is continuity to ground, the short to ground is in the cab main (CM) harness between relay base and connector X018 J1-18 wire 184 white. Locate the short and repair. 3. Use a multimeter to check for continuity between relay base (K31) pin 2 and chassis ground. A. If there is continuity to ground, continue with Step 4. B. If no continuity to ground is found, there is an open circuit in the cab main (CM) harness between relay base pin 2 and cab ground #3 wire 158 black. Locate the open and repair. 4. Turn the key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the rear work light relay K31. Use the multimeter to check for 12 volts between relay base (K 31) pin 1 and chassis ground. A. If 12 volts is not present, the open is in the cab main (CM) harness between the relay base K31 and connector X018 J1-18 wire 184 white. Locate the open and repair. B. If 12 volts is found, continue with Step 5. 5. Erase the fault code and continue operation.

55-251

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

50020070 10004693 50020087

47 1. CONNECTOR X018 2. REAR WORK LIGHTS RELAY K31

55-252

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

LIGHTING FRAME--42

E-27 = LH REAR WORK LIGHT E-28 = RH REAR WORK LIGHT F-55 = REAR WORK LTS FUSE K-31 = REAR WORK LTS RELAY

S-43 = WORK LIGHT SWITCH S-44 = REAR WORK LIGHT SWITCH

55-253

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0072-11 Side Work Lights Relay Unidentified Failure Code Cause: The side work lights relay (K35) circuit open or shorted to ground. Possible failure modes: 1. Circuit connection/wiring damaged between CCM1 and relay. 2. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with step 5. 2. Turn the key switch to the OFF position and remove the side work light relay K35 from relay base in cab. Use a multimeter to check for continuity between relay base (K 35) pin 1 and chassis ground. Flex the cab main (CM) harness while making this check. A. If no continuity to ground is found, continue with Step 3. B. If there is continuity to ground, the short to ground is in the cab main (CM) harness between relay base and connector X018 J1-24 wire 180 white. Locate the short and repair. 3. Use a multimeter to check for continuity between relay base (K35) pin 2 and chassis ground. A. If there is continuity to ground, continue with Step 4. B. If no continuity to ground is found, there is an open circuit in the cab main (CM) harness between relay base pin 2 and cab ground #3 wire 161 black. Locate the open and repair. 4. Turn the key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the side work light relay K35. Use the multimeter to check for 12 volts between relay base (K 35) pin 1 and chassis ground. A. If 12 volts is not present, the open is in the cab main (CM) harness between the relay base K35 and connector X018 J1-24 wire 180 white. Locate the open and repair. B. If 12 volts is found, continue with Step 5. 5. Erase the fault code and continue operation.

55-254

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

1 2 50020070 10004693 50020087

48 1. CONNECTOR X018 2. SIDE WORK LIGHT RELAY K35

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

E-25 = LH SIDE WORK LIGHT E-26 = RH SIDE WORK LIGHT E-37 = SIEVE LIGHT F-14 = SERVICE LTS FUSE

K-34 = TIMED SIDE WORK LIGHT RELAY K-35 = SIDE WORK LIGHT RELAY S-54 = SIEVE LIGHT SWITCH

55-256

LIGHTING FRAME--43

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0073-11 Field Lights Relay Unidentified Failure Code Context: Three relays are used to control the numerous work lights installed on the combine, but all relays are engaged using a single output signal from CCM1. Since the three relays are wired in parallel, it is possible to have a single relay fail, preventing certain lighting from coming on, without having a fault code indicated. This fault code will only occur if there is a short to ground anywhere on the supply wiring to the relays, or if there is an open circuit between the CCM1 module and the first relay (K-27). An open circuit on one of the relay ground paths, or in the supply wiring to K-22 or K-30 relay will not cause this error to be displayed. Cause: The front work lights relay(s) (K-27, K-22, or K-30) circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad relay(s). 3. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed, to change the circuit output to “ON”. The “STATUS” screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “ERROR”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with Step 4. 2. Key OFF. Remove the Road Lights relay K-27, and use a multimeter to check for continuity between relay base pin 1 and chassis ground. A. If there is not continuity to ground, continue with Step 3. B. If there is continuity to ground, there is a short to ground in the cab main (CM) harness between connector X018 pin J1-5 and the work lights relays on one of the following wires: --

wire 117 white, connector X018 pin J1-5 to relay K-27 pin 1.

wire 188 white, relay K-27 pin 1 to relay K-22 pin 1.

wire 187 white, relay K-22 pin 1 to relay K-30 pin 1.

Locate the short and repair. 3. Key OFF. Remove the Road Lights relay K-27. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the field lights relays. Use a multimeter to check for 12V power between relay base pin 1 and chassis ground. A. If 12V is not present, there is an open circuit in the cab main (CM) harness between connector X018 pin J1-5 and relay base (K-27) pin 1 wire 117 white. Locate the open and repair. B. If 12V is present, continue with Step 4. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-257

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

LIGHTING FRAME--40

E-21 = LH HEADER LIGHT E-22 = RH HEADER LIGHT E-23 = LH LOWER WORK LIGHT E-24 = RH LOWER WORK LIGHT

E-29 = UNLOAD TUBE LIGHT E-30 = GRAIN TANK LIGHT E-38 = CENTER WORK LIGHT F-30 = HEADER WORK LTS FUSE

55-258

F-50 = SIDE LTS FUSE F-54 = LOWER WORK LTS FUSE K-22 = HEADER WORK LTS RELAY K-30 = LOWER WORK LTS RELAY

K-32 = UNLOAD TUBE LIGHT RELAY

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

E-15 = LH CAB OUTER WORK LIGHT E-16 = RH CAB OUTER WORK LIGHT E-17 = LH CAB INNER WORK LIGHT E-18 = RH CAB INNER WORK LIGHT

E-19 = LH CAB MID WORK LIGHT E-20 = RH CAB MID WORK LIGHT F-06 = LH CAB WORK LTS FUSE F-07 = RH CAB WORK LTS FUSE

F-29 = DISTANCE WORK LTS FUSE F-31 = CAB ROOF WORK LTS FUSE K-01 = CAB ROOF WORK LTS RELAY K-21 = DISTANCE WORK LTS RELAY

55-259

K-27 = ROAD LIGHTS RELAY

LIGHTING FRAME--41

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0075-05 Leveling Shoe Motor Line Disconnected Context: The CCM has detected that the circuit current has been <0.7 Amps for at least 3 seconds, while the control circuit input is active. Lack of current flow in an activated circuit is an indication of an open circuit condition. However, it is also possible to get this error message from a direct short to ground. This is because the CCM contains built-in over temperature circuit protection logic that will electronically disconnect the motor in order to prevent damage to the module. When a direct short to ground is present, and the motor is energized, it is possible for the rapid spike in current to engage the circuit protection -opening the circuit. When this occurs, the fault detection software sees the open and may report the “Line disconnected” fault. Cause: The shoe leveling motor (M03) control voltage circuit open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad motor. 3. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed. A. Start the combine. B. Manually tilt the cleaning shoe in each direction. C. Record in which direction(s) the shoe leveling actuator operates. D. Reload error history. Check for fault codes E0043-06 and E0075-05. E. Use the following table to determine the location of the fault. Fault Code

Symptom

E0043-06 Leveling shoe motor operates in 1 direction only

Leveling g shoe motor d does not operate in either direction

Fault Type

E0075-05 X X

Go to Step 2

Binding

Go to Step 3

Short to ground

Go to Step 2

Binding

Go to Step 8

Open circuit

Go to Step 13

No power supply

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 4. Disconnect the batteries using the battery key. Use the multimeter to check for continuity between connector X088 pin E and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position. Power must be removed from the module prior to testing for short to ground condition on the motor circuit to remove this ground path. A. If continuity is found, continue with step 5. B. If no continuity is found, continue with step 6. 5. Disconnect connector X023. Use a multimeter to check for continuity between connector X023 pin 1 and chassis ground. A. If no continuity is found, the short to ground is in the lower frame (LF) harness between connector X023 pin 1 and connector X088 pin E wire 707 gray. Locate the short and repair. B. If continuity is found, the short to ground is in the front frame (FF) harness between connector X023 pin 1 and connector X020 pins J3-19 and 20 on one of the following wires: wire 707 gray, connector X023 pin 1 to harness splice wire 705 gray, harness splice to connector X020 pin J3-19 wire 706 gray, harness splice to connector X020 pin J3-20 Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. 6. Use a multimeter to check for continuity between connector X088 pin D and chassis ground. A. If continuity is found, continue with step 7. B. If no continuity is found, recheck the motor for continuity to ground at step 3. 7. Disconnect connector X023. Use a multimeter to check for continuity between connector X023 pin 2 and chassis ground. A. If no continuity is found, the short to ground is in the lower frame (LF) harness between connector X088 pin D and X023 pin 2 wire 710 white. Locate the short and repair. B. If continuity is found, the short to ground is in the front frame (FF) harness between connector X023 pin 2 and connector X020 pins J3-39 and 40 on one of the following wires: wire 710 white, connector X023 pin 2 to harness splice wire 708 white, harness splice to connector X020 pin J3-39 wire 709 white, harness splice to connector X020 pin J3-40 Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. 8. Fault codes indicate circuit fault due to open circuit condition. Disconnect shoe leveling motor connector X088. Measure the resistance of the motor between terminals D and E. The correct resistance is 1 to 5 ohms. A. The resistance is infinite, indicating an open condition in the motor. Replace the shoe leveling motor. B. The resistance is in specification. Continue with step 9. 9. Ensure that the batteries are connected using the battery key, and that fuse F22 is good. Use the multimeter to check for continuity between connector X088 pin E and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F22. This ground path may be used to test for an open circuit condition. A. If continuity is found, continue with step 11. B. If no continuity is found, continue with step 10.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 10. Disconnect connector X023. Use a multimeter to check for continuity between connector X023 pin 1 and chassis ground. A. If continuity is found, the open circuit is in the lower frame (LF) harness between connector X023 pin 1 and connector X088 pin E wire 707 white. Locate the open and repair. B. If no continuity is found, the open circuit is in the front frame (FF) harness between connector X023 pin 1 and connector X020 pins J3-19 and 20 on one of the following wires: wire 707 gray, connector X023 pin 1 to harness splice wire 705 gray, harness splice to connector X020 pin J3-19 wire 706 gray, harness splice to connector X020 pin J3-20 Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the open circuit and repair. 11. Use a multimeter to check for continuity between connector X088 pin D and chassis ground. A. If no continuity is found, continue with step 12. B. If continuity is found, recheck the motor for continuity at step 8. 12. Disconnect connector X023. Use a multimeter to check for continuity between connector X023 pin 2 and chassis ground. A. If continuity is found, the open circuit is in the lower frame (LF) harness between connector X088 pin D and X023 pin 2. Locate the open and repair. B. If no continuity is found, the open circuit is in the front frame (FF) harness between connector X023 pin 2 and connector X020 pins J3-39 and 40 on one of the following wires: wire 710 white, connector X023 pin 2 to harness splice wire 708 white, harness splice to connector X020 pin J3-39 wire 709 white, harness splice to connector X020 pin J3-40 Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the open circuit and repair. 13. If the shoe leveling motor does not operate in either direction, and there are no error codes indicated, the supply power for the circuit may not be present. Remove and inspect fuse F22. A. Fuse has failed. Go to step 14. B. Fuse is okay. Go to step 15. 14. If fuse has failed, replace the fuse. A. If fuse immediately fails, a short to ground exists on one of the following wires: wire 024 red, from the fuse panel through connector X031 pin 16 to harness splice in front frame (FF) harness wire 700 red, harness splice to connector X020 pin J3-29 on CCM1 module wire 701 red, harness splice to connector X020 pin J3-30 on CCM1 module Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. B. Fuse is okay. Go to step 15.

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55-263

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

10004665

10010898 50020089

49 1. SHOE LEVELING ACTUATOR M03 2. CONNECTOR X023 3. CONNECTOR X020

55-264

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

B-16 = CLEANING FAN RPM B-21 = SIEVES LOSS F-22 = SHOE LEVELING MOTOR FUSE L-44 = FAN DRIVE SOLENOID

M-03 = SHOE LEVELING ACTUATOR S-13 = UPPER SIEVE S-14 = LOWER SIEVE S-15 = FAN SPEED

55-265

CLEANING FRAME--19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0077-05 Reverser Motor Line Disconnected Context: The CCM has detected that the circuit current has been <0.7 Amps for at least 3 seconds, while the control circuit input is active. Lack of current flow in an activated circuit is an indication of an open circuit condition. However, it is also possible to get this error message from a direct short to ground. This is because the CCM contains built-in over temperature circuit protection logic that will electronically disconnect the motor in order to prevent damage to the module. When a direct short to ground is present, and the motor is energized, it is possible for the rapid spike in current to engage the circuit protection -opening the circuit. When this occurs, the fault detection software sees the open and may report the “Line disconnected” fault. Cause: The feeder reverser actuator (M10) circuit indicates high current draw. Possible failure modes: 1. Circuit connection shorted. 2. Excessive mechanical load on motor. 3. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed. A. Start the combine. B. Engage the threshing mechanism and operate feeder reverser circuits in both directions. C. Does feeder reverser engage? D. Reload error history. E. Check for the following fault codes: E0042-06 and E0077-05. F. Use the following table to determine the location of the fault. FAULT CODES

SYMPTOM

E0042-06 Reverser operates in 1 direction only

Reverser does not operate in either direction Reverser does not operate in either direction

E0077-05

Go to Step 2

Go to Step 3 X

NO FAULT CODE

Go to Step 8 Go to Step 17

2. The reverser motor actuator is bound up. See the appropriate service manual chapter for repair. 3. The reverser operates in one direction only. Fault codes indicate a short to ground. Disconnect the reverser motor connector X080. Measure the resistance on connector X080 between pin A and pin B. The proper resistance range for the coil is 4.0 to 8.0 ohms. A. If out of specification, replace reverser motor. B. If the motor coil resistance is within specification, continue with Step 4. 4. Measure the resistance on connector X080 between pin A and chassis ground. Flex the feeder and front frame (FF) harnesses while making this check. A. If no continuity to ground is found, continue with Step 5. B. If there is continuity to ground, continue with Step 6.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 5. Disconnect connector X007. Use the multimeter to check for continuity between connector X007 pin 2 and chassis ground. A. If continuity is found, the short is between connector X080 and CCM1 connector X020 J3-6 wires 713, 761 or 770 gray in front frame (FF) harness. Locate the short and repair. B. If no continuity is found, the short to ground is in the feeder (FE) harness between connector X007 and connector X080 wire 770 gray. Locate the short and repair. 6. Disconnect connector X007. Use the multimeter to check for continuity between connector X007 pin 1 and chassis ground. A. If continuity is found, continue with Step 7. B. If no continuity is found, the short to ground is in the feeder (FE) harness between connector X007 and connector X080 wire 719 white. Locate the short and repair. 7. Disconnect connector X031. Use the multimeter to check for continuity between connector X031 pin 10 and chassis ground. A. If continuity is found, the short to ground is in the cab main (CM) harness between connector X031 and the relay base for relay K17 terminal 3 wire 719 white or connector X031 pin 8 to K17 terminal 3 wire 714 white. Locate the short and repair. B. If no continuity is found, the short to ground is in the front frame (FF) harness between connector X031 and connector X007 wire 719 white or connector X020 CCM-1 J3-8 to connector X031 pin 8 wire 714 white. Locate the short and repair. 8. Reverser does not operate in either direction. Fault code indicates an open in circuit. Disconnect the reverser motor connector X080. Measure the resistance on connector X080 between pin A and pin B. The proper resistance range for the coil is 4.0 to 8.0 ohms. A. If out of specification, replace feeder reverser actuator. B. If the motor coil resistance is within specification, continue with Step 9. 9. Replace the fan/reverser relay K17 with a known good relay. Connect connector X080 and operate reverser. A. If the reverser is now working, troubleshooting is complete. B. If the reverser still does not work, continue with Step 10. 10. Disconnect reverser connector X080. Key switch on, engine running. Place straw elevator reverse tumbler switch in ON position. Activate reel speed increase to REVERSE. Use a multimeter to measure the voltage between connector X080 pin A and chassis ground. A. If 12 volts is read, continue with Step 11. B. If 12 volts is not read, continue with Step 13. 11. Key switch on engine running. Place straw elevator reverse tumbler switch in ON position. Activate reel speed decrease to ROCK. Use multimeter to measure the voltage between connector X080 pin B and chassis ground. A. If 12 volts is not read, continue with Step 12. B. If 12 volts is read, the open is in the feeder reverser actuator connector X080. 12. Disconnect connector X007. Key switch on, engine running. Activate reel speed decrease to ROCK. Use multimeter to measure the voltage between connector X007 pin 2 and chassis ground. A. If 12 volts is read, the open is in the feeder (FE) harness between connector X080 and connector X007 wire 770 gray. Locate the open and repair. B. If 12 volts is not read, the open is in the front frame (FF) harness between connector X007 and the next splice in wire 770 gray. Locate the open and repair. 13. Disconnect connector X007. Key switch on, engine running. Activate reel speed increase to REVERSE. Use a multimeter to measure the voltage between connector X007 pin 1 and chassis ground. A. If 12 volts is read, the open is in the feeder (FE) harness between connector X007 and connector X080 wire 719 white. Locate the open and repair. B. If 12 volts is not read, continue with Step 14.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 14. Disconnect connector X031. Key switch on, engine running. Activate reel speed increase to REVERSE. Use a multimeter to measure the voltage between connector X031 pin 10 and chassis ground. A. If 12 volts is read, the open is in the front frame (FF) harness between connector X031 and connector X007 wire 719 white. Locate the open and repair. B. If 12 volts is not read, the open is in the cab main (CM) harness between connector X031 and relay base terminal 3 on relay K17, wire 719 white. Locate the open and repair. 15. Both fan and reverser do not operate in either direction. Fault code indicates an open circuit. Remove the fan/reverser relay K17 from the relay base. Operate the fan/reverser through the display monitor -- ”Diagnose Info” screen. Use a multimeter to measure the voltage between relay base K17 terminal 1 and chassis ground. A. If 12 volts is read, the open is in the cab main (CM) harness between CCM1 connector X031 pin 10 and relay base K17 terminal 4 wire 719 white. Locate the open and repair. B. If 12 volts is not read, continue with Step 16. 16. Disconnect connector X031. Operate the fan/reverser through the display monitor diagnostics screen. Use a multimeter to measure the voltage between connector X031 pin 8 and chassis ground. A. If 12 volts is read, the open is in the cab main (CM) harness between connector X031 and relay base K17 terminal 3. Locate the open and repair. B. If 12 volts is not read, the open is in front frame (FF) harness between connector X031 and CCM1 connector X020 J3-8 wire 714 white. Locate the open and repair. 17. Reverser does not operate in either direction, and there are no error codes indicated, the supply power for the circuits may not be present. Remove fuse F24 and inspect. A. Fuse has failed. Go to step 18. B. Fuse is okay. Go to step 19. 18. If fuse has failed, replace the fuse. A. If fuse immediately fails, a short to ground exists in the cab main (CM) or front frame (FF) harnesses on wire 027 red from fuse F24 through connector X031 pin 3 to connector X020 pin J3-7 on CCM1 module. Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. B. Fuse is okay. Go to step 19. 19. Test for 12V power at connector X020 pin J3-7 on the CCM1 module under the cab. A. If there is no power, there is an open circuit in the cab main (CM) or front frame (FF) harnesses on wire 027 red from fuse F24 through connector X031 pin 3 to connector X020 pin J3-7 on CCM1 module. Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the open and repair. After repair, go to step 20. B. If there is power, go to step 20. 20. Test for continuity to ground at connector X020 pin J3-16 on the CCM1 module under the cab. A. If there is no continuity to ground, there is an open circuit in the front frame (FF) harness between connector X020 pin J3-16 and the front frame ground #2 wire 704 or 778 black. Locate the open and repair. After repair, go to step 21. B. If there is continuity to ground, go to step 21. 21. Once it has been verified that power is being supplied to the module, recheck the circuit operation as described in step 1. If the fuse fails during the testing, a short to ground on the circuit is causing the fuse to fail. Start the troubleshooting at step 3 to locate the short to ground.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

20021064

4 50020070

2 10010899

40024707 50020085

50 1. FEEDER REVERSER ACTUATOR M10 2. CONNECTOR X007 3. CONNECTOR X031

4. FAN/REVERSER RELAY K17 5. CONNECTOR X020

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FEEDER FRAME--16

B-09 = REVERSER DISENGAGE B-14 = FEEDER RPM B-24 = STONE DOOR CLOSED F-24 = FAN, REVERSER FUSE

K-17 = FAN/REVERSER RELAY K-19 = NOT USED L-20 = FEEDER JOG FORWARD L-21 = FEEDER JOG REVERSE

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L-24 = FEEDER CLUTCH M-05 = CLEANING FAN ADJUST MOTOR (EU) M-10 = FEEDER REVERSER ACTUATOR S-31 = FEEDER ENGAGE

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0078-05 Concave Clearance Motor Line Disconnected Context: The CCM has detected that the circuit current has been <0.7 Amps for at least 3 seconds, while the control circuit input is active. Lack of current flow in an activated circuit is an indication of an open circuit condition. However, it is also possible to get this error message from a direct short to ground. This is because the CCM contains built-in over temperature circuit protection logic that will electronically disconnect the motor in order to prevent damage to the module. When a direct short to ground is present, and the motor is energized, it is possible for the rapid spike in current to engage the circuit protection -opening the circuit. When this occurs, the fault detection software sees the open and may report the “Line disconnected” fault. Cause: The concave clearance motor (M04) circuit indicates zero or high current draw. Possible failure modes: 1. Circuit connection open or shorted. 2. Excessive mechanical load on motor. 3. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed. A. Start the combine. B. Operate concave clearance and bin covers circuits in both directions. C. Record in which direction(s) the concave clearance increases or decreases. D. Reload error history. E. Check for the following fault codes: E0044-06, E0045-06, E0078-05 and E0079-05. F. Use the following table to determine the location of the fault. SYMPTOM

FAULT CODES E0044-06

Concave operates in 1 direction only

E0045-06

E0078-05

E0079-05 Go to Step 2

Go to Step 3

X X

Concave does not operate in either direction

Go to Step 9

Go to Step 14

Covers operates in 1 direction only

Go to Step 15

Covers do not operate in either direction Both concave and covers do not operate in either direction Both concave and covers do not operate in either direction

Go to Step 6

Concave and covers operate in 1 direction only

X NO FAULT CODE

55-271

Go to Step 16

Go to Step 20

Go to Step 27

Go to Step 28 Go to Step 30

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 2. The concave clearance adjustment motor is bound up. See the appropriate service manual chapter for repair. 3. The concave clearance motor operates in one direction only. Fault codes indicate a short to ground. Disconnect the concave clearance motor connector X176. Measure the resistance on connector X176 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. A. If out of specification, replace concave motor. B. If the motor coil resistance is within specification, continue with Step 4. 4. Measure the resistance on connector X176 between pin A and chassis ground. Flex the main frame (MF) harness while making this check. A. If no continuity to ground is found, erase the fault code and continue operation. B. If there is continuity to ground, continue with Step 5. 5. Disconnect connector X004. Use the multimeter to check for continuity between connector X004 pin 30 and chassis ground. A. If continuity is found, the short to ground is in the cab (CM) frame harness between connector X004 and relay base K16 terminal 4 wire 695 white. Locate the short and repair. B. If no continuity is found, the short to ground is in the main frame (MF) harness between connector X004 and connector X176 wire 695 white. Locate the short and repair. 6. Concave and covers operate in one direction only. Fault codes indicate a short to ground. Disconnect both the concave motor connector X176 and covers motor connector X289. A. Measure the resistance on connector X176 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. If out of specification, replace concave motor. B. Measure the resistance on connector X289 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. If out of specification, replace covers motor. C. If the motor coil resistance is within specification, continue with Step 7. 7. Check for continuity on connector X176 between pin B and chassis ground. Flex the main frame (MF) harness while making this check. Next check for continuity on connector X289 between pin B and chassis ground. Flex the jumper (JP) and main harnesses while making this check. A. If no continuity to ground is found, erase fault code and continue operation. B. If there is continuity to ground, continue with Step 8. 8. Disconnect connector X195. Use the multimeter to check for continuity between connector X195 pin 3 and chassis ground. A. If continuity is found, the short is in the main frame (MF) harness between connector X176, the splice, connector X195 and connector X019 J2-1, wires 694, 693 and 522 gray. Locate the short and repair. B. If no continuity is found, the short to ground is in the jumper (JP) harness between connector X195 and connector X289 wire 693 gray. Locate the short and repair. 9. Concave does not operate in either direction. Fault code indicates an open in circuit. Disconnect the concave adjustment motor connector X176. Measure the resistance on connector X176 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. A. If out of specification, replace motor. B. If the motor coil resistance is within specification, continue with Step 10. 10. Replace the concave/covers relay K16 with a known good relay. Connect connector X176 and operate the concaves. A. If the concaves are now working troubleshooting is complete. B. If the concaves still do not work, continue with Step 11.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 11. Disconnect concave motor connector X176. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the concave motor. Use a multimeter to measure the voltage between connector X176 pin A and chassis ground. A. If 12 volts is read, continue with Step 12. B. If 12 volts is not read, continue with Step 13. 12. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the concave motor. Use a multimeter to measure the voltage between connector X176 pin B and chassis ground. A. If 12 volts is not read, the open is in main frame (MF) harness between connector X176 and connector X019 J2-1 wire 694 or 522 gray. Locate the open and repair. 13. Disconnect connector X004. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the concave motor. Use a multimeter to measure the voltage between connector X004 pin 30 and chassis ground. A. If 12 volts is read, the open is in the main frame (MF) harness between connector X004 and connector X176 wire 695 white. Locate the open and repair. B. If 12 volts is not read, the open is in the cab main (CM) harness between connector X004 and relay base terminal 4 on relay K16, wire 695 white. Locate the open and repair. 14. Disconnect connector X176 at the concave clearance motor. Use a multimeter to check for an internal short to ground between both pin A and B. If short to ground is found, replace motor. 15. The bin covers actuator is bound up. See the appropriate service manual chapter for repair. 16. The covers operates in one direction only. Fault codes indicate a short to ground. Disconnect the covers motor connector X289. Measure the resistance on connector X289 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. A. If out of specification, replace covers motor. B. If the motor coil resistance is within specification, continue with Step 17. 17. Measure the resistance on connector X289 between pin A and chassis ground. Flex the jumper (JP) and main frame (MF) harnesses while making this check. A. If no continuity to ground is found, erase the fault code and continue operation. B. If there is continuity to ground, continue with Step 18. 18. Disconnect connector X195. Use the multimeter to check for continuity between connector X195 pin 4 and chassis ground. A. If continuity is found, continue with Step 19. B. If no continuity is found, the short to ground is in the jumper (JP) harness between connector X195 and connector X289 wire 696 white. Locate the short and repair. 19. Disconnect connector X004. Use the multimeter to check for continuity between connector X004 pin 31 and chassis ground. A. If continuity is found, the short to ground is in the cab main (CM) harness between connector X004 and the relay base for relay K16 terminal 4 wire 695 white. Locate the short and repair. B. If no continuity is found, the short to ground is in the main frame (MF) harness between connector X004 and connector X195 wire 696 white. Locate the short and repair. 20. Covers do not operate in either direction. Fault code indicates an open in circuit. Disconnect the covers motor connector X289. Measure the resistance on connector X289 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. A. If out of specification, replace covers motor. B. If the motor coil resistance is within specification, continue with Step 21.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 21. Replace the concave/covers relay K16 with a known good relay. Connect connector X289 and operate covers. A. If the covers are now working, troubleshooting is complete. B. If the covers still do not work, continue with Step 22. 22. Disconnect the covers connector X289. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the covers motor. Use a multimeter to measure the voltage between connector X289 pin A and chassis ground. A. If 12 volts is read, continue with Step 23. B. If 12 volts is not read, continue with Step 25. 23. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the covers motor. Use multimeter to measure the voltage between connector X289 pin B and chassis ground. A. If 12 volts is not read, continue with Step 24. B. If 12 volts is read, recheck the motor for continuity at Step 20. Erase the fault codes and, continue operation. 24. Disconnect connector X195. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the covers motor. Use multimeter to measure the voltage between connector X195 pin 3 and chassis ground. A. If 12 volts is read, the open is in the jumper (JP) harness between connector X289 and connector X195 wire 693 gray. Locate the open and repair. B. If 12 volts is not read, the open is in the main frame (MF) harness between connector X195 and the next splice in wire 693 gray. Locate the open and repair. 25. Disconnect connector X195. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the covers motor. Use a multimeter to measure the voltage between connector X195 pin 4 and chassis ground. A. If 12 volts is read, the open is in the jumper (JP) harness between connector X195 and connector X289 wire 696 white. Locate the open and repair. B. If 12 volts is not read, continue with Step 26. 26. Disconnect connector X004. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the covers motor. Use a multimeter to measure the voltage between connector X004 pin 31 and chassis ground. A. If 12 volts is read, the open is in the main frame (MF) harness between connector X004 and connector X195 wire 696 white. Locate the open and repair. B. If 12 volts is not read, the open is in the cab main (CM) harness between connector X004 and relay base terminal 3 on relay K16, wire 696 white. Locate the open and repair. 27. Disconnect connector X289 at the covers motor. Use a multimeter to check for an internal short to ground between both pin A and B. If short to ground is found, replace motor. 28. Both concave and covers do not operate in either direction. Fault code indicates an open circuit. Remove the concave/covers relay K16 from the relay base. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the concave/covers. Use a multimeter to measure the voltage between relay base K16 terminal 3 and chassis ground. A. If 12 volts is read, the open is in the main frame (MF) harness between CCM1 connector X019 J2-1 and splice with wire 522 gray. Locate the open and repair. B. If 12 volts is not read, continue with Step 29. 29. Disconnect connector X004. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the concave/covers. Use a multimeter to measure the voltage between connector X004 pin 29 and chassis ground. A. If 12 volts is read, the open is in the cab main (CM) harness between connector X004 and relay base K16 terminal 3. Locate the open and repair. B. If 12 volts is not read, the open is in main frame (MF) harness between connector X004 and CCM1 connector X019 J2-21 wire 523 white. Locate the open and repair.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

40025229

2 3 50020070 10010899 50020091

51 1. CONCAVE CLEARANCE ACTUATOR M04 2. CONNECTOR X004

3. CONCAVE/COVERS RELAY K16 4. CONNECTOR X019

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

B-45 = GEARBOX CLUTCH TEMP K-16 = CONCAVE/COVERS RELAY M-04 = CONCAVE CLEARANCE MOTOR M-12 = COVERS MOTOR

R-06 = CONCAVE POSITION S-16 = CONCAVE CLEARANCE

THRESHER FRAME--17

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0079-05 Grain Bin Covers Motor Line Disconnected Context: The CCM has detected that the circuit current has been <0.7 Amps for at least 3 seconds, while the control circuit input is active. Lack of current flow in an activated circuit is an indication of an open circuit condition. However, it is also possible to get this error message from a direct short to ground. This is because the CCM contains built-in over temperature circuit protection logic that will electronically disconnect the motor in order to prevent damage to the module. When a direct short to ground is present, and the motor is energized, it is possible for the rapid spike in current to engage the circuit protection -opening the circuit. When this occurs, the fault detection software sees the open and may report the “Line disconnected” fault. Cause: The concave clearance motor (M04) circuit indicates zero or high current draw. Possible failure modes: 1. Circuit connection open or shorted. 2. Excessive mechanical load on motor. 3. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed. A. Start the combine. B. Operate concave clearance and bin covers circuits in both directions. C. Record in which direction(s) the concave clearance increases or decreases. D. Reload error history. E. Check for the following fault codes: E0044-06, E0045-06, E0078-05 and E0079-05. F. Use the following table to determine the location of the fault. SYMPTOM

FAULT CODES E0044-06

Concave operates in 1 direction only

E0045-06

E0078-05

E0079-05 Go to Step 2

Go to Step 3

X X

Concave does not operate in either direction

Go to Step 9

Go to Step 14

Covers operates in 1 direction only

Go to Step 15

Covers do not operate in either direction Both concave and covers do not operate in either direction Both concave and covers do not operate in either direction

Go to Step 6

Concave and covers operate in 1 direction only

X NO FAULT CODE

55-278

Go to Step 16

Go to Step 20

Go to Step 27

Go to Step 28 Go to Step 30

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 2. The concave clearance adjustment motor is bound up. See the appropriate service manual chapter for repair. 3. The concave clearance motor operates in one direction only. Fault codes indicate a short to ground. Disconnect the concave clearance motor connector X176. Measure the resistance on connector X176 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. A. If out of specification, replace concave motor. B. If the motor coil resistance is within specification, continue with Step 4. 4. Measure the resistance on connector X176 between pin A and chassis ground. Flex the main frame (MF) harness while making this check. A. If no continuity to ground is found, erase the fault code and continue operation. B. If there is continuity to ground, continue with Step 5. 5. Disconnect connector X004. Use the multimeter to check for continuity between connector X004 pin 30 and chassis ground. A. If continuity is found, the short to ground is in the cab (CM) frame harness between connector X004 and relay base K16 terminal 4 wire 695 white. Locate the short and repair. B. If no continuity is found, the short to ground is in the main frame (MF) harness between connector X004 and connector X176 wire 695 white. Locate the short and repair. 6. Concave and covers operate in one direction only. Fault codes indicate a short to ground. Disconnect both the concave motor connector X176 and covers motor connector X289. A. Measure the resistance on connector X176 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. If out of specification, replace concave motor. B. Measure the resistance on connector X289 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. If out of specification, replace covers motor. C. If the motor coil resistance is within specification, continue with Step 7. 7. Check for continuity on connector X176 between pin B and chassis ground. Flex the main frame (MF) harness while making this check. Next check for continuity on connector X289 between pin B and chassis ground. Flex the jumper (JP) and main harnesses while making this check. A. If no continuity to ground is found, erase fault code and continue operation. B. If there is continuity to ground, continue with Step 8. 8. Disconnect connector X195. Use the multimeter to check for continuity between connector X195 pin 3 and chassis ground. A. If continuity is found, the short is in the main frame (MF) harness between connector X176, the splice, connector X195 and connector X019 J2-1, wires 694, 693 and 522 gray. Locate the short and repair. B. If no continuity is found, the short to ground is in the jumper (JP) harness between connector X195 and connector X289 wire 693 gray. Locate the short and repair. 9. Concave does not operate in either direction. Fault code indicates an open in circuit. Disconnect the concave adjustment motor connector X176. Measure the resistance on connector X176 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. A. If out of specification, replace motor. B. If the motor coil resistance is within specification, continue with Step 10. 10. Replace the concave/covers relay K16 with a known good relay. Connect connector X176 and operate the concaves. A. If the concaves are now working troubleshooting is complete. B. If the concaves still do not work, continue with Step 11.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 11. Disconnect concave motor connector X176. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the concave motor. Use a multimeter to measure the voltage between connector X176 pin A and chassis ground. A. If 12 volts is read, continue with Step 12. B. If 12 volts is not read, continue with Step 13. 12. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the concave motor. Use a multimeter to measure the voltage between connector X176 pin B and chassis ground. A. If 12 volts is not read, the open is in main frame (MF) harness between connector X176 and connector X019 J2-1 wire 694 or 522 gray. Locate the open and repair. 13. Disconnect connector X004. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the concave motor. Use a multimeter to measure the voltage between connector X004 pin 30 and chassis ground. A. If 12 volts is read, the open is in the main frame (MF) harness between connector X004 and connector X176 wire 695 white. Locate the open and repair. B. If 12 volts is not read, the open is in the cab main (CM) harness between connector X004 and relay base terminal 4 on relay K16, wire 695 white. Locate the open and repair. 14. Disconnect connector X176 at the concave clearance motor. Use a multimeter to check for an internal short to ground between both pin A and B. If short to ground is found, replace motor. 15. The bin covers actuator is bound up. See the appropriate service manual chapter for repair. 16. The covers operates in one direction only. Fault codes indicate a short to ground. Disconnect the covers motor connector X289. Measure the resistance on connector X289 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. A. If out of specification, replace covers motor. B. If the motor coil resistance is within specification, continue with Step 17. 17. Measure the resistance on connector X289 between pin A and chassis ground. Flex the jumper (JP) and main frame (MF) harnesses while making this check. A. If no continuity to ground is found, erase the fault code and continue operation. B. If there is continuity to ground, continue with Step 18. 18. Disconnect connector X195. Use the multimeter to check for continuity between connector X195 pin 4 and chassis ground. A. If continuity is found, continue with Step 19. B. If no continuity is found, the short to ground is in the jumper (JP) harness between connector X195 and connector X289 wire 696 white. Locate the short and repair. 19. Disconnect connector X004. Use the multimeter to check for continuity between connector X004 pin 31 and chassis ground. A. If continuity is found, the short to ground is in the cab main (CM) harness between connector X004 and the relay base for relay K16 terminal 4 wire 695 white. Locate the short and repair. B. If no continuity is found, the short to ground is in the main frame (MF) harness between connector X004 and connector X195 wire 696 white. Locate the short and repair. 20. Covers do not operate in either direction. Fault code indicates an open in circuit. Disconnect the covers motor connector X289. Measure the resistance on connector X289 between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms. A. If out of specification, replace covers motor. B. If the motor coil resistance is within specification, continue with Step 21.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18 21. Replace the concave/covers relay K16 with a known good relay. Connect connector X289 and operate covers. A. If the covers are now working, troubleshooting is complete. B. If the covers still do not work, continue with Step 22. 22. Disconnect the covers connector X289. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the covers motor. Use a multimeter to measure the voltage between connector X289 pin A and chassis ground. A. If 12 volts is read, continue with Step 23. B. If 12 volts is not read, continue with Step 25. 23. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the covers motor. Use multimeter to measure the voltage between connector X289 pin B and chassis ground. A. If 12 volts is not read, continue with Step 24. B. If 12 volts is read, recheck the motor for continuity at Step 20. Erase the fault codes and, continue operation. 24. Disconnect connector X195. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the covers motor. Use multimeter to measure the voltage between connector X195 pin 3 and chassis ground. A. If 12 volts is read, the open is in the jumper (JP) harness between connector X289 and connector X195 wire 693 gray. Locate the open and repair. B. If 12 volts is not read, the open is in the main frame (MF) harness between connector X195 and the next splice in wire 693 gray. Locate the open and repair. 25. Disconnect connector X195. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the covers motor. Use a multimeter to measure the voltage between connector X195 pin 4 and chassis ground. A. If 12 volts is read, the open is in the jumper (JP) harness between connector X195 and connector X289 wire 696 white. Locate the open and repair. B. If 12 volts is not read, continue with Step 26. 26. Disconnect connector X004. Key switch ON. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the covers motor. Use a multimeter to measure the voltage between connector X004 pin 31 and chassis ground. A. If 12 volts is read, the open is in the main frame (MF) harness between connector X004 and connector X195 wire 696 white. Locate the open and repair. B. If 12 volts is not read, the open is in the cab main (CM) harness between connector X004 and relay base terminal 3 on relay K16, wire 696 white. Locate the open and repair. 27. Disconnect connector X289 at the covers motor. Use a multimeter to check for an internal short to ground between both pin A and B. If short to ground is found, replace motor. 28. Both concave and covers do not operate in either direction. Fault code indicates an open circuit. Remove the concave/covers relay K16 from the relay base. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the concave/covers. Use a multimeter to measure the voltage between relay base K16 terminal 3 and chassis ground. A. If 12 volts is read, the open is in the main frame (MF) harness between CCM1 connector X019 J2-1 and splice with wire 522 gray. Locate the open and repair. B. If 12 volts is not read, continue with Step 29. 29. Disconnect connector X004. Use the display monitor, reference Section 55 Chapter 2, if needed, to operate the concave/covers. Use a multimeter to measure the voltage between connector X004 pin 29 and chassis ground. A. If 12 volts is read, the open is in the cab main (CM) harness between connector X004 and relay base K16 terminal 3. Locate the open and repair. B. If 12 volts is not read, the open is in main frame (MF) harness between connector X004 and CCM1 connector X019 J2-21 wire 523 white. Locate the open and repair.

55-281

55-282

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

10004684

4 50020070 10010899

50020082

52 1. GRAIN BIN COVERS MOTOR M12 2. CONNECTOR X195 3. CONNECTOR X004

4. CONCAVE / COVERS RELAY K16 5. CONNECTOR X019

55-283

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

B-45 = GEARBOX CLUTCH TEMP K-16 = CONCAVE/COVERS RELAY M-04 = CONCAVE CLEARANCE MOTOR M-12 = COVERS MOTOR

R-06 = CONCAVE POSITION S-16 = CONCAVE CLEARANCE

THRESHER FRAME--17

55-284

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0080-12 HHC Module Bad Intelligent Device Cause: The HHC module (A07) software is incompatible with the current CCM1 module software. Possible failure modes: 1. Incorrect software loaded in either HHC module or CCM1 module. Solution: The HHC module communicates with the CCM1 module to report error messages and other operational information. In some cases, due to design changes, there may be some incompatibility between certain versions of the software installed in either module. If this error message appears, contact the New Holland service department to obtain information on software version compatibilities.

55-285

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0082-11 Feeder Speed Incr Unidentified Failure Code Cause: The feeder increase solenoid (L11) circuit is open or shorted to ground. Possible failure modes: 1. Supply wiring shorted to ground or open circuit. 2. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with step 6. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. 2. Turn the key switch to the OFF position and disconnect the feeder increase solenoid connector X283. Use a multimeter to check the resistance of the feeder increase solenoid coil. The proper resistance range for the coil is 2.0 to 6.0 ohms. A. If the coil is out of specification, replace the coil. B. If the coil is within specification, continue with step 3. 3. Use a multimeter to check for continuity between the harness end of connector X283 pin 1 and chassis ground. Flex the main frame harness while making this check. A. If there is no continuity to ground, continue with step 4. B. If there is continuity, there is a short to ground in the main frame (MF) harness between connector X283 pin 1 and connector X019 pin J2-7 wire 582 white. Locate the short and repair. 4. Turn the key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the feeder increase solenoid. Use a multimeter to check for 12 volts between connector X283 pin 1 and chassis ground. A. If 12 volts is not present, there is an open circuit in the main frame (MF) harness between connector X283 pin 1 and connector X019 pin J2-7 wire 582 white. Locate the open and repair. B. If 12 volts is found, continue with step 5. 5. Disconnect connector X283. Use a multimeter to check for continuity between connector X283 pin 2 and chassis ground. A. If there is continuity, the circuit should be functional. Continue with step 6. B. If there is no continuity, there is an open circuit in the main frame (MF) harness between connector X283 and front frame ground #2 wire 609 black, 501 black or 483 black. Locate the open and repair. 6. Erase the fault code and continue operation.

55-286

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

10020031

50031010

53 1. FEEDER SPEED INCREASE SOLENOID L11

55-287

2. FRONT FRAME GROUND #2 3. CONNECTOR X019

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

HEADER FRAME--14

A-07 = HHC MODULE B-29 = HEADER LIFT PRESSURE L-06 = HEADER HEIGHT ACCUMULATOR L-18 = LATERAL FLOAT CW

L-19 = LATERAL FLOAT CCW R-02 = LATERAL FLOAT POT R-03 = FEEDER ANGLE R-12 = LEFT STUBBLE HEIGHT

55-288

R-13 = RIGHT STUBBLE HEIGHT

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

A-08 = ASP AMPLIFIER B-48 = RH BOTTOM ASP SENSOR B-49 = LH BOTTOM ASP SENSOR F-46 = ASP POWER FUSE

L-11 = FEEDER INCREASE L-12 = FEEDER DECREASE L-31 = STONE DOOR OPEN S-07 = FEEDER REVERSER

FEEDER FRAME--15

55-289

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0083-11 Feeder Speed Decr Unidentified Failure Code Cause: The feeder decrease solenoid (L12) circuit is open or shorted to ground. Possible failure modes: 1. Supply wiring shorted to ground or open circuit. 2. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with step 6. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. 2. Turn the key switch to the OFF position and disconnect the feeder decrease solenoid connector X282. Use a multimeter to check the resistance of the feeder decrease solenoid coil. The proper resistance range for the coil is 2.0 to 6.0 ohms. A. If the coil is out of specification, replace the coil. B. If the coil is within specification, continue with step 3. 3. Use a multimeter to check for continuity between the harness end of connector X282 pin 1 and chassis ground. Flex the main frame harness while making this check. A. If there is no continuity to ground, continue with step 4. B. If there is continuity to ground, there is a short to ground in the main frame (MF) harness between connector X282 pin 1 and connector X019 pin J2-8 wire 581 white. Locate the short and repair. 4. Turn the key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, to manually power the feeder decrease solenoid. Use a multimeter to check for 12 volts between connector X282 pin 1 and chassis ground. A. If 12 volts is not present, there is an open circuit in the main frame (MF) harness between connector X282 pin 1 and connector X019 pin J2-8 wire 581 white. Locate the open and repair. B. If 12 volts is found, continue with step 5. 5. Disconnect connector X282. Use a multimeter to check for continuity between connector X282 pin 2 and chassis ground. A. If there is continuity, the circuit should be functional. Continue with step 6. B. If there is no continuity, there is an open circuit in the main frame (MF) harness between connector X282 and front frame ground #2 wire 608 black, 501 black or 483 black. Locate the open and repair. 6. Erase the fault code and continue operation.

55-290

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

10020031

50031010

54 1. FEEDER SPEED INCREASE SOLENOID L12

55-291

2. FRONT FRAME GROUND #2 3. CONNECTOR X019

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

HEADER FRAME--14

A-07 = HHC MODULE B-29 = HEADER LIFT PRESSURE L-06 = HEADER HEIGHT ACCUMULATOR L-18 = LATERAL FLOAT CW

L-19 = LATERAL FLOAT CCW R-02 = LATERAL FLOAT POT R-03 = FEEDER ANGLE R-12 = LEFT STUBBLE HEIGHT

55-292

R-13 = RIGHT STUBBLE HEIGHT

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

A-08 = ASP AMPLIFIER B-48 = RH BOTTOM ASP SENSOR B-49 = LH BOTTOM ASP SENSOR F-46 = ASP POWER FUSE

L-11 = FEEDER INCREASE L-12 = FEEDER DECREASE L-31 = STONE DOOR OPEN S-07 = FEEDER REVERSER

FEEDER FRAME--15

55-293

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 18

FAULT CODE – E0084-14 Voting Conflicts Found Special Instructions Cause: A data location has data which is different in all of the voting modules. Possible failure modes: 1. Vehicle configuration and calibration information corrupted. Solution: When installing a new or replacement CCM module into the vehicle, the other modules will supply current configuration information to this module based on true democratic voting rules. If all reporting modules have different configuration data, there is no majority consensus as to what the values should be. As a result, configuration information will not be written to the new or replacement module, and the configuration data will remain unchanged (and therefore different) in all modules. If this error message appears, review machine configurations to make sure that they are correct. Re-write configuration data using the electronic service tool (EST).

FAULT CODE – E0085-14 Voting Differences Found Special Instructions Cause: A data location has data which is different in one of the voting modules. Possible failure modes: 1. One of the voting modules has corrupted configuration and calibration data. Solution: When installing a new or replacement CCM module into the vehicle, the other modules will supply current configuration information to this module based on true democratic voting rules. If one reporting module has different configuration data, this will be reported, however, there is majority consensus as to what the value should be. The majority data is copied to all modules on the network so that the configuration data will be the same in all modules. This error message appears as a notification message, however, no further action is required, as the problem is automatically corrected.

55-294

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 19 -- CCM2 Error Codes CONTENTS Section

Description

Page

E0128 Trans Shift Gear N Sens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 E0129 Trans Shift Gear 3 Sens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 E0130 Trans Shift Gear 2 Sens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 E0131 Trans Shift Gear 1 Sens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 E0132 Trans Shift Gear 4 Sens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 E0133 Hydraulic Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 E0134 Brake Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 E0135 Charge Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 E0136 Beacon Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 E0137 Open Covers Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 E0138 Hazards Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 E0140 Operator Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 E0141 Header Reel RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 E0142 Groundspeed RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 E0143 Chopper RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 E0146 Thresher RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 E0148 Header Type Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 E0151 Thresher Clutch Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 E0152 Air Filter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 E0154 Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 E0159 Grain Bin Full Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 E0162 Control Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 E0164 V Supply Ground Spd Hydro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 E0165 CCM2 5V Ref Voltage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 E0166 CCM2 8V Ref Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 E0167 CCM2 5V Ref Voltage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 E0168 CCM2 Keyswitch Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 E0169 Current Sense Reel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 E0171 Curr Sense Transm Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 E0172 Curr Sense Rot Scr Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

55-1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 Section

Description

Page

E0174 CCM2 Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 E0175 V Supply Thresher Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 E0177 Isense Unload Cross Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 E0178 Isense Thresher Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 E0179 LoP Isense Grnd Spd Hydro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 E0180 Thresher Clutch Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 E0181 Parking Brake Disengage Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 E0183 Brake Limiting Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 E0184 Unload Cross Auger Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 E0185 Header Reel Fore Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 E0186 Header Reel Drive Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 E0187 Header Reel Up Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 E0188 Header Reel Down Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 E0189 Header Reel Back Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 E0191 Thresher Speed Increase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 E0192 Thresher Speed Decrease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 E0193 Unload Tube In Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 E0194 Unload Tube Out Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 E0195 Foot-an-Inch Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 E0198 Backlighting Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 E0199 Brake Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 E0200 Beacon Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 E0201 Flasher System Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 E0202 Ground Speed Hydrostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 E0203 Transmission Shift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 E0204 Header Reel Speed Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 E0206 Rotary Screen Brush Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 E0208 ECU Module Data Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

55-2

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0128-03 Trans Shift Gear N Sens Shorted to High Source Cause: The transmission shift position N sensor (B-37) circuit is shorted to 12 volts. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure).

Solution: 1. Use the display monitor, reference section 55 chapter 2, if needed, to record then erase the error history. Using the right hand console gear selector switch, shift the transmission in both directions, from 1 through 4, stopping at each gear, observe the gear indicator in the Display DOG area, note success or failure for each shift, note any alarms or errors that appear on the display. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, shift the transmission in both directions, from 1 through 4, stopping at each gear. Record the measured voltage at all gear positions. The proper voltage when in shift position N -- 5.6 to 7.3 volts The proper voltage when not in shift position N -- 0.5 to 5.6 volts A. If the voltage reading is greater than 9.0 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the lower frame harness from the front frame harness at connector X023. With the sensor now open circuit, the voltage indicated on the display should be 7.3 to 9 volts regardless of transmission position. A. If the voltage drops to 7.3 to 9.0 volts the short to 12 volt is in the lower frame harness between connector X023 pin 10 and connector X093 pin 1 wire 407 yellow. Locate the short and repair. B. If the voltage remains greater than 9.0 volts on display monitor, continue with Step 3. 3. With key “Off”, disconnect the front frame (FF) harness connector X017 on CCM-2. Extract pin J3-28 from the front frame (FF) harness connector. Reconnect connector X017 and recheck sensor voltage. With the sensor now open circuit, the voltage indicated on the display should be 7.3 to 9 volts regardless of transmission position. A. If the voltage is still > 9 V, replace CCM-2. B. If the voltage drops to 7.3 to 9 volts, then the problem is a short to 12 V in the front frame (FF) harness between connector X017 pin J3-28 and connector X023 pin 10 wire 407 yellow. Locate the short and repair. Completely re-assemble the system and recheck.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 4. Disconnect the battery. Disconnect the transmission shift position sensor connector X093 and the front frame (FF) harness connector X017 on CCM-2. Use a multi-meter to check for continuity on the front frame (FF) harness side between connector X017 pin J3-28 and all other pins in the connector. There should be no continuity. A. If continuity is measured continue with step 5. B. If no continuity is found, continue with step 6. 5. Disconnect the lower frame (LF) harness from the front frame (FF) harness at connector X023. Recheck the continuity found in step 4. There should be no continuity. A. If continuity is measured, the short to 12 V is in the front frame (FF) harness between connector X017 pin J3-28 and connector X023 pin 10 wire 407 yellow. Locate the short and repair. Completely re-assemble the system and recheck. B. If no continuity is measured, the short is in the lower frame (LF) harness between connector X023 pin 10 and connector X093 pin 1 wire 407 yellow. Locate the short and repair. Completely re-assemble the system and recheck. 6. The short to 12 volts is not persistent. It may be due to an intermittent electrical short or a switched 12 volt supply (such as the transmission shift motor -- the fault may only be visible while shifting). Completely re-assemble the system. Monitor the Transmission N Sensor on the display. Functionally operate the combine. Activate one function at a time, monitor the sensor voltage. Note the function that causes the short to 12 V. Use the wiring schematic to locate the short and repair. Completely re-assemble the system and recheck.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0128-04 Trans Shift Gear N Sens Shorted to Low Source Cause: The transmission shift position N sensor (B-37) circuit is shorted to ground. Possible failure modes: 1. Sensor shorted to ground. 2. Sensor supply wiring shorted to ground. 3. Controller internal failure (internal regulator failure).

CAUTION Perform this service with the combine on a flat surface where the combine cannot roll. If service must be performed on a slope, block the wheels to prevent motion. Serious injury could occur if combine were to move unexpectedly. Solution: 1. Use the display monitor, reference section 55 chapter 2, if needed, to record then erase the error history. Using the right hand console gear selector switch, shift the transmission in both directions, from 1 through 4, stopping at each gear, observe the gear indicator in the Display DOG area, note success or failure for each shift, note any alarms or errors that appear on the display. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, shift the transmission in both directions, from 1 through 4, stopping at each gear. Record the measured voltage at all gear positions. The proper voltage when in shift position N -- 5.6 to 7.3 volts The proper voltage when not in shift position N -- 0.5 to 5.6 volts A. If the voltage reading is 0 to 0.5 volts, continue with Step 2. B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low. Disconnect the transmission shift position sensor connector X093 at the transmission. With the sensor now open circuit, the voltage indicated on the display should be 7.3 to 9 volts regardless of transmission position. A. If the voltage increases to 7.3 to 9.0 volts the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low on display monitor continue with Step 3. 3. The voltage reading on the display monitor is low. Disconnect the lower frame harness from the front frame harness at connector X023. With the sensor now open circuit, the voltage indicated on the display should be 7.3 to 9 volts regardless of transmission position. A. If the voltage increases to 7.3 to 9.0 volts the short is in the lower frame harness between connector X023 pin 10 and connector X093 pin 1 wire 407 yellow. B. If the voltage remains at 0 to 0.5 volts on display monitor, continue with Step 4.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 4. Disconnect the front frame (FF) harness connector X017 on CCM-2. Extract pin J3-28 from the front frame (FF) harness connector. Reconnect connector X017 and recheck sensor voltage. With the sensor now open circuit, the voltage indicated on the display should be 7.3 to 9 volts regardless of transmission position. A. If the voltage remains at 0 to 0.5 volts on the display monitor, replace CCM-2. B. If the voltage rises to 7.3 to 9 volts, then the problem is a short to ground in the front frame (LF) harness between connector X023 pin 10 and connector X017 pin J3-28 wire 407 yellow. Locate the short and repair. Completely re-assemble the system and recheck. 5. Disconnect the battery. Disconnect the transmission shift position sensor connector X093 and front frame (FF) harness connector X017 on CCM-2. Use a multi-meter to check for continuity on the front frame (FF) harness side between connector X017 pin J3-28 and all other pins in the connector, also check for continuity to chassis ground. There should be no continuity A. If continuity is measured continue with step 6. B. If no continuity is found, continue with step 7. 6. Disconnect the lower frame (LF) harness from the front frame (FF) harness at connector X023. Recheck the continuity found in step 4. There should be no continuity. A. If continuity is measured, the short is in the front frame (FF) harness between connector X023 pin 10 and connector X017 pin J3-28 wire 407 yellow. Locate the short and repair. Completely re-assemble the system and recheck. B. If no continuity is measured, the short is in the lower frame (LF) harness between connector X023 pin 10 and connector X093 pin 1 wire 407 yellow. Locate the short and repair. Completely re-assemble the system and recheck. 7. The short to ground is not persistent. It may be due to an intermittent electrical short or a switched ground supply (such as the transmission shift motor -- the fault may only be visible while shifting). Completely re-assemble the system. Monitor the Transmission N Sensor on the display. Functionally operate the combine. Activate one function at a time, monitor the sensor voltage. Note the function that causes the short to ground. Use the wiring schematic to locate the short and repair. Completely re-assemble the system and recheck.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0128-05 Trans Shift Gear N Sens Line Disconnected Cause: The transmission shift position N sensor (B-37) circuit is open. Possible failure modes: 1. Sensor is open. 2. Sensor wiring is open. 3. Controller internal failure (open circuit).

CAUTION Perform this service with the combine on a flat surface where the combine cannot roll. If service must be performed on a slope, block the wheels to prevent motion. Serious injury could occur if combine were to move unexpectedly. Solution: 1. Use the display monitor, reference section 55 chapter 2, if needed, to record then erase the error history. Using the right hand console gear selector switch, shift the transmission in both directions, from 1 through 4, stopping at each gear, observe the gear indicator in the Display DOG area, note success or failure for each shift, note any alarms or errors that appear on the display. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, shift the transmission in both directions, from 1 through 4, stopping at each gear. Record the measured voltage at all gear positions. The proper voltage when in shift position N -- 5.6 to 7.3 volts The proper voltage when not in shift position N -- 0.5 to 5.6 volts A. If the voltage reading is 7.3 to 9.0 volts, continue with Step 2. B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 6. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Disconnect the transmission shift position sensor connector X093 at the transmission. With the key on, use a jumper wire to connect lower frame (LF) harness connector X093 pins 1 and 6. With the sensor now short to ground, the voltage indicated on the display should be <0.5 volts regardless of transmission position. A. If the voltage is <0.5 volts, the open is in the sensor or sensor wiring. Repair the wiring or replace the sensor. B. If the voltage remains 7.3 to 9 volts, continue with step 3. 3. Disconnect the transmission shift position sensor connector X093 at the transmission. With the key on, use a jumper wire to connect lower frame (LF) harness connector X093 pin 1 to chassis ground. With the sensor now short to ground, the voltage indicated on the display should be <0.5 volts regardless of transmission position. A. If the voltage is <0.5 volts, the open is in the harness ground wiring. Continue with step 4. B. If the voltage remains 7.3 to 9 volts, the open is in the 8V supply or wiring. Continue with step 5.

55-7

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 4. With key off, disconnect the front frame (FF) harness from the lower frame (LF) harness at connector X023. Use a multi-meter to check continuity on the front frame (FF) harness side between connector X023 pin 5 and chassis ground. There should be continuity. A. If no continuity is measured, there is an open in the front frame (FF) harness between connector X023 pin 5 and chassis ground wire 042 black. Locate the open and repair. Completely re-assemble the system and recheck. B. If continuity is measured, there is an open in the lower frame (LF) harness between either Connector X093 pin 6 and the lower frame (LF) harness splice wire 426 black or Connector X023 pin 5 and the harness splice wire 042 black. Locate the open and repair. Completely re-assemble the system and recheck. 5. Disconnect the front frame (FF) harness from the lower frame (LF) harness at connector X023. With the key on, use jumper wire to connect front frame (FF) harness connector X023 pin 10 to chassis ground. With the sensor now short to ground, the voltage indicated on the display should be <0.5 volts regardless of transmission position. A. If the voltage is <0.5 volts, the open is in the lower frame (LF) harness between connector X023 pin 10 and connector X093 pin 1 wire 407 yellow. Locate the open and repair. Completely re-assemble the system and recheck. B. If the voltage remains 7.3 to 9 volts, continue with step 6. 6. With the key off, disconnect the front frame (FF) harness from the lower frame (LF) harness at connector X023 and from CCM-2 at connector X017. Using a multi-meter to check continuity on the front frame (FF) harness side between connector X017 pin J3-28 and connector X023 pin 10. There should be continuity. A. If continuity is measured, replace CCM-2. B. If no continuity is measured, the open is in the front frame (FF) harness between connector X017 pin J3-28 and connector X023 pin 10 wire 407 yellow. Locate the open and repair. Completely re-assemble the system and recheck. 7. Shift the transmission to Neutral. Check the voltage on the Display. It should be 5.6 to 7.3 volts. Typical value is 6.6 volts. Continue to observe the sensor voltage while the wires and connectors X017, X023, and X093 in the front frame (FF) and lower frame (LF) harnesses are wiggled. If the voltage jumps to between 7.3 to 9 volts, localize the intermittent open circuit and repair. If no voltage jumps are noted, continue to monitor for an open circuit while operating the combine.

55-8

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Transmission Shift Position Sensor B37 Connector X023 Connector X017

55-9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

55-10

S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME-- 9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0129-03 Trans Shift Gear 3 Sens Shorted to High Source Cause: The transmission shift position 3 sensor (B-37) circuit is shorted to 12 volts. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage when in shift position 3 -- 5.6 to 7.3 volts The proper voltage when not in shift position 3 -- 0.5 to 5.6 volts A. If the voltage reading is high out of range continue with Step 2. B. If the voltage reading is within the proper limits, since the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the transmission shift position sensor connector X093 at the transmission. A. If the voltage drops to 7.3 to 9.0 volts the short is in the sensor, or sensor wiring. Replace the sensor. To temporarily bypass that sensor see Step 5. B. If the voltage remains high on display monitor continue with Step 3. 3. The voltage reading on the display monitor is high. Disconnect the lower frame harness from the front frame harness at connector X023. A. If the voltage drops to 7.3 to 9.0 volts the short is in the lower frame harness between connector X023 pin 11 and connector X093 pin 4 wire 408 yellow. B. If the voltage remains high on display monitor the short circuit is somewhere between connector X023 pin 11 and connector X017 pin J3-38 on CCM2 in the front frame harness wire 408 yellow. 4. Operate the transmission shift gear lever and monitor the display monitor voltage readings. A. If high voltage reading is now viewed continue with Step 2. B. If a high voltage reading cannot be generated erase the fault code and continue operation. 5. To bypass a bad sensor create a short circuit between the bad sensor wire and common ground (pin 6) in connector X093. The system will generate a fault code for “shorted to low source” and the operator can continue without that gear.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0129-04 Trans Shift Gear 3 Sens Shorted to Low Source Cause: The transmission shift position 3 sensor (B-37) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage when in shift position 3- 5.6 to 7.3 volts The proper voltage when not in shift position 3- 0.5 to 5.6 volts A. If the voltage reading is low 0 to 0.5 volts continue with Step 2. B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low. Disconnect the transmission shift position sensor connector X093 at the transmission. A. If the voltage increases to 7.3 to 9.0 volts the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low on display monitor continue with Step 3. 3. The voltage reading on the display monitor is low. Disconnect the lower frame harness from the front frame harness at connector X023. A. If the voltage increases to 7.3 to 9.0 volts the short is in the lower frame harness between connector X023 pin 11 and connector X093 pin 4 wire 408 yellow. B. If the voltage remains low on display monitor the short circuit is somewhere between connector X023 pin 11 and connector X017 pin J3-38 on CCM2 in the front frame harness wire 408 yellow. 4. Operate the transmission shift gear lever and monitor the display monitor voltage readings. A. If low voltage reading is now viewed continue with Step 2. B. If a low voltage reading cannot be generated erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0129-05 Trans Shift Gear 3 Sens Line Disconnected Cause: The transmission shift position 3 sensor (B-37) circuit is open. Possible failure modes: 1. Sensor supply or ground wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage when in shift position 3- 5.6 to 7.3 volts The proper voltage when not in shift position 3- 0.5 to 5.6 volts A. If the voltage reading is 7.3 to 9.0 volts continue with Step 2. B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 6. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is 7.3 to 9.0 volts. Disconnect the transmission shift position sensor connector X093 at the transmission. Use a jumper wire to short connector X093 pin 4 to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply side of the circuit. Continue with Step 4. B. If the display monitor still displays 7.3 to 9.0 volts continue with Step 3. 3. The voltage reading on the display monitor is 7.3 to 9.0 volts. Disconnect the lower frame harness from the front frame harness at connector X023. Use a jumper wire to short connector X023 pin 11 to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the lower frame (LF) harness between connector X023 pin 11 and connector X093 pin 4 wire 408 yellow. Locate the open and repair. B. If the display monitor still displays 7.3 to 9.0 volts, the open is in the front frame (FF) harness between connector X023 pin 11 and CCM2 connector X017 pin J3-38 wire 408 yellow. Locate the open and repair. 4. Disconnect the transmission shift position sensor connector X093. Use a multimeter to check for continuity between the harness end of connector X093 pin 6 and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity to ground, the ground path for the sensor is open. Continue with Step 5. 5. Disconnect the lower frame harness from the front frame harness at connector X023. Use a multimeter to check for continuity between the harness end of connector X023 pin 5 and chassis ground. A. If there is continuity, the open circuit is in the lower frame (LF) harness between connector X023 pin 5 and connector X093 pin 6 wire 426 blue or 042 blue. Locate the open and repair. B. If there is no continuity to ground, the open is in the front frame (FF) harness between connector X023 pin 5 and CCM2 connector X017 pin J3-18 wire 042 blue or 766 blue. Locate the open and repair. 6. Shift the transmission through all gears and monitor the voltage readings. A. If a 7.3 to 9.0 voltage reading is now viewed continue with Step 2. B. If 7.3 to 9.0 voltage reading cannot be generated erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Transmission Shift Position Sensor B37 Connector X023 Connector X017

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

55-16

S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME-- 9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0130-03 Trans Shift Gear 2 Sens Shorted to High Source Cause: The transmission shift position 2 sensor (B-37) circuit is shorted to 12 volts. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage when in shift position 2- 5.6 to 7.3 volts The proper voltage when not in shift position 2- 0.5 to 5.6 volts A. If the voltage reading is high out of range continue with Step 2. B. If the voltage reading is within the proper limits, since the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the transmission shift position sensor connector X093 pin 3 at the transmission. A. If the voltage drops to 7.3 to 9.0 volts the short is in the sensor, or sensor wiring. Replace the sensor. To temporarily bypass that sensor see Step 5. B. If the voltage remains high on display monitor continue with Step 3. 3. The voltage reading on the display monitor is high. Disconnect the lower frame harness from the front frame harness at connector X023. A. If the voltage drops to 7.3 to 9.0 volts the short is in the lower frame harness between connector X023 pin 9 and connector X093 pin 3 wire 406 yellow. B. If the voltage remains high on display monitor the short circuit is somewhere between connector X023 pin 9 and connector X017 pin J3-37 on CCM2 in the front frame harness wire 406 yellow. 4. Operate the transmission shift gear lever and monitor the display monitor voltage readings. A. If high voltage reading is now viewed continue with Step 2. B. If a high voltage reading cannot be generated erase the fault code and continue operation. 5. To bypass a bad sensor create a short circuit between the bad sensor wire and common ground (pin 6) in connector X093. The system will generate a fault code for “shorted to low source” and the operator can continue without that gear.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0130-04 Trans Shift Gear 2 Sens Shorted to Low Source Cause: The transmission shift position 2 sensor (B-37) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage when in shift position 2 -- 5.6 to 7.3 volts The proper voltage when not in shift position 2 -- 0.5 to 5.6 volts A. If the voltage reading is low 0 to 0.5 volts continue with Step 2. B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low. Disconnect the transmission shift position sensor connector X093 at the transmission. A. If the voltage increases to 7.3 to 9.0 volts the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low on display monitor continue with Step 3. 3. The voltage reading on the display monitor is low. Disconnect the lower frame harness from the front frame harness at connector X023. A. If the voltage increases to 7.3 to 9.0 volts the short is in the lower frame harness between connector X023 pin 9 and connector X093 pin 3 wire 406 yellow. B. If the voltage remains low on display monitor the short circuit is somewhere between connector X023 pin 9 and connector X017 pin J3-37 on CCM2 in the front frame harness wire 406 yellow. 4. Operate the transmission shift gear lever and monitor the display monitor voltage readings. A. If low voltage reading is now viewed continue with Step 2. B. If a low voltage reading cannot be generated erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0130-05 -- Trans Shift Gear 2 Sens Line Disconnected Cause: The transmission shift position 2 sensor (B-37) circuit is open. Possible failure modes: 1. Sensor supply or ground wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage when in shift position 2- 5.6 to 7.3 volts The proper voltage when not in shift position 2- 0.5 to 5.6 volts A. If the voltage reading is 7.3 to 9.0 volts continue with Step 2. B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 6. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is 7.3 to 9.0 volts. Disconnect the transmission shift position sensor connector X093 at the transmission. Use a jumper wire to short connector X093 pin 3 to ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply side of the circuit. Continue with Step 4. B. If the display monitor still displays 7.3 to 9.0 volts continue with Step 3. 3. The voltage reading on the display monitor is 7.3 to 9.0 volts. Disconnect the lower frame harness from the front frame harness at connector X023. Use a jumper wire to short connector X023 pin 9 to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the lower frame (LF) harness between connector X023 pin 9 and connector X093 pin 3 wire 406 yellow. Locate the open and repair. B. If the display monitor still displays 7.3 to 9.0 volts the open is in the front frame (FF) harness between connector X023 pin 9 and CCM2 connector X017 pin J3-37 wire 406 yellow. Locate the open and repair. 4. Disconnect the transmission shift position sensor connector X093. Use a multimeter to check for continuity between the harness end of connector X093 pin 6 and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity to ground, the ground path for the sensor is open. Continue with Step 5. 5. Disconnect the lower frame harness from the front frame harness at connector X023. Use a multimeter to check for continuity between the harness end of connector X023 pin 5 and chassis ground. A. If there is continuity, the open circuit is in the lower frame (LF) harness between connector X023 pin 5 and connector X093 pin 6 wire 426 blue or 042 blue. Locate the open and repair. B. If there is no continuity to ground, the open is in the front frame (FF) harness between connector X023 pin 5 and CCM2 connector X017 pin J3-18 wire 042 blue or 766 blue. Locate the open and repair. 6. Shift the transmission through all gears and monitor the voltage readings. A. If a 7.3 to 9.0 voltage reading is now viewed continue with Step 2. B. If 7.3 to 9.0 voltage reading cannot be generated erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Transmission Shift Position Sensor B37 Connector X023 Connector X017

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

55-22

S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME-- 9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0131-03 Trans Shift Gear 1 Sens Shorted to High Source Cause: The transmission shift position 1 sensor (B-37) circuit is shorted to 12 volts. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage when in shift position 1- 5.6 to 7.3 volts The proper voltage when not in shift position 1- 0.5 to 5.6 volts A. If the voltage reading is high out of range continue with Step 2. B. If the voltage reading is within the proper limits, since the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the transmission shift position sensor connector X093 at the transmission. A. If the voltage drops to 7.3 to 9.0 volts the short is in the sensor, or sensor wiring. Replace the sensor. To temporarily bypass that speed see Step 5. B.

If the voltage remains high on display monitor continue with Step 3.

3. The voltage reading on the display monitor is high. Disconnect the lower frame harness from the front frame harness at connector X023. A. If the voltage drops to 7.3 to 9.0 volts the short is in the lower frame harness between connector X023 pin 8 and connector X093 pin 2 wire 405 yellow. B. If the voltage remains high on display monitor the short circuit is somewhere between connector X023 pin 8 and connector X017 pin J3-36 on CCM2 in the front frame harness wire 405 yellow. 4. Operate the transmission shift gear lever and monitor the display monitor voltage readings. A. If high voltage reading is now viewed continue with Step 2. B. If a high voltage reading cannot be generated erase the fault code and continue operation. 5. To bypass a bad sensor create a short circuit between the bad sensor wire and common ground (pin 6) in connector X093. The system will generate a fault code for “shorted to low source” and the operator can continue without that gear.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0131-04 Trans Shift Gear 1 Sens Shorted to Low Source Cause: The transmission shift position 1 sensor (B-37) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage when in shift position 1- 5.6 to 7.3 volts The proper voltage when not in shift position 1- 0.5 to 5.6 volts A. If the voltage reading is low 0 to 0.5 volts continue with Step 2. B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low. Disconnect the transmission shift position sensor connector X093 at the transmission. A. If the voltage increases to 7.3 to 9.0 volts the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low on display monitor continue with Step 3. 3. The voltage reading on the display monitor is low. Disconnect the lower frame harness from the front frame harness at connector X023. A. If the voltage increases to 7.3 to 9.0 volts the short is in the lower frame harness between connector X023 pin 8 and connector X093 pin 2 wire 405 yellow. B. If the voltage remains low on display monitor the short circuit is somewhere between connector X023 pin 8 and connector X017 pin J3-36 on CCM2 in the front frame harness wire 405 yellow. 4. Operate the transmission shift gear lever and monitor the display monitor voltage readings. A. If low voltage reading is now viewed continue with Step 2. B. If a low voltage reading cannot be generated erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0131-05 Trans Shift Gear 1 Sens Line Disconnected Cause: The transmission shift position 1 sensor (B-37) circuit is open. Possible failure modes: 1. Sensor supply or ground wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage when in shift position 1- 5.6 to 7.3 volts The proper voltage when not in shift position 1- 0.5 to 5.6 volts A. If the voltage reading is 7.3 to 9.0 volts continue with Step 2. B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 6. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is 7.3 to 9.0 volts. Disconnect the transmission shift position sensor connector X093 at the transmission. Use a jumper wire to short connector X093 pin 2 to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply side of the circuit. Continue with Step 4. B. If the display monitor still displays 7.3 to 9.0 volts continue with Step 3. 3. The voltage reading on the display monitor is 7.3 to 9.0 volts. Disconnect the lower frame harness from the front frame harness at connector X023. Use a jumper wire to short connector X023 pin 8 to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the lower frame (LF) harness between connector X023 pin 8 and connector X093 pin 2 wire 405 yellow. Locate the open and repair. B. If the display monitor still displays 7.3 to 9.0 volts, the open is in the front frame (FF) harness between connector X023 pin 8 and CCM2 connector X017 pin J3-36 wire 405 yellow. Locate the open and repair. 4. Disconnect the transmission shift position sensor connector X093. Use a multimeter to check for continuity between the harness end of connector X093 pin 6 and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity to ground, the ground path for the sensor is open. Continue with Step 5. 5. Disconnect the lower frame harness from the front frame harness at connector X023. Use a multimeter to check for continuity between the harness end of connector X023 pin 5 and chassis ground. A. If there is continuity, the open circuit is in the lower frame (LF) harness between connector X023 pin 5 and connector X093 pin 6 wire 426 blue or 042 blue. Locate the open and repair. B. If there is no continuity to ground, the open is in the front frame (FF) harness between connector X023 pin 5 and CCM2 connector X017 pin J3-18 wire 042 blue or 766 blue. Locate the open and repair. 6. Shift the transmission through all gears and monitor the voltage readings. A. If a 7.3 to 9.0 voltage reading is now viewed continue with Step 2. B. If 7.3 to 9.0 voltage reading cannot be generated erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Transmission Shift Position Sensor B37 Connector X023 Connector X017

55-27

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

55-28

S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME-- 9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0132-03 Trans Shift Gear 4 Sens Shorted to High Source Cause: The transmission shift position 4 sensor (B-37) circuit is shorted to 12 volts. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage when in shift position 4- 5.6 to 7.3 volts The proper voltage when not in shift position 4- 0.5 to 5.6 volts A. If the voltage reading is high out of range continue with Step 2. B. If the voltage reading is within the proper limits, since the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the transmission shift position sensor connector X093 at the transmission. A. If the voltage drops to 7.3 to 9.0 volts the short is in the sensor, or sensor wiring. Replace the sensor. To temporarily bypass that speed see Step 5. B. If the voltage remains high on display monitor continue with Step 3. 3. The voltage reading on the display monitor is high. Disconnect the lower frame harness from the front frame harness at connector X023. A. If the voltage drops to 7.3 to 9.0 volts the short is in the lower frame harness between connector X023 pin 12 and connector X093 pin 5 wire 409 yellow. B. If the voltage remains high on display monitor the short circuit is somewhere between connector X023 pin 12 and connector X017 pin J3-27 on CCM2 in the front frame harness wire 409 yellow. 4. Operate the transmission shift gear lever and monitor the display monitor voltage readings. A. If high voltage reading is now viewed continue with Step 2. B. If a high voltage reading cannot be generated erase the fault code and continue operation. 5. To bypass a bad sensor create a short circuit between the bad sensor wire and common ground (pin 6) in connector X093. The system will generate a fault code for “shorted to low source” and the operator can continue without that gear.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0132-04 Trans Shift Gear 4 Sens Shorted to Low Source Cause: The transmission shift position 4 sensor (B-37) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage when in shift position 4- 5.6 to 7.3 volts The proper voltage when not in shift position 4- 0.5 to 5.6 volts A. If the voltage reading is low 0 to 0.5 volts continue with Step 2. B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low. Disconnect the transmission shift position sensor connector X093 at the transmission. A. If the voltage increases to 7.3 to 9.0 volts the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low on display monitor continue with Step 3. 3. The voltage reading on the display monitor is low. Disconnect the lower frame harness from the front frame harness at connector X023. A. If the voltage increases to 7.3 to 9.0 volts the short is in the lower frame harness between connector X023 pin 12 and connector X093 pin 5 wire 409 yellow. B. If the voltage remains low on display monitor the short circuit is somewhere between connector X023 pin 12 and connector X017 pin J3-27 on CCM2 in the front frame harness wire 409 yellow. 4. Operate the transmission shift gear lever and monitor the display monitor voltage readings. A. If low voltage reading is now viewed continue with Step 2. B. If a low voltage reading cannot be generated erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0132-05 Trans Shift Gear 4 Sens Line Disconnected Cause: The transmission shift position 4 sensor (B37) circuit is open. Possible failure modes: 1. Sensor supply or ground wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage when in shift position 4- 5.6 to 7.3 volts The proper voltage when not in shift position 4- 0.5 to 5.6 volts A. If the voltage reading is 7.3 to 9.0 volts continue with Step 2. B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 6. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is 7.3 to 9.0 volts. Disconnect the transmission shift position sensor connector X093 at the transmission. Use a jumper wire to short connector X093 pin 5 to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply side of the circuit. Continue with Step 4. B. If the display monitor still displays 7.3 to 9.0 volts continue with Step 3. 3. The voltage reading on the display monitor is 7.3 to 9.0 volts. Disconnect the lower frame harness from the front frame harness at connector X023. Use a jumper wire to short connector X023 pin 12 to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the lower frame (LF) harness between connector X023 pin 12 and connector X093 pin 5 wire 409 yellow. Locate the open and repair. B. If the display monitor still displays 7.3 to 9.0 volts, the open is in the front frame (FF) harness between connector X023 pin 12 and CCM2 connector X017 pin J3-27, wire 409 yellow. Locate the open and repair. 4. Disconnect the transmission shift position sensor connector X093. Use a multimeter to check for continuity between the harness end of connector X093 pin 6 and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity to ground, the ground path for the sensor is open. Continue with Step 5. 5. Disconnect the lower frame harness from the front frame harness at connector X023. Use a multimeter to check for continuity between the harness end of connector X023 pin 5 and chassis ground. A. If there is continuity, the open circuit is in the lower frame (LF) harness between connector X023 pin 5 and connector X093 pin 6 wire 426 blue or 042 blue. Locate the open and repair. B. If there is no continuity to ground, the open is in the front frame (FF) harness between connector X023 pin 5 and CCM2 connector X017 pin J3-18 wire 042 blue or 766 blue. Locate the open and repair. 6. Shift the transmission through all gears and monitor the voltage readings. A. If a 7.3 to 9.0 voltage reading is now viewed continue with Step 2. B. If 7.3 to 9.0 voltage reading cannot be generated erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Transmission Shift Position Sensor B37 Connector X023 Connector X017

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

55-34

S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME-- 9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0133-03 Hydraulic Reservoir Level Shorted to High Source Cause: The hydraulic reservoir level switch (S-33) circuit is shorted to 12 volts. Possible failure modes: 1. Switch supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range for the hydraulic reservoir level switch is -- 1.8 volts or less, oil level okay. The proper voltage for the hydraulic reservoir level switch when oil level is low is approximately 8.3 volts. A. If the voltage reading is high out of range (>10 volts), continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the hydraulic reservoir level switch connector X104 at the reservoir. A. If the voltage drops back into the proper range the short is in the switch, or switch wiring. Replace the switch. B. If the voltage remains high on display monitor continue with Step 3. 3. The voltage reading on the display monitor is high. Disconnect the gearbox harness from the main frame harness at connector X011. A. If the voltage drops back into the proper range the short is in the gearbox harness between connector X011 pin C and connector X104 pin B wire 424 yellow. Locate and repair. B. If the voltage remains high on display monitor the short circuit is somewhere between connector X011 pin C and connector X016 pin J2-39 on CCM2 in the main frame harness wire 424 yellow. Locate and repair. 4. Operate the machine while monitoring display. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Hydraulic Reservoir Level Switch S33 Connector X011 Connector X016

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

HYDRAULIC FRAME-- 10

B-18 = HYD OIL RESERVOIR TEMP B-32 = GEARBOX TEMPERATURE B-35 = LOW CONTROL PRESSURE S-17 = ROTOR SPEED

S-18 = FEEDER SPEED S-32 = RETURNS FILTER BYPASS S-33 = HYDRAULIC RESERVOIR LEVEL S-34 = GEARBOX FILTER BYPASS

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0134-03 Brake Pressure Switch Shorted to High Source Cause: The brake pressure switch (S-39) circuit is shorted to 12 volts. Possible failure modes: 1. Switch supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage for the brake pressure switch is approximately 8.3 volts -- brakes off. The proper voltage range for the brake pressure switch is 1.8 volts or less -- brakes on. A. If the voltage reading is high out of range (>10 volts), continue with Step 2. B. If the voltage is within range, the short may not be present at this time. Continue with Step 3. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the brake pressure switch connector X173. A. If the voltage drops back into the proper range the short is in the switch, or switch wiring. Replace the switch. B. If the voltage remains high on display monitor the short circuit is somewhere between connector X173 and connector X016 pin J2-34 on CCM2 in the main frame harness wire 418 yellow. Locate the short and repair. 3. Operate the machine while monitoring display. If no high out of range readings are indicated, erase the fault code and continue operation.

55-39

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Brake Pressure Switch S39 Connector X016

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

55-41

S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME-- 9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0135-01 Charge Pressure Switch Valid Below Normal Context: When the hydrostatic charge pressure drops below 5 bar (73 psi) for more than 1 second after the engine has been running for at least 4 seconds, the alarm message “A0081 Hydrostatic Charge Pressure LOW” will be displayed to the operator. The engine will be shutdown after the alarm has been active for 2 seconds to prevent damage to the hydrostatic systems. When the alarm message is displayed, a permanent record is created in the error history. The EST must be used to erase this fault code. Cause: CCM2 has detected that the charge pressure switch circuit voltage has dropped to < 1.8 volts with the engine running for > 1 second, indicating a low pressure condition. The “A0081 Hydrostatic Charge Pressure LOW” alarm has occurred at least once on the vehicle. Possible failure modes: 1. The charge pressure has dropped below acceptable limits during operation and the switch has closed -this is normal operation of the circuit and indicates a mechanical failure. 2. The charge pressure switch S-37 circuit is shorted to ground while the engine is running. 3. Charge pressure switch S-37 failure. IMPORTANT: Do not run the engine without first verifying there are no mechanical faults in the system and you are now only troubleshooting an electrical fault. Serious and costly damage to the hydraulic components of the system will occur. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. Install a pressure gauge to monitor hydrostatic charge pressure. A. With the engine off, the voltage reading should be < 1.8 volts. If the voltage is > 1.8 volts, another fault code will be present. Repair the E0135-03 or E0135-05 fault first. B. With the engine running, the voltage reading should be between 1.8-10.0 volts. If the voltage remains < 1.8 volts (the engine will shut down) and the charge pressure is above 5 bar (73 psi), continue troubleshooting with Step 2. 2. Verify charge pressure switch S-37 is functioning. Disconnect the charge pressure switch circuit 684 yellow at X101. With the key off, use an ohmmeter to measure the continuity between the switch side of X101 and ground. Start the engine and repeat the continuity check. A. If continuity is indicated with the engine off, and open with the engine running, then the switch is functioning properly. The fault will be in the wiring. Continue troubleshooting with Step 3. B. If continuity is indicated while the engine is running and the pump is known to be working properly mechanically, then the switch is faulty. Replace the charge pressure switch S-37. Continue troubleshooting with Step 4. 3. Verify circuit 684 yellow is not shorted to ground. Disconnect the charge pressure switch circuit 684 yellow at X101 and disconnect gearbox harness connector X011. Use an ohmmeter to check for continuity between circuit 684 yellow and ground. A. If continuity to ground is found, locate and repair the short to ground in the gearbox harness. Continue troubleshooting with Step 4. B. If no continuity to ground is found, locate and repair the short to ground in the main frame harness between connector X011 and connector X016. Continue troubleshooting with Step 4. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0135-03 Charge Pressure Switch Shorted to High Source Cause: The charge pressure switch (S-37) circuit is shorted to 12 volts. Possible failure modes: 1. Switch supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range for the charge pressure switch (engine not running) is 0 to 1.8 volts. The proper voltage range for the charge pressure switch (engine running) is -- 1.8 to 10.0 volts. A. If the voltage reading is high out of range (>10 volts), continue with Step 2. B. If the voltage reading is within the proper limits, since the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the charge pressure switch connector X101. A. If the voltage drops back into the proper range the short is in the switch. Replace the switch. B. If the voltage remains high on display monitor continue with Step 3. 3. The voltage reading on the display monitor is high. Disconnect the gearbox harness from the main frame harness at connector X011. A. If the voltage drops back into the proper range the short is in the gearbox harness between connector X011 pin W and connector X101 wire 684 yellow. Locate and repair. B. If the voltage remains high on display monitor the short circuit is somewhere between connector X011 pin W and connector X016 pin J2-35 on CCM2 in the main frame harness wire 684 yellow. Locate and repair. 4. Operate the machine while monitoring display. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0135-05 Charge Pressure Switch Line Disconnected Cause: The charge pressure switch (S-37) circuit is open. Possible failure modes: 1. Sensor supply or ground wiring is open. 2. Controller internal failure (internal regulator failure). Solution: The charge pressure switch is normally closed when there is no pressure (engine not running), and open when there is pressure (engine running). The check for an open circuit only occurs when the electrical system is initially powered up before the engine is started. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. Select “Driveline” sub menu. Select “Charge pressure switch” and check voltage range. The proper voltage range for the charge pressure switch when the engine is not running is 1.8 volts or less. A. If the voltage reading is high (1.8 to 10 volts), continue with Step 2. B. If the voltage reading is within the proper limits, the wire may not be open at this time. Continue the troubleshooting at Step 4. 2. The voltage reading on the display monitor is high. Disconnect the charge pressure switch connector X101 ring terminal and ground the terminal to the chassis. A. If the voltage drops back into the proper range (0 to 1.8 volts), the switch has failed open. Replace the switch. B. If the voltage remains high on display monitor, continue with Step 3. 3. The voltage reading on the display monitor is high. Disconnect the gearbox harness from the main frame harness at connector X011 and provide a ground to pin W. A. If the voltage drops back into the proper range (0 to 1,8 volts), the open is in the gearbox (GB) harness between the switch connector X101 and connector X011 pin W wire 684 yellow. Locate open and repair. B. If the voltage remains high on display monitor, the open circuit is in the main frame (MF) harness between connector X011 pin W and connector X016 pin J2-35 wire 684 yellow. Locate open and repair. 4. Operate the machine while monitoring display. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Charge Pressure Switch S37 Connector X011 Connector X016

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

55-46

S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME-- 9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0136-04 Beacon Lights Switch Shorted to Low Source Cause: The beacon light switch (S-41) circuit is shorted to ground. Possible failure modes: 1. Switch supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. Cycle the beacon light switch between the On and Off positions. The normal operating range for the beacon light in the “Off” position is 0.25 to 3.5 volts. The normal operating range for the beacon light in the “On” position is 3.5 to 5.0 volts. NOTE: The beacon light switch actually supplies 12 volts (battery voltage) to the module when in the On position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading is low (0 to 0.25 volts) continue with Step 2. B. If the voltage reading is within the proper limits continue the troubleshooting at Step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Check fuse F49. A. If fuse has failed, continue with Step 3. B. If fuse is okay, continue with Step 4. 3. Replace fuse F49. A. If fuse immediately fails, there is a short to ground on one of the following wires in the cab main (CM) or cab roof (CR) harnesses: wire 061 orange, fuse F49 to splice in cab main harness (CM) with wires 213, 046 and 045 orange wire 213 orange, to road lights switch S-26 connector X256 pin 5 wire 046 orange, fuse F49 through connector X073 pin A to seat switch S05 wire 045 orange, fuse F49 through connector X002 pin 1 to cab roof (CR) harness splice wire 901 orange, harness splice to HVAC module connector X128 pin C2 wire 240 orange, harness splice to work light switch S-48 connector X132 pin 2 wire 172 orange, harness splice to beacon light switch S-98 connector X130 pin 2 wire 124 orange, harness splice to tank extensions switch S-42 connector X125 pin 2 wire 239 orange, harness splice to rear work light switch S-44 connector X131 pin 2 wire 1708 orange, harness splice to crop edge scanner A-23 through connector X469 pin 11 to connector X468 pin 6 Locate the short to ground and repair. B. If fuse is okay, continue with Step 4.

55-47

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 4. Place the beacon light switch in the ON position. A. If fuse immediately fails, there is a short to ground in the cab main (CM) or cab roof (CR) harnesses between the beacon lights switch S-41 connector X130 pin 3 through connector X002 pin 12 to connector X015 pin J1-2 wire 166 yellow. Locate the short and repair. B. If fuse is okay, continue with Step 5. 5. Operate the machine while monitoring display. If no low out of range readings are indicated, erase the fault code and continue operation.

55-48

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

2 10010915

10004693

50020070

50020099

9 1. 2. 3. 4.

Beacon Light Switch S41 Connector X002 Fuse F49 Connector X015

55-49

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

55-50

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

E-31 = LH FRONT BEACON LIGHT E-32 = RH FRONT BEACON LIGHT E-33 = REAR BEACON LIGHT F-15 = SERVICE SOCKETS FUSE

F-53 = BEACON LT FUSE J-02 = LH FT SERVICE SOCKET J-03 = RH SIDE SERVICE SOCKET J-05 = ENGINE SERVICE SOCKET

55-51

K-29 = BEACON LIGHT RELAY S-41 = BEACON LIGHT SWITCH

LIGHTING FRAME-- 39

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0137-04 Open Covers Switch Shorted to Low Source Cause: The tank covers switch (S42) circuit is shorted to ground. Possible failure modes: 1. Switch supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. Cycle the tank extensions switch between the On and Off positions. The normal operating range for the tank extensions switch in the “Off” position is 0.25 to 3.5 volts. The normal operating range for the tank extensions switch in the “On” position is 3.5 to 5.0 volts. NOTE: The tank extensions switch actually supplies 12 volts (battery voltage) to the module when in the On position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading is low (0 to 0.25 volts) out of range, continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Check fuse F49. A. If fuse has failed, continue with Step 3. B. If fuse is okay, continue with Step 4. 3. Replace fuse F49. A. If fuse immediately fails, there is a short to ground on one of the following wires in the cab main (CM) or cab roof (CR) harnesses: wire 061 orange, fuse F49 to splice in cab main harness (CM) with wires 213, 046 and 045 orange wire 213 orange, to road lights switch S-26 connector X256 pin 5 wire 046 orange, fuse F49 through connector X073 pin A to seat switch S05 wire 045 orange, fuse F49 through connector X002 pin 1 to cab roof (CR) harness splice wire 901 orange, harness splice to HVAC module connector X128 pin C2 wire 240 orange, harness splice to work light switch S-48 connector X132 pin 2 wire 172 orange, harness splice to beacon light switch S-98 connector X130 pin 2 wire 124 orange, harness splice to tank extensions switch S-42 connector X125 pin 2 wire 239 orange, harness splice to rear work light switch S-44 connector X131 pin 2 wire 1708 orange, harness splice to crop edge scanner A-23 through connector X469 pin 11 to connector X468 pin 6 Locate the short to ground and repair. B. If fuse is okay, continue with Step 4. 4. Place the tank extensions switch in the ON position. A. If fuse immediately fails, there is a short to ground in the cab main (CM) or cab roof (CR) harnesses between the tank covers switch connector X125 pin 3 through connector X002 pin 13 to connector X015 pin J1-3 wire 167 yellow. Locate the short and repair. B. If fuse is okay, continue with Step 5. 5. Operate the machine while monitoring display. If no low out of range readings are indicated, erase the fault code and continue operation.

55-52

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

2 10010915

10004693

50020070

50020099

10 1. 2. 3. 4.

Tank Extensions Switch S42 Connector X002 Fuse F49 Connector X015

55-53

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

UNLOAD FRAME-- 22

B-38 = UNLOAD CRADLE B-47 = COVERS CLOSED L-03 = UNLOAD TUBE IN L-04 = UNLOAD TUBE OUT

L-08 = UNLOAD TUBE CLUTCH S-28 = GRAIN BIN 3/4 FULL S-29 = GRAIN BIN FULL S-42 = TANK COVERS SWITCH

55-54

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

55-55

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE -- E0138-04 Hazards Switch Shorted to Low Source Cause: The hazard warning lights switch (S25) circuit is shorted to ground. Possible failure modes: 1. Switch or CCM2 supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, to check the voltage range. Cycle the hazard warning lights switch between the On and Off position. The normal operating range for the hazards switch -- ON is 4.0 -- 5.0 volts. The normal operating range for the hazards switch -- OFF is 0.25 -- 4.0 volts. A. If the voltage reading is 0 -- 0.25 volts in either switch position, continue with Step 2. B. If the voltage reading is 0.25 -- 4.0 volts with the switch OFF and 0 -- 0.25 volts with the switch ON, continue with Step 3. NOTE: Check fuse 56. If a short to ground occurred on this circuit, the fuse will have blown. 2. The voltage reading remains near zero. The short to ground is between the switch and CCM2. Disconnect the cab main (CM) harness from the steering column (SC) harness at connector X033. A. If the voltage increases to 0.25 -- 4.0 volts, the short is in the electronic flasher, or steering column (SC) harness wire 1209 or 179 purple. Replace the electronic flasher before attempting to repair the steering column (SC) harness. Erase fault code and operate system. B. If the voltage remains low, the short is in the cab main (CM) harness between connector X033, CCM2 connector X015 and the road light switch connector X256 in wires 207,1209 or 179 purple. Locate the short and repair. 3. The voltage reading is 0.25 -- 4.0 volts with the switch OFF and 0 -- 0.25 volts with the switch ON. The short to ground is between the fuse and switch. A. The short is in the cab main (CM) or steering column (SC) harness wires 054, 040 or 102 red. Visually inspect the cab main (CM) harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair.

55-56

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

A-05 = FLASHER MODULE E-01 = LH HEADER FLASHING LT (NA) E-02 = RH HEADER FLASHING LT (NA) E-07 = LH NASO FLASHING LT (NA)

E-08 = RH NASO FLASHING LT (NA) E-09 = TURN INDICATOR E-10 = HIGH BEAM INDICATOR E-40 = HEADER LH MARKER LT (EU)

55-57

E-41 = HEADER RH MARKER LT (EU) F-56 = HAZARD LIGHTS FUSE S-25 = HAZARD SWITCH

LIGHTING FRAME-- 33

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0140-04 Operator Seat Switch Shorted to Low Source Cause: The seat switch (S-05) circuit is shorted to ground. Possible failure modes: 1. Switch supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. Sit on and raise out of the operator’s seat to cycle the seat switch. The normal operating range for the seat switch when off the seat is 0.25 to 3.5 volts. The normal operating range for the seat switch when sitting on the seat is 3.5 to 5.0 volts. NOTE: The seat switch actually supplies 12 volts (battery voltage) to the module when in the On position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading is low (0 to 0.25 volts) out of range continue with Step 2. B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. No operator in seat. Check fuse F49. A. If fuse has failed, continue with Step 3. B. If fuse is okay, continue with Step 4. 3. No operator in seat. Replace fuse F49. A. If fuse immediately fails, there is a short to ground on one of the following wires in the cab main (CM) or cab roof (CR) harnesses: wire 061 orange, fuse F49 to splice in cab main harness (CM) with wires 213, 046 and 045 orange wire 213 orange, to road lights switch S-26 connector X256 pin 5 wire 046 orange, fuse F49 through connector X073 pin A to seat switch S05 wire 045 orange, fuse F49 through connector X002 pin 1 to cab roof (CR) harness splice wire 901 orange, harness splice to HVAC module connector X128 pin C2 wire 240 orange, harness splice to work light switch S-48 connector X132 pin 2 wire 172 orange, harness splice to beacon light switch S-98 connector X130 pin 2 wire 124 orange, harness splice to tank extensions switch S-42 connector X125 pin 2 wire 239 orange, harness splice to rear work light switch S-44 connector X131 pin 2 wire 1708 orange, harness splice to crop edge scanner A-23 through connector X469 pin 11 to connector X468 pin 6 Locate the short to ground and repair. B. If fuse is okay, continue with Step 4. 4. Sit in the seat to close the seat switch. A. If fuse immediately fails, there is a short to ground in the cab main (CM) or jumper harnesses between the seat switch connector X317 pin B through connector X073 pin B to connector X015 pin J1-9 wire 168 yellow. Locate the short and repair. B. If fuse is okay, continue with Step 5. 5. Operate the machine while monitoring display. If no low out of range readings are indicated, erase the fault code and continue operation.

55-58

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

2 1

10010921

10004693

50020070

50026204

11 1. 2. 3. 4.

Seat Switch S05 Connector X073 Connector X015 Fuse F49

55-59

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

55-60

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0141-03 Header Reel RPM Sensor Shorted to High Source Cause: The header reel RPM sensor (B15) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage for sensor when blocked by ferrous metal -- 5.6 to 7.3 volts The proper voltage for sensor when not blocked by ferrous metal -- 0.5 to 5.6 volts A. If the voltage reading is high out of range 9.0 volts or more continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the reel RPM sensor connector X309. A. If the voltage drops to 7.3 to 9.0 volts the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains high on display monitor continue with Step 3. 3. The voltage reading on the display monitor is high. Disconnect the feeder harness at connector X032. A. If the voltage drops to 7.3 to 9.0 volts the short is in the header harness between connector X032 pin 7 and connector X309 pin 2 wire 737 yellow. B. If the voltage remains high on display monitor continue with Step 4. 4. The voltage reading on the display monitor is high. Disconnect the feeder harness and front frame harness at connector X007. A. If the voltage drops to 7.3 to 9.0 volts the short is in the feeder (FE) harness between connector X007 Pin 14 and connector X032 pin 7 wire 737 yellow. B. If the voltage remains high on display monitor the short circuit is in the front frame harness between connector X007 pin 14 and connector X017 pin J3-13 wire 737 yellow. 5. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state.

55-61

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0141-04 Header Reel RPM Sensor Shorted to Low Source Cause: The Header reel RPM sensor (B15) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts A. If the voltage reading is low (0 to 0.5 volts) continue with Step 2. B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low. Disconnect the reel RPM sensor connector X309. A. If the voltage increases to 7.3 to 9.0 volts the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains low, continue with Step 3. 3. The voltage reading on the display monitor is low. Disconnect the feeder harness at connector X032. A. If the voltage increases to 7.3 to 9.0 volts the short is in the header harness between connector X032 pin 7 and connector X309 pin 2 wire 737 yellow. B. If the voltage remains low, continue with Step 4. 4. The voltage reading on the display monitor is low. Disconnect the feeder harness from the front frame harness at connector X007. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the feeder(FE) harness between connector X032 pin 7 and connector X007 pin 14 wire 737 yellow. B. If the voltage remains low, the short circuit is in the front frame harness between connector X007 pin 14 and connector X017 pin J3-13 wire 737 yellow. 5. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state.

55-62

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0141-05 Header Reel RPM Sensor Line Disconnected Cause: The header reel RPM sensor (B15) circuit is open. Possible failure modes: 1. Sensor supply or ground wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts The proper voltage sensor disconnected 7.3 to 9.0 volts. A. If the voltage reading is high 7.3 to 9.0 volts, continue with Step 2. B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 8. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is 7.3 to 9.0 volts. Disconnect the reel RPM sensor connector X309. Use a jumper wire to short pin 2 on the harness end of connector X309 to ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply side of the circuit. Continue with Step 5. B. If the display monitor still displays 7.3 to 9.0 volts continue with Step 3. 3. The voltage reading on the display monitor is 7.3 to 9.0 volts. Disconnect the feeder harness at connector X032. Use a jumper wire to short pin 7 on connector X032 to ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the header harness between connector X032 and connector X309 wire 737 yellow. Locate the open and repair. B. If the display monitor still displays 7.3 to 9.0 continue with Step 4. 4. The voltage reading on the display monitor is 7.3 to 9.0 volts. Disconnect the feeder harness from the front frame harness at connector X007. Use a jumper wire to short pin 14 of connector X007 to ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the feeder (FE) harness between connector X007 pin 14 and connector X032 pin 7 wire 737 yellow. B. If the display monitor still displays 7.3 to 9.0 volts, the open circuit is in the front frame (FF) harness between connector X007 pin 14 and connector X017 pin J3-13 wire 737 yellow. Locate the open and repair. 5. Disconnect the header reel RPM sensor connector X309. Use a multimeter to check for continuity between the harness end of connector X309 pin 1 and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity to ground, the ground path for the sensor is open. Continue with Step 6.

55-63

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 6. Disconnect the header harness from the feeder harness at connector X032. Use a multimeter to check for continuity between the harness end of connector X032 pin 7 and chassis ground. A. If there is continuity, the open circuit is in the header (HE) harness between connector X032 pin 7 and connector X309 pin 1 wire 750 blue. Locate the open and repair. B. If there is no continuity to ground, continue with Step 7. 7. Disconnect the feeder harness from the front frame harness at connector X007. Use a multimeter to check for continuity between the harness end of connector X007 pin 14 and chassis ground. A. If there is continuity, the open circuit is in the feeder (FE) harness between connector X007 pin 14 and connector X032 pin 7 wire 750 blue. Locate the open and repair. B. If there is no continuity to ground, the open is in the front frame (FF) harness between connector X007 pin 14 and CCM2 connector X017 pin J3-18 wire 750 blue or 766 blue. Locate the open and repair. 8. Operate header reel and monitor the display monitor voltage readings. A. If a 7.3 to 9.0 voltage reading is now viewed continue with Step 2. B. If 7.3 to 9.0 voltage reading cannot be generated erase the fault code and continue operation.

55-64

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

2 10020040

50026205

40024707

12 1. 2. 3. 4.

Reel RPM Sensor B15 (On Header) Connector X032 Connector X007 Connector X017

55-65

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-15 = REEL RPM R-20 = HEADER TYPE MODULE R-24 = REEL HORIZONTAL POSITION R-25 = REEL VERTICAL POSITION

HEADER FRAME-- 13

55-66

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0142-03 Groundspeed RPM Sensor Shorted to High Source Cause: The ground speed RPM sensor (B17) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage for sensor when blocked by ferrous metal -- 5.6 to 7.3 volts The proper voltage for sensor when not blocked by ferrous metal -- 0.5 to 5.6 volts The proper voltage sensor disconnected 7.3 to 9.0 volts. A. If the voltage reading is high out of range 9.0 to 10.0 volts continue with Step 2. B. If the voltage reading is within the proper limits, since the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the ground speed RPM sensor connector X087. A. If the voltage drops to 7.3 to 9.0 volts the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains high on display monitor, continue with Step 3. 3. The voltage reading on the display monitor is high. Disconnect the lower frame harness and front frame harness at connector X023. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the lower frame (LF) harness between connector X023 pin 6 and connector X087 pin 2 wire 403 yellow. B. If the voltage remains high on display monitor the short circuit is in the front frame (FF) harness between connector X023 pin 6 and connector X017 pin J3-14 wire 403 yellow. 4. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state.

55-68

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0142-04 Groundspeed RPM Sensor Shorted to Low Source Cause: The ground speed RPM sensor (B17) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts The proper voltage sensor disconnected 7.3 to 9.0 volts. A. If the voltage reading is low (0 to 0.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low. Disconnect the ground speed RPM sensor connector X087. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the sensor or sensor wiring. Replace the sensor. B. If the voltage remains low on display, continue with Step 3. 3. The voltage reading on the display monitor is low. Disconnect the lower frame harness from the front frame harness at connector X023. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the lower frame (LF) harness between connector X023 pin 6 and connector X087 pin 2 wire 403 yellow. B. If the voltage remains low, the short circuit is in the front frame harness between connector X023 pin 6 and connector X017 pin J3-14 wire 403 yellow. 4. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state.

55-69

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0142-05 Groundspeed RPM Sensor Line Disconnected Cause: The ground speed RPM sensor (B17) circuit is open. Possible failure modes: 1. Sensor supply or ground wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts The proper voltage sensor disconnected 7.3 to 9.0 volts. A. If the voltage reading is high 7.3 to 9.0 volts continue with Step 2. B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 6. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. 2. The voltage reading on the display monitor is 7.3 to 9.0 volts. Disconnect the ground speed RPM sensor connector X087. Use a jumper wire to short pin B on the harness end of connector X087 to ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply side of the circuit. Continue with Step 4. B. If the display monitor still displays 7.3 to 9.0 volts continue with Step 3. 3. The voltage reading on the display monitor is 7.3 to 9.0 volts. Disconnect the lower frame harness from the front frame harness at connector X023. Use a jumper wire to short pin 6 on connector X023 to ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the lower frame (LF) harness between connector X023 pin 6 and connector X087 pin 2 wire 403 yellow. Locate the open and repair. B. If the display monitor still displays 7.3 to 9.0 volts, the open circuit is in the front frame (FF) harness between connector X023 pin 6 and connector X017 pin J3-14 wire 403 yellow. Locate the open and repair. 4. Disconnect the ground speed RPM sensor connector X087. Use a multimeter to check for continuity between the harness end of connector X087 pin A and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity to ground, the ground path for the sensor is open. Continue with Step 5. 5. Disconnect the lower frame harness from the front frame harness at connector X023. Use a multimeter to check for continuity between the harness end of connector X023 pin 5 and chassis ground. A. If there is continuity, the open circuit is in the lower frame (LF) harness between connector X023 pin 5 and connector X087 pin 1 wire 717 blue or 042 blue. Locate the open and repair. B. If there is no continuity to ground, the open is in the front frame (FF) harness between connector X023 pin 5 and CCM2 connector X017 pin J3-18 wire 042 blue or 766 blue. Locate the open and repair. 6. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

1 2 10004641

10010898

50020096

13 1. 2. 3.

Ground Speed Sensor B17 Connector X023 Connector X017

55-71

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

55-72

S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME-- 9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0143-03 Chopper RPM Sensor Shorted to High Source Cause: The chopper RPM sensor (B-10) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage for sensor when blocked by ferrous metal -- 5.6 to 7.3 volts The proper voltage for sensor when not blocked by ferrous metal -- 0.5 to 5.6 volts The proper voltage sensor disconnected 7.3 to 9.0 volts. A. If the voltage reading is high out of range 9.0 to 10.0 volts continue with Step 2. B. If the voltage reading is within the proper limits, since the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. 2. The voltage reading on the display monitor is high. Disconnect the chopper RPM sensor connector X253. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage remains high on display monitor, continue with Step 3. 3. The voltage reading on the display monitor is high. Disconnect the chopper harness from the main frame harness at connector X382. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the chopper (CH) harness between connector X382 pin 2 and connector X253 pin 2 wire 413 yellow. Locate the short and repair. B. If the voltage remains high on display monitor, the short circuit is in the main frame (MF) harness between connector X382 pin 2 and connector X016 pin J2-38 wire 413 yellow. 4. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0143-04 Chopper RPM Sensor Shorted to Low Source Cause: The chopper RPM sensor (B-10) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts The proper voltage sensor disconnected 7.3 to 9.0 volts. A. If the voltage reading is low (0 to 0.5 volts) continue with Step 2. B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. 2. The voltage reading on the display monitor is low. Disconnect the chopper RPM sensor connector X253. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the sensor or sensor wiring. Replace the sensor. B. If the voltage remains low on display continue with Step 3. 3. The voltage reading on the display monitor is low. Disconnect the chopper harness from the main frame harness at connector X382. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the chopper (CH) harness between connector X382 pin 2 and connector X253 pin 2 wire 413 yellow. B. If the voltage remains low on display monitor, the short to ground is in the main frame (MF) harness between connector X382 pin 2 and connector X016 pin J2-38 wire 413 yellow. 4. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0143-05 Chopper RPM Sensor Line Disconnected Cause: The chopper RPM sensor (B-10) circuit is open. Possible failure modes: 1. Sensor supply or ground wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts The proper voltage sensor disconnected 7.3 to 9.0 volts. A. If the voltage reading is high 7.3 to 9.0 volts continue with Step 2. B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 7. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is 7.3 to 9.0 volts. Disconnect the chopper RPM sensor connector X253. Use a jumper wire to short the harness end of connector X253 pin 2 to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply side of the circuit. Continue with Step 4. B. If the display monitor still displays 7.3 to 9.0 volts continue with Step 3. 3. The voltage reading on the display monitor is 7.3 to 9.0 volts. Disconnect the chopper harness from the main frame harness at connector X382. Use a jumper wire to short connector X382 pin 2 to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the chopper (CH) harness between connector X382 pin 2 and connector X253 pin 2 wire 413 yellow. Locate the open and repair. B. If the display monitor still displays 7.3 to 9.0 volts, the open circuit is in the main frame (MF) harness between connector X382 pin 2 and connector X016 pin J2-38 wire 413 yellow. Locate the open and repair.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 4. Disconnect the chopper RPM sensor connector X253. Use a multimeter to check for continuity between the harness end of connector X253 pin 1 and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity to ground, the ground path for the sensor is open. Continue with Step 5. 5. Disconnect the chopper harness from the main frame harness at connector X382. Use a multimeter to check for continuity between the harness end of connector X382 pin 1 and chassis ground. A. If there is continuity, the open circuit is in the chopper (CH) harness between connector X382 pin 1 and connector X253 pin 1 wire 632 blue. Locate the open and repair. B. If there is no continuity to ground, continue with Step 6. 6. Disconnect the main frame harness from the front frame harness at connector X008. Use a multimeter to check for continuity between the harness end of connector X008 pin 14 and chassis ground. A. If there is continuity, the open circuit is in the main frame (MF) harness between connector X382 pin 1 and connector X008 pin 14 wire 632 blue or 425 blue. Locate the open and repair. B. If there is no continuity to ground, the open circuit is in the front frame (FF) harness between connector X008 pin 14 and connector X017 pin J3-18 wire 425 blue or 766 blue. Locate the open and repair. 7. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

40024712

10020075

50026206

14 1. 2. 3. 4. 5.

Straw Chopper RPM Sensor B10 Connector X382 Connector X008 Connector X016 Connector X017

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-10 = CHOPPER RPM L-28 = CHAFF SPREADER M-11 = SPREADER PLATE MOTOR S-23 = SPREADER PLATE

B-74 = PSD RPM

TRASH FRAME-- 23

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0146-03 Thresher RPM Sensor Shorted to High Source Cause: The Rotor RPM sensor (B-01) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage for sensor when blocked by ferrous metal -- 5.6 to 7.3 volts The proper voltage for sensor when not blocked by ferrous metal -- 0.5 to 5.6 volts The proper voltage sensor disconnected 7.3 to 9.0 volts. A. If the voltage reading is high out of range 9.0 to 10.0 volts continue with Step 2. B. If the voltage reading is within the proper limits, since the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 3. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the rotor RPM sensor connector X177. A. If the voltage drops to 7.3 to 9.0 volts, the short is in the sensor or sensor wiring. Replace the sensor. B. If the voltage remains high on display monitor, the short circuit is in the main frame harness between connector X177 pin 2 and connector X016 pin J2-37 wire 416 yellow. Locate short and repair. 3. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0146-04 Thresher RPM Sensor Shorted to Low Source Cause: The Rotor RPM sensor (B-01) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal -- 5.6 to 7.3 volts The proper voltage sensor unblocked by ferrous metal -- 0.5 to 5.6 volts The proper voltage sensor disconnected 7.3 to 9.0 volts. A. If the voltage reading is low (0 to 0.5 volts) continue with Step 2. B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 3. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low. Disconnect the rotor RPM sensor connector X177. A. If the voltage increases to 7.3 to 9.0 volts, the short is in the sensor or sensor wiring. Replace the sensor. B. If the voltage remains low on display monitor, the short to ground is in the main frame harness between connector X177 pin 2 and connector X016 pin J2-37 wire 416 yellow. Locate and repair the short to ground. 3. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0146-05 Thresher RPM Sensor Line Disconnected Cause: The Rotor RPM sensor (B-01) circuit is open. Possible failure modes: 1. Sensor supply or ground wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage sensor blocked by ferrous metal is 5.6 to 7.3 volts The proper voltage sensor unblocked by ferrous metal is 0.5 to 5.6 volts The proper voltage sensor disconnected is 7.3 to 9.0 volts. A. If the voltage reading is high 7.3 to 9.0 volts, continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is 7.3 to 9.0 volts. Disconnect the rotor RPM sensor connector X177. Use a jumper wire to short the harness end of connector X177 pin 2 to chassis ground. A. If the display monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply side of the circuit. Continue with Step 3. B. If the display monitor still displays 7.3 to 9.0 volts, the open circuit is main frame (MF) harness between connector X177 and connector X016 pin J2-37 wire 416 yellow. Locate the open and repair. 3. The voltage reading on the display monitor is 7.3 to 9.0 volts. Disconnect the rotor RPM sensor connector X177. Use a multimeter to check for continuity between connector X177 pin 1 and chassis ground. A. If there is continuity to ground, the sensor has failed. Replace the sensor. B. If there is no continuity, the open circuit is in the main frame (MF) harness between connector X177 pin 1 and connector X016 pin J2-14 wire 495 blue or 465 blue. Locate the open and repair. 4. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal in front of sensor then remove. The sensor is functioning if LED changes state.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

40025213

50020098

15 1. 2.

Rotor RPM Sensor B01 Connector X016

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

THRESHER FRAME-- 18

B-01 = ROTOR RPM K-28 = THRESHER LATCHING L-22 = GEARBOX CLUTCH L-29 = ROTOR INCREASE

L-30 = ROTOR DECREASE S-30 = THRESHER ENGAGE

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0148-02 Header Type Module Data Incorrect Context: Headers used on the CR combines may be equipped with a header type module, which is used to identify the header type to the combine. This allows the operator to store configuration information in memory that may be recalled when the header is attached. This fault code will occur if the controller sees the header type “change” due to a significant voltage change on the signal wire while the thresher is running. This is typically the result of an intermittent open circuit on the 5 volt supply wire or on the signal wire, but may also be caused by the signal wire resistance changing due to bad connections. Cause: The header type module (R--20) circuit is intermittently open, or circuit resistance is changing due to bad connections. Possible failure modes: 1. Sensor supply or signal wiring open. 2. Sensor signal wiring has bad connections. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, to check the voltage range. The normal operating range for the header type module circuit is 0.3 -- 4.72 volts. Flex the front frame, feeder and header harnesses along their lengths while monitoring the voltage. The voltage should not vary at any time. The normal voltage readings for the different header types are as follows: Header Type

Sensor Voltage

Corn header

3.72 -- 4.72 volts

Grain header Draper header

2.93 -- 3.72 volts 2.02 -- 2.93 volts

Pick up header

1.22 -- 2.02 volts

Programmable header

0.3 -- 1.22 volts

No header installed

0 -- 0.3 volts

A. If the voltage reading fluctuates significantly while flexing the harnesses, continue with Step 2. B. If the voltage reading is within the proper limits, and does not vary while flexing the harnesses, the fault condition is not currently present. Continue the troubleshooting at Step 6. 2. Disconnect the header type module connector X434. Locate the wire 1238 pink in the connector using the following table: Header Type

Connector X434 5 volts Power Wire

Corn header Grain header

Pin A Pin A

Draper header

Pin A

Pick up header

Pin F

Programmable header

Pin F

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 Use a multimeter to check the voltage between connector X434 wire 1238 pink and chassis ground. There should be 5 volts. Flex the front frame, feeder and header harnesses along their lengths while monitoring the voltage. The voltage should not vary at any time. A. If the voltage drops significantly while flexing the wire harnesses, there is an intermittent open circuit on the 5 volts supply wire. Repair the open circuit in the harness that was being flexed when the voltage fluctuated. Check the wire 1223, as well as splice with wires 1238, 1239, and 1240 pink connection to the terminals at each connector on the problem harness. If necessary, install a jumper wire to bypass the area of failure, and replace the failed wire harness as soon as possible. B. If the voltage is 5 volts, and does not vary while flexing the harnesses, continue with Step 3. 3. Carefully disconnect connector X017 from the bottom of CCM2 module. Connect a jumper wire between connector X017 pin J3--24 wire 1116 yellow and chassis ground. Disconnect the header type module connector X434. Locate the wire 1116 yellow in the connector using the following table: Header Type

Connector X435 Signal Wire

Corn header

Pin B

Grain header

Pin E

Draper header

Pin B

Pick up header Programmable header

Pin E Pin B

Use a multimeter to check the resistance between connector X434 wire 1116 yellow and chassis ground. Flex the header (HE) harness while making this check. There should be 0 to 0.1 ohms resistance. A. If the resistance is correct, the header type module has failed internally. Replace the header type module. B. If there is high resistance (> 0.1 ohms), continue with Step 4. 4. Disconnect the header (HH) harness to feeder (FE) harness connector X032. Use a multimeter to check the resistance between the feeder (FE) harness end of connector X032 pin 27 and chassis ground. Flex the feeder (FE) harness while making this check. There should be 0 to 0.1 ohms resistance. A. If the resistance is correct, there is an open circuit in the header (HH) harness between connector X032 and connector X434 wire 1116 yellow. Locate the open and repair. B. If there is high resistance (> 0.1 ohms), continue with Step 5. 5. Disconnect the feeder (FE) harness to front frame (FF) harness connector X007. Use a multimeter to check the resistance between the front frame (FF) harness end of connector X007 pin 27 and chassis ground. Flex the front frame (FF) harness while making this check. There should be 0 to 0.1 ohms resistance. A. If the resistance is correct, there is an open circuit in the feeder (FE) harness between connector X032 and connector X007 wire 1116 yellow. Locate the open and repair. B. If there is high resistance (> 0.1 ohms), there is an open circuit in the front frame (FF) harness between connector X007 and connector X017 pin J3--24 wire 1116 yellow. Locate the open and repair. 6. Visually inspect the harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. A. If no damage is found, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0148-03 Header Type Module Shorted to High Source Context: Headers used on the CR combine may be equipped with a header type module, which is used to identify the header type to the combine. This allows the operator to store configuration information in memory that may be recalled when the header is attached. Cause: The header type module (R-20) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply or signal wiring shorted to 12 volts. 2. Sensor ground wiring is open. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, to check the voltage range. The normal operating range for the header type module circuit is 0.3 -- 4.72 volts. The normal voltage readings for the different header types are as follows: Header Type

Sensor Voltage

Corn header

3.72 -- 4.72 volts

Grain header

2.93 -- 3.72 volts

Draper header

2.02 -- 2.93 volts

Pick up header

1.22 -- 2.02 volts

Programmable header

0.3 -- 1.22 volts

No header installed

0 -- 0.3 volts

A. If the voltage reading is 4.72 volts or greater, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 9. 2. Disconnect the header type module connector X434. Locate the wire 1238 pink in the connector using the following table: Header Type

Connector X434 5 volts Power Wire

Corn header

Pin A

Grain header

Pin A

Draper header

Pin A

Pick up header

Pin F

Programmable header

Pin F

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 Use a multimeter to check the voltage between connector X434 wire 1238 pink and chassis ground. There should be 5 volts. A. If there is greater than 5 volts on the pink wire, there is a short to high voltage on the 5 volts supply wire. The fault code E0167-03 -- CCM2 J3 5V Reference should be displayed in the display monitor “Active Errors” screen. Correct that fault code condition, and then return to Step 1 to determine if this fault condition has been corrected. B. If the voltage is 5 volts, continue with Step 3. 3. Disconnect the header type module connector X434. Locate the wire 1635 blue in the connector using the following table: Header Type

Connector X435 Ground Wire

Corn header

Pin F

Grain header

Pin F

Draper header

Pin E

Pick up header

Pin A

Programmable header

Pin A

Use a multimeter to check for continuity between connector X434 wire 1635 blue and chassis ground. There should be continuity to ground. A. If there is no continuity to ground, continue with Step 4. B. If there is continuity to ground, continue with Step 6. 4. Disconnect the header (HH) harness to feeder (FE) harness connector X032. Use a multimeter to check for continuity between the feeder (FE) harness end of connector X032 pin 13 and chassis ground. There should be continuity to ground. A. If there is continuity to ground, there is an open circuit in the header (HH) harness between connector X032 and connector X434 wire 1635 blue. Locate the open and repair. B. If there is no continuity to ground, continue with Step 5. 5. Disconnect the feeder (FE) harness to front frame (FF) harness connector X007. Use a multimeter to check for continuity between the front frame (FF) harness end of connector X007 pin 13 and chassis ground. There should be continuity to ground. A. If there is continuity to ground, there is an open circuit in the feeder (FE) harness between connector X032 and connector X007 wire 1635 blue. Locate the open and repair. B. If there is no continuity to ground, there is an open circuit in the front frame (FF) harness between connector X007 and connector X017 pin J3-18 wire 750 blue or 766 blue. Locate the open and repair. 6. Disconnect the header type module connector X434. Locate the wire 1116 yellow in the connector using the following table: Header Type

Connector X435 Signal Wire

Corn header

Pin B

Grain header

Pin E

Draper header

Pin B

Pick up header

Pin E

Programmable header

Pin B

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 Use a multimeter to check for voltage between connector X434 wire 1116 yellow and chassis ground. There should not be any voltage. A. If there is no voltage, the module has failed internally. Replace the header type module. B. If there is voltage (> 4.72 volts), continue with Step 7. 7. Disconnect the header (HH) harness to feeder (FE) harness connector X032. Use a multimeter to check for voltage between the feeder (FE) harness end of connector X032 pin 27 and chassis ground. There should not be any voltage. A. If there is no voltage, there is a short circuit in the header (HH) harness between connector X032 and connector X435 wire 1116 yellow. Locate the short and repair. B. If there is voltage (> 4.72 volts), continue with Step 5. 8. Disconnect the feeder (FE) harness to front frame (FF) harness connector X007. Use a multimeter to check for voltage between the front frame (FF) harness end of connector X007 pin 27 and chassis ground. There should not be any voltage. A. If there is no voltage, there is a short circuit in the feeder (FE) harness between connector X032 and connector X007 wire 1116 yellow. Locate the short and repair. B. If there is voltage (> 4.72 volts), there is a short circuit in the front frame (FF) harness between connector X007 and connector X017 pin J3-24 wire 1116 yellow. Locate the short and repair. 9. Visually inspect the harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-15 = REEL RPM R-20 = HEADER TYPE MODULE R-24 = REEL HORIZONTAL POSITION R-25 = REEL VERTICAL POSITION

HEADER FRAME-- 13

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0151-03 Thresher Clutch Temp Shorted to High Source Cause: The thresher clutch temperature sensor (B-45) circuit is shorted to 12 volts. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is -- 0.5 to 4.9 volts. A. If the voltage reading is high out of range, continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the thresher clutch temperature sensor connector X099. A. If the voltage drops to 4.9 to 5.2 volts, the short is in the sensor or sensor wiring. Replace the sensor. B. If the voltage remains high on display monitor, continue with Step 3. 3. The voltage reading on the display monitor is high. Disconnect the gearbox harness from the main frame harness at connector X011. A. If the voltage drops to 4.9 to 5.2 volts, the short is in the gearbox harness between connector X011 pin U and connector X099 pin B wire 682 yellow. B. If the voltage remains high on display monitor, continue with Step 4. 4. The voltage reading on the display monitor is high. Disconnect the main frame harness from the front frame harness at connector X008. A. If the voltage drops to 4.9 to 5.2 volts the short is in the main frame harness between connector X008 pin17 and connector X011 pin U wire 682 yellow. B. If the voltage remains high on display monitor the short circuit is in the front frame harness between connector X008 pin 17 and connector X017 pin J3-33 wire 682 yellow. 5. Operate the machine while monitoring display. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0151-04 Thresher Clutch Temp Shorted to Low Source Cause: The thresher clutch temperature sensor (B-45) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.5 to 4.9 volts. A. If the voltage reading is low out of range (0 to 0.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low (0 to 0.5 volts). Disconnect the thresher clutch temperature sensor connector X099. A. If the voltage increases to 4.9 to 5.2 volts, the short is in the sensor or sensor wiring. Replace the sensor. B. If the voltage remains low, continue with Step 3. 3. The voltage reading on the display monitor is low (0 to 0.5 volts). Disconnect the gearbox harness from the main frame harness at connector X011. A. If the voltage increases to 4.9 to 5.2 volts, the short to ground is in the gearbox (GB) harness between connector X011 pin U and connector X099 pin B wire 682 yellow. Locate the short to ground and repair. B. If the voltage remains low, continue with Step 4. 4. The voltage reading on the display monitor is low (0 to 0.5 volts). Disconnect the main frame harness from the front frame harness at connector X008. A. If the voltage increases to 4.9 to 5.2 volts, the short to ground is in the main frame (MF) harness between connector X011 pin U and connector X008 pin 17 wire 682 yellow. Locate the short to ground and repair. B. If the voltage remains low, the short to ground is in the front frame (FF) harness between connector X008 pin 17 and connector X017 pin J3-33 wire 682 yellow. Locate the short to ground and repair. 5. Operate the machine while monitoring display. If no low out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0151-05 Thresher Clutch Temp Line Disconnected Cause: The thresher clutch temperature sensor (B45) circuit is open. Possible failure modes: 1. Sensor supply or ground wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.5 to 4.9 volts. A. If the voltage reading is high out of range (4.9 to 5.2 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 7. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high (4.9 to 5.2 volts). Disconnect the thresher clutch temperature sensor connector X099 and use a jumper wire to short connector X099 pin B to chassis ground. A. If voltage drops to less than 0.5 volts, the open circuit is not in the supply side of the circuit. Continue with Step 5. B. If the voltage remains high, continue with Step 3. 3. The voltage reading on the display monitor is high (4.9 to 5.2 volts). Disconnect the gearbox harness from the main frame harness at connector X011. Use a jumper wire to short connector X011 pin U to chassis ground. A. If voltage drops to 0 to 0.5 volts, the open circuit is in the gearbox (GB) harness between connector X011 pin U and thresher clutch temperature sensor connector X099 pin B wire 682 yellow. Locate the open and repair. B. If voltage remains high, continue with Step 4. 4. The voltage reading on the display monitor is high (4.9 to 5.2 volts). Disconnect the main frame harness from the front frame harness at connector X008. Use a jumper wire to short connector X008 pin 17 to chassis ground. A. If voltage drops to 0 to 0.5 volts, the open circuit is in the main frame harness between connector X008 pin 17 and connector X011 pin U wire 682 yellow. Locate the open and repair. B. If voltage remains high, the open circuit is in the front frame harness between connector X008 pin 17 and connector X017 pin J3-33 wire 682 yellow. Locate the open and repair. 5. Disconnect the thresher clutch temperature sensor connector X099. Use a multimeter to check for continuity between the harness end of connector X099 pin A and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity to ground, the ground path for the sensor is open. Continue with Step 6. 6. Disconnect the gearbox harness from the main frame harness at connector X011. Use a multimeter to check for continuity between the harness end of connector X011 pin V and chassis ground. A. If there is continuity, the open circuit is in the gearbox (GB) harness between connector X011 pin V and connector X099 pin A wire 685 blue or 683 blue. Locate the open and repair. B. If there is no continuity, the open circuit is in the main frame (MF) harness between connector X011 pin V and connector X016 pin J2-14 wire 683 blue or 465 blue. Locate the open and repair. 7. Operate the machine while monitoring display. If no high out of range readings are indicated, erase the fault code and continue operation.

55-96

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

10020076

10010872

10020075

50020097

16 1. 2. 3. 4. 5.

Gearbox Clutch Temp Sensor B45 Connector X011 Connector X008 Connector X016 Connector X017

55-97

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-45 = GEARBOX CLUTCH TEMP K-16 = CONCAVE/COVERS RELAY M-04 = CONCAVE CLEARANCE MOTOR M-12 = COVERS MOTOR

R-06 = CONCAVE POSITION S-16 = CONCAVE CLEARANCE

THRESHER FRAME-- 17

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0152-03 Air Filter Switch Shorted to High Source Cause: The air filter switch (S-61) circuit is shorted to 12 volts. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is -- 0.5 to 4.9 volts. A. If the voltage reading is high out of range (>5.2 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the air filter switch connector X202. A. If the voltage drops to 0.5 to 4.9 volts, the short is in the sensor or sensor wiring. Replace the sensor. B. If the voltage remains high on display monitor, continue with Step 3. 3. The voltage reading on the display monitor is high. Disconnect the engine harness from the main frame harness at connector X010. A. If the voltage drops to 0.5 to 4.9 volts, the short is in the engine (EN) harness between connector X010 pin 8 and connector X202 pin 2 wire 864 yellow. B. If the voltage remains high on display monitor the short circuit is in the main frame harness between connector X010 pin 8 and connector X016 pin J2-24 wire 864 yellow. 4. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0152-04 Air Filter Switch Shorted to Low Source Cause: The air filter switch (S-61) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.5 to 4.9 volts. A. If the voltage reading is low out of range (0 to 0.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low (0 volts). Disconnect the air filter switch connector X202. A. If the voltage increases to 0.5 to 4.9 volts, the short is in the sensor or sensor wiring. Replace the sensor. B. If the voltage remains low, continue with Step 3. 3. The voltage reading on the display monitor is low. Disconnect the engine harness from the main frame harness at connector X010. A. If the voltage increases to 0.5 to 4.9 volts, the short is in the engine (EN) harness between connector X010 pin 8 and connector 202 pin 2 wire 864 yellow. Locate the short to ground and repair. B. If the voltage remains low, the short is in the main frame (MF) harness between connector X010 pin 8 and connector X016 pin J2-24 wire 864 yellow. Locate the short and repair. 4. Operate the machine while monitoring display. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0152-05 Air Filter Switch Line Disconnected Cause: The air filter switch (S-61) circuit is open. Possible failure modes: 1. Sensor supply or ground wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.5 to 4.9 volts. A. If the voltage reading is high out of range (4.9 to 5.2 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 6. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high (4.9 to 5.2 volts). Disconnect the air filter switch connector X202. Use a jumper wire to short connector X202 pin 2 to chassis ground. A. If voltage drops to less than 0.5 volts, the open circuit is not in the supply side of the circuit. Continue with Step 4. B. If the voltage remains high, continue with Step 3. 3. The voltage reading on the display monitor is high (4.9 to 5.2 volts). Disconnect the engine harness from the main frame harness at connector X010. Use a jumper wire to short connector X010 pin 8 to chassis ground. A. If voltage drops to less than 0.5 volts, the open is in the engine (EN) harness between connector X010 pin 8 and air filter switch connector X202 pin 2 wire 864 yellow. Locate the open and repair. B. If voltage remains high, the open is in the main frame (MF) harness between connector X010 pin 8 and connector X016 pin J2-24 wire 864 yellow. Locate the open and repair. 4. Disconnect the air filter switch connector X202. Use a multimeter to check for continuity between the harness end of connector X202 pin 1 and chassis ground. A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself. Replace the sensor. B. If there is no continuity to ground, the ground path for the sensor is open. Continue with Step 5. 5. Disconnect the engine harness from the main frame harness at connector X010. Use a multimeter to check for continuity between the harness end of connector X010 pin 14 and chassis ground. A. If there is continuity, the open circuit is in the engine (EN) harness between connector X010 pin 14 and connector X202 pin 1 wire 851 blue or 468 blue. Locate the open and repair. B. If there is no continuity, the open circuit is in the main frame (MF) harness between connector X010 pin 14 and connector X016 pin J2-14 wire 468 blue or 465 blue. Locate the open and repair. 6. Operate the machine while monitoring display. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 1

40020128

3 2

10020076

50026207

17 1. 2. 3.

Air Filter Switch S-61 Connector X010 Connector X016

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-22 = REAR LADDER F-23 = SCREEN BRUSH FUSE F-28 = FUEL PUMP FUSE K-07 = FUEL PUMP RELAY

M-23 = FUEL PUMP M-27 = ROTARY SCREEN BRUSH R-01 = FUEL LEVEL S-36 = ENGINE THROTTLE

S-61 = AIR FILTER SWITCH S-67 = COOLANT LEVEL

STARTING FRAME-- 3

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0154-03 Fuel Level Sensor Shorted to High Source Cause: The fuel level sensor (R-01) circuit is shorted to 12 volts. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is -- 0.5 to 4.9 volts. A. If the voltage reading is high out of range, (> 5.2 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 3. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the fuel level sensor connector X184. A. If the voltage drops to 4.9 to 5.2 volts, the short is in the sensor or sensor wiring. Replace the sensor. B. If the voltage remains high on display monitor, the short circuit is in the main frame (MF) harness between connector X184 pin 2 and connector X016 pin J2-17 wire 427 yellow. 3. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0154-04 Fuel Level Sensor Shorted to Low Source Cause: The fuel level sensor (R01) circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.5 to 4.9 volts. A. If the voltage reading is low out of range (0 to 0.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low less than 0.5 volts. Disconnect the fuel level sensor connector X184. A. If the voltage increases to 4.9 to 5.2 volts, the short is in the sensor or sensor wiring. Replace the sensor. B. If the voltage remains low, the short is in the main frame (MF) harness between connector X184 pin 2 and connector X016 pin J2-17 wire 427 yellow. Locate the short and repair. 3. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0154-05 Fuel level Sensor Line Disconnected Cause: The fuel level sensor (R-01) circuit is open. Possible failure modes: 1. Sensor supply or ground wiring is open. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.5 to 4.9 volts. A. If the voltage reading is high out of range (4.9 to 5.2 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high (4.9 to 5.2 volts). Disconnect the fuel level sensor connector X184. Use a jumper wire to short connector X184 pin 2 to chassis ground. A. If voltage drops to less than 0.5 volts, the open circuit is not in the supply side of the circuit. Continue with Step 3. B. If the voltage remains high, the open circuit is in the main frame (MF) harness between connector X184 pin 2 and connector X016 pin J2-17 wire 427 yellow. Locate the open and repair. 3. Disconnect the fuel level sensor Connector X184. Use a multimeter to check for continuity between the harness end of Connector X184 pin 1 and chassis ground. A. If there is continuity, the sensor has failed. Replace the sensor. B. If there is no continuity to ground, continue with Step 4. 4. Disconnect the main frame harness from the front frame harness at connector X008. Use a multimeter to check for continuity between the front frame harness end of connector X008 pin 14 and chassis ground. A. If there is continuity, the open circuit is in the main frame (MF) harness between connector X184 pin 1 and connector X008 pin 14 wire 467 blue or 425 blue. Locate the open and repair. B. If there is no continuity to ground, the open circuit is in the front frame (FF) harness between connector X008 pin 14 and connector X017 pin J3-18 wire 425 blue or 766 blue. Locate the open and repair. 5. Operate the machine while monitoring display. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

40024714

10020075

50026206

18 1. 2. 3. 4.

Fuel Level Sensor R01 Connector X008 Connector X016 Connector X017

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-22 = REAR LADDER F-23 = SCREEN BRUSH FUSE F-28 = FUEL PUMP FUSE K-07 = FUEL PUMP RELAY

M-23 = FUEL PUMP M-27 = ROTARY SCREEN BRUSH R-01 = FUEL LEVEL S-36 = ENGINE THROTTLE

S-61 = AIR FILTER SWITCH S-67 = COOLANT LEVEL

STARTING FRAME-- 3

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0159-03 Grain Bin Full Sensor Shorted to High Source Cause: The grain bin switch (S-28 & S-29) circuit is shorted to high voltage. Possible failure modes: 1. Switch supply or ground wiring shorted to 12 volts. 2. Open circuit on switch ground path. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The normal voltage range is 0 to 4.9 volts. The proper voltage range with both switches neutral is approximately 2.5 volts. The proper voltage range with the ¾ full switch depressed is approx. 3.3 volts. The proper voltage range with both bin switches depressed is approx. 3.7 volts. A. If the voltage reading is high out of range (> 4.9volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 10. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the grain bin full switch S29 connector X109. A. If the voltage drops to 0 to 4.9 volts, the short is in the reference ground wire for the circuit. Continue with Step 3. B. If the voltage remains high on display monitor, continue with Step 4. 3. Disconnect the main frame harness from the grain tank harness at connector X009. Use a multimeter to check for voltage on MF harness end of connector X009 pin H. A. If there is no voltage present, there is a short in the grain tank (GT) harness between connector X009 pin H and connector X109 pin A wire 443 blue. Locate the short and repair. B. If there is voltage present, there is a short in the main frame (MF) harness between connector X009 pin H and connector X016 pin J2-14 wire 443 blue or 465 blue. Locate the short and repair. 4. The voltage reading on the display monitor is high. Disconnect the grain bill full switch S29 connector X109. Use a multimeter to check for continuity between connector X109 pin A and chassis ground. A. If continuity is found, continue with Step 6. B. If no continuity is found, continue with Step 5.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 5. Disconnect the grain tank harness from the main frame harness at connector X009. Use a multimeter to check for continuity between the harness end of connector X009 pin H and chassis ground. A. If there is continuity, the open circuit is in the grain tank (GT) harness between connector X009 pin H and connector X109 pin A wire 443 blue. Locate the open and repair. B. If there is no continuity, the open circuit is in the main frame (MF) harness between connector X009 pin H and connector X016 pin J2-14 wire 443 blue or 465 blue. Locate the open and repair. 6. The voltage reading on the display monitor is high. Disconnect the grain bin ¾ full sensor S28 connector X107. A. If the voltage drops to 0 to 4.9 volts, continue with Step 7. B. If the voltage remains high on display monitor, continue with Step 8. 7. The voltage reading on the display monitor is high. Disconnect the grain bin 3/4 full sensor S28 connector X107. Use a multimeter to check for voltage on connector X107 pins A and B. A. If there is high voltage on connector X107 pin A, the regulated voltage supply is incorrect. The error “E0165-03 CCM2 5V Ref Voltage 3 Shorted to High Source” should be listed in the “Active Errors” screen in the display monitor. Correct that error, and then check to determine if this error has been resolved. B. If there is high voltage on connector X107 pin B, there is a short to high voltage in the grain tank (GT) harness between connector X109 pin B and connector X107 pin B wire 445 yellow. Locate the short and repair. 8. The voltage reading on the display monitor is high. Disconnect the grain bin 3/4 full sensor S28 connector X107. Use a multimeter to check for voltage on connector X107 pin C. A. If no voltage is found, continue with Step 10. B. If high (>4.9 volts) voltage is found, continue with Step 9. 9. Disconnect the grain tank harness from the main frame harness at connector X009. Use a multimeter to check for voltage on connector X009 pin E. A. If no voltage is found, the short is in the grain tank (GT) harness between connector X107 pin C and connector X009 pin E wire 400 yellow. Locate the short and repair. B. If high (>4.9 volts) voltage is found, the short is in the main frame (MF) harness between connector X009 pin E and connector X016 pin J2-22 wire 400 yellow. Locate the short and repair. 10. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0159-05 Grain Bin Full Sensor Line Disconnected Cause: The grain bin switch (S-28 & S-29) circuit is open, or shorted to ground. Possible failure modes: 1. Switch supply wiring is open. 2. Switch signal wiring is open, or shorted to ground. 3. Grain bin 3/4 full switch S28 shorted to ground. 4. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The normal voltage range is 0 to 4.9 volts. The proper voltage range with both switches neutral is approximately 2.5 volts. The proper voltage range with the 3/4 full switch depressed is approx. 3.3 volts. The proper voltage range with both bin switches depressed is approx. 3.7 volts. A. If the voltage reading is low out of range (< 0.3 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 9. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on display monitor is low. Manually move the paddle on the grain bin 3/4 full switch S28 while monitoring the reading on the display monitor. A. If the voltage remains low, continue with Step 3. B. If the voltage increases to approximately 2.5 volts, there is a short to ground in the grain tank (GT) harness between connector X107 pin B and connector X109 pin B wire 445 yellow. Locate the short and repair. 3. The voltage reading on the display monitor is low. Disconnect the grain bin 3/4 full switch S28 connector X107. Use a multimeter to check for voltage on connector X107 pin A. There should be 5 volts present. A. If there is no voltage, continue with Step 4. B. If there is 5 volts present, continue with Step 5. 4. Disconnect connector X009. Use a multimeter to check for voltage on connector X009 pin G. There should be 5 volts present. A. If there is 5 volts present, there is an open circuit in the grain tank (GT) harness between connector X009 pin G and connector X107 pin A wire 440 pink. Locate the open and repair. B. If there is no voltage, there is an open circuit in the main frame (MF) harness between connector X009 pin G and connector X016 pin J2-31 wire 440 pink or 459 pink. Locate the open and repair.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 5. The voltage reading on the display monitor is low. Disconnect the grain bill 3/4 full switch S28 connector X107. Use a multimeter to check for continuity between connector X107 pin C and chassis ground. A. If continuity is found, continue with Step 6. B. If no continuity is found, continue with Step 7. 6. Disconnect the grain tank harness from the main frame harness at connector X009. Use a multimeter to check for continuity between the main frame (MF) harness end of connector X009 pin E and chassis ground. A. If there is no continuity, there is a short to ground in the grain tank (GT) harness between connector X009 pin E and connector X107 pin C wire 400 yellow. Locate the short and repair. B. If there is continuity to ground, there is a short to ground in the main frame (MF) harness between connector X009 pin E and connector X016 pin J2-22 wire 400 yellow. Locate the short and repair. 7. Disconnect the grain tank harness from the main frame harness at connector X009. Use a multimeter to check for continuity between connector X009 pin E and connector X107 pin C. A. If there is no continuity, there is an open circuit in the grain tank (GT) harness between connector X009 pin E and connector X107 pin C wire 400 yellow. Locate the open and repair. B. If there is continuity, continue with Step 8. 8. Key off. Carefully disconnect connector X016 from the bottom of CCM2 module. Use a jumper wire to short connector X009 pin E to chassis ground. Use a multimeter to check for continuity between connector X016 pin J2-22 and chassis ground. A. If there is no continuity, there is an open circuit in the main frame (MF) harness between connector X009 pin E and connector X016 pin J2-22 wire 400 yellow. Locate the open and repair. B. If there is continuity, continue with Step 9. 9. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 1 2

40025217

10010900

50026208

19 1. 2. 3. 4.

Grain Bin Full Sensor S29 Grain Bin 3/4 Full Sensor S28 Connector X009 Connector X016

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

UNLOAD FRAME-- 22

B-38 = UNLOAD CRADLE B-47 = COVERS CLOSED L-03 = UNLOAD TUBE IN L-04 = UNLOAD TUBE OUT

L-08 = UNLOAD TUBE CLUTCH S-28 = GRAIN BIN 3/4 FULL S-29 = GRAIN BIN FULL S-42 = TANK COVERS SWITCH

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0162-01 Control Pressure Sensor Valid Below Normal Context: When the control oil pressure drops below 20 bar (290 psi) for more than 2 seconds after the engine has been running for at least 3 seconds, the alarm message “A0012 Control Pressure LOW” will be displayed to the operator. If the engine has been running for 5 seconds and the alarm occurs, the engine will be shutdown within 2 seconds to prevent damage to the hydraulic systems. When the alarm message is displayed, a permanent record is created in the error history. The EST must be used to erase this fault code. Cause: The “A0012 Control Pressure LOW” alarm has occurred at least once on the vehicle. Possible failure modes: 1. The control pressure sensor B-35 reports that the control pressure is below acceptable limits -- this is normal operation of the circuit and indicates a hydraulic pressure failure. 2. Control pressure sensor B-35 failure. Solution: 1. This fault code appears as a permanent record that the control pressure has dropped below 20 bar (290 psi) while the engine has been running for over 3 seconds. If this fault code appears, remove and inspect the PTO gearbox oil for indication of internal damage. A. Locate and repair the mechanical fault in the hydraulic system. B. If no hydraulic system fault can be found, replace the control pressure sensor B-35. Continue troubleshooting with Step 2. 2. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

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FAULT CODE – E0162-03 Control Pressure Sensor Shorted to High Source Cause: The control pressure sensor (B-35) circuit is shorted to 12 volts. Possible failure modes: 1. Switch supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range for the control pressure sensor (key On, engine OFF) is – 0.5 to 2.8 volts. The proper voltage range for the control pressure sensor (key On, engine Running) is – 2.8 to 4.9 volts. A. If the voltage reading is high out of range (>5.2 volts), continue with Step 2. B. If the voltage reading is normal, the shorted wire may not be energized at this time. Continue with Step 7. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the control pressure sensor connector X098. Use a multimeter to check for voltage on connector X098 pin B. There should be 5 volts present. A. If high (>5.5 volts) voltage is found, the regulated voltage supply is incorrect. The error “E0165-03 CCM2 5V Ref Voltage 3 Shorted to High Source” should be listed in the “Active Errors” screen in the display monitor. Correct that error, and then check to determine if this error has been resolved. B. If correct voltage is found, continue with Step 3. 3. The voltage reading on the display monitor is high. Disconnect the control pressure sensor connector X098. Use a multimeter to check for continuity between connector X098 pin A and chassis ground. A. If continuity is found, continue with Step 5. B. If no continuity is found, continue with Step 4. 4. Disconnect the gearbox harness from the main frame harness at connector X011. Use a multimeter to check for continuity between the harness end of connector X011 pin V and chassis ground. A. If there is continuity, the open circuit is in the gearbox (GB) harness between connector X011 pin V and connector X098 pin A wire 434 blue or 683 blue. Locate the open and repair. B. If there is continuity, the open circuit is in the main frame (MF) harness between connector X011 pin V and connector X016 pin J2-14 wire 683 blue or 465 blue. Locate the open and repair.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 5. The voltage reading on the display monitor is high. Disconnect the control pressure sensor connector X098. Use a multimeter to check for voltage on connector X098 pin C. A. If no voltage is found, continue with Step 7. B. If high (>5.2 volts) voltage is found, continue with Step 6. 6. Disconnect the gearbox harness from the main frame harness at connector X011. Use a multimeter to check for voltage on connector X011 pin B. A. If no voltage is found, the short is in the gearbox (GB) harness between connector X098 pin C and connector X011 pin B wire 423 yellow. Locate the short and repair. B. If high (>5.2 volts) voltage is found, the short is in the main frame (MF) harness between connector X011 pin B and connector X016 pin J2-19 wire 423 yellow. Locate the short and repair. 7. Operate the machine while monitoring display. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0162-05 Control Pressure Sensor Line Disconnected Cause: The control pressure sensor (B-35) circuit is open or shorted to ground. Possible failure modes: 1. Sensor signal wiring open or shorted to ground. 2. Loss of power to sensor. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range for the control pressure sensor (key On, engine OFF) is 0.5 to 2.8 volts. The proper voltage range for the control pressure sensor (key On, engine Running) is 2.8 to 4.9 volts. A. If the voltage reading is low out of range (<0.3 volts), continue with Step 2. B. If the voltage reading is normal, the shorted wire may not be open or grounded at this time. Continue with Step 9. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low (<0.3 volts). Disconnect the control pressure sensor connector X098. Use a multimeter to check for voltage on connector X098 pin B. There should be 5 volts present. A. If no voltage is found, continue with Step 3. B. If correct voltage is found, continue with Step 5. 3. Disconnect the gearbox harness from the main frame harness at connector X011. Use a multimeter to check for voltage on connector X011 pin D. There should be 5 volts present. A. If voltage is found, there is an open circuit in the gearbox (GB) harness between connector X098 pin B and connector X011 pin D wire 486 pink. Locate the open and repair. B. If no voltage is found, continue with Step 4. 4. Carefully disconnect the main frame harness from the CCM2 module at connector X016. Use a multimeter to check for voltage on the CCM2 module connector X016 pin J2-31. There should be 5 volts present. A. If voltage is found, there is an open circuit in the main frame (MF) harness between connector X011 pin D and connector X016 pin J2-31 wire 459 pink or 486 pink. Locate the open and repair. B. If no voltage is found, there is an internal fault with the CCM2 module. Replace the module. 5. The voltage reading on the display monitor is low (<0.3 volts). Disconnect the control pressure sensor connector X098. Use a multimeter to check for continuity between connector X098 pin C and chassis ground. A. If continuity is found, continue with Step 6. B. If no continuity is found, continue with Step 7.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 6. Disconnect the gearbox harness from the main frame harness at connector X011. Use a multimeter to check for continuity between the harness end of connector X011 pin B and chassis ground. A. If there is no continuity, there is a short to ground in the gearbox (GB) harness between connector X011 pin B and connector X098 pin C wire 423 yellow. Locate the short and repair. B. If there is continuity to ground, there is a short to ground in the main frame (MF) harness between connector X011 pin B and connector X016 pin J2-19 wire 423 yellow. Locate the short and repair. 7. Carefully disconnect the main frame harness from the CCM2 module at connector X016. Install a jumper wire between the harness end of connector X016 pin J2-19 and chassis ground. Use a multimeter to check for continuity between connector X098 pin C and chassis ground. A. If continuity is found, continue with Step 9. B. If no continuity is found, continue with Step 8. 8. Disconnect the gearbox harness from the main frame harness at connector X011. Use a multimeter to check for continuity between the harness end of connector X011 pin B and chassis ground. A. If there is continuity, there is an open circuit in the gearbox (GB) harness between connector X011 pin B and connector X098 pin C wire 423 yellow. Locate the open and repair. B. If there is no continuity to ground, there is an open circuit in the main frame (MF) harness between connector X011 pin B and connector X016 pin J2-19 wire 423 yellow. Locate the open and repair. 9. Operate the machine while monitoring display. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

10020076

50020057

50020097

20 1. 2. 3.

Control Pressure Sensor B35 Connector X011 Connector X016

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

HYDRAULIC FRAME-- 10

B-18 = HYD OIL RESERVOIR TEMP B-32 = GEARBOX TEMPERATURE B-35 = LOW CONTROL PRESSURE S-17 = ROTOR SPEED

S-18 = FEEDER SPEED S-32 = RETURNS FILTER BYPASS S-33 = HYDRAULIC RESERVOIR LEVEL S-34 = GEARBOX FILTER BYPASS

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0164-03 V Supply Ground Spd Hydro Shorted to High Source NOTE: This fault code may occur if the propulsion handle is moved very slowly out of the neutral position, such as when ”inching” the combine forward or reverse. This is due to the software looking at both the calibrated neutral position of the ground speed potentiometer R-04 and the power input from the neutral switch S-22; if the handle is moved slowly, one event may occur slightly before the other. This is normal, and does not necessarily indicate a problem with the system. Context: The neutral switch S-22 is mounted on the multi-function handle (MFH) assembly, and is used to supply battery power to CCM2 connector X015 pin J1-17 when the MFH is moved out of the neutral position. This battery power is used by the controller to power the ground speed hydrostat electronic displacement control (EDC) valve. This provides a margin of safety by immediately disconnecting the power supply to the EDC valve when the MFH is moved to the neutral position. The MFH neutral position is determined by both the neutral switch position and the calibrated neutral position of the ground speed potentiometer R-04. If the controller determines that the MFH is in neutral based on the ground speed potentiometer R-04 position, but there is battery voltage at connector X015 pin J1-17, then this fault code will occur. Cause: The MFH is in the neutral position, and voltage is greater than 9 volts at CCM2 connector X015 pin J1-17. Possible failure modes: 1. Multifunction handle out of calibration. 2. Wire 113 YE shorted to battery voltage. 3. Ground speed potentiometer not mounted securely. 4. Ground speed potentiometer R-04 failed. 5. Neutral switch S-22 failed. Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check the voltage while moving the multi-function handle (MFH) in and out of neutral. The proper voltage with the MFH in neutral is 0 volts. The proper voltage with the MFH out of neutral is 12 volts (battery voltage). A. If the voltage reading is greater than 9 volts with the MFH in neutral, continue with Step 2. B. If the voltage reading is within the proper limits, continue with Step 4. 2. Remove the top portion of the right hand console, and carefully turn it over. Remove connector X059 from the neutral switch. Turn the key switch to the “On” position. Use a multimeter to check for voltage at connector X059 pin 3. There should not be voltage. A. If there is voltage, there is a short circuit in the cab main (CM) or right console (RC) harnesses between connector X059 pin 3, connector X001 pin 17 and connector X015 pin J1-17 wire 113 yellow. Locate the short and repair. B. If there is no voltage, continue with Step 3.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 3. Key switch in the “Off” position. Use a multimeter to check for continuity between pins 1 and 3 of the neutral switch S-22 with the MFH handle in the neutral position. There should not be continuity. A. If there is continuity, the neutral switch has failed. Replace the neutral switch. B. If there is no continuity, continue with Step 6. 4. Key switch in the “On” position. Use the display monitor, reference Section 55 Chapter 2, if needed, to calibrate the MFH. After the calibration is complete, operate the combine normally and check for the fault code. A. If the fault code continues to appear after the MFH has been calibrated, continue with Step 5. B. If the fault code no longer appears after the MFH has been calibrated, continue with Step 6. 5. Remove the top portion of the right hand console, and carefully turn it over. Inspect the MFH potentiometer mounting to ensure that it is tight, and that the potentiometer shaft is securely engaged with the MFH linkage. A. If the potentiometer mounting is loose, tighten the potentiometer mounting screws so that the potentiometer does not move when moving the MFH. Return to Step 4. B. If the potentiometer mounting is secure, the potentiometer moves properly with the MFH movement, and the fault code still occurs, the potentiometer has failed. Replace the potentiometer. 6. Erase the fault code and continue operation. A. If the fault code reappears, return to Step 1.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0164-04 V Supply Ground Spd Hydro Shorted to Low Source NOTE: This fault code may occur if the propulsion handle is moved very slowly out of the neutral position, such as when ”inching” the combine forward or reverse. This is due to the software looking at both the calibrated neutral position of the ground speed potentiometer R-04 and the power input from the neutral switch S-22; if the handle is moved slowly, one event may occur slightly before the other. This is normal, and does not necessarily indicate a problem with the system. Context: The neutral switch S-22 is mounted on the multi-function handle (MFH) assembly, and is used to supply battery power to CCM2 connector X015 pin J1-17 when the MFH is moved out of the neutral position. This battery power is used by the controller to power the ground speed hydrostat electronic displacement control (EDC) valve. This provides a margin of safety by immediately disconnecting the power supply to the EDC valve when the MFH is moved to the neutral position. The MFH neutral position is determined by both the neutral switch position and the calibrated neutral position of the ground speed potentiometer R-04. If the controller determines that the MFH is out of neutral based on the ground speed potentiometer R-04 position, and there is not battery voltage at connector X015 pin J1-17, then this fault code will occur. Cause: The MFH is not in the neutral position, and voltage is less than 9 volts at CCM2 pin connector X015 J1-17. Possible failure modes: 1. Multifunction handle out of calibration. 2. Wire 113 YE shorted to ground or open (fuse F48 or F42 failed). 3. Neutral switch S-22 mounting loose. 4. Neutral switch S-22 failed. 5. Ground speed potentiometer R-04 failed. Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check the voltage while moving the multi-function handle (MFH) in and out of neutral. The proper voltage with the MFH in neutral is 0 volts. The proper voltage with the MFH out of neutral is 12 volts (battery voltage). B. If the voltage reading is less than 9 volts with the MFH out of neutral, continue with Step 5. C. If the voltage reading is within the proper limits, continue with Step 2. 2. Key switch in the “On” position. Use the display monitor, reference Section 55 Chapter 2, if needed, to calibrate the MFH. After the calibration is complete, operate the combine normally and check for the fault code. A. If the fault code continues to appear after the MFH has been calibrated, continue with Step 3. B. If the fault code no longer appears after the MFH has been calibrated, continue with Step 11.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 3. Remove the top portion of the right hand console, and carefully turn it over. Inspect the ground speed potentiometer R-04 mounting to ensure that it is tight, and that the potentiometer shaft is securely engaged with the MFH linkage. A. If the potentiometer mounting is loose, tighten the potentiometer mounting screws so that the potentiometer does not move when moving the MFH. Return to Step 2. B. If the potentiometer mounting is secure, and the potentiometer moves properly with the MFH movement, the potentiometer has failed. Continue with Step 4. 4. Replace the ground speed potentiometer R-04. Calibrate the MFH handle as described in Step 2. Operate the combine to determine if the fault reoccurs. A. If the fault reoccurs after replacing the ground speed potentiometer R-04, continue with Step 10. B. If the fault does not reoccur after replacing the ground speed potentiometer R-04, continue with Step 11. 5. Check the condition of fuses F-42 and F-48 in the fuse panel. If one or both of the fuses have failed, replace them. A. If fuse F-42 is replaced, and fails immediately after being replaced, there is short to ground in the cab main (CM) harness between fuse F-42 and the cab power relay K-26 wire 010 red, or between the cab power relay K-26 and the fuse panel buss strip wire 007 orange. Locate the short and repair. Return to Step 1. B. If fuse F-48 is replaced, and fails immediately after being replaced, there is a short to ground in the one of the following wires: -- wire 109 orange, fuse F48 to thresher latching relay K28, terminal 3 -- wire 108 orange, fuse F48 to connector X001, pin 3 -- switch power wires from splice block B, W02 in the RH console Locate the short and repair. Return to Step 1. C. If both fuses are in good condition, continue with Step 6. 6. Remove the top portion of the right hand console, and carefully turn it over. Inspect the neutral switch mounting to ensure it is tight, and the roller is centered in the notch with the MFH in the neutral position. When the MFH is moved out of neutral, there should be an audible “click” as the neutral switch roller climbs out of the notch. A. If the neutral switch mounting is loose, properly position the switch and tighten the mounting screws. Return to Step 1. B. If the neutral switch is securely mounted in the proper position, continue with Step 7. 7. Remove connector X059 from the neutral switch. Turn the key switch to the “On” position. Use a multimeter to check for voltage at connector X059 pin 1. There should be approximately 12 volts. A. If there is no voltage, there is an open circuit in the cab main (CM) harness or right console (RC) harnesses between fuse F48, connector X001 pin 3 and connector X059 pin 1 wires 108 or 300 orange. Locate the open and repair. Return to Step 1. B. If there is less than 9 volts, there is excessive resistance in the cab main (CM) or right console (RC) harnesses between fuse F48, connector X001 pin 3 and connector X059 pin 1 wires 108 or 300 orange. Locate the source of the resistance and repair. Return to Step 1. C. If there is greater than 9 volts, continue with Step 8. 8. Use a multimeter to check for continuity between pin 1 and pin 3 of the neutral switch S-22 with the MFH out of the neutral position. There should be continuity. A. If there is no continuity, the neutral switch has failed internally. Replace the neutral switch. Return to Step 1. B. If there is continuity, continue with Step 9.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 9. Reconnect connector X059 at the neutral switch. Remove the instructional seat and storage bin to gain access to the CCM controllers. Turn the key switch to the “On” position. Use a multimeter to check for voltage at CCM2 connector X015 pin J1-17 when the MFH is out of the neutral position. There should be approximately 12 volts. A. If there is no voltage, there is an open circuit in the right console (RC) or cab main (CM) harnesses between connector X059, connector X001 pin 17 and connector X015 pin J1-17 wire 113 yellow. Locate the open and repair. Return to Step 1. B. If there is less than 9 volts, there is excessive resistance in the right console (RC) or cab main (CM) harnesses between connector X059, connector X001 pin 17 and connector X015 pin J1-17 wire 113 yellow. Locate the source of the resistance and repair. Return to Step 1. C. If there is greater than 9 volts, continue with Step 10. 10. Use the electronic service tool (EST) to reload the CCM2 software. After reloading the software, operate the combine and check for the fault code. A. If the fault still occurs, there is a failure in the CCM2 controller. Replace the CCM2 controller. Return to Step 1. B. If the fault no longer occurs, continue with Step 11. 11. Erase the fault code and continue normal operation. A. If the fault code reappears, return to Step 1.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

40020081

10010921

1 2 5

10004693

50020070

50026204

21 1. 2. 3. 4. 5.

Fuse F42 Fuse F48 Connector X001 Neutral Switch S22 Connector X015

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

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S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME-- 9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-48 = RH CONSOLE FUSE H-01 = AUDIO ALARM W-01 = SPLICE BLOCK A W-02 = SPLICE BLOCK B

W-05 = SPLICE BLOCK E W-06 = SPLICE BLOCK F

DISTRIBUTION FRAME-- 25

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

DISTRIBUTION FRAME-- 28

F-36 = CCM-2A FUSE F-37 = CCM-2B FUSE F-40 = CCM-1 POWER FUSE F-41 = CCM-2 POWER FUSE

F-42 = CCM-3, CAB POWER FUSE K-24 = CCM-1 POWER RELAY K-25 = CCM-2 POWER RELAY K-26 = CCM-3, CAB POWER RELAY

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0165-03 CCM2 5V Ref Voltage 3 Shorted to High Source Cause: The CCM2 5V Ref Voltage 3 circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: The CCM2 5V Ref Voltage 3 circuit supplies power from connector X016 pin J2-31 to two different sensors; the grain bin sensors S28 & S29 in the grain tank harness, and the control pressure sensor B35 in the gearbox harness. A short to high voltage on any of these supply wires will result in this fault code being displayed. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage supply is 4.5 to 5.5 volts. A. If the voltage reading is high out of range (>5.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the grain tank harness from the main frame harness at connector X009. A. If the voltage decreases to 4.5 to 5.5 volts, the short is in the grain tank (GT) harness between connector X009 pin G and connector X107 pin A wire 440 pink. Locate the short and repair. B. If the voltage remains high on display monitor, continue with Step 3. 3. The voltage reading on the display monitor is high. Disconnect the gearbox harness from the main frame harness at connector X011. A. If the voltage decreases to 4.5 to 5.5 volts, the short is in the gearbox (GB) harness between connector X011 pin D and connector X098 pin B wire 486 pink. Locate the short and repair. B. If the voltage remains high on display monitor, continue with Step 4. 4. Carefully disconnect connector X016 from the bottom of the CCM2 module. Use a multimeter to check for voltage at connector X016 pin J2-31. There should be 4.5 to 5.5 volts. A. If the voltage is within 4.5 to 5.5 volts, the short is in the main frame harness. Carefully inspect the main frame harness between connector X016 and the grain tank and gearbox harnesses for any signs of chaffing, pinch marks, or other damage which could result in an internal short. Repair any damage found. B. If the voltage is greater than 5.5 volts, there is a problem with an internal component in the CCM2 module. Replace the module. 5. Operate the machine while monitoring the display monitor. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0165-04 CCM2 5V Ref Voltage 3 Shorted to Low Source Cause: The CCM2 5V Ref Voltage 3 circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: The CCM2 5V Ref Voltage 3 circuit supplies power from connector X016 pin J2-31 to two different sensors; the grain bin sensors S28 & S29 in the grain tank harness, and the control pressure sensor B35 in the gearbox harness. A short to ground on any of these supply wires will result in this fault code being displayed. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage supply is 4.5 to 5.5 volts. A. If the voltage reading is low (<4.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low. Disconnect the grain tank harness from the main frame harness at connector X009. A. If the voltage increases to 4.5 to 5.5 volts, the short is in the grain tank (GT) harness between connector X009 pin G and connector X107 pin A wire 440 pink. Locate the short and repair. B. If the voltage remains low on display monitor, continue with Step 3. 3. The voltage reading on the display monitor is low. Disconnect the gearbox harness from the main frame harness at connector X011. A. If the voltage increases to 4.5 to 5.5 volts, the short is in the gearbox (GB) harness between connector X011 pin D and connector X098 pin B wire 486 pink. Locate the short and repair. B. If the voltage remains low on display monitor, continue with Step 4. 4. Carefully disconnect connector X016 from the bottom of the CCM2 module. Use a multimeter to check for voltage at connector X016 pin J2-31. There should be 4.5 to 5.5 volts. A. If the voltage is within 4.5 to 5.5 volts, the short is in the main frame harness. Carefully inspect the main frame harness between connector X016 and the grain tank and gearbox harnesses for any signs of chaffing, pinch marks, or other damage which could result in an internal short. Repair any damage found. B. If the voltage is less than 4.5 volts, there is a problem with an internal component in the CCM2 module. Replace the module. 5. Operate the machine while monitoring the display monitor. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

2 40025217

10010900

50020057

10020076

50026209

22 1. 2. 3. 4.

Grain Bin Full Sensor S29 Grain Bin 3/4 Full Sensor S28 Control Pressure Sensor B35 Connector X010

5. 6. 7.

Connector X011 Connector X009 Connector X016

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

HYDRAULIC FRAME-- 10

B-18 = HYD OIL RESERVOIR TEMP B-32 = GEARBOX TEMPERATURE B-35 = LOW CONTROL PRESSURE S-17 = ROTOR SPEED

S-18 = FEEDER SPEED S-32 = RETURNS FILTER BYPASS S-33 = HYDRAULIC RESERVOIR LEVEL S-34 = GEARBOX FILTER BYPASS

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

UNLOAD FRAME-- 22

B-38 = UNLOAD CRADLE B-47 = COVERS CLOSED L-03 = UNLOAD TUBE IN L-04 = UNLOAD TUBE OUT

L-08 = UNLOAD TUBE CLUTCH S-28 = GRAIN BIN 3/4 FULL S-29 = GRAIN BIN FULL S-42 = TANK COVERS SWITCH

55-140

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0166-03 CCM2 8V Ref Voltage Shorted to High Source Cause: The CCM2 8V Ref Voltage circuit is shorted to a higher than normal source. Possible failure modes: 1. 12V short on 8V regulated power circuit. 2. Controller internal failure (internal regulator failure). Solution: 1. The 8V regulated power supply is provided from the key switch power to the module, and is used to provide power to all the speed and position sensor circuits. In some cases, a 12V short on one of the sensor signal wires could result in backfeeding that upsets the 8V regulator, and may cause the short to high source fault. 2. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage is 7.5 to 8.5 volts. A. If the reading is high out of range, continue with Step 2. B. If the reading is within the proper range, reload the software in CCM2. Erase the Fault code and continue operation. If the fault code persists, replace the module. 3. Turn off the key switch, and disconnect the battery key to remove all power from the module. Carefully remove connector X016 and connector X017 from the bottom of CCM2 module. Reconnect the battery key and using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage is 7.5 to 8.5 volts. A. If the voltage reading is normal, there is a short to high source on one of the sensor wires. Continue with Step 3. B. If the voltage reading is still high out of range then CCM2 has an internal failure. Replace the controller. 4. Turn off the key switch, and disconnect the battery key to remove all power from the module. Carefully reconnect connector X016 and connector X017 from the bottom of CCM2 module. Reconnect the battery key and use the display monitor, reference section 55 chapter 2, if needed, to check for any errors for sensor circuits short to high source on CCM2 module. A. If there are any sensor circuits on CCM2 that are shorted to high source, correct those circuits, and then continue with Step 1 of this troubleshooting to verify this concern is resolved. B. If there are no sensor circuits errors on CCM2, reload the software in CCM2. Erase the Fault code and continue operation. If the fault code persists, replace the module.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0166-04 CCM2 8V Ref Voltage Shorted to Low Source Cause: The CCM2 8V Ref Voltage circuit is shorted to ground. Possible failure modes: 1. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage is 7.5 to 8.5 volts. A. If the voltage reading is low out of range then CCM2 has an internal failure. Replace the controller.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0167-03 CCM2 5V Ref Voltage 1 Shorted to High Source Cause: The CCM2 5V Ref Voltage 1 circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: The CCM2 5V Ref Voltage 1 circuit supplies power from connector X017 pin J3-26 to the park brake pressure sensor B53 in the front frame harness, to the header type module R-20 and the reel horizontal/vertical position R-24/25 on the header. A short to high voltage on this supply wire will result in this fault code being displayed. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage supply is 4.5 to 5.5 volts. A. If the voltage reading is high out of range (>5.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 6. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect the park brake pressure sensor connector X368. A. If the voltage decreases to 4.5 to 5.5 volts, the short is in the sensor. Replace the sensor. B. If the voltage remains high on display monitor, continue with Step 3. 3. Disconnect connector X032 from the header. A. If the voltage decreases to 4.5 to 5.5 volts, the short is in the header harnesses. Locate the short and repair. B. If the voltage remains high on the display monitor, continue with Step 4. 4. Disconnect connector X007 from the front frame (FF) harness. A. If the voltage decreases to 4.5 to 5.5 volts, the short is in the feeder harness (FE) between connector X007 and connector X032 wire 1223 pink. B. If the voltage remains high on the display monitor, continue with Step 5. 5. Carefully disconnect connector X017 from the bottom of the CCM2 module. Use a multimeter to check for voltage at connector X017 pin J3-26. There should be 4.5 to 5.5 volts. A. If the voltage is within 4.5 to 5.5 volts, the short is in the front frame (FF) harness between connector X017 and connector X368 wire 1537 pink or connector X007 wire 1223 pink. Locate the short and repair. B. If the voltage is greater than 5.5 volts, there is a problem with an internal component in the CCM2 module. Replace the module. 6. Operate the machine while monitoring the display monitor. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0167-04 CCM2 5V Ref Voltage 1 Shorted to Low Source Cause: The CCM2 5V Ref Voltage 1 circuit is shorted to ground. Possible failure modes: 1. Sensor supply wiring shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: The CCM2 5V Ref Voltage 1 circuit supplies power from connector X017 pin J3-26 to the park brake pressure sensor B53 in the front frame harness, to the header type module R-20 and the reel horizontal/vertical position R-24/25 on the header. A short to ground on this supply wire will result in this fault code being displayed. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage supply is 4.5 to 5.5 volts. A. If the voltage reading is low (<4.5 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 6. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low. Disconnect the park brake pressure sensor connector X368. A. If the voltage increases to 4.5 to 5.5 volts, the short is in the sensor. Replace the sensor. B. If the voltage remains low on display monitor, continue with Step 3. 3. Disconnect connector X032 from the header. A. If the voltage increases to 4.5 to 5.5 volts, the short is in the header harnesses. Locate the short and repair. B. If the voltage remains low on the display monitor, continue with Step 4. 4. Disconnect connector X007 from the front frame (FF) harness. A. If the voltage increases to 4.5 to 5.5 volts, the short is in the feeder harness (FE) between connector X007 and connector X032 wire 1223 pink. B. If the voltage remains low on the display monitor, continue with Step 5. 5. Carefully disconnect connector X017 from the bottom of the CCM2 module. Use a multimeter to check for voltage at connector X017 pin J3-26. There should be 4.5 to 5.5 volts. A. If the voltage is within 4.5 to 5.5 volts, the short is in the front frame (FF) harness between connector X016 and connector X368 wire 1537 pink or connector X007 wire 1223 pink. Locate the short and repair. B. If the voltage is less than 4.5 volts, there is a problem with an internal component in the CCM2 module. Replace the module. 6. Operate the machine while monitoring the display monitor. If no high out of range readings are indicated, erase the fault code and continue operation.

55-145

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

2 10020040

50026205

40024707

23 1. 2. 3. 4.

Header Type Module R-20 and Reel Horizontal/Vertical Position R-24/25 Connector X032 Connector X007 Connector X017

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

55-147

S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME-- 9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-15 = REEL RPM R-20 = HEADER TYPE MODULE R-24 = REEL HORIZONTAL POSITION R-25 = REEL VERTICAL POSITION

HEADER FRAME-- 13

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

55-149

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0168-03 CCM2 Keyswitch Voltage Shorted to High Source Cause: The CCM2 Keyswitch Voltage circuit is shorted to a higher than normal source. Possible failure modes: 1. The keyswitch voltage circuit to the CCM2 controller is shorted to a high source. 2. Faulty alternator/regulator. 3. Controller internal failure (internal regulator failure). Solution: Key switch voltage is used to initialize (wake-up) the module, and also supplies power to the 5V and 8V regulators for the regulated voltage circuits. The module will shutdown if the voltage is less than 9 volts, but there is no shutdown for excessive voltage. 1. Start the combine engine. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, increase the engine RPM to high idle (maximum) and check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is greater than 18 volts, continue with Step 2. B. If the voltage reading is between 10 and 18 volts, go to Step 5. 2. Shut off the combine engine, and then turn the key switch on again. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, the alternator and/or regulator has failed, and is producing excessive voltage. Refer to “Charging Systems” in Chapter 5 -- Engine Systems in this Section for additional alternator testing information. B. If the voltage reading is greater than 18 volts, continue with Step 3. 3. Turn the key switch off to power down the system. Check the voltage at fuse F38 using a multi-meter. A. If the voltage reading is greater than 18 volts, then the batteries have been mistakenly connected in series, or there is a fault in the wiring of the 24V starting system. Refer to “Starting Systems” in Chapter 5 -- Engine Systems in this Section for additional information. B. If the voltage reading is between 10 and 18 volts, continue with Step 4.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 4. Remove the buddy seat and storage bin to gain access to connector X015 on CCM2. Turn the key on. Check the voltage at connector X015 pin J1-4. A. If the voltage reading is greater than 18 volts, then a high voltage source has been connected to one of the following wires: wire 096 orange, key switch S02 to CM harness splice wire 100 orange, harness splice to CCM2 connector X015, pin J1-4 wire 099 orange, harness splice to CCM1 connector X018, pin J1-4 wire 101 orange, harness splice to CCM3 connector X012, pin J1-4 wire 055 orange, harness splice to road light switch connector X256, pin 6 wire 095, 103 or 104 orange, harness splice to power relays K24, K25 & K26, pins 1 wire 222 orange, power relay K26 pin 1 to time delay module K20, pin 30 All wires listed are located in the cab main (CM) harness. Visually inspect the cab main harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the high voltage short and repair. B. If the voltage reading is 10 to 18 volts, and the diagnostic screen is still indicating voltage in excess of 18 volts, there is an internal fault in CCM2. Reload the software for CCM2. If that does not correct the concern, replace the module. 5. Erase the error code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0168-04 CCM2 Keyswitch Voltage Shorted to Low Source Cause: The CCM2 Keyswitch Voltage circuit is shorted to a lower than normal source. Possible failure modes: 1. Loose or corroded connections, or damaged wires. 2. Batteries are discharged, and/or alternator/regulator failure. 3. The keyswitch voltage circuit to the CCM2 controller is shorted to ground. NOTE: Check fuse F38. If a short to ground occurred on this circuit the fuse will have blown. 4. Controller internal failure (internal regulator failure). Solution: Key switch voltage is used to initialize (wake-up) the module, and also supplies power to the 5V and 8V regulators for the regulated voltage circuits. The module will shutdown if the voltage is less than 9 volts, but there is no shutdown for excessive voltage. 1. Key switch in “Off” position. Check fuse F38. A. If fuse F38 is okay, continue with Step 6. B. If the fuse is blown, go to Step 2. 2. Replace the failed fuse F38. A. If the fuse is okay, continue with Step 3. B. If the fuse immediately fails again, a short to ground exists in wire 053 red between the fuse and the key switch in the cab main (CM) harness. Visually inspect the cab main harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair. 3. If the fuse does not fail when it is replaced, turn the key switch to the “Acc” position. A. If the fuse is okay, continue with Step 4. B. If the fuse immediately fails, there is a short to ground in one of the following wires: wire 123 orange, key switch to the Wiper relay K06 wire 241 orange, Wiper relay K06 to Accessory 1 relay K08 wire 126 orange, Accessory 1 relay K08 to Accessory 2 relay K03 All three wires are in the cab main harness. Visually inspect the cab main harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 4. If the fuse does not fail with the key switch in the “Acc” position, turn the key switch to the “On” position. A. If the fuse is okay, continue with Step 5. B. If the fuse immediately fails, there is a short to ground in one of the following wires: wire 096 orange, key switch S02 to CM harness splice wire 100 orange, harness splice to CCM2 connector X015, pin J1-4 wire 099 orange, harness splice to CCM1 connector X018, pin J1-4 wire 101 orange, harness splice to CCM3 connector X012, pin J1-4 wire 055 orange, harness splice to road light switch connector X256, pin 6 wire 095, 103 or 104 orange, harness splice to power relays K24, K25 & K26, pins 1 wire 222 orange, power relay K26 pin 1 to time delay module K20, pin 30 All wires are in the cab main harness. Visually inspect the cab main harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair. 5. If the fuse does not fail with the key switch in the “On” position, turn the key switch briefly to the “Start” position. A. If the fuse is okay, continue with Step 6. B. If the fuse immediately fails, there is a short to ground in wire 091 orange from the key switch to Neutral start relay K23, or wire 090 orange from the relay to CCM2, connector X015, pin J1-21. Both wires are in the cab main harness. Visually inspect the cab main harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair. 6. Key switch in “Off” position. Check the voltage at fuse F38 using a multi-meter. A. If the voltage reading is between 10 and 18 volts, continue with Step 7. B. If the voltage reading is less than 10 volts, there is excessive resistance between the batteries and the cab fuse panel, due to loose or corroded connections, or the batteries have discharged excessively, and are not capable of supplying the minimum voltage requirement for CCM2. Inspect the wiring from the batteries to the engine compartment, and from there to the cab. Recharge or replace the batteries. 7. Key switch in “On” position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, continue with Step 8. B. If the voltage reading is less than 10 volts, there is excessive resistance between the fuse panel and CCM2. Inspect wire 053 red to the key switch, and wires 096 and 100 orange to CCM2 connector X015 pin J1-4 for loose or corroded connections, or damage to the wires. 8. Start the combine engine. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, with the engine RPM at low idle, engage road and work lights. Check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, continue with Step 9. B. If the voltage reading is less than 10 volts, the alternator and/or regulator may have failed, and the charging system is not producing sufficient voltage. Refer to “Charging Systems” in Chapter 5 -- Engine Systems in this Section for additional alternator testing information. 9. Erase the error code and continue operation.

55-153

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

20013706

10004693

50020070

50026204

24 1. 2. 3.

Fuse F38 Key Switch S02 Connector X015

55-154

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

STARTING FRAME-- 2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

55-155

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0 L

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

DISTRIBUTION FRAME-- 28

F-36 = CCM-2A FUSE F-37 = CCM-2B FUSE F-40 = CCM-1 POWER FUSE F-41 = CCM-2 POWER FUSE

F-42 = CCM-3, CAB POWER FUSE K-24 = CCM-1 POWER RELAY K-25 = CCM-2 POWER RELAY K-26 = CCM-3, CAB POWER RELAY

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME-- 29

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

LIGHTING FRAME-- 36

A-05 = FLASHER MODULE E-13 = LH ROAD LIGHT E-14 = RH ROAD LIGHT F-32 = HIGH BEAM FUSE

F-33 = LOW BEAM FUSE F-51 = HORN, MARKER LTS FUSE H-02 = HORN K-02 = LIGHT CONTROL RELAY

55-158

K-04 = HIGH BEAM RELAY K-05 = LOW BEAM RELAY S-26 = ROAD LIGHT SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

LIGHTING FRAME-- 38

E-34 = DOME LIGHT E-35 = CONSOLE LIGHT E-42 = LH FRONT SHIELD LT E-43 = LH REAR SHIELD LT

E-44 = RH FRONT SHIELD LT E-45 = RH REAR SHIELD LT E-46 = ENGINE LT F-34 = UNDERSHIELD LIGHTS

55-159

F-52 = DOME/BRAKE LT FUSE K-20 = TIME DELAY MODULE K-33 = BRAKE LIGHTS RELAY S-40 = LH DOOR SWITCH

S-63 = LEFT SHIELD LT SW S-64 = ENGINE LT SW S-65 = RIGHT SHIELD LT SW

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-03 = ACCESSORY 1 FUSE F-04 = WIPER FUSE F-05 = CIGAR LIGHTER FUSE F-08 = ACCESSORY OUTLET FUSE

F-09 = WASHER/MIRROR FUSE F-10 = NOT USED J-06 = ACCESSORY SOCKET J-08 = ACCESSORY OUTLET

K-06 = WIPER RELAY K-08 = ACCESSORY 1 RELAY M-24 = WIPER WASHER MOTOR M-25 = WIPER MOTOR

55-160

R-08 = CIGAR LIGHTER S-20 = WIPER SWITCH S-38 = WASHER SWITCH

ACCESSORY FRAME-- 45

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

ACCESSORY FRAME-- 46

A-04 = RADIO F-02 = ACCESSORY 2 FUSE F-11 = RADIO FUSE F-13 = TRANSCEIVER FUSE

F-16 = SEAT PUMP FUSE F-35 = RADIO KAPWR FUSE H-04 = REAR LEFT SPEAKER H-05 = FRONT LEFT SPEAKER

55-161

H-06 = REAR RIGHT SPEAKER H-07 = FRONT RIGHT SPEAKER J-07 = TRANSCEIVER OUTLET K-03 = ACCESSORY 2 RELAY

M-26 = SEAT PUMP MOTOR S-45 = SEAT ADJUST SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0169-06 Current Sense Reel Speed Short Circuit Cause: The reel speed motor (M-09) circuit indicates high current draw. (European Heads Only) Possible failure modes: 1. Circuit connection shorted to ground. 2. Excessive mechanical load on motor. 3. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference section 55 chapter 2, if needed. A. Start the combine. B. Engage the thresher and feeder circuits, and operate the reel speed motor in both directions. C. Record in which direction(s) the reel speed increase or decrease operates. D. Check for fault codes 0169-06 and 0204-05. E. Use the following table to determine the location of the fault. Symptom

Fault Code 0169-06

Reel Speed adjust operates in 1 direction only

Reel Speed adjust does not operate in either direction

Fault Type

0204-05 X X

Go to Step 2

Binding

Go to Step 3

Short to ground

Go to Step 2

Binding

Go to Step 10

Open circuit

Go to Step 17

No power supply

2. The reel speed motor or reel mechanism is mechanically bound up, resulting in high current draw. See the appropriate repair manual chapter for repair and adjustment of the reel speed linkage. 3. Fault codes indicate circuit fault due to short to ground. Disconnect reel speed motor connector X308. Measure between terminals A or B on the motor connector and a known good ground. There should be no continuity to ground. A. There is continuity to ground, indicating a short to ground in the motor. Replace the reel speed motor. B. There is no continuity to ground. Continue with Step 4.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 4. Disconnect the batteries using the battery key. Use the multimeter to check for continuity between connector X308 pin B and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position. Power must be removed from the module prior to testing for short to ground condition on the motor circuit to remove this ground path. A. If continuity is found, continue with Step 5. B. If no continuity is found, continue with Step 7. 5. Disconnect inline connector X032. Use a multimeter to check for continuity between connector X032 pin 26 and chassis ground. A. If no continuity is found the short to ground is in the harness between connector X032 pin 26 and connector X308 pin B. Locate the short and repair. B. If continuity is found, continue with Step 6. 6. Disconnect connector X007. Use a multimeter to check for continuity between connector X007 pin 19 and chassis ground. A. If no continuity is found, the short to ground is in the harness between connector X032 pin 26 and connector X007 pin 19 wire 711 gray. Locate the short and repair. B. If continuity is found, the short to ground is in the harness between connector X007 pin 19 and connector X017 pin J3-6 wire 711 gray. Locate the short and repair. 7. Use a multimeter to check for continuity between connector X308 pin A and chassis ground. A. If continuity is found, continue with Step 8. B. If no continuity is found, recheck the motor for continuity to ground at Step 3. 8. Disconnect connector X032. Use a multimeter to check for continuity between connector X032 pin 20 and chassis ground. A. If no continuity is found, the short to ground is in the harness between connector X308 pin A and X032 pin 20. Locate the short and repair. B. If continuity is found, continue with Step 9. 9. Disconnect connector X007. Use a multimeter to check for continuity between connector X007 pin 3 and chassis ground. A. If no continuity is found, the short to ground is between connector X007 pin 3 and connector X017 pin J3-8 wire 712 white. Locate the short and repair. B. If continuity is found, the short to ground is in the harness between connector X032 pin 20 and connector X007 pin 3 wire 712 white. Locate the short and repair. 10. Fault codes indicate circuit fault due to open circuit condition. Disconnect reel speed motor connector X308. Measure the resistance of the motor between terminals A and B. The correct resistance is XX to XX ohms. A. The resistance is infinite, indicating an open condition in the motor. Replace the reel speed motor. B. The resistance is in specification. Continue with Step 11.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 11. Ensure that the batteries are connected using the battery key, and that fuse F23 is good. Use the multimeter to check for continuity between connector X308 pin B and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F23. This ground path may be used to test for an open circuit condition. A. If continuity is found, continue with Step 14. B. If no continuity is found, continue with Step 12. 12. Disconnect inline connector X032. Use a multimeter to check for continuity between connector X032 pin 26 and chassis ground. A. If continuity is found the open circuit is in the harness between connector X032 pin 26 and connector X308 pin B. Locate the open and repair. B. If no continuity is found, continue with Step 13. 13. Disconnect connector X007. Use a multimeter to check for continuity between connector X007 pin 19 and chassis ground. A. If continuity is found, the open circuit is in the harness between connector X032 pin 26 and connector X007 pin 19 wire 711 gray. Locate the open and repair. B. If no continuity is found, the open circuit is in the harness between connector X007 pin 19 and connector X017 pin J3-6 wire 711 gray. Locate the open and repair. 14. Use a multimeter to check for continuity between connector X308 pin A and chassis ground. A. If no continuity is found, continue with Step 15. B. If continuity is found, recheck the motor for continuity at Step 10. 15. Disconnect connector X032. Use a multimeter to check for continuity between connector X032 pin 20 and chassis ground. A. If continuity is found, the open circuit is in the harness between connector X308 pin A and X032 pin 20. Locate the open and repair. B. If no continuity is found, continue with Step 16. 16. Disconnect connector X007. Use a multimeter to check for continuity between connector X007 pin 3 and chassis ground. A. If continuity is found, the open circuit is between connector X007 pin 3 and connector X017 pin J3-8 wire 712 white. Locate the open and repair. B. If no continuity is found, the open circuit is in the harness between connector X032 pin 20 and connector X007 pin 3 wire 712 white. Locate the open and repair. 17. If the header reel speed motor does not operate in either direction, and there are no error codes indicated, the supply power for the circuit may not be present. Remove fuse F23 and inspect. A. Fuse has failed. Go to Step 18. B. Fuse is okay. Go to Step 19.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 18. If fuse has failed, replace the fuse. A. If fuse immediately fails, a short to ground exists on one of the two following wires: wire 025 red, from the fuse panel through connector X005 pin 1 to connector X016 pin J2-11 on CCM2 module. wire 028 red, from the fuse panel through connector X031 pin 4 to connector X017 pin J3-7 on CCM2 module. Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. B. Fuse is okay. Go to Step 19. 19. Test for 12V power at connector X017 pin J3-7 on the CCM2 module under the cab. A. If there is no power, there is an open circuit on wire 028 red, from the fuse panel through connector X031 pin 4 to connector X017 pin J3-7 on CCM2 module. Locate the open and repair. After repair, go to Step 20. B. If there is power, go to Step 20. 20. Test for continuity to ground at connector X017 pin J3-16 on the CCM2 module under the cab. A. If there is no continuity to ground, there is an open circuit on wire 515 black, from connector X017 pin J3-16 on CCM2 module to the front frame ground #2. Locate the open and repair. After repair, go to Step 21. B. If there is power, go to Step 21. 21. Once it has been verified that power is being supplied to the module, recheck the circuit operation as described in Step 1. If the fuse fails during the testing, a short to ground on the circuit is causing the fuse to fail. Start the troubleshooting at Step 3 to locate the short to ground.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

2 10020040

50026205

40024707

25 1. 2. 3. 4.

Reel Speed Motor M09 (On Header) Connector X032 Connector X007 Connector X017

55-166

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-22 = REAR LADDER F-23 = SCREEN BRUSH FUSE F-28 = FUEL PUMP FUSE K-07 = FUEL PUMP RELAY

M-23 = FUEL PUMP M-27 = ROTARY SCREEN BRUSH R-01 = FUEL LEVEL S-36 = ENGINE THROTTLE

S-61 = AIR FILTER SWITCH S-67 = COOLANT LEVEL

STARTING FRAME-- 3

55-167

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

HEADER FRAME-- 12

K-42 = RH VERTICAL KNIFE RELAY (OP) K-43 = LH VERTICAL KNIFE RELAY (OP) L-13 = REEL DOWN L-14 = REEL UP

L-15 = REEL AFT L-16 = REEL FORE L-17 = REEL DRIVE M-09 = REEL SPEED MOTOR

55-168

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0171-06 Curr Sense Transm Shift Short Circuit Cause: The Transmission shift motor (M-02) circuit indicates high current draw. Possible failure modes: 1. Mechanical Defect -- binding or jammed shift mechanism 2. Motor Defect -- motor does not generate sufficient torque to turn shift mechanism 3. Electrical Defect -- fuse, wiring, or connector has an open or short circuit 4. Controller Defect -- CCM-2 does not generate proper voltage or currents

CAUTION Perform this service with the combine on a flat surface where the combine cannot roll. If service must be performed on a slope, block the wheels to prevent motion. Serious injury could occur if combine were to move unexpectedly. Solution: 1. Use the display monitor, reference section 55 chapter 2, if needed, to record then erase the error history. Start the combine and shift the transmission in both directions, observe the gear indicator in the Display DOG area, note success or failure for each shift, note any alarms or errors that appear on the display. Turn the combine engine off. With the key on, and engine not running, use the Display Monitor diagnostic capability to view “Item” status, reference Section 55 Chapter 2, if needed, to observe gear readout and to operate transmission shift motor in each direction; clockwise to shift down, counterclockwise to shift up. NOTE: Do not drive motor at high current (>26 amps) for more than one second -- this will happen when driving into stops at 1 & 4 gear. A. If Fault Code E0171-06 is in error history and zero current is shown on display, check and replace, if necessary, fuse F-25. Repeat this step after replacing fuse. B. If Fault Code E0171-06 is active, continue with step 2. NOTE: Do not attempt to manually shift the transmission with a wrench while the transmission shift motor connected. Because of internal gearing, the transmission shift motor cannot be manually turned. Attempting to do so will destroy the transmission shift motor. 2. The transmission shift mechanism may be mechanically bound, resulting in high current draw, refer to the appropriate chapter in this Repair Manual. Without disconnecting the motor connector, remove the transmission shift motor. Tie the motor in place so the harness will not be damaged. Use the display monitor, reference section 55 chapter 2, if needed, to recheck the transmission shift motor function. The transmission shift motor should turn each direction (visual check) with less than 5 amps. A. If the motor functions properly, the problem is with the transmission, refer to the appropriate chapter in this Repair Manual to troubleshoot and correct. B. If the motor does not function, continue with step 3

55-169

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 3. The transmission shift motor may be mechanically bound or electrically shorted to ground, resulting in high current draw. Disconnect the transmission shift motor connector X094. Use the display monitor, reference section 55 chapter 2, if needed, to recheck the motor function. With the transmission shift motor disconnected, the current should be zero. A. If the current is zero in both directions, replace the motor. Recheck the system. B. If current is not zero in both directions, continue with step 4. 4. The harness may be shorted to ground. With ignition key OFF and batteries disconnected, by removing the negative battery cables, use a multi-meter to check for continuity between the lower frame (LF) harness end of connector X094 pin B and chassis ground. There should not be any continuity to ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to lock the motor in position. Power must be removed from the module prior to testing for short to ground condition on the motor circuit to remove this ground path. A. If continuity is found, continue with Step 5. B. If no continuity is found, continue with Step 6. 5. There is a short in either the lower frame (LF) or front frame (FF) harness. Disconnect connector X023 and use a multi-meter to check for continuity between the lower frame (LF) harness side of connector X094 pin B and chassis ground. There should not be any continuity to ground. A. If continuity is found, there is a short to ground in the lower frame (LF) harness in wire 715 grey between connector X023 pin 3 and connector X094 pin B. Locate the short and repair. Re-assemble the system and recheck. B. If no continuity is found, there is a short to ground in the front frame (FF) harness in either; wire 715 grey between connector X023 pin 3 and the front frame (FF) harness splice or wire 526 grey between the harness splice and connector X017 pin J3-19 or wire 527 grey between the harness splice and connector X017 pin J3-20. Locate the short and repair. Re-assemble the system and recheck. 6. Use a multi-meter to check for continuity between the harness end of connector X094 pin A and chassis ground. There should not be any continuity to ground. A. If continuity is found, continue with Step 7. B. If no continuity is found, continue with Step 8. 7. There is a short in either the lower frame (LF) or front frame (FF) harness. Disconnect connector X023. Use a multi-meter to check for continuity between the lower frame (LF) harness side of connector X094 pin A and chassis ground. There should not be any continuity to ground. A. If continuity is found, there is a short to ground in the lower frame (LF) harness in wire 716 white between connector X023 pin 4 and connector X094 pin A. Locate the short and repair. Re-assemble the system and recheck. B. If no continuity is found, there is a short to ground in the front frame (FF) harness in either; wire 716 white between connector X023 pin 4 and the front frame (FF) harness splice or wire 528 white between the harness splice and connector X017 pin J3-39 or wire 529 white between the harness splice and connector X017 pin J3-40. Locate the short and repair. Re-assemble the system and recheck. 8. CCM-2 may be shorted internally. Disconnect connector X017 and extract pins J3-19, J3-20, J3-39, and J3-40 from the front frame (FF) harness side of the connector (if the wire numbers are not visible, mark the wires to ensure proper reassembly). Reconnect connector X017 and reconnect the batteries. Use the display monitor, reference section 55 chapter 2, if needed, to recheck the motor function. With the transmission shift motor disconnected, the current should be zero. A. If the current is not zero, replace CCM-2. B. If the current is zero, re-assemble the system and re-check for functionality. Check harness for locations that could have an intermittent short due to chaffing or pinching.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

1 10004664

10010898

50020096

26 1. 2. 3.

Transmission Shift Motor -- M02 Connector X023 Connector X017

55-171

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

55-172

S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME-- 9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0172-06 Curr Sense Rot Scr Brush Short Circuit Cause: The Rotary Screen Brush motor (M-27) circuit indicates high current draw. Possible failure modes: 1. Circuit wiring short to ground. 2. Excessive mechanical load on motor. 3. Controller internal failure (internal regulator failure). Solution: 1. Use the display monitor, reference section 55 chapter 2, if needed. A. Manually operate the motor in both directions. B. Record in which direction the circuit operates. C. Check for fault codes 0172-06 and 0206-05. D. Use the following table to determine the location of the fault. Errors

Symptom

0172-06 Rotary screen brush motor operates in 1 direction only

0206-05 Go to Step 2

Motor bound up

Go to Step 3

Short to ground

Go to Step 8

Open

Go to Step 13

Fuse 23 blown or open

Rotary screen brush motor does not operate in either direction

2. The rotary screen brush mechanism is mechanically bound up, resulting in high current draw. See the appropriate repair manual chapter for repair and adjustment of the rotary screen brush linkage. 3. Fault code indicates circuit has shorted to ground. Disconnect rotary screen brush motor connector X206. Measure between terminals A or B on the motor connector and a known good ground. There should be no continuity to ground. A. There is continuity to ground, indicating a short to ground in the motor. Replace the rotary screen brush motor. B. There is no continuity to ground. Continue with Step 4. 4. Disconnect the batteries using the battery key. Unplug the rotary screen brush motor connector X206. Use the multimeter to check for continuity between connector X206 pin B and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position. Power must be removed from the module prior to testing for short to ground condition on the motor circuit to remove this ground path. A. If continuity is found, continue with Step 5. B. If no continuity is found, continue with Step 6.

55-173

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 5. Disconnect inline connector X010. Use a multimeter to check for continuity between connector X010 pin 1 on the main frame (MF) side and chassis ground. A. If continuity is found, the short to ground is in the main frame (MF) harness between connector X010 pin 1 and connector X016 pin J2-1 wire 524 gray. Locate the short and repair. B. If no continuity is found, the short to ground is in the engine (EN) harness between connector X010 pin 1 and connector X206 pin B on wire 524 gray. Locate the short to ground and repair. 6. Use a multimeter to check for continuity between connector X206 pin A and chassis ground. A. If continuity is found, continue with Step 7. B. If no continuity is found, erase the fault codes and continue operation. 7. Disconnect connector X010. Use a multimeter to check for continuity between connector X010 pin 2 on the main frame (MF) side and chassis ground. A. If no continuity is found, the short to ground is in the harness between connector X206 pin A and connector X010 pin 2 wire 821 white. Locate the short and repair. B. If continuity is found, the short to ground is in the main frame (MF) harness between connector X016 CCM-2 J2-21 and connector X010 pin 2 wire 821 white. Locate the short and repair. 8. Fault codes indicate circuit fault due to open circuit condition. Disconnect the rotary screen brush motor connector X206. Measure the resistance of the motor between terminals A and B. The correct resistance is xx to xx ohms. A. The resistance is infinite, indicating an open condition in the motor. Replace the rotary screen brush motor. B. The resistance is in specification. Continue with Step 9. 9. Ensure that the batteries are connected using the battery key, and that fuse F23 is good. Use the multimeter to check for continuity between connector X206 pin B and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F23. This ground path may be used to test for an open circuit condition. A. If continuity is found, continue with Step 11. B. If no continuity is found, continue with Step 10. 10. Disconnect inline connector X010. Use a multimeter to check for continuity between connector X010 pin 1 and chassis ground. A. If continuity is found the open circuit is in the harness between connector X010 pin 1 and connector X206 pin B. Locate the open and repair. B. If no continuity is found, the open circuit is in the harness between connector X010 pin 1 and connector X016 pin J2-1 on wire 524 gray. Locate the open and repair. 11. Use a multimeter to check for continuity between connector X206 pin A and chassis ground. A. If no continuity is found, continue with Step 12. B. If continuity is found, recheck the motor for continuity at Step 8. Erase the fault codes and continue operation. 12. Disconnect connector X010. Use a multimeter to check for continuity between connector X010 pin 2 and chassis ground. A. If continuity is found, the open circuit is in the harness between connector X206 pin A and connector X010 pin 2 wire 821 white. Locate the open and repair. B. If no continuity is found, the open circuit is in the main frame (MF) harness between connector X010 pin 2 and connector X016 CCM-2 J2-21 wire 821 white. Locate the open and repair.

55-174

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 13. If the rotary brush screen motor does not operate in either direction, and there are no error codes indicated, the supply power for the circuit may not be present. Remove fuse F23 and inspect. A. Fuse has failed. Go to Step 14. B. Fuse is okay. Go to Step 15. 14. If fuse has failed, replace the fuse. A. If fuse immediately fails, a short to ground exists on one of the two following wires: wire 025 red, from the fuse panel through connector X005 pin 1 to connector X016 pin J2-11 on CCM2 module wire 028 red, from the fuse panel through connector X031 pin 4 to connector X017 pin J3-7 on CCM2 module Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. B. Fuse is okay. Go to Step 15. 15. Test for 12V power at connector X016 pin J2-11 on the CCM2 module under the cab. A. If there is no power, there is an open circuit on wire 025 red, from the fuse panel through connector X005 pin 1 to connector X016 pin J2-11 on CCM2 module. Locate the open and repair. After repair, go to Step 16. B. If there is power, go to Step 16. 16. Test for continuity to ground at connector X016 pin J2-3 on the CCM2 module under the cab. A. If there is no continuity to ground, there is an open circuit on wire 514 or 584 black, from connector X016 pin J2-3 on CCM2 module to the front frame ground #2. Locate the open and repair. After repair, go to Step 17. B. If there is continuity to ground, go to Step 17. 17. Once it has been verified that power is being supplied to the module, recheck the circuit operation as described in Step 1. If the fuse fails during the testing, a short to ground on the circuit being operated at the time of failure is causing the fuse to fail. Start the troubleshooting at Step 3 to locate the short to ground.

55-175

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

10004648

10010899

10020076

50026210

27 1. 2. 3. 4.

Rotary Screen Brush Motor M27 Connector X010 Connector X004 Connector X016

55-176

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-22 = REAR LADDER F-23 = SCREEN BRUSH FUSE F-28 = FUEL PUMP FUSE K-07 = FUEL PUMP RELAY

M-23 = FUEL PUMP M-27 = ROTARY SCREEN BRUSH R-01 = FUEL LEVEL S-36 = ENGINE THROTTLE

S-61 = AIR FILTER SWITCH S-67 = COOLANT LEVEL

STARTING FRAME-- 3

55-177

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

HEADER FRAME-- 12

K-42 = RH VERTICAL KNIFE RELAY (OP) K-43 = LH VERTICAL KNIFE RELAY (OP) L-13 = REEL DOWN L-14 = REEL UP

L-15 = REEL AFT L-16 = REEL FORE L-17 = REEL DRIVE M-09 = REEL SPEED MOTOR

55-178

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0174-03 CCM2 Battery Voltage Shorted to High Source Cause: The CCM2 Battery Voltage circuit is shorted to a higher than normal source. Possible failure modes: 1. Circuit wiring is shorted to a high voltage source. 2. Faulty alternator/regulator. 3. Controller internal failure (internal regulator failure). Solution: Battery voltage is used as “keep alive memory” power in the module to retain settings and configuration information. The module will not initialize (wake-up at “key on”) if battery voltage drops below 9V, but there is no shutdown for excessive voltage. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage is 10.0 to 18.0 volts. A. If the voltage reading is greater than 18 volts, continue with Step 2. B. If the voltage reading is between 10 and 18 volts, go to Step 5. 2. Shut off the combine engine, and then turn the key switch on again. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, the alternator and/or regulator has failed, and is producing excessive voltage. Refer to “Charging Systems” in Chapter 5 -- Engine Systems in this Section for additional alternator testing information. B. If the voltage reading is greater than 18 volts, continue with Step 3. 3. Turn the key switch off to power down the system. Check the voltage at fuse F39 using a multi-meter. A. If the voltage reading is greater than 18 volts, then the batteries have been mistakenly connected in series, or there is a fault in the wiring of the 24V starting system. Refer to “Starting Systems” in Chapter 5 -- Engine Systems in this Section for additional information. B. If the voltage reading is between 10 and 18 volts, continue with Step 4.

55-179

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 4. Remove the buddy seat and storage bin to gain access to connector X015 on CCM2. Check the voltage at connector X015 pin J1-1. A. If the voltage reading is greater than 18 volts, then a high voltage source has been connected to one of the following wires in the cab main harness: wire 047 red, fuse F39 to harness splice wire 052 red, harness splice to CCM1 connector X018 pin J1-1 wire 049 red, harness splice to CCM3 connector X012 pin J1-1 wire 050 red, harness splice to CCM2 connector X015 pin J1-1 wire 051 or 307 red, harness splice through connector X001 pin 2 to RHM connector X026 pin 13 wire 1276 red, harness splice to display monitor through connector X506 pin G to connector X502 pin 13 wire 142 red, harness splice to DAM connector X065 pin B Locate the high voltage source and correct. B. If the voltage reading is 10 to 18 volts, and the diagnostic screen is still indicating voltage in excess of 18 volts, there is an internal fault in CCM2. Reload the software for CCM2. If that does not correct the concern, replace the module. 5. The short to high voltage is not present at this time. Erase the error code and continue operation.

55-180

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0174-04 CCM2 Battery Voltage Shorted to Low Source Cause: The CCM2 Battery Voltage circuit is shorted to a lower than normal source. Possible failure modes: 1. Loose or corroded connections, or damaged wires. 2. Batteries are discharged, and/or alternator/regulator failure. NOTE: Check fuse F39. If a short to ground occurred on this circuit the fuse will have blown. 3. Controller internal failure (internal regulator failure). Solution: Battery voltage is used as “keep alive memory” power in the module to retain settings and configuration information. The module will not initialize (wake-up at “key on”) if battery voltage drops below 9V, but there is no shutdown for excessive voltage. This fault code would typically be seen when battery voltage drops below 10V (threshold for the fault) but is above 9V (shutdown threshold). 1. Key switch in “Off” position. Check fuse F39. A. If fuse F39 is okay, continue with Step 6. B. If the fuse is blown, go to Step 2. 2. Replace the failed fuse F39. A. If the fuse is okay, continue with Step 3. B. If the fuse immediately fails again, a short to ground exists in one of the following wires: wire 047 red, fuse F39 to splice in the cab main (CM) harness wire 052 red, harness splice to CCM1 connector X018, pin J1-1 wire 050 red, harness splice to CCM2 connector X015, pin J1-1 wire 049 red, harness splice to CCM3 connector X012, pin J1-1 wire 051 or 307 red, harness splice through connector X001 pin 2 to RHM connector X026 pin 13 wire 1276 red, harness splice to display monitor through connector X506 pin G to connector X502 pin 13 wire 142 red, harness splice to DAM connector X065, pin B Visually inspect the cab main and cab roof harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair. 3. Key switch in “Off” position. Check the voltage at fuse F39 using a multi-meter. A. If the voltage reading is between 10 and 18 volts, continue with Step 4. B. If the voltage reading is less than 10 volts, there is excessive resistance between the batteries and the cab fuse panel, due to loose or corroded connections, or the batteries have discharged excessively, and are not capable of supplying the minimum voltage requirement for CCM2. Inspect the wiring from the batteries to the engine compartment, and from there to the cab. Recharge or replace the batteries.

55-181

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 4. Key switch in “On” position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, continue with Step 5. B. If the voltage reading is less than 10 volts, there is excessive resistance between the fuse panel and CCM2. Inspect wires 047 & 050 red to CCM2 connector X015 pin J1-1 for loose or corroded connections, or damage to the wires. 5. Start the combine engine. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, with the engine RPM at low idle, engage road and work lights. Check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, continue with Step 6. B. If the voltage reading is less than 10 volts, the alternator and/or regulator may have failed, and the charging system is not producing sufficient voltage. Refer to “Charging Systems” in Chapter 5 -- Engine Systems in this Section for additional alternator testing information. 6. Erase the error code and continue operation.

55-182

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

10004693

50020070

50026204

28 1. 2.

Fuse F39 Connector X015

55-183

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME-- 29

55-184

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

DISTRIBUTION/ AUTO GUIDANCE FRAME-- 32

A-02 = DISPLAY MODULE A-11 = DGPS MODULE A-24 = NAVIGATION MODULE L-57 = STEER LEFT SOLENOID

L-58 = STEER RIGHT SOLENOID L-59 = STEER ENABLE SOLENOID S-78 = AUTOGUIDANCE SWITCH S-79 = ROTARY ENCODER SWITCH

55-185

S-80 = DISPLAY HOME SWITCH S-81 = DISPLAY ESCAPE SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0175-03 V Supply Thresher Clutch Shorted to High Source Cause: The V Supply Thresher Clutch (S-30) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. V Supply Thresher Clutch wiring shorted to a high source. 2. Faulty alternator/regulator. 3. Controller internal failure (internal regulator failure). Solution: 1. Start the combine engine. Engage the thresher engage switch. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage is 10.0 to 18.0 volts (Thresher switch engaged). A. If the voltage reading is greater than 18 volts, continue with Step 2. B. If the voltage reading is between 10 and 18 volts, go to Step 5. 2. Shut off the combine engine, and then turn the key switch on again. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, the alternator and/or regulator has failed, and is producing excessive voltage. Refer to “Charging Systems” in Chapter 5 -- Engine Systems in this Section for additional alternator testing information. B. If the voltage reading is greater than 18 volts, continue with Step 3. 3. Key switch in the “Off” position. Check the voltage at fuse F42 using a multi-meter. A. If the voltage reading is greater than 18 volts, then the batteries have been mistakenly connected in series, or there is a fault in the wiring of the 24V starting system. Refer to “Starting Systems” in Chapter 5 -- Engine Systems in this Section for additional information. B. If the voltage reading is between 10 and 18 volts, continue with Step 4. 4. Key switch in the “On” position. Engage the thresher engage switch S30. Remove the buddy seat and storage bin to gain access to connector X015 on CCM2. Check the voltage at connector X015 pin J1-7. A. If the voltage reading is greater than 18 volts, then a high voltage source has been connected to one of the following wires: wire 109 orange, fuse F48 to thresher latching relay K28, terminal 3 wire 108 orange, fuse F48 through connector X001, pin 3 to harness splice wire 300 orange, harness splice to neutral switch S22 connector X059 pin 1 wire 110 orange, harness splice to thresher engage switch connector X055 pin 3 wire 147, 111 or 1061 yellow, thresher engage switch connector X055 pin 5 to CCM2 connector X015 pin J1-7 or CCM-3 connector X012 pin J1-7 switch power wires from splice block B, W02 in the RH console B. If the voltage reading is 10 to 18 volts, and the diagnostic screen is still indicating voltage in excess of 18 volts, there is an internal fault in CCM2. Reload the software for CCM2. If that does not correct the concern, replace the module. 5. Erase the error code and continue operation.

55-186

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0175-04 V Supply Thresher Clutch Shorted to Low Source Cause: Low battery voltage to CCM2 through the thresher engage switch S30, or the circuit is shorted to ground. Possible failure modes: 1. Loose or corroded connections, or damaged wires. 2. Batteries are discharged, and/or alternator/regulator failure. 3. Thresher engage switch supply wiring shorted to ground. 4. Controller internal failure (internal regulator failure). Solution: 1. Key switch in “Off” position. Check fuse F42. A. If fuse F42 is okay, continue with Step 3. B. If the fuse is blown, go to Step 2. 2. Replace the failed fuse F42. A. If the fuse is okay, continue with Step 3. B. If the fuse immediately fails again, a short to ground exists in wire 010 red to Cab Power Relay K26 pin 3. Locate short and repair. 3. Key switch in “On” position. Check fuse F42. A. If the fuse is okay, continue with Step 4. B. If the fuse immediately fails, a short to ground exists in wire 007 orange from the Cab Power relay K26 to fuse panel buss strip. Locate short and repair. 4. Key switch in “On” position. Check fuse F48. A. If fuse F48 is okay, continue with Step 6. B. If the fuse is blown, go to Step 5. 5. Replace the failed fuse F48. A. If the fuse is okay, continue with Step 6. B. If the fuse immediately fails again, a short to ground exists in one of the following wires: wire 109 orange, fuse F48 to thresher latching relay K28, terminal 3 wire 108 orange, fuse F48 through connector X001, pin 3 to harness splice wire 300 orange, harness splice to neutral switch S22 connector X059 pin 1 wire 110 orange, harness splice to thresher engage switch S30 connector X055 pin 3 switch power wires from splice block B, W02 in the RH console

55-187

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 6. Engage the thresher engage switch S30, and observe the fuse F48. A. If the fuse is okay, continue with Step 7. B. If the fuse immediately fails, a short to ground exists in one of the following wires: wire 118, 857 or 858 yellow, thresher engage switch S30, pins 2 & 6 to thresher latching relay K28, terminal 5 wire 115 yellow, thresher latching relay K28, terminal 5 to terminal 1 wire 302 or 861 yellow, thresher engage switch S30, pin 5 to feeder engage switch S31, pin 6 wires 147, 111, and 1061 yellow, thresher engage switch S30, pin 5 to CCM2 connector X015, J1-7 and CCM3 connector X012, J1-7 Locate short and repair. 7. Engage the feeder engage switch S31, and observe fuse F48. A. If the fuse is okay, continue with Step 8. B. If the fuse immediately fails, a short to ground exists in wire 112 yellow from feeder engage switch S31, pin 5 to CCM1 connector X018, J1-7. Locate short and repair. 8. Key switch in “Off” position. Check the voltage at fuse F42 using a multi-meter. A. If the voltage reading is between 10 and 18 volts, continue with Step 9. B. If the voltage reading is less than 10 volts, there is excessive resistance between the batteries and the cab fuse panel, due to loose or corroded connections, or the batteries have discharged excessively, and are not capable of supplying the minimum voltage requirement for CCM2. Inspect the wiring from the batteries to the engine compartment, and from there to the cab. Recharge or replace the batteries. 9. Key switch in “On” position. Engage thresher engage switch S30. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The acceptable voltage range is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, continue with Step 10. B. If the voltage reading is less than 10 volts, there is excessive resistance between the fuse panel and CCM2. Inspect the following wires for loose or corroded connections, or damage to the wires. wire 010 red, fuse F42 to Cab Power relay K26, terminal 3 wire 007 orange, Cab Power relay K26, terminal 5 to fuse panel buss strip wire 108 orange, fuse F48 through connector X001, pin 3, to right console (RC) harness splice wire 110 orange, RC harness splice to thresher engage switch S30, pin 3 wire 118, 857 or 858 yellow, thresher engage switch S30, pins 2 & 6 to thresher latching relay K28, terminal 5 wire 115 yellow, thresher latching relay K28, terminal 5 to terminal 1 wire 147, 302, 111 or 1061 yellow, thresher engage switch S30, pin 5 to CCM2 connector X015 pin J1-7 and CCM-3 connector X012 pin J1-7 10. Start the combine engine. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, with the engine RPM at low idle, engage road and work lights. Check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, continue with Step 11. B. If the voltage reading is less than 10 volts, the alternator and/or regulator may have failed, and the charging system is not producing sufficient voltage. Refer to “Charging Systems” in Chapter 5 -- Engine Systems in this Section for additional alternator testing information. 11. Erase the error code and continue operation.

55-188

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 3

4 10010921 10010919

1 2

10004693

50020070

50026204

29 1. 2. 3. 4. 5.

Fuse F48 Thresher Latching Relay K28 Connector X001 Thresher Engage Switch S30 Connector X015

55-189

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FEEDER FRAME-- 16

B-09 = REVERSER DISENGAGE B-14 = FEEDER RPM B-24 = STONE DOOR CLOSED F-24 = FAN, REVERSER FUSE

K-17 = FAN/REVERSER RELAY K-19 = NOT USED L-20 = FEEDER JOG FORWARD L-21 = FEEDER JOG REVERSE

55-190

L-24 = FEEDER CLUTCH M-05 = CLEANING FAN ADJUST MOTOR (EU) M-10 = FEEDER REVERSER ACTUATOR S-31 = FEEDER ENGAGE

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

THRESHER FRAME-- 18

B-01 = ROTOR RPM K-28 = THRESHER LATCHING L-22 = GEARBOX CLUTCH L-29 = ROTOR INCREASE

L-30 = ROTOR DECREASE S-30 = THRESHER ENGAGE

55-191

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-48 = RH CONSOLE FUSE H-01 = AUDIO ALARM W-01 = SPLICE BLOCK A W-02 = SPLICE BLOCK B

W-05 = SPLICE BLOCK E W-06 = SPLICE BLOCK F

DISTRIBUTION FRAME-- 25

55-192

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

DISTRIBUTION FRAME-- 28

F-36 = CCM-2A FUSE F-37 = CCM-2B FUSE F-40 = CCM-1 POWER FUSE F-41 = CCM-2 POWER FUSE

F-42 = CCM-3, CAB POWER FUSE K-24 = CCM-1 POWER RELAY K-25 = CCM-2 POWER RELAY K-26 = CCM-3, CAB POWER RELAY

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FAULT CODE – E0177-03 Isense Unload Cross Auger Shorted to High Source Cause: The Unload cross auger solenoid (L-08) circuit has excessive current draw, or is shorted to a high voltage source. Possible failure modes: 1. Bad solenoid. 2. Return side wiring shorted to 12 volts. 3. Controller internal failure (internal regulator failure). Solution: 1. The Isense Unload Cross Auger circuit is the ground path for the cross auger PWM solenoid. By monitoring current flow on the return path of the cross auger solenoid, the module can provide precise control of the solenoid engagement. When this error message is reported, this is an indication of excessive current draw on the circuit, or a result of a high voltage short on the return line. 2. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, increase the output to 100%. Check the current. The proper unload cross auger solenoid current should be approximately 1.0 to 1.5 amps. The fault code is triggered by current flow greater than 3.3 amps. NOTE: If the current reading is high, immediately shut off the circuit to prevent module damage. A. If the reading is greater than 3.3 amps, continue with Step 3. B. If the reading is normal (1.0 to 1.5 amps), continue the troubleshooting at Step 8. C. If there is no current reading, the module may have failed as a result of a 12V short on the Isense circuit. Continue with Step 6. 3. The current reading on the display monitor is high. Turn the key switch to the OFF position and disconnect the unload cross auger solenoid connector X035. Use a multimeter to check the resistance of the unload cross auger solenoid L08 between connector X035 pins 5 & 6. The proper resistance range for the unload clutch solenoid is 7.2 to 11.2 ohms. A. If out of specification, replace the solenoid. Continue with Step 8. B. If the coil is within specification, continue with Step 4. 4. Disconnect inline connector X011. Use a multimeter to check the resistance of the unload cross auger solenoid circuit between connector X011 pins S & T on the gearbox (GB) harness side. The resistance should be the same as, or slightly higher than the resistance of the solenoid as measured in Step 3. A. If the resistance is lower than the previously measured resistance, there is a short in the harness between connector X035 and connector X011 wires 568 white and 601 blue. Locate the short and repair. Continue with Step 8. B. If the resistance is the same as previously measured, continue with Step 5.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 5. Disconnect connector X016 on the bottom of CCM2 module. Use a multimeter to check the resistance of the unload cross auger solenoid circuit between connector X016 pins J2-4 & J2-20 on the main frame (MF) side. A. If the resistance is lower than the previously measured resistance, there is a short in the harness between connector X011 and connector X016 wires 568 white and 601 blue. Locate the short and repair. Continue with Step 8. B. If the resistance is the same as previously measured, continue with Step 6. 6. Key on. Disconnect connector X035. Use a multimeter to check for voltage at connector X035 pin 6 on the gearbox (GB) harness side. There should be no voltage on this wire. NOTE: The high voltage source may not be present as it may not be currently powered up. If the fault code typically appears when operating another circuit, activate that circuit while performing this check. A. There is no voltage present on the wire. Continue with Step 8. B. There is voltage present on the wire. Continue with Step 7. 7. Key on. Disconnect connector X011. Use a multimeter to check for voltage at connector X011 pin T on the main frame (MF) harness side. There should be no voltage on this wire. NOTE: The high voltage source may not be present as it may not be currently powered up. If the fault code typically appears when operating another circuit, activate that circuit while performing this check. A. There is no voltage on the wire. The short to voltage is between connector X035 and connector X011 wire 601 black. Locate the short and repair. Continue with Step 8. B. There is voltage on the wire. The short to voltage is between connector X011 and connector X016 wire 601 black. Locate the short and repair. Continue with Step 8. 8. The sense resistor in the module for the Isense Unload Auger Clutch circuit is easily damaged as a result of excessive current draw or a short to high voltage. After locating the source of the problem and correcting, the module must be checked for damage. Disconnect connector X011. Use a multimeter to check resistance between connector X011 pin T and chassis ground. There should be less than 1 ohm resistance. A. There is infinite resistance. The sense resistor in the CCM2 module has failed. Replace the module. B. The resistance is correct. The sense resistor in the CCM2 module is okay, and the circuit should function correctly. Continue with Step 9. 9. Erase fault code and continue operation. If the fault immediately reoccurs, replace CCM2 with a known good controller.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Unload Tube Clutch Solenoid L08 Connector X035 Connector X011 Connector X016

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

UNLOAD FRAME-- 22

B-38 = UNLOAD CRADLE B-47 = COVERS CLOSED L-03 = UNLOAD TUBE IN L-04 = UNLOAD TUBE OUT

L-08 = UNLOAD TUBE CLUTCH S-28 = GRAIN BIN 3/4 FULL S-29 = GRAIN BIN FULL S-42 = TANK COVERS SWITCH

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FAULT CODE – E0178-03 Isense Thresher Clutch Shorted to High Source Cause: The Thresher clutch solenoid (L-22) circuit has excessive current draw, or is shorted to a high voltage source. Possible failure modes: 1. Bad solenoid. 2. Return side wiring shorted to 12 volts. 3. Controller internal failure (internal regulator failure). Solution: 1. The Isense Thresher Clutch circuit is the ground path for the thresher clutch PWM solenoid. By monitoring current flow on the return path of the thresher clutch solenoid, the module can provide precise control of the solenoid engagement. When this error message is reported, this is an indication of excessive current draw on the circuit, or a result of a high voltage short on the return line. 2. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, increase the output to 100%. Check the current. The proper thresher clutch solenoid current should be approximately 1.0 to 1.5 amps. The fault code is triggered by current flow greater than 3.3 amps. NOTE: If the current reading is high, immediately shut off the circuit to prevent module damage. A. If the reading is greater than 3.3 amps, continue with Step 3. B. If the reading is normal (1.0 to 1.5 amps), continue the troubleshooting at Step 8. C. If there is no current reading, the module may have failed as a result of a 12V short on the Isense circuit. Continue with Step 6. 3. The current reading on the display monitor is high. Turn the key switch to the OFF position and disconnect the thresher clutch solenoid connector X035. Use a multimeter to check the resistance of the thresher clutch solenoid L22 between connector X035 pins 7 & 8. The proper resistance range for the thresher clutch solenoid is 7.2 to 11.2 ohms. A. If out of specification, replace the solenoid. Continue with Step 8. B. If the coil is within specification, continue with Step 4. 4. Disconnect inline connector X011. Use a multimeter to check the resistance of the unload cross auger solenoid circuit between connector X011 pins N & O on the gearbox (GB) harness side. The resistance should be the same as, or slightly higher than the resistance of the solenoid as measured in Step 3. A. If the resistance is lower than the previously measured resistance, there is a short in the harness between connector X035 and connector X011 wires 878 white and 877 blue. Locate the short and repair. Continue with Step 8. B. If the resistance is the same as previously measured, continue with Step 5.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 5. Disconnect connector X016 on the bottom of CCM2 module. Use a multimeter to check the resistance of the thresher clutch solenoid circuit between connector X016 pins J2-30 & J2-40 on the main frame (MF) harness side. A. If the resistance is lower than the previously measured resistance, there is a short in the harness between connector X011 and connector X016 wires 878 white and 877 blue. Locate the short and repair. Continue with Step 8. B. If the resistance is the same as previously measured, continue with Step 6. 6. Key on. Disconnect connector X035. Use a multimeter to check for voltage at connector X035 pin 8 on the gearbox (GB) harness side. There should be no voltage on this wire. NOTE: The high voltage source may not be present as it may not be currently powered up. If the fault code typically appears when operating another circuit, activate that circuit while performing this check. A. There is no voltage present on the wire. Continue with Step 8. B. There is voltage present on the wire. Continue with Step 7. 7. Key on. Disconnect connector X011. Use a multimeter to check for voltage at connector X011 pin N on the main frame (MF) harness side. There should be no voltage on this wire. NOTE: The high voltage source may not be present as it may not be currently powered up. If the fault code typically appears when operating another circuit, activate that circuit while performing this check. A. There is no voltage on the wire. The short to voltage is between connector X035 and connector X011 wire 877 black. Locate the short and repair. Continue with Step 8. B. There is voltage on the wire. The short to voltage is between connector X011 and connector X016 wire 877 black. Locate the short and repair. Continue with Step 8. 8. The sense resistor in the module for the Isense Thresher Clutch circuit is easily damaged as a result of excessive current draw or a short to high voltage. After locating the source of the problem and correcting, the module must be checked for damage. Disconnect connector X011. Use a multimeter to check resistance between connector X011 pin N and chassis ground. There should be less than 1 ohm resistance. A. There is infinite resistance. The sense resistor in the CCM2 module has failed. Replace the module. B. The resistance is correct. The sense resistor in the CCM2 module is okay, and the circuit should function correctly. Continue with Step 9. 9. Erase fault code and continue operation. If the fault immediately reoccurs, replace CCM2 with a known good controller.

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2 10004669

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Thresher Clutch Solenoid L22 Connector X035 Connector X011 Connector X016

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

THRESHER FRAME-- 18

B-01 = ROTOR RPM K-28 = THRESHER LATCHING L-22 = GEARBOX CLUTCH L-29 = ROTOR INCREASE

L-30 = ROTOR DECREASE S-30 = THRESHER ENGAGE

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0179-03 LoP Isense Grnd Spd Hydro Shorted to High Source Context: The LoP Isense Grnd Spd Hydro circuit is the ground path for the Ground Speed Hydrostat solenoid circuit. By monitoring the current flow on the return path of the ground speed hydrostat solenoid, the module can provide precise control of the solenoid engagement, and monitor the circuit for faults. When this error message is reported, this is an indication that the ground speed hydrostat circuit is shorted to battery voltage. The short may be on the output or return side of the circuit. Cause: CCM2 has detected that the LoP Isense Grnd Spd Hydro circuit is >4.7 volts while the MFH handle is in neutral. Possible failure modes: 1. The LoP Isense Grnd Spd Hydro wiring is shorted to battery voltage. 2. CCM2 internal failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage with the MFH handle in neutral. The normal operating range for the LoP Isense Grnd Spd Hydro circuit is 0 -- 4.4 volts. With the MFH handle in neutral, the voltage indicated should be 0 volts. A. If the voltage reading is >4.7 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue troubleshooting at Step 12. 2. Key switch ON, MFH handle in neutral. Disconnect the ground speed hydrostat connector X100. Use a multimeter to check for voltage between connector X100 pins B and C on the gearbox (GB) harness side and chassis ground. There should not be any voltage. A. If there is voltage, then there is a short to battery voltage on the ground speed hydrostat sense circuit. Continue the troubleshooting at Step 5. B. If there is no voltage, continue the troubleshooting at Step 3. 3. Key switch ON, MFH handle in neutral. Disconnect the ground speed hydrostat connector X100. Use a multimeter to check for voltage between connector X100 pin A on the gearbox (GB) harness side and chassis ground. There should not be any voltage. A. If there is voltage, then there is a short to battery voltage on the ground speed hydrostat reverse circuit. Continue the troubleshooting at Step 8. B. If there is no voltage, continue the troubleshooting at Step 4. 4. Key switch ON, MFH handle in neutral. Disconnect the ground speed hydrostat connector X100. Use a multimeter to check for voltage between connector X100 pin D on the gearbox (GB) harness side and chassis ground. There should not be any voltage. A. If there is voltage, then there is a short to battery voltage on the ground speed hydrostat forward circuit. Continue the troubleshooting at Step 10. B. If there is no voltage, the ground speed hydrostat circuit tests okay. Continue the troubleshooting at Step 12.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 5. Key switch ON, MFH handle in neutral. Disconnect connector X011 between the gearbox (GB) and main frame (MF) harnesses. Use a multimeter to check for voltage between connector X011 pin G on the main frame (MF) harness side and chassis ground. There should not be any voltage. A. If there is no voltage, there is a short to battery voltage in the gearbox (GB) harness between connector X011 and connector X100 wires 886 blue, 887 blue or 881 blue. Locate the short and repair. Continue the troubleshooting at Step 7. B. If there is voltage, continue the troubleshooting at Step 6. 6. Key switch ON, MFH handle in neutral. Disconnect connector X008 between the front frame (FF) and main frame (MF) harnesses. Use a multimeter to check for voltage between connector X008 pin 22 on the front frame (FF) harness side and chassis ground. There should not be any voltage. A. If there is no voltage, there is a short to battery voltage in the mainframe (MF) harness between connector X011 and connector X008 wire 881 blue. Locate the short and repair. Continue the troubleshooting at Step 7. B. If there is voltage, there is a short to battery voltage in the front frame (FF) harness between connector X008 and connector X017 wire 881 blue. Locate the short and repair. Continue the troubleshooting at Step 7. 7. The sense resistor in the CCM2 module for the “LoP Isense Grnd Spd Hydro” ground drive circuit is easily damaged as a result of excessive current draw or a short to high voltage. After locating the source of the problem and correcting, the module must be checked for damage. Carefully disconnect connector X017 from the bottom of CCM2. Use a multimeter to check resistance between connector X017 pin J3-35 on the module and chassis ground. There should be 47 ohms resistance. A. If there is infinite resistance, the sense resistor in the CCM2 module has failed. Replace the module, and continue with Step 12. B. If the resistance is correct, the sense resistor in the CCM2 module is okay, and the circuit should function correctly. Continue with Step 12. 8. Key switch ON, MFH handle in neutral. Disconnect connector X011 between the gearbox (GB) and main frame (MF) harnesses. Use a multimeter to check for voltage between connector X011 pin P on the main frame (MF) harness side and chassis ground. There should not be any voltage. A. If there is no voltage, there is a short to battery voltage in the gearbox (GB) harness between connector X011 and connector X100 wire 879 gray. Locate the short and repair. Continue the troubleshooting at Step 12. B. If there is voltage, continue the troubleshooting at Step 9. 9. Key switch ON, MFH handle in neutral. Disconnect connector X008 between the front frame (FF) and main frame (MF) harnesses. Use a multimeter to check for voltage between connector X008 pin 11 on the front frame (FF) harness side and chassis ground. There should not be any voltage. A. If there is no voltage, there is a short to battery voltage in the mainframe (MF) harness between connector X011 and connector X008 wire 879 gray. Locate the short and repair. Continue the troubleshooting at Step 12. B. If there is voltage, there is a short to battery voltage in the front frame (FF) harness between connector X008 and connector X017 wire 879 gray. Locate the short and repair. Continue the troubleshooting at Step 12.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 10. Key switch ON, MFH handle in neutral. Disconnect connector X011 between the gearbox (GB) and main frame (MF) harnesses. Use a multimeter to check for voltage between connector X011 pin Q on the main frame (MF) harness side and chassis ground. There should not be any voltage. A. If there is no voltage, there is a short to battery voltage in the gearbox (GB) harness between connector X011 and connector X100 wire 880 white. Locate the short and repair. Continue the troubleshooting at Step 12. B. If there is voltage, continue the troubleshooting at Step 11. 11. Key switch ON, MFH handle in neutral. Disconnect connector X008 between the front frame (FF) and main frame (MF) harnesses. Use a multimeter to check for voltage between connector X008 pin 12 on the front frame (FF) harness side and chassis ground. There should not be any voltage. A. If there is no voltage, there is a short to battery voltage in the mainframe (MF) harness between connector X011 and connector X008 wire 880 white. Locate the short and repair. Continue the troubleshooting at Step 12. B. If there is voltage, there is a short to battery voltage in the front frame (FF) harness between connector X008 and connector X017 wire 880 white. Locate the short and repair. Continue the troubleshooting at Step 12. 12. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. Repair any damage found during visual inspection. If no damage is found, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0179-04 LoP Isense Grnd Spd Hydro Shorted to Low Source NOTE: It is possible that this fault could occur at the same time as E0202-11 -- Ground Speed Hydrostat Unidentified Failure Code. This would indicate that the short to ground has occurred on the output side of the ground drive hydrostat circuit, and the combine should not move in the direction that generated the fault. Context: The LoP Isense Grnd Spd Hydro circuit is the ground path for the Ground Speed Hydrostat solenoid circuit. By monitoring the current flow on the return path of the ground speed hydrostat solenoid, the module can provide precise control of the solenoid engagement, and monitor the circuit for faults. When this error message is reported, this is an indication that the ground speed hydrostat circuit is shorted to ground. Cause: CCM2 has detected that the LoP Isense Grnd Spd Hydro circuit current is <5 mA while the MFH handle is not in neutral, and the combine is moving. Possible failure modes: 1. The LoP Isense Grnd Spd Hydro wiring is shorted to ground. 2. CCM2 internal failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage with the MFH handle in neutral. The normal operating range for the LoP Isense Grnd Spd Hydro circuit is 0 -- 4.4 volts. With the MFH handle out of neutral and the combine moving, the voltage indicated should be greater than 0.2 volts. A. If the voltage reading is less than 0.2 volts, there is a short to ground in the sense circuit. Continue the troubleshooting at Step 2. B. If the voltage reading is within the proper limits, the shorted wire may be intermittent at this time. Continue troubleshooting at Step 12. 2. Stop the combine and turn off the ignition switch. Disconnect the ground speed hydrostat solenoid connector X100. Use a multimeter to check for continuity between the valve end of connector X100 pin B or C and chassis ground. There should not be continuity to ground. A. If there is continuity to ground, there is a short to ground in the ground speed hydrostat solenoid L-23. Replace the solenoid, and continue troubleshooting at Step 12. B. If there is no continuity to ground, continue with Step 3. 3. Carefully disconnect connector X017 under the cab from the bottom of CCM2. Use a multimeter to check for continuity between the harness end of connector X100 pin B and chassis ground, and then between pin C and chassis ground. There should not be continuity to ground. A. If there is continuity to ground, continue with Step 4. B. If there is no continuity to ground, the shorted wire may be on the output side of the ground drive hydrostat circuit. Continue the troubleshooting at Step 6.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 4. Disconnect connector X011 between the gearbox (GB) and main frame (MF) harnesses. Use a multimeter to check for continuity between the main frame (MF) harness end of connector X011 pin G and chassis ground. There should not be continuity to ground. A. If there is no continuity to ground, there is a short to ground in the gearbox (GB) harness between connector X011 and connector X100 wires 886 blue, 887 blue or 881 blue. Locate the short and repair. Continue the troubleshooting at Step 12. B. If there is continuity to ground, continue with Step 5. 5. Disconnect connector X008 between the front frame (FF) and main frame (MF) harnesses. Use a multimeter to check for continuity between the front frame (FF) harness end of connector X008 pin 22 and chassis ground. There should not be continuity to ground. A. If there is no continuity, there is a short to ground in the mainframe (MF) harness between connector X011 and connector X008 wire 881 blue. Locate the short and repair. Continue the troubleshooting at Step 12. B. If there is continuity, there is a short to ground in the front frame (FF) harness between connector X008 and connector X017 wire 881 blue. Locate the short and repair. Continue the troubleshooting at Step 12. 6. Use a multimeter to check for continuity between the harness end of connector X100 pin D and chassis ground. There should not be continuity to ground. A. If there is continuity to ground, continue with Step 7. B. If there is no continuity to ground, continue with Step 9. 7. Disconnect connector X011. Use a multimeter to check for continuity between the main frame (MF) harness end of connector X011 pin Q on the main frame (MF) harness side and chassis ground. There should not be continuity to ground. A. If there is no continuity to ground, there is a short to ground in the gearbox (GB) harness between connector X011 and connector X100 wire 880 white. Locate the short and repair. Continue with Step 12. B. If there is continuity to ground, continue with Step 8. 8. Disconnect connector X008. Use a multimeter to check for continuity between the front frame (FF) harness end of connector X008 pin 12 on the front frame (FF) harness side and chassis ground. There should not be continuity to ground. A. If there is no continuity to ground, there is a short to ground in the main frame (MF) harness between connector X011 and connector X008 wire 880 white. Locate the short and repair. Continue at Step 12. B. If there is continuity to ground, there is a short to ground in the front frame (FF) harness between connector X008 and connector X017 pin J3-31 wire 880 white. Locate the short and repair. Continue at Step 12. 9. Use a multimeter to check for continuity between the harness end of connector X100 pin A and chassis ground. There should not be continuity to ground. A. If there is continuity to ground, continue with Step 10. B. If there is no continuity to ground, the shorted wire may be intermittent. Continue the troubleshooting at Step 12. 10. Disconnect connector X011. Use a multimeter to check for continuity between the main frame (MF) harness end of connector X011 pin P and chassis ground. There should not be continuity to ground. A. If there is no continuity to ground, there is a short to ground in the gearbox (GB) harness between connector X011 and connector X100 wire 879 grey. Locate the short and repair. Continue with Step 12. B. If there is continuity to ground, continue with Step 11.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 11. Disconnect connector X008. Use a multimeter to check for continuity between the front frame (FF) harness end of connector X008 pin 11 and chassis ground. There should not be continuity to ground. A. If there is no continuity to ground, there is a short to ground in the main frame (MF) harness between connector X011 and connector X008 wire 879 grey. Locate the short and repair. Continue with Step 12. B. If there is continuity to ground, there is a short to ground in the front frame (FF) harness between connector X008 and connector X017 pin J3-21 wire 879 grey. Locate the short and repair. Continue with Step 12. 12. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. Reinstall all connectors and wiring disconnected during troubleshooting. Repair any damage found during visual inspection. If no damage is found, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0179-05 LoP Isense Grnd Spd Hydro Line Disconnected Context: The LoP Isense Grnd Spd Hydro circuit is the ground path for the Ground Speed Hydrostat solenoid circuit. By monitoring the current flow on the return path of the ground speed hydrostat solenoid, the CCM2 module can provide precise control of the solenoid engagement, and monitor the circuit for faults. When this error message is reported, this is an indication that the ground speed hydrostat circuit is open. The open circuit could be on the output or return side of the circuit. Cause: CCM2 has detected that the LoP Isense Grnd Spd Hydro circuit current is <5 mA while the MFH handle is not in neutral, and the combine is not moving. Possible failure modes: 1. Failed solenoid. 2. Circuit output or return side wiring is open. 3. Controller internal failure. Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check the voltage range. Move the MFH handle to the full forward position, the full rearward position, and back to the neutral position while monitoring the voltage. With the MFH handle in neutral, the voltage indicated should be 0 volts. With the MFH handle in the full forward position, the voltage indicated should be approximately 4.4 volts. With the MFH handle in the full rearward position, the voltage indicated should be approximately 2.5 volts. The fault code is generated if the current flow is less than 5 mA (0.2 volts indicated on bar graph) at any time when the MFH handle is out of neutral. A. If one or both of the readings are less than 0.2 volts, continue with Step 2. B. If the readings are normal, continue the troubleshooting at Step 13. 2. Turn the key switch to the OFF position. Disconnect the ground speed hydrostat solenoid connector X100. Use a multimeter to check the resistance of the ground speed solenoid L-23 between connector X100 pins A and B (rev) and connector X100 pins C and D (fwd). The proper resistance range for the ground speed solenoid is 16k -- 20k ohms. A. If out of specification, replace the solenoid. Continue at Step 13. B. If the solenoid is within specification, continue with Step 3. 3. Use a multimeter to check for continuity between the gearbox (GB) harness end of connector X100 pin B and chassis ground, and between pin C and chassis ground. There should be approximately 47 ohms resistance measured between each pin and chassis ground. A. If there is continuity to ground on connector X100 pin B, but not pin C, there is an open circuit in the gearbox (GB) harness between connector X100 pin C and the harness splice wire 887 blue. Locate the open and repair. Continue with Step 13. B. If there is continuity to ground on connector X100 pin C, but not pin B, there is an open circuit in the gearbox (GB) harness between connector X100 pin B and the harness splice wire 886 blue. Locate the open and repair. Continue with Step 13. C. If there is no continuity on either pin, continue with Step 4. D. If there is continuity on both pins, continue with Step 7.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 4. Disconnect connector X011. Use a multimeter to check for continuity between the main frame (MF) harness end of connector X011 pin G and chassis ground. There should be approximately 47 ohms resistance to chassis ground. A. If there is continuity, there is an open circuit in the gearbox (GB) harness between the harness splice with wires 886 blue and 887 blue, and connector X011 pin 7 wire 881 blue. Locate the open and repair. Continue with Step 13. B. If there is no continuity, continue with Step 5. 5. Disconnect connector X008 behind the caUse a multimeter to check for continuity between the front frame harness end of connector X008 pin 22 and chassis ground. There should be approximately 47 ohms resistance to chassis ground. A. If there is continuity, there is an open circuit in the main frame (MF) harness between connector X011 pin 7 and connector X008 pin 22 wire 881 blue. Locate the open and repair. Continue with Step 13. B. If there is no continuity, continue with Step 6. 6. Carefully disconnect connector X017 from the bottom of the CCM2 module. Use a multimeter to check for continuity between connector X017 pin J3-35 on the module and chassis ground. There should be approximately 47 ohms resistance to chassis ground. A. If there is continuity, there is an open circuit in the front frame (FF) harness between connector X008 pin 22 and connector X017 pin J3-35 wire 881 blue. Locate the open and repair. Continue with Step 13. B. If there is no continuity, the sense resistor in the CCM2 module has failed. Replace the module. Continue with Step 13. 7. Carefully disconnect connector X017 under the cab from the bottom of CCM2. Connect a jumper wire on the front frame (FF) harness side, between connector X017 pin J3-31 and chassis ground. Use a multimeter to check from continuity between gearbox (GB) harness end of connector X100 pin D and chassis ground. There should be continuity to ground. A. If there is continuity to ground, continue with Step 10. B. If there is no continuity, continue with Step 8. 8. Disconnect connector X011 between the gearbox (GB) and main frame (MF) harnesses. Use a multimeter to check for continuity between connector X011 pin Q on the main frame (MF) harness side and chassis ground. There should be continuity. A. If there is continuity, there is an open circuit in the gearbox (GB) harness between connector X011 and connector X100 wire 880 white. Locate the open and repair. Continue the troubleshooting at Step 13. B. If there is no continuity, continue the troubleshooting at Step 9. 9. Disconnect connector X008 between the front frame (FF) and main frame (MF) harnesses. Use a multimeter to check for continuity between connector X008 pin 12 on the front frame (FF) harness side and chassis ground. There should be continuity. A. If there is continuity, there is an open circuit in the mainframe (MF) harness between connector X011 and connector X008 wire 880 white. Locate the open and repair. Continue the troubleshooting at Step 13. B. If there is no continuity, there is an open circuit in the front frame (FF) harness between connector X008 and connector X017 wire 880 white. Locate the open and repair. Continue the troubleshooting at Step 13. 10. Remove the jumper wire from connector X017 pin J3-31, and connect the jumper wire between connector X017 pin J3-21 on the front frame (FF) harness side and chassis ground. Use a multimeter to check from continuity between gearbox (GB) harness end of connector X100 pin A and chassis ground. There should be continuity to ground. A. If there is continuity to ground, the open wire may be intermittent. Continue with Step 13. B. If there is no continuity, continue with Step 11.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 11. Disconnect connector X011 between the gearbox (GB) and main frame (MF) harnesses. Use a multimeter to check for continuity between connector X011 pin P on the main frame (MF) harness side and chassis ground. There should be continuity. A. If there is continuity, there is an open circuit in the gearbox (GB) harness between connector X011 and connector X100 wire 879 gray. Locate the open and repair. Continue the troubleshooting at Step 13. B. If there is no continuity, continue the troubleshooting at Step 12. 12. Disconnect connector X008 between the front frame (FF) and main frame (MF) harnesses. Use a multimeter to check for continuity between connector X008 pin 11 on the front frame (FF) harness side and chassis ground. There should be continuity. A. If there is continuity, there is an open circuit in the mainframe (MF) harness between connector X011 and connector X008 wire 879 gray. Locate the open and repair. Continue the troubleshooting at Step 13. B. If there is no continuity, there is an open circuit in the front frame (FF) harness between connector X008 and connector X017 wire 879 gray. Locate the open and repair. Continue the troubleshooting at Step 13. 13. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. Repair any damage found during visual inspection. A. If no damage is found, operate the machine while monitoring the display monitor. If no low (<0.2 volts) out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Ground Speed Hydrostat L23 Connector X011 Connector X008 Connector X017

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

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S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME-- 9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0180-11 Thresher Clutch Valve Unidentified Failure Code Cause: The Thresher Clutch Valve (L-22) circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad solenoid. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, engage the thresher engage switch S30. The proper current is approximately 1.0 to 1.5 amps. A. If the current reading goes to maximum, and then back to zero, the circuit is shorted to ground and the software has shut off the output to protect the module and wiring. Continue with Step 2. B. If the reading is 0 amps, the circuit is open. Continue with Step 5. C. If the reading is within the proper range, the circuit is working properly. Continue with Step 11. 2. Disconnect connector X035. Use a multimeter to check between connector X035 pin 7 (valve side) and chassis ground. A. If there is continuity, the thresher clutch solenoid is shorted to ground. Replace the solenoid. B. If there is no continuity, continue with Step 3. 3. Use a multimeter to check for continuity between connector X035 pin 7 (harness side) and chassis ground. Flex the gearbox (GB) harness between the clutch valve and connector X011 while making this check. A. If there is continuity to ground, continue with Step 4. B. If there is no continuity to ground, erase the fault code and continue operation. 4. Disconnect connector X011. Use a multimeter to check for continuity between connector X011 pin O on the main frame (MF) harness side and chassis ground. Flex the main frame (MF) harness between the connector X011 and connector X016 while making this check. A. If there is no continuity to ground, the short to ground is in the gearbox (GB) harness between connector X011 and connector X035 wire 878 white. Locate the short and repair. B. If there is continuity to ground, the short to ground is in the main frame (MF) harness between connector X011 and connector X016 wire 878 white. Locate the short and repair. 5. Disconnect connector X035. Use a multimeter to check the resistance of the thresher clutch valve coil between connector X035 pins 7 & 8. The proper resistance range is 7.2 to 11.2 ohms. A. If there is no continuity, replace solenoid. B. If the coil is within specification, continue with Step 6. 6. Use a multimeter to check for continuity between connector X035 pin 8 (harness side) and chassis ground. Flex the gearbox (GB) harness between the clutch valve and connector X011 while making this check. A. If there is no continuity to ground, continue with Step 7. B. If there is continuity to ground, continue with Step 9.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 7. Disconnect connector X011. Use a multimeter to check for continuity between connector X011 pin N on the main frame (MF) harness side and chassis ground. Flex the main frame (MF) harness between the connector X011 and connector X016 while making this check. A. If there is continuity to ground, the open circuit is in the gearbox (GB) harness between connector X011 and connector X035 wire 877 blue. Locate the open and repair. B. If there is no continuity to ground, continue with Step 8. 8. Disconnect connector X016 on the bottom of CCM2 module. Use a multimeter to check for continuity between connector X016 pin 40 on the module and chassis ground. NOTE: The sense resistor in the module for the Isense Thresher Clutch circuit is easily damaged as a result of excessive current draw or a short to high voltage. A. There is infinite resistance. The sense resistor in the CCM2 module has failed. Replace the module. B. There is less than 1 ohm resistance, indicating the sense resistor in the CCM2 module is okay. The open circuit is in the main frame (MF) harness between connector X011 and connector X016 wire 877 blue. Locate the open and repair. 9. Turn the key switch to the ON position. Use the display monitor, reference section 55 chapter 2, if needed, manually power the thresher clutch valve. Use a multimeter to check for 12 volts between connector X035 pin 7 and chassis ground. NOTE: The thresher engage switch S30 must be engaged to supply power to the circuit. A. If 12 volts is not present, continue with Step 10. B. If 12 volts is found, continue with Step 11. 10. Turn the key switch to the ON position. Use the display monitor, reference section 55 chapter 2, if needed, manually power the thresher clutch valve. Use a multimeter to check for 12 volts between connector X011 pin O and chassis ground. NOTE: The thresher engage switch S30 must be engaged to supply power to the circuit. A. If 12 volts is present, the open circuit is in the gearbox (GB) harness between connector X035 pin 7 and connector X011 pin O wire 878 white. Locate the open circuit and repair. B. If 12 volts is not present there is an open circuit in the main frame (MF) harness between connector X011 pin O and connector X016 pin J2-30 wire 878 white. Locate the open and repair. 11. Erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Thresher Clutch Solenoid L22 Connector X035 Connector X011 Connector X016

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

THRESHER FRAME-- 18

B-01 = ROTOR RPM K-28 = THRESHER LATCHING L-22 = GEARBOX CLUTCH L-29 = ROTOR INCREASE

L-30 = ROTOR DECREASE S-30 = THRESHER ENGAGE

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0181-11 Parking Brake Disengage Valve Unidentified Failure Code Cause: The parking brake disengage valve (L-10) circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad solenoid. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with Step 9. 2. Disconnect connector X035. Use a multimeter to check between connector X035 pin 3 (valve side) and chassis ground. A. If there is continuity, the park brake disengage solenoid is shorted to ground. Replace the solenoid. B. If there is no continuity, continue with Step 3. 3. Use a multimeter to check for continuity between connector X035 pin 3 (harness side) and chassis ground. Flex the gearbox (GB) harness between the clutch valve and connector X011 while making this check. A. If there is continuity to ground, continue with Step 4. B. If there is no continuity to ground, continue with Step 5. 4. Disconnect connector X011. Use a multimeter to check for continuity between connector X011 pin R on the main frame (MF) harness side and chassis ground. Flex the main frame (MF) harness between the connector X011 and connector X016 while making this check. A. If there is no continuity to ground, the short to ground is in the gearbox (GB) harness between connector X011 and connector X035 wire 572 white. Locate the short and repair. B. If there is continuity to ground, the short to ground is in the main frame (MF) harness between connector X011 and connector X016 wire 572 white. Locate the short and repair. 5. Disconnect connector X035. Use a multimeter to check the resistance of the park brake disengage valve coil between connector X035 pins 3 & 4. The proper resistance range is 7.2 to 11.2 ohms. A. If there is no continuity, replace solenoid. B. If the coil is within specification, continue with Step 6.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 6. Use a multimeter to check for continuity between connector X035 pin 4 (harness side) and chassis ground. Flex the gearbox (GB) harness between the clutch valve and engine ground 5 while making this check. A. If there is no continuity to ground, there is an open circuit in the gearbox (GB) harness between connector X035 pin 4 and the engine ground 5. Locate the open and repair. B. If there is continuity to ground, continue with Step 7. 7. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the park brake disengage valve. Use a multimeter to check for 12 volts between connector X035 pin 3 and chassis ground. A. If 12 volts is not present, continue with Step 8. B. If 12 volts is found, continue with Step 9. 8. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the park brake disengage valve. Use a multimeter to check for 12 volts between connector X011 pin R and chassis ground. A. If 12 volts is present, the open circuit is in the gearbox (GB) harness between connector X035 pin 3 and connector X011 pin R wire 572 white. Locate the open circuit and repair. B. If 12 volts is not present there is an open circuit in the main frame (MF) harness between connector X011 pin R and connector X016 pin J2-15 wire 572 white. Locate the open and repair. 9. Erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Park Brake Disengage Solenoid L10 Connector X035 Connector X011 Connector X016

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

55-220

S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME-- 9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0183-11 Brake Limiting Valve Unidentified Failure Code Cause: The brake limiting valve (L-32) circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad solenoid. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the brake limiting valve. The “Status” screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “ERROR”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with Step 6. 2. Disconnect connector X329. Use a multimeter to check the resistance of the brake limiting valve coil (L32). The proper resistance range is 3 -- 5 ohms. A. If there is zero resistance, the brake limiting solenoid is shorted internally. Replace the solenoid. B. If there is infinite resistance, the brake limiting solenoid is open. Replace the solenoid. C. If the resistance is correct, continue with Step 3. 3. Use a multimeter to check for continuity between connector X329 pin A (harness side) and chassis ground. Flex the main frame (MF) harness while making this check. A. If there is continuity to ground, the short to ground is in the main frame (MF) harness between connector X329 and connector X016 pin J2-5 wire 1504 white. Locate the short and repair. B. If there is no continuity to ground, continue with Step 4. 4. Use a multimeter to check for continuity between connector X329 pin B (harness side) and chassis ground. Flex the main frame (MF) harness while making this check. A. If there is no continuity to ground, there is an open circuit in the main frame (MF) harness between connector X329 pin B and the front frame ground #2 wire 1505 or 677 black. Locate the open and repair. B. If there is continuity to ground, continue with Step 5. 5. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the brake limiting valve. Use a multimeter to check for 12 volts between connector X329 pin A on the main frame (MF) harness side and chassis ground. A. If 12 volts is not present there is an open circuit in the main frame (MF) harness between connector X329 pin A and connector X016 pin J2-5 wire 1504 white. Locate the open and repair. B. If 12 volts is found, continue with Step 6. 6. Visually inspect the harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

55-222

S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME-- 9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0184-11 Unload Cross Auger Valve Unidentified Failure Code Cause: The unload cross auger valve (L-08) circuit open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad solenoid. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The proper current is approximately 1.0 to 1.5 amps. A. If the current reading goes to maximum, and then back to zero, the circuit is shorted to ground and the software has shut off the output to protect the module and wiring. Continue with Step 2. B. If the reading is 0 amps, the circuit is open. Continue with Step 5. C. If the reading is within the proper range, the circuit is working properly. Continue with Step 11. 2. Disconnect connector X035. Use a multimeter to check between connector X035 pin 5 (valve side) and chassis ground. A. If there is continuity, the Unload cross auger valve solenoid is shorted to ground. Replace the solenoid. B. If there is no continuity, continue with Step 3. 3. Use a multimeter to check for continuity between connector X035 pin 5 (harness side) and chassis ground. Flex the gearbox (GB) harness between the clutch valve and connector X011 while making this check. A. If there is continuity to ground, continue with Step 4. B. If there is no continuity to ground, erase the fault code and continue operation. 4. Disconnect connector X011. Use a multimeter to check for continuity between connector X011 pin S on the main frame (MF) harness side and chassis ground. Flex the main frame (MF) harness between the connector X011 and connector X016 while making this check. A. If there is no continuity to ground, the short to ground is in the gearbox (GB) harness between connector X011 and connector X035 wire 568 white. Locate the short and repair. B. If there is continuity to ground, the short to ground is in the main frame (MF) harness between connector X011 and connector X016 wire 568 white. Locate the short and repair. 5. Disconnect connector X035. Use a multimeter to check the resistance of the unload cross auger valve coil between connector X035 pins 5 & 6. The proper resistance range is 7.2 to 11.2 ohms. A. If there is no continuity, replace solenoid. B. If the coil is within specification, continue with Step 6.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 6. Use a multimeter to check for continuity between connector X035 pin 6 (harness side) and chassis ground. Flex the gearbox (GB) harness between the clutch valve and connector X011 while making this check. A. If there is no continuity to ground, continue with Step 7. B. If there is continuity to ground, continue with Step 9. 7. Disconnect connector X011. Use a multimeter to check for continuity between connector X011 pin T on the main frame (MF) harness side and chassis ground. Flex the main frame (MF) harness between the connector X011 and connector X016 while making this check. A. If there is continuity to ground, the open circuit is in the gearbox (GB) harness between connector X011 and connector X035 wire 601 black. Locate the open and repair. B. If there is no continuity to ground, continue with Step 8. 8. Disconnect connector X016 on the bottom of CCM2 module. Use a multimeter to check for continuity between connector X016 pin 20 on the module and chassis ground. NOTE: The sense resistor in the module for the Isense Unload Cross Auger circuit is easily damaged as a result of excessive current draw or a short to high voltage. A. There is infinite resistance. The sense resistor in the CCM2 module has failed. Replace the module. B. There is less than 1 ohm resistance, indicating the sense resistor in the CCM2 module is okay. The open circuit is in the main frame (MF) harness between connector X011 and connector X016 wire 601 black. Locate the open and repair. 9. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the unload cross auger valve. Use a multimeter to check for 12 volts between connector X035 pin 5 on the gearbox (GB) harness side and chassis ground. A. If 12 volts is not present, continue with Step 10. B. If 12 volts is found, continue with Step 11. 10. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the unload cross auger valve. Use a multimeter to check for 12 volts between connector X011 pin S on the main frame (MF) harness side and chassis ground. A. If 12 volts is present, the open circuit is in the gearbox (GB) harness between connector X035 pin 5 and connector X011 pin S wire 568 white. Locate the open circuit and repair. B. If 12 volts is not present there is an open circuit in the main frame (MF) harness between connector X011 pin S and connector X016 pin J2-4 wire 568 white. Locate the open and repair. 11. Erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Unload Tube Clutch Solenoid L08 Connector X035 Connector X011 Connector X016

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

UNLOAD FRAME-- 22

B-38 = UNLOAD CRADLE B-47 = COVERS CLOSED L-03 = UNLOAD TUBE IN L-04 = UNLOAD TUBE OUT

L-08 = UNLOAD TUBE CLUTCH S-28 = GRAIN BIN 3/4 FULL S-29 = GRAIN BIN FULL S-42 = TANK COVERS SWITCH

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0185-11 Header Reel Fore Valve Unidentified Failure Code Cause: The header reel fore valve (L-16) circuit open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad solenoid. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with Step 9. 2. Disconnect connector X272. Use a multimeter to check the resistance of the header reel fore valve coil (L16). The proper resistance range is 3 to 5 ohms. A. If there is zero resistance, the header reel fore solenoid is shorted internally. Replace the solenoid. B. If there is infinite resistance, the header reel fore solenoid is open. Replace the solenoid. C. If the resistance is correct, continue with Step 3. 3. Use a multimeter to check for continuity between connector X272 pin 1 (harness side) and chassis ground. Flex the feeder valves (FV) harness while making this check. A. If there is continuity to ground, continue with Step 4. B. If there is no continuity to ground, continue with Step 5. 4. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin P on the front frame (FF) harness side and chassis ground. Flex the front frame (FF) harness between the connector X021 and connector X017 while making this check. A. If there is no continuity to ground, the short to ground is in the feeder valves (FV) harness between connector X021 and connector X272 wire 560 white. Locate the short and repair. B. If there is continuity to ground, the short to ground is in the front frame (FF) harness between connector X021 and connector X017 wire 560 white. Locate the short and repair. 5. Use a multimeter to check for continuity between connector X272 pin 2 (harness side) and chassis ground. Flex the feeder valves (FV) harness while making this check. A. If there is no continuity to ground, continue with Step 6. B. If there is continuity to ground, continue with Step 7.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 6. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin Q (harness side) and chassis ground. Flex the front frame (FF) harness between connector X021 and the front frame ground 2 while making this check. A. If there is continuity to ground, there is an open circuit in the feeder valves (FV) harness between connector X272 and connector X021 wire 589 black. Locate the open and repair. B. If there is no continuity to ground, there is an open circuit in the front frame (FF) harness between connector X021 pin Q and the front frame ground 2 wire 589 or 592 black. Locate the open and repair. 7. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the header reel fore valve. Use a multimeter to check for 12 volts between connector X272 pin 1 on the feeder valves (FV) harness side and chassis ground. A. If 12 volts is not present, continue with Step 8. B. If 12 volts is found, continue with Step 9. 8. Turn the key switch to the ON position. Use the display monitor -- “Diagnose info” screen to manually power the header reel fore valve. Use a multimeter to check for 12 volts between connector X021 pin P on the front frame (FF) harness side and chassis ground. A. If 12 volts is present, the open circuit is in the feeder valves (FV) harness between connector X272 pin 1 and connector X021 pin P wire 560 white. Locate the open circuit and repair. B. If 12 volts is not present there is an open circuit in the front frame (FF) harness between connector X021 pin P and connector X017 pin J3-1 wire 560 white. Locate the open and repair. 9. Erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

2 1

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Reel Fore Solenoid L16 (Front, Third From Top) Connector X021 Connector X017 Front Frame Ground 2

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

HEADER FRAME-- 12

K-42 = RH VERTICAL KNIFE RELAY (OP) K-43 = LH VERTICAL KNIFE RELAY (OP) L-13 = REEL DOWN L-14 = REEL UP

L-15 = REEL AFT L-16 = REEL FORE L-17 = REEL DRIVE M-09 = REEL SPEED MOTOR

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0186-11 Header Reel Drive Valve Unidentified Failure Code Cause: The header reel drive valve (L-17) circuit open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad solenoid. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with Step 9. 2. Disconnect connector X274. Use a multimeter to check the resistance of the header reel drive valve coil (L17). The proper resistance range is 3 to 5 ohms. A. If there is zero resistance, the header reel drive solenoid is shorted internally. Replace the solenoid. B. If there is infinite resistance, the header reel drive solenoid is open. Replace the solenoid. C. If the resistance is correct, continue with Step 3. 3. Use a multimeter to check for continuity between connector X274 pin 1 (harness side) and chassis ground. Flex the feeder valves (FV) harness while making this check. A. If there is continuity to ground, continue with Step 4. B. If there is no continuity to ground, continue with Step 5. 4. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin E on the front frame (FF) harness side and chassis ground. Flex the front frame (FF) harness between the connector X021 and connector X017 while making this check. A. If there is no continuity to ground, the short to ground is in the feeder valves (FV) harness between connector X021 and connector X274 wire 556 white. Locate the short and repair. B. If there is continuity to ground, the short to ground is in the front frame (FF) harness between connector X021 and connector X017 wire 556 white. Locate the short and repair. 5. Use a multimeter to check for continuity between connector X274 pin 2 (harness side) and chassis ground. Flex the feeder valves (FV) harness while making this check. A. If there is no continuity to ground, continue with Step 6. B. If there is continuity to ground, continue with Step 7.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 6. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin F (harness side) and chassis ground. Flex the front frame (FF) harness between connector X021 and the front frame ground 2 while making this check. A. If there is continuity to ground, there is an open circuit in the feeder valves (FV) harness between connector X274 and connector X021 wire 585 black. Locate the open and repair. B. If there is no continuity to ground, there is an open circuit in the front frame (FF) harness between connector X021 pin F and the front frame ground 2 wire 585 black. Locate the open and repair. 7. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the header reel drive valve. Use a multimeter to check for 12 volts between connector X274 pin 1 on the feeder valves (FV) harness side and chassis ground. A. If 12 volts is not present, continue with Step 8. B. If 12 volts is found, continue with Step 9. 8. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the header reel fore valve. Use a multimeter to check for 12 volts between connector X021 pin E on the front frame (FF) harness side and chassis ground. A. If 12 volts is present, the open circuit is in the feeder valves (FV) harness between connector X274 pin 1 and connector X021 pin E wire 556 white. Locate the open circuit and repair. B. If 12 volts is not present there is an open circuit in the front frame (FF) harness between connector X021 pin E and connector X017 pin J3-2 wire 556 white. Locate the open and repair. 9. Erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Reel Drive Solenoid L17 (Front, Fifth From Top) Connector X021 Connector X017 Front Frame Ground 2

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

HEADER FRAME-- 12

K-42 = RH VERTICAL KNIFE RELAY (OP) K-43 = LH VERTICAL KNIFE RELAY (OP) L-13 = REEL DOWN L-14 = REEL UP

L-15 = REEL AFT L-16 = REEL FORE L-17 = REEL DRIVE M-09 = REEL SPEED MOTOR

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0187-11 Header Reel Up Valve Unidentified Failure Code Cause: The header reel up valve (L-14) circuit open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad solenoid. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with Step 9. 2. Disconnect connector X273. Use a multimeter to check the resistance of the header reel up valve coil (L14). The proper resistance range is 3 to 5 ohms. A. If there is zero resistance, the header reel up solenoid is shorted internally. Replace the solenoid. B. If there is infinite resistance, the header reel up solenoid is open. Replace the solenoid. C. If the resistance is correct, continue with Step 3. 3. Use a multimeter to check for continuity between connector X273 pin 1 (harness side) and chassis ground. Flex the feeder valves (FV) harness while making this check. A. If there is continuity to ground, continue with Step 4. B. If there is no continuity to ground, continue with Step 5. 4. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin L on the front frame (FF) harness side and chassis ground. Flex the front frame (FF) harness between the connector X021 and connector X017 while making this check. A. If there is no continuity to ground, the short to ground is in the feeder valves (FV) harness between connector X021 and connector X273 wire 558 white. Locate the short and repair. B. If there is continuity to ground, the short to ground is in the front frame (FF) harness between connector X021 and connector X017 wire 558 white. Locate the short and repair. 5. Use a multimeter to check for continuity between connector X273 pin 2 (harness side) and chassis ground. Flex the feeder valves (FV) harness while making this check. A. If there is no continuity to ground, continue with Step 6. B. If there is continuity to ground, continue with Step 7.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 6. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin M (harness side) and chassis ground. Flex the front frame (FF) harness between connector X021 and the front frame ground 2 while making this check. A. If there is continuity to ground, there is an open circuit in the feeder valves (FV) harness between connector X273 and connector X021 wire 587 black. Locate the open and repair. B. If there is no continuity to ground, there is an open circuit in the front frame (FF) harness between connector X021 pin M and the front frame ground 2 wire 587 black. Locate the open and repair. 7. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the header reel up valve. Use a multimeter to check for 12 volts between connector X273 pin 1 on the feeder valves (FV) harness side and chassis ground. A. If 12 volts is not present, continue with Step 8. B. If 12 volts is found, continue with Step 9. 8. Turn the key switch to the ON position. Use the display monitor -- “Diagnose info” screen to manually power the header reel up valve. Use a multimeter to check for 12 volts between connector X021 pin L on the front frame (FF) harness side and chassis ground. A. If 12 volts is present, the open circuit is in the feeder valves (FV) harness between connector X273 pin 1 and connector X021 pin L wire 558 white. Locate the open circuit and repair. B. If 12 volts is not present there is an open circuit in the front frame (FF) harness between connector X021 pin L and connector X017 pin J3-3 wire 558 white. Locate the open and repair. 9. Erase the fault code and continue operation.

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Reel Up Solenoid L14 (Front, Fourth From Top) Connector X021 Connector X017 Front Frame Ground 2

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

HEADER FRAME-- 12

K-42 = RH VERTICAL KNIFE RELAY (OP) K-43 = LH VERTICAL KNIFE RELAY (OP) L-13 = REEL DOWN L-14 = REEL UP

L-15 = REEL AFT L-16 = REEL FORE L-17 = REEL DRIVE M-09 = REEL SPEED MOTOR

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0188-11 Header Reel Down Valve Unidentified Failure Code Cause: The header reel down valve (L-13) circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad solenoid. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with Step 9. 2. Disconnect connector X269. Use a multimeter to check the resistance of the header reel down valve coil (L13). The proper resistance range is 3 to 5 ohms. A. If there is zero resistance, the header reel down solenoid is shorted internally. Replace the solenoid. B. If there is infinite resistance, the header reel down solenoid is open. Replace the solenoid. C. If the resistance is correct, continue with Step 3. 3. Use a multimeter to check for continuity between connector X269 pin 1 (harness side) and chassis ground. Flex the feeder valves (FV) harness while making this check. A. If there is continuity to ground, continue with Step 4. B. If there is no continuity to ground, continue with Step 5. 4. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin N on the front frame (FF) harness side and chassis ground. Flex the front frame (FF) harness between the connector X021 and connector X017 while making this check. A. If there is no continuity to ground, the short to ground is in the feeder valves (FV) harness between connector X021 and connector X269 wire 557 white. Locate the short and repair. B. If there is continuity to ground, the short to ground is in the front frame (FF) harness between connector X021 and connector X017 wire 557 white. Locate the short and repair. 5. Use a multimeter to check for continuity between connector X269 pin 2 (harness side) and chassis ground. Flex the feeder valves (FV) harness while making this check. A. If there is no continuity to ground, continue with Step 6. B. If there is continuity to ground, continue with Step 7.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 6. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin O (harness side) and chassis ground. Flex the front frame (FF) harness between connector X021 and the front frame ground 2 while making this check. A. If there is continuity to ground, there is an open circuit in the feeder valves (FV) harness between connector X269 and connector X021 wire 586 black. Locate the open and repair. B. If there is no continuity to ground, there is an open circuit in the front frame (FF) harness between connector X021 pin O and the front frame ground 2 wire 586 black. Locate the open and repair. 7. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the header reel down valve. Use a multimeter to check for 12 volts between connector X269 pin 1 on the feeder valves (FV) harness side and chassis ground. A. If 12 volts is not present, continue with Step 8. B. If 12 volts is found, continue with Step 9. 8. Turn the key switch to the ON position. Use the display monitor -- “Diagnose info” screen to manually power the header reel down valve. Use a multimeter to check for 12 volts between connector X021 pin N on the front frame (FF) harness side and chassis ground. A. If 12 volts is present, the open circuit is in the feeder valves (FV) harness between connector X269 pin 1 and connector X021 pin N wire 557 white. Locate the open circuit and repair. B. If 12 volts is not present there is an open circuit in the front frame (FF) harness between connector X021 pin N and connector X017 pin J3-4 wire 557 white. Locate the open and repair. 9. Erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Reel Down Solenoid L13 (Back, Fourth From Top) Connector X021 Connector X017 Front Frame Ground 2

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

HEADER FRAME-- 12

K-42 = RH VERTICAL KNIFE RELAY (OP) K-43 = LH VERTICAL KNIFE RELAY (OP) L-13 = REEL DOWN L-14 = REEL UP

L-15 = REEL AFT L-16 = REEL FORE L-17 = REEL DRIVE M-09 = REEL SPEED MOTOR

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0189-11 Header Reel Back Valve Unidentified Failure Code Cause: The header reel back valve (L-15) circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad solenoid. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with Step 9. 2. Disconnect connector X268. Use a multimeter to check the resistance of the header reel back valve coil (L15). The proper resistance range is 3 to 5 ohms. A. If there is zero resistance, the header reel back solenoid is shorted internally. Replace the solenoid. B. If there is infinite resistance, the header reel back solenoid is open. Replace the solenoid. C. If the resistance is correct, continue with Step 3. 3. Use a multimeter to check for continuity between connector X268 pin 1 (harness side) and chassis ground. Flex the feeder valves (FV) harness while making this check. A. If there is continuity to ground, continue with Step 4. B. If there is no continuity to ground, continue with Step 5. 4. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin R on the front frame (FF) harness side and chassis ground. Flex the front frame (FF) harness between the connector X021 and connector X017 while making this check. A. If there is no continuity to ground, the short to ground is in the feeder valves (FV) harness between connector X021 and connector X268 wire 559 white. Locate the short and repair. B. If there is continuity to ground, the short to ground is in the front frame (FF) harness between connector X021 and connector X017 wire 559 white. Locate the short and repair. 5. Use a multimeter to check for continuity between connector X268 pin 2 (harness side) and chassis ground. Flex the feeder valves (FV) harness while making this check. A. If there is no continuity to ground, continue with Step 6. B. If there is continuity to ground, continue with Step 7.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 6. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin S (harness side) and chassis ground. Flex the front frame (FF) harness between connector X021 and the front frame ground 2 while making this check. A. If there is continuity to ground, there is an open circuit in the feeder valves (FV) harness between connector X268 and connector X021 wire 588 black. Locate the open and repair. B. If there is no continuity to ground, there is an open circuit in the front frame (FF) harness between connector X021 pin S and the front frame ground 2 wire 588 black. Locate the open and repair. 7. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the header reel back valve. Use a multimeter to check for 12 volts between connector X268 pin 1 on the feeder valves (FV) harness side and chassis ground. A. If 12 volts is not present, continue with Step 8. B. If 12 volts is found, continue with Step 9. 8. Turn the key switch to the ON position. Use the display monitor -- “Diagnose info” screen to manually power the header reel back valve. Use a multimeter to check for 12 volts between connector X021 pin R on the front frame (FF) harness side and chassis ground. A. If 12 volts is present, the open circuit is in the feeder valves (FV) harness between connector X268 pin 1 and connector X021 pin R wire 559 white. Locate the open circuit and repair. B. If 12 volts is not present there is an open circuit in the front frame (FF) harness between connector X021 pin R and connector X017 pin J3-5 wire 559 white. Locate the open and repair. 9. Erase the fault code and continue operation.

55-244

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Reel Back Solenoid L15 (Back, Third From Top) Connector X021 Connector X017 Front Frame Ground 2

55-245

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

HEADER FRAME-- 12

K-42 = RH VERTICAL KNIFE RELAY (OP) K-43 = LH VERTICAL KNIFE RELAY (OP) L-13 = REEL DOWN L-14 = REEL UP

L-15 = REEL AFT L-16 = REEL FORE L-17 = REEL DRIVE M-09 = REEL SPEED MOTOR

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0191-11 Thresher Speed Increase Unidentified Failure Code Cause: The rotor increase valve (L-29) circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad solenoid. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with Step 6. 2. Disconnect connector X278. Use a multimeter to check the resistance of the drum increase valve coil (L29). The proper resistance range is 3 to 5 ohms. A. If there is zero resistance, the drum increase solenoid is shorted internally. Replace the solenoid. B. If there is infinite resistance, the drum increase solenoid is open. Replace the solenoid. C. If the resistance is correct, continue with Step 3. 3. Use a multimeter to check for continuity between connector X278 pin 1 (harness side) and chassis ground. Flex the main frame (MF) harness while making this check. A. If there is continuity to ground, the short to ground is in the main frame (MF) harness between connector X278 and connector X016 wire 567 white. Locate the short and repair. B. If there is no continuity to ground, continue with Step 4. 4. Use a multimeter to check for continuity between connector X278 pin 2 (harness side) and chassis ground. Flex the main frame (MF) harness while making this check. A. If there is no continuity to ground, there is an open circuit in the main frame (MF) harness between connector X278 pin 2 and the front frame ground 2 wire 597 or 600 black. Locate the open and repair. B. If there is continuity to ground, continue with Step 5. 5. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the thresher increase valve. Use a multimeter to check for 12 volts between connector X278 pin 1 on the main frame (MF) harness side and chassis ground. A. If 12 volts is not present, there is an open circuit in the main frame (MF) harness between connector X278 pin 1 and connector X016 pin J2-7 wire 567 white. Locate the open and repair. B. If 12 volts is found, continue with Step 6. 6. Erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

1 10020035

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Rotor Increase Solenoid L29 (Back Of Stack) Connector X016 Front Frame Ground 2

55-248

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

THRESHER FRAME-- 18

B-01 = ROTOR RPM K-28 = THRESHER LATCHING L-22 = GEARBOX CLUTCH L-29 = ROTOR INCREASE

L-30 = ROTOR DECREASE S-30 = THRESHER ENGAGE

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0192-11 Thresher Speed Decrease Unidentified Failure Code Cause: The rotor decrease valve (L-30) circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad solenoid. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with Step 6. 2. Disconnect connector X275. Use a multimeter to check the resistance of the drum decrease valve coil (L30). The proper resistance range is 3 to 5 ohms. A. If there is zero resistance, the drum decrease solenoid is shorted internally. Replace the solenoid. B. If there is infinite resistance, the drum decrease solenoid is open. Replace the solenoid. C. If the resistance is correct, continue with Step 3. 3. Use a multimeter to check for continuity between connector X275 pin 1 (harness side) and chassis ground. Flex the main frame (MF) harness while making this check. A. If there is continuity to ground, the short to ground is in the main frame (MF) harness between connector X275 and connector X016 wire 566 white. Locate the short and repair. B. If there is no continuity to ground, continue with Step 4. 4. Use a multimeter to check for continuity between connector X275 pin 2 (harness side) and chassis ground. Flex the main frame (MF) harness while making this check. A. If there is no continuity to ground, there is an open circuit in the main frame (MF) harness between connector X275 pin 2 and the front frame ground 2 wire 596 or 600 black. Locate the open and repair. B. If there is no continuity to ground, continue with Step 5. 5. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the thresher decrease valve. Use a multimeter to check for 12 volts between connector X275 pin 1 on the main frame (MF) harness side and chassis ground. A. If 12 volts is not present, there is an open circuit in the main frame (MF) harness between connector X275 pin 1 and connector X016 pin J2-8 wire 566 white. Locate the open and repair. B. If 12 volts is found, continue with Step 6. 6. Erase the fault code and continue operation.

55-250

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Rotor Decrease Solenoid L30 (Front Of Stack) Connector X016 Front Frame Ground 2

55-251

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

THRESHER FRAME-- 18

B-01 = ROTOR RPM K-28 = THRESHER LATCHING L-22 = GEARBOX CLUTCH L-29 = ROTOR INCREASE

L-30 = ROTOR DECREASE S-30 = THRESHER ENGAGE

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0193-11 Unload Tube In Valve Unidentified Failure Code Cause: The unload tube in valve (L-03) circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad solenoid. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with Step 6. 2. Disconnect connector X276. Use a multimeter to check the resistance of the unload tube in valve coil (L03). The proper resistance range is 3 to 5 ohms. A. If there is zero resistance, the unload tube in solenoid is shorted internally. Replace the solenoid. B. If there is infinite resistance, the unload tube in solenoid is open. Replace the solenoid. C. If the resistance is correct, continue with Step 3. 3. Use a multimeter to check for continuity between connector X276 pin 1 (harness side) and chassis ground. Flex the main frame (MF) harness while making this check. A. If there is continuity to ground, the short to ground is in the main frame (MF) harness between connector X276 and connector X016 wire 574 white. Locate the short and repair. B. If there is no continuity to ground, continue with Step 4. 4. Use a multimeter to check for continuity between connector X276 pin 2 (harness side) and chassis ground. Flex the main frame (MF) harness while making this check. A. If there is no continuity to ground, there is an open circuit in the main frame (MF) harness between connector X276 pin 2 and the front frame ground 2 wire 599 or 600 black. Locate the open and repair. B. If there is continuity to ground, continue with Step 5. 5. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the unload tube in valve. Use a multimeter to check for 12 volts between connector X276 pin 1 on the main frame (MF) harness side and chassis ground. A. If 12 volts is not present, there is an open circuit in the main frame (MF) harness between connector X276 pin 1 and connector X016 pin J2-6 wire 574 white. Locate the open and repair. B. If 12 volts is found, continue with Step 6. 6. Erase the fault code and continue operation.

55-253

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Unload Tube In Solenoid L03 (Back Of Stack) Connector X016 Front Frame Ground 2

55-254

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

UNLOAD FRAME-- 22

B-38 = UNLOAD CRADLE B-47 = COVERS CLOSED L-03 = UNLOAD TUBE IN L-04 = UNLOAD TUBE OUT

L-08 = UNLOAD TUBE CLUTCH S-28 = GRAIN BIN 3/4 FULL S-29 = GRAIN BIN FULL S-42 = TANK COVERS SWITCH

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0194-11 Unload Tube Out Valve Unidentified Failure Code Cause: The unload tube out valve (L-04) circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad solenoid. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with Step 6. 2. Disconnect connector X277. Use a multimeter to check the resistance of the unload tube out valve coil (L04). The proper resistance range is 3 to 5 ohms. A. If there is zero resistance, the unload tube out solenoid is shorted internally. Replace the solenoid. B. If there is infinite resistance, the unload tube out solenoid is open. Replace the solenoid. C. If the resistance is correct, continue with Step 3. 3. Use a multimeter to check for continuity between connector X277 pin 1 (harness side) and chassis ground. Flex the main frame (MF) harness while making this check. A. If there is continuity to ground, the short to ground is in the main frame (MF) harness between connector X277 and connector X016 wire 573 white. Locate the short and repair. B. If there is no continuity to ground, continue with Step 4. 4. Use a multimeter to check for continuity between connector X277 pin 2 (harness side) and chassis ground. Flex the main frame (MF) harness while making this check. A. If there is no continuity to ground, there is an open circuit in the main frame (MF) harness between connector X277 pin 2 and the front frame ground 2 wire 598 or 600 black. Locate the open and repair. B. If there is continuity to ground, continue with Step 5. 5. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the unload tube out valve. Use a multimeter to check for 12 volts between connector X277 pin 1 on the main frame (MF) harness side and chassis ground. A. If 12 volts is not present, there is an open circuit in the main frame (MF) harness between connector X277 pin 1 and connector X016 pin J2-16 wire 573 white. Locate the open and repair. B. If 12 volts is found, continue with Step 6. 6. Erase the fault code and continue operation.

55-256

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

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Unload Tube Out Solenoid L04 (Front Of Stack) Connector X016 Front Frame Ground 2

55-257

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

UNLOAD FRAME-- 22

B-38 = UNLOAD CRADLE B-47 = COVERS CLOSED L-03 = UNLOAD TUBE IN L-04 = UNLOAD TUBE OUT

L-08 = UNLOAD TUBE CLUTCH S-28 = GRAIN BIN 3/4 FULL S-29 = GRAIN BIN FULL S-42 = TANK COVERS SWITCH

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0195-11 Foot-an-Inch Valve Unidentified Failure Code Cause: The foot-and-inch valve (L-05) circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad solenoid. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with Step 9. 2. Disconnect connector X092. Use a multimeter to check the resistance of the foot and inch valve coil (L05). The proper resistance range is 8 to 12 ohms. A. If there is zero resistance, the foot and inch solenoid is shorted internally. Replace the solenoid. B. If there is infinite resistance, the foot and inch solenoid is open. Replace the solenoid. C. If the resistance is correct, continue with Step 3. 3. Use a multimeter to check for continuity between connector X092 pin A (harness side) and chassis ground. Flex the lower frame (LF) harness while making this check. A. If there is continuity to ground, continue with Step 4. B. If there is no continuity to ground, continue with Step 5. 4. Disconnect connector X023. Use a multimeter to check for continuity between connector X023 pin 13 and chassis ground. Flex the front frame (FF) harness between the connector X023 and connector X017 while making this check. A. If there is no continuity to ground, the short to ground is in the lower frame (LF) harness between connector X023 and connector X092 wire 575 white. Locate the short and repair. B. If there is continuity to ground, the short to ground is in the front frame (FF) harness between connector X023 and connector X017 wire 575 white. Locate the short and repair. 5. Use a multimeter to check for continuity between connector X092 pin B (harness side) and chassis ground. Flex the lower frame (LF) harness while making this check. A. If there is no continuity to ground, continue with Step 6. B. If there is continuity to ground, continue with Step 7.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 6. Disconnect connector X023. Use a multimeter to check for continuity between connector X023 pin 25 (harness side) and chassis ground. Flex the front frame (FF) harness between connector X023 and the front frame ground 2 while making this check. A. If there is continuity to ground, there is an open circuit in the lower frame (LF) harness between connector X092 and connector X023 wire 606 or 765 black. Locate the open and repair. B. If there is no continuity to ground, there is an open circuit in the front frame (FF) harness between connector X023 pin 25 and the front frame ground 2 wire 765 black. Locate the open and repair. 7. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the foot and inch valve. Use a multimeter to check for 12 volts between connector X092 pin A and chassis ground. A. If 12 volts is not present, continue with Step 8. B. If 12 volts is found, continue with Step 9. 8. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the foot and inch valve. Use a multimeter to check for 12 volts between connector X023 pin 13 and chassis ground. A. If 12 volts is present, the open circuit is in the lower frame (LF) harness between connector X092 pin A and connector X023 pin 13 wire 575 white. Locate the open circuit and repair. B. If 12 volts is not present there is an open circuit in the front frame (FF) harness between connector X023 pin 13 and connector X017 pin J3-15 wire 575 white. Locate the open and repair. 9. Erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

10013278

10010898

50020096

45 1. 2. 3. 4.

Foot and Inch Solenoid L05 Connector X023 Connector X017 Front Frame Ground 2

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

DRIVES FRAME-- 8

B-46 = HYDROSTAT MOTOR TEMP H-08 = BACK UP ALARM L-05 = PRESSURE RELEASE L-26 = REAR WHEEL ASSIST

L-27 = DUAL RANGE S-49 = BRAKE FLUID LEVEL SWITCH S-55 = LH BRAKE WEAR SWITCH S-56 = RH BRAKE WEAR SWITCH

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0198-11 Backlighting Lamps Unidentified Failure Code Cause: The Backlighting Lamps circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Controller internal failure (internal regulator failure). Solution: The backlighting circuit is used to power the backlights in the HVAC module and all cab roof switches. Power is sent from CCM2 to the splice block C, W03, in the cab roof. From there, power is distributed to all switches for backlighting. The backlighting circuits in each cab roof switch are grounded to the cab roof ground 4. A short to ground between the module and any one of the switch backlights fed by this circuit will cause this error, while an open circuit must be between the CCM2 module and the splice block C, W03, in order to generate this error. An open circuit between the splice block and one of the switches will result in that backlight not functioning, while the overall circuit will still perform properly. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with Step 15. 2. Key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the backlighting lamps circuit. Use the multimeter to check for 12 volts between connector X015 J1-11 and chassis ground. A. If 12 volts is not present, replace the CCM2 with a known good controller. B. If 12 volts is present, continue with Step 3. 3. Key off. Remove the HVAC controller from its DIN slot to provide access to the cab roof harness. Remove the cap/buss strip from the cab roof harness splice block C connector X133. Use the multimeter to check for continuity between connector X133 pin B and chassis ground. There should be no continuity, or very high continuity to ground, depending on the type of multimeter used. A. If there is continuity to ground, there is a short to ground in the cab main (CM) harness or cab roof (CR) harness between connector X015 pin J1-11 through connector X002 pin 18 [pin U, below SN HAJ100074] to connector X133 pin B on one of the following wires: wire 231 purple, connector X015 pin J1-11 to cab main harness splice wire 247 purple, cab main harness splice to connector X075 on accessory socket J08 wire 206 purple, cab main harness splice to connector X070 on cigar lighter R08 wire 232 purple, cab main harness splice to connector X002, pin 18 [pin U, below SN HAJ100074] wire 232 purple, connector X002 pin 18 to connector X133 pin B Locate short and repair. B. If there is no continuity to ground, continue with Step 4.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 4. Key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the backlighting lamps circuit. Use the multimeter to check for 12 volts between connector X133 pin B and chassis ground. A. If 12 volts is not present, there is an open circuit in the cab main (CM) harness or cab roof (CR) harness between connector X015 pin J1-11 through connector X002 pin 18 to connector X133 pin B on wires 231 purple or 232 purple. Locate open and repair. B. If 12 volts is present, continue with Step 5. 5. Key off. Use the multimeter to check for continuity between connector X133 pin A and chassis ground. There should be no continuity, or very high continuity to ground, depending on the type of multimeter used. A. If there is continuity to ground, there is a short to ground in the cab roof (CR) harness between connector X133 pin A to connector X138 pin 1 wire 175 purple to the console light E35. B. If there is no continuity to ground, continue with Step 6. 6. Key off. Use the multimeter to check for continuity between connector X133 pin C and chassis ground. There should be no continuity, or very high continuity to ground, depending on the type of multimeter used. A. If there is continuity to ground, there is a short to ground in the cab roof (CR) harness between connector X133 pin C to connector X131 pin 7 wire 233 purple to the rear work lights switch S44. B. If there is no continuity to ground, continue with Step 7. 7. Key off. Use the multimeter to check for continuity between connector X133 pin D and chassis ground. There should be no continuity, or very high continuity to ground, depending on the type of multimeter used. A. If there is continuity to ground, there is a short to ground in the cab roof (CR) harness between connector X133 pin D to connector X132 pin 7 wire 235 purple to the work lights switch S43. B. If there is no continuity to ground, continue with Step 8. 8. Key off. Use the multimeter to check for continuity between connector X133 pin E and chassis ground. There should be no continuity, or very high continuity to ground, depending on the type of multimeter used. A. If there is continuity to ground, there is a short to ground in the cab roof (CR) harness between connector X133 pin E to connector X135 pin 7 wire 273 purple to the wiper switch S20. B. If there is no continuity to ground, continue with Step 9. 9. Key off. Use the multimeter to check for continuity between connector X133 pin F and chassis ground. There should be no continuity, or very high continuity to ground, depending on the type of multimeter used. A. If there is continuity to ground, there is a short to ground in the cab roof (CR) harness between connector X133 pin F to connector X130 pin 7 wire 283 purple to the beacon light switch S41. B. If there is no continuity to ground, continue with Step 10. 10. Key off. Use the multimeter to check for continuity between connector X133 pin G and chassis ground. There should be no continuity, or very high continuity to ground, depending on the type of multimeter used. A. If there is continuity to ground, there is a short to ground in the cab roof (CR) harness between connector X133 pin G to connector X125 pin 7 wire 284 purple to the tank extensions switch S42. B. If there is no continuity to ground, continue with Step 11. 11. Key off. Use the multimeter to check for continuity between connector X133 pin H and chassis ground. There should be no continuity, or very high continuity to ground, depending on the type of multimeter used. A. If there is continuity to ground, there is a short to ground in the cab roof (CR) harness between connector X133 pin H to connector X127 pin 7 wire 285 purple to the mirror heat switch S19. B. If there is no continuity to ground, continue with Step 12.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 12. Key off. Use the multimeter to check for continuity between connector X133 pin J and chassis ground. There should be no continuity, or very high continuity to ground, depending on the type of multimeter used. A. If there is continuity to ground, there is a short to ground in the cab roof (CR) harness between connector X133 pin J to connector X134 pin 7 wire 286 purple to the washer switch S38. B. If there is no continuity to ground, continue with Step 13. 13. Key off. Use the multimeter to check for continuity between connector X133 pin M and chassis ground. There should be no continuity, or very high continuity to ground, depending on the type of multimeter used. A. If there is continuity to ground, there is a short to ground in the cab roof (CR) harness between connector X133 pin M to connector X128 pin C1 wire 972 purple to the HVAC control module A09. B. If there is no continuity to ground, continue with Step 14. 14. Remove the tank extensions switch S42 from the cab roof head liner, and unplug connector X125. Use the multimeter to check for continuity between connector X125 pin 9 and chassis ground. A. If there is no continuity to ground, remove the cab headliner and check the condition of the cab roof ground 4. If all switch backlighting ground wires were disconnected from this ground point, this could also generate this fault code. B. If there is continuity to ground, continue with Step 15. 15. Erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

ZDA2687A

14 12 13

10004693

50026213

46 1. 2. 3. 4. 5.

Connector X015 Console Light E35 Mirror Heat Switch S19 Covers Open Switch S42 Climate Control Module A09

6. 7. 8. 9. 10.

Splice Block C, W03 Wiper Switch S20 Washer Switch S38 Beacon Light Switch S41 Rear Work Lights Switch S44

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11. 12. 13. 14.

Front Work Lights Switch S43 Cigar Lighter R08 Accessory Outlet J08 Cab Roof Ground #4

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

UNLOAD FRAME-- 22

B-38 = UNLOAD CRADLE B-47 = COVERS CLOSED L-03 = UNLOAD TUBE IN L-04 = UNLOAD TUBE OUT

L-08 = UNLOAD TUBE CLUTCH S-28 = GRAIN BIN 3/4 FULL S-29 = GRAIN BIN FULL S-42 = TANK COVERS SWITCH

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-49 = CAB FUSE S-05 = SEAT SWITCH W-03 = SPLICE BLOCK C

DISTRIBUTION FRAME-- 27

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

LIGHTING FRAME-- 38

E-34 = DOME LIGHT E-35 = CONSOLE LIGHT E-42 = LH FRONT SHIELD LT E-43 = LH REAR SHIELD LT

E-44 = RH FRONT SHIELD LT E-45 = RH REAR SHIELD LT E-46 = ENGINE LT F-34 = UNDERSHIELD LIGHTS

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F-52 = DOME/BRAKE LT FUSE K-20 = TIME DELAY MODULE K-33 = BRAKE LIGHTS RELAY S-40 = LH DOOR SWITCH

S-63 = LEFT SHIELD LT SW S-64 = ENGINE LT SW S-65 = RIGHT SHIELD LT SW

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

E-31 = LH FRONT BEACON LIGHT E-32 = RH FRONT BEACON LIGHT E-33 = REAR BEACON LIGHT F-15 = SERVICE SOCKETS FUSE

F-53 = BEACON LT FUSE J-02 = LH FT SERVICE SOCKET J-03 = RH SIDE SERVICE SOCKET J-05 = ENGINE SERVICE SOCKET

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K-29 = BEACON LIGHT RELAY S-41 = BEACON LIGHT SWITCH

LIGHTING FRAME-- 39

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

LIGHTING FRAME-- 42

E-27 = LH REAR WORK LIGHT E-28 = RH REAR WORK LIGHT F-55 = REAR WORK LTS FUSE K-31 = REAR WORK LTS RELAY

S-43 = WORK LIGHT SWITCH S-44 = REAR WORK LIGHT SWITCH

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

ACCESSORY FRAME-- 44

F-64 = SWITCH BYPASS FUSES M-19 = RH MIRROR UP/DOWN M-20 = RH MIRROR IN/OUT M-21 = LH MIRROR UP/DOWN

M-22 = LH MIRROR IN/OUT M-30 = GERMAN MIRROR UP/DOWN M-31 = GERMAN MIRROR IN/OUT R-10 = RH MIRROR HEAT

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R-11 = LH MIRROR HEAT R-14 = RH GERMAN MIRROR HEAT S-19 = MIRROR HEAT SWITCH S-27 = MIRROR ADJUST SWITCH

S-57 = MIRROR SELECT SWITCH (D)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

F-03 = ACCESSORY 1 FUSE F-04 = WIPER FUSE F-05 = CIGAR LIGHTER FUSE F-08 = ACCESSORY OUTLET FUSE

F-09 = WASHER/MIRROR FUSE F-10 = NOT USED J-06 = ACCESSORY SOCKET J-08 = ACCESSORY OUTLET

K-06 = WIPER RELAY K-08 = ACCESSORY 1 RELAY M-24 = WIPER WASHER MOTOR M-25 = WIPER MOTOR

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R-08 = CIGAR LIGHTER S-20 = WIPER SWITCH S-38 = WASHER SWITCH

ACCESSORY FRAME-- 45

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

A-09 = HVAC CONTROL MODULE A-14 = BLOWER SPEED CONTROL A-15 = ATC MODULE B-26 = CAB TEMP SENSOR

B-27 = OUTLET TEMP SENSOR B-28 = EVAPORATOR TEMP SENSOR M-15 = COLD BOX DOOR M-16 = WATER VALVE

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M-17 = MAIN BLOWER S-48 = A/C LOW PRESSURE

HVAC FRAME-- 47

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0199-11 Brake Lights Relay Unidentified Failure Code Cause: The Brake lights Relay (K-33) circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad relay. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the reading is within the proper range, the circuit is working properly. Continue with Step 7. 2. Turn the key switch to the OFF position and remove the Brake Lights Relay K33. Use a multimeter to check the resistance of the relay coil. The proper resistance range for the relay coil is 74.3 to 78.3 ohms. A. If out of specification replace relay. B. If the coil is within specification continue with Step 3. 3. Use a multimeter to check for continuity between relay socket pin 1 and chassis ground. A. If no continuity to ground is found continue with Step 4. B. If there is continuity to ground, there is a short to ground on wire 183 white in the cab main (CM) harness between the fuse panel and connector X015 pin J1-18. Locate the short and repair. 4. Use a multimeter to check for continuity between relay socket pin 2 and chassis ground. A. If continuity to ground is found continue with Step 5. B. If there is no continuity to ground, there is an open circuit on wire 159 black in the cab main (CM) harness between the fuse panel and cab ground 3. Locate the open and repair. 5. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the brake lights relay. Use the multimeter to check for 12 volts between relay socket pin 1 and chassis ground. A. If 12 volts is not present continue with Step 6. B. If 12 volts is found continue with Step 7. 6. Key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the brake lights relay. Use the multimeter to check for 12 volts between connector X015 J1-18 and chassis ground. A. If 12 volts is not present, replace the CCM2 with a known good controller. B. If 12 volts is present, the open is between connector X015 J1-18 and relay socket pin 1 wire 183 white. Locate the open and repair. 7. Erase the fault code and continue operation.

55-275

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

1 2 10004693

50020070

50026204

47 1. 2.

Connector X015 Brake Lights Relay K33

55-276

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

LIGHTING FRAME-- 38

E-34 = DOME LIGHT E-35 = CONSOLE LIGHT E-42 = LH FRONT SHIELD LT E-43 = LH REAR SHIELD LT

E-44 = RH FRONT SHIELD LT E-45 = RH REAR SHIELD LT E-46 = ENGINE LT F-34 = UNDERSHIELD LIGHTS

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F-52 = DOME/BRAKE LT FUSE K-20 = TIME DELAY MODULE K-33 = BRAKE LIGHTS RELAY S-40 = LH DOOR SWITCH

S-63 = LEFT SHIELD LT SW S-64 = ENGINE LT SW S-65 = RIGHT SHIELD LT SW

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0200-11 Beacon Lights Relay Unidentified Failure Code Cause: The Beacon lights relay (K-29) circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad relay. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the reading is within the proper range, the circuit is working properly. Continue with Step 7. 2. Turn the key switch to the OFF position and remove the Beacon Lights Relay K29. Use a multimeter to check the resistance of the relay coil. The proper resistance range for the relay coil is 74.3 to 78.3 ohms. A. If out of specification replace relay. B. If the coil is within specification continue with Step 3. 3. Use a multimeter to check for continuity between relay socket pin 1 and chassis ground. A. If no continuity to ground is found continue with Step 4. B. If there is continuity to ground, there is a short to ground on wire 182 white in the cab main (CM) harness between the fuse panel and connector X015 pin J1-24. Locate the short and repair. 4. Use a multimeter to check for continuity between relay socket pin 2 and chassis ground. A. If continuity to ground is found continue with Step 5. B. If there is no continuity to ground, there is an open circuit on wire 160 black in the cab main (CM) harness between the fuse panel and cab ground 3. Locate the open and repair. 5. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the beacon lights relay. Use the multimeter to check for 12 volts between relay socket pin 1 and chassis ground. A. If 12 volts is not present continue with Step 6. B. If 12 volts is found continue with Step 7. 6. Key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the beacon lights relay. Use the multimeter to check for 12 volts between connector X015 J1-24 and chassis ground. A. If 12 volts is not present, replace the CCM2 with a known good controller. B. If 12 volts is present, the open is between connector X015 J1-24 and relay socket pin 1 wire 182 white. Locate the open and repair. 7. Erase the fault code and continue operation.

55-278

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

10004693

50020070

50026204

48 1. 2.

Connector X015 Beacon Light Relay K29

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

E-31 = LH FRONT BEACON LIGHT E-32 = RH FRONT BEACON LIGHT E-33 = REAR BEACON LIGHT F-15 = SERVICE SOCKETS FUSE

F-53 = BEACON LT FUSE J-02 = LH FT SERVICE SOCKET J-03 = RH SIDE SERVICE SOCKET J-05 = ENGINE SERVICE SOCKET

55-280

K-29 = BEACON LIGHT RELAY S-41 = BEACON LIGHT SWITCH

LIGHTING FRAME-- 39

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0201-11 Flasher System Selection Unidentified Failure Code Cause: The Flasher System Selection circuit open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad flasher module. 3. Controller internal failure (internal regulator failure). Solution: The CCM2 module is used to control the flashing lights operating mode, depending on which market area the combine is operating in. The correct flashing light mode is selected in the Toolbox, ELECTR (Electrical Setup) screen. “NASO” should be selected if the combine is being used in North America, while “ISO” should be used for all other market areas. This ensures that the flashing lights respond correctly to meet legal and homologation requirements. When “ISO” is selected, the CCM2 module will send a 12 volt signal to the flasher module A05 to switch it into the “ISO” operating mode. If a 12 volt signal is not applied, then the flasher module will operate in the “NASO” operating mode. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the reading is within the proper range, the circuit is working properly. Continue with Step 6. 2. Key Off. Disconnect connector X255 from the Flasher module A05. Use a multimeter to check for continuity between connector X255 pin 9 (harness side) and chassis ground. Flex the steering column (SC) harness between the flasher module and connector X033 while making this check. A. If there is continuity to ground, continue with Step 3. B. If there is no continuity to ground, continue with Step 4. 3. Disconnect connector X033. Use a multimeter to check for continuity between connector X033 pin 10 and chassis ground. Flex the cab main (CM) harness between the connector X033 and connector X015 while making this check. A. If there is no continuity to ground, the short to ground is in the steering column (SC) harness between connector X033 and connector X255 wire 204 purple. Locate the short and repair. B. If there is continuity to ground, the short to ground is in the cab main (CM) harness between connector X033 and connector X015 wire 204 purple. Locate the short and repair. 4. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. Use a multimeter to check for 12 volts between connector X255 pin 9 and chassis ground. A. If 12 volts is not present, continue with Step 5. B. If 12 volts is found, continue with Step 6.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 5. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. Use a multimeter to check for 12 volts between connector X033 pin 10 and chassis ground. A. If 12 volts is present, the open circuit is in the steering column (SC) harness between connector X255 pin 9 and connector X033 pin 10 wire 204 purple. Locate the open circuit and repair. B. If 12 volts is not present there is an open circuit in the cab main (CM) harness between connector X033 pin 10 and connector X015 pin J1-5 wire 204 purple. Locate the open and repair. 6. Erase the fault code and continue operation.

55-282

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

3 2 10010914

10004693

50026204

49 1. 2. 3.

Connector X015 Connector X033 Flasher Module A05

55-283

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

LIGHTING FRAME-- 36

A-05 = FLASHER MODULE E-13 = LH ROAD LIGHT E-14 = RH ROAD LIGHT F-32 = HIGH BEAM FUSE

F-33 = LOW BEAM FUSE F-51 = HORN, MARKER LTS FUSE H-02 = HORN K-02 = LIGHT CONTROL RELAY

55-284

K-04 = HIGH BEAM RELAY K-05 = LOW BEAM RELAY S-26 = ROAD LIGHT SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0202-11 Ground Speed Hydrostat Unidentified Failure Code NOTE: The error history should be checked before starting this diagnostic procedure. If any of the following fault codes have occurred, they should be corrected first. E0179-03 -- LoP Isense Grnd Spd Hydro Shorted to High Source. E0179-04 -- LoP Isense Grnd Spd Hydro Shorted to Low Source. E0179-05 -- LoP Isense Grnd Spd Hydro Line Disconnected. Cause: The ground speed hydrostat valve (L-23) circuit is shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad solenoid. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper ground speed hydrostat valve control voltage is as follows: Handle in neutral -- 0V. Handle full forward -- 4.4 to 5V. Handle full rearward -- 2.5V. The voltage should increase progressively with handle position. When moving the handle out of neutral, if the voltage spikes to maximum, and then abruptly drops to zero, there is a short to ground on the output lead to the control valve. A. If the voltage reading goes high (>4.7V in either forward or reverse) and then drops to zero, continue with Step 2. B. If the readings are within the proper ranges, continue with Step 10. 2. Turn the key switch to the OFF position. Disconnect the ground speed hydrostat valve connector X100. Use a multimeter to check the resistance of the ground speed hydrostat valve coil between terminals D and C, and then between terminals A and B. The proper resistance range for the ground speed hydrostat valve coil L23 is 16K to 20K ohms. A. If out of specification, replace the solenoid. B. If the coil is within specification, continue with Step 3. 3. Use a multimeter to check for continuity between the ground speed hydrostat valve coil connector terminals D or C and chassis ground. There should not be continuity to ground. A. If there is continuity, replace the solenoid. B. If there is no continuity to ground, continue with Step 4. 4. Use a multimeter to check for continuity between the harness end of connector X100 pin D and chassis ground. Flex the harness while making this check. There should not be continuity to ground. A. If there is continuity to ground, continue with Step 5. B. If there is no continuity to ground, continue with Step 7.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 5. Disconnect connector X011. Use the multimeter to check for continuity between the main frame (MF) harness end of connector X011 pin Q and chassis ground. There should not be continuity to ground. A. If there is no continuity to ground, a short to ground is located in the gearbox (GB) harness between connector X011 and connector X100 wire 880 white. Locate the short and repair. B. If there is continuity to ground, continue with Step 6. 6. Disconnect connector X008. Use a multimeter to check for continuity between the front frame (FF) harness end of connector X008 pin 12 and chassis ground. There should not be continuity to ground. A. If there is no continuity to ground, a short to ground is located in the main frame (MF) harness between connector X011 and connector X008 wire 880 white. Locate the short and repair. B. If there is continuity to ground, the short to ground is in the front frame (FF) harness between connector X017 J3-31 and connector X008 wire 880 white. Locate the short and repair. 7. Use a multimeter to check for continuity between the harness end of connector X100 pin A and chassis ground. A. If there is continuity to ground, continue with Step 8. B. If there is no continuity to ground, continue with Step 10. 8. Disconnect connector X011. Use a multimeter to check for continuity between the main frame (MF) harness end of connector X011 pin P and chassis ground. There should not be continuity to ground. A. If there is no continuity to ground, a short to ground is located in the gearbox (GB) harness between connector X100 pin A and connector X011 pin P wire 879 gray. Locate the short and repair. B. If there is continuity to ground, continue with Step 9. 9. Disconnect connector X008. Use a multimeter to check for continuity between the front frame (FF) harness end of connector X008 pin 11 and chassis ground. There should not be continuity to ground. A. If there is no continuity to ground, a short to ground is located in the main frame (MF) harness between connector X011 pin P and connector X008 pin 11 wire 879 gray. Locate the short and repair. B. If there is continuity to ground, the short to ground is located in the front frame (FF) harness between connector X017 J3-21and connector X008 wire 879 gray. Locate the short and repair. 10. Visually inspect the harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. A. If no damage is found, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

10020076

4 1

10010872

10020075

50020097

50 1. 2. 3. 4.

Ground Speed Hydrostat L23 Connector X011 Connector X008 Connector X017

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

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S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME-- 9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0203-05 Transmission Shift Motor Line Disconnected Context: The CCM has detected that the circuit current has been <0.7 Amps for at least 3 seconds, while the control circuit input is active. Lack of current flow in an activated circuit is an indication of an open circuit condition. However, it is also possible to get this error message from a direct short to ground. This is because the CCM contains built-in over temperature circuit protection logic that will electronically disconnect the motor in order to prevent damage to the module. When a direct short to ground is present, and the motor is energized, it is possible for the rapid spike in current to engage the circuit protection -opening the circuit. When this occurs, the fault detection software sees the open and may report the “Line disconnected” fault. Cause: The transmission shift motor (M-02) control voltage circuit open, or shorted to ground. Possible failure modes: 1. Mechanical Defect -- binding or jammed shift mechanism 2. Motor Defect -- motor does not generate sufficient torque to turn shift mechanism 3. Electrical Defect -- fuse, wiring, or connector has an open or short circuit 4. Controller Defect -- CCM-2 does not generate proper voltage or currents

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 2. Fuse F-25 may have opened. Check and replace the fuse with one of the proper amperage if necessary. A. If the fuse immediately fails, continue with step 3. B. If the fuse is okay, continue with Step 6. 3. There may be a short in the cab main (CM) or front frame (FF) harnesses. Disconnect batteries. Remove fuse F-25. Disconnect front frame (FF) harness connector X017 on CCM-2. Use a multi-meter to check for continuity from front frame (FF) harness side of connector X017 pin 29 and pin 30 to chassis ground. There should be no continuity. A. If continuity is found, continue with Step 4. B. If no continuity is found, continue with Step 5. 4. There is a short in the cab main (CM) or front frame (FF) harnesses. Disconnect cab main harness from the front frame (FF) harness at connector X031. Use a multi-meter to check for continuity from front frame (FF) harness side of connector X031 pin 14 to chassis ground. There should be no continuity. A. If continuity is not found, there is a short to ground in the cab main (CM) harness in wire 029 red between fuse F-25 pin B and connector X031 pin 14. Locate the short and repair. Re-assemble the system and recheck. B. If continuity is found, there is a short to ground in the front frame (FF) harness in either wire 029 red between connector X031 pin 14 and the front frame (FF) harness splice or wire 507 red between the harness splice and connector X017 pin J3-29 or wire 508 red between the harness splice and connector X017 pin J3-30. Locate the short and repair. Re-assemble the system and recheck. 5. There may be a short internal to CCM-2. Reconnect connector X031 and disconnect connector X017. Re-connect batteries. Replace fuse F-25. A. If the fuse does not immediately fail, replace CCM-2. Recheck circuit operation. B. If the fuse immediately fails, return to step 3. 6. The transmission shift motor harness may be open circuit. Disconnect the transmission shift motor connector X094. Remove the pins from the transmission shift motor connector by removing the lock on rear of connector, then push pins out. Couple the individual pins into the lower frame (LF) harness connector X094 (brown into pin A, blue into pin B). Use a multi-meter to measure the voltage between connector X094 pins A and B. Use the display monitor, reference section 55 chapter 2, if needed, to recheck the transmission shift motor and monitor current. NOTE: CCM2 reverses the voltage polarity pins A and B to control motor direction. A digital multi-meter will display the positive and negative voltages. If an analog multi-meter is used, then the polarity of the leads needs to be adjusted to always read positive voltage. A. If the multi-meter reads ± 12 volts depending on direction and the current draw is zero on the display, replace the transmission shift motor. Re-assemble the system and recheck. B. Otherwise, leave connector X094 disconnected and continue with step 7.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 7. Connect a multi-meter between the transmission shift motor connector X094 pin B (in the configuration described in step 6) and a known good ground. Use the display monitor, reference section 55 chapter 2, if needed, to move the motor CW. A. If the measured voltage is 12 V, continue with step 10. B. Otherwise, continue with step 8. 8. There may be an open in the lower frame (LF) harness. Disconnect batteries. Disconnect connector X023. Check for continuity between connector X094 pin B, and connector X023 pin 3. There should be continuity. A. If there is no continuity, there is an open between connector X023 pin 3 and connector X094 pin B wire 715 grey. Locate and repair the open circuit. Re-assemble the system and recheck. B. If there is continuity, continue with step 9. 9. There may be an open in the front frame (FF) harness. Disconnect connector X017 from CCM-2. Check for continuity between connector X023 pin 3 and connector X017 pin J3-19 and pin J3-20. There should be continuity. A. If there is no continuity, there is an open between connector X023 pin 3 and connector X017 pin J3-19 or J3-20 wire 715, 526 or 527 grey. Locate and repair the open circuit. Re-assemble the system and recheck. B. If there is continuity, there may be an internal problem with CCM-2. Replace the module. 10. Connect a multi-meter between the transmission shift motor connector X094 pin A (in the configuration described in step 6) and a known good ground. Use the display monitor, reference section 55 chapter 2, if needed, to move the motor CCW. A. If the measured voltage is 12 V, continue with step 13. B. Otherwise, continue with step 11. 11. There may be an open in the lower frame (LF) harness. Disconnect batteries. Disconnect connector X023. Check for continuity between connector X094 pin A and connector X023 pin 4. There should be continuity. A. If there is no continuity, there is an open between connector X023 pin 4 and connector X094 pin A wire 716 white. Locate and repair the open circuit. Re-assemble the system and recheck. B. If there is continuity, continue with step 12. 12. There may be an open in the front frame (FF) harness. Disconnect connector X017 from CM2. Check for continuity between connector X023 pin 4 and connector X017 pins J3-39 and J3-40. There should be continuity. A. If there is no continuity, there is an open between connector X023 pin 4 and connector X017 pin J3-39 or J3-40 wire 716, 528 or 529 white. Locate and repair the open circuit. Re-assemble the system and recheck. B. If there is continuity, there may be an internal problem with CCM-2. Replace the module. 13. There may be an open in the front frame (FF) harness. Disconnect batteries. Disconnect connector X017. Check for continuity on the front frame (FF) harness side from connector X017 pin J3-9 and J3-10 to chassis ground. There should be continuity. A. If there is no continuity, there is an open between connector X017 pin J3-9 or J3-10 and chassis ground wire 516, 517 or 538 black. Locate and repair the open circuit. Re-assemble the system and recheck. B. If there is continuity, there may be an internal problem with CCM-2. Replace the module.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0203-11 Transmission Shift Motor Unidentified Failure Code Cause: The transmission shift motor (M-02) open circuit or short to ground. Possible failure modes: 1. Mechanical Defect -- binding or jammed shift mechanism 2. Motor Defect -- motor does not generate sufficient torque to turn shift mechanism 3. Electrical Defect -- fuse, wiring, or connector has an open or short circuit 4. Controller Defect -- CCM-2 does not generate proper voltage or currents

Solution: 1. Use the display monitor, reference section 55 chapter 2, if needed, to record then erase the error history. Start the combine and shift the transmission in both directions, observe the gear indicator in the Display DOG area, note success or failure for each shift, note any alarms or errors that appear on the display. Turn the combine engine off. With the key on, and engine not running, use the Display Monitor diagnostic capability to view “Item” status, reference Section 55 Chapter 2, if needed, to observe gear readout and to operate transmission shift motor in each direction; clockwise to shift down, counterclockwise to shift up. NOTE: Do not drive motor at high current (>26 amps) for more than one second -- this will happen when driving into stops at 1 & 4 gear. A. If the motor does not operate in either or in only one direction and Fault Code E0171-06 or E0203-11 occurs, continue with step 2. B. If the motor does not operate in either or in only one direction and Fault Code E0203-05 was in error history, continue with step 9. NOTE: Do not attempt to manually shift the transmission with a wrench while the transmission shift motor connected. Because of internal gearing, the transmission shift motor cannot be manually turned. Attempting to do so will destroy the transmission shift motor. 2. The transmission shift mechanism may be mechanically bound, resulting in high current draw, refer to the appropriate chapter in this Repair Manual. Without disconnecting the motor connector, remove the transmission shift motor. Tie the motor in place so the harness will not be damaged. Use the display monitor, reference section 55 chapter 2, if needed, to recheck the transmission shift motor function. The transmission shift motor should turn each direction (visual check) with less than 5 amps. A. If the motor functions properly, the problem is with the transmission, refer to the appropriate chapter in this Repair Manual to troubleshoot and correct. B. If the motor does not function, continue with step 3

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 3. The transmission shift motor may be mechanically bound or electrically shorted to ground, resulting in high current draw. Disconnect the transmission shift motor connector X094. Use the display monitor, reference section 55 chapter 2, if needed, to recheck the motor function. With the transmission shift motor disconnected, the current should be zero. A. If the current is zero in both directions, replace the motor. Recheck the system. B. If current is not zero in both directions, continue with step 4. 4. The harness may be shorted to ground. With ignition key OFF and batteries disconnected, by removing the negative battery cables, use a multi-meter to check for continuity between the lower frame (LF) harness end of connector X094 pin A and chassis ground. There should not be any continuity to ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to lock the motor in position. Power must be removed from the module prior to testing for short to ground condition on the motor circuit to remove this ground path. A. If continuity is found, continue with Step 5. B. If no continuity is found, continue with Step 6. 5. There is a short in either the lower frame (LF) or front frame (FF) harness. Disconnect connector X023 and use a multi-meter to check for continuity between the lower frame (LF) harness side of connector X094 pin B and chassis ground. There should not be any continuity to ground. A. If continuity is found, there is a short to ground in the lower frame (LF) harness in wire 715 grey between connector X023 pin 3 and connector X094 pin B. Locate the short and repair. Re-assemble the system and recheck. B. If no continuity is found, there is a short to ground in the front frame (FF) harness in either; wire 715 grey between connector X023 pin 3 and the front frame (FF) harness splice or wire 526 grey between the harness splice and connector X017 pin J3-19 or wire 527 grey between the harness splice and connector X017 pin J3-20. Locate the short and repair. Re-assemble the system and recheck. 6. Use a multi-meter to check for continuity between the harness end of connector X094 pin A and chassis ground. There should not be any continuity to ground. A. If continuity is found, continue with Step 7. B. If no continuity is found, continue with Step 8. 7. There is a short in either the lower frame (LF) or front frame (FF) harness. Disconnect connector X023. Use a multi-meter to check for continuity between the lower frame (LF) harness side of connector X094 pin A and chassis ground. There should not be any continuity to ground. A. If continuity is found, there is a short to ground in the lower frame (LF) harness in wire 716 white between connector X023 pin 4 and connector X094 pin A. Locate the short and repair. Re-assemble the system and recheck. B. If no continuity is found, there is a short to ground in the front frame (FF) harness in either; wire 716 white between connector X023 pin 4 and the front frame (FF) harness splice or wire 528 white between the harness splice and connector X017 pin J3-39 or wire 529 white between the harness splice and connector X017 pin J3-40. Locate the short and repair. Re-assemble the system and recheck. 8. CCM-2 may be shorted internally. Disconnect connector X017 and extract pins J3-19, J3-20, J3-39, and J3-40 from the front frame (FF) harness side of the connector (if the wire numbers are not visible, mark the wires to ensure proper reassembly). Reconnect connector X017 and reconnect the batteries. Use the display monitor, reference section 55 chapter 2, if needed, to recheck the motor function. With the transmission shift motor disconnected, the current should be zero. A. If the current is not zero, replace CCM-2. B. If the current is zero, re-assemble the system and re-check for functionality. Check harness for locations that could have an intermittent short due to chaffing or pinching.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 9. Fuse F-25 may have opened. Check and replace the fuse with one of the proper amperage if necessary. A. If the fuse immediately fails, continue with step 10. B. If the fuse is okay, continue with Step 13. 10. There may be a short in the cab main (CM) or front frame (FF) harnesses. Disconnect batteries. Remove fuse F-25. Disconnect front frame (FF) harness connector X017 on CCM-2. Use a multi-meter to check for continuity from front frame (FF) harness side of connector X017 pin 29 and pin 30 to chassis ground. There should be no continuity. A. If continuity is found, continue with Step 11. B. If no continuity is found, continue with Step 12. 11. There is a short in the cab main (CM) or front frame (FF) harnesses. Disconnect cab main harness from the front frame (FF) harness at connector X031. Use a multi-meter to check for continuity from front frame (FF) harness side of connector X031 pin 14 to chassis ground. There should be no continuity. A. If continuity is not found, there is a short to ground in the cab main (CM) harness in wire 029 red between fuse F-25 pin B and connector X031 pin 14. Locate the short and repair. Re-assemble the system and recheck. B. If continuity is found, there is a short to ground in the front frame (FF) harness in either wire 029 red between connector X031 pin 14 and the front frame (FF) harness splice or wire 507 red between the harness splice and connector X017 pin J3-29 or wire 508 red between the harness splice and connector X017 pin J3-30. Locate the short and repair. Re-assemble the system and recheck. 12. There may be a short internal to CCM-2. Reconnect connector X031 and disconnect connector X017. Re-connect batteries. Replace fuse F-25. A. If the fuse does not immediately fail, replace CCM-2. Recheck circuit operation. B. If the fuse immediately fails, return to step 11. 13. The transmission shift motor harness may be open circuit. Disconnect the transmission shift motor connector X094. Remove the pins from the transmission shift motor connector by removing the lock on rear of connector, then push pins out. Couple the individual pins into the lower frame (LF) harness connector X094 (brown into pin A, blue into pin B). Use a multi-meter to measure the voltage between connector X094 pins A and B. Use the display monitor, reference section 55 chapter 2, if needed, to recheck the transmission shift motor and monitor current. NOTE: CCM2 reverses the voltage polarity pins A and B to control motor direction. A digital multi-meter will display the positive and negative voltages. If an analog multi-meter is used, then the polarity of the leads needs to be adjusted to always read positive voltage. A. If the multi-meter reads ± 12 volts depending on direction and the current draw is zero on the display, replace the transmission shift motor. Re-assemble the system and recheck. B. Otherwise, leave connector X094 disconnected and continue with step 14. 14. Connect a multi-meter between the transmission shift motor connector X094 pin B (in the configuration described in step 13) and a known good ground. Use the display monitor, reference section 55 chapter 2, if needed, to move the motor CW. A. If the measured voltage is 12 V, continue with step 17. B. Otherwise, continue with step 15. 15. There may be an open in the lower frame (LF) harness. Disconnect batteries. Disconnect connector X023. Check for continuity between connector X094 pin B, and connector X023 pin 3. There should be continuity. A. If there is no continuity, there is an open between connector X023 pin 3 and connector X094 pin B wire 715 grey. Locate and repair the open circuit. Re-assemble the system and recheck. B. If there is continuity, continue with step 16.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 16. There may be an open in the front frame (FF) harness. Disconnect connector X017 from CCM-2. Check for continuity between connector X023 pin 3 and connector X017 pin J3-19 and pin J3-20. There should be continuity. A. If there is no continuity, there is an open between connector X023 pin 3 and connector X017 pin J3-19 or J3-20 wire 715, 526 or 527 grey. Locate and repair the open circuit. Re-assemble the system and recheck. B. If there is continuity, there may be an internal problem with CCM-2. Replace the module. 17. Connect a multi-meter between the transmission shift motor connector X094 pin A (in the configuration described in step 13) and a known good ground. Use the display monitor, reference section 55 chapter 2, if needed, to move the motor CCW. A. If the measured voltage is 12 V, continue with step 20. B. Otherwise, continue with step 18. 18. There may be an open in the lower frame (LF) harness. Disconnect batteries. Disconnect connector X023. Check for continuity between connector X094 pin A and connector X023 pin 4. There should be continuity. A. If there is no continuity, there is an open between connector X023 pin 4 and connector X094 pin A wire 716 white. Locate and repair the open circuit. Re-assemble the system and recheck. B. If there is continuity, continue with step 19. 19. There may be an open in the front frame (FF) harness. Disconnect connector X017 from CM2. Check for continuity between connector X023 pin 4 and connector X017 pins J3-39 and J3-40. There should be continuity. A. If there is no continuity, there is an open between connector X023 pin 4 and connector X017 pin J3-39 or J3-40 wire 716, 528 or 529 white. Locate and repair the open circuit. Re-assemble the system and recheck. B. If there is continuity, there may be an internal problem with CCM-2. Replace the module. 20. There may be an open in the front frame (FF) harness. Disconnect batteries. Disconnect connector X017. Check for continuity on the front frame (FF) harness side from connector X017 pin J3-9 and J3-10 to chassis ground. There should be continuity. A. If there is no continuity, there is an open between connector X017 pin J3-9 or J3-10 and chassis ground wire 516, 517 or 538 black. Locate and repair the open circuit. Re-assemble the system and recheck. B. If there is continuity, there may be an internal problem with CCM-2. Replace the module.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

1 10004664

10010898

50020096

51 1. 2. 3.

Transmission Shift Motor -- M02 Connector X023 Connector X017

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-17 = GROUND SPEED RPM B-37 = TRANS SHIFT POSITION B-53 = PARK BRAKE PRESSURE F-25 = TRANSMISSION SHIFT FUSE

L-10 = PARK BRAKE DISENGAGE L-23 = GROUND SPEED HYDROSTAT L-32 = BRAKE LIMITING M-02 = TRANSMISSION SHIFT MOTOR

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S-22 = NEUTRAL S-37 = CHARGE PRESSURE S-39 = BRAKE PRESSURE

DRIVES FRAME-- 9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0204-05 Header Reel Speed Motor Line Disconnected Context: The CCM has detected that the circuit current has been <0.7 Amps for at least 3 seconds, while the control circuit input is active. Lack of current flow in an activated circuit is an indication of an open circuit condition. However, it is also possible to get this error message from a direct short to ground. This is because the CCM contains built-in over temperature circuit protection logic that will electronically disconnect the motor in order to prevent damage to the module. When a direct short to ground is present, and the motor is energized, it is possible for the rapid spike in current to engage the circuit protection -opening the circuit. When this occurs, the fault detection software sees the open and may report the “Line disconnected” fault. Cause: The header reel speed motor (M-09) control voltage circuit open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad motor. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed. A. Start the combine. B. Engage the thresher and feeder circuits, and operate the reel speed motor in both directions. C. Record in which direction(s) the reel speed increase or decrease operates. D. Check for fault codes 0169-06 and 0204-05. E. Use the following table to determine the location of the fault. Symptom

Fault Code 0169-06

Reel Speed adjust operates in 1 direction only

Reel Speed adjust does not operate in either direction

Fault Type

0204-05 X X

Go to Step 2

Binding

Go to Step 3

Short to ground

Go to Step 2

Binding

Go to Step 10

Open circuit

Go to Step 17

No power supply

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 4. Disconnect the batteries using the battery key. Use the multimeter to check for continuity between connector X308 pin B on the header harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position. Power must be removed from the module prior to testing for short to ground condition on the motor circuit to remove this ground path. A. If continuity is found, continue with Step 5. B. If no continuity is found, continue with Step 7. 5. Disconnect inline connector X032. Use a multimeter to check for continuity between connector X032 pin 26 on the feeder (FE) harness side and chassis ground. A. If no continuity is found the short to ground is in the harness between connector X032 pin 26 and connector X308 pin B. Locate the short and repair. B. If continuity is found, continue with Step 6. 6. Disconnect connector X007. Use a multimeter to check for continuity between connector X007 pin 19 on the front frame (FF) harness side and chassis ground. A. If no continuity is found, the short to ground is in the harness between connector X032 pin 26 and connector X007 pin 19 wire 711 gray. Locate the short and repair. B. If continuity is found, the short to ground is in the harness between connector X007 pin 19 and connector X017 pin J3-6 wire 711 gray. Locate the short and repair. 7. Use a multimeter to check for continuity between connector X308 pin A on the header harness side and chassis ground. A. If continuity is found, continue with Step 8. B. If no continuity is found, recheck the motor for continuity to ground at Step 3. 8. Disconnect connector X032. Use a multimeter to check for continuity between connector X032 pin 20 on the feeder (FE) harness side and chassis ground. A. If no continuity is found, the short to ground is in the harness between connector X308 pin A and connector X032 pin 20. Locate the short and repair. B. If continuity is found, continue with Step 9. 9. Disconnect connector X007. Use a multimeter to check for continuity between connector X007 pin 3 on the front frame (FF) harness side and chassis ground. A. If no continuity is found, the short to ground is between connector X007 pin 3 and connector X017 pin J3-8 wire 712 white. Locate the short and repair. B. If continuity is found, the short to ground is in the harness between connector X032 pin 20 and connector X007 pin 3 wire 712 white. Locate the short and repair. 10. Fault codes indicate circuit fault due to open circuit condition. Disconnect reel speed motor connector X308. Measure the resistance of the motor between terminals A and B. The correct resistance is XX to XX ohms. A. The resistance is infinite, indicating an open condition in the motor. Replace the reel speed motor. B. The resistance is in specification. Continue with Step 11. 11. Ensure that the batteries are connected using the battery key, and that fuse F23 is good. Use the multimeter to check for continuity between connector X308 pin B on the header harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F23. This ground path may be used to test for an open circuit condition. A. If continuity is found, continue with Step 14. B. If no continuity is found, continue with Step 12.

55-299

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 12. Disconnect inline connector X032. Use a multimeter to check for continuity between connector X032 pin 26 on the feeder (FE) harness side and chassis ground. A. If continuity is found the open circuit is in the harness between connector X032 pin 26 and connector X308 pin B. Locate the open and repair. B. If no continuity is found, continue with Step 13. 13. Disconnect connector X007. Use a multimeter to check for continuity between connector X007 pin 19 on the front frame (FF) harness side and chassis ground. A. If continuity is found, the open circuit is in the harness between connector X032 pin 26 and connector X007 pin 19 wire 711 gray. Locate the open and repair. B. If no continuity is found, the open circuit is in the harness between connector X007 pin 19 and connector X017 pin J3-6 wire 711 gray. Locate the open and repair. 14. Use a multimeter to check for continuity between connector X308 pin A on the header harness side and chassis ground. A. If no continuity is found, continue with Step 15. B. If continuity is found, recheck the motor for continuity at Step 10. 15. Disconnect connector X032. Use a multimeter to check for continuity between connector X032 pin 20 on the feeder (FE) harness side and chassis ground. A. If continuity is found, the open circuit is in the harness between connector X308 pin A and connector X032 pin 20. Locate the open and repair. B. If no continuity is found, continue with Step 16. 16. Disconnect connector X007. Use a multimeter to check for continuity between connector X007 pin 3 on the front frame (FF) harness side and chassis ground. A. If continuity is found, the open circuit is between connector X007 pin 3 and connector X017 pin J3-8 wire 712 white. Locate the open and repair. B. If no continuity is found, the open circuit is in the harness between connector X032 pin 20 and connector X007 pin 3 wire 712 white. Locate the open and repair. 17. If the header reel speed motor does not operate in either direction, and there are no error codes indicated, the supply power for the circuit may not be present. Remove fuse F23 and inspect. A. Fuse has failed. Go to Step 18. B. Fuse is okay. Go to Step 19. 18. If fuse has failed, replace the fuse. A. If fuse immediately fails, a short to ground exists on one of the two following wires: wire 025 red, from the fuse panel through connector X005 pin 1 to connector X016 pin J2-11 on CCM2 module wire 028 red, from the fuse panel through connector X031 pin 4 to connector X017 pin J3-7 on CCM2 module Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. B. Fuse is okay. Go to Step 19. 19. Test for 12V power at connector X017 pin J3-7 on the CCM2 module under the cab. A. If there is no power, there is an open circuit on wire 028 red, from the fuse panel through connector X031 pin 4 to connector X017 pin J3-7 on CCM2 module. Locate the open and repair. After repair, go to Step 20. B. If there is power, go to Step 20.

55-300

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 20. Test for continuity to ground at connector X017 pin J3-16 on the CCM2 module under the cab. A. If there is no continuity to ground, there is an open circuit on wire 515 or 538 black, from connector X017 pin J3-16 on CCM2 module to the front frame ground #2. Locate the open and repair. After repair, go to Step 21. B. If there is power, go to Step 21. 21. Once it has been verified that power is being supplied to the module, recheck the circuit operation as described in Step 1. If the fuse fails during the testing, a short to ground on the circuit is causing the fuse to fail. Start the troubleshooting at Step 3 to locate the short to ground.

55-301

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

2 10020040

50026205

40024707

52 1. 2. 3. 4.

Reel Speed Motor M09 (On Header) Connector X032 Connector X007 Connector X017

55-302

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-22 = REAR LADDER F-23 = SCREEN BRUSH FUSE F-28 = FUEL PUMP FUSE K-07 = FUEL PUMP RELAY

M-23 = FUEL PUMP M-27 = ROTARY SCREEN BRUSH R-01 = FUEL LEVEL S-36 = ENGINE THROTTLE

S-61 = AIR FILTER SWITCH S-67 = COOLANT LEVEL

STARTING FRAME-- 3

55-303

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

HEADER FRAME-- 12

K-42 = RH VERTICAL KNIFE RELAY (OP) K-43 = LH VERTICAL KNIFE RELAY (OP) L-13 = REEL DOWN L-14 = REEL UP

L-15 = REEL AFT L-16 = REEL FORE L-17 = REEL DRIVE M-09 = REEL SPEED MOTOR

55-304

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0206-05 Rotary Screen Brush Motor Line Disconnected Context: The CCM has detected that the circuit current has been <0.7 Amps for at least 3 seconds, while the control circuit input is active. Lack of current flow in an activated circuit is an indication of an open circuit condition. However, it is also possible to get this error message from a direct short to ground. This is because the CCM contains built-in over temperature circuit protection logic that will electronically disconnect the motor in order to prevent damage to the module. When a direct short to ground is present, and the motor is energized, it is possible for the rapid spike in current to engage the circuit protection -opening the circuit. When this occurs, the fault detection software sees the open and may report the “Line disconnected” fault. Cause: The rotary screen brush motor (M-27) control voltage circuit open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad motor. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed. A. Manually operate the motor in both directions. B. Record in which direction the circuit operates. C. Reload error history. Check for fault codes 0172-06 and 0206-05. D. Use the following table to determine the location of the fault. Errors

Symptom

0172-06 Rotary screen brush motor operates in 1 direction only

0206-05 Go to Step 2

Motor bound up

Go to Step 3

Short to ground

Go to Step 8

Open

Go to Step 13

Fuse 23 blown or open

Rotary screen brush motor does not operate in either direction

55-305

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 4. Disconnect the batteries using the battery key. Unplug the rotary screen brush motor connector X206. Use the multimeter to check for continuity between connector X206 pin B on the engine (EN) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position. Power must be removed from the module prior to testing for short to ground condition on the motor circuit to remove this ground path. A. If continuity is found, continue with Step 5. B. If no continuity is found, continue with Step 6. 5. Disconnect inline connector X010. Use a multimeter to check for continuity between connector X010 pin 1 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the short to ground is in the main frame (MF) harness between connector X010 pin 1 and connector X016 pin J2-1 wire 524 gray. Locate the short and repair. B. If no continuity is found, the short to ground is in the engine (EN) harness between connector X010 pin 1 and connector X206 pin B on wire 524 gray. Locate the short to ground and repair. 6. Use a multimeter to check for continuity between connector X206 pin A on the engine (EN) harness side and chassis ground. A. If continuity is found, continue with Step 7. B. If no continuity is found, erase the fault codes and continue operation. 7. Disconnect connector X010. Use a multimeter to check for continuity between connector X010 pin 2 on the main frame (MF) harness side and chassis ground. A. If no continuity is found, the short to ground is in the harness between connector X206 pin A and connector X010 pin 2 wire 821 white. Locate the short and repair. B. If continuity is found, the short to ground in the harness between connector X010 pin 2 and connector X016 pin J2-21 wire 821 white. Locate the short and repair. 8. Fault codes indicate circuit fault due to open circuit condition. Disconnect the rotary screen brush motor connector X206. Measure the resistance of the motor between terminals A and B. The correct resistance is xx to xx ohms. A. The resistance is infinite, indicating an open condition in the motor. Replace the rotary screen brush motor. B. The resistance is in specification. Continue with Step 9. 9. Ensure that the batteries are connected using the battery key, and that fuse F23 is good. Use the multimeter to check for continuity between connector X206 pin B on the engine (EN) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F23. This ground path may be used to test for an open circuit condition. A. If continuity is found, continue with Step 11. B. If no continuity is found, continue with Step 10. 10. Disconnect inline connector X010. Use a multimeter to check for continuity between connector X010 pin 1 and chassis ground. A. If continuity is found the open circuit is in the harness between connector X010 pin 1 and connector X206 pin B. Locate the open and repair. B. If no continuity is found, the open circuit is in the harness between connector X010 pin 1 and connector X016 pin J2-1 on wire 524 gray. Locate the open and repair.

55-306

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19 11. Use a multimeter to check for continuity between connector X206 pin A on the engine (EN) harness side and chassis ground. A. If no continuity is found, continue with Step 12. B. If continuity is found, recheck the motor for continuity at Step 8. Erase the fault codes and continue operation. 12. Disconnect connector X010. Use a multimeter to check for continuity between connector X010 pin 2 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the open circuit is in the harness between connector X206 pin A and connector X010 pin 2 wire 821 white. Locate the open and repair. B. If no continuity is found, the open circuit is in the harness between connector X010 pin 2 and connector X016 pin J2-21 wire 821 white. Locate the open and repair. 13. If the rotary brush screen motor does not operate in either direction, and there are no error codes indicated, the supply power for the circuit may not be present. Remove fuse F23 and inspect. A. Fuse has failed. Go to Step 14. B. Fuse is okay. Go to Step 15. 14. If fuse has failed, replace the fuse. A. If fuse immediately fails, a short to ground exists on one of the two following wires: wire 025 red, from the fuse panel through connector X005 pin 1 to connector X016 pin J2-11 on CCM2 module wire 028 red, from the fuse panel through connector X031 pin 4 to connector X017 pin J3-7 on CCM2 module Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. B. Fuse is okay. Go to Step 15. 15. Test for 12V power at connector X016 pin J2-11 on the CCM2 module under the cab. A. If there is no power, there is an open circuit on wire 025 red, from the fuse panel through connector X005 pin 1 to connector X016 pin J2-11 on CCM2 module. Locate the open and repair. After repair, go to Step 16. B. If there is power, go to Step 16. 16. Test for continuity to ground at connector X016 pin J2-3 on the CCM2 module under the cab. A. If there is no continuity to ground, there is an open circuit on wire 514 or 584 black, from connector X016 pin J2-3 on CCM2 module to the front frame ground #2. Locate the open and repair. After repair, go to Step 17. B. If there is continuity to ground, go to Step 17. 17. Once it has been verified that power is being supplied to the module, recheck the circuit operation as described in Step 1. If the fuse fails during the testing, a short to ground on the circuit being operated at the time of failure is causing the fuse to fail. Start the troubleshooting at Step 3 to locate the short to ground.

55-307

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

10004648

10010899

10020076

50026210

53 1. 2. 3. 4.

Rotary Screen Brush Motor M27 Connector X010 Connector X004 Connector X016

55-308

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

B-22 = REAR LADDER F-23 = SCREEN BRUSH FUSE F-28 = FUEL PUMP FUSE K-07 = FUEL PUMP RELAY

M-23 = FUEL PUMP M-27 = ROTARY SCREEN BRUSH R-01 = FUEL LEVEL S-36 = ENGINE THROTTLE

S-61 = AIR FILTER SWITCH S-67 = COOLANT LEVEL

STARTING FRAME-- 3

55-309

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

HEADER FRAME-- 12

K-42 = RH VERTICAL KNIFE RELAY (OP) K-43 = LH VERTICAL KNIFE RELAY (OP) L-13 = REEL DOWN L-14 = REEL UP

L-15 = REEL AFT L-16 = REEL FORE L-17 = REEL DRIVE M-09 = REEL SPEED MOTOR

55-310

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

FAULT CODE – E0208-02 ECU Module Data Incorrect Cause: The ECU module (A-01) software is incompatible with the current CCM2 module software. Possible failure modes: 1. Incorrect software loaded in either ECU module or CCM2 module. Solution: The ECU module communicates with the CCM2 module to report error messages and other operational information. In some cases, due to design changes, there may be some incompatibility between certain versions of the software installed in either module. If this error message appears, contact the New Holland service department to obtain information on software version compatibilities.

55-311

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 19

55-312

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 20 -- CCM3 Error Codes CONTENTS Section

Description

Page

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

55-1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0261-03 Lower Sieve Decrease -- Rear Switch Shorted to High Source Cause: The lower sieve rear adjust switch (S-46) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check the voltage range. The normal operating range for the lower sieve rear adjust circuit is 1.8 -- 10.0 volts when the switch is not depressed. The normal operating range for the lower sieve rear adjust circuit is 0.5 -- 1.8 volts when the switch is depressed. A. If the voltage reading is 10.0 volts or greater, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. 2. Disconnect the lower sieve rear adjust switch connector X226. A. If the voltage drops below 10 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage is above 10.0 volts, continue with Step 3. 3. Disconnect the straw hood front (SW) harness from the expansion (EX) harness at connector X025. A. If the voltage drops back within range, the short is in the straw hood front (SW) harness between connector X025 and connector X226 wire 541 yellow. Locate the short and repair. B. If the voltage remains above 10.0 volts, the short is in the expansion (EX) harness between connector X025 and connector X013 pin J2-39 wire 541 yellow. Locate the short and repair. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-2

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0261-04 Lower Sieve Decrease -- Rear Switch Shorted to Low Source Cause: The lower sieve rear adjust switch (S-46) circuit is shorted to ground since power up. Possible failure modes: 1. Switch wiring shorted to ground. 2. Switch failure (stuck closed). 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the lower sieve rear adjust circuit is 1.8 -- 10.0 volts when the switch is not depressed. The normal operating range for the lower sieve rear adjust circuit is 0.5 -- 1.8 volts when the switch is depressed. A. If the voltage reading is <0.5 volts or less, continue with Step 2. B. If the voltage reading is within the proper limits, the wire may not be shorted at this time. Continue troubleshooting at Step 4. 2. Disconnect the lower sieve rear adjust switch straw hood front (SW) harness connector X226. Observe the display monitor voltage. A. If the voltage returns to 1.8 -- 10 volts, the short is in the switch. Replace lower sieve rear adjust switch S-46. Continue troubleshooting at Step 4. B. If the voltage remains at <0.5 volts, continue with Step 3. 3. Disconnect the straw hood front (SW) harness from the expansion (EX) harness at connector X025. A. If the voltage returns to 1.8 -- 10 volts, the short is in the straw hood front (SW) harness between connector X025 and connector X226 wire 541 yellow. Locate the short and repair. Continue troubleshooting at Step 4. B. If the voltage remains at <0.5 volts, the short is in the expansion (EX) harness between connector X025 and connector X013 pin J2-39 wire 541 yellow. Locate the short and repair. If no short can be found, replace CCM3. Continue troubleshooting at Step 4. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-3

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

10020076

86060952

50026216

1 1. 2. 3.

Upper/Lower Sieve Rear Adjust S-35/46 Connector X025 Connector X013

55-4

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-27 = SIEVE/SPREADER FUSE K-18 = UPPER/LOWER SIEVE RELAY M-06 = UPPER SIEVE ACTUATOR M-07 = LOWER SIEVE ACTUATOR

S-35 = UPPER SIEVE REAR ADJUST S-46 = LOWER SIEVE REAR ADJUST

CLEANING FRAME--21

55-5

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0262-03 Upper Sieve Decrease -- Rear Switch Shorted to High Source Cause: The upper sieve rear adjust switch (S-35) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check the voltage range. The normal operating range for the upper sieve rear adjust circuit is 1.8 -- 10.0 volts when the switch is not depressed. The normal operating range for the upper sieve rear adjust circuit is 0.5 -- 1.8 volts when the switch is depressed. A. If the voltage reading is 10.0 volts or greater, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. 2. Disconnect the upper sieve rear adjust switch connector X225. A. If the voltage drops below 10 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage is above 10.0 volts, continue with Step 3. 3. Disconnect the straw hood front (SW) harness from the expansion (EX) harness at connector X025. A. If the voltage drops back within range, the short is in the straw hood front (SW) harness between connector X025 and connector X225 wire 539 yellow. Locate the short and repair. B. If the voltage remains above 10.0 volts, the short is in the expansion (EX) harness between connector X025 and connector X013 pin J2-34 wire 539 yellow. Locate the short and repair. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-6

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0262-04 Upper Sieve Decrease -- Rear Switch Shorted to Low Source Cause: The upper sieve rear adjust switch (S-35) circuit is shorted to ground since power up. Possible failure modes: 1. Switch wiring shorted to ground. 2. Switch failure (stuck closed). 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the upper sieve rear adjust circuit is 1.8 -- 10.0 volts when the switch is not depressed. The normal operating range for the upper sieve rear adjust circuit is 0.5 -- 1.8 volts when the switch is depressed. A. If the voltage reading is <0.5 volts or less, continue with Step 2. B. If the voltage reading is within the proper limits, the wire may not be shorted at this time. Continue troubleshooting at Step 4. 2. Disconnect the upper sieve rear adjust switch straw hood front (SW) harness connector X226. Observe the display monitor voltage. A. If the voltage returns to 1.8 -- 10 volts, the short is in the switch. Replace upper sieve rear adjust switch S-35. Continue troubleshooting at Step 4. B. If the voltage remains at <0.5 volts, continue with Step 3. 3. Disconnect the straw hood front (SW) harness from the expansion (EX) harness at connector X025. A. If the voltage returns to 1.8 -- 10 volts, the short is in the straw hood front (SW) harness between connector X025 and connector X226 wire 539 yellow. Locate the short and repair. Continue troubleshooting at Step 4. B. If the voltage remains at <0.5 volts, the short is in the expansion (EX) harness between connector X025 and connector X013 pin J2-34 wire 539 yellow. Locate the short and repair. If no short can be found, replace CCM3. Continue troubleshooting at Step 4. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-7

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

10020076

86060952

50026216

2 1. 2. 3.

Upper/Lower Sieve Rear Adjust S-35/46 Connector X025 Connector X013

55-8

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-27 = SIEVE/SPREADER FUSE K-18 = UPPER/LOWER SIEVE RELAY M-06 = UPPER SIEVE ACTUATOR M-07 = LOWER SIEVE ACTUATOR

S-35 = UPPER SIEVE REAR ADJUST S-46 = LOWER SIEVE REAR ADJUST

CLEANING FRAME--21

55-9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0263-03 Lower Sieve Increase -- Rear Switch Shorted to High Source Cause: The lower sieve rear adjust switch (S-46) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check the voltage range. The normal operating range for the lower sieve rear adjust circuit is 1.8 -- 10.0 volts when the switch is not depressed. The normal operating range for the lower sieve rear adjust circuit is 0.5 -- 1.8 volts when the switch is depressed. A. If the voltage reading is 10.0 volts or greater, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. 2. Disconnect the lower sieve rear adjust switch connector X226. A. If the voltage drops below 10 volts, the short is in the switch. Replace the switch. B. If the voltage is above 10.0 volts, continue with Step 3. 3. Disconnect the straw hood front (SW) harness from the expansion (EX) harness at connector X025. A. If the voltage drops back within range, the short is in the straw hood front (SW) harness between connector X025 and connector X226 wire 542 yellow. Locate the short and repair. B. If the voltage remains above 10.0 volts, the short is in the expansion (EX) harness between connector X025 and connector X013 pin J2-35 wire 542 yellow. Locate the short and repair. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-10

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0263-04 Lower Sieve Increase -- Rear Switch Shorted to Low Source Cause: The lower sieve rear adjust switch (S-46) circuit is shorted to ground since power up. Possible failure modes: 1. Switch wiring shorted to ground. 2. Switch failure (stuck closed). 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the lower sieve rear adjust circuit is 1.8 -- 10.0 volts when the switch is not depressed. The normal operating range for the lower sieve rear adjust circuit is 0.5 -- 1.8 volts when the switch is depressed. A. If the voltage reading is <0.5 volts or less, continue with Step 2. B. If the voltage reading is within the proper limits, the wire may not be shorted at this time. Continue troubleshooting at Step 4. 2. Disconnect the lower sieve rear adjust switch straw hood front (SW) harness connector X226. Observe the display monitor voltage. A. If the voltage returns to 1.8 -- 10 volts, the short is in the switch. Replace lower sieve rear adjust switch S-46. Continue troubleshooting at Step 4. B. If the voltage remains at <0.5 volts, continue with Step 3. 3. Disconnect the straw hood front (SW) harness from the expansion (EX) harness at connector X025. A. If the voltage returns to 1.8 -- 10 volts, the short is in the straw hood front (SW) harness between connector X025 and connector X226 wire 542 yellow. Locate the short and repair. Continue troubleshooting at Step 4. B. If the voltage remains at <0.5 volts, the short is in the expansion (EX) harness between connector X025 and connector X013 pin J2-35 wire 542 yellow. Locate the short and repair. If no short can be found, replace CCM3. Continue troubleshooting at Step 4. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-11

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

10020076

86060952

50026216

3 1. 2. 3.

Upper/Lower Sieve Rear Adjust S-35/46 Connector X025 Connector X013

55-12

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-27 = SIEVE/SPREADER FUSE K-18 = UPPER/LOWER SIEVE RELAY M-06 = UPPER SIEVE ACTUATOR M-07 = LOWER SIEVE ACTUATOR

S-35 = UPPER SIEVE REAR ADJUST S-46 = LOWER SIEVE REAR ADJUST

55-13

CLEANING FRAME--21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0267-04 Auto Steering Enable Shorted to Low Source Cause: The auto steering enable switch S-78 circuit is open or shorted to ground. Possible Failure Modes: 1. Switch or circuit wiring open or shorted to ground. 2. Controller internal failure (Internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the auto steering enable switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the auto steering enable switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. NOTE: Check fuse 48. If a short to ground occurred on this circuit the fuse may have blown. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 6. 2. Turn the ignition switch off. Disconnect connector X484 from the Auto Steering Enable switch S-78. Use a multimeter to check for continuity between the harness side of connector X484 pin 3 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Auto Steering Enable switch S-78 has failed. Replace the switch. 3. Disconnect connector X001. With the Auto Steering Enable switch in the “Off” position, use a multimeter to check for continuity between connector X001 pin 21 on the RH Console (RC) harness and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between connector X001 pin 21 and connector X484 pin 3 wire 1744 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X012 from the CCM-3. Use a multimeter to check for continuity between connector X012 pin J1-21 on the Cab Main (CM) harness side and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the Cab Main (CM) harness between connector X001 pin 21 and connector X012 pin J1-21 wire 1744 yellow. Locate and repair the short. B. If no continuity is found, continue with step 5. 5. With connector X012 disconnected, use a multimeter to check for continuity between connector X012 pin J1-21 on the module and chassis ground. There should not be continuity to ground. A. If continuity is found, the module has failed. Replace the module. B. If no continuity is found, continue with step 6. 6. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload CCM-3 software. If that does not correct the concern, replace CCM-3.

55-14

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 4

10010921

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Fuse F-48 Connector X012 Connector X001 AutoGuidance Switch S-78

55-15

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-48 = RH CONSOLE FUSE H-01 = AUDIO ALARM W-01 = SPLICE BLOCK A W-02 = SPLICE BLOCK B

W-05 = SPLICE BLOCK E W-06 = SPLICE BLOCK F

DISTRIBUTION FRAME--25

55-16

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

DISTRIBUTION/ AUTO GUIDANCE FRAME--32

A-02 = DISPLAY MODULE A-11 = DGPS MODULE A-24 = NAVIGATION MODULE L-57 = STEER LEFT SOLENOID

L-58 = STEER RIGHT SOLENOID L-59 = STEER ENABLE SOLENOID S-78 = AUTOGUIDANCE SWITCH S-79 = ROTARY ENCODER SWITCH

55-17

S-80 = DISPLAY HOME SWITCH S-81 = DISPLAY ESCAPE SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0268-04 Auto Feedrate Enable Shorted to Low Source Cause: The auto steering enable switch S-78 circuit is open or shorted to ground. Possible Failure Modes: 1. Switch or circuit wiring open or shorted to ground. 2. Controller internal failure (Internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the auto feedrate enable switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the auto feedrate enable switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. NOTE: Check fuse 48. If a short to ground occurred on this circuit the fuse may have blown. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 6. 2. Turn the ignition switch off. Disconnect connector X484 from the Auto Feedrate Enable switch S-78. Use a multimeter to check for continuity between the harness side of connector X484 pin 1 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Auto Feedrate Enable switch S-78 has failed. Replace the switch. 3. Disconnect connector X001. With the Auto Feedrate Enable switch in the “Off” position, use a multimeter to check for continuity between connector X001 pin 22 on the RH Console (RC) harness and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between connector X001 pin 22 and connector X484 pin 1 wire 1745 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X012 from the CCM-3. Use a multimeter to check for continuity between connector X012 pin J1-22 on the Cab Main (CM) harness side and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the Cab Main (CM) harness between connector X001 pin 22 and connector X012 pin J1-22 wire 1745 yellow. Locate and repair the short. B. If no continuity is found, continue with step 5. 5. With connector X012 disconnected, use a multimeter to check for continuity between connector X012 pin J1-22 on the module and chassis ground. There should not be continuity to ground. A. If continuity is found, the module has failed. Replace the module. B. If no continuity is found, continue with step 6. 6. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload CCM-3 software. If that does not correct the concern, replace CCM-3.

55-18

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 4

10010921

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Fuse F-48 Connector X012 Connector X001 AutoGuidance Switch S-78

55-19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-48 = RH CONSOLE FUSE H-01 = AUDIO ALARM W-01 = SPLICE BLOCK A W-02 = SPLICE BLOCK B

W-05 = SPLICE BLOCK E W-06 = SPLICE BLOCK F

DISTRIBUTION FRAME--25

55-20

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

DISTRIBUTION/ AUTO GUIDANCE FRAME--32

A-02 = DISPLAY MODULE A-11 = DGPS MODULE A-24 = NAVIGATION MODULE L-57 = STEER LEFT SOLENOID

L-58 = STEER RIGHT SOLENOID L-59 = STEER ENABLE SOLENOID S-78 = AUTOGUIDANCE SWITCH S-79 = ROTARY ENCODER SWITCH

55-21

S-80 = DISPLAY HOME SWITCH S-81 = DISPLAY ESCAPE SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0273-03 Steering Wheel Motion Shorted to High Source Cause: The steering wheel motion sensor B-69 circuit is shorted to a higher than normal source. Possible Failure Modes: 1. Sensor or circuit wiring shorted to 12 volts. 2. Controller internal failure (Internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, check voltage range. The normal operating range for the sensor, when blocked by ferrous metal is 5.6 – 7.3 volts. The normal operating range for the sensor, when not blocked by ferrous metal is 0.5 – 5.6 volts. The normal operating range for the sensor, when it is disconnected is 7.3 – 9.0 volts. A. If the voltage reading is high out of range (> 9.0 volts), continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 10. 2. Disconnect connector X464 from the Steering Wheel Position sensor B-69. A. If the voltage reading remains high out of range (> 9.0 volts) on the display monitor, continue with step 3. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 6. 3. Disconnect the Cab Main (CM) harness from the Main Frame (MF) harness at connector X005. A. If the voltage reading remains high out of range (> 9.0 volts) on the display monitor, continue with step 4. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 6. 4. Disconnect the Main Frame (MF) harness from the Expansion (EX) harness at connector X487. A. If the voltage reading remains high out of range (> 9.0 volts) on the display monitor, continue with step 5. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 6. 5. Carefully disconnect connector X013 from the CCM-3 module. Use a multimeter to check the voltage on the module between connector X013 pin J2-36 and chassis ground. A. If the voltage reading is high out of range (> 9.0 volts) the module has failed. Replace the module. B. If the voltage reading is within the proper limits, the short to high source is in the Expansion (EX) harness between connector X013 pin J2-36 and connector X487 pin 4, wire 1739 yellow. Locate and repair the short to high source. 6. Disconnect connector X464 from the Steering Wheel Position sensor B-69. Use a multimeter to check the voltage on the Cab Main (CM) harness side of connector X464 pin 1 and chassis ground. A. If the voltage reading is high out of range (> 9.0 volts), continue with step 7. B. If the voltage reading is zero volts, continue troubleshooting with step 10. 7. Disconnect the Cab Main (CM) harness from the Main Frame (MF) harness at connector X005. Use a multimeter to check the voltage on the Main Frame (MF) harness side of connector X005 pin 22 and chassis ground. A. If the voltage reading is high out of range (> 9.0 volts), continue with step 8. B. If the voltage reading is zero volts, continue troubleshooting with step 9.

55-22

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 8. Disconnect the Main Frame (MF) harness from the Expansion (EX) harness at connector X487. Use a multimeter to check the voltage on the Expansion (EX) harness side of connector X487 pin 2 and chassis ground. A. If the voltage reading is high out of range (> 9.0 volts), the short to high source is in the Expansion (EX) harness. Locate and repair the short to high source. B. If the voltage reading is zero volts, the short to high source is in the Main Frame (MF) harness between connector X487 pin 2 and connector X005 pin 22, wire 1718 blue. Locate and repair the short to high source. 9. Disconnect the Cab Main (CM) harness from the Cab Roof (CR) harness at connector X003. Use a multimeter to check the voltage on the Cab Roof (CR) harness side of connector X003 pin 34 and chassis ground. A. If the voltage reading is high out of range (> 9.0 volts), the short to high source is in the Cab Roof (CR) harness, wire 1704 blue. Locate and repair the short to high source. B. If the voltage reading is zero volts, the short to high source is in the Cab Main (CM) harness between connector X003 pin 34, connector X005 pin 22 and connector X464 pin 1, wires 1704, 1718 and 1720 blue. Locate and repair the short to high source. 10. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload CCM-3 software. If that does not correct the concern, replace CCM-3.

55-23

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0273-04 Steering Wheel Motion Shorted to Low Source Cause: The steering wheel motion sensor B-69 circuit is shorted to ground. Possible Failure Modes: 1. Sensor or circuit wiring shorted to ground. 2. Controller internal failure (Internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the sensor, when blocked by ferrous metal is 5.6 – 7.3 volts. The normal operating range for the sensor, when not blocked by ferrous metal is 0.5 – 5.6 volts. The normal operating range for the sensor, when it is disconnected is 7.3 – 9.0 volts. A. If the voltage reading is low out of range (< 0.5 volts), continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 7. 2. Disconnect connector X464 from the Steering Wheel Position sensor B-69. A. If the voltage reading remains low out of range (< 0.5 volts) on the display monitor, continue with step 3. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 6. 3. Disconnect the Cab Main (CM) harness from the Main Frame (MF) harness at connector X005. A. If the voltage reading remains low out of range (< 0.5 volts) on the display monitor, continue with step 4. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 6. 4. Disconnect the Main Frame (MF) harness from the Expansion (EX) harness at connector X487. A. If the voltage reading remains low out of range (< 0.5 volts) on the display monitor, continue with step 5. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 6. 5. Turn the Ignition key to the OFF position. Carefully disconnect connector X013 from the CCM-3 module. Use a multimeter to check for continuity on the module between connector X013 pin J2-36 and chassis ground. A. If continuity is found the module has failed. Replace the module. B. If no continuity is found the short to ground is in the Expansion (EX) harness between connector X013 pin J2-36 and connector X487 pin 4, wire 1739 yellow. Locate and repair the short to ground. 6. Turn the Ignition key to the OFF position. Disconnect connector X464 from the Steering Wheel Position sensor B-69. Use a multimeter to check for continuity on the sensor side of connector X464 pin 1 and chassis ground. There should not be continuity to ground. A. If continuity is found, the sensor has failed. Replace the sensor. B. If no continuity is found, continue troubleshooting with step 7. 7. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload CCM-3 software. If that does not correct the concern, replace CCM-3.

55-24

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0273-05 Steering Wheel Motion Line Disconnected Cause: The steering wheel motion sensor B-69 or circuit wiring is open. Possible Failure Modes: 1. Sensor or circuit wiring is open. 2. Controller internal failure (Internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, check voltage range. The normal operating range for the sensor, when blocked by ferrous metal is 5.6 – 7.3 volts. The normal operating range for the sensor, when not blocked by ferrous metal is 0.5 – 5.6 volts. The normal operating range for the sensor, when it is disconnected is 7.3 – 9.0 volts. A. If the voltage reading is high (7.3 to 9.0 volts), continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 10. 2. Disconnect connector X464 from the Steering Wheel Position sensor B-69. Use a jumper wire to short the sensor harness side of connector X464 pin 2 to chassis ground. A. If the voltage reading on the display monitor drops to 0.0 to 0.5 volts indicating the ground, the open is not in the supply side of the circuit. Continue with step 6. B. If the voltage remains high (7.3 to 9.0 volts), continue with step 3. 3. Disconnect the Cab Main (CM) harness from the Main Frame (MF) harness at connector X005. Use a jumper wire to short the Main Frame (MF) harness side of connector X005 pin 20 to chassis ground. A. If the voltage reading on the display monitor drops to 0.0 to 0.5 volts indicating the ground, the open is in the Cab Main (CM) harness between connector X005 pin 20 and connector X464 pin 2, wire 1739 yellow. Locate and repair the open. B. If the voltage remains high (7.3 to 9.0 volts), continue with step 4. 4. Disconnect the Main Frame (MF) harness from the Expansion (EX) harness at connector X487. Use a jumper wire to short the Expansion (EX) harness side of connector X487 pin 4 to chassis ground. A. If the voltage reading on the display monitor drops to 0.0 to 0.5 volts indicating the ground, the open is in the Main Frame (MF) harness between connector X487 pin 4 and connector X005 pin 20, wire 1739 yellow. Locate and repair the open. B. If the voltage remains high (7.3 to 9.0 volts), continue with step 5. 5. Carefully disconnect connector X013 from the CCM-3 module. Use a multimeter to check the voltage on the module between connector X013 pin J2-36 and chassis ground. There should be 7.3 to 9.0 volts present. A. If the voltage reading is not 7.3 to 9.0 volts the module has failed. Replace the module. B. If the voltage reading is within the proper limits, the open is in the Expansion (EX) harness between connector X013 pin J2-36 and connector X487 pin 4, wire 1739 yellow. Locate and repair the open. 6. Disconnect connector X464 from the Steering Wheel Position sensor B-69. Use a multimeter to check for continuity between the Cab Main (CM) harness side of connector X464 pin 1 and chassis ground. A. If continuity is found, the ground path for the sensor is complete and the sensor has failed. Replace the sensor. B. If no continuity is found, continue with step 7.

55-25

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 7. Disconnect the Cab Main (CM) harness from the Main Frame (MF) harness at connector X005. Use a multimeter to for continuity between the Main Frame (MF) harness side of connector X005 pin 22 and chassis ground. A. If continuity is found, the open is in the Cab Main (CM) harness between connector X005 pin 22 and connector X464 pin 1, wire 1718 or 1720 blue. Locate and repair the open. B. If no continuity is found, continue with step 8. 8. Disconnect the Main Frame (MF) harness from the Expansion (EX) harness at connector X487. Use a multimeter to check for continuity between the Expansion (EX) harness side of connector X487 pin 2 and chassis ground. A. If continuity is found, the open is in the Main Frame (MF) harness between connector X487 pin 2 and connector X005 pin 22, wire 1718 blue. Locate and repair the open. B. If no continuity is found, continue with step 9. 9. Carefully disconnect connector X013 from the CCM-3 module. Use a multimeter to check for continuity between connector X013 pin J2-36 on the module and chassis ground. A. If continuity is found, the open is in the Expansion (EX) harness, wire 1718 or 1723 blue. Locate and repair the open. B. If no continuity is found, the module has failed. Replace the module. 10. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload CCM-3 software. If that does not correct the concern, replace CCM-3.

55-26

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

3 2 10010914

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Connector X013 Connector X464 Steering Wheel Motion Sensor B-69

55-27

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

AUTO GUIDANCE/ PRECISION FRAME--24

B-12 = MOISTURE SENSOR B-69 = STEERING WHEEL POSITION B-70 = REAR AXLE ANGLE F-47 = CCM-3 FUSE

M-28 = SAMPLE MOTOR M-35 = TURNTABLE ACTUATOR R-05 = YIELD SENSOR

55-28

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-29

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0282-03 Upper Sieve Increase -- Rear Switch Shorted to High Source Cause: The upper sieve rear adjust switch (S-35) circuit is shorted to a higher than normal voltage source. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check the voltage range. The normal operating range for the upper sieve rear adjust circuit is 1.8 -- 10.0 volts when the switch is not depressed. The normal operating range for the upper sieve rear adjust circuit is 0.5 -- 1.8 volts when the switch is depressed. A. If the voltage reading is 10.0 volts or greater, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue the troubleshooting at Step 4. 2. Disconnect the upper sieve rear adjust switch connector X225. A. If the voltage drops below 10 volts, the short is in the sensor, or sensor wiring. Replace the sensor. B. If the voltage is above 10.0 volts, continue with Step 3. 3. Disconnect the straw hood front (SW) harness from the expansion (EX) harness at connector X025. A. If the voltage drops back within range, the short is in the straw hood front (SW) harness between connector X025 and connector X225 wire 540 yellow. Locate the short and repair. B. If the voltage remains above 10.0 volts, the short is in the expansion (EX) harness between connector X025 and connector X013 pin J2-17 wire 540 yellow. Locate the short and repair. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-30

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0282-04 Upper Sieve Increase -- Rear Switch Shorted to Low Source Cause: The upper sieve rear adjust switch (S-35) circuit is shorted to ground since power up. Possible failure modes: 1. Switch wiring shorted to ground. 2. Switch failure (stuck closed). 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the upper sieve rear adjust circuit is 1.8 -- 10.0 volts when the switch is not depressed. The normal operating range for the upper sieve rear adjust circuit is 0.5 -- 1.8 volts when the switch is depressed. A. If the voltage reading is <0.5 volts or less, continue with Step 2. B. If the voltage reading is within the proper limits, the wire may not be shorted at this time. Continue troubleshooting at Step 4. 2. Disconnect the upper sieve rear adjust switch straw hood front (SW) harness connector X225. Observe the display monitor voltage. A. If the voltage returns to 1.8 -- 10 volts, the short is in the switch. Replace upper sieve rear adjust switch S-35. Continue troubleshooting at Step 4. B. If the voltage remains at <0.5 volts, continue with Step 3. 3. Disconnect the straw hood front (SW) harness from the expansion (EX) harness at connector X025. A. If the voltage returns to 1.8 -- 10 volts, the short is in the straw hood front (SW) harness between connector X025 and connector X225 wire 539 yellow. Locate the short and repair. Continue troubleshooting at Step 4. B. If the voltage remains at <0.5 volts, the short is in the expansion (EX) harness between connector X025 and connector X013 pin J2-17 wire 540 yellow. Locate the short and repair. If no short can be found, replace CCM3. Continue troubleshooting at Step 4. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, corroded terminals or broken wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-31

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

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7 1. 2. 3.

Upper/Lower Sieve Rear Adjust S-35/46 Connector X025 Connector X013

55-32

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-27 = SIEVE/SPREADER FUSE K-18 = UPPER/LOWER SIEVE RELAY M-06 = UPPER SIEVE ACTUATOR M-07 = LOWER SIEVE ACTUATOR

S-35 = UPPER SIEVE REAR ADJUST S-46 = LOWER SIEVE REAR ADJUST

55-33

CLEANING FRAME--21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0283-03 Moisture Temp Sensor Shorted to High Source Cause: The moisture sensor (B-12) temperature circuit is shorted to a high source. Possible failure modes: 1. Temperature sensor wiring is shorted to high source. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.1 to 9.4 volts. A. If the voltage reading is high out of range (>9.4 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 3. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high out of range. Disconnect the sensor connector X221. Use a multimeter to check for voltage on connector X221 pin 5 on the expansion (EX) harness side. A. If there is voltage, there is a short to high voltage in the expansion (EX) harness between connector X221 pin 5 and connector X014 pin J3--34 wire 595 yellow. Locate short and repair. B. If there is no voltage, there is a fault in the moisture sensor. Replace the moisture sensor. 3. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation.

55-34

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0283-05 Moisture Temp Sensor Line Disconnected Cause: The moisture sensor (B-12) temperature circuit is open or shorted to ground. Possible failure modes: 1. Temperature sensor wiring is open or shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.1 to 9.4 volts. A. If the voltage reading is low out of range (0.0 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low out of range. Disconnect the sensor connector X221. Use a multimeter to check for continuity between connector X221 pin 5 on the expansion (EX) harness side and chassis ground. A. If there is continuity to ground, there is a short to ground in the expansion (EX) harness between connector X221 pin 5 and connector X014 pin J3-34 wire 595 yellow. Locate short and repair. B. If there is no continuity, continue with Step 3. 3. Key off. Carefully disconnect connector X014 from the bottom of the CCM3 module. Install a jumper wire to short connector X221 pin 5 on the expansion (EX) harness side to ground. Use a multimeter to check continuity between connector X014 pin J3-34 on the expansion (EX) harness side to chassis ground. A. If there is no continuity, there is an open circuit in the expansion (EX) harness between connector X014 pin J3-34 and connector X221 pin 5 wire 595 yellow. Locate the open and repair. B. If there is continuity, there is a fault in the moisture sensor. Replace the moisture sensor. 4. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation.

55-35

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E0283 MOISTURE TEMP SENSOR

1 2

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Moisture Sensor -- B12 Connector X221 Connector X014

55-36

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

AUTO GUIDANCE/ PRECISION FRAME--24

B-12 = MOISTURE SENSOR B-69 = STEERING WHEEL POSITION B-70 = REAR AXLE ANGLE F-47 = CCM-3 FUSE

M-28 = SAMPLE MOTOR M-35 = TURNTABLE ACTUATOR R-05 = YIELD SENSOR

55-37

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0284-03 Moisture Sensor -- Shorted to High Source Cause: The moisture sensor (B- 12) “- “ circuit is shorted to a high source. Possible failure modes: 1. Moisture sensor “--“ wiring is shorted to high source. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.1 to 9.4 volts. A. If the voltage reading is high out of range (>9.4 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 3. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high out of range. Disconnect the sensor connector X221. Use a multimeter to check for voltage on connector X221 pin 4 on the expansion (EX) harness side. A. If there is voltage, there is a short to high voltage in the expansion (EX) harness between connector X221 pin 4 and connector X014 pin J3-23 wire 594 yellow. Locate short and repair. B. If there is no voltage, there is a fault in the moisture sensor. Replace the moisture sensor. 3. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation.

55-38

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0284-05 Moisture Sensor -- Line Disconnected Cause: The moisture sensor (B- 12) “- “ circuit is open or shorted to ground. Possible failure modes: 1. Moisture sensor “--“ circuit wiring is open or shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.1 to 9.4 volts. A. If the voltage reading is low out of range (0.0 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low out of range. Disconnect the sensor connector X221. Use a multimeter to check for continuity between connector X221 pin 4 on the expansion (EX) harness side and chassis ground. A. If there is continuity to ground, there is a short to ground in the expansion (EX) harness between connector X221 pin 4 and connector X014 pin J3-23 wire 594 yellow. Locate short and repair. B. If there is no continuity, continue with Step 3. 3. Key off. Carefully disconnect connector X014 from the bottom of the CCM3 module. Install a jumper wire to short connector X221 pin 4 on the expansion (EX) harness side to ground. Use a multimeter to check continuity between connector X014 pin J3-23 on the expansion (EX) harness side to chassis ground. A. If there is no continuity, there is an open circuit in the expansion (EX) harness between connector X014 pin J3-23 and connector X221 pin 4 wire 594 yellow. Locate the open and repair. B. If there is continuity, there is a fault in the moisture sensor. Replace the moisture sensor. 4. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation.

55-39

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E0284 MOISTURE SENSOR ( -- )

1 2

40024715

50026214

9 1. 2. 3.

Moisture Sensor -- B12 Connector X221 Connector X014

55-40

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

AUTO GUIDANCE/ PRECISION FRAME--24

B-12 = MOISTURE SENSOR B-69 = STEERING WHEEL POSITION B-70 = REAR AXLE ANGLE F-47 = CCM-3 FUSE

M-28 = SAMPLE MOTOR M-35 = TURNTABLE ACTUATOR R-05 = YIELD SENSOR

55-41

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0285-03 Moisture Sensor + Shorted to High Source Cause: The moisture sensor (B- 12) “+” circuit is shorted to a high source. Possible failure modes: 1. Moisture sensor “+” wiring is shorted to high source. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.1 to 9.4 volts. A. If the voltage reading is high out of range (>9.4 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 3. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high out of range. Disconnect the sensor connector X221. Use a multimeter to check for voltage on connector X221 pin 3 on the expansion (EX) harness side. A. If there is voltage, there is a short to high voltage in the expansion (EX) harness between connector X221 pin 3 and connector X014 pin J3--17 wire 593 yellow. Locate short and repair. B. If there is no voltage, there is a fault in the moisture sensor. Replace the moisture sensor. 3. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation.

55-42

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0285-05 Moisture Sensor + Line Disconnected Cause: The moisture sensor (B- 12) “+” circuit is open or shorted to ground. Possible failure modes: 1. Moisture sensor “+” circuit wiring is open or shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.1 to 9.4 volts. A. If the voltage reading is low out of range (0.0 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low out of range. Disconnect the sensor connector X221. Use a multimeter to check for continuity between connector X221 pin 3 on the expansion (EX) harness side and chassis ground. A. If there is continuity to ground, there is a short to ground in the expansion (EX) harness between connector X221 pin 3 and connector X014 pin J3--17 wire 593 yellow. Locate short and repair. B. If there is no continuity, continue with Step 3. 3. Key off. Carefully disconnect connector X014 from the bottom of the CCM3 module. Install a jumper wire to short connector X221 pin 3 on the expansion (EX) harness side to ground. Use a multimeter to check continuity between connector X014 pin J3--17 on the expansion (EX) harness side to chassis ground. A. If there is no continuity, there is an open circuit in the expansion (EX) harness between connector X014 pin J3--17 and connector X221 pin 3 wire 593 yellow. Locate the open and repair. B. If there is continuity, there is a fault in the moisture sensor. Replace the moisture sensor. 4. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation.

55-43

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E0285 MOISTURE SENSOR ( + )

1 2

40024715

50026214

10 1. 2. 3.

Moisture Sensor -- B12 Connector X221 Connector X014

55-44

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

AUTO GUIDANCE/ PRECISION FRAME--24

B-12 = MOISTURE SENSOR B-69 = STEERING WHEEL POSITION B-70 = REAR AXLE ANGLE F-47 = CCM-3 FUSE

M-28 = SAMPLE MOTOR M-35 = TURNTABLE ACTUATOR R-05 = YIELD SENSOR

55-45

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0286-03 Rear Axle Angle Sensor Shorted to High Source Cause: The rear axle angle sensor B-70 circuit is shorted to a higher than normal source. Possible Failure Modes: 1. Sensor or circuit wiring shorted to 12 volts. 2. Controller internal failure (Internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, check voltage range. The normal operating range for the sensor is 1.0 – 4.3 volts. NOTE: The high voltage source may not be present as it may not be currently powered up. If the fault code typically appears when operating another circuit, activate that circuit while performing this check. A. If the voltage reading is high out of range (> 5.2 volts), continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 4. 2. Disconnect connector X462 from the Rear Axle Angle Sensor B-70. NOTE: The high voltage source may not be present as it may not be currently powered up. If the fault code typically appears when operating another circuit, activate that circuit while performing this check. A. If the voltage reading remains high out of range (> 5.2 volts) on the display monitor, continue with step 3. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 4. 3. Carefully disconnect connector X014 from the CCM-3 module. Use a multimeter to check the voltage on the module between connector X014 pin J3-25 and chassis ground. NOTE: The high voltage source may not be present as it may not be currently powered up. If the fault code typically appears when operating another circuit, activate that circuit while performing this check. A. If the voltage reading is high out of range (> 5.2 volts) the module has failed. Replace the module. B. If the voltage reading is within the proper limits, the short to high source is in the Expansion (EX) harness between connector X014 pin J3-25 and connector X462 pin C, wire 1732 yellow. Locate and repair the short to high source. 4. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload CCM-3 software. If that does not correct the concern, replace CCM-3.

55-46

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0286-05 Rear Axle Angle Sensor Line Disconnected Cause: The rear axle angle sensor B-70 circuit is open. Possible Failure Modes: 1. Sensor or circuit wiring is open. 2. Controller internal failure (Internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, check voltage range. The normal operating range for the sensor is 1.0 – 4.3 volts. A. If the voltage reading is low out of range (< 0.1 volts), continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 7. 2. Disconnect connector X462 from the Rear Axle Angle Sensor B-70. Use a multimeter to check for voltage on the Expansion (EX) harness side between connector X462 pin A and chassis ground. There should be 12 volts. A. If there is voltage, continue with step 3. B. If there is no voltage, continue with step 5. 3. Disconnect connector X462 from the Rear Axle Angle Sensor B-70. Use a multimeter to check for continuity on the Expansion (EX) harness side between connector X462 pin B and chassis ground. There should be continuity. A. If there is continuity, continue with step 4. B. If there is no continuity, continue with step 6. 4. Turn the Ignition key switch to the OFF position. Disconnect connector X462 from the Rear Axle Angle Sensor B-70. Install a jumper wire from the Expansion (EX) harness side of connector X462 pin C and chassis ground. Carefully disconnect connector X014 from the CCM-3 module. Use a multimeter to check for continuity between the Expansion (EX) harness side of connector X014 pin J3-25 and chassis ground. A. If there is continuity, there is a fault in the rear axle angle sensor. Replace the rear axle cylinder. B. If there is no continuity, there is an open in the Expansion (EX) harness between connector X014 pin J3-25 and connector X462 pin C, wire 1732 yellow. Locate and repair the open. 5. Disconnect the Expansion (EX) harness from the Main Frame (MF) harness at connector X034. Use a multimeter to check for voltage on the Expansion (EX) harness side between connector X034 pin 4 and chassis ground. There should be 12 volts. A. If there is voltage, there is an open in the Expansion (EX) harness between connector X034 pin 4 and connector X462 pin B, wire 1735 or 036 orange. Locate and repair the open. B. If there is no voltage, check fuse F-47 and check for other CCM-3 faults. Locate and correct the source of the problem.

55-47

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 6. Turn the Ignition key switch to the OFF position. Carefully disconnect connector X013 from the CCM-3 module. Use a multimeter to check for continuity between connector X013 pin J2-14 on the module and chassis ground. A. If there is continuity, there is an open in the Expansion (EX) harness between connector X462 pin B and connector X013 pin J2-14 wire 1719 or 1723 blue. Locate and repair the open. B. If there is no continuity, the module has failed. Replace the module. 7. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload CCM-3 software. If that does not correct the concern, replace CCM-3.

55-48

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

10020076

66064129

50016215

11 1. 2. 3.

Rear Axle Angle Sensor -- B70 Connector X025 Connector X014

55-49

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

AUTO GUIDANCE/ PRECISION FRAME--24

B-12 = MOISTURE SENSOR B-69 = STEERING WHEEL POSITION B-70 = REAR AXLE ANGLE F-47 = CCM-3 FUSE

M-28 = SAMPLE MOTOR M-35 = TURNTABLE ACTUATOR R-05 = YIELD SENSOR

55-50

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-51

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0287-03 Upper Sieve Position Sensor Shorted to High Source Cause: The Upper Sieve Position sensor (M-06) circuit is shorted to high voltage, or the sensor ground is open. Possible failure modes: 1. Sensor supply or signal wiring is shorted to high voltage >5.2 volts. 2. Sensor ground wiring is open. 3. Module internal failure (internal regulator failure). Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. Raise and lower the sieves several times while monitoring the voltage; the voltage should stay within range, and should change smoothly with sieve movement. The normal operating range is 0.3 -- 5.2 volts. A. If the voltage reading is >5.2 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the circuit may not be shorted at this time. Continue the troubleshooting at Step 5. 2. Verify the power supply and ground function. Check for an E0293-03 -- CCM3 5V Ref Voltage 3 fault. If present, correct that fault and resume operation. Disconnect and measure the voltage at lower frame rear (LR) connector X227 between pin B(-) and pin A(+) on the lower frame rear (LR) harness side. A. If the voltage is <4.5 volts, there is an open in the ground circuit. Continue with Step 3. B. If the voltage reads between 4.5 and 5.5 volts, then the CCM3 5V REF and circuit ground function properly. The fault is in the sense circuit. Continue with Step 4. 3. Check for multiple faults on common circuits. If fault codes E0287-03, E0290-03, and E0289-03 (if installed) are all active, the fault will most likely be found between CCM3 and straw hood front (SW) harness connector X072. A. If these fault codes are all present, then check the continuity between straw hood front (SW) harness connector X072 pin F wire 795 blue and straw hood front (SW) harness connector X025 pin 2 wire 439 blue. Also check the segment from expansion (EX) harness connector X025 pin 2 to expansion (EX) harness connector X013 pin 14. Locate and repair the open. Continue with Step 5. B. If only one code is present, then check the continuity between lower frame rear (LR) harness connector X227 pin B and straw hood front (SW) harness connector X072 pin F. Also check the segment from straw hood front (SW) harness connector X072 pin F to straw hood front (SW) harness connector X025 pin 2. Locate and repair the open. Continue with Step 5.

55-52

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 4. Verify the sense circuit function. Disconnect and then measure the voltage at lower frame rear (LR) connector X227 between pin B(-) and pin C(+). A. If the voltage reading is >5.2 volts, then there is a voltage source shorted to this circuit. Observe the voltage on the display monitor. Disconnect lower frame rear (LR) connector X072 and note if the voltage drops. Repeat for expansion (EX) harness connector X025. Locate the short and repair. Reconnect all harness connectors. Continue with Step 5. B. If the above steps have not located the problem, then replace CCM3. Continue with Step 5. 5. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-53

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0287-05 Upper Sieve Position Sensor Line Disconnected Cause: The upper sieve position sensor (M-06) circuit is open or shorted to ground. Possible failure modes: 1. Sensor signal wiring is open or shorted to ground. 2. Loss of power to the sensor. 3. Upper sieve position sensor failure (M-06). Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. Raise and lower the sieves several times while monitoring the voltage; the voltage should stay within range, and should change smoothly with sieve movement. The proper voltage range is 0.3 -- 5.2 volts. A. If the voltage reading is < 0.3 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the circuit may not be open or shorted to ground at this time. Continue the troubleshooting at Step 7. NOTE: Visually inspect the wiring harness and connectors. Verify that each connector was fully installed. Inspect the terminals and wires at each connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Verify the power supply and ground function. Check for an E0293-04 -- CCM3 5V Ref Voltage 3 fault. If present, correct that fault and resume operation. Disconnect and measure the voltage at lower frame rear (LR) connector X227 between pin B(-) and pin A(+). A. If the voltage reads between 4.5 and 5.5 volts, then the CCM3 5V REF and circuit ground function properly. The fault is in the sense circuit. Continue with Step 3. 3. Verify lower frame rear (LR) circuit 475 yellow is functioning. Measure the continuity between lower frame rear (LR) harness connector X227 pin C and lower frame rear (LR) harness connector X072 pin G. A. If continuity is found, continue troubleshooting at Step 4. B. If the circuit is open, locate the open and repair. Continue troubleshooting at Step 7. 4. Verify straw hood front (SW) circuit 475 yellow is functioning. Measure the continuity between straw hood front (SW) harness connector X072 pin G and straw hood front (SW) harness connector X025 pin 3. A. If continuity is found, continue troubleshooting at Step 5. B. If the circuit is open, locate the open and repair. Continue troubleshooting at Step 7.

55-54

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 5. Verify expansion (EX) circuit 475 yellow is functioning. Measure the continuity between expansion (EX) harness connector X025 pin 3 and expansion (EX) harness connector X013 pin 22. A. If continuity is found, continue troubleshooting at Step 5. B. If the circuit is open, locate the open and repair. Continue troubleshooting at Step 7. 6. Test upper sieve position sensor. Disconnect lower frame rear (LR) harness connector X227 from Upper Sieve Actuator (M-06). Use a multimeter to measure resistance between pins A and C, then between pins B and C of Upper Sieve Actuator (M-06). A. If no resistance is found, the potentiometer is open. Replace Upper Sieve Actuator (M-06). Continue with Step 7. B. If resistance is found, then the fault will be in CCM3. Replace CCM3. Continue with Step 7. 7. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. Reconnect all harness connectors examined during troubleshooting. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-55

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

40020080

10020076

10010864

50026216

12 1. 2. 3. 4.

Upper Sieve Actuator M06 Connector X072 Connector X025 Connector X013

55-56

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-27 = SIEVE/SPREADER FUSE K-18 = UPPER/LOWER SIEVE RELAY M-06 = UPPER SIEVE ACTUATOR M-07 = LOWER SIEVE ACTUATOR

S-35 = UPPER SIEVE REAR ADJUST S-46 = LOWER SIEVE REAR ADJUST

55-57

CLEANING FRAME--21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-58

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0288-03 Grain Yield Sensor Shorted to High Source Cause: The grain yield sensor (R05) circuit is shorted to a high source. Possible failure modes: 1. Yield sensor wiring is shorted to high source. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.1 to 5.2 volts. A. If the voltage reading is high out of range (>5.2 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 3. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high out of range. Disconnect the sensor connector X223. Use a multimeter to check for voltage on connector X223 pin C on the expansion (EX) harness side to frame ground. A. If there is voltage, there is a short to high voltage in the expansion (EX) harness between connector X223 pin C and connector X014 pin J3--32 wire 552 yellow. Locate short and repair. B. If there is no voltage, there is a fault in the yield sensor. Replace the yield sensor. 3. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation.

55-59

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0288-05 Grain Yield Sensor Line Disconnected Cause: The yield sensor (R- 05) circuit is open or shorted to ground. Possible failure modes: 1. Sensor wiring is open or shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage range is 0.1 to 5.2 volts. A. If the voltage reading is low out of range(0.0 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low out of range. Disconnect the sensor connector X223. Use a multimeter to check for continuity between connector X223 pin C on the expansion (EX) harness side and chassis ground. A. If there is continuity to ground, there is a short to ground in the expansion (EX) harness between connector X223 pin C and connector X014 pin J3--32 wire 552 yellow. Locate short and repair. B. If there is no continuity, continue with Step 3. 3. Key off. Carefully disconnect connector X014 from the bottom of the CCM3 module. Install a jumper wire to short connector X223 pin C on the expansion (EX) harness side to ground. Use a multimeter to check continuity between connector X014 pin J3--32 on the expansion (EX) harness side to chassis ground. A. If there is no continuity, there is an open circuit in the expansion (EX) harness between connector X014 pin J3--32 and connector X223 pin C wire 552 yellow. Locate the open and repair. B. If there is continuity, there is a fault in the yield sensor. Replace the yield sensor. 4. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation.

55-60

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E0288 GRAIN YIELD SENSOR

10004680

50026214 50026214

13 1. 2. 3.

Yield Sensor R05 Connector X223 Connector X014

55-61

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

AUTO GUIDANCE/ PRECISION FRAME--24

B-12 = MOISTURE SENSOR B-69 = STEERING WHEEL POSITION B-70 = REAR AXLE ANGLE F-47 = CCM-3 FUSE

M-28 = SAMPLE MOTOR M-35 = TURNTABLE ACTUATOR R-05 = YIELD SENSOR

55-62

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0289-03 Spreader Plate Position Sensor Shorted to High Source Cause: The Spreader Plate Position sensor (M-11) circuit is shorted to high voltage, or the sensor ground is open. Possible failure modes: 1. Sensor supply or signal wiring is shorted to high voltage >5.2 volts. 2. Sensor ground wiring is open. 3. Module internal failure (internal regulator failure). Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. Raise and lower the spreader plate several times while monitoring the voltage; the voltage should stay within range, and should change smoothly with sieve movement. The normal operating range is 0.3 -- 5.2 volts. A. If the voltage reading is >5.2 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the circuit may not be shorted at this time. Continue the troubleshooting at Step 5. 2. Verify the power supply and ground function. Check for an E0293-03 -- CCM3 5V Ref Voltage 3 fault. If present, correct that fault and resume operation. Disconnect and measure the voltage at lower frame rear (LR) connector X224 between pin B(-) and pin A(+) on the straw hood (SH) harness side. A. If the voltage is <4.5 volts, there is an open in the ground circuit. Continue with Step 3. B. If the voltage reads between 4.5 and 5.5 volts, then the CCM3 5V REF and circuit ground function properly. The fault is in the sense circuit. Continue with Step 4. 3. Check for multiple faults on common circuits. If fault codes E0287-03, E0290-03, and E0289-03 are all active, the fault will most likely be found between CCM3 and straw hood front (SW) harness connector X072. A. If these fault codes are all present, then check the continuity between straw hood front (SW) harness connector X071 pin 2 wire 471 blue and straw hood front (SW) harness connector X025 pin 2 wire 439 blue. Also check the segment from expansion (EX) harness connector X025 pin 2 to expansion (EX) harness connector X013 pin 14. Locate and repair the open. Continue with Step 5. B. If only one code is present, then check the continuity between straw hood (SH) harness connector X224 pin B and straw hood (SH) harness connector X071 pin 2. Also check the segment from straw hood front (SW) harness connector X071 pin 2 to straw hood front (SW) harness connector X025 pin 2. Locate and repair the open. Continue with Step 5.

55-63

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 4. Verify the sense circuit function. Disconnect and then measure the voltage at lower frame rear (LR) connector X224 between pin B(-) and pin C(+). A. If the voltage reading is >5.2 volts, then there is a voltage source shorted to this circuit. Observe the voltage on the display monitor. Disconnect straw hood (SH) connector X071 and note if the voltage drops. Repeat for expansion (EX) harness connector X025. Locate the short and repair. Reconnect all harness connectors. Continue with Step 5. B. If the above steps have not located the problem, then replace CCM3. Continue with Step 5. 5. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-64

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0289-05 Spreader Plate Position Sensor Line Disconnected Cause: The spreader plate position sensor (M-11) circuit is open or shorted to ground. Possible failure modes: 1. Sensor signal wiring is open or shorted to ground. 2. Loss of power to the sensor. 3. Spreader plate position sensor failure (M-11). Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. Move the spreader plate fully left and right several times while monitoring the voltage; the voltage should stay within range, and should change smoothly with plate movement. The proper voltage range is 0.3 -- 5.2 volts. A. If the voltage reading is < 0.3 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the circuit may not be open or shorted to ground at this time. Continue the troubleshooting at Step 7. NOTE: Visually inspect the wiring harness and connectors. Verify that each connector was fully installed. Inspect the terminals and wires at each connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Verify the power supply and ground function. Check for an E0293-04 -- CCM3 5V Ref Voltage 3 fault. If present, correct that fault and resume operation. Disconnect and measure the voltage at straw hood (SH) connector X224 between pin B(-) and pin A(+) on the straw hood (SH) harness side. A. If the voltage reads between 4.5 and 5.5 volts, then the CCM3 5V REF and circuit ground function properly. The fault is in the sense circuit. Continue with Step 3. 3. Verify straw hood (SH) circuit 477 yellow is functioning. Measure the continuity between lower frame rear (LR) harness connector X224 pin C and straw hood (SH) harness connector X071 pin 10. A. If continuity is found, continue troubleshooting at Step 4. B. If the circuit is open, locate the open and repair. Continue troubleshooting at Step 7. 4. Verify straw hood front (SW) circuit 477 yellow is functioning. Measure the continuity between straw hood front (SW) harness connector X071 pin 10 and straw hood front (SW) harness connector X025 pin 5. A. If continuity is found, continue troubleshooting at Step 5. B. If the circuit is open, locate the open and repair. Continue troubleshooting at Step 7.

55-65

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 5. Verify expansion (EX) circuit 477 yellow is functioning. Measure the continuity between expansion (EX) harness connector X025 pin 5 and expansion (EX) harness connector X013 pin J2-33. A. If continuity is found, continue troubleshooting at Step 5. B. If the circuit is open, locate the open and repair. Continue troubleshooting at Step 7. 6. Test spreader plate position sensor. Disconnect straw hood (SH) harness connector X224 from Spreader Plate Motor (M-11). Use a multimeter to measure resistance between pins A and C, then between pins B and C of Spreader Plate Motor (M-11). A. If no resistance is found, the potentiometer is open. Replace Spreader Plate Motor (M-11). Continue with Step 7. B. If resistance is found, then the fault will be in CCM3. Replace CCM3. Continue with Step 7. 7. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. Reconnect all harness connectors examined during troubleshooting. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-66

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

2 3

40025219

50026220

10020076

50016215

1. 2. 3. 4. 5.

Connector X025 Connector X071 Connector X224 Spreader Plate Motor M11 Connector X013

55-67

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

B-10 = CHOPPER RPM L-28 = CHAFF SPREADER M-11 = SPREADER PLATE MOTOR S-23 = SPREADER PLATE

B-74 = PSD RPM

TRASH FRAME--23

55-68

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-69

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0290-03 Lower Sieve Position Sensor Shorted To High Source Cause: The Lower Sieve Position sensor (M-07) circuit is shorted to high voltage, or the sensor ground is open. Possible failure modes: 1. Sensor supply or signal wiring is shorted to high voltage >5.2 volts. 2. Sensor ground wiring is open. 3. Module internal failure (internal regulator failure). Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. Raise and lower the sieves several times while monitoring the voltage; the voltage should stay within range, and should change smoothly with sieve movement. The normal operating range is 0.3 -- 5.2 volts. A. If the voltage reading is >5.2 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the circuit may not be shorted at this time. Continue the troubleshooting at Step 5. 2. Verify the power supply and ground function. Check for an E0293-03 -- CCM3 5V Ref Voltage 3 fault. If present, correct that fault and resume operation. Disconnect and measure the voltage at lower frame rear (LR) connector X228 between pin B(-) and pin A(+) on the lower frame rear (LR) harness side. A. If the voltage is <4.5 volts, there is an open in the ground circuit. Continue with Step 3. B. If the voltage reads between 4.5 and 5.5 volts, then the CCM3 5V REF and circuit ground function properly. The fault is in the sense circuit. Continue with Step 4. 3. Check for multiple faults on common circuits. If fault codes E0287-03, E0290-03, and E0289-03 (if installed) are all active, the fault will most likely be found between CCM3 and straw hood front (SW) harness connector X072. A. If these fault codes are all present, then check the continuity between straw hood front (SW) harness connector X072 pin L wire 796 blue and straw hood front (SW) harness connector X025 pin 2 wire 439 blue. Also check the segment from expansion (EX) harness connector X025 pin 2 to expansion (EX) harness connector X013 pin 14. Locate and repair the open. Continue with Step 5. B. If only one code is present, then check the continuity between lower frame rear (LR) harness connector X228 pin B and straw hood front (SW) harness connector X072 pin F. Also check the segment from straw hood front (SW) harness connector X072 pin F to straw hood front (SW) harness connector X025 pin 2. Locate and repair the open. Continue with Step 5.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 4. Verify the sense circuit function. Disconnect and then measure the voltage at lower frame rear (LR) connector X228 between pin B(-) and pin C(+) on the lower frame rear (LR) harness side. A. If the voltage reading is >5.2 volts, then there is a voltage source shorted to this circuit. Observe the voltage on the display monitor. Disconnect lower frame rear (LR) connector X072 and note if the voltage drops. Repeat for expansion (EX) harness connector X025. Locate the short and repair. Reconnect all harness connectors. Continue with Step 5. B. If the above steps have not located the problem, then replace CCM3. Continue with Step 5. 5. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0290-05 Lower Sieve Position Sensor Line Disconnected Cause: The lower sieve position sensor (M-07) circuit is open or shorted to ground. Possible failure modes: 1. Sensor signal wiring is open or shorted to ground. 2. Loss of power to the sensor. 3. Lower sieve position sensor failure (M-07). Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. Raise and lower the sieves several times while monitoring the voltage; the voltage should stay within range, and should change smoothly with sieve movement. The proper voltage range is 0.3 -- 5.2 volts. A. If the voltage reading is < 0.3 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the circuit may not be open or shorted to ground at this time. Continue the troubleshooting at Step 7. NOTE: Visually inspect the wiring harness and connectors. Verify that each connector was fully installed. Inspect the terminals and wires at each connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Verify the power supply and ground function. Check for an E0293-04 -- CCM3 5V Ref Voltage 3 fault. If present, correct that fault and resume operation. Disconnect and measure the voltage at lower frame rear (LR) connector X228 between pin B(-) and pin A(+) on the lower frame rear (LR) harness side. A. If the voltage reads between 4.5 and 5.5 volts, then the CCM3 5V REF and circuit ground function properly. The fault is in the sense circuit. Continue with Step 3. 3. Verify lower frame rear (LR) circuit 476 yellow is functioning. Measure the continuity between lower frame rear (LR) harness connector X228 pin C and lower frame rear (LR) harness connector X072 pin M. A. If continuity is found, continue troubleshooting at Step 4. B. If the circuit is open, locate the open and repair. Continue troubleshooting at Step 7. 4. Verify straw hood front (SW) circuit 476 yellow is functioning. Measure the continuity between straw hood front (SW) harness connector X072 pin M and straw hood front (SW) harness connector X025 pin 4. A. If continuity is found, continue troubleshooting at Step 5. B. If the circuit is open, locate the open and repair. Continue troubleshooting at Step 7.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 5. Verify expansion (EX) circuit 476 yellow is functioning. Measure the continuity between expansion (EX) harness connector X025 pin 4 and expansion (EX) harness connector X013 pin 19. A. If continuity is found, continue troubleshooting at Step 5. B. If the circuit is open, locate the open and repair. Continue troubleshooting at Step 7. 6. Test lower sieve position sensor. Disconnect lower frame rear (LR) harness connector X228 from Lower Sieve Actuator (M-07). Use a multimeter to measure resistance between pins A and C, then between pins B and C of Lower Sieve Actuator (M-07). A. If no resistance is found, the potentiometer is open. Replace Lower Sieve Actuator (M-07). Continue with Step 7. B. If resistance is found, then the fault will be in CCM3. Replace CCM3. Continue with Step 7. 7. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. Reconnect all harness connectors examined during troubleshooting. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-73

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

10020076

40020080

10010874

50016215

1. 2. 3. 4.

Connector X025 Connector X072 Lower Sieve Actuator M07 Connector X013

55-74

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-27 = SIEVE/SPREADER FUSE K-18 = UPPER/LOWER SIEVE RELAY M-06 = UPPER SIEVE ACTUATOR M-07 = LOWER SIEVE ACTUATOR

S-35 = UPPER SIEVE REAR ADJUST S-46 = LOWER SIEVE REAR ADJUST

55-75

CLEANING FRAME--21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-76

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0293-03 CCM3 5V Ref Voltage 3 Shorted to High Source Cause: The CCM3 5V Reference Voltage 3 circuit is shorted to a higher than normal source. Possible failure modes: 1. CCM3 5V Reference Voltage 3 wiring shorted to a higher than normal source. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage is 4.5 to 5.5 volts. A. If the voltage reading is high, out of range (>5.5 volts), continue with Step 2. B. If the voltage reading is within proper limits. The shorted wire may not be powered up at this time. Continue diagnosis with Step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high out of range. Disconnect connector X071. Monitor voltage reading. A. If the voltage drops to the normal range, there is a short to high voltage in the straw hood (SH) harness between connector X071 pin 1 and connector X224 pin A wire 473 pink. Locate the short and repair. B. If the voltage remains high, continue with Step 3. 3. The voltage reading on the display monitor is high out of range. Disconnect connector X072. Monitor the voltage reading. A. If the voltage drops to the normal range, there is a short to high voltage in the lower frame rear (LR) harness between connector X072 pin E and connector X227 pin A wire 793 pink or between connector X072 pin K and connector X228 pin A wire 794 pink. Locate the short and repair. B. If the voltage remains high, continue with Step 4. 4. The voltage reading on the display monitor is high out of range. Disconnect connector X025. Monitor the voltage reading. A. If the voltage drops to the normal range, there is a short to high voltage in the straw hood front (SW) harness between connector X025 pin 1, connector X071 pin 1 and connector X072 pins E & K on one of the following wires: Wire 683 pink, connector X025 pin 1 to SW harness splice Wire 473 pink, SW harness splice to connector X071 pin 1 Wire 793 pink, SW harness splice to connector X072 pin E Wire 794 pink, SW harness splice to connector X072 pin K Locate the short and repair. B. If the voltage remains high, there is a short to high voltage in the expansion (EX) harness between connector X025 pin 1 and connector X013 pin J2-31 wire 683 pink. Locate the short and repair.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 5. Operate the upper sieve actuator M06 in both directions while observing the voltage scale. If remote adjust sieves are not installed, continue with Step 7. A. If the voltage reading is high, out of range (>5.5 volts), go to Step 8. B. If the voltage reading stays within the proper limits, continue with Step 6. 6. Operate the lower sieve actuator M07 in both directions while observing the voltage scale. A. If the voltage reading is high, out of range (>5.5 volts), go to Step 11. B. If the voltage reading stays within the proper limits, continue with Step 7. 7. Operate the chopper spreader plates (M11) in both directions while observing the voltage scale. If chopper spreader plates are not installed, continue with Step 17. A. If the voltage reading is high, out of range (>5.5 volts), go to Step 14. B. If the voltage reading stays within the proper limits, continue with Step 17. 8. The voltage reading on the display monitor is high. Disconnect connector X227 to the upper sieve actuator M06. Operate the upper sieve actuator in both directions and monitor voltage reading. A. The voltage remains in the normal range. The short to high voltage is occurring on wire 793 pink in the pigtail harness of the upper sieve actuator M06. Locate the short and repair. B. If the voltage remains high, continue with Step 9. 9. Disconnect connector X072. Operate the upper sieve actuator in both directions and monitor voltage reading. A. The voltage remains in the normal range. The short to high voltage is in the lower frame rear (LR) harness between connector X072 pin E and connector X227 pin A wire 793 pink. Locate the short and repair. B. If the voltage remains high, continue with Step 10. 10. Disconnect connector X025. Operate the upper sieve actuator in both directions and monitor voltage reading. A. The voltage remains in the normal range. The short to high voltage is in the straw hood front (SW) harness between connector X072 pin E and connector X025 pin 1 wire 793 pink or 683 pink. Locate the short and repair. B. If the voltage remains high, there is a short to high voltage in the expansion (EX) harness between connector X025 pin 1 and connector X013 pin J2-31 wire 683 pink. Locate the short and repair. 11. The voltage reading on the display monitor is high. Disconnect connector X228 to the lower sieve actuator M07. Operate the lower sieve actuator in both directions and monitor voltage reading. A. The voltage remains in the normal range. The short to high voltage is occurring on wire 794 pink in the pigtail harness of the lower sieve actuator M07. Locate the short and repair. B. If the voltage remains high, continue with Step 12. 12. Disconnect connector X072. Operate the lower sieve actuator in both directions and monitor voltage reading. A. The voltage remains in the normal range. The short to high voltage is in the lower frame rear (LR) harness between connector X072 pin K and connector X228 pin A wire 794 pink. Locate the short and repair. B. If the voltage remains high, continue with Step 13.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 13. Disconnect connector X025. Operate the upper sieve actuator in both directions and monitor voltage reading. A. The voltage remains in the normal range. The short to high voltage is in the straw hood front (SW) harness between connector X072 pin K and connector X025 pin 1 wire 794 pink or 683 pink. Locate the short and repair. B. If the voltage remains high, there is a short to high voltage in the expansion (EX) harness between connector X025 pin 1 and connector X013 pin J2-31 wire 683 pink. Locate the short and repair. 14. The voltage reading on the display monitor is high. Disconnect connector X224 to the spreader plates motor M11. Monitor voltage reading. A. The voltage drops to the normal range. There is a short to high voltage on wire 473 pink in the harness to the spreader plates motor M11. Locate the short and repair. B. If the voltage remains high, continue with Step 15. 15. Disconnect connector X071. Operate the spreader plates in both directions and monitor voltage reading. A. The voltage remains in the normal range. The short to high voltage is in the straw hood (SH) harness between connector X071 pin 1 and connector X224 pin A wire 473 pink. Locate the short and repair. B. If the voltage remains high, continue with Step 16. 16. Disconnect connector X025. Operate the spreader plates in both directions and monitor voltage reading. A. The voltage remains in the normal range. The short to high voltage is in the straw hood front (SW) harness between connector X071 pin 1 and connector X025 pin 1 wire 473 pink or 683 pink. Locate the short and repair. B. If the voltage remains high, there is a short to high voltage in the expansion (EX) harness between connector X025 pin 1 and connector X013 pin J2-31 wire 683 pink. Locate the short and repair. 17. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0293-04 CCM3 5V Ref Voltage 3 Shorted to Low Source Cause: The CCM3 5V Reference Voltage 3 circuit is shorted to a lower than normal source. Possible failure modes: 1. CCM3 5V Reference Voltage 3 wiring is shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage is 4.5 to 5.5 volts. A. If the voltage reading is low, out of range (<4.5 volts), continue with Step 2. B. If the voltage reading is within proper limits, the shorted wire may not be grounded at this time. Continue diagnosis with Step 8. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low. Disconnect connector X224 at the spreader plates motor M11. Monitor voltage reading. A. The voltage increases to the normal range. There is a short to ground on wire 473 pink in the pigtail harness to the spreader plates motor M11. Locate the short and repair. B. If the voltage reading remains low out of range, continue with Step 3. 3. The voltage reading on the display monitor is in the normal range. Disconnect connector X071. Monitor voltage reading. A. The voltage increases to the normal range. There is a short to ground in the straw hood (SH) harness between connector X071 pin 1 and connector X224 pin A wire 473 pink. Locate the short and repair. B. If the voltage reading remains low out of range, continue with Step 4. 4. The voltage reading on the display monitor is low. Disconnect connector X227 at the upper sieve actuator M06. Monitor voltage reading. A. The voltage increases to the normal range. There is a short to ground on wire 793 pink in the pigtail harness to the upper sieve actuator M06. Locate the short and repair. B. If the voltage reading remains low out of range, continue with Step 5. 5. The voltage reading on the display monitor is low. Disconnect connector X228 at the lower sieve actuator M07. Monitor voltage reading. A. The voltage increases to the normal range. There is a short to ground on wire 794 pink in the pigtail harness to the lower sieve actuator M07. Locate the short and repair. B. If the voltage reading remains low out of range, continue with Step 6.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 6. The voltage reading on the display monitor is in the normal range. Disconnect connector X072. Monitor voltage reading. A. The voltage increases to the normal range. There is a short to ground in the lower frame rear (LR) harness between connector X072 pin E and connector X227 pin A wire 793 pink or between connector X072 pin K and connector X228 pin A wire 794 pink. Locate the short and repair. B. If the voltage reading remains low out of range, continue with Step 7. 7. The voltage reading on the display monitor is in the normal range. Disconnect connector X025. Monitor voltage reading. A. The voltage increases to the normal range. There is a short to ground in the straw hood front (SW) harness between connector X071 pin 1, connector X072 pins E & K and connector X025 pin 1 on one of the following wires: Wire 683 pink, connector X025 pin 1 to SW harness splice Wire 473 pink, SW harness splice to connector X071 pin 1 Wire 793 pink, SW harness splice to connector X072 pin E Wire 794 pink, SW harness splice to connector X072 pin K Locate the short and repair. B. If the voltage reading remains low out of range, there is a short to ground in the expansion harness between connector X025 pin 1 and connector X013 pin J2-31 wire 683 pink. Locate the short and repair. 8. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation.

55-81

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E0293 CCM3 5V REF VOLTAGE 3

40025219

50026220

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1. 2. 3. 4. 5. 6. 7. 8.

Connector X025 Connector X071 Connector X224 Spreader Plate Motor M11 Connector X072 Upper Sieve Actuator M06 Lower Sieve Actuator M07 Connector X013

55-82

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-27 = SIEVE/SPREADER FUSE K-18 = UPPER/LOWER SIEVE RELAY M-06 = UPPER SIEVE ACTUATOR M-07 = LOWER SIEVE ACTUATOR

S-35 = UPPER SIEVE REAR ADJUST S-46 = LOWER SIEVE REAR ADJUST

55-83

CLEANING FRAME--21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

B-10 = CHOPPER RPM L-28 = CHAFF SPREADER M-11 = SPREADER PLATE MOTOR S-23 = SPREADER PLATE

B-74 = PSD RPM

TRASH FRAME--23

55-84

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-85

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0294-03 CCM3 8V Ref Voltage Shorted to High Source Cause: The CCM3 8V Ref Voltage circuit is shorted to a higher than normal source. Possible failure modes: 1. 12V short on 8V regulated power circuit. 2. Controller internal failure (internal regulator failure). Solution: The 8V regulated power supply is provided from the key switch power to the module, and is used to provide power to all the speed and position sensor circuits. In some cases, a 12V short on one of the sensor signal wires could result in backfeeding that upsets the 8V regulator, and may cause the short to high source fault. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage is 7.5 to 8.5 volts. A. If the reading is high out of range, continue with Step 2. B. If the reading is within the proper range, reload the software in CCM3. Erase the Fault code and continue operation. If the fault code persists, replace the module. 2. Turn off the key switch, and disconnect the battery key to remove all power from the module. Carefully remove connector X013 and connector X014 from the bottom of CCM3 module. Reconnect the battery key and using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage is 7.5 to 8.5 volts. A. If the voltage reading is normal, there is a short to high source on one of the sensor wires. Continue with Step 3. B. If the voltage reading is still high out of range then CCM3 has an internal failure. Replace the controller. 3. Turn off the key switch, and disconnect the battery key to remove all power from the module. Carefully reconnect connector X013 and connector X014 from the bottom of CCM3 module. Reconnect the battery key and check for any errors for sensor circuits short to high source on CCM3 module. A. If there are any sensor circuits on CCM3 that are shorted to high source, correct those circuits, and then continue with Step 1 of this troubleshooting to verify this concern is resolved. B. If there are no sensor circuits errors on CCM3, reload the software in CCM3. Erase the fault code and continue operation. If the fault code persists, replace the module.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0294-04 CCM3 8V Ref Voltage Shorted to Low Source Cause: The CCM3 8V Ref Voltage circuit is shorted to ground. Possible failure modes: 1. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage is 7.5 to 8.5 volts. A. If the voltage reading is low out of range then CCM3 has an internal failure. Replace the controller. B. If the voltage reading is within proper limits. The failure may not be present at this time. Continue diagnosis with Step 2. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0295-03 CCM3 5V Ref Voltage 1 Shorted to High Source Cause: The CCM3 5V Reference Voltage 1 circuit is shorted to a higher than normal source. Possible failure modes: 1. CCM3 5V Reference Voltage 1 wiring shorted to a higher than normal source. 2. Controller internal failure (internal regulator failure). Solution: The CCM3 5V Reference Voltage 1 circuit is not currently being used at this time, and there is no wiring connected to this output from the module. If this fault code occurs, there may be moisture in connector X014 that is shorting this pin to power, or there may be an internal fault in the module. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage is 4.5 to 5.5 volts. A. If the voltage reading is high, out of range (>5.5 volts), continue with Step 2. B. If the voltage reading is within proper limits. The condition that generated the fault is not present at this time. Continue diagnosis with Step 3. 2. Disconnect connector X014 from the bottom of the CCM3 module. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for bent pins, pushed back or corroded terminals or damaged wires. Thoroughly clean and dry the connector and reinstall it. A. If the voltage reading remains high, out of range (>5.5 volts), there is an internal fault with the CCM3 module. If there are no other faults with the circuits attached to this module, it should be possible to continue operation without replacing the module. If fault code E0293-03 CCM3 5V Ref Voltage 3 is also present and can not be corrected, then the module will need to be replaced. B. If the voltage reading is within proper limits, continue with Step 3. 3. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0295-04 CCM3 5V Ref Voltage 1 Shorted to Low Source Cause: The CCM3 5V Reference Voltage 1 circuit is shorted to a lower than normal source. Possible failure modes: 1. CCM3 5V Reference Voltage 1 wiring is shorted to ground. 2. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage is 4.5 to 5.5 volts. A. If the voltage reading is low, out of range (<4.5 volts), continue with Step 2. B. If the voltage reading is within proper limits. The condition that generated the fault is not present at this time. Continue diagnosis with Step 3. 2. Disconnect connector X014 from the bottom of the CCM3 module. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for bent pins, pushed back or corroded terminals or damaged wires. Thoroughly clean and dry the connector and reinstall it. A. If the voltage reading remains low, out of range (<4.5 volts), there is an internal fault with the CCM3 module. If there are no other faults with the circuits attached to this module, it should be possible to continue operation without replacing the module. If fault code E0293-04 CCM3 5V Ref Voltage 3 is also present and can not be corrected, then the module will need to be replaced. B. If the voltage reading is within proper limits, continue with Step 3. 3. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0296-03 CCM3 Keyswitch Voltage Shorted to High Source Cause: The CCM3 Keyswitch Voltage circuit is shorted to a higher than normal source. Possible failure modes: 1. The keyswitch voltage circuit to the CCM2 controller is shorted to a high source. 2. Faulty alternator/regulator. 3. Controller internal failure (internal regulator failure). Solution: Key switch voltage is used to initialize (wake-up) the module, and also supplies power to the 5V and 8V regulators for the regulated voltage circuits. The module will shutdown if the voltage is less than 9 volts, but there is no shutdown for excessive voltage. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is greater than 18 volts, continue with Step 2. B. If the voltage reading is between 10 and 18 volts, go to Step 5. 2. Shut off the combine engine, and then turn the key switch on again. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, the alternator and/or regulator has failed, and is producing excessive voltage. Refer to “Charging Systems” in Chapter 5 -- Engine Systems in this section for additional alternator testing information. B. If the voltage reading is greater than 18 volts, continue with Step 3. 3. Turn the key switch off to power down the system. Check the voltage at fuse F38 using a multi-meter. A. If the voltage reading is greater than 18 volts, then the batteries have been mistakenly connected in series, or there is a fault in the wiring of the 24V starting system. Refer to “Starting Systems” in Chapter 5 -- Engine Systems in this section for additional information. B. If the voltage reading is between 10 and 18 volts, continue with Step 4.

55-90

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 4. Remove the buddy seat and storage bin to gain access to connector X012 on CCM3. Turn the key on. Check the voltage at connector X012 pin J1-4. A. If the voltage reading is greater than 18 volts, then a high voltage source has been connected to one of the following wires: wire 096 orange, key switch S02 to CM harness splice wire 100 orange, harness splice to CCM2 connector X015, pin J1-4 wire 099 orange, harness splice to CCM1 connector X018, pin J1-4 wire 101 orange, harness splice to CCM3 connector X012, pin J1-4 wire 055 orange, harness splice to road light switch connector X256, pin 6 wire 095 orange, harness splice to power relays K24, K25 & K26, pins 1 wire 222 orange, power relay K26 to time delay module K20, pin 30 All wires listed are located in the cab main (CM) harness. Visually inspect the cab main harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the high voltage short and repair. B. If the voltage reading is 10 to 18 volts, and the diagnostic screen is still indicating voltage in excess of 18 volts, there is an internal fault in CCM2. Reload the software for CCM2. If that does not correct the concern, replace the module. 5. Erase the error code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0296-04 CCM3 Keyswitch Voltage Shorted to Low Source Cause: The CCM3 Keyswitch Voltage circuit is shorted to a lower than normal source. Possible failure modes: 1. Loose or corroded connections, or damaged wires. 2. Batteries are discharged, and/or alternator/regulator failure. 3. The keyswitch voltage circuit to the CCM3 controller is shorted to ground. NOTE: Check fuse F38. If a short to ground occurred on this circuit the fuse will have blown. 4. Controller internal failure (internal regulator failure). Solution: Key switch voltage is used to initialize (wake-up) the module, and also supplies power to the 5V and 8V regulators for the regulated voltage circuits. The module will shutdown if the voltage is less than 9 volts, but there is no shutdown for excessive voltage. 1. Key switch in “Off” position. Check fuse F38. A. If fuse F38 is okay, continue with Step 6. B. If the fuse is blown, go to Step 2. 2. Replace the failed fuse F38. A. If the fuse is okay, continue with Step 3. B. If the fuse immediately fails again, a short to ground exists in wire 053 red between the fuse and the key switch in the cab main (CM) harness. Visually inspect the cab main harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair. 3. If the fuse does not fail when it is replaced, turn the key switch to the “Acc” position. A. If the fuse is okay, continue with Step 4. B. If the fuse immediately fails, there is a short to ground in one of the following wires: wire 123 orange, key switch to the Wiper relay K06 wire 241 orange, Wiper relay K06 to Accessory 1 relay K08 wire 126 orange, Accessory 1 relay K08 to Accessory 2 relay K03 All three wires are in the cab main harness. Visually inspect the cab main harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 4. If the fuse does not fail with the key switch in the “Acc” position, turn the key switch to the “On” position. A. If the fuse is okay, continue with Step 5. B. If the fuse immediately fails, there is a short to ground in one of the following wires: wire 096 orange, key switch S02 to CM harness splice wire 100 orange, harness splice to CCM2 connector X015, pin J1-4 wire 099 orange, harness splice to CCM1 connector X018, pin J1-4 wire 101 orange, harness splice to CCM3 connector X012, pin J1-4 wire 055 orange, harness splice to road light switch connector X256, pin 6 wire 095 orange, harness splice to power relays K24, K25 & K26, pins 1 wire 222 orange, power relay K26 to time delay module K20, pin 30 All wires are in the cab main harness. Visually inspect the cab main harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair. 5. If the fuse does not fail with the key switch in the “On” position, turn the key switch briefly to the “Start” position. A. If the fuse is okay, continue with Step 6. B. If the fuse immediately fails, there is a short to ground in wire 091 orange from the key switch to Neutral start relay K23, or wire 090 orange from the relay to CCM2, connector X015, pin J1-21. Both wires are in the cab main harness. Visually inspect the cab main harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair. 6. Key switch in “Off” position. Check the voltage at fuse F38 using a multi-meter. A. If the voltage reading is between 10 and 18 volts, continue with Step 7. B. If the voltage reading is less than 10 volts, there is excessive resistance between the batteries and the cab fuse panel, due to loose or corroded connections, or the batteries have discharged excessively, and are not capable of supplying the minimum voltage requirement for CCM3. Inspect the wiring from the batteries to the engine compartment, and from there to the cab. Recharge or replace the batteries. 7. Key switch in “On” position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, continue with Step 8. B. If the voltage reading is less than 10 volts, there is excessive resistance between the fuse panel and CCM3. Inspect wire 053 red to the key switch, and wires 096 and 101 orange to CCM3 connector X012 pin J1-4 for loose or corroded connections, or damage to the wires. 8. Start the combine engine. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed. With the engine RPM at low idle, engage road and work lights. Check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, continue with Step 9. B. If the voltage reading is less than 10 volts, the alternator and/or regulator may have failed, and the charging system is not producing sufficient voltage. Refer to “Charging Systems” in Chapter 5 -- Engine Systems for additional alternator testing information. 9. Erase the error code and continue operation.

55-93

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E0296 KEY SWITCH VOLTAGE

20013706

2 1

10004693

50020070

50026204

17 1. 2. 3.

Connector X012 Fuse F38 Key Switch S02

55-94

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

55-95

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0 L

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

DISTRIBUTION FRAME--28

F-36 = CCM-2A FUSE F-37 = CCM-2B FUSE F-40 = CCM-1 POWER FUSE F-41 = CCM-2 POWER FUSE

F-42 = CCM-3, CAB POWER FUSE K-24 = CCM-1 POWER RELAY K-25 = CCM-2 POWER RELAY K-26 = CCM-3, CAB POWER RELAY

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

LIGHTING FRAME--36

A-05 = FLASHER MODULE E-13 = LH ROAD LIGHT E-14 = RH ROAD LIGHT F-32 = HIGH BEAM FUSE

F-33 = LOW BEAM FUSE F-51 = HORN, MARKER LTS FUSE H-02 = HORN K-02 = LIGHT CONTROL RELAY

55-98

K-04 = HIGH BEAM RELAY K-05 = LOW BEAM RELAY S-26 = ROAD LIGHT SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

LIGHTING FRAME--38

E-34 = DOME LIGHT E-35 = CONSOLE LIGHT E-42 = LH FRONT SHIELD LT E-43 = LH REAR SHIELD LT

E-44 = RH FRONT SHIELD LT E-45 = RH REAR SHIELD LT E-46 = ENGINE LT F-34 = UNDERSHIELD LIGHTS

55-99

F-52 = DOME/BRAKE LT FUSE K-20 = TIME DELAY MODULE K-33 = BRAKE LIGHTS RELAY S-40 = LH DOOR SWITCH

S-63 = LEFT SHIELD LT SW S-64 = ENGINE LT SW S-65 = RIGHT SHIELD LT SW

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-03 = ACCESSORY 1 FUSE F-04 = WIPER FUSE F-05 = CIGAR LIGHTER FUSE F-08 = ACCESSORY OUTLET FUSE

F-09 = WASHER/MIRROR FUSE F-10 = NOT USED J-06 = ACCESSORY SOCKET J-08 = ACCESSORY OUTLET

K-06 = WIPER RELAY K-08 = ACCESSORY 1 RELAY M-24 = WIPER WASHER MOTOR M-25 = WIPER MOTOR

55-100

R-08 = CIGAR LIGHTER S-20 = WIPER SWITCH S-38 = WASHER SWITCH

ACCESSORY FRAME--45

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

ACCESSORY FRAME--46

A-04 = RADIO F-02 = ACCESSORY 2 FUSE F-11 = RADIO FUSE F-13 = TRANSCEIVER FUSE

F-16 = SEAT PUMP FUSE F-35 = RADIO KAPWR FUSE H-04 = REAR LEFT SPEAKER H-05 = FRONT LEFT SPEAKER

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H-06 = REAR RIGHT SPEAKER H-07 = FRONT RIGHT SPEAKER J-07 = TRANSCEIVER OUTLET K-03 = ACCESSORY 2 RELAY

M-26 = SEAT PUMP MOTOR S-45 = SEAT ADJUST SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0297-06 Current Sense Spreader Pl Short Circuit Cause: The spreader plates motor (M-11) circuit indicates high current draw. Possible failure modes: 1. Circuit connection shorted to ground. 2. Excessive mechanical load on motor. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2. A. Start the combine. B. Operate the chopper spreader plates in both directions. C. Record in which direction(s) the spreader plates operate. D. Check for fault codes 0297-06 and 0332-05. E. Use the following table to determine the location of the fault. Symptom

Fault Code 0297-06

Spreader plates motor operates in 1 direction only

Spreader plates motor does not operate in either direction

Fault Type

0332-05 X X

Go to Step 2

Binding

Go to Step 3

Short to ground

Go to Step 2

Binding

Go to Step 10

Open circuit

Go to Step 17

No power supply

2. The spreader plates mechanism is mechanically bound up, resulting in high current draw. See the appropriate repair manual chapter for repair and adjustment of the straw chopper spreader plates linkage. 3. Fault codes indicate circuit fault due to short to ground. Disconnect spreader plates motor connector X224. Measure between terminals A or B on the motor connector and a known good ground. There should be no continuity to ground. A. There is continuity to ground, indicating a short to ground in the motor. Replace the spreader plates motor. B. There is no continuity to ground. Continue with Step 4.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 4. Disconnect the batteries using the battery key. Use the multimeter to check for continuity between connector X224 pin D on the straw hood (SH) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position. Power must be removed from the module prior to testing for short to ground condition on the motor circuit to remove this ground path. A. If continuity is found, continue with Step 5. B. If no continuity is found, continue with Step 7. 5. Disconnect inline connector X071. Use a multimeter to check for continuity between connector X071 pin 15 on the straw hood front (SW) harness side and chassis ground. A. If no continuity is found, the short to ground is in the straw hood (SH) harness between connector X071 pin 15 and connector X224 pin D wire 510 white. Locate the short and repair. B. If continuity is found, continue with Step 6. 6. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 10 on the expansion (EX) harness side and chassis ground. A. If no continuity is found, the short to ground is in the straw hood front (SW) harness between connector X071 pin 15 and connector X025 pin 10 wire 510 white. Locate the short and repair. B. If continuity is found, the short to ground is in the expansion (EX) harness between connector X025 pin 10 and connector X014 pins J3-8 wire 510 red. Locate the short to ground and repair. 7. Use a multimeter to check for continuity between connector X224 pin E on the straw hood (SH) harness side and chassis ground. A. If continuity is found, continue with Step 8. B. If no continuity is found, recheck the motor for continuity to ground at Step 3. 8. Disconnect connector X071. Use a multimeter to check for continuity between connector X071 pin 16 on the straw hood front (SW) harness side and chassis ground. A. If no continuity is found, the short to ground is in the straw hood (SH) harness between connector X224 pin E and X071 pin 16 wire 509 gray. Locate the short and repair. B. If continuity is found, continue with Step 9. 9. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 8 on the expansion (EX) harness side and chassis ground. A. If no continuity is found, the short to ground is in the straw hood front (SW) harness between connector X071 pin 16 and connector X025 pin 8 wire 509 gray. Locate the short and repair. B. If continuity is found, the short to ground is in the expansion (EX) harness between connector X025 pin 8 and connector X014 pins J3-6 wire 509 grey. Locate the short to ground and repair. 10. Fault codes indicate circuit fault due to open circuit condition. Disconnect spreader plates motor connector X224. Measure the resistance of the motor between terminals D and E. The correct resistance is 15 to 30 ohms. A. The resistance is infinite, indicating an open condition in the motor. Replace the spreader plates motor. B. The resistance is in specification. Continue with Step 11.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 11. Ensure that the batteries are connected using the battery key, and that fuse F27 is good. Use the multimeter to check for continuity between connector X224 pin D on the straw hood (SH) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F27. This ground path may be used to test for an open circuit condition. A. If continuity is found, continue with Step 14. B. If no continuity is found, continue with Step 12. 12. Disconnect inline connector X071. Use a multimeter to check for continuity between connector X071 pin 15 on the straw hood front (SW) harness side and chassis ground. A. If continuity is found the open circuit is in the harness between connector X071 pin 15 and connector X224 pin D wire 510 white. Locate the open and repair. B. If no continuity is found, continue with Step 13. 13. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 10 on the expansion (EX) harness side and chassis ground. A. If continuity is found the open circuit is in the harness between connector X071 pin 15 and connector X025 pin 10 wire 510 white. Locate the open and repair. B. If no continuity is found, the open circuit is in the harness between connector X025 pin 10 and connector X014 pins J3-8 wire 510 red. Locate the open and repair. 14. Use a multimeter to check for continuity between connector X224 pin E on the straw hood (SH) harness side and chassis ground. A. If no continuity is found, continue with Step 15. B. If continuity is found, recheck the motor for continuity at Step 10. 15. Disconnect inline connector X071. Use a multimeter to check for continuity between connector X071 pin 16 on the straw hood front (SW) harness side and chassis ground. A. If continuity is found the open circuit is in the harness between connector X071 pin 16 and connector X224 pin E wire 509 gray. Locate the open and repair. B. If no continuity is found, continue with Step 16. 16. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 8 on the expansion (EX) harness side and chassis ground. A. If continuity is found the open circuit is in the harness between connector X071 pin 6 and connector X025 pin 8 wire 509 grey. Locate the open and repair. B. If no continuity is found, the open circuit is in the harness between connector X025 pin 8 and connector X014 pins J3-6 wire 509 grey. Locate the open and repair. 17. If the spreader plates motor does not operate in either direction, and there are no error codes indicated, the supply power for the circuit may not be present. Remove fuse F27 and inspect. A. Fuse has failed. Go to Step 18. B. Fuse is okay. Go to Step 19.

55-104

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 18. If fuse has failed, replace the fuse. A. If fuse immediately fails, a short to ground exists on one of the following wires: Wire 031 red, from fuse F27 to connector X005 pin 4 Wire 031 red, connector X005 pin 4 to connector X034 pin 2 Wire 031 red, connector X034 pin 2 to splice in expansion (EX) harness Wire 511 red, harness splice to connector X013 pin J2-11 on CCM3 module. Wire 512 red, harness splice to connector X014 pin J3-7 on CCM3 module. Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. B. Fuse is okay. Go to Step 19. 19. Test for 12V power at connector X014 pin J3-7 on the CCM3 module under the cab. A. If there is no power, there is an open circuit on one of the following wires: Wire 031 red, from fuse F27 to connector X005 pin 4 Wire 031 red, connector X005 pin 4 to connector X034 pin 2 Wire 031 red, connector X034 pin 2 to splice in expansion (EX) harness Wire 512 red, harness splice to connector X014 pin J3-7 on CCM3 module. Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the open and repair. After repair, go to Step 20. B. If there is power, go to Step 20. 20. Test for continuity to ground at connector X014 pin J3-16 on the expansion (EX) harness side on the CCM3 module under the cab. A. If there is no continuity to ground, there is an open circuit in the expansion (EX) harness between connector X014 pin J3-16 and chassis ground 2 wire 521 black. Locate the open and repair. After repair, go to Step 21. B. If there is continuity to ground, go to Step 21. 21. Once it has been verified that power is being supplied to the module, recheck the circuit operation as described in Step 1. If the fuse fails during the testing, a short to ground on the circuit is causing the fuse to fail. Start the troubleshooting at Step 3 to locate the short to ground.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 EN0297 CURR SENSE SPREADER PLATE

50026220

4 2

40025219

10020076

50016215

1. 2. 3. 4. 5.

Spreader Plate Motor M11 Connector X224 Connector X071 Connector X025 Connector X014

55-106

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-27 = SIEVE/SPREADER FUSE K-18 = UPPER/LOWER SIEVE RELAY M-06 = UPPER SIEVE ACTUATOR M-07 = LOWER SIEVE ACTUATOR

S-35 = UPPER SIEVE REAR ADJUST S-46 = LOWER SIEVE REAR ADJUST

55-107

CLEANING FRAME--21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

B-10 = CHOPPER RPM L-28 = CHAFF SPREADER M-11 = SPREADER PLATE MOTOR S-23 = SPREADER PLATE

B-74 = PSD RPM

TRASH FRAME--23

55-108

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0300-06 Current Sense Lower Sieve Short Circuit Cause: The lower sieve motor (M-07) circuit indicates high current draw. Possible failure modes: 1. Circuit wiring short to ground. 2. Excessive mechanical load on motor. 3. Controller internal failure (internal regulator failure). Solution: NOTE: This is an H-bridge-controlled circuit (refer to Chapter 2 for more information on H-bridge circuit operation). The lower sieve motor (M07) circuit is paired with the upper sieve motor (M06) circuit, and the module switches between these two circuits using the Upper/Lower sieve relay K-18. Because these circuits are connected and driven from the same module outputs, the troubleshooting procedure must consider both circuits at the same time. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2. A. Manually operate the lower sieve motor in both directions. B. Manually operate the upper sieve motor in both directions. C. Record in which direction(s) each circuit operates. D. Check for fault codes 0300-06 and 0334-05 (Lower Sieve motor) and fault codes 0301-06 and 0335-05 (Upper Sieve motor).

55-109

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E. Use the following table to determine the location of the fault. Errors

Symptom 0300-06 Lower sieve motor operates in 1 direction only

0301-06

0334-05

0335-05

X X

Go to Step 2

Motor bound up

Go to Step 3

Short to ground

Go to Step 8

Short to ground

Lower sieve motor and upper sieve motor operate in 1 direction only

Lower Sieve motor does not operate in either direction

Go to Step 14

Open

Go to Step 26

Short to ground

Go to Step 27

Motor bound up

Go to Step 28

Short to ground

Go to Step 33

Open

Go to Step 45

Short to ground

Go to Step 46

Open

Go to Step 52

Fuse 27 blown or open

Upper sieve motor operates in 1 direction only

Upper sieve motor does not operate in either direction Both lower sieve motor and upper sieve motor do not operate in either direction

2. The lower sieve mechanism is mechanically bound up, resulting in high current draw. Disconnect the motor from the sieve, and manually open the louvers to fully clean the sieve. Inspect the control linkage for wear or binding. See the appropriate repair manual chapter for repair and adjustment of the lower sieve and control linkage. 3. Fault codes indicate circuit fault due to short to ground between the lower sieve motor and the Upper/lower sieve relay K18. Disconnect the batteries using the battery key. Unplug the lower sieve motor connector X228. Use a multimeter to check for continuity between connector X228 pin D on the lower frame rear (LR) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position. Power must be removed from the module prior to testing for short to ground condition on the motor circuit to remove this ground path. A. If continuity is found, continue with Step 4. B. If no continuity is found, erase the fault codes and continue operation.

55-110

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 4. Disconnect connector X072. Use a multimeter to check for continuity between connector X072 pin N on the straw hood front (SW) harness side and chassis ground. A. If no continuity is found, the short to ground is in the lower frame rear (LR) harness between connector X228 pin D and connector X072 pin N wire 790 white. Locate the short and repair. B. If continuity is found, continue with Step 5. 5. Disconnect connector X025. Use a multimeter to check for continuity between connector X025 pin 15 on the expansion (EX) harness side and chassis ground. A. If no continuity is found, the short to ground is in the straw hood front (SW) harness between connector X072 pin N and connector X025 pin 15 wire 790 white. Locate the short and repair. B. If continuity is found, continue with Step 6. 6. Disconnect connector X219. Use a multimeter to check for continuity between connector X219 pin 2 on the main frame (MF) harness side and chassis ground. A. If no continuity is found, the short to ground is in the expansion (EX) harness between connector X025 pin 15 and connector X219 pin 2 wire 790 white. Locate the short and repair. B. If continuity is found, continue with Step 7. 7. Disconnect connector X005. Use a multimeter to check for continuity between connector X005 pin 16 on the cab main (CM) harness side and chassis ground. A. If no continuity is found, the short to ground is in the main frame (MF) harness between connector X219 pin 2 and connector X005 pin 16 wire 790 white. Locate the short and repair. B. If continuity is found, the short to ground is in the cab main (CM) harness between connector X005 pin 16 and the Upper/lower sieve relay K18 pin 5 on the fuse panel. Locate the short and repair. 8. Fault codes indicate circuit fault due to short to ground between the lower sieve motor and/or the upper sieve motor and the CCM3 module. Disconnect the batteries using the battery key. Unplug the lower sieve motor connector X228 and the upper sieve motor connector X227. Use the multimeter to check for continuity between connector X228 pin E on the lower frame rear (LR) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position. Power must be removed from the module prior to testing for short to ground condition on the motor circuit to remove this ground path. A. If continuity is found, continue with Step 9. B. If no continuity is found, erase the fault codes and continue operation. 9. Disconnect inline connector X072. Use a multimeter to check for continuity between connector X072 pin P on the straw hood front (SW) harness side and chassis ground. A. If no continuity is found, the short to ground is in the lower frame rear (LR) harness between connector X072 pin P and connector X228 pin E wire 789 gray. Locate the short and repair. B. If continuity is found, continue with Step 10.

55-111

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 10. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 14 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the short to ground is in the expansion (EX) harness between connector X025 pin 14 and connector X013 pin J2-1 wire 785 gray. Locate the short and repair. B. If no continuity is found, the short to ground is in the straw hood front (SW) harness between connector X025 pin 14 and connector X072 pin J or P on one of the following wires: Wire 785 gray, connector X025 pin 14 to harness splice Wire 791 gray, harness splice to connector X072 pin J Wire 789 gray, harness splice to connector X072 pin P Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. 11. Remove the Upper/lower sieve relay K18 from the fuse panel. Use a multimeter to check for continuity between the relay terminal 3 on the cab main (CM) harness side and chassis ground. A. If continuity is found, continue with Step 12. B. If no continuity is found, erase the fault codes and continue operation. 12. Disconnect inline connector X005. Use a multimeter to check for continuity between connector X005 pin 15 on the main frame (MF) harness side and chassis ground. A. If continuity is found, continue with Step 13. B. If no continuity is found, the short to ground is in the cab main (CM) harness between connector X005 pin 15 and the Upper/lower sieve relay K18 pin 3 on the fuse panel wire 786 red. Locate the short and repair. 13. Disconnect inline connector X219. Use a multimeter to check for continuity between connector X219 pin 1 on the expansion (EX) harness side and chassis ground. A. If continuity is found the short to ground is in the expansion (EX) harness between connector X219 pin 1 and connector X013 pin J2-21 wire 786 red. Locate the short and repair. B. If no continuity is found, the short to ground is in the main frame (MF) harness between connector X005 pin 15 and connector X219 pin 1 wire 786 red. Locate the short and repair. 14. Fault codes indicate circuit fault due to open circuit condition. Disconnect the lower sieve motor connector X228. Measure the resistance of the motor between terminals D and E. The correct resistance is 3 to 12 ohms. A. The resistance is infinite, indicating an open condition in the motor. Replace the lower sieve motor. B. The resistance is in specification. Continue with Step 15. 15. Replace the Upper/lower sieve relay K18 on the fuse panel with a known good relay, and retest the upper sieve circuit function. A. If the lower sieve circuit now functions properly, the relay was faulty, and was not providing continuity between terminals 3 & 5 when energized. Replace the relay. B. If the lower sieve circuit still does not work, continue with Step 16. 16. Ensure that the batteries are connected using the battery key, and that fuse F27 is good. Use the multimeter to check for continuity between connector X228 pin E on the lower frame rear (LR) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F27. This ground path may be used to test for an open circuit condition. A. If continuity is found, continue with Step 19. B. If no continuity is found, continue with Step 17.

55-112

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 17. Disconnect inline connector X072. Use a multimeter to check for continuity between connector X072 pin P on the straw hood front (SW) harness side and chassis ground. A. If continuity is found, the open circuit is in the lower frame rear (LR) harness between connector X072 pin P and connector X228 pin E wire 789 gray. Locate the open and repair. B. If no continuity is found, continue with Step 18. 18. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 14 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the straw hood front (SW) harness between connector X025 pin 14 and connector X072 pin P wire 789 gray or 785 gray. Locate the open and repair. B. If no continuity is found, the open circuit is in the expansion (EX) harness between connector X025 pin 14 and connector X013 pin J2-1 on wire 785 gray. Locate the open and repair. 19. Remove the Upper/lower sieve relay K18 on the fuse panel, and install a jumper wire between terminals 3 & 5. Use a multimeter to check for continuity between connector X228 pin D on the lower frame rear (LR) harness side and chassis ground. A. If no continuity is found, continue with Step 20. B. If continuity is found, recheck the motor for continuity at Step 14. Erase the fault codes and continue operation. 20. Disconnect connector X072. Use a multimeter to check for continuity between connector X072 pin N on the straw hood front (SW) harness side and chassis ground. A. If continuity is found, the open circuit is in the lower frame rear (LR) harness between connector X228 pin D and connector X072 pin N wire 790 white. Locate the open and repair. B. If no continuity is found, continue with Step 21. 21. Disconnect connector X025. Use a multimeter to check for continuity between connector X025 pin 15 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the straw hood front (SW) harness between connector X025 pin 15 and connector X072 pin N wire 790 white. Locate the open and repair. B. If no continuity is found, continue with Step 22. 22. Disconnect connector X219. Use a multimeter to check for continuity between connector X219 pin 2 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the open circuit is in the expansion (EX) harness between connector X219 pin 2 and connector X025 pin 15 wire 790 white. Locate the open and repair. B. If no continuity is found, continue with Step 23. 23. Remove the jumper wire between terminals 3 & 5 for relay K18 on the fuse panel. Use a multimeter to check for continuity between Upper/lower sieve relay K18 terminal 5 on the cab main (CM) harness side and chassis ground. NOTE: Continuity check is being done back through circuit through the motor. The resistance will read significantly higher than previous tests, but should not be higher than 10 ohms above the motor resistance measured in Step 14. A. If no continuity is found, the open circuit is in wire 790 white from the fuse panel through connector X005 pin 16 to connector X219 pin 2. Locate the open and repair. B. If continuity is found, continue with Step 24.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 24. Disconnect connector X005. Use a multimeter to check for continuity between connector X005 pin 15 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the open circuit is in the cab main (CM) harness between the Upper/lower sieve relay K18 terminal 3 on the fuse panel connector X005 pin 15 wire 786 red. Locate the open and repair. B. If no continuity is found, continue with Step 25. 25. Disconnect connector X219. Use a multimeter to check for continuity between connector X219 pin 1 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the main frame (MF) harness between connector X005 pin 15 and connector X219 pin 1 wire 786 red. Locate the open and repair. B. If no continuity is found, , the open circuit is in the expansion (EX) harness between connector X219 pin 1 and connector X013 pin J2-21 wire 786 red. Locate the open and repair. 26. Fault codes and operating condition indicate that the motor has shorted to ground. Disconnect lower sieve motor connector X228. Measure between terminals D or E on the motor connector and a known good ground. There should be no continuity to ground. A. There is continuity to ground, indicating a short to ground in the motor. Replace the lower sieve motor. B. There is no continuity to ground. Erase the fault codes and continue operation. 27. The upper sieve mechanism is mechanically bound up, resulting in high current draw. See the appropriate repair manual chapter for repair and adjustment of the upper sieve linkage. 28. Fault codes indicate circuit fault due to short to ground between the upper sieve motor and the Upper/lower sieve relay K18. Disconnect the batteries using the battery key. Unplug the upper sieve motor connector X227. Use a multimeter to check for continuity between connector X227 pin D on the lower frame rear (LR) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position. Power must be removed from the module prior to testing for short to ground condition on the motor circuit to remove this ground path. A. If continuity is found, continue with Step 29. B. If no continuity is found, erase the fault codes and continue operation. 29. Disconnect connector X072. Use a multimeter to check for continuity between connector X072 pin H on the straw hood front (SW) harness side and chassis ground. A. If no continuity is found, the short to ground is in the lower frame rear (LR) harness between connector X227 pin D and connector X072 pin H wire 792 white. Locate the short and repair. B. If continuity is found, continue with Step 30. 30. Disconnect connector X025. Use a multimeter to check for continuity between connector X025 pin 17 on the expansion (EX) harness side and chassis ground. A. If no continuity is found, the short to ground is in the straw hood front (SW) harness between connector X072 pin H and connector X025 pin 17 wire 792 white. Locate the short and repair. B. If continuity is found, continue with Step 31. 31. Disconnect connector X219. Use a multimeter to check for continuity between connector X219 pin 3 on the main frame (MF) harness side and chassis ground. A. If no continuity is found, the short to ground is in the expansion (EX) harness between connector X025 pin 17 and connector X219 pin 3 wire 792 white. Locate the short and repair. B. If continuity is found, continue with Step 32.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 32. Disconnect connector X005. Use a multimeter to check for continuity between connector X005 pin 17 on the cab main (CM) harness side and chassis ground. A. If no continuity is found, the short to ground is in the main frame (MF) harness between connector X219 pin 3 and connector X005 pin 17 wire 792 white. Locate the short and repair. B. If continuity is found, the short to ground is in the cab main (CM) harness between connector X005 pin 17 and the Upper/lower sieve relay K18 pin 4 on the fuse panel wire 792 white. Locate the short and repair. 33. Fault codes indicate circuit fault due to open circuit condition. Disconnect the upper sieve motor connector X227. Measure the resistance of the motor between terminals A and B. The correct resistance is 3 to 12 ohms. A. The resistance is infinite, indicating an open condition in the motor. Replace the upper sieve motor. B. The resistance is in specification. Continue with Step 34. 34. Ensure that the batteries are connected using the battery key, and that fuse F27 is good. Use the multimeter to check for continuity between connector X227 pin E on the lower frame rear (LR) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F27. This ground path may be used to test for an open circuit condition. A. If continuity is found, continue with Step 37. B. If no continuity is found, continue with Step 35. 35. Disconnect inline connector X072. Use a multimeter to check for continuity between connector X072 pin J on the straw hood front (SW) harness side and chassis ground. A. If continuity is found, the open circuit is in the lower frame rear (LR) harness between connector X072 pin J and connector X227 pin E wire 791 gray. Locate the open and repair. B. If no continuity is found, continue with Step 36. 36. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 14 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the straw hood front (SW) harness between connector X072 pin J and connector X025 pin 14 wires 791 gray or 785 gray. Locate the open and repair. B. If no continuity is found, the open circuit is in the expansion (EX) harness between connector X025 pin 14 and connector X013 pin J2-1 wire 785 gray. Locate the open and repair. 37. Use a multimeter to check for continuity between connector X227 pin D on the lower frame rear (LR) harness side and chassis ground. A. If no continuity is found, continue with Step 38. B. If continuity is found, recheck the motor for continuity at Step 33. Erase the fault codes and continue operation. 38. Disconnect connector X072. Use a multimeter to check for continuity between connector X072 pin H on the straw hood front (SW) harness side and chassis ground. A. If continuity is found, the open circuit is in the lower frame rear (LR) harness between connector X227 pin D and connector X072 pin H wire 792 white. Locate the open and repair. B. If no continuity is found, continue with Step 39.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 39. Disconnect connector X025. Use a multimeter to check for continuity between connector X025 pin 17 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the straw hood front (SW) harness between connector X072 pin H and connector X025 pin 17 wire 792 white. Locate the open and repair. B. If no continuity is found, continue with Step 40. 40. Disconnect connector X219. Use a multimeter to check for continuity between connector X219 pin 3 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the open circuit is in the expansion (EX) harness between connector X025 pin 17 and connector X219 pin 3 wire 792 white. Locate the open and repair. B. If no continuity is found, continue with Step 41. 41. Remove the upper/lower sieve relay K18 from the fuse panel. Use a multimeter to check for continuity between Upper/lower sieve relay K18 terminal 4 on the cab main (CM) harness side and chassis ground. NOTE: Continuity check is being done back through circuit through the motor. The resistance will read significantly higher than previous tests, but should not be higher than 10 ohms above the motor resistance measured in Step 33. A. If no continuity is found, the open circuit is in the cab main (CM) or main frame (MF) harness wire 792 white from the fuse panel through connector X005 pin 17 to connector X219 pin 3. Locate the open and repair. B. If continuity is found, continue with Step 42. 42. Reconnect connector X005. Use a multimeter to check for continuity between Upper/lower sieve relay K18 terminal 3 on the cab main (CM) harness side and chassis ground. A. If continuity is found, the relay has failed open between terminals 3 and 4. Replace the relay. B. If no continuity is found, continue with Step 43. 43. Disconnect connector X005. Use a multimeter to check for continuity between connector X005 pin 15 on the main frame (MF) harneses side and chassis ground. A. If continuity is found, the open circuit is in the cab main (CM) harness between the Upper/lower sieve relay K18 terminal 3 on the fuse panel and connector X005 pin 15 wire 786 red. Locate the open and repair. B. If no continuity is found, continue with Step 44. 44. Disconnect connector X219. Use a multimeter to check for continuity between connector X219 pin 1 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the main frame (MF) harness between connector X219 pin 1 and connector X005 pin 15 wire 786 red. Locate the open and repair. B. If no continuity is found, , the open circuit is in the expansion (EX) harness between connector X219 pin 1 and connector X013 pin J2-21 wire 786 red. Locate the open and repair. 45. Fault codes and operating condition indicate that the motor has shorted to ground. Disconnect upper sieve motor connector X227. Measure between terminals D or E on the motor connector and a known good ground. There should be no continuity to ground. A. There is continuity to ground, indicating a short to ground in the motor. Replace the upper sieve motor. B. There is no continuity to ground. Erase the fault codes and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 46. Fault codes and operating condition indicates that there is an open circuit on shared wiring between the upper sieve motor and lower sieve motor circuits. Replace the Upper/lower sieve relay K18 on the fuse panel with a known good relay, and retest the upper and lower sieve circuit function. A. If both circuits now function properly, the relay was faulty, and was not providing continuity between the work terminal 3 and terminals 4 & 5. Replace the relay. B. If both circuits still do not work, continue with Step 47. 47. Ensure that the batteries are connected using the battery key, and that fuse F27 is good. Remove the Upper/lower sieve relay K18 on the fuse panel. Use a multimeter to check for continuity between Upper/lower sieve relay K18 terminal 3 on the cab main (CM) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F27. This ground path may be used to test for an open circuit condition. A. If no continuity is found, continue with Step 48. B. If continuity is found, continue with Step 50. 48. Disconnect connector X005. Use a multimeter to check for continuity between connector X005 pin 15 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the open circuit is in the cab main (CM) harness between the Upper/lower sieve relay K18 terminal 3 on the fuse panel connector X005 pin 15 wire 786 red. Locate the open and repair. B. If no continuity is found, continue with Step 49. 49. Disconnect connector X219. Use a multimeter to check for continuity between connector X219 pin 1 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the main frame (MF) harness between connector 219 pin 1 and connector X005 pin 15 wire 786 red. Locate the open and repair. B. If no continuity is found, , the open circuit is in the expansion (EX) harness between connector X219 pin 1 and connector X016 pin J2-21 wire 786 red. Locate the open and repair. 50. Disconnect inline connector X072. Use a multimeter to check for continuity between connector X072 pin J or P on the straw hood front (SW) harness side and chassis ground. A. If continuity is found, erase the fault code and continue operation. B. If no continuity is found, continue with Step 51. 51. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 14 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the straw hood front (SW) harness between connector X025 pin 14 and the harness splice on wire 785 gray. Locate the open and repair. B. If no continuity is found, the open circuit is in the expansion (EX) harness between connector X025 pin 14 and connector X013 pin J2-1 on wire 791 gray. Locate the open and repair. 52. If the upper sieve motor and lower sieve motor do not operate in either direction, and there are no error codes indicated, the supply power for the circuit may not be present. Remove fuse F27 and inspect. A. Fuse has failed. Go to Step 53. B. Fuse is okay. Go to Step 56. 53. If fuse has failed, replace the fuse. A. If fuse immediately fails, a short to ground exists on the wires to the CCM3 module connectors. Continue with Step 54. B. Fuse is okay. Go to Step 56.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 54. Disconnect inline connector X005. Use a multimeter to check for continuity between the harness end of connector X005 pin 4 and chassis ground. A. If no continuity is found, there is a short to ground in the cab main (CM) harness between fuse F27 on the fuse panel and connector X005 pin 4 wire 031 red. Locate the short and repair. B. If continuity is found, continue with Step 55. 55. Disconnect inline connector X034. Use a multimeter to check for continuity between the expansion (EX) harness end of connector X034 pin 2 and chassis ground. A. If no continuity is found, there is a short to ground in the main frame (MF) harness between connector X034 pin 2 and connector X005 pin 4 wire 031 red. Locate the short and repair. B. If continuity is found, there is a short to ground in the expansion (EX) harness between connector X034 pin 2, connector X013 pin J2-11 and connector X014 pin J3-7 on one of the following wires: Wire 031 red, connector X034 pin 2 to harness splice Wire 511 red, harness splice to connector X013 pin J2-11 Wire 512 red, harness splice to connector X014 pin J3-7 Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. 56. Test for 12V power at connector X013 pin J2-11 on the CCM3 module under the cab. A. If there is no power, there is an open circuit on the power wires to the CCM3 module. Continue with step 57. B. If there is power, go to Step 59. 57. Disconnect inline connector X005. Use a multimeter to check for 12V at connector X005 pin 4 on the cab main (CM) harness side. A. If there is no power, there is an open circuit in the cab main (CM) harness between fuse F27 on the fuse panel and connector X005 pin 4 wire 031 red. Locate the open and repair. B. If power is found, continue with Step 58. 58. Disconnect inline connector X034. Use a multimeter to check for 12V at connector X034 pin 2 on the main frame (MF) harness side. A. If there is no power, there is an open circuit in the main frame (MF) harness between connector X034 pin 2 and connector X005 pin 4 wire 031 red. Locate the open and repair. B. If power is found, there is an open circuit in the expansion (EX) harness between connector X034 pin 2 and connector X013 pin J2-11 wire 031 red or 511 red. Locate the open and repair. 59. Test for continuity to ground at connector X013 pin J2-3 on the CCM3 module under the cab. A. If there is no continuity to ground, there is an open circuit in the expansion (EX) harness from connector X013 pin J2-3 on CCM3 module to the front frame ground #2 wire 520 black. Locate the open and repair. After repair, go to Step 60. B. If there is continuity to ground, go to Step 60. 60. Once it has been verified that power is being supplied to the module, recheck the circuit operation as described in Step 1. If the fuse fails during the testing, a short to ground on the circuit being operated at the time of failure is causing the fuse to fail.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E0300 CURRENT SENSE LOWER SIEVE

40020080

10010899

50020070

40025228

10020076

10010874

50026216

19 1. 2. 3. 4. 5. 6. 7.

Lower Sieve Actuator M07 Connector X072 Connector X025 Connector X219 Connector X005 Upper/Lower Sieve Relay K18 Connector X013

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-27 = SIEVE/SPREADER FUSE K-18 = UPPER/LOWER SIEVE RELAY M-06 = UPPER SIEVE ACTUATOR M-07 = LOWER SIEVE ACTUATOR

S-35 = UPPER SIEVE REAR ADJUST S-46 = LOWER SIEVE REAR ADJUST

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CLEANING FRAME--21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0301-06 Current Sense Upper Sieve Short Circuit Cause: The upper sieve motor (M-06) circuit indicates high current draw. Possible failure modes: 1. Circuit wiring short to ground. 2. Excessive mechanical load on motor. 3. Controller internal failure (internal regulator failure). Solution: This is an H-bridge-controlled circuit (refer to Chapter 2 for more information on H-bridge circuit operation). The lower sieve motor (M07) circuit is paired with the upper sieve motor (M06) circuit, and the module switches between these two circuits using the Upper/Lower sieve relay K-18. Because these circuits are connected and driven from the same module outputs, the troubleshooting procedure must consider both circuits at the same time. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2. A. Manually operate the lower sieve motor in both directions. B. Manually operate the upper sieve motor in both directions. C. Record in which direction(s) each circuit operates. D. Check for fault codes 0300-06 and 0334-05 (Lower Sieve motor) and fault codes 0301-06 and 0335-05 (Upper Sieve motor).

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E. Use the following table to determine the location of the fault. Errors

Symptom 0300-06 Lower sieve motor operates in 1 direction only

0301-06

0334-05

0335-05

X X

Go to Step 2

Motor bound up

Go to Step 3

Short to ground

Go to Step 8

Short to ground

Lower sieve motor and upper sieve motor operate in 1 direction only

Lower Sieve motor does not operate in either direction

Go to Step 14

Open

Go to Step 26

Short to ground

Go to Step 27

Motor bound up

Go to Step 28

Short to ground

Go to Step 33

Open

Go to Step 45

Short to ground

Go to Step 46

Open

Go to Step 52

Fuse 27 blown or open

Upper sieve motor operates in 1 direction only

Upper sieve motor does not operate in either direction Both lower sieve motor and upper sieve motor do not operate in either direction

2. The lower sieve mechanism is mechanically bound up, resulting in high current draw. Disconnect the motor from the sieve, and manually open the louvers to fully clean the sieve. Inspect the control linkage for wear or binding. See the appropriate repair manual chapter for repair and adjustment of the lower sieve and control linkage. 3. Fault codes indicate circuit fault due to short to ground between the lower sieve motor and the Upper/lower sieve relay K18. Disconnect the batteries using the battery key. Unplug the lower sieve motor connector X228. Use a multimeter to check for continuity between connector X228 pin D lower frame rear (LR) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position. Power must be removed from the module prior to testing for short to ground condition on the motor circuit to remove this ground path. A. If continuity is found, continue with Step 4. B. If no continuity is found, erase the fault codes and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 10. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 14 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the short to ground is in the expansion (EX) harness between connector X025 pin 14 and connector X013 pin J2-1 wire 785 gray. Locate the short and repair. B. If no continuity is found, the short to ground is in the straw hood front (SW) harness between connector X025 pin 14 and connector X072 pin J or P on one of the following wires: Wire 785 gray, connector X025 pin 14 to harness splice Wire 791 gray, harness splice to connector X072 pin J Wire 789 gray, harness splice to connector X072 pin P Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. 11. Remove the Upper/lower sieve relay K18 from the fuse panel. Use a multimeter to check for continuity between the relay terminal 3 on the cab main (CM) harness side and chassis ground. A. If continuity is found, continue with Step 12. B. If no continuity is found, erase the fault codes and continue operation. 12. Disconnect inline connector X005. Use a multimeter to check for continuity between connector X005 pin 15 on the main frame (MF) harness side and chassis ground. A. If continuity is found, continue with Step 13. B. If no continuity is found, the short to ground is in the cab main (CM) harness between connector X005 pin 15 and the Upper/lower sieve relay K18 pin 3 on the fuse panel wire 786 red. Locate the short and repair. 13. Disconnect inline connector X219. Use a multimeter to check for continuity between connector X219 pin 1 on the expansion (EX) harness side and chassis ground. A. If continuity is found the short to ground is in the expansion (EX) harness between connector X219 pin 1 on the expansion (EX) harness side and connector X013 pin J2-21 wire 786 red. Locate the short and repair. B. If no continuity is found, the short to ground is in the main frame (MF) harness between connector X005 pin 15 and connector X219 pin 1 wire 786 red. Locate the short and repair. 14. Fault codes indicate circuit fault due to open circuit condition. Disconnect the lower sieve motor connector X228. Measure the resistance of the motor between terminals D and E. The correct resistance is 3 to 12 ohms. A. The resistance is infinite, indicating an open condition in the motor. Replace the lower sieve motor. B. The resistance is in specification. Continue with Step 15. 15. Replace the Upper/lower sieve relay K18 on the fuse panel with a known good relay, and retest the upper sieve circuit function. A. If the lower sieve circuit now functions properly, the relay was faulty, and was not providing continuity between terminals 3 & 5 when energized. Replace the relay. B. If the lower sieve circuit still does not work, continue with Step 16. 16. Ensure that the batteries are connected using the battery key, and that fuse F27 is good. Use the multimeter to check for continuity between connector X228 pin E on the lower frame rear (LR) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F27. This ground path may be used to test for an open circuit condition. A. If continuity is found, continue with Step 19. B. If no continuity is found, continue with Step 17.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 17. Disconnect inline connector X072. Use a multimeter to check for continuity between connector X072 pin P on the straw hood front (SW) harness side and chassis ground. A. If continuity is found, the open circuit is in the lower frame rear (LR) harness between connector X072 pin P and connector X228 pin E wire 789 gray. Locate the open and repair. B. If no continuity is found, continue with Step 18. 18. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 14 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the straw hood front (SW) harness between connector X025 pin 14 and connector X072 pin P wire 789 gray or 785 gray. Locate the open and repair. B. If no continuity is found, the open circuit is in the expansion (EX) harness between connector X025 pin 14 and connector X013 pin J2-1 on wire 785 gray. Locate the open and repair. 19. Remove the Upper/lower sieve relay K18 on the fuse panel, and install a jumper wire between terminals 3 and 5. Use a multimeter to check for continuity between connector X228 pin D on the lower frame rear (LR) harness side and chassis ground. A. If no continuity is found, continue with Step 20. B. If continuity is found, recheck the motor for continuity at Step 14. Erase the fault codes and continue operation. 20. Disconnect connector X072. Use a multimeter to check for continuity between connector X072 pin N on the straw hood front (SW) harness side and chassis ground. A. If continuity is found, the open circuit is in the lower frame rear (LR) harness between connector X228 pin D and connector X072 pin N wire 790 white. Locate the open and repair. B. If no continuity is found, continue with Step 21. 21. Disconnect connector X025. Use a multimeter to check for continuity between connector X025 pin 15 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the straw hood front (SW) harness between connector X025 pin 15 and connector X072 pin N wire 790 white. Locate the open and repair. B. If no continuity is found, continue with Step 22. 22. Disconnect connector X219. Use a multimeter to check for continuity between connector X219 pin 2 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the open circuit is in the expansion (EX) harness between connector X219 pin 2 and connector X025 pin 15 wire 790 white. Locate the open and repair. B. If no continuity is found, continue with Step 23. 23. Remove the jumper wire between terminals 3 & 5 for relay K18 on the fuse panel. Use a multimeter to check for continuity between Upper/lower sieve relay K18 terminal 5 on the cab main (CM) harness side and chassis ground. NOTE: Continuity check is being done back through circuit through the motor. The resistance will read significantly higher than previous tests, but should not be higher than 10 ohms above the motor resistance measured in Step 14. A. If no continuity is found, the open circuit is in wire 790 white from the fuse panel through connector X005 pin 16 to connector X219 pin 2. Locate the open and repair. B. If continuity is found, continue with Step 24.

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55-127

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 39. Disconnect connector X025. Use a multimeter to check for continuity between connector X025 pin 17 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the straw hood front (SW) harness between connector X072 pin H and connector X025 pin 17 wire 792 white. Locate the open and repair. B. If no continuity is found, continue with Step 40. 40. Disconnect connector X219. Use a multimeter to check for continuity between connector X219 pin 3 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the open circuit is in the expansion (EX) harness between connector X025 pin 17 and connector X219 pin 3 wire 792 white. Locate the open and repair. B. If no continuity is found, continue with Step 41. 41. Remove the upper/lower sieve relay K18 from the fuse panel. Use a multimeter to check for continuity between Upper/lower sieve relay K18 terminal 4 on the cab main (CM) harness side and chassis ground. NOTE: Continuity check is being done back through circuit through the motor. The resistance will read significantly higher than previous tests, but should not be higher than 10 ohms above the motor resistance measured in Step 33. A. If no continuity is found, the open circuit is in the cab main (CM) or main frame (MF) harness wire 792 white from the fuse panel through connector X005 pin 17 to connector X219 pin 3. Locate the open and repair. B. If continuity is found, continue with Step 42. 42. Reconnect connector X005. Use a multimeter to check for continuity between Upper/lower sieve relay K18 terminal 3 on the cab main (CM) harness side and chassis ground. A. If continuity is found, the relay has failed open between terminals 3 and 4. Replace the relay. B. If no continuity is found, continue with Step 43. 43. Disconnect connector X005. Use a multimeter to check for continuity between connector X005 pin 15 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the open circuit is in the cab main (CM) harness between the Upper/lower sieve relay K18 terminal 3 on the fuse panel and connector X005 pin 15 wire 786 red. Locate the open and repair. B. If no continuity is found, continue with Step 44. 44. Disconnect connector X219. Use a multimeter to check for continuity between connector X219 pin 1 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the main frame (MF) harness between connector X219 pin 1 and connector X005 pin 15 wire 786 red. Locate the open and repair. B. If no continuity is found, , the open circuit is in the expansion (EX) harness between connector X219 pin 1 and connector X013 pin J2-21 wire 786 red. Locate the open and repair. 45. Fault codes and operating condition indicate that the motor has shorted to ground. Disconnect upper sieve motor connector X227. Measure between terminals D or E on the motor connector and a known good ground. There should be no continuity to ground. A. There is continuity to ground, indicating a short to ground in the motor. Replace the upper sieve motor. B. There is no continuity to ground. Erase the fault codes and continue operation.

55-129

55-130

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 54. Disconnect inline connector X005. Use a multimeter to check for continuity between the harness end of connector X005 pin 4 and chassis ground. A. If no continuity is found, there is a short to ground in the cab main (CM) harness between fuse F27 on the fuse panel and connector X005 pin 4 wire 031 red. Locate the short and repair. B. If continuity is found, continue with Step 55. 55. Disconnect inline connector X034. Use a multimeter to check for continuity between the expansion (EX) harness end of connector X034 pin 2 and chassis ground. A. If no continuity is found, there is a short to ground in the main frame (MF) harness between connector X034 pin 2 and connector X005 pin 4 wire 031 red. Locate the short and repair. B. If continuity is found, there is a short to ground in the expansion (EX) harness between connector X034 pin 2, connector X013 pin J2-11 and connector X014 pin J3-7 on one of the following wires: Wire 031 red, connector X034 pin 2 to harness splice Wire 511 red, harness splice to connector X013 pin J2-11 Wire 512 red, harness splice to connector X014 pin J3-7 Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. 56. Test for 12V power at connector X013 pin J2-11 on the CCM3 module under the cab. A. If there is no power, there is an open circuit on the power wires to the CCM3 module. Continue with Step 57. B. If there is power, go to Step 59. 57. Disconnect inline connector X005. Use a multimeter to check for 12V at connector X005 pin 4 on the cab main (CM) harness side. A. If there is no power, there is an open circuit in the cab main (CM) harness between fuse F27 on the fuse panel and connector X005 pin 4 wire 031 red. Locate the open and repair. B. If power is found, continue with Step 58. 58. Disconnect inline connector X034. Use a multimeter to check for 12V at connector X034 pin 2 on the main frame (MF) harness side. A. If there is no power, there is an open circuit in the main frame (MF) harness between connector X034 pin 2 and connector X005 pin 4 wire 031 red. Locate the open and repair. B. If there is power, there is an open circuit in the expansion (EX) harness between connector X034 pin 2 and connector X013 pin J2-11 wire 031 red or 511 red. Locate the open and repair. 59. Test for continuity to ground at connector X013 pin J2-3 on the CCM3 module under the cab. A. If there is no continuity to ground, there is an open circuit in the expansion (EX) harness from connector X013 pin J2-3 on CCM3 module to the front frame ground #2 wire 520 black. Locate the open and repair. After repair, go to Step 60. B. If there is continuity to ground, go to Step 60. 60. Once it has been verified that power is being supplied to the module, recheck the circuit operation as described in Step 1. If the fuse fails during the testing, a short to ground on the circuit being operated at the time of failure is causing the fuse to fail.

55-131

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E0301 CURRENT SENSE UPPER SIEVE

10020076

86060952

50026216

20 1. 2. 3.

Upper/Lower Sieve Rear Adjust S-35/46 Connector X025 Connector X013

55-132

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-27 = SIEVE/SPREADER FUSE K-18 = UPPER/LOWER SIEVE RELAY M-06 = UPPER SIEVE ACTUATOR M-07 = LOWER SIEVE ACTUATOR

S-35 = UPPER SIEVE REAR ADJUST S-46 = LOWER SIEVE REAR ADJUST

55-133

CLEANING FRAME--21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

DISTRIBUTION FRAME--26

F-43 = CCM-1A FUSE F-44 = CCM-1B FUSE

55-134

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0302-03 CCM3 Battery Voltage Shorted to High Source Cause: The CCM3 Battery Voltage circuit is shorted to a higher than normal source. Possible failure modes: 1. Circuit wiring is shorted to a high voltage source. 2. Faulty alternator/regulator. 3. Controller internal failure (internal regulator failure). Solution: Battery voltage is used as “keep alive memory” power in the module to retain settings and configuration information. The module will not initialize (wake-up at “key on”) if battery voltage drops below 9V, but there is no shutdown for excessive voltage. 1. Start the combine engine, and run it at high idle (full throttle). Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage is 10.0 to 18.0 volts. A. If the voltage reading is greater than 18 volts, continue with Step 2. B. If the voltage reading is between 10 and 18 volts, go to Step 5. 2. Shut off the combine engine, and then turn the key switch on again. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, the alternator and/or regulator has failed, and is producing excessive voltage. Refer to “Charging Systems” in Chapter 5 -- Engine Systems in this section for additional alternator testing information. B. If the voltage reading is greater than 18 volts, continue with Step 3. 3. Turn the key switch off to power down the system. Check the voltage at fuse F39 using a multi-meter. A. If the voltage reading is greater than 18 volts, then the batteries have been mistakenly connected in series, or there is a fault in the wiring of the 24V starting system. Refer to “Starting Systems” in Chapter 5 -- Engine Systems in this section for additional information. B. If the voltage reading is between 10 and 18 volts, continue with Step 4.

55-135

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 4. Remove the buddy seat and storage bin to gain access to connector X012 on CCM3. Check the voltage at connector X012 pin J1-1. A. If the voltage reading is greater than 18 volts, then a high voltage source has been connected to one of the following wires in the cab main harness: wire 047 red, fuse F39 to harness splice wire 052 red, harness splice to CCM1 connector X018 pin J1-1 wire 049 red, harness splice to CCM3 connector X012 pin J1-1 wire 050 red, harness splice to CCM2 connector X015 pin J1-1 wire 051 red, harness splice through connector X001 pin 2 to RHM connector X026 pin 13 wire 1276 red, harness splice to display monitor A-02 connector X502 pin 13 wire 142 red, harness splice to DAM connector X065 pin B Locate the high voltage source and correct. B. If the voltage reading is 10 to 18 volts, and the diagnostic screen is still indicating voltage in excess of 18 volts, there is an internal fault in CCM3. Reload the software for CCM3. If that does not correct the concern, replace the module. 5. The short to high voltage is not present at this time. Erase the error code and continue operation.

55-136

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0302-04 CCM3 Battery Voltage Shorted to Low Source Cause: The CCM3 Battery Voltage circuit is shorted to a lower than normal source. Possible failure modes: 1. Loose or corroded connections, or damaged wires. 2. Batteries are discharged, and/or alternator/regulator failure. NOTE: Check fuse F39. If a short to ground occurred on this circuit the fuse will have blown. 3. Controller internal failure (internal regulator failure). Solution: Battery voltage is used as “keep alive memory” power in the module to retain settings and configuration information. The module will not initialize (wake-up at “key on”) if battery voltage drops below 9V, but there is no shutdown for excessive voltage. This fault code would typically be seen when battery voltage drops below 10V (threshold for the fault) but is above 9V (shutdown threshold). 1. Key switch in “Off” position. Check fuse F39. A. If fuse F39 is okay, continue with Step 6. B. If the fuse is blown, go to Step 2. 2. Replace the failed fuse F39. A. If the fuse is okay, continue with Step 3. B. If the fuse immediately fails again, a short to ground exists in one of the following wires: wire 047 red, fuse F39 to splice in the cab main (CM) harness wire 052 red, harness splice to CCM1 connector X018, pin J1-1 wire 050 red, harness splice to CCM2 connector X015, pin J1-1 wire 049 red, harness splice to CCM3 connector X012, pin J1-1 wire 051 red, harness splice through connector X001, pin 2 to RHM connector X026, pin 13 wire 1276 red, harness splice to display monitor connector X502, pin 13 wire 142 red, harness splice to DAM connector X065, pin B Visually inspect the cab main and cab roof harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair. 3. Key switch in “Off” position. Check the voltage at fuse F39 using a multi-meter. A. If the voltage reading is between 10 and 18 volts, continue with Step 4. B. If the voltage reading is less than 10 volts, there is excessive resistance between the batteries and the cab fuse panel, due to loose or corroded connections, or the batteries have discharged excessively, and are not capable of supplying the minimum voltage requirement for CCM3. Inspect the wiring from the batteries to the engine compartment, and from there to the cab. Recharge or replace the batteries.

55-137

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 4. Key switch in “On” position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, continue with Step 5. B. If the voltage reading is less than 10 volts, there is excessive resistance between the fuse panel and CCM3. Inspect wires 047 & 049 red in the cab main (CM) harness to CCM3 connector X012 pin J1-1 for loose or corroded connections, or damage to the wires. 5. Start the combine engine. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed. With the engine RPM at low idle, engage road and work lights. Check voltage range. The acceptable voltage range for the module is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, continue with Step 6. B. If the voltage reading is less than 10 volts, the alternator and/or regulator may have failed, and the charging system is not producing sufficient voltage. Refer to “Charging Systems” in Chapter 5 -- Engine Systems in this section for additional alternator testing information. 6. Erase the error code and continue operation.

55-138

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E0302 CCM3 BATTERY VOLTAGE

50020070

10004693

50026204

21 1. 2.

Fuse F39 Connector X012

55-139

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-140

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

DISTRIBUTION/ AUTO GUIDANCE FRAME--32

A-02 = DISPLAY MODULE A-11 = DGPS MODULE A-24 = NAVIGATION MODULE L-57 = STEER LEFT SOLENOID

L-58 = STEER RIGHT SOLENOID L-59 = STEER ENABLE SOLENOID S-78 = AUTOGUIDANCE SWITCH S-79 = ROTARY ENCODER SWITCH

55-141

S-80 = DISPLAY HOME SWITCH S-81 = DISPLAY ESCAPE SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0310-11 Bypass Unit Engage Output Unidentified Failure Code Cause: The sample motor (M28) engage circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad relay in moisture sensor assembly. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with Step 6. 2. Disconnect connector X222 at the sample motor M28. Use a multimeter to check the resistance of the sample motor engage relay between connector X222 pins 2 & 4. The proper resistance range is 65 to 80 ohms. A. If there is zero resistance, the sample motor engage relay is shorted internally. Replace the relay. B. If there is infinite resistance, the sample motor engage relay is open. Replace the relay. C. If the resistance is correct, continue with Step 3. 3. Use a multimeter to check for continuity between connector X222 pin 4 (harness side) and chassis ground. Flex the expansion (EX) harness while making this check. A. If there is continuity to ground, there is a short to ground in the expansion harness between connector X222 pin 4 and connector X013 pin J2-13 wire 837 white. Locate the short and repair. B. If there is no continuity to ground, continue with Step 4. 4. Use a multimeter to check for continuity between connector X222 pin 2 (harness side) and chassis ground. Flex the expansion (EX) harness while making this check. A. If there is no continuity to ground, there is an open circuit in the expansion (EX) harness between connector X222 pin 2 and front frame ground #2 wire 564 black or 543 black. Locate the open and repair. B. If there is continuity to ground, continue with Step 5. 5. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the bypass unit engage output. Use a multimeter to check for 12 volts between connector X222 pin 4 and chassis ground. A. If 12 volts is not present, there is an open circuit in the expansion harness between connector X222 pin 4 and connector X013 pin J2-13 wire 837 white. Locate the open and repair. B. If 12 volts is found, continue with Step 6. 6. Erase the fault code and continue operation.

55-142

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E0310 BYPASS UNIT ENGAGE OUTPUT

2 1

40025212

50026214

22 1. 2. 3.

Sample Motor -- M28 Connector X222 Connector X013

55-143

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

AUTO GUIDANCE/ PRECISION FRAME--24

B-12 = MOISTURE SENSOR B-69 = STEERING WHEEL POSITION B-70 = REAR AXLE ANGLE F-47 = CCM-3 FUSE

M-28 = SAMPLE MOTOR M-35 = TURNTABLE ACTUATOR R-05 = YIELD SENSOR

55-144

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE – E0317-11 Steering Enable Valve Unidentified Failure Code Cause: The steering enable valve L-59 circuit is open. Possible Failure Modes: 1. Valve or circuit wiring is open. 2. Controller internal failure (Internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, manually power the circuit. A. If the display monitor indicates an error, continue with step 2. B. If the display monitor does not indicate an error, continue with step 7. 2. Turn the Ignition key switch to the OFF position. Disconnect connector X486 from the Steer Enable Solenoid L-59. Use a multimeter to check for resistance on the solenoid between connector X486 pin 1 and 2. There should be approximately 6.0 ohms. A. If the resistance is out of specification, replace the solenoid. B. If the resistance is within specification, continue with step 3. 3. Turn the Ignition key switch to the OFF position. Disconnect connector X486 from the Steer Enable Solenoid L-59. Use a multimeter to check for continuity on the Autoguidance (AG4) harness side between connector X486 pin 1 and chassis ground. There should be continuity. A. If there is continuity, continue with step 4. B. If there is no continuity, continue with step 6. 4. Turn the Ignition key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, manually power the circuit. Disconnect the Expansion (EX) harness from the Autoguidance (AG4) harness at connector X476. Use a multimeter to check for voltage between the Expansion (EX) harness side of connector X476 pin 5 and chassis ground. A. If there is voltage, there is an open in the Autoguidance (AG4) harness between connector X476 pin 5 and connector X486 pin 2, wire 1758 white. Locate and repair the open. B. If there is no voltage, continue with step 5 5. Turn the Ignition key switch to the ON position. Use the display monitor, reference Section 55 Chapter 2, if needed, manually power the circuit. Carefully disconnect connector X014 from the CCM-3 module. Use a multimeter to check for voltage on the module between connector X014 pin J3-5 and chassis ground. There should be voltage. A. If there is voltage, there is an open in the Expansion (EX) harness between connector X014 pin J3-5 and connector X476 pin 5, wire 1758 white. Locate and repair the open. B. If there is no voltage, the module has failed. Replace the module. 6. Turn the Ignition key switch to the OFF position. Disconnect the Expansion (EX) harness from the Autoguidance (AG4) harness at connector X476. Use a multimeter to check for continuity on the Expansion (EX) harness side of connector X476 pin 6 and chassis ground. A. If there is continuity, there is an open in the Autoguidance (AG4) harness between connector X476 pin 6 and connector X486 pin 1 wire 1759 black. Locate and repair the open. B. If there is no continuity, there is an open in the Expansion (EX) harness between connector X476 pin 6 and chassis ground wire 1759 black. Locate and repair the open. 7. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload CCM-3 software. If that does not correct the concern, replace CCM-3.

55-145

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

63064136

50026214

23 1. 2.

Steering Enable Valve (Solenoid) L-59) Connector X014

55-146

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

DISTRIBUTION/ AUTO GUIDANCE FRAME--32

A-02 = DISPLAY MODULE A-11 = DGPS MODULE A-24 = NAVIGATION MODULE L-57 = STEER LEFT SOLENOID

L-58 = STEER RIGHT SOLENOID L-59 = STEER ENABLE SOLENOID S-78 = AUTOGUIDANCE SWITCH S-79 = ROTARY ENCODER SWITCH

55-147

S-80 = DISPLAY HOME SWITCH S-81 = DISPLAY ESCAPE SWITCH

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0325-11 Upper/Lower Sieve Sel Unidentified Failure Code Cause: The Upper/Lower Sieve Relay (K-18) circuit is open, or shorted to ground. Possible failure modes: 1. Supply wiring damaged. 2. Bad relay. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with Step 7. 2. Turn the key switch to the OFF position and remove the Upper/Lower Sieve Relay K18. Use a multimeter to check the resistance of the upper/lower sieve relay coil. The proper resistance range for the upper/lower sieve relay coil is 74.3 to 78.3 ohms. A. If out of specification replace relay. B. If the coil is within specification continue with Step 3. 3. Use a multimeter to check for continuity between relay socket pin 1 and chassis ground. A. If no continuity to ground is found continue with Step 4. B. If there is continuity to ground, there is a short to ground on wire 787 white in the cab main (CM) harness between the fuse panel and connector X012 pin J1-6. Locate the short and repair. 4. Use a multimeter to check for continuity between relay socket pin 2 and chassis ground. A. If continuity to ground is found continue with Step 5. B. If there is no continuity to ground, there is an open circuit on wire 788 black in the cab main (CM) harness between the fuse panel and cab ground 3. Locate the open and repair. 5. Turn the key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the upper/lower sieve relay. Use the multimeter to check for 12 volts between relay socket pin 1 and chassis ground. A. If 12 volts is not present continue with Step 6. B. If 12 volts is found continue with Step 7. 6. Key switch to the ON position. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the upper/lower sieve relay. Use the multimeter to check for 12 volts between connector X012 J1-6 and chassis ground. A. If 12 volts is not present, replace the CCM3 with a known good controller. B. If 12 volts is present, there is an open circuit between connector X012 J1-6 and relay socket pin 1 wire 787 white. Locate the open and repair. 7. Erase the fault code and continue operation.

55-148

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E0325 UPPER/LOWER SIEVE SEL

2 1

10004693

50020070

50026204

24 1. 2.

Upper/Lower Sieve Relay K18 Connector X012

55-149

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-27 = SIEVE/SPREADER FUSE K-18 = UPPER/LOWER SIEVE RELAY M-06 = UPPER SIEVE ACTUATOR M-07 = LOWER SIEVE ACTUATOR

S-35 = UPPER SIEVE REAR ADJUST S-46 = LOWER SIEVE REAR ADJUST

55-150

CLEANING FRAME--21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0332-05 Spreader Plates Motor Line Disconnected Context: The CCM has detected that the circuit current has been <0.7 Amps for at least 3 seconds, while the control circuit input is active. Lack of current flow in an activated circuit is an indication of an open circuit condition. However, it is also possible to get this error message from a direct short to ground. This is because the CCM contains built-in over temperature circuit protection logic that will electronically disconnect the motor in order to prevent damage to the module. When a direct short to ground is present, and the motor is energized, it is possible for the rapid spike in current to engage the circuit protection -opening the circuit. When this occurs, the fault detection software sees the open and may report the “Line disconnected” fault. Cause: The Spreader Plates Motor (M-11) circuit is open, or shorted to ground. Possible failure modes: 1. Circuit connection open or shorted to ground. 2. Excessive mechanical load on motor. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed. A. Start the combine. B. Operate the chopper spreader plates in both directions. C. Record in which direction(s) the spreader plates operate. D. Check for fault codes 0297-06 and 0332-05. E. Use the following table to determine the location of the fault. Symptom

Fault Code 0297-06

Spreader plates motor operates in 1 direction only

Spreader plates motor does not operate in either direction

Fault Type

0332-05 X X

Go to Step 2

Binding

Go to Step 3

Short to ground

Go to Step 2

Binding

Go to Step 10

Open circuit

Go to Step 17

No power supply

2. The spreader plates mechanism is mechanically bound up, resulting in high current draw. See the appropriate repair manual chapter for repair and adjustment of the straw chopper spreader plates linkage. 3. Fault codes indicate circuit fault due to short to ground. Disconnect spreader plates motor connector X224. Measure between terminals D or E on the motor connector and a known good ground. There should be no continuity to ground. A. There is continuity to ground, indicating a short to ground in the motor. Replace the spreader plates motor. B. There is no continuity to ground. Continue with Step 4.

55-151

55-152

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 11. Ensure that the batteries are connected using the battery key, and that fuse F27 is good. Use the multimeter to check for continuity between connector X224 pin D on the straw hood (SH) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F27. This ground path may be used to test for an open circuit condition. A. If continuity is found, continue with Step 14. B. If no continuity is found, continue with Step 12. 12. Disconnect inline connector X071. Use a multimeter to check for continuity between connector X071 pin 15 on the straw hood front (SW) harness side and chassis ground. A. If continuity is found the open circuit is in the harness between connector X071 pin 15 and connector X224 pin D wire 510 white. Locate the open and repair. B. If no continuity is found, continue with Step 13. 13. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 10 on the expansion (EX) harness side and chassis ground. A. If continuity is found the open circuit is in the harness between connector X071 pin 15 and connector X025 pin 10 wire 510 white. Locate the open and repair. B. If no continuity is found, the open circuit is in the harness between connector X025 pin 10 and connector X014 pins J3-8 wire 510 red. Locate the open and repair. 14. Use a multimeter to check for continuity between connector X224 pin E on the straw hood (SH) harness side and chassis ground. A. If no continuity is found, continue with Step 15. B. If continuity is found, recheck the motor for continuity at Step 10. 15. Disconnect inline connector X071. Use a multimeter to check for continuity between connector X071 pin 16 on the straw hood front (SW) harness side and chassis ground. A. If continuity is found the open circuit is in the harness between connector X071 pin 16 and connector X224 pin E wire 509 gray. Locate the open and repair. B. If no continuity is found, continue with Step 16. 16. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 8 on the expansion (EX) harness side and chassis ground. A. If continuity is found the open circuit is in the harness between connector X071 pin 10 and connector X025 pin 8 wire 509 grey. Locate the open and repair. B. If no continuity is found, the open circuit is in the harness between connector X025 pin 8 and connector X014 pins J3-6 wire 509 grey. Locate the open and repair. 17. If the spreader plates motor does not operate in either direction, and there are no error codes indicated, the supply power for the circuit may not be present. Remove fuse F27 and inspect. A. Fuse has failed. Go to Step 18. B. Fuse is okay. Go to Step 19.

55-153

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 18. If fuse has failed, replace the fuse. A. If fuse immediately fails, a short to ground exists on one of the following wires: Wire 031 red, from fuse F27 to connector X005 pin 4 Wire 031 red, connector X005 pin 4 to connector X034 pin 2 Wire 031 red, connector X034 pin 2 to splice in expansion (EX) harness Wire 511 red, harness splice to connector X013 pin J2-11 on CCM3 module. Wire 512 red, harness splice to connector X014 pin J3-7 on CCM3 module. Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. B. Fuse is okay. Go to Step 19. 19. Test for 12V power at connector X014 pin J3-7 on the CCM3 module under the cab. A. If there is no power, there is an open circuit on one of the following wires: Wire 031 red, from fuse F27 to connector X005 pin 4 Wire 031 red, connector X005 pin 4 to connector X034 pin 2 Wire 031 red, connector X034 pin 2 to splice in expansion (EX) harness Wire 512 red, harness splice to connector X014 pin J3-7 on CCM3 module. Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the open and repair. After repair, go to Step 20. B. If there is power, go to Step 20. 20. Test for continuity to ground at connector X014 pin J3-16 on the CCM3 module under the cab. A. If there is no continuity to ground, there is an open circuit in the expansion (EX) harness between connector X014 pin J3-16 and chassis ground 2 wire 521 black. Locate the open and repair. After repair, go to Step 21. B. If there is continuity to ground, go to Step 21. 21. Once it has been verified that power is being supplied to the module, recheck the circuit operation as described in Step 1. If the fuse fails during the testing, a short to ground on the circuit is causing the fuse to fail. Start the troubleshooting at Step 3 to locate the short to ground.

55-154

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E0332 SPREADER PLATES MOTOR

50026220

4 2

40025219

10020076

50016215

1. 2. 3. 4. 5.

Spreader Plate Motor M11 Connector X224 Connector X071 Connector X025 Connector X014

55-155

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-27 = SIEVE/SPREADER FUSE K-18 = UPPER/LOWER SIEVE RELAY M-06 = UPPER SIEVE ACTUATOR M-07 = LOWER SIEVE ACTUATOR

S-35 = UPPER SIEVE REAR ADJUST S-46 = LOWER SIEVE REAR ADJUST

55-156

CLEANING FRAME--21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

B-10 = CHOPPER RPM L-28 = CHAFF SPREADER M-11 = SPREADER PLATE MOTOR S-23 = SPREADER PLATE

B-74 = PSD RPM

TRASH FRAME--23

55-157

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0334-05 Lower Sieve Motor Line Disconnected Context: The CCM has detected that the circuit current has been <0.7 Amps for at least 3 seconds, while the control circuit input is active. Lack of current flow in an activated circuit is an indication of an open circuit condition. However, it is also possible to get this error message from a direct short to ground. This is because the CCM contains built-in over temperature circuit protection logic that will electronically disconnect the motor in order to prevent damage to the module. When a direct short to ground is present, and the motor is energized, it is possible for the rapid spike in current to engage the circuit protection -opening the circuit. When this occurs, the fault detection software sees the open and may report the “Line disconnected” fault. Cause: The lower sieve motor (M-07) circuit is open, or shorted to ground. Possible failure modes: 1. Circuit wiring is open, or shorted to ground. 2. Excessive mechanical load on motor. 3. Controller internal failure (internal regulator failure). Solution: This is an H-bridge-controlled circuit (refer to Chapter 2 for more information on H-bridge circuit operation). The lower sieve motor (M07) circuit is paired with the upper sieve motor (M06) circuit, and the module switches between these two circuits using the Upper/Lower sieve relay K-18. Because these circuits are connected and driven from the same module outputs, the troubleshooting procedure must consider both circuits at the same time. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed. A. Manually operate the lower sieve motor in both directions. B. Manually operate the upper sieve motor in both directions. C. Record in which direction(s) each circuit operates. D. Check for fault codes 0300-06 and 0334-05 (Lower Sieve motor) and fault codes 0301-06 and 0335-05 (Upper Sieve motor).

55-158

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E. Use the following table to determine the location of the fault. Errors

Symptom 0300-06 Lower sieve motor operates in 1 direction only

0301-06

0334-05

0335-05

X X

Go to Step 2

Motor bound up

Go to Step 3

Short to ground

Go to Step 8

Short to ground

Lower sieve motor and upper sieve motor operate in 1 direction only

Lower Sieve motor does not operate in either direction

Go to Step 14

Open

Go to Step 26

Short to ground

Go to Step 27

Motor bound up

Go to Step 28

Short to ground

Go to Step 33

Open

Go to Step 45

Short to ground

Go to Step 46

Open

Go to Step 52

Fuse 27 blown or open

Upper sieve motor operates in 1 direction only

Upper sieve motor does not operate in either direction Both lower sieve motor and upper sieve motor do not operate in either direction

55-159

55-160

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 10. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 14 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the short to ground is in the expansion (EX) harness between connector X025 pin 14 and connector X013 pin J2-1 wire 785 gray. Locate the short and repair. B. If no continuity is found, the short to ground is in the straw hood front (SW) harness between connector X025 pin 14 and connector X072 pin J or P on one of the following wires: Wire 785 gray, connector X025 pin 14 to harness splice Wire 791 gray, harness splice to connector X072 pin J Wire 789 gray, harness splice to connector X072 pin P Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. 11. Remove the Upper/lower sieve relay K18 from the fuse panel. Use a multimeter to check for continuity between the relay terminal 3 on the cab main (CM) harness side and chassis ground. A. If continuity is found, continue with Step 12. B. If no continuity is found, erase the fault codes and continue operation. 12. Disconnect inline connector X005. Use a multimeter to check for continuity between connector X005 pin 15 on the main frame (MF) harness side and chassis ground. A. If continuity is found, continue with Step 13. B. If no continuity is found, the short to ground is in the cab main (CM) harness between connector X005 pin 15 and the Upper/lower sieve relay K18 pin 3 on the fuse panel wire 786 red. Locate the short and repair. 13. Disconnect inline connector X219. Use a multimeter to check for continuity between connector X219 pin 1 on the expansion (EX) harness side and chassis ground. A. If continuity is found the short to ground is in the expansion (EX) harness between connector X219 pin 1 and connector X013 pin J2-21 wire 786 red. Locate the short and repair. B. If no continuity is found, the short to ground is in the main frame (MF) harness between connector X005 pin 15 and connector X219 pin 1 wire 786 red. Locate the short and repair. 14. Fault codes indicate circuit fault due to open circuit condition. Disconnect the lower sieve motor connector X228. Measure the resistance of the motor between terminals D and E. The correct resistance is 3 to 12 ohms. A. The resistance is infinite, indicating an open condition in the motor. Replace the lower sieve motor. B. The resistance is in specification. Continue with Step 15. 15. Replace the Upper/lower sieve relay K18 on the fuse panel with a known good relay, and retest the lower sieve circuit function. A. If the lower sieve circuit now functions properly, the relay was faulty, and was not providing continuity between terminals 3 & 5 when energized. Replace the relay. B. If the lower sieve circuit still does not work, continue with Step 16. 16. Ensure that the batteries are connected using the battery key, and that fuse F27 is good. Use the multimeter to check for continuity between connector X228 pin E on the lower frame rear (LR) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F27. This ground path may be used to test for an open circuit condition. A. If continuity is found, continue with Step 19. B. If no continuity is found, continue with Step 17.

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55-162

55-163

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 32. Disconnect connector X005. Use a multimeter to check for continuity between connector X005 pin 17 on the cab main (CM) harness side and chassis ground. A. If no continuity is found, the short to ground is in the main frame (MF) harness between connector X219 pin 3 and connector X005 pin 17 wire 792 white. Locate the short and repair. B. If continuity is found, the short to ground is in the cab main (CM) harness between connector X005 pin 17 and the Upper/lower sieve relay K18 pin 4 on the fuse panel wire 792 white. Locate the short and repair. 33. Fault codes indicate circuit fault due to open circuit condition. Disconnect the upper sieve motor connector X227. Measure the resistance of the motor between terminals D and E. The correct resistance is 3 to 12 ohms. A. The resistance is infinite, indicating an open condition in the motor. Replace the upper sieve motor. B. The resistance is in specification. Continue with Step 34. 34. Ensure that the batteries are connected using the battery key, and that fuse F27 is good. Use the multimeter to check for continuity between connector X227 pin E on the lower frame rear (LR) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F27. This ground path may be used to test for an open circuit condition. A. If continuity is found, continue with Step 37. B. If no continuity is found, continue with Step 35. 35. Disconnect inline connector X072. Use a multimeter to check for continuity between connector X072 pin J on the straw hood front (SW) harness side and chassis ground. A. If continuity is found, the open circuit is in the lower frame rear (LR) harness between connector X072 pin J and connector X227 pin E wire 791 gray. Locate the open and repair. B. If no continuity is found, continue with Step 36. 36. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 14 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the straw hood front (SW) harness between connector X072 pin J and connector X025 pin 14 wires 791 gray or 785 gray. Locate the open and repair. B. If no continuity is found, the open circuit is in the expansion (EX) harness between connector X025 pin 14 and connector X013 pin J2-1 wire 785 gray. Locate the open and repair. 37. Use a multimeter to check for continuity between connector X227 pin D on the lower frame rear (LR) harness side and chassis ground. A. If no continuity is found, continue with Step 38. B. If continuity is found, recheck the motor for continuity at Step 33. Erase the fault codes and continue operation. 38. Disconnect connector X072. Use a multimeter to check for continuity between connector X072 pin H on the straw hood front (SW) harness side and chassis ground. A. If continuity is found, the open circuit is in the lower frame rear (LR) harness between connector X227 pin D and connector X072 pin H wire 792 white. Locate the open and repair. B. If no continuity is found, continue with Step 39. 39. Disconnect connector X025. Use a multimeter to check for continuity between connector X025 pin 17 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the straw hood front (SW) harness between connector X072 pin H and connector X025 pin 17 wire 792 white. Locate the open and repair. B. If no continuity is found, continue with Step 40.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 40. Disconnect connector X219. Use a multimeter to check for continuity between connector X219 pin 3 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the open circuit is in the expansion (EX) harness between connector X025 pin 17 and connector X219 pin 3 wire 792 white. Locate the open and repair. B. If no continuity is found, continue with Step 41. 41. Remove the upper/lower sieve relay K18 from the fuse panel. Use a multimeter to check for continuity between Upper/lower sieve relay K18 terminal 4 on the cab main (CM) harness side and chassis ground. NOTE: Continuity check is being done back through circuit through the motor. The resistance will read significantly higher than previous tests, but should not be higher than 10 ohms above the motor resistance measured in Step 33. A. If no continuity is found, the open circuit is in the cab main (CM) or main frame (MF) harness wire 792 white from the fuse panel through connector X005 pin 17 to connector X219 pin 3. Locate the open and repair. B. If continuity is found, continue with Step 42. 42. Reconnect connector X005. Use a multimeter to check for continuity between Upper/lower sieve relay K18 terminal 3 on the cab main (CM) harness side and chassis ground. A. If continuity is found, the relay has failed open between terminals 3 and 4. Replace the relay. B. If no continuity is found, continue with Step 43. 43. Disconnect connector X005. Use a multimeter to check for continuity between connector X005 pin 15 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the open circuit is in the cab main (CM) harness between the Upper/lower sieve relay K18 terminal 3 on the fuse panel and connector X005 pin 15 wire 786 red. Locate the open and repair. B. If no continuity is found, continue with Step 44. 44. Disconnect connector X219. Use a multimeter to check for continuity between connector X219 pin 1 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the main frame (MF) harness between connector X219 pin 1 and connector X005 pin 15 wire 786 red. Locate the open and repair. B. If no continuity is found, , the open circuit is in the expansion (EX) harness between connector X219 pin 1 and connector X013 pin J2-21 wire 786 red. Locate the open and repair. 45. Fault codes and operating condition indicate that the motor has shorted to ground. Disconnect upper sieve motor connector X227. Measure between terminals D or E on the motor connector and a known good ground. There should be no continuity to ground. A. There is continuity to ground, indicating a short to ground in the motor. Replace the upper sieve motor. B. There is no continuity to ground. Erase the fault codes and continue operation. 46. Fault codes and operating condition indicates that there is an open circuit on shared wiring between the upper sieve motor and lower sieve motor circuits. Replace the Upper/lower sieve relay K18 on the fuse panel with a known good relay, and retest the upper and lower sieve circuit function. A. If both circuits now function properly, the relay was faulty, and was not providing continuity between the work terminal 3 and terminals 4 & 5. Replace the relay. B. If both circuits still do not work, continue with Step 47.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 47. Ensure that the batteries are connected using the battery key, and that fuse F27 is good. Remove the Upper/lower sieve relay K18 on the fuse panel. Use a multimeter to check for continuity between Upper/lower sieve relay K18 terminal 3 on the cab main (CM) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F27. This ground path may be used to test for an open circuit condition. A. If no continuity is found, continue with Step 48. B. If continuity is found, continue with Step 50. 48. Disconnect connector X005. Use a multimeter to check for continuity between connector X005 pin 15 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the open circuit is in the cab main (CM) harness between the Upper/lower sieve relay K18 terminal 3 on the fuse panel connector X005 pin 15 wire 786 red. Locate the open and repair. B. If no continuity is found, continue with Step 49. 49. Disconnect connector X219. Use a multimeter to check for continuity between connector X219 pin 1 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the main frame (MF) harness between connector 219 pin 1 and connector X005 pin 15 wire 786 red. Locate the open and repair. B. If no continuity is found, , the open circuit is in the expansion (EX) harness between connector X219 pin 1 and connector X016 pin J2-21 wire 786 red. Locate the open and repair. 50. Disconnect inline connector X072. Use a multimeter to check for continuity between connector X072 pin J or P on the straw hood front (SW) harness side and chassis ground. A. If continuity is found, erase the fault code and continue operation. B. If no continuity is found, continue with Step 51. 51. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 14 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the straw hood front (SW) harness between connector X025 pin 14 and the harness splice on wire 785 gray. Locate the open and repair. B. If no continuity is found, the open circuit is in the expansion (EX) harness between connector X025 pin 14 and connector X013 pin J2-1 on wire 785 gray. Locate the open and repair. 52. If the upper sieve motor and lower sieve motor do not operate in either direction, and there are no error codes indicated, the supply power for the circuit may not be present. Remove fuse F27 and inspect. A. Fuse has failed. Go to Step 53. B. Fuse is okay. Go to Step 56. 53. If fuse has failed, replace the fuse. A. If fuse immediately fails, a short to ground exists on the wires to the CCM3 module connectors. Continue with Step 54. B. Fuse is okay. Go to Step 56. 54. Disconnect inline connector X005. Use a multimeter to check for continuity between the harness end of connector X005 pin 4 on the main frame (MF) harness side and chassis ground. A. If no continuity is found, there is a short to ground in the cab main (CM) harness between fuse F27 on the fuse panel and connector X005 pin 4 wire 031 red. Locate the short and repair. B. If continuity is found, continue with Step 55.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 55. Disconnect inline connector X034. Use a multimeter to check for continuity between the harness end of connector X034 pin 2 on the expansion (EX) harness side and chassis ground. A. If no continuity is found, there is a short to ground in the main frame (MF) harness between connector X034 pin 2 and connector X005 pin 4 wire 031 red. Locate the short and repair. B. If continuity is found, there is a short to ground in the expansion (EX) harness between connector X034 pin 2, connector X013 pin J2-11 and connector X014 pin J3-7 on one of the following wires: Wire 031 red, connector X034 pin 2 to harness splice Wire 511 red, harness splice to connector X013 pin J2-11 Wire 512 red, harness splice to connector X014 pin J3-7 Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. 56. Test for 12V power at connector X013 pin J2-11 on the CCM3 module under the cab. A. If there is no power, there is an open circuit on the power wires to the CCM3 module. Continue with Step 57. B. If there is power, go to Step 59. 57. Disconnect inline connector X005. Use a multimeter to check for 12V at connector X005 pin 4 on the cab main (CM) harness side. A. If there is no power, there is an open circuit in the cab main (CM) harness between fuse F27 on the fuse panel and connector X005 pin 4 wire 031 red. Locate the open and repair. B. If power is found, continue with Step 58. 58. Disconnect inline connector X034. Use a multimeter to check for 12V at connector X034 pin 2 on the main frame (MF) harness side. A. If no power is found, there is an open circuit in the main frame (MF) harness between connector X034 pin 2 and connector X005 pin 4 wire 031 red. Locate the open and repair. B. If power is found, there is an open circuit in the expansion (EX) harness between connector X034 pin 2 and connector X013 pin J2-11 wire 031 red or 511 red. Locate the open and repair. 59. Test for continuity to ground at connector X013 pin J2-3 on the expansion (EX) harness side of CCM3 module under the cab. A. If there is no continuity to ground, there is an open circuit in the expansion (EX) harness from connector X013 pin J2-3 on CCM3 module to the front frame ground #2 wire 520 black. Locate the open and repair. After repair, go to Step 60. B. If there is continuity to ground, go to Step 60. 60. Once it has been verified that power is being supplied to the module, recheck the circuit operation as described in Step 1. If the fuse fails during the testing, a short to ground on the circuit being operated at the time of failure is causing the fuse to fail.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E0334 LOWER SIEVE MOTOR

40020080

10010899

50020070

40025228

10020076

10010874

50026216

26 1. 2. 3. 4. 5. 6. 7.

Lower Sieve Actuator M07 Connector X072 Connector X025 Connector X219 Connector X005 Upper/Lower Sieve Relay K18 Connector X013

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-27 = SIEVE/SPREADER FUSE K-18 = UPPER/LOWER SIEVE RELAY M-06 = UPPER SIEVE ACTUATOR M-07 = LOWER SIEVE ACTUATOR

S-35 = UPPER SIEVE REAR ADJUST S-46 = LOWER SIEVE REAR ADJUST

55-169

CLEANING FRAME--21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

B-10 = CHOPPER RPM L-28 = CHAFF SPREADER M-11 = SPREADER PLATE MOTOR S-23 = SPREADER PLATE

B-74 = PSD RPM

TRASH FRAME--23

55-170

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

FAULT CODE -- E0335-05 Upper Sieve Motor Line Disconnected Context: The CCM has detected that the circuit current has been <0.7 Amps for at least 3 seconds, while the control circuit input is active. Lack of current flow in an activated circuit is an indication of an open circuit condition. However, it is also possible to get this error message from a direct short to ground. This is because the CCM contains built-in over temperature circuit protection logic that will electronically disconnect the motor in order to prevent damage to the module. When a direct short to ground is present, and the motor is energized, it is possible for the rapid spike in current to engage the circuit protection -opening the circuit. When this occurs, the fault detection software sees the open and may report the “Line disconnected” fault. Cause: The upper sieve motor (M-06) circuit is open, or shorted to ground. Possible failure modes: 1. Circuit wiring is open, or shorted to ground. 2. Excessive mechanical load on motor. 3. Controller internal failure (internal regulator failure). Solution: This is an H-bridge-controlled circuit (refer to Chapter 2 for more information on H-bridge circuit operation). The lower sieve motor (M07) circuit is paired with the upper sieve motor (M06) circuit, and the module switches between these two circuits using the Upper/Lower sieve relay K-18. Because these circuits are connected and driven from the same module outputs, the troubleshooting procedure must consider both circuits at the same time. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed. A. Manually operate the lower sieve motor in both directions. B. Manually operate the upper sieve motor in both directions. C. Record in which direction(s) each circuit operates. D. Check for fault codes 0300-06 and 0334-05 (Lower Sieve motor) and fault codes 0301-06 and 0335-05 (Upper Sieve motor).

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E. Use the following table to determine the location of the fault. Errors

Symptom 0300-06 Lower sieve motor operates in 1 direction only

0301-06

0334-05

0335-05

X X

Go to Step 2

Motor bound up

Go to Step 3

Short to ground

Go to Step 8

Short to ground

Lower sieve motor and upper sieve motor operate in 1 direction only

Lower Sieve motor does not operate in either direction

Go to Step 14

Open

Go to Step 26

Short to ground

Go to Step 27

Motor bound up

Go to Step 28

Short to ground

Go to Step 33

Open

Go to Step 45

Short to ground

Go to Step 46

Open

Go to Step 52

Fuse 27 blown or open

Upper sieve motor operates in 1 direction only

Upper sieve motor does not operate in either direction Both lower sieve motor and upper sieve motor do not operate in either direction

55-172

55-173

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 10. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 14 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the short to ground is in the expansion (EX) harness between connector X025 pin 14 and connector X013 pin J2-1 wire 785 gray. Locate the short and repair. B. If no continuity is found, the short to ground is in the straw hood front (SW) harness between connector X025 pin 14 and connector X072 pin J or P on one of the following wires: Wire 785 gray, connector X025 pin 14 to harness splice Wire 791 gray, harness splice to connector X072 pin J Wire 789 gray, harness splice to connector X072 pin P Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. 11. Remove the Upper/lower sieve relay K18 from the fuse panel. Use a multimeter to check for continuity between the relay terminal 3 on the cab main (CM) harness side and chassis ground. A. If continuity is found, continue with Step 12. B. If no continuity is found, erase the fault codes and continue operation. 12. Disconnect inline connector X005. Use a multimeter to check for continuity between connector X005 pin 15 on the main frame (MF) harness side and chassis ground. A. If continuity is found, continue with Step 13. B. If no continuity is found, the short to ground is in the cab main (CM) harness between connector X005 pin 15 and the Upper/lower sieve relay K18 pin 3 on the fuse panel wire 786 red. Locate the short and repair. 13. Disconnect inline connector X219. Use a multimeter to check for continuity between connector X219 pin 1 on the expansion (EX) harness side and chassis ground. A. If continuity is found the short to ground is in the expansion (EX) harness between connector X219 pin 1 and connector X013 pin J2-21 wire 786 red. Locate the short and repair. B. If no continuity is found, the short to ground is in the main frame (MF) harness between connector X005 pin 15 and connector X219 pin 1 wire 786 red. Locate the short and repair. 14. Fault codes indicate circuit fault due to open circuit condition. Disconnect the lower sieve motor connector X228. Measure the resistance of the motor between terminals D and E. The correct resistance is 3 to 12 ohms. A. The resistance is infinite, indicating an open condition in the motor. Replace the lower sieve motor. B. The resistance is in specification. Continue with Step 15. 15. Replace the Upper/lower sieve relay K18 on the fuse panel with a known good relay, and retest the lower sieve circuit function. A. If the lower sieve circuit now functions properly, the relay was faulty, and was not providing continuity between terminals 3 & 5 when energized. Replace the relay. B. If the lower sieve circuit still does not work, continue with Step 16. 16. Ensure that the batteries are connected using the battery key, and that fuse F27 is good. Use the multimeter to check for continuity between connector X228 pin E on the lower frame rear (LR) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F27. This ground path may be used to test for an open circuit condition. A. If continuity is found, continue with Step 19. B. If no continuity is found, continue with Step 17.

55-174

55-175

55-176

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 32. Disconnect connector X005. Use a multimeter to check for continuity between connector X005 pin 17 on the cab main (CM) harness side and chassis ground. A. If no continuity is found, the short to ground is in the main frame (MF) harness between connector X219 pin 3 and connector X005 pin 17 wire 792 white. Locate the short and repair. B. If continuity is found, the short to ground is in the cab main (CM) harness between connector X005 pin 17 and the Upper/lower sieve relay K18 pin 4 on the fuse panel wire 792 white. Locate the short and repair. 33. Fault codes indicate circuit fault due to open circuit condition. Disconnect the upper sieve motor connector X227. Measure the resistance of the motor between terminals D and E. The correct resistance is 3 to 12 ohms. A. The resistance is infinite, indicating an open condition in the motor. Replace the upper sieve motor. B. The resistance is in specification. Continue with Step 34. 34. Ensure that the batteries are connected using the battery key, and that fuse F27 is good. Use the multimeter to check for continuity between connector X227 pin E on the lower frame rear (LR) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F27. This ground path may be used to test for an open circuit condition. A. If continuity is found, continue with Step 37. B. If no continuity is found, continue with Step 35. 35. Disconnect inline connector X072. Use a multimeter to check for continuity between connector X072 pin J on the straw hood front (SW) harness side and chassis ground. A. If continuity is found, the open circuit is in the lower frame rear (LR) harness between connector X072 pin J and connector X227 pin E wire 791 gray. Locate the open and repair. B. If no continuity is found, continue with Step 36. 36. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 14 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the straw hood front (SW) harness between connector X072 pin J and connector X025 pin 14 wires 791 gray or 785 gray. Locate the open and repair. B. If no continuity is found, the open circuit is in the expansion (EX) harness between connector X025 pin 14 and connector X013 pin J2-1 wire 785 gray. Locate the open and repair. 37. Use a multimeter to check for continuity between connector X227 pin D on the lower frame rear (LR) harness side and chassis ground. A. If no continuity is found, continue with Step 38. B. If continuity is found, recheck the motor for continuity at Step 33. Erase the fault codes and continue operation. 38. Disconnect connector X072. Use a multimeter to check for continuity between connector X072 pin H on the straw hood front (SW) harness side and chassis ground. A. If continuity is found, the open circuit is in the lower frame rear (LR) harness between connector X227 pin D and connector X072 pin H wire 792 white. Locate the open and repair. B. If no continuity is found, continue with Step 39.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 39. Disconnect connector X025. Use a multimeter to check for continuity between connector X025 pin 17 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the straw hood front (SW) harness between connector X072 pin H and connector X025 pin 17 wire 792 white. Locate the open and repair. B. If no continuity is found, continue with Step 40. 40. Disconnect connector X219. Use a multimeter to check for continuity between connector X219 pin 3 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the open circuit is in the expansion (EX) harness between connector X025 pin 17 and connector X219 pin 3 wire 792 white. Locate the open and repair. B. If no continuity is found, continue with Step 41. 41. Remove the upper/lower sieve relay K18 from the fuse panel. Use a multimeter to check for continuity between Upper/lower sieve relay K18 terminal 4 on the cab main (CM) harness side and chassis ground. NOTE: Continuity check is being done back through circuit through the motor. The resistance will read significantly higher than previous tests, but should not be higher than 10 ohms above the motor resistance measured in Step 33. A. If no continuity is found, the open circuit is in the cab main (CM) or main frame (MF) harness wire 792 white from the fuse panel through connector X005 pin 17 to connector X219 pin 3. Locate the open and repair. B. If continuity is found, continue with Step 42. 42. Reconnect connector X005. Use a multimeter to check for continuity between Upper/lower sieve relay K18 terminal 3 on the cab main (CM) harness side and chassis ground. A. If continuity is found, the relay has failed open between terminals 3 and 4. Replace the relay. B. If no continuity is found, continue with Step 43. 43. Disconnect connector X005. Use a multimeter to check for continuity between connector X005 pin 15 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the open circuit is in the cab main (CM) harness between the Upper/lower sieve relay K18 terminal 3 on the fuse panel and connector X005 pin 15 wire 786 red. Locate the open and repair. B. If no continuity is found, continue with Step 44. 44. Disconnect connector X219. Use a multimeter to check for continuity between connector X219 pin 1 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the main frame (MF) harness between connector X219 pin 1 and connector X005 pin 15 wire 786 red. Locate the open and repair. B. If no continuity is found, , the open circuit is in the expansion (EX) harness between connector X219 pin 1 and connector X013 pin J2-21 wire 786 red. Locate the open and repair. 45. Fault codes and operating condition indicate that the motor has shorted to ground. Disconnect upper sieve motor connector X227. Measure between terminals D or E on the motor connector and a known good ground. There should be no continuity to ground. A. There is continuity to ground, indicating a short to ground in the motor. Replace the upper sieve motor. B. There is no continuity to ground. Erase the fault codes and continue operation.

55-178

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 46. Fault codes and operating condition indicates that there is an open circuit on shared wiring between the upper sieve motor and lower sieve motor circuits. Replace the Upper/lower sieve relay K18 on the fuse panel with a known good relay, and retest the upper and lower sieve circuit function. A. If both circuits now function properly, the relay was faulty, and was not providing continuity between the work terminal 3 and terminals 4 & 5. Replace the relay. B. If both circuits still do not work, continue with Step 47. 47. Ensure that the batteries are connected using the battery key, and that fuse F27 is good. Remove the Upper/lower sieve relay K18 on the fuse panel. Use a multimeter to check for continuity between Upper/lower sieve relay K18 terminal 3 on the cab main (CM) harness side and chassis ground. NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in position, irregardless of key switch position, as long as it receives power through fuse F27. This ground path may be used to test for an open circuit condition. A. If no continuity is found, continue with Step 48. B. If continuity is found, continue with Step 50. 48. Disconnect connector X005. Use a multimeter to check for continuity between connector X005 pin 15 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the open circuit is in the cab main (CM) harness between the Upper/lower sieve relay K18 terminal 3 on the fuse panel connector X005 pin 15 wire 786 red. Locate the open and repair. B. If no continuity is found, continue with Step 49. 49. Disconnect connector X219. Use a multimeter to check for continuity between connector X219 pin 1 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the main frame (MF) harness between connector 219 pin 1 and connector X005 pin 15 wire 786 red. Locate the open and repair. B. If no continuity is found, , the open circuit is in the expansion (EX) harness between connector X219 pin 1 and connector X013 pin J2-21 wire 786 red. Locate the open and repair. 50. Disconnect inline connector X072. Use a multimeter to check for continuity between connector X072 pin J or P on the straw hood front (SW) harness side and chassis ground. A. If continuity is found, erase the fault code and continue operation. B. If no continuity is found, continue with Step 51. 51. Disconnect inline connector X025. Use a multimeter to check for continuity between connector X025 pin 14 on the expansion (EX) harness side and chassis ground. A. If continuity is found, the open circuit is in the straw hood front (SW) harness between connector X025 pin 14 and the harness splice on wire 785 gray. Locate the open and repair. B. If no continuity is found, the open circuit is in the expansion (EX) harness between connector X025 pin 14 and connector X013 pin J2-1 on wire 785 gray. Locate the open and repair. 52. If the upper sieve motor and lower sieve motor do not operate in either direction, and there are no error codes indicated, the supply power for the circuit may not be present. Remove fuse F27 and inspect. A. Fuse has failed. Go to Step 53. B. Fuse is okay. Go to Step 56. 53. If fuse has failed, replace the fuse. A. If fuse immediately fails, a short to ground exists on the wires to the CCM3 module connectors. Continue with Step 54. B. Fuse is okay. Go to Step 56.

55-179

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 54. Disconnect inline connector X005. Use a multimeter to check for continuity between the harness end of connector X005 pin 4 on the main frame (MF) harness side and chassis ground. A. If no continuity is found, there is a short to ground in the cab main (CM) harness between fuse F27 on the fuse panel and connector X005 pin 4 wire 031 red. Locate the short and repair. B. If continuity is found, continue with Step 55. 55. Disconnect inline connector X034. Use a multimeter to check for continuity between the harness end of connector X034 pin 2 on the expansion (EX) harness side and chassis ground. A. If no continuity is found, there is a short to ground in the main frame (MF) harness between connector X034 pin 2 and connector X005 pin 4 wire 031 red. Locate the short and repair. B. If continuity is found, there is a short to ground in the expansion (EX) harness between connector X034 pin 2, connector X013 pin J2-11 and connector X014 pin J3-7 on one of the following wires: Wire 031 red, connector X034 pin 2 to harness splice Wire 511 red, harness splice to connector X013 pin J2-11 Wire 512 red, harness splice to connector X014 pin J3-7 Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Locate the short to ground and repair. 56. Test for 12V power at connector X013 pin J2-11 on the CCM3 module under the cab. A. If there is no power, there is an open circuit on the power wires to the CCM3 module. Continue with step 57. B. If there is power, go to Step 59. 57. Disconnect inline connector X005. Use a multimeter to check for 12V at connector X005 pin 4 on the cab main (CM) harness side. A. If there is no power, there is an open circuit in the cab main (CM) harness between fuse F27 on the fuse panel and connector X005 pin 4 wire 031 red. Locate the open and repair. B. If power is found, continue with Step 58. 58. Disconnect inline connector X034. Use a multimeter to check for 12V at connector X034 pin 2 on the main frame (MF) harness side. A. If no power is found, there is an open circuit in the main frame (MF) harness between connector X034 pin 2 and connector X005 pin 4 wire 031 red. Locate the open and repair. B. If power is found, there is an open circuit in the expansion (EX) harness between connector X034 pin 2 and connector X013 pin J2-11 wire 031 red or 511 red. Locate the open and repair. 59. Test for continuity to ground at connector X013 pin J2-3 on the expansion (EX) harness side of CCM3 module under the cab. A. If there is no continuity to ground, there is an open circuit in the expansion (EX) harness from connector X013 pin J2-3 on CCM3 module to the front frame ground #2 wire 520 black. Locate the open and repair. After repair, go to Step 60. B. If there is continuity to ground, go to Step 60. 60. Once it has been verified that power is being supplied to the module, recheck the circuit operation as described in Step 1. If the fuse fails during the testing, a short to ground on the circuit being operated at the time of failure is causing the fuse to fail.

55-180

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20 E0335 UPPER SIEVE MOTOR

40020080

10010899

50020070

40025228

10020076

10010864

50026216

27 1. 2. 3. 4. 5. 6. 7.

Upper Sieve Actuator M06 Connector X072 Connector X025 Connector X219 Connector X005 Upper/Lower Sieve Relay K18 Connector X013

55-181

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

F-27 = SIEVE/SPREADER FUSE K-18 = UPPER/LOWER SIEVE RELAY M-06 = UPPER SIEVE ACTUATOR M-07 = LOWER SIEVE ACTUATOR

S-35 = UPPER SIEVE REAR ADJUST S-46 = LOWER SIEVE REAR ADJUST

55-182

CLEANING FRAME--21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

B-10 = CHOPPER RPM L-28 = CHAFF SPREADER M-11 = SPREADER PLATE MOTOR S-23 = SPREADER PLATE

B-74 = PSD RPM

TRASH FRAME--23

55-183

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 20

55-184

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 21 -- HHC Diagnostic Codes CONTENTS Section

Description

Page

55-1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE – E0512-03 Feeder Angle Sensor Shorted to High Source Cause: The Header Height Control (HHC) has detected that the Feeder Angle sensor (R-03) circuit is >7.65 volts. Possible failure modes: 1. The HHC Feeder Angle sensor wiring is shorted to 12 volts. 2. HHC internal failure. Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the Feeder Angle sensor circuit is 2.0 -- 7.65 volts. A. If the voltage reading is >7.65 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connectors are fully installed. Inspect the terminals and wires at each connector for pushed back or corroded terminals or damaged wires. Flex the harness involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Verify the HHC is good. Turn off the ignition switch. Disconnect the Main Frame harness connector X281. Using the proper tool, remove pin 14 wire 740 yellow from connector X281. With the wire removed from the connector, reconnect connector X281.Turn the ignition back on and recheck the Feeder Angle sensor voltage. A. If the voltage now reads <2.0 volts, the HHC is good. Continue with Step 3. B. If the voltage reading is still >7.65 volts, then the fault is in the HHC. Reinstall the wire removed for troubleshooting. Reload the system software to see if the fault code clears. If the fault is still present after reloading the software, replace the HHC. Continue with Step 4. 3. Locate the shorted wire. Turn off the ignition switch. Disconnect Feeder Angle sensor R-03, connector X174. Turn the ignition on. Using a voltmeter, measure the voltage at pin 2 of the Main Frame harness connector X174. A. If the voltage reading is <2.0 volts, then the fault may be intermittent. Continue with Step 4. B. If the voltage reads >7.65 volts, then the fault is in the respective wire 740 yellow. Locate and repair the short in the main frame (MF) harness between connector X174 pin 2 and connector X281 pin 14. Continue with Step 4. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-2

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0512-05 Feeder Angle Sensor Line Disconnected Cause: The feeder angle sensor (R-03) circuit is open or shorted to ground. Possible failure modes: 1. Sensor signal wiring is open or shorted to ground. 2. Loss of power to the sensor. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. Fully raise and lower the feeder several times while monitoring the voltage; the voltage should stay within range, and should change smoothly with feeder movement. The proper voltage range for a properly adjusted sensor is 2.5 to 7.5 volts. A. If the voltage reading is low (0 to 2.0 volts) out of range continue with Step 2. B. If the voltage reading is out of range, but between 2.0 to 7.7 volts, the sensor is operating properly, but needs to be adjusted into the proper range. Refer to Chapter 1 in this section for more information. C. If the voltage reading is within the proper limits, the circuit may not be open at this time. Continue the troubleshooting at Step 8. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Disconnect connector X174, and use a multimeter to test for voltage on connector X174 pin 3 on the main frame (MF) harness side. There should be 10 volts present. A. If 10 volts is found, continue with Step 5. B. If no voltage is found, continue with Step 3. 3. Disconnect connector X281 from the HHC module. Use a multimeter to test for continuity between connector X174 pin 3 and connector X281 pin 5. A. If continuity is found, continue with Step 4. B. If no continuity is found, there is an open circuit in the main frame (MF) harness between connector X174 pin 3 and connector X281 pin 5 on one of the following wires: Wire 751 pink, connector X174 pin 3 to MF harness splice Wire 474 pink, MV harness splice to connector X281 pin 5 Locate the open and repair.

55-3

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 4. Use a multimeter to test for continuity between connector X281 pin 5 and chassis ground. A. If continuity is found, the regulated voltage circuit is shorted to ground, and the HHC module is no longer powering this circuit. Check for fault code E0525 HHC 10V Reference Voltage in the error history, and correct this fault. B. If no continuity is found, the HHC module is not powering the 10V Reference Voltage circuit due to an internal fault. Replace the HHC module. 5. The voltage reading on the display monitor is low out of range. Disconnect connector X174. Use a multimeter to check for continuity between connector X174 pin 2 on the main frame (MF) harness side and ground. A. If continuity is found, continue with Step 6. B. If no continuity is found, continue with Step 7. 6. The voltage on the display monitor is low out of range. Disconnect connector X281. Check for continuity between connector X281 pin 14 on the module and chassis ground. A. If no continuity is found, there is a short to ground in the main frame (MF) harness between connector X281 pin 14 and connector X174 pin 2 wire 740 yellow. Find the short to ground and repair. B. If continuity is found, there is an internal short to ground within the HHC module. Replace the module. 7. The voltage reading on the display monitor is low out of range. Disconnect connector X174 and connector X281. Use a multimeter to check for continuity between connector X174 pin 2 and connector X281 pin 14. A. If continuity is found, the open is in the sensor. Replace the sensor. B. If no continuity is found, there is an open circuit in the main frame (MF) harness between connector X174 pin 2 and connector X281 pin 14 wire 740 yellow. Locate the open and repair. 8. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation.

55-4

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0512-11 Feeder Angle Sensor Unidentified Failure Code Cause: The feeder angle sensor (R-03) circuit is shorted to high voltage, or the sensor ground is open. Possible failure modes: 1. Sensor supply or signal wiring is shorted to high voltage (12V). 2. Sensor ground wiring is open. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. Fully raise and lower the feeder several times while monitoring the voltage; the voltage should stay within range, and should change smoothly with feeder movement. The proper voltage range for a properly adjusted sensor is 2.5 to 7.5 volts. A. If the voltage reading is high (7.7 to 12.0 volts) out of range continue with Step 2. B. If the voltage reading is out of range, but between 2.0 to 7.7 volts, the sensor is operating properly, but needs to be adjusted into the proper range. Refer to Chapter 1 in this section for more information. C. If the voltage reading is within the proper limits, the circuit may not be shorted at this time. Continue the troubleshooting at Step 8. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low out of range. Disconnect connector X174, and use a multimeter to test for continuity to ground on connector X174 pin 1 on the main frame (MF) harness side. A. If continuity is found, continue with Step 4. B. If no continuity is found, continue with Step 3. 3. Disconnect connector X281 from the HHC module. Use a multimeter to test for continuity between connector X174 pin 1 and connector X281 pin 4. A. If continuity is found, the HHC module is not supplying a ground path for the sensor. Use the display monitor, reference Section 55 Chapter 2, if needed, to verify that the HHC module is online. If the HHC module is online, and other hydraulic functions are operating, replace the HHC module. B. If no continuity is found, there is an open circuit in the main frame (MF) harness between connector X174 pin 1 and connector X281 pin 4 on one of the following wires: Wire 756 blue, connector X174 pin 1 to MF harness splice Wire 472 blue, MF harness splice to connector X281 pin 4 Locate the open and repair. 4. Disconnect connector X174, and use a multimeter to test for voltage on connector X174 pin 2 on the main frame (MF) harness side. There should not be any voltage present. A. If no voltage is found, continue with Step 5. B. If high (>7.7V) voltage is found, there is a short to high voltage in the main frame (MF) harness between connector X174 pin 2 and connector X281 pin 14 wire 740 yellow. Locate the short and repair.

55-5

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 5. Disconnect connector X174, and use a multimeter to test for voltage on connector X174 pin 3 on the main frame (MF) harness side. There should be 10 volts present. A. If 10 volts is found, continue with Step 9. B. If high (>10V) voltage is found, continue with Step 6. NOTE: This supply circuit is also used to supply power to the header lift pressure and stubble height sensors, so a short to 12 volts anywhere on the supply circuit will activate this error code. 6. Disconnect connector X032 (header connector), and use a multimeter to test for voltage on the feeder (FE) harness end of connector X032 pin 5 or 23. A. If 10 volts is found, there is a short to high voltage in the header (HH) harness to the sensor supply circuit. Refer to the appropriate header Operator’s manual for wiring information. Locate the short and repair. B. If high voltage is found, continue with Step 7. 7. Disconnect connector X007, and use a multimeter to test for voltage on the front frame (FF) harness end of connector X007 pin 26. A. If 10 volts is found, there is a short to high voltage in the feeder (FE) harness between connector X007 pin 26 and connector X032 pin 5 or 23 on one of the following wires: Wire 758 pink, connector X007 pin 26 to FE harness splice Wire 848 pink, FE harness splice to connector X032 pin 5 Wire 849 pink, FE harness splice to connector X032 pin 23 Locate the short and repair. B. If high voltage is found, continue with Step 8. 8. Disconnect connector X008, and use a multimeter to test for voltage on the main frame (MF) harness end of connector X008 pin 18. A. If 10 volts is found, there is a short to high voltage in the front frame (FF) harness between connector X008 pin 18 and connector X007 pin 26 wire 758 pink. Locate the short and repair. B. If high voltage is found, there is a short to high voltage in the main frame (MF) harness between connector X008 pin 18 and connector X281 pin 5 on one of the following wires: Wire 751 pink, connector X174 pin 3 to MF harness splice Wire 758 pink, MF harness splice to connector X008 pin 18 Wire 728 pink, connector X279 pin 3 to MF harness splice Wire 474 pink, MF harness splice to connector X281 pin 5 Locate the short and repair. 9. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation. If the fault code immediately resets, replace the HHC module with a known good one.

55-6

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE – E0512-14 Feeder Angle Sensor Special Instructions Cause: The Header Height Control (HHC) has detected that the Feeder Angle sensor (R-03) circuit connection was interrupted and then restored. Possible failure modes: 1. The HHC Feeder Angle sensor wiring is intermittent. 2. HHC internal failure. Solution: 1. This fault will appear when the connection is intermittent, or when the header is disconnected and then re-connected. A. If the header was just disconnected, clear the error by pressing the Header Up button and continue operation. B. If the header has not been disconnected, continue troubleshooting at Step 2. 2. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. Specifically check HHC Module A-07 connector X281 and Feeder Angle potentiometer R-03 connector X174. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-7

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 E0512 FEEDER ANGLE SENSOR

1 2

40025215

10020031

50026217

1 1. 2.

Feeder Angle Sensor R03 Connector X281

55-8

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

HEADER FRAME--14

A-07 = HHC MODULE B-29 = HEADER LIFT PRESSURE L-06 = HEADER HEIGHT ACCUMULATOR L-18 = LATERAL FLOAT CW

L-19 = LATERAL FLOAT CCW R-02 = LATERAL FLOAT POT R-03 = FEEDER ANGLE R-12 = LEFT STUBBLE HEIGHT

55-9

R-13 = RIGHT STUBBLE HEIGHT

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE – E0513-03 Header Lift Pressure Sensor Shorted to High Source Cause: The Header Height Control (HHC) has detected that the Header Lift Pressure sensor (B-29) circuit is >7.85 volts. Possible failure modes: 1. The HHC Header Lift Pressure sensor wiring is shorted to 12 volts. 2. HHC internal failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the Header Lift Pressure sensor circuit is 0.3 -- 7.65 volts. A. If the voltage reading is >7.85 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connectors are fully installed. Inspect the terminals and wires at each connector for pushed back or corroded terminals or damaged wires. Flex the harness involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Verify the HHC is good. Turn off the ignition switch. Disconnect the Main Frame (MF) harness connector X281. Using the proper tool, remove pin 9 wire 722 yellow from connector X281. With the wire removed from the connector, reconnect connector X281.Turn the ignition back on and recheck the Header Lift Pressure sensor voltage. A. If the voltage now reads <0.3 volts, the HHC is good. Continue with Step 3. B. If the voltage reading is still >7.85 volts, then the fault is in the HHC. Reinstall the wire removed for troubleshooting. Reload the system software to see if the fault code clears. If the fault is still present after reloading the software, replace the HHC. Continue with Step 4. 3. Locate the shorted wire. Turn off the ignition switch. Disconnect Header Lift Pressure sensor B-29, connector X279. Turn the ignition on. Using a voltmeter, measure the voltage at pin 2 of the Main Frame (MF) harness connector X279. A. If the voltage reading is <0.3 volts, then the fault may be intermittent. Continue with Step 4. B. If the voltage reads >7.85 volts, then the fault is in the respective wire 722 yellow. Locate and repair the short in the Main Frame (MF) harness between connector X279 pin 2 and connector X281 pin 9. Continue with Step 4. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-10

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0513-05 Header Lift Pressure sens Line Disconnected Cause: The header lift pressure sensor (B-29) circuit is open or shorted to ground. Possible failure modes: 1. Sensor signal wiring is open or shorted to ground. 2. Loss of power to the sensor. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. Fully raise and lower the feeder several times while monitoring the voltage; the voltage should stay within the range, and should change smoothly with feeder movement. The proper operating voltage range of the sensor is 2.5 to 7.5 volts. A. If the voltage reading is low (<0.3V) out of range continue with Step 2. B. If the voltage reading is within the proper limits, the circuit may not be open at this time. Continue the troubleshooting at Step 8. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Disconnect connector X279, and use a multimeter to test for voltage on connector X279 pin 3 on the main frame (MF) harness side. There should be 10 volts present. A. If 10 volts is found, continue with Step 5. B. If no voltage is found, continue with Step 3. 3. Disconnect connector X281 from the HHC module. Use a multimeter to test for continuity between connector X279 pin 3 and connector X281 pin 5. A. If continuity is found, continue with Step 4. B. If no continuity is found, there is an open circuit in the main frame (MF) harness between connector X279 pin 3 and connector X281 pin 5 wire 728 pink or 474 pink. Locate the open and repair. 4. Use a multimeter to test for continuity between connector X281 pin 5 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the regulated voltage circuit is shorted to ground, and the HHC module is no longer powering this circuit. Check for fault code E0525 HHC 10V Reference Voltage in the error history, and correct this fault. B. If no continuity is found, the HHC module is not powering the 10V Reference Voltage circuit due to an internal fault. Replace the HHC module.

55-11

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 5. The voltage reading on the display monitor is low out of range. Disconnect connector X279. Use a multimeter to check for continuity between connector X279 pin 2 on the main frame (MF) harness side and ground. A. If continuity is found, continue with Step 6. B. If no continuity is found, continue with Step 7. 6. The voltage on the display monitor is low out of range. Disconnect connector X281. Check for continuity between connector X281 pin 9 on the module and chassis ground. A. If no continuity is found, there is a short to ground in the main frame (MF) harness between connector X281 pin 9 and connector X279 pin 2 wire 722 yellow. Find the short to ground and repair. B. If continuity is found, there is an internal short to ground within the HHC module. Replace the module. 7. The voltage reading on the display monitor is low out of range. Disconnect connector X279 and connector X281. Use a multimeter to check for continuity between connector X279 pin 2 and connector X281 pin 9. A. If continuity is found, the open is in the sensor. Replace the sensor. B. If no continuity is found, there is an open circuit in the main frame (MF) harness between connector X279 pin 2 and connector X281 pin 9 wire 722 yellow. Locate the open and repair. 8. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation.

55-12

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0513-11 Header Lift Pressure sens Unidentified Failure Code Cause: The header lift pressure sensor (B-29) circuit is shorted to high voltage, or the sensor ground is open. Possible failure modes: 1. Sensor supply or signal wiring is shorted to high voltage (12V). 2. Sensor ground wiring is open. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. Fully raise and lower the feeder several times while monitoring the voltage; the voltage should stay within the range, and should change smoothly with feeder movement. The proper operating voltage range of the sensor is 2.5 to 7.5 volts. A. If the voltage reading is high (>9.8V) out of range continue with Step 2. B. If the voltage reading is within the proper limits, the circuit may not be open or shorted to ground at this time. Continue the troubleshooting at Step 9. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high out of range. Disconnect connector X279, and use a multimeter to test for continuity to ground on connector X279 pin 1 on the main frame (MF) harness side. A. If continuity is found, continue with Step 4. B. If no continuity is found, continue with Step 3. 3. Disconnect connector X281 from the HHC module. Use a multimeter to test for continuity between connector X279 pin 1 and connector X281 pin 4. A. If continuity is found, the HHC module is not supplying a ground path for the sensor. Use the display monitor, reference Section 55 Chapter 2, if needed, to verify that the HHC module is online. If the HHC module is online, and other hydraulic functions are operating, replace the HHC module. B. If no continuity is found, there is an open circuit in the main frame (MF) harness between connector X279 pin 1 and connector X281 pin 4 wire 725 blue or 472 blue. Locate the open and repair. 4. Disconnect connector X279, and use a multimeter to test for voltage on connector X279 pin 2 on the main frame (MF) harness side. There should not be any voltage present. A. If no voltage is found, continue with Step 5. B. If high (>7.7V) voltage is found, there is a short to high voltage in the main frame (MF) harness between connector X279 pin 2 and connector X281 pin 9 wire 722 yellow. Locate the short and repair.

55-13

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 5. Disconnect connector X279, and use a multimeter to test for voltage on connector X279 pin 3. There should be 10 volts present. A. If 10 volts is found, continue with Step 9. B. If high (>10V) voltage is found, continue with Step 6. NOTE: This supply circuit is also used to supply power to the feeder angle and stubble height sensors, so a short to 12 volts anywhere on the supply circuit will activate this error code. 6. Disconnect connector X032 (header connector), and use a multimeter to test for voltage on the feeder (FE) harness end of connector X032 pin 5 or 23. A. If 10 volts is found, there is a short to high voltage in the header (HH) harness to the sensor supply circuit. Refer to the appropriate header Operator’s manual for wiring information. Locate the short and repair. B. If high voltage is found, continue with Step 7. 7. Disconnect connector X007, and use a multimeter to test for voltage on the front frame (FF) harness end of connector X007 pin 26. A. If 10 volts is found, there is a short to high voltage in the feeder (FE) harness between connector X007 pin 26 and connector X032 pin 5 or 23 on one of the following wires: Wire 758 pink, connector X007 pin 26 to FE harness splice Wire 848 pink, FE harness splice to connector X032 pin 5 Wire 849 pink, FE harness splice to connector X032 pin 23 Locate the short and repair. B. If high voltage is found, continue with Step 8. 8. Disconnect connector X008, and use a multimeter to test for voltage on the main frame (MF) harness end of connector X008 pin 18. A. If 10 volts is found, there is a short to high voltage in the front frame (FF) harness between connector X008 pin 18 and connector X007 pin 26 wire 758 pink. Locate the short and repair. B. If high voltage is found, there is a short to high voltage in the main frame (MF) harness between connector X008 pin 18 and connector X281 pin 5 on one of the following wires: Wire 751 pink, connector X174 pin 3 to MF harness splice Wire 758 pink, MF harness splice to connector X008 pin 18 Wire 728 pink, connector X279 pin 3 to MF harness splice Wire 474 pink, MF harness splice to connector X281 pin 5 Locate the short and repair. 9. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation. If the fault code immediately resets, replace the HHC module with a known good one.

55-14

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE – E0513-14 Header Lift Pressure Sensor Special Instructions Cause: The Header Height Control (HHC) has detected that the Header Lift Pressure sensor (B-29) circuit connection was interrupted and then restored. Possible failure modes: 1. The HHC Header Lift sensor wiring is intermittent. 2. HHC internal failure. Solution: 1. This fault will appear when the connection is intermittent, or when the header is disconnected and then re-connected. A. If the header was just disconnected, clear the error by pressing the Header Up button and continue operation. B. If the header has not been disconnected, continue troubleshooting at Step 2. 2. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. Specifically check HHC Module A-07 connector X281, and Header Lift Pressure sensor B-29 connector X279. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-15

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 E0513 HEADER LIFT PRESSURE SENSOR

1 2 10020031

50026217

2 1. 2.

Header Lift Pressure Sensor B29 Connector X281

55-16

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

HEADER FRAME--14

A-07 = HHC MODULE B-29 = HEADER LIFT PRESSURE L-06 = HEADER HEIGHT ACCUMULATOR L-18 = LATERAL FLOAT CW

L-19 = LATERAL FLOAT CCW R-02 = LATERAL FLOAT POT R-03 = FEEDER ANGLE R-12 = LEFT STUBBLE HEIGHT

55-17

R-13 = RIGHT STUBBLE HEIGHT

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0514-00 R Stubble Height / Flex R Valid Above Normal Context: The header height control function works by measuring the voltage of sensors linked to the header skid plates (or shoes). The skid plates move independently of the header, tracking the ground to the full limit of their up and down movement. When the voltage indicates that the header is too low or too high, the system will compensate by adjusting the header height. There is a low and a high limit to the movement of the skid plate, one limit is when the head is fully lowered, with the full weight of the head resting on the skid plates, the other limit is when the head is just off the ground, and the skid plates hang down without touching the ground. There must be a 4 volt minimum range of voltage change from fully lowered to an off the ground position to provide smooth operation of the system. The maximum change permitted is 5 volts or a fault will occur. Cause: The Header Height Control (HHC) has detected that the R Stubble Height / Flex R (R-13) circuit voltage is >7.5 volts and <7.85 volts. Possible failure modes: 1. The Right Stubble Height sensor (R-13) out of adjustment. 2. The Right Stubble Height sensor (R-13) is faulty. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. Check the header raised voltage limit with the header just off the ground. The skid plates will be supported by chains or straps that are part of the header when the header is off the ground. Check the header lowered voltage limit with the header completely lowered. NOTE: If the header is not fully lowered on the ground, the voltage may go out of range during operation, causing a malfunction of the header height control. Be sure to take voltage readings with the header fully lowered. The normal operating range for the R Stubble Height / Flex R circuit is 2.5 -- 7.5 volts. A. If the high limit voltage reading is >7.5 volts, or the low limit voltage is <2.5 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue with Step 3. 2. Adjust the sensor. Locate the Right Stubble Height sensor. (Header configurations vary; refer to your header manual as necessary.) Loosen the sensor mounting bolts. Rotate the sensor CW to increase voltage and CCW to decrease voltage. (Again, header configurations vary, and this may be reversed.) The difference between high and low voltage limits must stay between 4 and 5 volts. Re-tighten the sensor mounting bolts. A. Repeat the high and low voltage checks as described previously. If the voltage now reads between 2.5 and 7.5 volts, the HHC is good and the adjustment of the sensor is complete. Continue with Step 3. B. If the voltage reading is still out of tolerance after several adjustment attempts then replace the sensor and re-test. If replacing the sensor does not correct the fault, then reload the system software and retest. If the fault still persists, replace the HHC. Continue with Step 3. 3. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-18

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0514-01 R Stubble Height / Flex R Valid Below Normal Context: The header height control function works by measuring the voltage of sensors linked to the header skid plates (or shoes). The skid plates move independently of the header, tracking the ground to the full limit of their up and down movement. When the voltage indicates that the header is too low or too high, the system will compensate by adjusting the header height. There is a low and a high limit to the movement of the skid plate, one limit is when the head is fully lowered, with the full weight of the head resting on the skid plates, the other limit is when the head is just off the ground, and the skid plates hang down without touching the ground. There must be a 4 volt minimum range of voltage change from fully lowered to an off the ground position to provide smooth operation of the system. The maximum change permitted is 5 volts or a fault will occur. Cause: The Header Height Control (HHC) has detected that the R Stubble Height / Flex R (R-13) circuit voltage is <2.5 volts and >0.3 volts. Possible failure modes: 1. The Right Stubble Height sensor (R-13) out of adjustment. 2. The Right Stubble Height sensor (R-13) is faulty. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. Check the header raised voltage limit with the header just off the ground. The skid plates will be supported by chains or straps that are part of the header when the header is off the ground. Check the header lowered voltage limit with the header completely lowered. NOTE: If the header is not fully lowered on the ground, the voltage may go out of range during operation, causing a malfunction of the header height control. Be sure to take voltage readings with the header fully lowered. The normal operating range for the R Stubble Height / Flex R circuit is 2.5 -- 7.5 volts. A. If the high limit voltage reading is >7.5 volts, or the low limit voltage is <2.5 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue with Step 3. 2. Adjust the sensor. Locate the Right Stubble Height sensor. (Header configurations vary; refer to your header manual as necessary.) Loosen the sensor mounting bolts. Rotate the sensor CW to increase voltage and CCW to decrease voltage. (Again, header configurations vary, and this may be reversed.) The difference between high and low voltage limits must stay between 4 and 5 volts. Re-tighten the sensor mounting bolts. A. Repeat the high and low voltage checks as described previously. If the voltage now reads between 2.5 and 7.5 volts, the HHC is good and the adjustment of the sensor is complete. Continue with Step 3. B. If the voltage reading is still out of tolerance after several adjustment attempts then replace the sensor and re-test. If replacing the sensor does not correct the fault, then reload the system software and retest. If the fault still persists, replace the HHC. Continue with Step 3. 3. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE – E0514-03 R Stubble Height / Flex R Shorted to High Source Cause: The Header Height Control (HHC) has detected that the R Stubble Height / Flex R (R-13) circuit is >7.85 volts. Possible failure modes: 1. The HHC Right Stubble Height sensor wiring is shorted to 12 volts. 2. HHC internal failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the R Stubble Height / Flex R circuit is 2.5 -- 7.5 volts. A. If the voltage reading is >7.85 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connectors are fully installed. Inspect the terminals and wires at each connector for pushed back or corroded terminals or damaged wires. Flex the harness involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Verify the HHC is good. Turn off the ignition switch. Disconnect the Main Frame harness connector X281. Using the proper tool, remove pin 16 wire 739 yellow from connector X281. With the wire removed from the connector, reconnect connector X281.Turn the ignition back on and recheck the Header Lift Pressure sensor voltage. A. If the voltage now reads <0.3 volts, the HHC is good. Continue with Step 3. B. If the voltage reading is still >7.85 volts, then the fault is in the HHC. Reinstall the wire removed for troubleshooting. Reload the system software to see if the fault code clears. If the fault is still present after reloading the software, replace the HHC. Continue with Step 4. 3. Locate the shorted wire. Turn off the ignition switch. Disconnect Right Stubble Height sensor R-13, connector X306. Turn the ignition on. Using a voltmeter, measure the voltage at pin 2 of the Header harness (HH) connector X306. A. If the voltage reading is <0.3 volts, then the fault may be intermittent. Continue with Step 4. B. If the voltage reads >7.85 volts, then the fault is in the respective wire 739 yellow. Locate and repair the short. Inspect the Header harness (HH) between connector X306 pin 2 and connector X032 pin 2, and then between Feeder (FE) harness connector X306 pin 2 and connector X007 pin 16. Then inspect the Front Frame (FF) harness between connector X007 pin 16 and connector X008 pin 24, and finally between Main Frame (MF) harness connector X008 pin 24 and connector X281 pin 16. Continue with Step 4. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-20

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0514-05 R Stubble Height / Flex R Line Disconnected Cause: The right stubble height sensor (R-13) circuit is open or shorted to ground. Possible failure modes: 1. Sensor signal wiring is open or shorted to ground. 2. Loss of power to the sensor. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. Manually raise the header above the ground, and then lower the header fully against the ground to move the sensors through their operating range. The voltage should stay within the range, and should change smoothly with header movement. The proper voltage range for a properly adjusted sensor is 2.5 to 7.5 volts. A. If the voltage reading is low (<0.3V) out of range, continue with Step 2. B. If the voltage reading is out of range, but between 0.3 to 7.9 volts, the sensor is operating properly, but needs to be adjusted into the proper range. Refer to the header Operator’s manual for proper adjustment information. C. If the voltage reading is within the proper limits, the circuit may not be open at this time. Continue the troubleshooting at Step 17. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Disconnect connector X306, and use a multimeter to test for voltage on connector X306 pin 3 on the header (HH) harness side. There should be 10 volts present. A. If 10 volts is found, continue with Step 8. B. If no voltage is found, continue with Step 3. 3. Disconnect connector X032, and use a multimeter to test for voltage on connector X032 pin 23 on the feeder (FE) harness side. There should be 10 volts present. A. If 10 volts is found, there is an open circuit in the header (HH) harness between connector X306 pin 3 and connector X032 pin 23 wire 849 pink. Locate the open and repair. B. If no voltage is found, continue with Step 4. 4. Disconnect connector X007, and use a multimeter to test for voltage on connector X007 pin 26 on the front frame (FF) harness side. There should be 10 volts present. A. If 10 volts is found, there is an open circuit in the feeder (FE) harness between connector X032 pin 23 and connector X007 pin 26 wire 849 pink or 758 pink. Locate the open and repair. B. If no voltage is found, continue with Step 5.

55-21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 5. Disconnect connector X008, and use a multimeter to test for voltage on connector X008 pin 18 on the main frame (MF) harness side. There should be 10 volts present. A. If 10 volts is found, there is an open circuit in the front frame (FF) harness between connector X007 pin 26 and connector X008 pin 18 wire 758 pink. Locate the open and repair. B. If no voltage is found, continue with Step 6. 6. Disconnect connector X281 from the HHC module. Use a multimeter to test for continuity between connector X008 pin 18 and connector X281 pin 5. A. If continuity is found, continue with Step 7. B. If no continuity is found, there is an open circuit in the main frame (MF) harness between connector X008 pin 18 and connector X281 pin 5 on wire 758 pink or 474 pink. Locate the open and repair. 7. Use a multimeter to test for continuity between connector X281 pin 5 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the regulated voltage circuit is shorted to ground, and the HHC module is no longer powering this circuit. Check for fault code E0525 HHC 10V Reference Voltage in the error history, and correct this fault. B. If no continuity is found, the HHC module is not powering the 10V Reference Voltage circuit due to an internal fault. Replace the HHC module. 8. The voltage reading on the display monitor is low out of range. Disconnect connector X306. Use a multimeter to check for continuity between connector X306 pin 2 on the header (HH) harness side and ground. A. If continuity is found, continue with Step 9. B. If no continuity is found, continue with Step 13. 9. Disconnect connector X032. Check for continuity between connector X032 pin 2 on the feeder (FE) harness side and chassis ground. A. If continuity is found continue with Step 10. B. If no continuity is found, there is a short to ground in the header (HH) harness between connector X306 pin 2 and connector X032 pin 2 wire 739 yellow. Find the short to ground and repair. 10. Disconnect connector X007. Check for continuity between connector X007 pin 16 on the front frame (FF) harness side and chassis ground. A. If continuity is found continue with Step 11. B. If no continuity is found, there is a short to ground in the feeder (FE) harness between connector X032 pin 2 and connector X007 pin 16 wire 739 yellow. Find the short to ground and repair. 11. Disconnect connector X008. Check for continuity between connector X008 pin 24 on the main frame (MF) harness side and chassis ground. A. If continuity is found continue with Step 12. B. If no continuity is found, there is a short to ground in the front frame (FF) harness between connector X007 pin 16 and connector X008 pin 24 wire 739 yellow. Find the short to ground and repair.

55-22

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 12. The voltage on the display monitor is low out of range. Disconnect connector X281. Check for continuity between connector X281 pin 16 on the module and chassis ground. A. If no continuity is found, there is a short to ground in the main frame (MF) harness between connector X281 pin 16 and connector X008 pin 24 wire 739 yellow. Find the short to ground and repair. B. If continuity is found, there is an internal short to ground within the HHC module. Replace the module. 13. Key off. Disconnect connector X281, and install a jumper wire between connector X281 pin 16 on the main frame (MF) harness side and chassis ground. Use a multimeter to check for continuity between connector X306 pin 2 on the header (HH) harness side and chassis ground. A. If continuity is found, the open is in the sensor. Replace the sensor. B. If no continuity is found, continue with Step 14. 14. Disconnect connector X032. Use a multimeter to check for continuity between connector X032 pin 2 on the feeder (FE) harness side and chassis ground. A. If continuity is found, there is an open circuit in the header (HH) harness between connector X306 pin 2 and connector X032 pin 2 wire 739 yellow. Locate the open and repair. B. If no continuity is found, continue with Step 15. 15. Disconnect connector X007. Use a multimeter to check for continuity between connector X007 pin 16 on the front frame (FF) harness side and chassis ground. A. If continuity is found, there is an open circuit in the feeder (FE) harness between connector X032 pin 2 and connector X007 pin 16 wire 739 yellow. Locate the open and repair. B. If no continuity is found, continue with Step 16. 16. Disconnect connector X008. Use a multimeter to check for continuity between connector X008 pin 24 on the main frame (MF) harness side and chassis ground. A. If continuity is found, there is an open circuit in the front frame (FF) harness between connector X007 pin 16 and connector X008 pin 24 wire 739 yellow. Locate the open and repair. B. If no continuity is found, there is an open circuit in the main frame (MF) harness between connector X008 pin 24 and connector X281 pin 16 wire 739 yellow. Locate the open and repair. 17. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation. If the fault code immediately resets, replace the HHC module with a known good one.

55-23

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0514-11 R Stubble Height / Flex R Unidentified Failure Code Cause: The right stubble height sensor (R-13) circuit is shorted to high voltage, or the sensor ground is open. Possible failure modes: 1. Sensor supply or signal wiring is shorted to high voltage (12V). 2. Sensor ground wiring is open. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. Manually raise the header above the ground, and then lower the header fully against the ground to move the sensors through their operating range. The voltage should stay within the range, and should change smoothly with header movement. The proper voltage range for a properly adjusted sensor is 2.5 to 7.5 volts. A. If the voltage reading is high (>9.8V) out of range, continue with Step 2. B. If the voltage reading is out of range, but between 0.3 to 7.9 volts, the sensor is operating properly, but needs to be adjusted into the proper range. Refer to the header Operator’s manual for proper adjustment information. C. If the voltage reading is within the proper limits, the circuit may not be open at this time. Continue the troubleshooting at Step 15. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high out of range. Disconnect connector X306, and use a multimeter to test for continuity to ground on connector X306 pin 1 on the header (HH) harness side). A. If continuity is found, continue with Step 7. B. If no continuity is found, continue with Step 3. 3. Disconnect connector X032, and use a multimeter to test for continuity to ground on connector X032 pin 25 on the feeder (FE) harness side. A. If continuity is found, there is an open circuit in the header (HH) harness between connector X306 pin 1 and connector X032 pin 25 wire 846 blue. Locate the open and repair. B. If no continuity is found, continue with Step 4. 4. Disconnect connector X007, and use a multimeter to test for continuity to ground on connector X007 pin 28 on the front frame (FF) harness side. A. If continuity is found, there is an open circuit in the feeder (FE) harness between connector X032 pin 25 and connector X007 pin 28 wire 846 blue or 748 blue. Locate the open and repair. B. If no continuity is found, continue with Step 5.

55-24

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 5. Disconnect connector X008, and use a multimeter to test for continuity to ground on connector X008 pin 20 on the main frame (MF) harness side. A. If continuity is found, there is an open circuit in the front frame (FF) harness between connector X007 pin 28 and connector X008 pin 20 wire 748 blue. Locate the open and repair. B. If no continuity is found, continue with Step 6. 6. Disconnect connector X281 from the HHC module. Use a multimeter to test for continuity between connector X008 pin 20 and connector X281 pin 4. A. If continuity is found, the HHC module is not supplying a ground path for the sensor. Reconnect connectors X008 and X281, and use the display monitor, reference Section 55 Chapter 2, if needed, to verify that the HHC module is online. If the HHC module is online, and other hydraulic functions are operating, replace the HHC module. B. If no continuity is found, there is an open circuit in the main frame (MF) harness between connector X008 pin 20 and connector X281 pin 4 on wire 748 blue or 472 blue. Locate the open and repair. 7. Disconnect connector X306, and use a multimeter to test for voltage on connector X306 pin 2 on the header (HH) harness side. There should not be any voltage present. A. If no voltage is found, continue with Step 11. B. If high (>9.8V) voltage is found, continue with Step 8. 8. Disconnect connector X032, and use a multimeter to test for voltage on the feeder (FE) harness end of connector X032 pin 2. There should not be any voltage present. A. If no voltage is found, there is a short to high voltage in the header (HH) harness between connector X306 pin 2 and connector X032 pin 2 wire 739 yellow. Locate the short and repair. B. If high (>9.8V) voltage is found, continue with Step 9. 9. Disconnect connector X007, and use a multimeter to test for voltage on the front frame (FF) harness end of connector X007 pin 16. There should not be any voltage present. A. If no voltage is found, there is a short to high voltage in the feeder (FE) harness between connector X032 pin 2 and connector X007 pin 16 wire 739 yellow. Locate the short and repair. B. If high (>9.8V) voltage is found, continue with Step 10. 10. Disconnect connector X008, and use a multimeter to test for voltage on the main frame (MF) harness end of connector X008 pin 24. There should not be any voltage present. A. If no voltage is found, there is a short to high voltage in the front frame (FF) harness between connector X007 pin 16 and connector X008 pin 24 wire 739 yellow. Locate the short and repair. B. If high (>9.8V) voltage is found, there is a short to high voltage in the main frame (MF) harness between connector X008 pin 24 and connector X281 pin 16 wire 739 yellow. Locate the short and repair. 11. Disconnect connector X306, and use a multimeter to test for voltage on connector X306 pin 3. There should be 10 volts present. A. If 10 volts is found, continue with Step 15. B. If high (>10V) voltage is found, continue with Step 12. NOTE: This supply circuit is also used to supply power to the header lift pressure and feeder angle sensors, so a short to 12 volts anywhere on the supply circuit will activate this error code.

55-25

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 12. Disconnect connector X032 (header connector), and use a multimeter to test for voltage on the feeder (FE) harness end of connector X032 pin 5 or 23. A. If 10 volts is found, there is a short to high voltage in the header (HH) harness to the sensor supply circuit. Refer to the appropriate header Operator’s manual for wiring information. Locate the short and repair. B. If high voltage is found, continue with Step 13. 13. Disconnect connector X007, and use a multimeter to test for voltage on the front frame (FF) harness end of connector X007 pin 26. A. If 10 volts is found, there is a short to high voltage in the feeder (FE) harness between connector X007 pin 26 and connector X032 pin 5 or 23 on one of the following wires: Wire 758 pink, connector X007 pin 26 to FE harness splice Wire 848 pink, FE harness splice to connector X032 pin 5 Wire 849 pink, FE harness splice to connector X032 pin 23 Locate the short and repair. B. If high voltage is found, continue with Step 14. 14. Disconnect connector X008, and use a multimeter to test for voltage on the main frame (MF) harness end of connector X008 pin 18. A. If 10 volts is found, there is a short to high voltage in the front frame (FF) harness between connector X008 pin 18 and connector X007 pin 26 wire 758 pink. Locate the short and repair. B. If high voltage is found, there is a short to high voltage in the main frame (MF) harness between connector X008 pin 18 and connector X281 pin 5 on one of the following wires: Wire 751 pink, connector X174 pin 3 to MF harness splice Wire 758 pink, MF harness splice to connector X008 pin 18 Wire 728 pink, connector X279 pin 3 to MF harness splice Wire 474 pink, MF harness splice to connector X281 pin 5 Locate the short and repair. 15. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation. If the fault code immediately resets, replace the HHC module with a known good one.

55-26

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE – E0514-14 R Stubble Height / Flex R Special Instructions Cause: The Header Height Control (HHC) has detected that the R Stubble Height / Flex R (R-13) sensor circuit connection was interrupted and then restored. Possible failure modes: 1. The HHC R Stubble Height / Flex R sensor wiring is intermittent. 2. HHC internal failure. Solution: 1. This fault will appear when the connection is intermittent, or when the header is disconnected and then re-connected. A. If the header was just disconnected, clear the error by pressing the Header Up button and continue operation. B. If the header has not been disconnected, continue troubleshooting at Step 2. 2. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. Specifically check HHC Module A-07 connector X281, Main Frame harness connector X008, Front Frame harness connector X007, Feeder harness connector X032, and Right Stubble Height sensor R-13 connector X306. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-27

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 E0514 R STUBBLE HEIGHT / FLEX R

3 10020075

10020040

6 40024707

10020031

50026218

3 1. 2. 3. 4. 5. 6.

Right Stubble Height Sensor R13 Left Stubble Height Sensor R12 Connector X032 Connector X007 Connector X008 Connector X281

55-28

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

HEADER FRAME--14

A-07 = HHC MODULE B-29 = HEADER LIFT PRESSURE L-06 = HEADER HEIGHT ACCUMULATOR L-18 = LATERAL FLOAT CW

L-19 = LATERAL FLOAT CCW R-02 = LATERAL FLOAT POT R-03 = FEEDER ANGLE R-12 = LEFT STUBBLE HEIGHT

55-29

R-13 = RIGHT STUBBLE HEIGHT

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0515-00 L Stubble Height / Flex L Valid Above Normal Context: The header height control function works by measuring the voltage of sensors linked to the header skid plates (or shoes). The skid plates move independently of the header, tracking the ground to the full limit of their up and down movement. When the voltage indicates that the header is too low or too high, the system will compensate by adjusting the header height. There is a low and a high limit to the movement of the skid plate, one limit is when the head is fully lowered, with the full weight of the head resting on the skid plates, the other limit is when the head is just off the ground, and the skid plates hang down without touching the ground. There must be a 4 volt minimum range of voltage change from fully lowered to an off the ground position to provide smooth operation of the system. The maximum change permitted is 5 volts or a fault will occur. Cause: The Header Height Control (HHC) has detected that the L Stubble Height / Flex L (R-12) circuit voltage is >7.5 volts and <7.85 volts. Possible failure modes: 1. The Left Stubble Height sensor (R-12) out of adjustment. 2. The Left Stubble Height sensor (R-12) is faulty. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. Check the header raised voltage limit with the header just off the ground. The skid plates will be supported by chains or straps that are part of the header when the header is off the ground. Check the header lowered voltage limit with the header completely lowered. NOTE: If the header is not fully lowered on the ground, the voltage may go out of range during operation, causing a malfunction of the header height control. Be sure to take voltage readings with the header fully lowered. The normal operating range for the L Stubble Height / Flex L circuit is 2.5 -- 7.5 volts. A. If the high limit voltage reading is >7.5 volts, or the low limit voltage is <2.5 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue with Step 3. 2. Adjust the sensor. Locate the Left Stubble Height sensor. (Header configurations vary; refer to your header manual as necessary.) Loosen the sensor mounting bolts. Rotate the sensor CW to increase voltage and CCW to decrease voltage. (Again, header configurations vary, and this may be reversed.) The difference between high and low voltage limits must stay between 4 and 5 volts. Re-tighten the sensor mounting bolts. A. Repeat the high and low voltage checks as described previously. If the voltage now reads between 2.5 and 7.5 volts, the HHC is good and the adjustment of the sensor is complete. Continue with Step 3. B. If the voltage reading is still out of tolerance after several adjustment attempts then replace the sensor and re-test. If replacing the sensor does not correct the fault, then reload the system software and retest. If the fault still persists, replace the HHC. Continue with Step 3. 3. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0515-01 L Stubble Height / Flex L Valid Below Normal Context: The header height control function works by measuring the voltage of sensors linked to the header skid plates (or shoes). The skid plates move independently of the header, tracking the ground to the full limit of their up and down movement. When the voltage indicates that the header is too low or too high, the system will compensate by adjusting the header height. There is a low and a high limit to the movement of the skid plate, one limit is when the head is fully lowered, with the full weight of the head resting on the skid plates, the other limit is when the head is just off the ground, and the skid plates hang down without touching the ground. There must be a 4 volt minimum range of voltage change from fully lowered to an off the ground position to provide smooth operation of the system. The maximum change permitted is 5 volts or a fault will occur. Cause: The Header Height Control (HHC) has detected that the L Stubble Height / Flex L (R-12) circuit voltage is <2.5 volts and >0.3 volts. Possible failure modes: 1. The Left Stubble Height sensor (R-12) out of adjustment. 2. The Left Stubble Height sensor (R-12) is faulty. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. Check the header raised voltage limit with the header just off the ground. The skid plates will be supported by chains or straps that are part of the header when the header is off the ground. Check the header lowered voltage limit with the header completely lowered. NOTE: If the header is not fully lowered on the ground, the voltage may go out of range during operation, causing a malfunction of the header height control. Be sure to take voltage readings with the header fully lowered. The normal operating range for the L Stubble Height / Flex L circuit is 2.5 -- 7.5 volts. A. If the high limit voltage reading is >7.5 volts, or the low limit voltage is <2.5 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue with Step 3. 2. Adjust the sensor. Locate the Left Stubble Height sensor. (Header configurations vary; refer to your header manual as necessary.) Loosen the sensor mounting bolts. Rotate the sensor CW to increase voltage and CCW to decrease voltage. (Again, header configurations vary, and this may be reversed.) The difference between high and low voltage limits must stay between 4 and 5 volts. Re-tighten the sensor mounting bolts. A. Repeat the high and low voltage checks as described previously. If the voltage now reads between 2.5 and 7.5 volts, the HHC is good and the adjustment of the sensor is complete. Continue with Step 3. B. If the voltage reading is still out of tolerance after several adjustment attempts then replace the sensor and re-test. If replacing the sensor does not correct the fault, then reload the system software and retest. If the fault still persists, replace the HHC. Continue with Step 3. 3. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE – E0515-03 L Stubble Height / Flex L Shorted to High Source Cause: The Header Height Control (HHC) has detected that the L Stubble Height / Flex L (R-12) circuit is >7.85 volts. Possible failure modes: 1. The HHC Feeder Angle sensor wiring is shorted to 12 volts. 2. HHC internal failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the L Stubble Height / Flex L circuit is 2.5 -- 7.5 volts. A. If the voltage reading is >7.85 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue troubleshooting at Step 4. NOTE: Visually inspect the wiring harness and connectors. Verify that the connectors are fully installed. Inspect the terminals and wires at each connector for pushed back or corroded terminals or damaged wires. Flex the harness involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Verify the HHC is good. Turn off the ignition switch. Disconnect the Main Frame harness connector X281. Using the proper tool, remove pin 15 wire 738 yellow from connector X281. With the wire removed from the connector, reconnect connector X281.Turn the ignition back on and recheck the Header Lift Pressure sensor voltage. A. If the voltage now reads <0.3 volts, the HHC is good. Continue with Step 3. B. If the voltage reading is still >7.85 volts, then the fault is in the HHC. Reinstall the wire removed for troubleshooting. Reload the system software to see if the fault code clears. If the fault is still present after reloading the software, replace the HHC. Continue with Step 4. 3. Locate the shorted wire. Turn off the ignition switch. Disconnect Left Stubble Height sensor R-12, connector X305. Turn the ignition on. Using a voltmeter, measure the voltage at pin 2 of the Header harness (HH) connector X305. A. If the voltage reading is <0.3 volts, then the fault may be intermittent. Continue with Step 4. B. If the voltage reads >7.85 volts, then the fault is in the respective wire 738 yellow. Locate and repair the short. Inspect the Header harness (HH) between connector X305 pin 2 and connector X032 pin 1, and then between Feeder (FE) harness connector X306 pin 1 and connector X007 pin 15. Then inspect the Front Frame (FF) harness between connector X007 pin 15 and connector X008 pin 23, and finally between Main Frame (MF) harness connector X008 pin 23 and connector X281 pin 15. Continue with Step 4. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0515-05 L Stubble Height / Flex L Line Disconnected Cause: The left stubble height sensor (R-12) circuit is open or shorted to ground. Possible failure modes: 1. Sensor signal wiring is open or shorted to ground. 2. Loss of power to the sensor. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. Manually raise the header above the ground, and then lower the header fully against the ground to move the sensors through their operating range. The voltage should stay within the range, and should change smoothly with header movement. The proper voltage range for a properly adjusted sensor is 2.5 to 7.5 volts. A. If the voltage reading is low (<0.3V) out of range, continue with Step 2. B. If the voltage reading is out of range, but between 0.3 to 7.9 volts, the sensor is operating properly, but needs to be adjusted into the proper range. Refer to the header Operator’s manual for proper adjustment information. C. If the voltage reading is within the proper limits, the circuit may not be open at this time. Continue the troubleshooting at Step 17. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Disconnect connector X305, and use a multimeter to test for voltage on connector X305 pin 3 on the header (HH) harness side. There should be 10 volts present. A. If 10 volts is found, continue with Step 8. B. If no voltage is found, continue with Step 3. 3. Disconnect connector X032, and use a multimeter to test for voltage on connector X032 pin 5 on the feeder (FE) harness side. There should be 10 volts present. A. If 10 volts is found, there is an open circuit in the header (HH) harness between connector X305 pin 3 and connector X032 pin 5 wire 848 pink. Locate the open and repair. B. If no voltage is found, continue with Step 4. 4. Disconnect connector X007, and use a multimeter to test for voltage on connector X007 pin 26 on the front frame (FF) harness side. There should be 10 volts present. A. If 10 volts is found, there is an open circuit in the feeder (FE) harness between connector X032 pin 5 and connector X007 pin 26 wire 848 pink or 758 pink. Locate the open and repair. B. If no voltage is found, continue with Step 5.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 5. Disconnect connector X008, and use a multimeter to test for voltage on connector X008 pin 18 on the main frame (MF) harness side. There should be 10 volts present. A. If 10 volts is found, there is an open circuit in the front frame (FF) harness between connector X007 pin 26 and connector X008 pin 18 wire 758 pink. Locate the open and repair. B. If no voltage is found, continue with Step 6. 6. Disconnect connector X281 from the HHC module. Use a multimeter to test for continuity between connector X008 pin 18 and connector X281 pin 5. A. If continuity is found, continue with Step 7. B. If no continuity is found, there is an open circuit in the main frame (MF) harness between connector X022 pin L and connector X281 pin 5 on wire 758 pink or 474 pink. Locate the open and repair. 7. Use a multimeter to test for continuity between connector X281 pin 5 on the main frame (MF) harness side and chassis ground. A. If continuity is found, the regulated voltage circuit is shorted to ground, and the HHC module is no longer powering this circuit. Check for fault code E0525 HHC 10V Reference Voltage in the error history, and correct this fault. B. If no continuity is found, the HHC module is not powering the 10V Reference Voltage circuit due to an internal fault. Replace the HHC module. 8. The voltage reading on the display monitor is low out of range. Disconnect connector X305. Use a multimeter to check for continuity between connector X305 pin 2 on the header (HH) harness side and ground. A. If continuity is found, continue with Step 9. B. If no continuity is found, continue with Step 13. 9. Disconnect connector X032. Check for continuity between connector X032 pin 1 on the feeder (FE) harness side and chassis ground. A. If continuity is found continue with Step 10. B. If no continuity is found, there is a short to ground in the header (HH) harness between connector X305 pin 2 and connector X032 pin 1 wire 738 yellow. Find the short to ground and repair. 10. Disconnect connector X007. Check for continuity between connector X007 pin 15 on the front frame (FF) harness side and chassis ground. A. If continuity is found continue with Step 11. B. If no continuity is found, there is a short to ground in the feeder (FE) harness between connector X032 pin 1 and connector X007 pin 15 wire 738 yellow. Find the short to ground and repair. 11. Disconnect connector X008. Check for continuity between connector X008 pin 23 on the main frame (MF) harness side and chassis ground. A. If continuity is found continue with Step 12. B. If no continuity is found, there is a short to ground in the front frame (FF) harness between connector X007 pin 15 and connector X008 pin 23 wire 738 yellow. Find the short to ground and repair. 12. The voltage on the display monitor is low out of range. Disconnect connector X281. Check for continuity between connector X281 pin 15 on the module and chassis ground. A. If no continuity is found, there is a short to ground in the main frame (MF) harness between connector X281 pin 15 and connector X008 pin 23 wire 738 yellow. Find the short to ground and repair. B. If continuity is found, there is an internal short to ground within the HHC module. Replace the module.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 13. Key off. Disconnect connector X281, and install a jumper wire between connector X281 pin 15 on the main frame (MF) harness side and chassis ground. Use a multimeter to check for continuity between connector X305 pin 2 on the header (HH) harness side and chassis ground. A. If continuity is found, the open is in the sensor. Replace the sensor. B. If no continuity is found, continue with Step 14. 14. Disconnect connector X032. Use a multimeter to check for continuity between connector X032 pin 1 on the feeder (FE) harness side and chassis ground. A. If continuity is found, there is an open circuit in the header (HH) harness between connector X305 pin 2 and connector X032 pin 1 wire 738 yellow. Locate the open and repair. B. If no continuity is found, continue with Step 15. 15. Disconnect connector X007. Use a multimeter to check for continuity between connector X007 pin 15 on the front frame (FF) harness side and chassis ground. A. If continuity is found, there is an open circuit in the feeder (FE) harness between connector X032 pin 1 and connector X007 pin 15 wire 738 yellow. Locate the open and repair. B. If no continuity is found, continue with Step 16. 16. Disconnect connector X008. Use a multimeter to check for continuity between connector X008 pin 23 on the main frame (MF) harness side and chassis ground. A. If continuity is found, there is an open circuit in the front frame (FF) harness between connector X007 pin 15 and connector X008 pin 23 wire 738 yellow. Locate the open and repair. B. If no continuity is found, there is an open circuit in the main frame (MF) harness between connector X008 pin 23 and connector X281 pin 15 wire 738 yellow. Locate the open and repair. 17. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation. If the fault code immediately resets, replace the HHC module with a known good one.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0515-11 L Stubble Height / Flex L Unidentified Failure Code Cause: The left stubble height sensor (R-12) circuit is shorted to high voltage, or the sensor ground is open. Possible failure modes: 1. Sensor supply or signal wiring is shorted to high voltage (12V). 2. Sensor ground wiring is open. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. Manually raise the header above the ground, and then lower the header fully against the ground to move the sensors through their operating range. The voltage should stay within the range, and should change smoothly with header movement. The proper voltage range for a properly adjusted sensor is 2.5 to 7.5 volts. A. If the voltage reading is high (>9.8V) out of range, continue with Step 2. B. If the voltage reading is out of range, but between 0.3 to 7.9 volts, the sensor is operating properly, but needs to be adjusted into the proper range. Refer to the header Operator’s manual for proper adjustment information. C. If the voltage reading is within the proper limits, the circuit may not be open at this time. Continue the troubleshooting at Step 15. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high out of range. Disconnect connector X305, and use a multimeter to test for continuity to ground on connector X305 pin 1 on the header (HH) harness side. A. If continuity is found, continue with Step 7. B. If no continuity is found, continue with Step 3. 3. Disconnect connector X032, and use a multimeter to test for continuity to ground on connector X032 pin 6 on the feeder (FE) harness side. A. If continuity is found, there is an open circuit in the header (HH) harness between connector X305 pin 1 and connector X032 pin 6 wire 847 blue. Locate the open and repair. B. If no continuity is found, continue with Step 4. 4. Disconnect connector X007, and use a multimeter to test for continuity to ground on connector X007 pin 28 on the front frame (FF) harness side. A. If continuity is found, there is an open circuit in the feeder (FE) harness between connector X032 pin 6 and connector X007 pin 28 wire 847 blue or 748 blue. Locate the open and repair. B. If no continuity is found, continue with Step 5.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 5. Disconnect connector X008, and use a multimeter to test for continuity to ground on connector X008 pin 20 on the main frame (MF) harness side. A. If continuity is found, there is an open circuit in the front frame (FF) harness between connector X007 pin 28 and connector X008 pin 20 wire 748 blue. Locate the open and repair. B. If no continuity is found, continue with Step 6. 6. Disconnect connector X281 from the HHC module. Use a multimeter to test for continuity between connector X008 pin 20 and connector X281 pin 4. A. If continuity is found, the HHC module is not supplying a ground path for the sensor. Reconnect connectors X008 and X281, and use the display monitor, reference Section 55 Chapter 2, if needed, to verify that the HHC module is online. If the HHC module is online, and other hydraulic functions are operating, replace the HHC module. B. If no continuity is found, there is an open circuit in the main frame (MF) harness between connector X008 pin 20 and connector X281 pin 4 on wire 748 blue or 472 blue. Locate the open and repair. 7. Disconnect connector X305, and use a multimeter to test for voltage on connector X305 pin 2 on the header (HH) harness side. There should not be any voltage present. A. If no voltage is found, continue with Step 11. B. If high (>9.8V) voltage is found, continue with Step 8. 8. Disconnect connector X032, and use a multimeter to test for voltage on the feeder (FE) harness end of connector X032 pin 1. There should not be any voltage present. A. If no voltage is found, there is a short to high voltage in the header (HH) harness between connector X305 pin 2 and connector X032 pin 1 wire 738 yellow. Locate the short and repair. B. If high (>9.8V) voltage is found, continue with Step 9. 9. Disconnect connector X007, and use a multimeter to test for voltage on the front frame (FF) harness end of connector X007 pin 15. There should not be any voltage present. A. If no voltage is found, there is a short to high voltage in the feeder (FE) harness between connector X032 pin 1 and connector X007 pin 15 wire 738 yellow. Locate the short and repair. B. If high (>9.8V) voltage is found, continue with Step 10. 10. Disconnect connector X008, and use a multimeter to test for voltage on the main frame (MF) harness end of connector X008 pin 23. There should not be any voltage present. A. If no voltage is found, there is a short to high voltage in the front frame (FF) harness between connector X007 pin 15 and connector X008 pin 23 wire 738 yellow. Locate the short and repair. B. If high (>9.8V) voltage is found, there is a short to high voltage in the main frame (MF) harness between connector X008 pin 23 and connector X008 pin 15 wire 738 yellow. Locate the short and repair.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 11. Disconnect connector X305, and use a multimeter to test for voltage on connector X305 pin 3. There should be 10 volts present. A. If 10 volts is found, continue with Step 15. B. If high (>10V) voltage is found, continue with Step 12. NOTE: This supply circuit is also used to supply power to the header lift pressure and feeder angle sensors, so a short to 12 volts anywhere on the supply circuit will activate this error code. 12. Disconnect connector X032 (header connector), and use a multimeter to test for voltage on the feeder (FE) harness end of connector X032 pin 5 or 23. A. If 10 volts is found, there is a short to high voltage in the header (HH) harness to the sensor supply circuit. Refer to the appropriate header Operator’s manual for wiring information. Locate the short and repair. B. If high voltage is found, continue with Step 13. 13. Disconnect connector X007, and use a multimeter to test for voltage on the front frame (FF) harness end of connector X007 pin 26. A. If 10 volts is found, there is a short to high voltage in the feeder (FE) harness between connector X007 pin 26 and connector X032 pin 5 or 23 on one of the following wires: Wire 758 pink, connector X007 pin 26 to FE harness splice Wire 848 pink, FE harness splice to connector X032 pin 5 Wire 849 pink, FE harness splice to connector X032 pin 23 Locate the short and repair. B. If high voltage is found, continue with Step 14. 14. Disconnect connector X008, and use a multimeter to test for voltage on the main frame (MF) harness end of connector X008 pin 18. A. If 10 volts is found, there is a short to high voltage in the front frame (FF) harness between connector X008 pin 18 and connector X007 pin 26 wire 758 pink. Locate the short and repair. B. If high voltage is found, there is a short to high voltage in the main frame (MF) harness between connector X008 pin 18 and connector X281 pin 5 on one of the following wires: Wire 751 pink, connector X174 pin 3 to MF harness splice Wire 758 pink, MF harness splice to connector X008 pin 18 Wire 728 pink, connector X279 pin 3 to MF harness splice Wire 474 pink, MF harness splice to connector X281 pin 5 Locate the short and repair. 15. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation. If the fault code immediately resets, replace the HHC module with a known good one.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE – E0515-14 L Stubble Height / Flex L Special Instructions Cause: The Header Height Control (HHC) has detected that the L Stubble Height / Flex L (R-12) sensor circuit connection was interrupted and then restored. Possible failure modes: 1. The HHC L Stubble Height / Flex L sensor wiring is intermittent. 2. HHC internal failure. Solution: 1. This fault will appear when the connection is intermittent, or when the header is disconnected and then re-connected. A. If the header was just disconnected, clear the error by pressing the Header Up button and continue operation. B. If the header has not been disconnected, continue troubleshooting at Step 2. 2. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. Specifically check HHC Module A-07 connector X281, Main Frame harness connector X008, Front Frame harness connector X007, Feeder harness connector X032, and Left Stubble Height sensor R-12 connector X305. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 E0515 L STUBBLE HEIGHT / FLEX L

3 10020075

10020040

6 40024707

10020031

50026218

4 1. 2. 3. 4. 5. 6.

Right Stubble Height Sensor R13 Left Stubble Height Sensor R12 Connector X032 Connector X007 Connector X008 Connector X281

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

HEADER FRAME--14

A-07 = HHC MODULE B-29 = HEADER LIFT PRESSURE L-06 = HEADER HEIGHT ACCUMULATOR L-18 = LATERAL FLOAT CW

L-19 = LATERAL FLOAT CCW R-02 = LATERAL FLOAT POT R-03 = FEEDER ANGLE R-12 = LEFT STUBBLE HEIGHT

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R-13 = RIGHT STUBBLE HEIGHT

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0516-05 Lateral Float CCW Valve Line Disconnected Cause: The lateral float CCW valve (L-19) circuit is open. Possible failure modes: 1. Valve supply wiring is open. 2. Bad solenoid. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The proper current range is approximately 1.0 to 1.5 amps. A. If the reading is 0 amps, the circuit is open. Continue with Step 2. B. If the reading is within the proper limits, the circuit is working properly. Continue with Step 16. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Disconnect connector X271 at the lateral float CCW solenoid L19. Use a multimeter to check the resistance of the lateral float CCW solenoid between the two terminals on the coil. The proper resistance range is 2 to 6 ohms. A. If there is no continuity, replace the solenoid. B. If the solenoid is within specification, continue with Step 3. 3. Key off. Disconnect connector X281 at the HHC module, and install a jumper wire between connector X281 pin 13 on the main frame (MF) harness side and chassis ground. Use a multimeter to check for continuity between connector X271 pin 2 on the feeder valve (FV) harness side and chassis ground. A. If there is no continuity, continue with Step 4. B. If there is continuity, continue with Step 6. 4. Key off. Disconnect connector X021, and use a multimeter to check for continuity between connector X021 pin K on the front frame (FF) harness side and chassis ground. A. If there is no continuity to ground, continue with Step 5. B. If there is continuity to ground, there is an open circuit in the feeder valve (FV) harness between connector X271 pin 2 and connector X021 pin K wire 553 blue. Locate the open and repair.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 5. Key off. Disconnect connector X008, and use a multimeter to check for continuity between connector X008 pin 13 on the main frame (MF) harness side and chassis ground. A. If there is no continuity to ground, there is an open circuit in the main frame (MF) harness between connector X008 pin 13 and connector X281 pin 13 wire 555 blue. Locate the open and repair. B. If there is continuity to ground, there is an open circuit in the front frame (FF) harness between connector X021 pin K and connector X008 pin 13 wire 553 blue or 555 blue. Locate the open and repair. 6. Key off. Disconnect connector X281 at the HHC module, and install a jumper wire between connector X281 pin 7 on the main frame (MF) harness side and chassis ground. Use a multimeter to check for continuity between connector X271 pin 1 on the feeder valve (FV) harness side and chassis ground. A. If there is no continuity, continue with Step 7. B. If there is continuity, continue with Step 9. 7. Key off. Disconnect connector X021, and use a multimeter to check for continuity between connector X021 pin J on the front frame (FF) harness side and chassis ground. A. If there is no continuity to ground, continue with Step 8. B. If there is continuity to ground, there is an open circuit in the feeder valve (FV) harness between connector X271 pin 1 and connector X021 pin J wire 548 white. Locate the open and repair. 8. Key off. Disconnect connector X008, and use a multimeter to check for continuity between connector X008 pin 25 on the main frame (MF) harness side and chassis ground. A. If there is no continuity to ground, there is an open circuit in the main frame (MF) harness between connector X008 pin 25 and connector X281 pin 7 wire 548 white. Locate the open and repair. B. If there is continuity to ground, there is an open circuit in the front frame (FF) harness between connector X021 pin J and connector X008 pin 25 wire 548 white. Locate the open and repair. 9. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation. If the fault code immediately resets, replace the HHC module with a known good one.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0516-11 Lateral Float CCW Valve Unidentified Fault Code Cause: The lateral float CCW valve (L-19) circuit is shorted to ground. Possible failure modes: 1. Valve supply wiring is shorted to ground. 2. Bad solenoid. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The proper current range is approximately 1.0 to 1.5 amps. A. If the current reading goes to maximum, and then back to zero, the circuit is shorted to ground and the software has shut off the output to protect the module and wiring. Continue with Step 2. B. If the reading is within the proper limits, the circuit is working properly. Continue with Step 6. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Disconnect connector X271 at the lateral float CCW solenoid L19. Use a multimeter to check for continuity between either terminal on the solenoid L19 and chassis ground. A. If there is continuity, the lateral float CCW valve solenoid is shorted to ground. Replace the solenoid. B. If there is no continuity, continue with Step 3. 3. Use a multimeter to check for continuity between connector X271 pin 1 on the feeder valve (FV) harness side and chassis ground. A. If there is continuity to ground, continue with Step 4. B. If there is no continuity to ground, erase the fault code and continue operation. 4. Disconnect connector X021, and use a multimeter to check for continuity between connector X021 pin J on the front frame (FF) harness side and chassis ground. A. If there is continuity to ground, continue with Step 5. B. If there is no continuity to ground, there is a short to ground in the feeder valve (FV) harness between connector X271 pin 1 and connector X021 pin J wire 548 white. Locate the short and repair. 5. Disconnect connector X008, and use a multimeter to check for continuity between connector X008 pin 25 on the main frame (MF) harness side and chassis ground. A. If there is continuity to ground, there is a short to ground in the main frame (MF) harness between connector X008 pin 25 and connector X281 pin 7 wire 548 white. Locate the short and repair. B. If there is no continuity to ground, there is a short to ground in the front frame (FF) harness between connector X021 pin J and connector X008 pin 25 wire 548 white. Locate the short and repair. 6. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation. If the fault code immediately resets, replace the HHC module with a known good one.

55-44

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 E0516 LATERAL FLOAT CCW VALVE

10020075

40024707

5 10020032

10020031

50026219

5 1. 2. 3. 4. 5.

Lateral Float CW Solenoid L18 (Second Fr. Top, Front) Lateral Float CCW Solenoid L19 (Second Fr. Top, Back) Connector X021 Connector X008 Connector X281

55-45

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

HEADER FRAME--14

A-07 = HHC MODULE B-29 = HEADER LIFT PRESSURE L-06 = HEADER HEIGHT ACCUMULATOR L-18 = LATERAL FLOAT CW

L-19 = LATERAL FLOAT CCW R-02 = LATERAL FLOAT POT R-03 = FEEDER ANGLE R-12 = LEFT STUBBLE HEIGHT

55-46

R-13 = RIGHT STUBBLE HEIGHT

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0517-05 Lateral Float CW Valve Line Disconnected Cause: The lateral float CW valve (L-18) circuit is open. Possible failure modes: 1. Valve supply wiring is open. 2. Bad solenoid. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The proper current range is approximately 1.0 to 1.5 amps. A. If the reading is 0 amps, the circuit is open. Continue with Step 2. B. If the reading is within the proper limits, the circuit is working properly. Continue with Step 9. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Disconnect connector X267 at the lateral float CW solenoid L18. Use a multimeter to check the resistance of the lateral float CW solenoid between the two terminals on the coil. The proper resistance range is 2 to 6 ohms. A. If there is no continuity, replace the solenoid. B. If the solenoid is within specification, continue with Step 3. 3. Key off. Disconnect connector X281 at the HHC module, and install a jumper wire between connector X281 pin 13 on the main frame (MF) harness side and chassis ground. Use a multimeter to check for continuity between connector X267 pin 2 on the feeder valve (FV) harness side and chassis ground. A. If there is no continuity, continue with Step 4. B. If there is continuity, continue with Step 6. 4. Key off. Disconnect connector X021, and use a multimeter to check for continuity between connector X021 pin H on the front frame (FF) harness side and chassis ground. A. If there is no continuity to ground, continue with Step 5. B. If there is continuity to ground, there is an open circuit in the feeder valve (FV) harness between connector X267 pin 2 and connector X021 pin H wire 554 blue. Locate the open and repair.

55-47

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 5. Key off. Disconnect connector X008, and use a multimeter to check for continuity between connector X008 pin 13 on the main frame (MF) harness side and chassis ground. A. If there is no continuity to ground, there is an open circuit in the main frame (MF) harness between connector X008 pin 13 and connector X281 pin 13 wire 555 blue. Locate the open and repair. B. If there is continuity to ground, there is an open circuit in the front frame (FF) harness between connector X021 pin H and connector X008 pin 13 wire 554 blue or 555 blue. Locate the open and repair. 6. Key off. Disconnect connector X281 at the HHC module, and install a jumper wire between connector X281 pin 8 on the main frame (MF) harness side and chassis ground. Use a multimeter to check for continuity between connector X267 pin 1 on the feeder valve (FV) harness side and chassis ground. A. If there is no continuity, continue with Step 7. B. If there is continuity, continue with Step 9. 7. Key off. Disconnect connector X021, and use a multimeter to check for continuity between connector X021 pin G on the front frame (FF) harness side and chassis ground. A. If there is no continuity to ground, continue with Step 8. B. If there is continuity to ground, there is an open circuit in the feeder valve (FV) harness between connector X267 pin 1 and connector X021 pin G wire 549 white. Locate the open and repair. 8. Key off. Disconnect connector X008, and use a multimeter to check for continuity between connector X008 pin 26 on the main frame (MF) harness side and chassis ground. A. If there is no continuity to ground, there is an open circuit in the main frame (MF) harness between connector X008 pin 26 and connector X281 pin 8 wire 549 white. Locate the open and repair. B. If there is continuity to ground, there is an open circuit in the front frame (FF) harness between connector X021 pin G and connector X008 pin 26 wire 549 white. Locate the open and repair. 9. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation. If the fault code immediately resets, replace the HHC module with a known good one.

55-48

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0517-11 Lateral Float CW Valve Unidentified Failure Code Cause: The lateral float CW valve (L-18) circuit is shorted to ground. Possible failure modes: 1. Valve supply wiring is shorted to ground. 2. Bad solenoid. 3. Module internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The proper current range is approximately 1.0 to 1.5 amps. A. If the current reading goes to maximum, and then back to zero, the circuit is shorted to ground and the software has shut off the output to protect the module and wiring. Continue with Step 2. B. If the reading is within the proper limits, the circuit is working properly. Continue with Step 6. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Disconnect connector X267 at the lateral float CW solenoid L18. Use a multimeter to check for continuity between either terminal on the solenoid L18 and chassis ground. A. If there is continuity, the lateral float CW valve solenoid is shorted to ground. Replace the solenoid. B. If there is no continuity, continue with Step 3. 3. Use a multimeter to check for continuity between connector X267 pin 1 on the feeder valve (FV) harness side and chassis ground. A. If there is continuity to ground, continue with Step 4. B. If there is no continuity to ground, erase the fault code and continue operation. 4. Disconnect connector X021, and use a multimeter to check for continuity between connector X021 pin G on the front frame (FF) harness side and chassis ground. A. If there is continuity to ground, continue with Step 5. B. If there is no continuity to ground, there is a short to ground in the feeder valve (FV) harness between connector X267 pin 1 and connector X021 pin G wire 549 white. Locate the short and repair. 5. Disconnect connector X008, and use a multimeter to check for continuity between connector X008 pin 26 on the main frame (MF) harness side and chassis ground. A. If there is continuity to ground, there is a short to ground in the main frame (MF) harness between connector X008 pin 26 and connector X281 pin 8 wire 549 white. Locate the short and repair. B. If there is no continuity to ground, there is a short to ground in the front frame (FF) harness between connector X021 pin G and connector X008 pin 26 wire 549 white. Locate the short and repair. 6. Operate the machine while monitoring display monitor. If no low out of range readings are indicated, erase the fault code and continue operation. If the fault code immediately resets, replace the HHC module with a known good one.

55-49

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 E0517 LATERAL FLOAT CW VALVE

10020075

40024707

5 10020032

10020031

50026219

6 1. 2. 3. 4. 5.

Lateral Float CW Solenoid L18 (Second Fr. Top, Front) Lateral Float CCW Solenoid L19 (Second Fr. Top, Back) Connector X021 Connector X008 Connector X281

55-50

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

HEADER FRAME--14

A-07 = HHC MODULE B-29 = HEADER LIFT PRESSURE L-06 = HEADER HEIGHT ACCUMULATOR L-18 = LATERAL FLOAT CW

L-19 = LATERAL FLOAT CCW R-02 = LATERAL FLOAT POT R-03 = FEEDER ANGLE R-12 = LEFT STUBBLE HEIGHT

55-51

R-13 = RIGHT STUBBLE HEIGHT

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0518-11 Header Up Valve Unidentified Failure Code Cause: The Header Up valve circuit is open, or shorted to ground. Possible Failure Modes: 1. There is an internal failure in the HHC module. Solution: 1. The Header Up valve solenoid is an integral part of the HHC module. There is no external wiring between the HHC module and the valve, so if this fault occurs, it indicates an internal problem with the module. However, the problem should be verified as indicated below before replacing the HHC module.

CAUTION Be certain everyone is clear of the machine before raising or lowering the header and feeder. 2. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The proper current range is approximately 0.5 to 1.5 amps. A. If the current reading goes to maximum, and then back to zero, the circuit is shorted to ground and the software has shut off the output to protect the module and wiring. B. If the reading is 0 amps, the circuit is open. C. If the reading is within the proper limits, the circuit is working properly. 3. Key on, engine running. Remove the plastic cap on the end of the Header Up solenoid, and depress the button. The header should raise. A. If the header/feeder does not raise, a hydraulic concern exists. Refer to the troubleshooting in Section 29 Hydraulics for information on correcting this concern. B. If the header/feeder raises, there is an internal fault in the HHC module. Replace the module.

55-52

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0519-11 Header Down Valve Unidentified Failure Code Cause: The Header Down valve circuit is open, or shorted to ground. Possible Failure Modes: 1. There is an internal failure in the HHC module. Solution: 1. The Header Down valve solenoid is an integral part of the HHC module. There is no external wiring between the HHC module and the valve, so if this fault occurs, it indicates an internal problem with the module. However, the problem should be verified as indicated below before replacing the HHC module.

CAUTION Be certain everyone is clear of the machine before raising or lowering the header and feeder. 2. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The proper current range is approximately 0.5 to 1.5 amps. A. If the current reading goes to maximum, and then back to zero, the circuit is shorted to ground and the software has shut off the output to protect the module and wiring. B. If the reading is 0 amps, the circuit is open. C. If the reading is within the proper limits, the circuit is working properly. 3. Key on, engine running. Remove the plastic cap on the end of the Header Down solenoid, and depress the button. The header should lower. A. If the header/feeder does not lower, a hydraulic concern exists. Refer to the troubleshooting in Section 29 Hydraulics for information on correcting this concern. B. If the header/feeder lowers, there is an internal fault in the HHC module. Replace the module.

55-53

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE – E0520-11 HHC 12V Supply Voltage Unidentified Failure Code Cause: The Header Height Control (HHC) has detected that the 12V Supply Voltage to the module has exceeded 19 volts for >4 seconds. When the voltage drops below 16 volts the module will reset. Possible Failure Modes: 1. Circuit wiring is shorted to a high voltage source. 2. Faulty alternator/regulator. Solution: The HHC 12 V Supply voltage has gone over voltage. The module will reset itself when voltage returns to normal. When this happens, it will be necessary to press the Header Up button to clear this fault. 1. Start the combine engine, and run it at high idle (full throttle). Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check the voltage range. The proper voltage range is 10 to 18 volts. A. If the voltage reading is greater than 18 volts, continue with step 2. B. If the voltage reading is between 10 and 18 volts, go to step 5. 2. Shut off the combine engine, and then turn the key switch on again. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check the voltage range. The proper voltage range is 10 to 18 volts. A. If the voltage reading is between 10 and 18 volts, the alternator and/or regulator has failed, and is producing excessive voltage. Refer to “Charging Systems” in Chapter 5 -- Engine Systems in this section for additional alternator testing information. B. If the voltage reading is greater than 18 volts, continue with step 3. 3. Turn the key switch off to reset A-07 (HHC module), then turn key switch back on. Check the voltage at fuse F45 using a multimeter. A. If the voltage reading is greater than 18 volts, then the batteries have been mistakenly connected in series, or there is a fault in the wiring of the 24V starting system. Refer to “Starting Systems” in Chapter 5 -- Engine Systems in this section for additional information. B. If the voltage reading is between 10 and 18 volts, continue with step 4.

55-54

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 4. Disconnect connector X281 from the HHC module. Use a multimeter to check the voltage between connector X281 pin 2 and chassis ground. There should be approximately 12 volts. A. If the voltage reading is greater than 18 volts, then a high voltage source has been connected to one of the following wires: --

Wire 781 orange (MF harness), HHC module connector X281 pin 2 to harness splice

Wire 1290 orange (MF harness), connector X424 pin 3 to harness splice

Wire 013 orange (MF harness), harness splice to connector X005 pin 5

Wire 013 orange (CM harness), connector X005 pin 5 to fuse F45

Locate the high voltage source and correct. B. If the voltage reading is 10 to 18 volts, and the HHC module is still displaying the fault (will not clear), there is an internal fault in the HHC module. Reload the software for the HHC module. If that does not correct the concern, replace the module. 5. The short to high voltage is not present at this time. Erase the fault code and continue operation.

55-55

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

55-56

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0 L

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

A-01 = ENGINE CONTROL UNIT A-07 = HHC MODULE A-08 = ASP AMPLIFIER A-16 = CUMMINS ECU

F-45 = HHC MODULE FUSE R-16 = ENG CAN TERMINATION (9.0 L)

55-57

IVECO 10 L

CUMMINS 9.0 L

CAN NETWORK FRAME--31

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE – E0521-11 HHC Internal Temperature Unidentified Failure Code Cause: The Header Height Control (HHC) module’s on-board temperature sensing circuit is out of safe operating range. Possible Failure Modes: 1. The HHC module is overheated. Solution: 1. Insure the supply voltage to the HHC is within normal operating range. Disconnect connector X281 from the HHC module. Use a multimeter to check the voltage on the harness side of connector X281 pin 2 and chassis ground. There should be approximately 12 volts. A. If voltage reading is greater than 10 to 18 volts, use the display monitor; reference Section 55 Chapter 2 if needed, to check for error E0520-11. If fault is present, correct that fault and resume operation. B. If the voltage reading is less than 10 to 18 volts, visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. 2. If the voltage reading is 10 to 18 volts, and the fault is still displaying (will not clear) there is an internal fault in the HHC module. Reload the software for the HHC module. If that does not correct the concern, replace the HHC module.

55-58

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE – E0522-11 HHC Module Status Unidentified Failure Code Cause: The Header Height Control (HHC) module has experienced an internal fault. Possible Failure Modes: 1. The HHC module is disabled. Solution: 1. Check the HHC diagnostic LED to see if it is flashing, reference Fault Code – E0523-11 for LED Status. If no initial LED indication, recycle power to HHC module. 2. Insure the supply voltage to the HHC is within normal operating range. Disconnect connector X281 from the HHC module. Use a multimeter to check the voltage on the harness side of connector X281 pin 2 and chassis ground. There should be approximately 12 volts. A. If voltage reading is greater than 10 to 18 volts, use the display monitor; reference Section 55 Chapter 2 if needed, to check for error E0520-11. If fault is present, correct that fault and resume operation. B. If the voltage reading is less than 10 to 18 volts, visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. 3. If the voltage reading is 10 to 18 volts, and the fault is still displaying (will not clear) there is an internal fault in the HHC module. Reload the software for the HHC module. If that does not correct the concern, replace the HHC module.

55-59

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0523-11 HHC Diagnostic LED Status Unidentified Failure Code Cause: The diagnostic LED circuit within the HHC module has failed. Possible Failure Modes: 1. The HHC module diagnostic LED circuit is open or shorted to ground. Solution: The diagnostic LED is integrated into the HHC module, and is not repairable. If this fault code occurs, the LED will no longer provide a visual indication of HHC module operation, but the HHC module should continue to function normally with no other loss of functions. Under normal conditions, the diagnostic LED provides an indication of the HHC module status, as follows: •

If status-LED is flashing at 1 Hz, then field software is running in “Override-mode”.

•

If status-LED is flashing at 8 Hz, then field software is running in “Automatic-mode”.

•

If status-LED is lighting permanently for 8 seconds, then a calibration procedure was done successful.

•

Anything else means “field software is not running”.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE -- E0524-11 10V Reference Voltage Unidentified Failure Code Cause: The 10V Reference Voltage Supply circuit is shorted to a high source, or shorted to ground. Possible failure modes: 1. 10V reference voltage supply wiring is shorted to ground. 2. 10V reference voltage supply wiring is shorted to a high source (>10V). 3. Module internal failure (internal regulator failure). Solution: The HHC module provides a 10V regulated power supply to the header lift pressure sensor B29, feeder angle sensor R03, left stubble height sensor R12 and right stubble height sensor R13. There is no diagnostic screen currently available for troubleshooting this concern. 1. Disconnect connector X279 from the header lift pressure sensor B29. Use a multimeter to check for voltage on connector X279 pin 3 on the main frame (MF) harness side. The proper voltage range is 9.5 to 10.5 volts. A. If the voltage reading is zero, the regulated voltage circuit is shorted to ground, and the HHC module is no longer powering this circuit. Continue with Step 2. B. If the voltage reading is high out of range continue with Step 7. C. If the voltage reading is within the proper limits, the circuit may not be shorted high or shorted to ground at this time. Continue the troubleshooting at Step 11. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Key off. Disconnect connector X279 from the header lift pressure sensor B29, and use a multimeter to test for continuity between connector X279 pin 3 on the main frame (MF) harness side and chassis ground. A. If continuity to ground is found, continue with Step 3. B. If no continuity is found, the HHC module is not powering the 10V Reference Voltage circuit due to an internal fault. Replace the HHC module. 3. Disconnect connector X008, and use a multimeter to test for continuity between the front frame (FF) harness end of connector X008 pin 18 and chassis ground. A. If no continuity to ground is found, there is a short to ground in the main frame (MF) harness between connector X281 pin 5, connector X279 pin 3, connector X174 pin 3 and connector X008 pin 18 on one of the following wires: wire 728 pink, MF harness splice to connector X279 pin 3 wire 751 pink, MF harness splice to connector X174 pin 3 wire 758 pink, MF harness splice to connector X008 pin 18 wire 474 pink, MF harness splice to connector X281 pin 5 Locate the short and repair. B. If continuity to ground is found, continue with Step 4.

55-61

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 4. Disconnect connector X007, and use a multimeter to test for continuity between the feeder (FE) harness end of connector X007 pin 26 and chassis ground. A. If no continuity to ground is found, there is a short to ground in the front frame (FF) harness between connector X007 pin 26 and connector X008 pin 18 wire 758 pink. Locate the short and repair. B. If continuity to ground is found, continue with Step 5. 5. Disconnect connector X032 from the header, and use a multimeter to test for continuity between the feeder (FE) harness end of connector X032 pin 5 or 23 and chassis ground. A. If continuity is found, there is a short to ground in the feeder (FE) harness between connector X007 pin 26 and connector X032 pin 5 or 23 on one of the following wires: wire 758 pink, connector X007 pin 26 to FE harness splice wire 848 pink, FE harness splice to connector X032 pin 5 wire 849 pink, FE harness splice to connector X032 pin 23 Locate the short and repair. B. If no continuity to ground is found, continue with Step 6. 6. Use a multimeter to test for continuity between the header end of connector X032 pin 5 and the header frame. A. If continuity to ground is found, there is a short to ground in the header (HH) harness between connector X032 pin 5 and connector X305 pin 3 wire 848 pink. Locate the short and repair. B. If no continuity to ground is found, there is a short to ground in the header (HH) harness between connector X032 pin 23 and connector X306 pin 3 wire 849 pink. Locate the short and repair. 7. Disconnect connector X306, and use a multimeter to test for voltage on connector X306 pin 3. There should be 10 volts present. A. If 10 volts is found, continue with Step 13. B. If high (>10V) voltage is found, continue with Step 8. NOTE: This supply circuit is also used to supply power to the header lift pressure and feeder angle sensors, so a short to 12 volts anywhere on the supply circuit will activate this error code. 8. Disconnect connector X032 (header connector), and use a multimeter to test for voltage on the feeder (FE) harness end of connector X032 pin 5 or 23. A. If 10 volts is found, there is a short to high voltage in the header (HH) harness to the sensor supply circuit. Refer to the appropriate header Operator’s manual for wiring information. Locate the short and repair. B. If high voltage is found, continue with Step 9. 9. Disconnect connector X007, and use a multimeter to test for voltage on the front frame (FF) harness end of connector X007 pin 26. A. If 10 volts is found, there is a short to high voltage in the feeder (FE) harness between connector X007 pin 26 and connector X032 pin 5 or 23 on one of the following wires: Wire 758 pink, connector X007 pin 26 to FE harness splice Wire 848 pink, FE harness splice to connector X032 pin 5 Wire 849 pink, FE harness splice to connector X032 pin 23 Locate the short and repair. B. If high voltage is found, continue with Step 10.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 10. Disconnect connector X008, and use a multimeter to test for voltage on the main frame (MF) harness end of connector X008 pin 18. A. If 10 volts is found, there is a short to high voltage in the front frame (FF) harness between connector X008 pin 18 and connector X007 pin 26 wire 758 pink. Locate the short and repair. B. If high voltage is found, there is a short to high voltage in the main frame (MF) harness between connector X008 pin 18 and connector X281 pin 5 on one of the following wires: Wire 751 pink, connector X174 pin 3 to MF harness splice Wire 758 pink, MF harness splice to connector X008 pin 18 Wire 728 pink, connector X279 pin 3 to MV harness splice Wire 474 pink, MV harness splice to connector X281 pin 5 Locate the short and repair. 11. Operate the machine while monitoring display monitor. If no high out of range readings are indicated, erase the fault code and continue operation. If the fault code immediately resets, replace the HHC module with a known good one.

55-63

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21 E0525 10V REFERENCE VOLTAGE

3 10020075

40025215

10020040

4 7 8 40024707

10020031

50026218

7 1. 2. 3. 4. 5.

Right Stubble Height Sensor R13 Left Stubble Height Sensor R12 Connector X032 Connector X007 Feeder Angle Sensor R03

6. 7. 8.

55-64

Connector X008 Header Lift Pressure Sensor B29 Connector X281

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

HEADER FRAME--14

A-07 = HHC MODULE B-29 = HEADER LIFT PRESSURE L-06 = HEADER HEIGHT ACCUMULATOR L-18 = LATERAL FLOAT CW

L-19 = LATERAL FLOAT CCW R-02 = LATERAL FLOAT POT R-03 = FEEDER ANGLE R-12 = LEFT STUBBLE HEIGHT

55-65

R-13 = RIGHT STUBBLE HEIGHT

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

FAULT CODE – E0525-11 HHC Accumulator Valve Unidentified Failure Code Cause: The Header Height Control (HHC) has detected that the Accumulator Valve circuit is disconnected or faulty. Possible Failure Modes: 1. The HHC Accumulator Valve circuit is disconnected or faulty. 2. Header Height Accumulator solenoid (L-06) failure. Solution: 1. Verify the fault is present. Disconnect Main Frame (MF) harness connector X281. Use a multimeter to measure the continuity between pins 1 and 2 of the solenoid. The reading should be 4.5 ohms +/- 0.5 ohms. A. If the multimeter indicates high resistance or an open circuit, replace Header Height Accumulator solenoid (L-06). B. If the reading is within the proper limits, the solenoid is good. Continue troubleshooting at Step 2. NOTE: Visually inspect the wiring harness and connectors. Verify that the connectors are fully installed. Inspect the terminals and wires at each connector for pushed back or corroded terminals or damaged wires. Flex the harness involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Verify the Accumulator Valve power circuit is good. Turn off the ignition switch. Disconnect the Main Frame (MF) harness connector X281. Use a multimeter to measure the continuity between Main Frame (MF) harness wire 759 white connector X281 pin 1 and connector X280 pin 1. A. If the meter indicates continuity, this segment of the circuit is good. Continue with Step 3. B. If the meter indicates an open, Locate and repair the open. Continue with Step 4. 3. Verify the Accumulator Valve ground circuit is good. Disconnect the Main Frame (MF) harness connector X280. Use a multimeter to measure the continuity between Main Frame (MF) harness wire 760 black connector X280 pin 2 on the Main Frame (MF) harness side to chassis ground. A. If the meter indicates continuity, this segment of the circuit is good. The fault must be intermittent. Inspect front frame ground wire 483 black. Continue with Step 4. B. If the meter indicates an open, locate and repair the open. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

HEADER FRAME--14

A-07 = HHC MODULE B-29 = HEADER LIFT PRESSURE L-06 = HEADER HEIGHT ACCUMULATOR L-18 = LATERAL FLOAT CW

L-19 = LATERAL FLOAT CCW R-02 = LATERAL FLOAT POT R-03 = FEEDER ANGLE R-12 = LEFT STUBBLE HEIGHT

55-67

R-13 = RIGHT STUBBLE HEIGHT

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 21

55-68

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 22

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 22 -- ASP Fault Codes CONTENTS Section

Description

Page

55-1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 22

FAULT CODE -- E1281--05 ASP Bottom Sensor (One) Line Disconnected Cause: One of the Bottom ASP sensors (B48/B49) circuits is open. Possible failure modes: 1. Sensor supply wiring has an open. 2. Sensor has an internal failure. 3. Controller internal failure (internal regulator failure). Solution: Error checking only occurs at one minute intervals when the feeder is disengaged. Once the threshing and feeder drives are engaged, the ASP module is activated to enable stone protection, and the system is no longer able to detect errors. The ASP module can detect if one sensor of the pair is off-line (open or failed), but it cannot detect which of the two sensors is off-line. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage reading is 3.0 volts. A. If the voltage reading is low (2.0 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 8. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low. Disconnect connector X086 from the bottom of the ASP module. Use a multimeter to check resistance between the harness end of connector X086 pin 4 and pin 5. There should approximately 5 M ohms resistance through the RH Bottom ASP sensor B48. A. If there is infinite resistance, continue with step 3. B. If the resistance reading is correct, continue with Step 5. 3. Disconnect connector X261, and install a jumper wire between pins 1 and 2. Use a multimeter to check continuity between connector X086 pin 4 and pin 5. There should be continuity. A. If there is no continuity, there is an open circuit in the feeder (FE) harness between connector X086 and connector X261 wire 984 yellow or wire 985 blue. Locate the open and repair. B. If there is continuity, continue with Step 4. 4. Reconnect connector X261. Disconnect connector X263 at the RH Bottom ASP sensor B48, and install a jumper wire between pins 1 and 2. Use a multimeter to check continuity between connector X086 pin 4 and pin 5. There should be continuity. A. If there is no continuity, there is an open circuit in the feeder bottom (FB) harness between connector X261 and connector X263 wire 984 yellow or wire 985 blue. Locate the open and repair. B. If there is continuity, the sensor has failed. Replace the sensor.

55-2

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 22 5. The voltage reading on the display monitor is low. Disconnect connector X086 from the bottom of the ASP module. Use a multimeter to check resistance between the harness end of connector X086 pin 3 and pin 6. There should approximately 5 M ohms resistance through the LH Bottom ASP sensor B49. A. If there is infinite resistance, continue with step 6. B. If the resistance reading is correct, continue with Step 8. 6. Disconnect connector X261, and install a jumper wire between pins 3 and 4. Use a multimeter to check continuity between connector X086 pin 3 and pin 6. There should be continuity. A. If there is no continuity, there is an open circuit in the feeder (FE) harness between connector X086 and connector X261 wire 986 yellow or wire 987 blue. Locate the open and repair. B. If there is continuity, continue with Step 7. 7. Reconnect connector X261. Disconnect connector X262 at the LH Bottom ASP sensor B49, and install a jumper wire between pins 1 and 2. Use a multimeter to check continuity between connector X086 pin 3 and pin 6. There should be continuity. A. If there is no continuity, there is an open circuit in the feeder bottom (FB) harness between connector X261 and connector X262 wire 986 yellow or wire 987 blue. Locate the open and repair. B. If there is continuity, the sensor has failed. Replace the sensor. 8. Operate the machine for at least two minutes while monitoring the display monitor. If no low (2.0 volts) readings are indicated, erase the fault code and continue operation.

55-3

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 22 E1281 ASP BOTTOM SENSOR (ONE)

2 10021064

10020074

10020040

50031014

1 1. 2. 3. 4.

Connector X086 Connector X261 Connector X262 (LH Bottom ASP Sensor B49) Connector X263 (RH Bottom ASP Sensor B48)

55-4

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 22

A-08 = ASP AMPLIFIER B-48 = RH BOTTOM ASP SENSOR B-49 = LH BOTTOM ASP SENSOR F-46 = ASP POWER FUSE

L-11 = FEEDER INCREASE L-12 = FEEDER DECREASE L-31 = STONE DOOR OPEN S-07 = FEEDER REVERSER

FEEDER FRAME--15

55-5

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 22

FAULT CODE -- E1283--03 ASP Bottom Sensor (Both) Shorted to High Source Cause: One of the Bottom ASP sensors (B48/B49) circuits is shorted to high voltage. Possible failure modes: 1. Sensor supply wiring shorted to 12 volts. 2. Controller internal failure (internal regulator failure). Solution: Error checking only occurs at one minute intervals when the feeder is disengaged. Once the threshing and feeder drives are engaged, the ASP module is activated to enable stone protection, and the system is no longer able to detect errors. For this fault code, the ASP module has detected that one of the bottom sensors has been shorted to high voltage. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage reading is 3.0 volts. A. If the voltage reading is high (5.0 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 5. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is high. Disconnect connector X263 at the RH Bottom ASP sensor B48. A. If the voltage drops to low (2.0 volts), the sensor has failed. Replace the sensor. B. If the voltage reading is still high, continue with Step 3. 3. The voltage reading on the display monitor is high. Disconnect connector X262 at the LH Bottom ASP sensor B49. A. If the voltage drops to low (2.0 volts), the sensor has failed. Replace the sensor. B. If the voltage reading is still high, continue with Step 4. 4. The voltage reading on the display monitor is high. Disconnect connector X261 between the feeder top and feeder harnesses. A. If the voltage drops to low (0.3 volts), there is short in the feeder bottom (FB) harness between connector X261, connector X262 and connector X263 wires 984 or 986 yellow or wires 985 or 987 blue. Locate the short and repair. B. If the voltage reading is still high, there is short in the feeder (FE) harness between connector X261 and connector X086 wires 984 or 986 yellow or wires 985 or 987 blue. Locate the short and repair. 5. Operate the machine for at least two minutes while monitoring the display monitor. If no high (5.0 volts) readings are indicated, erase the fault code and continue operation.

55-6

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 22

FAULT CODE -- E1283--05 ASP Bottom Sensor (Both) Line Disconnected Cause: Both of the Bottom ASP sensors (B48/B49) circuits are open. Possible failure modes: 1. Sensor supply wiring has an open. 2. Sensor has an internal failure. 3. Controller internal failure (internal regulator failure). Solution: Error checking only occurs at one minute intervals when the feeder is disengaged. Once the threshing and feeder drives are engaged, the ASP module is activated to enable stone protection, and the system is no longer able to detect errors. For this fault code, the ASP module has detected that both bottom sensors are off-line. 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, check voltage range. The proper voltage reading is 3.0 volts. A. If the voltage reading is low (0.3 volts), continue with Step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting at step 8. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. The voltage reading on the display monitor is low. Disconnect connector X086 from the bottom of the ASP module. Use a multimeter to check resistance between the harness end of connector X086 pin 4 and pin 5. There should approximately 5 M ohms resistance through the RH Bottom ASP sensor B48. A. If there is infinite resistance, continue with step 3. B. If the resistance reading is correct, continue with Step 5. 3. Disconnect connector X261, and install a jumper wire between pins 1 and 2. Use a multimeter to check continuity between connector X086 pin 4 and pin 5. There should be continuity. A. If there is no continuity, there is an open circuit in the feeder (FE) harness between connector X086 and connector X261 wire 984 yellow or wire 985 blue. Locate the open and repair. B. If there is continuity, continue with Step 4. 4. Reconnect connector X261. Disconnect connector X263 at the RH Bottom ASP sensor B48, and install a jumper wire between pins 1 and 2. Use a multimeter to check continuity between connector X086 pin 4 and pin 5. There should be continuity. A. If there is no continuity, there is an open circuit in the feeder bottom (FB) harness between connector X261 and connector X263 wire 984 yellow or wire 985 blue. Locate the open and repair. Continue with step 5. B. If there is continuity, the sensor has failed. Replace the sensor. Continue with step 5.

55-7

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 22 5. The voltage reading on the display monitor is low. Disconnect connector X086 from the bottom of the ASP module. Use a multimeter to check resistance between the harness end of connector X086 pin 3 and pin 6. There should approximately 5 M ohms resistance through the LH Bottom ASP sensor B49. A. If there is infinite resistance, continue with step 6. B. If the resistance reading is correct, continue with Step 8. 6. Disconnect connector X261, and install a jumper wire between pins 3 and 4. Use a multimeter to check continuity between connector X086 pin 3 and pin 6. There should be continuity. A. If there is no continuity, there is an open circuit in the feeder (FE) harness between connector X086 and connector X261 wire 986 yellow or wire 987 blue. Locate the open and repair. B. If there is continuity, continue with Step 7. 7. Reconnect connector X261. Disconnect connector X262 at the LH Bottom ASP sensor B49, and install a jumper wire between pins 1 and 2. Use a multimeter to check continuity between connector X086 pin 3 and pin 6. There should be continuity. A. If there is no continuity, there is an open circuit in the feeder bottom (FB) harness between connector X261 and connector X262 wire 986 yellow or wire 987 blue. Locate the open and repair. B. If there is continuity, the sensor has failed. Replace the sensor. 8. Operate the machine for at least two minutes while monitoring the display monitor. If no low (0.3 volts) readings are indicated, erase the fault code and continue operation.

55-8

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 22 E1283 ASP BOTTOM SENSOR (BOTH)

2 10021064

10020074

10020040

50031014

2 1. 2. 3. 4.

Connector X086 Connector X261 Connector X262 (LH Bottom ASP Sensor B49) Connector X263 (RH Bottom ASP Sensor B48)

55-9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 22

A-08 = ASP AMPLIFIER B-48 = RH BOTTOM ASP SENSOR B-49 = LH BOTTOM ASP SENSOR F-46 = ASP POWER FUSE

L-11 = FEEDER INCREASE L-12 = FEEDER DECREASE L-31 = STONE DOOR OPEN S-07 = FEEDER REVERSER

FEEDER FRAME--15

55-10

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 22

FAULT CODE -- E1284--11 ASP Stonedoor Output Unidentified Failure Code Cause: The Stone Door Open solenoid (L31) circuit is open or shorted to ground. Possible failure modes: 1. Solenoid supply wiring has an open. 2. Solenoid supply wiring is shorted to ground. 3. Controller internal failure (internal regulator failure). Solution: 1. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, manually power the circuit. The status screen should indicate “OK” if the circuit is working properly. A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2. B. If the status screen indicates “OK”, the circuit is working properly. Continue with step 6. NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned. 2. Disconnect connector X292 at the stone door open solenoid L31. Use a multimeter to check the resistance of the stone door open solenoid (L31). The proper resistance range is 3 to 5 ohms. A. If there is zero resistance, the stone door open solenoid is shorted internally. Replace the solenoid. B. If there is infinite resistance, the stone door open solenoid is open. Replace the solenoid. C. If the resistance is correct, continue with step 3. 3. Use a multimeter to check for continuity between connector X292 pin 1 (harness side) and chassis ground. Flex the feeder (FE) harness between the solenoid and connector X082 while making this check. A. If there is continuity to ground, there is a short to ground in the feeder (FE) harness between connector X292 and connector X082 wire 731 white. Locate the short and repair. B. If there is no continuity to ground, continue with step 4. 4. Unplug connector X082 from the bottom of the ASP module. Use a multimeter to check for continuity between connector X292 pin 2 (harness side) and connector X082 pin 8. Flex the feeder (FE) harness between the connectors while making this check. A. If there is no continuity, there is an open circuit in the feeder (FE) harness between connector X292 and connector X082 wire 732 black. Locate the open and repair. B. If there is continuity, continue with step 5.

55-11

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 22 5. Turn the key switch to the ON position. Use the display monitor to manually power the stone door open solenoid. Use a multimeter to check for 12 volts between connector X292 pin 1 and chassis ground. A. If 12 volts is not present, there is an open circuit in the feeder (FE) harness between connector X292 pin 1 and connector X082 pin 2 wire 731 white. Locate the open and repair. B. If 12 volts is present, the circuit is working properly. Continue with step 6. 6. Erase the fault code and continue operation.

55-12

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 22 E1284 ASP STONEDOOR OUTPUT

1 10020074

10020032

50031014

3 1. 2. 3.

Connector X082 Connector X292 Stone Door Open Solenoid L31 (Bottom Valve)

55-13

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 22

A-08 = ASP AMPLIFIER B-48 = RH BOTTOM ASP SENSOR B-49 = LH BOTTOM ASP SENSOR F-46 = ASP POWER FUSE

L-11 = FEEDER INCREASE L-12 = FEEDER DECREASE L-31 = STONE DOOR OPEN S-07 = FEEDER REVERSER

FEEDER FRAME--15

55-14

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 22

FAULT CODE – E1286-14 ASP Sensitivity Off Special Instructions Cause: The ASP Module has detected that the ASP Sensitivity has been set to 0, disabling the ASP system. Possible failure modes: This is normal operation of the system. Solution: This “fault” will appear when the ASP sensitivity is adjusted to 0. The “fault” is simply notification that this event has occurred. The date and time of this action along with the number of times the ASP system sensitivity has been set to 0 will be permanently stored.

FAULT CODE – E1287-14 ASP Sensitivity On Special Instructions Cause: The ASP Module has detected that the ASP Sensitivity has been set above 0, enabling the ASP system. Possible failure modes: This is normal operation of the system. Solution: This “fault” will appear when the ASP sensitivity is adjusted from 0 to 10 or greater. The “fault” is simply notification that this event has occurred. The date and time of this action along with the number of times the ASP system sensitivity has been set above 0 (enabled) will be permanently stored.

55-15

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 22

55-16

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 23 -- RHM Fault Codes CONTENTS Section

Description

Page

E0641

RHM 5V Reference Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

E0643

MFH Position Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

E0645

Gear Select Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

E0646

RHM Feeder Reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

E0648

RHM Spreader Plate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

E0649

RHM Header Height Mode (HHC Auto Height) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

E0652

RHM Engine Throttle Increase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

E0653

RHM Header Height Mode (HHC Compensation) . . . . . . . . . . . . . . . . . . . . . . . . . 26

E0654

RHM On the Road Switch (Road Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

E0655

RHM Spreader Plate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

E0656

RHM Engine Throttle Decrease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

E0657

RHM Reel Speed Mode (Set/Automatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

E0661

RHM Reel Speed Mode (Set/Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

E0662

RHM Fan Speed (Increase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

E0663

RHM Fan Speed (Decrease) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

E0664

RHM Rotor Speed (Increase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

E0665

RHM Rotor Speed (Decrease) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

E0666

RHM Feeder Speed (Increase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

E0667

RHM Feeder Speed (Decrease) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

E0668

RHM Park Brake (On) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

E0669

RHM Park Brake (Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

E0670

RHM Concave Clearance (Decrease) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

E0671

RHM Concave Clearance (Increase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

E0672

RHM Upper Sieve (Decrease) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

E0673

RHM Upper Sieve (Increase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

E0674

RHM Lower Sieve (Decrease) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

E0675

RHM Lower Sieve (Increase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

E0676

RHM Work Width (Increase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

E0677

RHM HHC Fine Adjust (Decrease) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

55-1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23 Section

Description

Page

E0678

Current Protection Line 0 Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

E0679

Current Protection Line 1 Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

E0680

Current Protection Line 2 Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

E0681

HSW Unload Tube Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

E0682

HSW Unload Tube Out Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

E0683

HSW Unload Auger – Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

E0684

HSW Unload Tube In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

E0685

HSW Unload Tube In Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

E0686

HSW ILM (Handle) Unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

E0688

HSW Reel Fore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

E0689

HSW Reel Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

E0690

HSW Reel Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

E0691

HSW Reel Speed Decr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

E0692

HSW Reel Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

E0693

HSW Reel Speed Incr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

E0694

HSW Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

E0695

HSW Lateral Tilt CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

E0696

HSW Header Down Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

E0697

HSW Header Up Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

E0698

HSW Header Up Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

E0699

HSW HHC Resume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

E0700

HSW Lateral Tilt CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

E0701

HSW Header Down Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

55-2

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0641-03 RHM 5V Reference Voltage Shorted to High Source Cause: The Right Hand Module (RHM) has detected that the RHM 5V Reference Voltage circuit is >5.5 volts. Possible failure modes: 1. The RHM 5V Reference wiring is shorted to 12 volts. 2. RHM internal failure. Solution: The RHM 5V reference voltage is supplied to the ground speed pot R-04 and the gear select switch S-24. 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the RHM 5V Reference Voltage circuit is 4.5 -- 5.5 volts. A. If the voltage reading is 5.5 volts or greater, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue troubleshooting at Step 4. 2. Look for the shorted wire. Turn off the ignition switch. Disconnect the Right Console Harness connector X026. Using the proper tool, remove pin 16 wire 316 pink from connector X026. With the wire removed from the connector, reconnect X026 to the RHM. Turn the ignition back on and recheck the RHM 5V Reference Voltage. A. If the voltage is still above 5.5 volts, then continue to Step 3. B. If the voltage now reads between 4.5 -- 5.5 volts, the short is in the wiring harness. Locate and repair the short. Reinstall the wire removed for troubleshooting, continue at Step 4. 3. Verify the RHM is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X026. Using the proper tool, remove pin 17 wire 319 pink from connector X026. With the wire removed from the connector, reconnect X026 to the RHM. Turn the ignition back on and recheck the RHM 5V Reference Voltage. A. If the voltage is above 5.5 volts, then the fault is in the RHM. Replace the RHM. Continue troubleshooting at Step 4. B. If the voltage now reads between 4.5 -- 5.5 volts, the short is in the wiring harness. Locate and repair the short. Reinstall the wire removed for troubleshooting, continue at Step 4. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-3

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0641-04 RHM 5V Reference Voltage Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the RHM 5V Reference Voltage circuit is <4.5 volts. Possible failure modes: 1. The RHM 5V Reference wiring is shorted to ground. 2. RHM internal failure. Solution: The RHM 5V reference voltage is supplied to the ground speed pot R-04 and the gear select switch S-24. 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the RHM 5V Reference Voltage circuit is 4.5 -- 5.5 volts. A. If the voltage reading is 4.5 volts or less, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be grounded at this time. Continue troubleshooting at Step 4. 2. Look for the shorted wire. Turn off the ignition switch. Disconnect the Right Console Harness connector X026. Using the proper tool, remove pin 16 wire 316 pink from connector X026. With the wire removed from the connector, reconnect X026 to the RHM. Turn the ignition back on and recheck the RHM 5V Reference Voltage. A. If the voltage is below 4.5 volts, then continue to Step 3. B. If the voltage now reads between 4.5 -- 5.5 volts, the short is in the wiring harness. Locate and repair the short. Reinstall the wire removed for troubleshooting, continue at Step 4. 3. Verify the RHM is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X026. Using the proper tool, remove pin 17 wire 319 pink from connector X026. With the wire removed from the connector, reconnect X026 to the RHM. Turn the ignition back on and recheck the RHM 5V Reference voltage. A. If the voltage is below 4.5 volts, then the fault is in the RHM. Replace the RHM. Continue troubleshooting at Step 4. B. If the voltage now reads between 4.5 -- 5.5 volts, the short is in the wiring harness. Locate and repair the short. Reinstall the wire removed for troubleshooting, continue at Step 4. 4. Visually inspect the harness and connectors for damage, bent, corroded or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-4

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

L-01 = NEUTRAL LOCK SOLENOID R-04 = GROUND SPEED POT S-09 = PARK BRAKE S-10 = REAR WHEEL ASSIST

S-11 = DUAL RANGE S-12 = ON THE ROAD SWITCH S-24 = GEAR SELECT

DRIVES FRAME--7

55-5

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0643-03 MFH Position Input Shorted to High Source Cause: The Right Hand Module (RHM) has detected that the Multifunction Handle (MFH) Position Input circuit, Ground Speed Pot R-04 voltage is >4.5 volts. Possible failure modes: 1. The MFH Position Input circuit is shorted to >4.5 volts. 2. RHM internal failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the MFH Position Input circuit is 0.5 -- 4.5 volts. A. If the voltage reading is >4.5 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue troubleshooting at Step 4. 2. Verify the RHM is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X027. Using the proper tool, remove pin 1 wire 381 yellow from X027. With the wire removed from the connector, reconnect X027. Turn the ignition back on and recheck the ”MFH Position Input” voltage. A. If the voltage now reads <0.5 volts, the RHM is good. Continue troubleshooting at Step 3. B. If the voltage is still >4.5 volts, then the fault is in the RHM. Reinstall the wire removed for troubleshooting. Reload the system software to see if the fault code clears. If the fault is still present after reloading the software, replace the RHM. Continue troubleshooting at Step 4. 3. Locate the shorted wire. Turn off the ignition switch. Disconnect Ground Speed Potentiometer R-04. Turn the ignition on. Using a voltmeter, measure the voltage at pin C wire 381 yellow of the harness side of connector X057. A. If the voltage reading is <0.5 volts then the fault may be intermittent. Continue troubleshooting at Step 4. B. If the voltage reads >4.5 volts then the fault is in the respective wire 381 yellow. Locate and repair the short. Continue troubleshooting at Step 4. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-6

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0643-04 MFH Position Input Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Multifunction Handle (MFH) Position Input circuit voltage, Ground Speed Pot R-04 is <0.5 volts. Possible failure modes: 1. The MFH Position Input circuit is shorted to ground. 2. Ground Speed Potentiometer R-04 failure. 3. RHM internal failure. Solution: 1. Verify the fault is present.Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the MFH Position Input circuit is 0.5 -- 4.5 volts. A. If the voltage reading is <0.5 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 6. 2. Verify the power supply and ground are good. Using a voltmeter, measure the voltage between the connector X057 pin B (--) and pin A (+) at Ground Speed Potentiometer R-04. A. If the voltage reads between 4.500 -- 5.500 volts, the RHM 5V Reference Voltage and circuit ground are both good. Continue troubleshooting at Step 3. B. If the voltage is below 4.500 volts, then the RHM 5V Reference Voltage is missing. Check for an E0641-04 -- RHM 5V Reference Voltage fault. If present, correct that fault and resume operation. Otherwise, repair the open between the Right Console harness connector X026 pin 16 and Ground Speed Potentiometer connector X057 pin A, or between Right Console harness connector X026 pin 6 and Ground Speed Potentiometer connector X057 pin B. Continue troubleshooting at Step 6. 3. Verify Ground Speed Potentiometer R-04 is good. Select ”MFH Position Input” and observe the voltage. While watching the voltage reading, gradually vary the position of the Ground Speed Potentiometer R-04 through its entire range. A. If the voltage varies smoothly as the position of the Ground Speed Potentiometer R-04 changes between 1.2 -- 3.4 volts, then the potentiometer is good. Continue at Step 4. B. If the voltage is erratic or out of range while moving the Ground Speed Potentiometer, then the fault is in R-04. Replace the Ground Speed Potentiometer R-04. Continue troubleshooting at Step 6. 4. Verify circuit 381 yellow is good. Measure the continuity between RHM X027 pin 1 and Ground Speed Potentiometer R-04 connector X057 (harness side) pin C. Check for a short to ground. A. If the circuit tests good, continue troubleshooting at Step 5. B. If the circuit is open, or shorted to ground, locate the fault and repair. Continue troubleshooting at Step 6. 5. Verify the RHM is good. Observe the MFH Position Input voltage on the display monitor. A. If the MFH Position Input voltage is still <0.5 volts, reload the system software to see if the fault code clears. If the fault is still present after reloading the software, replace the RHM. Continue troubleshooting at Step 6. B. If the fault is still present after replacing the RHM, continue troubleshooting at Step 6. 6. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-7

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0643-13 MFH Position Input Needs Calibration Cause: The Right Hand Module (RHM) has detected that the Multifunction Handle (MFH) Position Input, Ground Speed Pot R-04 reading is >105% or calibration has been lost. Possible failure modes: 1. The MFH Position is not calibrated. 2. Ground Speed Potentiometer R-04 failure. 3. RHM internal failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the “Relative Position” percentage. With the engine off, move the MFH fully forward and aft while observing the display. The normal operating range for the Propulsion Handle Position circuit is 0 -- 100 %. A. If the percentage reading is >105 %, or you are unable to move the handle, continue with Step 2. B. If the percentage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 4. 2. Use the display monitor, reference Section 55 Chapter 2, if needed, calibrate the MFH position. When finished, recheck the MFH Position Input percentage. A. If the percentage reading is still able to reach >105 %, continue troubleshooting at Step 3. B. If the percentage reads between 0 -- 100 %. Continue troubleshooting at Step 4. 3. Verify the RHM is good. Reload the system software to see if the fault code clears. Perform Multifunctional Handle calibration. Recheck the MFH Position Input percentage throughout the range of movement. A. If the percentage now reads between 0 -- 100 %, the RHM is good. Continue troubleshooting at Step 4. B. If the percentage is still >105 %, then the fault is in the RHM. Replace the RHM. Repeat calibration. If calibration fails again, replace the Ground Speed Potentiometer R-04. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, but the symptoms are still present, replace the multifunction handle position.

55-8

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

L-01 = NEUTRAL LOCK SOLENOID R-04 = GROUND SPEED POT S-09 = PARK BRAKE S-10 = REAR WHEEL ASSIST

S-11 = DUAL RANGE S-12 = ON THE ROAD SWITCH S-24 = GEAR SELECT

DRIVES FRAME--7

55-9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0645-03 Gear Select Input Shorted to High Source Cause: The Right Hand Module (RHM) has detected that the Gear Select Input circuit, Gear Selector Switch S-24 voltage is >4.75 volts. Possible failure modes: 1. The Gear Select Input circuit shorted to >4.75 volts. 2. RHM internal failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the Gear Select Input circuit is 0.2 -- 4.75 volts. A. If the voltage reading is >4.75 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time. Continue troubleshooting at Step 4. 2. Verify the RHM is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X027. Using the proper tool, remove pin 11 wire 391 yellow from X027. With the wire removed from the connector, reconnect X027. Turn the ignition back on and recheck the Gear Select Input voltage. A. If the voltage now reads <0.2 volts, the RHM is good. Continue troubleshooting at Step 3. B. If the voltage is still >4.75 volts, then the fault is in the RHM. Reinstall the wire removed for troubleshooting. Reload the system software to see if the fault code clears. If the fault is still present after reloading the software, replace the RHM. Continue troubleshooting at Step 4. 3. Locate the shorted wire. Turn off the ignition switch. Disconnect Gear Select Switch S-24. Turn the ignition on. Using a voltmeter, measure the voltage at pin C of the harness side of connector X048. A. If the voltage reading is <0.2 volts then the fault may be intermittent. Continue troubleshooting at Step 4. B. If the voltage reads >4.75 volts then the fault is in the respective wire 391 yellow. Locate and repair the short. Continue troubleshooting at Step 4. 4. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-10

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0645-05 Gear Select Input Line Disconnected Cause: The Right Hand Module (RHM) has detected that the Gear Select Input circuit, Gear Selector Switch S-24 voltage is <0.2 volts. Possible failure modes: 1. The Gear Select Input circuit is open or reduced to <0.2 volts. 2. Gear Select Switch S-24 failure. 3. RHM internal failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the Gear Select Input circuit is 0.2 -- 4.75 volts. A. If the voltage reading is <0.2 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 6. 2. Verify the power supply and ground are good. Using a voltmeter, measure the voltage between the connector X048 pin 1 (--) and pin 3 (+) at Gear Select Switch S-24. A. If the voltage reads between 4.500 -- 5.500 volts, the RHM 5V Reference and circuit ground are both good. Continue troubleshooting at Step 3. B. If the voltage is below 4.500 volts, then the RHM 5V Reference is missing. Check for a E0641-04 -- RHM 5V Reference fault. If present, correct that fault and resume operation. Otherwise, repair the open between the Right Console harness connector X026 pin 17 and Gear Select Switch connector X048 pin 3, or between Right Console harness connector X026 pin 7 and Gear Select Switch connector X048 pin 1. Continue troubleshooting at Step 6. 3. Verify Gear Select Switch S-24 is good. Disconnect Gear Select Switch S-24. Using an ohmmeter, measure the resistance between the pins of the Gear Select Switch S-24 connector X048 according to the table below.

Switch Position

OHMS

1121-1239

192-212

971-1073

1121-1239

242-268

1021-1129

1121-1239

342-378

1121-1239

542-599

1321-1460

1121-1239

1596-1764

2375-2625

A. If the switch tests good, continue troubleshooting at Step 4. B. If any resistor circuit is found to be open or out of range, replace Gear Select Switch S-24. Continue troubleshooting at Step 6.

55-11

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23 4. Verify circuit 391 yellow is good. Measure the continuity between RHM X027 pin 11 and Gear Select Switch S-24 connector X048 (harness side) pin 2. A. If the circuit tests good, continue troubleshooting at Step 5. B. If the circuit is open, locate and repair the open. Continue troubleshooting at Step 6. 5. Verify the RHM is good. Observe the “Gear Select Input” voltage on the display monitor. A. If the Gear Select Input voltage is still <0.2 volts, reload the system software to see if the fault code clears. If the fault is still present after reloading the software, replace the RHM. Continue troubleshooting at Step 6. B. If the fault is still present after replacing the RHM, continue troubleshooting at Step 6. 6. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-12

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0645-07 Gear Select Input Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Gear Select Input circuit, Gear Selector Switch S-24 voltage is >0.25 volts from one of five setpoints. Possible failure modes: 1. The Gear Select Input circuit voltage is out of range by >0.25 volts. 2. Gear Select Switch S-24 failure. 3. RHM internal failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. Observe the voltage as you select each switch position. Note where the voltage falls in relation to the range markings as displayed on the bar graph. The normal operating range for the Gear Shift Control circuit is 0.2 -- 4.75 volts.

Switch Position

Display Range

Nominal Value

Acceptable Range

0.54 volts

0.29 -- 0.79 volts

1.47 volts

1.22 -- 1.72 volts

2.50 volts

2.25 -- 2.75 volts

3.42 volts

3.17 -- 3.67 volts

4.46 volts

4.21 -- 4.71 volts

A. If the voltage reading is outside the range, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 6. 2. Verify the power supply and ground are good. Using a voltmeter, measure the voltage between the connector X048 pin 1 (--) and pin 3 (+) at Gear Select Switch S-24. A. If the voltage reads between 4.50 -- 5.50 volts, the RHM 5V Reference and circuit ground are both good. Continue troubleshooting at Step 3. B. If the voltage is below 4.50 volts, then the RHM 5V Reference is missing. Check for an E0641-04 -- RHM 5V Reference fault. If present, correct that fault and resume operation. Otherwise, repair the open between the Right Console harness connector X026 pin 17 and Gear Select Switch connector X048 pin 3, or between Right Console harness connector X026 pin 7 and Gear Select Switch connector X048 pin 1. Continue troubleshooting at Step 6.

55-13

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23 3. Verify Gear Select Switch S-24 is good. Disconnect Gear Select Switch S-24. Using an ohmmeter, measure the resistance between the pins of the Gear Select Switch S-24 connector X048 according to the table below.

Switch Position

OHMS

1121-1239

192-212

971-1073

1121-1239

242-268

1021-1129

1121-1239

342-378

1121-1239

542-599

1321-1460

1121-1239

1596-1764

2375-2625

A. If the switch tests good, continue troubleshooting at Step 4. B. If any resistor circuit is found to be open or out of range, replace Gear Select Switch S-24. Continue troubleshooting at Step 6. 4. Verify circuit 391 yellow is good. Measure the continuity between RHM X027 pin 11 and Gear Select Switch S-24 connector X048 (harness side) pin 2. A. If the circuit tests good, continue troubleshooting at Step 5. B. If the circuit is open, locate and repair the open. Continue troubleshooting at Step 6. 5. Verify the RHM is good. Observe the “Gear Select Input” voltage on the display monitor. A. If the Gear Select Input voltage is still out of range, reload the system software to see if the fault code clears. If the fault is still present after reloading the software, replace the RHM. Continue troubleshooting at Step 6. B. If the fault is still present after replacing the RHM, continue troubleshooting at Step 6. 6. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

55-14

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

L-01 = NEUTRAL LOCK SOLENOID R-04 = GROUND SPEED POT S-09 = PARK BRAKE S-10 = REAR WHEEL ASSIST

S-11 = DUAL RANGE S-12 = ON THE ROAD SWITCH S-24 = GEAR SELECT

DRIVES FRAME--7

55-15

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0646-04 RHM Feeder Reverser Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Feeder Reverser switch S-07 circuit voltage is <0.5 volts. Possible Failure Modes: 1. The Feeder Reverser circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the feeder reverser switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the feeder reverser switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X039 from the Feeder Reverser switch S-07. Use a multimeter to check for continuity between the harness side of connector X039 pin 3 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Feeder Reverser switch S-07 has failed. Replace the switch. 3. Disconnect connector X029 from the RHM. With the Feeder Reverser switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X029 pin 5 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X029 pin 5 and connector X039 pin 3 wire 326 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X029 from the RHM. Use a multimeter to check for continuity between connector X029 pin 5 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

55-16

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

A-08 = ASP AMPLIFIER B-48 = RH BOTTOM ASP SENSOR B-49 = LH BOTTOM ASP SENSOR F-46 = ASP POWER FUSE

L-11 = FEEDER INCREASE L-12 = FEEDER DECREASE L-31 = STONE DOOR OPEN S-07 = FEEDER REVERSER

FEEDER FRAME--15

55-17

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0648-04 RHM Spreader Plate Right Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Spreader Plate switch S-23 right circuit voltage is <0.5 volts. Possible Failure Modes: 1. The spreader plate right circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the spreader plate switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the spreader plate switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X037 from the Spreader Plate switch S-23. Use a multimeter to check for continuity between the harness side of connector X037 pin 3 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Spreader Plate switch S-23 has failed. Replace the switch. 3. Disconnect connector X029 from the RHM. With the Spreader Plate switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X029 pin 18 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X029 pin 18 and connector X037 pin 3 wire 324 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X029 from the RHM. Use a multimeter to check for continuity between connector X029 pin 18 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

55-18

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0648-07 RHM Spreader Plate Right Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Spreader Plate switch S-23 right circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The spreader plate right circuit is out of range. 2. The RHM has failed internally. 3. The Spreader Plate switch S-23 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the spreader plate switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the spreader plate switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X037 from the Spreader Plate switch S-23. Turn the ignition switch on and actuate the Spreader Plate switch S-23. Use a multimeter to check for 12 volts on the switch side of connector X037 pin 3 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the Spreader Plate switch S-23 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X037 and disconnect connector X029 from the RHM. With the Spreader Plate switch S-23 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X029 pin 18 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X029 pin 18 and connector X037 pin 3 wire 324 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X029 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X029 pin 18 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

55-19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

B-10 = CHOPPER RPM L-28 = CHAFF SPREADER M-11 = SPREADER PLATE MOTOR S-23 = SPREADER PLATE

B-74 = PSD RPM

TRASH FRAME--23

55-20

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0649-04 RHM Header Height Mode (HHC Auto Height) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Header Height Mode switch S-04 Auto Height circuit voltage is <0.5 volts. Possible Failure Modes: 1. The auto height circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the header height mode switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the header height mode switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X061 from the Header Height Mode switch S-04. Use a multimeter to check for continuity between the harness side of connector X061 pin 3 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Header Height Mode switch S-04 has failed. Replace the switch. 3. Disconnect connector X029 from the RHM. With the Header Height Mode switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X029 pin 3 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X029 pin 3 and connector X061 pin 3 wire 330 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X029 from the RHM. Use a multimeter to check for continuity between connector X029 pin 3 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

55-21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0652-04 RHM Engine Throttle Increase Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Engine Throttle switch S-36 increase circuit voltage is <0.5 volts. Possible Failure Modes: 1. The engine throttle increase circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the engine throttle increase switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the engine throttle increase switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X060 from the Engine Throttle switch S-36. Use a multimeter to check for continuity between the harness side of connector X060 pin 3 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Engine Throttle switch S-36 has failed. Replace the switch. 3. Disconnect connector X029 from the RHM. With the Engine Throttle switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X029 pin 13 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X029 pin 13 and connector X060 pin 3 wire 318 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X029 from the RHM. Use a multimeter to check for continuity between connector X029 pin 13 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0652-07 RHM Engine Throttle Increase Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Engine Throttle switch S-36 increase circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The engine throttle increase circuit is out of range. 2. The RHM has failed internally. 3. The Engine Throttle switch S-36 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the engine throttle increase switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the engine throttle increase switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X060 from the Engine Throttle switch S-36. Turn the ignition switch on and actuate the Engine Throttle switch S-36. Use a multimeter to check for 12 volts on the switch side of connector X060 pin 3 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the Engine Throttle switch S-36 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X060 and disconnect connector X029 from the RHM. With the Engine Throttle switch S-36 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X029 pin 13 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X029 pin 13 and connector X060 pin 3 wire 318 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X029 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X029 pin 13 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

B-22 = REAR LADDER F-23 = SCREEN BRUSH FUSE F-28 = FUEL PUMP FUSE K-07 = FUEL PUMP RELAY

M-23 = FUEL PUMP M-27 = ROTARY SCREEN BRUSH R-01 = FUEL LEVEL S-36 = ENGINE THROTTLE

S-61 = AIR FILTER SWITCH S-67 = COOLANT LEVEL

STARTING FRAME--3

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0653-04 RHM Header Height Mode (HHC Compensation) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Header Height Mode switch S-04 Compensation circuit voltage is <0.5 volts. Possible Failure Modes: 1. The compensation circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the header height mode switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the header height mode switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X061 from the Header Height Mode switch S-04. Use a multimeter to check for continuity between the harness side of connector X061 pin 1 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Header Height Mode switch S-04 has failed. Replace the switch. 3. Disconnect connector X029 from the RHM. With the Header Height Mode switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X029 pin 11 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X029 pin 11 and connector X061 pin 1 wire 331 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X029 from the RHM. Use a multimeter to check for continuity between connector X029 pin 11 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0654-04 RHM On the Road Switch (Road Mode) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the On the Road Switch S-12 road mode circuit voltage is <0.5 volts. Possible Failure Modes: 1. The road mode circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the road mode switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the road mode switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X049 from the On the Road Switch S-12. Use a multimeter to check for continuity between the harness side of connector X049 pin 3 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the On the Road Switch S-12 has failed. Replace the switch. 3. Disconnect connector X029 from the RHM. With the On the Road Switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X029 pin 16 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X029 pin 16 and connector X049 pin 3 wire 339 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X029 from the RHM. Use a multimeter to check for continuity between connector X029 pin 16 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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FAULT CODE – E0654-07 RHM On the Road Switch (Road Mode) Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the On the Road Switch S-12 road mode circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The road mode circuit is out of range. 2. The RHM has failed internally. 3. The On the Road Switch S-12 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the road mode switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the road mode switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X049 from the On the Road Switch S-12. Turn the ignition switch on and actuate the On the Road Switch S-12. Use a multimeter to check for 12 volts on the switch side of connector X049 pin 3 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the On the Road Switch S-12 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X049 and disconnect connector X029 from the RHM. With the On the Road Switch S-12 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X029 pin 16 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X029 pin 16 and connector X049 pin 3 wire 339 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X029 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X029 pin 16 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

L-01 = NEUTRAL LOCK SOLENOID R-04 = GROUND SPEED POT S-09 = PARK BRAKE S-10 = REAR WHEEL ASSIST

S-11 = DUAL RANGE S-12 = ON THE ROAD SWITCH S-24 = GEAR SELECT

DRIVES FRAME--7

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0655-04 RHM Spreader Plate Left Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Spreader Plate switch S-23 left circuit voltage is <0.5 volts. Possible Failure Modes: 1. The spreader plate left circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the spreader plate switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the spreader plate switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X037 from the Spreader Plate switch S-23. Use a multimeter to check for continuity between the harness side of connector X037 pin 1 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Spreader Plate switch S-23 has failed. Replace the switch. 3. Disconnect connector X029 from the RHM. With the Spreader Plate switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X029 pin 14 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X029 pin 14 and connector X037 pin 1 wire 325 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X029 from the RHM. Use a multimeter to check for continuity between connector X029 pin 14 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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FAULT CODE – E0655-07 RHM Spreader Plate Left Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Spreader Plate switch S-23 left circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The spreader plate left circuit is out of range. 2. The RHM has failed internally. 3. The Spreader Plate switch S-23 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the spreader plate switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the spreader plate switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X037 from the Spreader Plate switch S-23. Turn the ignition switch on and actuate the Spreader Plate switch S-23. Use a multimeter to check for 12 volts on the switch side of connector X037 pin 1 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the Spreader Plate switch S-23 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X037 and disconnect connector X029 from the RHM. With the Spreader Plate switch S-23 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X029 pin 14 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X029 pin 14 and connector X037 pin 1 wire 325 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X029 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X029 pin 14 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

B-10 = CHOPPER RPM L-28 = CHAFF SPREADER M-11 = SPREADER PLATE MOTOR S-23 = SPREADER PLATE

B-74 = PSD RPM

TRASH FRAME--23

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0656-04 RHM Engine Throttle Decrease Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Engine Throttle switch S-36 decrease circuit voltage is <0.5 volts. Possible Failure Modes: 1. The engine throttle decrease circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the engine throttle decrease switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the engine throttle decrease switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X060 from the Engine Throttle switch S-36. Use a multimeter to check for continuity between the harness side of connector X060 pin 1 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Engine Throttle switch S-36 has failed. Replace the switch. 3. Disconnect connector X029 from the RHM. With the Engine Throttle switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X029 pin 4 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X029 pin 4 and connector X060 pin 1 wire 322 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X029 from the RHM. Use a multimeter to check for continuity between connector X029 pin 4 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0656-07 RHM Engine Throttle Decrease Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Engine Throttle switch S-36 decrease circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The engine throttle decrease circuit is out of range. 2. The RHM has failed internally. 3. The Engine Throttle switch S-36 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the engine throttle decrease switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the engine throttle decrease switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X060 from the Engine Throttle switch S-36. Turn the ignition switch on and actuate the Engine Throttle switch S-36. Use a multimeter to check for 12 volts on the switch side of connector X060 pin 1 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the Engine Throttle switch S-36 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X060 and disconnect connector X029 from the RHM. With the Engine Throttle switch S-36 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X029 pin 4 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X029 pin 4 and connector X060 pin 1 wire 322 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X029 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X029 pin 4 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

B-22 = REAR LADDER F-23 = SCREEN BRUSH FUSE F-28 = FUEL PUMP FUSE K-07 = FUEL PUMP RELAY

M-23 = FUEL PUMP M-27 = ROTARY SCREEN BRUSH R-01 = FUEL LEVEL S-36 = ENGINE THROTTLE

S-61 = AIR FILTER SWITCH S-67 = COOLANT LEVEL

STARTING FRAME--3

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0657-04 RHM Reel Speed Mode (Set/Automatic) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Reel Speed Mode switch S-08 set circuit voltage is <0.5 volts. Possible Failure Modes: 1. The reel speed set circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the reel speed set switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the reel speed set switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X040 from the Reel Speed Mode switch S-08. Use a multimeter to check for continuity between the harness side of connector X040 pin 3 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Reel Speed Mode switch S-08 has failed. Replace the switch. 3. Disconnect connector X029 from the RHM. With the Reel Speed Mode switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X029 pin 2 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X029 pin 2 and connector X040 pin 3 wire 332 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X029 from the RHM. Use a multimeter to check for continuity between connector X029 pin 2 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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FAULT CODE – E0657-07 RHM Reel Speed Mode (Set/Automatic) Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Reel Speed Mode switch S-08 set circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The reel speed set circuit is out of range. 2. The RHM has failed internally. 3. The Reel Speed Mode switch S-08 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the reel speed set switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the reel speed set switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X040 from the Reel Speed Mode switch S-08. Turn the ignition switch on and actuate the Reel Speed Mode switch S-08. Use a multimeter to check for 12 volts on the switch side of connector X040 pin 3 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the Reel Speed Mode switch S-08 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X040 and disconnect connector X029 from the RHM. With the Reel Speed Mode switch S-08 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X029 pin 2 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X029 pin 2 and connector X040 pin 3 wire 332 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X029 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X029 pin 2 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0661-04 RHM Reel Speed Mode (Set/Manual) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Reel Speed Mode switch S-08 set circuit voltage is <0.5 volts. Possible Failure Modes: 1. The reel speed set circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the reel speed set switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the reel speed set switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X040 from the Reel Speed Mode switch S-08. Use a multimeter to check for continuity between the harness side of connector X040 pin 1 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Reel Speed Mode switch S-08 has failed. Replace the switch. 3. Disconnect connector X029 from the RHM. With the Reel Speed Mode switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X029 pin 10 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X029 pin 10 and connector X040 pin 1 wire 333 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X029 from the RHM. Use a multimeter to check for continuity between connector X029 pin 10 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0662-04 RHM Fan Speed (Increase) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Fan Speed switch S-15 increase circuit voltage is <0.5 volts. Possible Failure Modes: 1. The fan speed increase circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the fan speed increase switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the fan speed increase switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X045 from the Fan Speed switch S-15. Use a multimeter to check for continuity between the harness side of connector X045 pin 3 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Fan Speed switch S-15 has failed. Replace the switch. 3. Disconnect connector X030 from the RHM. With the Fan Speed switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X030 pin 10 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X030 pin 10 and connector X045 pin 3 wire 345 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X030 from the RHM. Use a multimeter to check for continuity between connector X030 pin 10 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0662-07 RHM Fan Speed (Increase) Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Fan Speed switch S-15 increase circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The fan speed increase circuit is out of range. 2. The RHM has failed internally. 3. The Fan Speed switch S-15 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the fan speed increase switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the fan speed increase switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X045 from the Fan Speed switch S-15. Turn the ignition switch on and actuate the Fan Speed switch S-15. Use a multimeter to check for 12 volts on the switch side of connector X045 pin 3 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the Fan Speed switch S-15 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X045 and disconnect connector X030 from the RHM. With the Fan Speed switch S-15 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X030 pin 10 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X030 pin 10 and connector X045 pin 3 wire 345 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X030 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X030 pin 10 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

B-16 = CLEANING FAN RPM B-21 = SIEVES LOSS F-22 = SHOE LEVELING MOTOR FUSE L-44 = FAN DRIVE SOLENOID

M-03 = SHOE LEVELING ACTUATOR S-13 = UPPER SIEVE S-14 = LOWER SIEVE S-15 = FAN SPEED

55-43

CLEANING FRAME--19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0663-04 RHM Fan Speed (Decrease) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Fan Speed switch S-15 decrease circuit voltage is <0.5 volts. Possible Failure Modes: 1. The fan speed decrease circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the fan speed decrease switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the fan speed decrease switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X045 from the Fan Speed switch S-15. Use a multimeter to check for continuity between the harness side of connector X045 pin 1 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Fan Speed switch S-15 has failed. Replace the switch. 3. Disconnect connector X030 from the RHM. With the Fan Speed switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X030 pin 9 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X030 pin 9 and connector X045 pin 1 wire 344 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X030 from the RHM. Use a multimeter to check for continuity between connector X030 pin 9 on the RHM and chassis ground. There should not be continuity to ground. C. If continuity is found, the RHM has failed. Replace the module. A. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0663-07 RHM Fan Speed (Decrease) Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Fan Speed switch S-15 decrease circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The fan speed decrease circuit is out of range. 2. The RHM has failed internally. 3. The Fan Speed switch S-15 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the fan speed decrease switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the fan speed decrease switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X045 from the Fan Speed switch S-15. Turn the ignition switch on and actuate the Fan Speed switch S-15. Use a multimeter to check for 12 volts on the switch side of connector X045 pin 1 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the Fan Speed switch S-15 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X045 and disconnect connector X030 from the RHM. With the Fan Speed switch S-15 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X030 pin 9 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X030 pin 9 and connector X045 pin 1 wire 344 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X030 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X030 pin 9 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

B-16 = CLEANING FAN RPM B-21 = SIEVES LOSS F-22 = SHOE LEVELING MOTOR FUSE L-44 = FAN DRIVE SOLENOID

M-03 = SHOE LEVELING ACTUATOR S-13 = UPPER SIEVE S-14 = LOWER SIEVE S-15 = FAN SPEED

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CLEANING FRAME--19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0664-04 RHM Rotor Speed (Increase) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Rotor Speed switch S-17 increase circuit voltage is <0.5 volts. Possible Failure Modes: 1. The rotor speed increase circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the rotor speed increase switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the rotor speed increase switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X046 from the Rotor Speed switch S-17. Use a multimeter to check for continuity between the harness side of connector X046 pin 3 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Rotor Speed switch S-17 has failed. Replace the switch. 3. Disconnect connector X030 from the RHM. With the Rotor Speed switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X030 pin 11 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X030 pin 11 and connector X046 pin 3 wire 349 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X030 from the RHM. Use a multimeter to check for continuity between connector X030 pin 11 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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FAULT CODE – E0664-07 RHM Rotor Speed (Increase) Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Rotor Speed switch S-17 increase circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The fan speed increase circuit is out of range. 2. The RHM has failed internally. 3. The Rotor Speed switch S-17 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the rotor speed increase switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the rotor speed increase switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X046 from the Rotor Speed switch S-17. Turn the ignition switch on and actuate the Rotor Speed switch S-17. Use a multimeter to check for 12 volts on the switch side of connector X046 pin 3 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the Rotor Speed switch S-17 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X046 and disconnect connector X030 from the RHM. With the Rotor Speed switch S-17 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X030 pin 11 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X030 pin 11 and connector X046 pin 3 wire 349 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X030 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X030 pin 11 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

HYDRAULIC FRAME--10

B-18 = HYD OIL RESERVOIR TEMP B-32 = GEARBOX TEMPERATURE B-35 = LOW CONTROL PRESSURE S-17 = ROTOR SPEED

S-18 = FEEDER SPEED S-32 = RETURNS FILTER BYPASS S-33 = HYDRAULIC RESERVOIR LEVEL S-34 = GEARBOX FILTER BYPASS

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0665-04 RHM Rotor Speed (Decrease) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Rotor Speed switch S-17 decrease circuit voltage is <0.5 volts. Possible Failure Modes: 1. The rotor speed decrease circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the rotor speed decrease switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the rotor speed decrease switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X046 from the Rotor Speed switch S-17. Use a multimeter to check for continuity between the harness side of connector X046 pin 1 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Rotor Speed switch S-17 has failed. Replace the switch. 3. Disconnect connector X030 from the RHM. With the Rotor Speed switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X030 pin 4 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X030 pin 4 and connector X046 pin 1 wire 348 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X030 from the RHM. Use a multimeter to check for continuity between connector X030 pin 4 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0665-07 RHM Rotor Speed (Decrease) Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Rotor Speed switch S-17 decrease circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The rotor speed decrease circuit is out of range. 2. The RHM has failed internally. 3. The Rotor Speed switch S-17 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the rotor speed decrease switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the rotor speed decrease switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X046 from the Rotor Speed switch S-17. Turn the ignition switch on and actuate the Rotor Speed switch S-17. Use a multimeter to check for 12 volts on the switch side of connector X046 pin 1 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the Rotor Speed switch S-17 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X046 and disconnect connector X030 from the RHM. With the Rotor Speed switch S-17 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X030 pin 4 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X030 pin 4 and connector X046 pin 1 wire 348 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X030 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X030 pin 4 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

HYDRAULIC FRAME--10

B-18 = HYD OIL RESERVOIR TEMP B-32 = GEARBOX TEMPERATURE B-35 = LOW CONTROL PRESSURE S-17 = ROTOR SPEED

S-18 = FEEDER SPEED S-32 = RETURNS FILTER BYPASS S-33 = HYDRAULIC RESERVOIR LEVEL S-34 = GEARBOX FILTER BYPASS

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0666-04 RHM Feeder Speed (Increase) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Feeder Speed switch S-18 increase circuit voltage is <0.5 volts. Possible Failure Modes: 1. The feeder speed increase circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the feeder speed increase switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the feeder speed increase switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X047 from the Feeder Speed switch S-18. Use a multimeter to check for continuity between the harness side of connector X047 pin 3 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Feeder Speed switch S-18 has failed. Replace the switch. 3. Disconnect connector X030 from the RHM. With the Feeder Speed switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X030 pin 12 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X030 pin 12 and connector X047 pin 3 wire 351 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X030 from the RHM. Use a multimeter to check for continuity between connector X030 pin 12 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0666-07 RHM Feeder Speed (Increase) Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Feeder Speed switch S-18 increase circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The feeder speed increase circuit is out of range. 2. The RHM has failed internally. 3. The Feeder Speed switch S-18 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the feeder speed increase switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the feeder speed increase switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X047 from the Feeder Speed switch S-18. Turn the ignition switch on and actuate the Feeder Speed switch S-18. Use a multimeter to check for 12 volts on the switch side of connector X047 pin 3 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the Feeder Speed switch S-18 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X047 and disconnect connector X030 from the RHM. With the Feeder Speed switch S-18 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X030 pin 12 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X030 pin 12 and connector X047 pin 3 wire 351 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X030 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X030 pin 12 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

HYDRAULIC FRAME--10

B-18 = HYD OIL RESERVOIR TEMP B-32 = GEARBOX TEMPERATURE B-35 = LOW CONTROL PRESSURE S-17 = ROTOR SPEED

S-18 = FEEDER SPEED S-32 = RETURNS FILTER BYPASS S-33 = HYDRAULIC RESERVOIR LEVEL S-34 = GEARBOX FILTER BYPASS

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0667-04 RHM Feeder Speed (Decrease) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Feeder Speed switch S-18 decrease circuit voltage is <0.5 volts. Possible Failure Modes: 1. The feeder speed decrease circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the feeder speed decrease switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the feeder speed decrease switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X047 from the Feeder Speed switch S-18. Use a multimeter to check for continuity between the harness side of connector X047 pin 1 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Feeder Speed switch S-18 has failed. Replace the switch. 3. Disconnect connector X030 from the RHM. With the Feeder Speed switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X030 pin 5 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X030 pin 5 and connector X047 pin 1 wire 350 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X030 from the RHM. Use a multimeter to check for continuity between connector X030 pin 5 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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FAULT CODE – E0667-07 RHM Feeder Speed (Decrease) Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Feeder Speed switch S-18 decrease circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The feeder speed decrease circuit is out of range. 2. The RHM has failed internally. 3. The Feeder Speed switch S-18 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the feeder speed decrease switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the feeder speed decrease switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X047 from the Feeder Speed switch S-18. Turn the ignition switch on and actuate the Feeder Speed switch S-18. Use a multimeter to check for 12 volts on the switch side of connector X047 pin 1 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the Feeder Speed switch S-18 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X047 and disconnect connector X030 from the RHM. With the Feeder Speed switch S-18 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X030 pin 5 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X030 pin 5 and connector X047 pin 1 wire 350 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X030 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X030 pin 5 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

HYDRAULIC FRAME--10

B-18 = HYD OIL RESERVOIR TEMP B-32 = GEARBOX TEMPERATURE B-35 = LOW CONTROL PRESSURE S-17 = ROTOR SPEED

S-18 = FEEDER SPEED S-32 = RETURNS FILTER BYPASS S-33 = HYDRAULIC RESERVOIR LEVEL S-34 = GEARBOX FILTER BYPASS

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0668-04 RHM Park Brake (On) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Park Brake switch S-09 on circuit voltage is <0.5 volts. Possible Failure Modes: 1. The park brake on circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the park brake on switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the park brake on switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X052 from the Park Brake switch S-09. Use a multimeter to check for continuity between the harness side of connector X052 pin 3 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Park Brake switch S-09 has failed. Replace the switch. 3. Disconnect connector X029 from the RHM. With the Park Brake on switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X029 pin 9 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X029 pin 9 and connector X052 pin 3 wire 334 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X029 from the RHM. Use a multimeter to check for continuity between connector X029 pin 9 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

L-01 = NEUTRAL LOCK SOLENOID R-04 = GROUND SPEED POT S-09 = PARK BRAKE S-10 = REAR WHEEL ASSIST

S-11 = DUAL RANGE S-12 = ON THE ROAD SWITCH S-24 = GEAR SELECT

DRIVES FRAME--7

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FAULT CODE – E0669-04 RHM Park Brake (Off) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Park Brake switch S-09 off circuit voltage is <0.5 volts. Possible Failure Modes: 1. The park brake off circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the park brake off switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the park brake off switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X052 from the Park Brake switch S-09. Use a multimeter to check for continuity between the harness side of connector X052 pin 1 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Park Brake switch S-09 has failed. Replace the switch. 3. Disconnect connector X029 from the RHM. With the Park Brake off switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X029 pin 1 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X029 pin 1 and connector X052 pin 1 wire 335 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X029 from the RHM. Use a multimeter to check for continuity between connector X029 pin 1 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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L-01 = NEUTRAL LOCK SOLENOID R-04 = GROUND SPEED POT S-09 = PARK BRAKE S-10 = REAR WHEEL ASSIST

S-11 = DUAL RANGE S-12 = ON THE ROAD SWITCH S-24 = GEAR SELECT

DRIVES FRAME--7

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0670-04 RHM Concave Clearance (Decrease) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Concave Clearance switch S-16 decrease circuit voltage is <0.5 volts. Possible Failure Modes: 1. The concave clearance decrease circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the concave clearance decrease switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the concave clearance decrease switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X044 from the Concave Clearance switch S-16. Use a multimeter to check for continuity between the harness side of connector X044 pin 1 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Concave Clearance switch S-16 has failed. Replace the switch. 3. Disconnect connector X030 from the RHM. With the Concave Clearance switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X030 pin 8 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X030 pin 8 and connector X044 pin 1 wire 346 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X030 from the RHM. Use a multimeter to check for continuity between connector X030 pin 8 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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FAULT CODE – E0670-07 RHM Concave Clearance (Decrease) Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Concave Clearance switch S-16 decrease circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The concave clearance decrease circuit is out of range. 2. The RHM has failed internally. 3. The Concave Clearance switch S-16 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the concave clearance decrease switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the concave clearance decrease switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X044 from the Concave Clearance switch S-16. Turn the ignition switch on and actuate the Concave Clearance switch S-16. Use a multimeter to check for 12 volts on the switch side of connector X044 pin 1 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the Concave Clearance switch S-16 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X044 and disconnect connector X030 from the RHM. With the Concave Clearance switch S-16 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X030 pin 8 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X030 pin 8 and connector X044 pin 1 wire 346 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X030 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X030 pin 8 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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B-45 = GEARBOX CLUTCH TEMP K-16 = CONCAVE/COVERS RELAY M-04 = CONCAVE CLEARANCE MOTOR M-12 = COVERS MOTOR

R-06 = CONCAVE POSITION S-16 = CONCAVE CLEARANCE

THRESHER FRAME--17

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FAULT CODE – E0671-04 RHM Concave Clearance (Increase) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Concave Clearance switch S-16 increase circuit voltage is <0.5 volts. Possible Failure Modes: 1. The concave clearance increase circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the concave clearance increase switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the concave clearance increase switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X044 from the Concave Clearance switch S-16. Use a multimeter to check for continuity between the harness side of connector X044 pin 3 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Concave Clearance switch S-16 has failed. Replace the switch. 3. Disconnect connector X030 from the RHM. With the Concave Clearance switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X030 pin 3 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X030 pin 3 and connector X044 pin 3 wire 347 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X030 from the RHM. Use a multimeter to check for continuity between connector X030 pin 3 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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FAULT CODE – E0671-07 RHM Concave Clearance (Increase) Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Concave Clearance switch S-16 increase circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The concave clearance increase circuit is out of range. 2. The RHM has failed internally. 3. The Concave Clearance switch S-16 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the concave clearance increase switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the concave clearance increase switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X044 from the Concave Clearance switch S-16. Turn the ignition switch on and actuate the Concave Clearance switch S-16. Use a multimeter to check for 12 volts on the switch side of connector X044 pin 3 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the Concave Clearance switch S-16 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X044 and disconnect connector X030 from the RHM. With the Concave Clearance switch S-16 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X030 pin 3 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X030 pin 3 and connector X044 pin 3 wire 347 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X030 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X030 pin 3 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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B-45 = GEARBOX CLUTCH TEMP K-16 = CONCAVE/COVERS RELAY M-04 = CONCAVE CLEARANCE MOTOR M-12 = COVERS MOTOR

R-06 = CONCAVE POSITION S-16 = CONCAVE CLEARANCE

THRESHER FRAME--17

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FAULT CODE – E0672-04 RHM Upper Sieve (Decrease) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Upper Sieve switch S-13 decrease circuit voltage is <0.5 volts. Possible Failure Modes: 1. The upper sieve decrease circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the upper sieve decrease switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the upper sieve decrease switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X043 from the Upper Sieve switch S-13. Use a multimeter to check for continuity between the harness side of connector X043 pin 1 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Upper Sieve switch S-13 has failed. Replace the switch. 3. Disconnect connector X030 from the RHM. With the Upper Sieve switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X030 pin 7 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X030 pin 7 and connector X043 pin 1 wire 340 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X030 from the RHM. Use a multimeter to check for continuity between connector X030 pin 7 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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FAULT CODE – E0672-07 RHM Upper Sieve (Decrease) Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Upper Sieve switch S-13 decrease circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The upper sieve decrease circuit is out of range. 2. The RHM has failed internally. 3. The Upper Sieve switch S-13 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the upper sieve decrease switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the upper sieve decrease switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X043 from the Upper Sieve switch S-13. Turn the ignition switch on and actuate the Upper Sieve switch S-13. Use a multimeter to check for 12 volts on the switch side of connector X043 pin 1 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the Upper Sieve switch S-13 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X043 and disconnect connector X030 from the RHM. With the Concave Clearance switch S-16 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X030 pin 7 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X030 pin 7 and connector X043 pin 1 wire 340 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X030 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X030 pin 7 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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B-16 = CLEANING FAN RPM B-21 = SIEVES LOSS F-22 = SHOE LEVELING MOTOR FUSE L-44 = FAN DRIVE SOLENOID

M-03 = SHOE LEVELING ACTUATOR S-13 = UPPER SIEVE S-14 = LOWER SIEVE S-15 = FAN SPEED

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0673-04 RHM Upper Sieve (Increase) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Upper Sieve switch S-13 increase circuit voltage is <0.5 volts. Possible Failure Modes: 1. The upper sieve increase circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the upper sieve increase switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the upper sieve increase switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X043 from the Upper Sieve switch S-13. Use a multimeter to check for continuity between the harness side of connector X043 pin 3 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Upper Sieve switch S-13 has failed. Replace the switch. 3. Disconnect connector X030 from the RHM. With the Upper Sieve switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X030 pin 2 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X030 pin 2 and connector X043 pin 3 wire 341 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X030 from the RHM. Use a multimeter to check for continuity between connector X030 pin 2 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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FAULT CODE – E0673-07 RHM Upper Sieve (Increase) Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Upper Sieve switch S-13 increase circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The upper sieve increase circuit is out of range. 2. The RHM has failed internally. 3. The Upper Sieve switch S-13 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the upper sieve increase switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the upper sieve increase switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X043 from the Upper Sieve switch S-13. Turn the ignition switch on and actuate the Upper Sieve switch S-13. Use a multimeter to check for 12 volts on the switch side of connector X043 pin 3 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the Upper Sieve switch S-13 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X043 and disconnect connector X030 from the RHM. With the Upper Sieve switch S-13 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X030 pin 2 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X030 pin 2 and connector X043 pin 3 wire 341 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X030 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X030 pin 2 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

B-16 = CLEANING FAN RPM B-21 = SIEVES LOSS F-22 = SHOE LEVELING MOTOR FUSE L-44 = FAN DRIVE SOLENOID

M-03 = SHOE LEVELING ACTUATOR S-13 = UPPER SIEVE S-14 = LOWER SIEVE S-15 = FAN SPEED

55-74

CLEANING FRAME--19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0674-04 RHM Lower Sieve (Decrease) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Lower Sieve switch S-14 decrease circuit voltage is <0.5 volts. Possible Failure Modes: 1. The lower sieve decrease circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the lower sieve decrease switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the lower sieve decrease switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X042 from the Lower Sieve switch S-14. Use a multimeter to check for continuity between the harness side of connector X042 pin 1 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Lower Sieve switch S-14 has failed. Replace the switch. 3. Disconnect connector X030 from the RHM. With the Lower Sieve switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X030 pin 1 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X030 pin 1 and connector X042 pin 1 wire 342 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X030 from the RHM. Use a multimeter to check for continuity between connector X030 pin 1 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0674-07 RHM Lower Sieve (Decrease) Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Lower Sieve switch S-14 decrease circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The lower sieve decrease circuit is out of range. 2. The RHM has failed internally. 3. The Lower Sieve switch S-14 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the lower sieve decrease switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the lower sieve decrease switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X042 from the Lower Sieve switch S-14. Turn the ignition switch on and actuate the Lower Sieve switch S-14. Use a multimeter to check for 12 volts on the switch side of connector X042 pin 1 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the Lower Sieve switch S-14 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X042 and disconnect connector X030 from the RHM. With the Lower Sieve switch S-14 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X030 pin 1 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X030 pin 1 and connector X042 pin 1 wire 342 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X030 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X030 pin 1 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

B-16 = CLEANING FAN RPM B-21 = SIEVES LOSS F-22 = SHOE LEVELING MOTOR FUSE L-44 = FAN DRIVE SOLENOID

M-03 = SHOE LEVELING ACTUATOR S-13 = UPPER SIEVE S-14 = LOWER SIEVE S-15 = FAN SPEED

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CLEANING FRAME--19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0675-04 RHM Lower Sieve (Increase) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Lower Sieve switch S-14 increase circuit voltage is <0.5 volts. Possible Failure Modes: 1. The lower sieve increase circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the lower sieve increase switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the lower sieve increase switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X042 from the Lower Sieve switch S-14. Use a multimeter to check for continuity between the harness side of connector X042 pin 3 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Lower Sieve switch S-14 has failed. Replace the switch. 3. Disconnect connector X030 from the RHM. With the Concave Clearance switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X030 pin 6 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X030 pin 6 and connector X042 pin 3 wire 343 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X030 from the RHM. Use a multimeter to check for continuity between connector X030 pin 6 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0675-07 RHM Lower Sieve (Increase) Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Lower Sieve switch S-14 increase circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The lower sieve increase circuit is out of range. 2. The RHM has failed internally. 3. The Lower Sieve switch S-14 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the lower sieve increase switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the lower sieve increase switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X042 from the Lower Sieve switch S-14. Turn the ignition switch on and actuate the Lower Sieve switch S-14. Use a multimeter to check for 12 volts on the switch side of connector X042 pin 3 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the Lower Sieve switch S-14 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X042 and disconnect connector X030 from the RHM. With the Lower Sieve switch S-14 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X030 pin 6 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X030 pin 6 and connector X042 pin 3 wire 343 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X030 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X030 pin 6 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

B-16 = CLEANING FAN RPM B-21 = SIEVES LOSS F-22 = SHOE LEVELING MOTOR FUSE L-44 = FAN DRIVE SOLENOID

M-03 = SHOE LEVELING ACTUATOR S-13 = UPPER SIEVE S-14 = LOWER SIEVE S-15 = FAN SPEED

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CLEANING FRAME--19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0676-04 RHM Work Width (Increase) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the HHC Fine Adjust switch S-06 increase circuit voltage is <0.5 volts. Possible Failure Modes: 1. The work width increase circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the HHC Fine Adjust increase switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the HHC Fine Adjust increase switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X062 from the HHC Fine Adjust switch S-06. Use a multimeter to check for continuity between the harness side of connector X062 pin 1 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the HHC Fine Adjust switch S-06 has failed. Replace the switch. 3. Disconnect connector X027 from the RHM. With the HHC Fine Adjust switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X027 pin 7 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X027 pin 7 and connector X062 pin 1 wire 303 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X027 from the RHM. Use a multimeter to check for continuity between connector X027 pin 7 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0676-07 RHM HHC Fine Adjust (Increase) Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the HHC Fine Adjust switch S-06 increase circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The work width increase circuit is out of range. 2. The RHM has failed internally. 3. The HHC Fine Adjust switch S-06 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the HHC Fine Adjust increase switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the HHC Fine Adjust increase switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X062 from the HHC Fine Adjust switch S-06. Turn the ignition switch on and actuate the HHC Fine Adjust switch S-06. Use a multimeter to check for 12 volts on the switch side of connector X062 pin 7 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the HHC Fine Adjust switch S-06 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X062 and disconnect connector X027 from the RHM. With the HHC Fine Adjust switch S-06 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X027 pin 7 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X027pin 7 and connector X062 pin 1 wire 303 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X030 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X027 pin 7 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0677-04 RHM HHC Fine Adjust (Decrease) Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the HHC Fine Adjust switch S-06 decrease circuit voltage is <0.5 volts. Possible Failure Modes: 1. The work width decrease circuit is shorted to ground. 2. The RHM has failed internally. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the HHC Fine Adjust decrease switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the HHC Fine Adjust decrease switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains low (0.0 to 0.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X062 from the HHC Fine Adjust switch S-06. Use a multimeter to check for continuity between the harness side of connector X062 pin 3 and chassis ground. There should not be continuity to ground. A. If continuity is found, continue with step 3. B. If no continuity is found, the Upper Sieve switch S-13 has failed. Replace the switch. 3. Disconnect connector X027 from the RHM. With the HHC Fine Adjust switch in the “Off” position, use a multimeter to check for continuity between the harness side of connector X027 pin 6 and chassis ground. There should not be continuity to ground. A. If continuity is found, there is a short to ground in the RH Console (RC) harness between RHM connector X027 pin 6 and connector X062 pin 3 wire 304 yellow. Locate and repair the short. B. If no continuity is found, continue with step 4. 4. Disconnect connector X027 from the RHM. Use a multimeter to check for continuity between connector X027 pin 6 on the RHM and chassis ground. There should not be continuity to ground. A. If continuity is found, the RHM has failed. Replace the module. B. If no continuity is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0677-07 RHM HHC Fine Adjust (Decrease) Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the HHC Fine Adjust switch S-06 decrease circuit voltage is >3.5 volts since power up. Possible Failure Modes: 1. The work width decrease circuit is out of range. 2. The RHM has failed internally. 3. The HHC Fine Adjust switch S-06 is stuck or shorted to >3.5 volts. Solution: 1. Using the display monitor diagnostic capability to view “Item” status; reference Section 55 Chapter 2, if needed, observe the voltage while operating the switch. The normal operating range for the HHC Fine Adjust decrease switch in the “Off” position is 0.5 – 3.5 volts. The normal operating range for the HHC Fine Adjust decrease switch in the “On” position is 3.5 – 5.0 volts. NOTE: The switch actually supplies 12 volts (battery voltage) to the module when in the “On” position, however, the Diagnostic screen bar graph only displays to 5 volts. A. If the voltage reading remains high (> 3.5 volts) out of range, continue with step 2. B. If the voltage reading is within the proper limits, continue the troubleshooting with step 5. 2. Turn the ignition switch off. Disconnect connector X062 from the HHC Fine Adjust switch S-06. Turn the ignition switch on and actuate the HHC Fine Adjust switch S-06. Use a multimeter to check for 12 volts on the switch side of connector X062 pin 3 and chassis ground. There should be 12 volts to ground. A. If 12 volts is found, continue with step 3. B. If 12 volts is not found, the HHC Fine Adjust switch S-06 has failed. Replace the switch. 3. Turn the ignition switch off. Reconnect connector X062 and disconnect connector X027 from the RHM. With the HHC Fine Adjust switch S-06 in the off position, turn the ignition switch on. Use a multimeter to check for 12 volts between the harness side of connector X027 pin 6 and chassis ground. There should not be 12 volts to ground. A. If 12 volts is found, there is a short to a high source in the RH Console (RC) harness between RHM connector X027 pin 6 and connector X062 pin 3 wire 304 yellow. Locate and repair the short. B. If 12 volts is not found, continue with step 4. 4. With connector X027 disconnected from the RHM and the ignition switch on. Use a multimeter to check for voltage at connector X027 pin 6 on the RHM and chassis ground. There should not be any voltage to ground. A. If > 3.5 volts is found, the RHM has failed. Replace the module. B. If no voltage is found, continue with step 5. 5. The fault is either intermittent or is no longer valid. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires and repair any damage found. Erase the error code and continue operation. If the fault reoccurs, reload the RHM software. If that does not correct the concern, replace the RHM.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0678-06 Current Protection Line 0 Short Circuit Cause: The Right Hand Module (RHM) has detected that the Current Protection Line 0 circuit current is >0.2 amps. Possible failure modes: 1. The Current Protection Line 0 circuit is shorted to another circuit causing excessive current flow. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: The “Line 0” circuit is the common line for the unloader switches and unlock switch in the multifunction handle, and connects between RHM connector X028 pin 1 and MFH connector X385 pin 10. 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the current. The normal operating range for the Current Protection Line 0 circuit is 0.00 -- 0.20 amps. A. If the current reading is >0.20 amps, continue with Step 2. B. If the current reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-87

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23 A. If all of the switches and wires test good, then the MFH is good. Reload the system software to see if the fault code clears. If the fault is still present after reloading the software, replace the RHM. Continue troubleshooting at Step 3. B. If the ohmmeter reads outside the range given above, then the fault is in the MFH. Replace the MFH. Continue troubleshooting at Step 3. 3. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires. A. Repair any damage found during visual inspection. B. If no damage is found, erase the fault code and continue operation.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0679-06 Current Protection Line 1 Short Circuit Cause: The Right Hand Module (RHM) has detected that the Current Protection Line 1 circuit current is >0.2 amps. Possible failure modes: 1. The Current Protection Line 1 circuit is shorted to another circuit causing excessive current flow. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: The “Line 1” circuit is the common line for the reel position and emergency stop switches in the multifunction handle, and connects between RHM connector X028 pin 7 and MFH connector X385 pin 8. 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the current. The normal operating range for the Current Protection Line 1 circuit is 0.00 -- 0.20 amps. A. If the current reading is >0.20 amps, continue with Step 2. B. If the current reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-90

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-92

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0680-06 Current Protection Line 2 Short Circuit Cause: The Right Hand Module (RHM) has detected that the Current Protection Line 2 circuit current is >0.2 amps. Possible failure modes: 1. The Current Protection Line 2 circuit is shorted to another circuit causing excessive current flow. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: The “Line 2” circuit is the common line for the header position switches in the multifunction handle, and connects between RHM connector X028 pin 6 and MFH connector X385 pin 9. 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the current. The normal operating range for the Current Protection Line 2 circuit is 0.00 -- 0.20 amps. A. If the current reading is >0.20 amps, continue with Step 2. B. If the current reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-93

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-94

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-95

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0681-04 HSW Unload Tube Out Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Unload Tube Out circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Unload Tube Out circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Unload Tube Out circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-96

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-97

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0681-07 HSW Unload Tube Out Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Unload Tube Out circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Unload Tube Out circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Unload Tube Out circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. + Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

55-98

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-99

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-100

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0682-04 HSW Unload Tube Out Lock Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Unload Tube Out Lock circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Unload Tube Out Lock circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Unload Tube Out Lock circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-101

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-102

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0682-07 HSW Unload Tube Out Lock Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Unload Tube Out Lock circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Unload Tube Out Lock circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Unload Tube Out Lock circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. + Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-103

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-104

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-105

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0683-04 HSW Unload Auger – Engage Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Unload Auger Engage circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Unload Auger Engage circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Unload Auger Engage circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-106

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-107

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0683-07 HSW Unload Auger – Engage Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Unload Auger Engage circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Unload Auger Engage circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Unload Auger Engage circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. + Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-108

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-109

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-110

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0684-04 HSW Unload Tube In Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Unload Tube In circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Unload Tube In circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Unload Tube In circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-111

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-112

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0684-07 HSW Unload Tube In Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Unload Tube In circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Unload Tube In circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Unload Tube In circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. + Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-113

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-114

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-115

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0685-04 HSW Unload Tube In Lock Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Unload Tube In Lock circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Unload Tube In Lock circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Unload Tube In Lock circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-116

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-117

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0685-07 HSW Unload Tube In Lock Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Unload Tube In Lock circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Unload Tube In Lock circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Unload Tube In Lock circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. + Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-118

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-119

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-120

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0686-04 HSW ILM (Handle) Unlock Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) ILM Handle Unlock circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Handle Unlock circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW ILM Handle Unlock circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-121

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-122

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0686-07 HSW ILM (Handle) Unlock Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) ILM Handle Unlock circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Handle Unlock circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Handle Unlock circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. + Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-123

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-124

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-125

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0688-04 HSW Reel Fore Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Reel Fore circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Reel Fore circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Reel Fore circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-126

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-127

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0688-07 HSW Reel Fore Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Reel Fore circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Reel Fore circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Reel Fore circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-128

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-129

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-130

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0689-04 HSW Reel Down Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Reel Down circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Reel Down circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Reel Down circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-131

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-132

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0689-07 HSW Reel Down Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Reel Down circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Reel Down circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Reel Down circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-133

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-134

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-135

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0690-04 HSW Reel Up Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Reel Up circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Reel Up circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Reel Up circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. + Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-136

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-137

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0690-07 HSW Reel Up Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Reel Up circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Reel Up circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Reel Up circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-138

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-139

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-140

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0691-04 HSW Reel Speed Decr. Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Reel Speed Decr. circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Reel Speed Decr. circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Reel Speed Decr. circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-141

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-142

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0691-07 HSW Reel Speed Decr. Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Reel Speed Decr. circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Reel Speed Decr. circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Reel Speed Decr. circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. + Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-143

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-144

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-145

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0692-04 HSW Reel Back Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Reel Back circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Reel Back circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Reel Back circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-146

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-147

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0692-07 HSW Reel Back Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Reel Back circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Reel Back circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Reel Back circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-148

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-149

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-150

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0693-04 HSW Reel Speed Incr. Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Reel Speed Incr. circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Reel Speed Incr. circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Reel Speed Incr. circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-151

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-152

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0693-07 HSW Reel Speed Incr. Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Reel Speed Incr. circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Reel Speed Incr. circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Reel Speed Incr. circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. + Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-153

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-154

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-155

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0694-04 HSW FAULT CODE – Emergency Stop Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Emergency Stop circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Emergency Stop circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Emergency Stop circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-156

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-157

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0694-07 HSW FAULT CODE – Emergency Stop Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Emergency Stop circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Emergency Stop circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Emergency Stop circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. + Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-158

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-159

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-160

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0695-04 HSW Lateral Tilt CCW Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Lateral Tilt CCW circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Lateral Tilt CCW circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Lateral Tilt CCW circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-161

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-162

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0695-07 HSW Lateral Tilt CCW Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Lateral Tilt CCW circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Lateral Tilt CCW circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Lateral Tilt CCW circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. + Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-163

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-164

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-165

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0696-04 HSW Header Down Fast Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Header Down Fast circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Header Down Fast circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Header Down Fast circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-166

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-167

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0696-07 HSW Header Down Fast Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Header Down Fast circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Header Down Fast circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Header Down Fast circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. + Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-168

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-169

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-170

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0697-04 HSW Header Up Slow Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Header Up Slow circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Header Up Slow circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Header Up Slow circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-171

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-172

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0697-07 HSW Header Up Slow Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Header Up Slow circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Header Up Slow circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Header Up Slow circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. + Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-173

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-174

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-175

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0698-04 HSW Header Up Fast Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Header Up Fast circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Header Up Fast circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Header Up Fast circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-176

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-177

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0698-07 HSW Header Up Fast Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Header Up Fast circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Header Up Fast circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Header Up Fast circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. + Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-178

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-179

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-180

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0699-04 HSW HHC Resume Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) HHC Resume circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW HHC Resume circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW HHC Resume circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-181

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-182

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0699-07 HSW HHC Resume Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) HHC Resume circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW HHC Resume circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW HHC Resume circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-183

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-184

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-185

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0700-04 HSW Lateral Tilt CW Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Lateral Tilt CW circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Lateral Tilt CW circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Lateral Tilt CW circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-186

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-187

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0700-07 HSW Lateral Tilt CW Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Lateral Tilt CW circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Lateral Tilt CW circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Lateral Tilt CW circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-188

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-189

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-190

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0701-04 HSW Header Down Slow Shorted to Low Source Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Header Down Slow circuit voltage is <0.25 volts. Possible failure modes: 1. The HSW Header Down Slow circuit is shorted to ground. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Header Down Slow circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <0.25 volts, continue with Step 2. B. If the voltage reading is within the proper limits, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-191

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-192

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

FAULT CODE – E0701-07 HSW Header Down Slow Mechanical Out of Range Cause: The Right Hand Module (RHM) has detected that the Handle Switch (HSW) Header Down Slow circuit voltage is <4.0 volts since startup. Possible failure modes: 1. The HSW Header Down Slow circuit is shorted to <4.0 volts -- this can happen if the switch is stuck closed. 2. RHM internal failure. 3. Multi Function Handle (MFH) failure. Solution: 1. Verify the fault is present. Using the display monitor diagnostic capability to view “item” status, reference Section 55 Chapter 2, if needed, observe the voltage. The normal operating range for the HSW Header Down Slow circuit is 0.25 -- 5.5 volts. A. If the voltage reading is <4.0 volts, continue with Step 2. B. If the voltage reading is >4.0 volts, the fault may be intermittent. Continue troubleshooting at Step 3. 2. Verify the MFH is good. Turn off the ignition switch. Disconnect the Right Console Harness connector X028. Using an ohmmeter, measure the continuity between the positive (+) and negative (--) pins of the Right Console Harness connector X028 according to the table below. Operate the respective switch while observing the ohmmeter. When a switch is activated the meter should read between 1.5M -- 1.7M ohms, and open when idle. Check for shorted wiring to other pins as you test each circuit. Refer to the schematic as needed. MFH Switch Unload Tube Out Unload Tube Out Lock Unload Auger Engage Unload Tube In Unload Tube In Lock Handle Unlock Reel Fore Reel Down Reel Up Reel Speed Decr. Reel Back Reel Speed Incr. Emergency Stop Lateral Tilt CCW Header Down Fast Header Up Slow Header Up Fast HHC Resume Lateral Tilt CW Header Down Slow

+ Pin 5 11 4 10 9 2 5 11 4 10 9 2 8 5 11 4 10 9 2 8

55-193

-- Pin 1 1 1 1 1 1 7 7 7 7 7 7 7 6 6 6 6 6 6 6

55-194

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

S-03 = MULTIFUNCTION HANDLE S-04 = HEADER HEIGHT MODE S-06 = HHC FINE ADJUST S-08 = REEL SPEED MODE

S-21 = ALTERNATE SETTINGS S-51 = VERTICAL KNIVES

HEADER FRAME--11

55-195

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 23

55-196

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

SECTION 55 -- ELECTRICAL SYSTEMS Chapter 24 -- Cursor 10.3L Engine Error Codes CONTENTS Section

Description

Page

55-1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 IVECO 10.3L ENGINE FAULT CODE CROSS REFERENCE The following listing provides a cross reference from the Iveco Diagnostic Trouble Code (DTC) and Failure Mode Indicator (FMI) as reported by the EST ”Easy Engine Diagnostic and Download Tool -- Cursor (EDC7UC31)” to the CR9070 combine fault code number. •

Use the EST ”Easy Engine Diagnostic and Download Tool -- Cursor (EDC7UC31)” to access the ECU directly, and select ”DIAGNOSIS -- Faults Memory Reading”.

•

Select the desired fault, and click the ”Environmental Conditions” button to view the detailed fault information. Iveco DTC

Combine Fault Code

Failure Description, Cursor (CR) Vehicle 1 (Sensors/Plausibility checks)

111

E1536--02

111

E1536--03

111

E1536--04

111

E1536--12

211

E1537--02

211

E1537--03

211

E1537--04

211

E1537--12

311

E1538--02

311

E1538--03

311

E1538--04

112

E1539--03

112

E1539--04

112

E1539--12

212

E1540--03

212

E1540--04

212

E1540--12

119

E1541--02

No terminal 40 signal detected (Key On)

11A

E1542--03

Terminal 50 always pressed

11B

E1543--02

High resolution wheel speed CAN message

21B

E1544--02

Vehicle dynamics control unit CAN message

11C

E1545--03

Water in fuel

Fault path 1 for vehicle Speed sensing

Fault path 2 for vehicle Speed sensing(CAN)

Fault p path 3 for vehicle Speed p sensing g (max. ( pulse p width))

Accelerator Pedal 1

Accelerator Pedal 2

55-2

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Iveco DTC

Combine Fault Code

Failure Description, Cursor (CR) Vehicle 2 (Lamps/relays/actuators)

122

E1546--02

122

E1546--03

122

E1546--04

122

E1546--12

123

E1547--02

123

E1547--03

123

E1547--04

123

E1547--12

124

E1548--02

124

E1548--03

124

E1548--04

124

E1548--12

125

E1549--03

125

E1549--04

126

E1550--03

126

E1550--04

128

E1551--03

Main relay SCBatt (Lambda H./Grid H./Batt.switch)

228

E1552--04

Main relay SCGND (Lambda H./Grid H./Batt.switch)

129

E1553--03

129

E1553--04

12B

E1554--02

12B

E1554--03

12B

E1554--04

12C

E1555--02

12C

E1555--03

12C

E1555--04

12D

E1556--03

12D

E1556--04

22D

E1557--03

22D

E1557--04

12E

E1558--03

Power stage fault status for MIL

Power stage for system lamp

Cold start lamp

Main relay defect (for engine brake decompr. decompr valve P342) Battery voltage fault

Main relay 3 (A/C compr./fuel compr /fuel filter heater)

Power stage g air heater 1 actuator

Power stage g air heater 2 actuator

Air heater test switch on (volt. (volt below lower threshold) Air heater test switch off (volt. (volt exceeds higher threshold) Grid heater always switched on

55-3

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Iveco DTC

Combine Fault Code

Failure Description, Cursor (CR) Engine 1 (Temperature and Pressure Sensors)

131

E1559--02

131

E1559--03

131

E1559--04

131

E1559--12

132

E1560--12

133

E1561--02

133

E1561--03

133

E1561--04

134

E1562--02

134

E1562--03

134

E1562--04

134

E1562--12

135

E1563--03

135

E1563--04

138

E1564--02

138

E1564--03

138

E1564--04

138

E1564--12

238

E1565--12

13A

E1566--02

13A

E1566--03

13A

E1566--04

13A

E1566--12

23A

E1567--12

13D

E1568--02

13D

E1568--03

13D

E1568--04

13E

E1569--12

Coolant temperature sensor

Coolant temperature sensor dynamic test Boost Temp. p Signal g

Boost pressure sensor

Fuel Temp. Temp Signal

Oil Pressure Sensor

Oil Pressure too low

Oil Temp. Temp Sensor

Oil Temperature above normal Fuel pressure p sensor Coolant temperature sensor absolute test

55-4

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Iveco DTC

Combine Fault Code

Failure Description, Cursor (CR) Engine 2 (Speed sensing/actuators)

141

E1570--03

141

E1570--04

142

E1571--04

143

E1572--03

143

E1572--04

144

E1573--03

144

E1573--12

145

E1574--02

145

E1574--03

145

E1574--04

145

E1574--12

146

E1575--02

146

E1575--03

146

E1575--04

147

E1576--03

147

E1576--04

149

E1577--02

149

E1577--03

149

E1577--04

149

E1577--12

14A

E1578--02

Engine Compartment Start Button is stuck

14D

E1579--03

Engine overspeed protection

14E

E1580--02

14E

E1580--03

14E

E1580--04

14E

E1580--12

Crankshaft sensor failure Running with camshaft sensor only Camshaft sensor failure Offset between camshaft and crankshaft

Power stage Fan actuator

Power stage g Fan 2 actuator

Fan speed sensor signal

Fuel filter heating output

TurboCompound monitoring

Fuel Metering Unit Injector Systems 151

E1581--02

151

E1581--03

151

E1581--04

151

E1581--12

152

E1582--02

152

E1582--03

152

E1582--04

152

E1582--12

Cylinder 1 specific errors

Cylinder 2 specific errors

55-5

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Iveco DTC

Combine Fault Code

153

E1583--02

153

E1583--03

153

E1583--04

153

E1583--12

154

E1584--02

154

E1584--03

154

E1584--04

154

E1584--12

155

E1585--02

155

E1585--03

155

E1585--04

155

E1585--12

156

E1586--02

156

E1586--03

156

E1586--04

156

E1586--12

157

E1587--02

Failure Description, Cursor (CR)

Cylinder 3 specific errors

Cylinder 4 specific errors

Cylinder 5 specific errors

Cylinder 6 specific errors

Disabled Cylinder Shutoff function Injectors 1

161

E1588--02

161

E1588--03

161

E1588--04

161

E1588--12

162

E1589--02

162

E1589--03

162

E1589--04

162

E1589--12

163

E1590--02

163

E1590--03

163

E1590--04

163

E1590--12

164

E1591--02

164

E1591--03

164

E1591--04

164

E1591--12

Cylinder 1 -- Short circuit Low/High

Cylinder 2 -- Short circuit Low/High

Cylinder 3 -- Short circuit Low/High

Cylinder 4 -- Short circuit Low/High

55-6

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Iveco DTC

Combine Fault Code

165

E1592--02

165

E1592--03

165

E1592--04

165

E1592--12

166

E1593--02

166

E1593--03

166

E1593--04

166

E1593--12

167

E1594--02

167

E1594--03

167

E1594--04

167

E1594--12

168

E1595--02

168

E1595--03

168

E1595--04

168

E1595--12

169

E1596--02

169

E1596--03

169

E1596--04

169

E1596--12

16A

E1597--02

16A

E1597--03

16A

E1597--04

16A

E1597--12

16B

E1598--02

16B

E1598--03

16B

E1598--04

16B

E1598--12

16C

E1599--02

16C

E1599--03

16C

E1599--04

16C

E1599--12

16D

E1600--03

16E

E1601--02

16E

E1601--03

16E

E1601--04

16E

E1601--12

Failure Description, Cursor (CR)

Cylinder 5 -- Short circuit Low/High

Cylinder 6 -- Short circuit Low/High

Cylinder 1 -- Open load

Cylinder 2 -- Open load

Cylinder 3 -- Open load

Cylinder 4 -- Open load

Cylinder 5 -- Open load

Cylinder 6 -- Open load

Fault path to disable rail monitor. while compr. test active

The minimum number of injections was not reached ----> > stop the engine

55-7

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Iveco DTC

Combine Fault Code

Failure Description, Cursor (CR) Injectors 2

171

E1602--02

171

E1602--03

171

E1602--04

171

E1602--12

172

E1603--02

172

E1603--03

172

E1603--04

172

E1603--12

173

E1604--02

173

E1604--03

173

E1604--04

173

E1604--12

174

E1605--02

174

E1605--03

174

E1605--04

174

E1605--12

175

E1606--03

275

E1607--03

275

E1607--04

176

E1608--03

276

E1609--03

276

E1609--04

177

E1610--03

277

E1611--03

277

E1611--04

178

E1612--03

278

E1613--03

278

E1613--04

179

E1614--03

279

E1615--03

279

E1615--04

17A

E1616--03

27A

E1617--03

27A

E1617--04

17B

E1618--03

Bank 1 specific errors -- Short circuit / not classifiable

Bank 1 specific warnings -- Open load

Bank 2 specific errors -- Short circuit / not classifiable

Bank 2 specific warnings -- Open load

Misfire Cylinder 1 Leakage or misfiring in cylinder 1 Misfire Cylinder 2 Leakage or misfiring in cylinder 2 Misfire Cylinder 3 Leakage or misfiring in cylinder 3 Misfire Cylinder 4 Leakage or misfiring in cylinder 4 Misfire Cylinder 5 Leakage or misfiring in cylinder 5 Misfire Cylinder 6 Leakage or misfiring in cylinder 6 Misfire in multiple cylinders

55-8

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Iveco DTC

Combine Fault Code

17C

E1619--02

17C

E1619--03

17C

E1619--04

17C

E1619--12

27C

E1620--02

27C

E1620--03

27C

E1620--04

27C

E1620--12

17D

E1621--02

17E

E1622--02

17E

E1622--03

17E

E1622--04

Failure Description, Cursor (CR)

Chip specific errors---->stop Chip--specific errors >stop engine

Common fault in combustion monitoring Fault p path of injection j limitation Air Inlet System / EGR

181

E1623--03

181

E1623--04

184

E1624--03

Messages SRA2EDC

187

E1625--03

AirCtl permanent positive governor deviaton

188

E1626--04

AirCtl permanent negative governor deviaton

18C

E1627--12

Monitoring of the controller

18F

E1628--12

Too long time spent in transition mode RgnNrm

Induction exhaust differential pressure

Boost System and Turbine Speed 191

E1629--02

191

E1629--03

191

E1629--04

192

E1630--03

Short circuit to Battery for BPA powerstage

292

E1631--04

Short circuit to Ground for BPA powerstage

392

E1632--02

392

E1632--12

193

E1633--02

193

E1633--03

193

E1633--04

193

E1633--12

293

E1634--02

293

E1634--03

293

E1634--04

293

E1634--12

Boost p pressure actuator current AD--channel

No load/excessive temperature for BPA power stage

Turbine speed

Actual turbo speed evaluation for interface

55-9

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Iveco DTC

Combine Fault Code

194

E1635--03

195

E1636--02

195

E1636--03

195

E1636--04

196

E1637--02

196

E1637--03

197

E1638--02

197

E1638--03

197

E1638--12

198

E1639--03

199

E1640--02

199

E1640--03

199

E1640--04

19A

E1641--02

19A

E1641--03

19B

E1642--03

19C

E1643--02

19C

E1643--03

19D

E1644--03

19D

E1644--04

19E

E1645--03

19E

E1645--04

Failure Description, Cursor (CR) Multi signal defects in EPCtl P2 pressure p errors in EPCtl

P3 pressure errors in EPCtl

Turbine speed p errors in EPCtl Multi signal defects in PCR P2 pressure p errors in PCR

Turbine speed errors in PCR High turbine speed and high air pressure P3 pressure errors in PCR Temperature of Inner control loop Temperature of Outer control loop Exhaust System (After Treatment)

1AB

E1646--03

1AB

E1646--04

2AB

E1647--03

2AB

E1647--04

2AB

E1647--12

2AC

E1648--02

1AD

E1649--02

1AD

E1649--03

1AD

E1649--04

1AD

E1649--12

Exhaust gas temperature sensor before turbine

Exhaust Gas Pipe p p pressure sensor CAN message EngGsFlowRt

Recirculated Engine Exhaust Gas Temp. Temp sensor

55-10

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Iveco DTC

Combine Fault Code

Failure Description, Cursor (CR) Interfaces 1 (CAN--Bus)

1B1

E1650--03

Busoff in CAN A

1B2

E1651--03

Busoff in CAN B

1B3

E1652--03

Busoff in CAN C

1B4

E1653--03

Timeout for BC2EDC1

2B4

E1654--03

Timeout for BC2EDC2

1B5

E1655--03

Timeout for VM2EDC

1B6

E1656--02

Timeout of CAN message WSI

1B7

E1657--02

Timeout in CAN send messages

1B8

E1658--03

Physical unplausibility of TSC-demand

1B9

E1659--03

MIL visualization for BC2EDC1

1BA

E1660--03

Message Dashboard Display timeout

1BB

E1661--03

Message ERC1DR timeout

1BC

E1662--03

Message RxAMCONlv timeout

1BD

E1663--02

Timeout error of RxCCVS message

1BE

E1664--03

Physical plausibility DCS

1BF

E1665--02

CAN message RxEngTemp2 Interfaces 2 (CAN messages timeout)

1C1

E1666--02

Timeout of CAN message EBC1

1C2

E1667--02

Timeout of CAN message ETC1

1C3

E1668--02

Timeout of CAN message TCO1

2C2

E1669--02

Timeout of CAN message ETC2

1C4

E1670--02

1C4

E1670--03

2C4

E1671--02

2C4

E1671--03

1C5

E1672--02

1C5

E1672--03

2C5

E1673--02

2C5

E1673--03

1C6

E1674--02

1C6

E1674--03

1C6

E1674--04

1C7

E1675--02

1C7

E1675--03

Timeout of CAN message TSC1--AE TSC1 AE Timeout of CAN message TSC1--AR TSC1 AR Timeout of CAN message TSC1--DE TSC1 DE Timeout of CAN message TSC1--DR TSC1 DR

Timeout of CAN message g TSC1--PE

Timeout of CAN message TSC1--TE TSC1 TE

55-11

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Iveco DTC

Combine Fault Code

2C7

E1676--02

2C7

E1676--03

1C8

E1677--02

1C8

E1677--03

2C8

E1678--02

2C8

E1678--03

1C9

E1679--03

Timeout of CAN message TF

2C9

E1680--03

Timeout for message TimeDate

3C9

E1681--03

Timeout for message HRVD (high resolution vehicle distance)

Failure Description, Cursor (CR) Timeout of CAN message TSC1--TR TSC1 TR Timeout of CAN message TSC1--VE TSC1 VE Timeout of CAN message TSC1--VR TSC1 VR

ECU 1 (Internal Checks) 1D1

E1682--03

Communication error of CJ940

1D2

E1683--02

1D2

E1683--03

1D2

E1683--04

1D2

E1683--12

1D3

E1684--12

Recovery which is locked

2D3

E1685--12

Recovery which is suppressed

3D3

E1686--12

Recovery which is visible

1D4

E1687--12

Communic. supervision Watchdog/Contr.--Flag

1D5

E1688--02

1D5

E1688--04

1D5

E1688--12

1D6

E1689--12

1D7

E1690--02

1D7

E1690--12

1D8

E1691--12

1D9

E1692--02

1D9

E1692--03

1D9

E1692--04

1D9

E1692--12

1DA

E1693--12

Error state of EEPROM

Redundant shutoff paths p during g initial. Deviation between TPU and system time Dataset variant coding Supervision of SPI-handler Flag

Error status ADC monitoring

Fault FMTC_trq2qBas_MAP containes non strictly monotonous q curves

55-12

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Iveco DTC

Combine Fault Code

Failure Description, Cursor (CR) ECU 2 (Powerst./Immobil./Overrun/Sensor supply)

1E1

E1694--03

1E1

E1694--04

2E1

E1695--02

2E1

E1695--03

2E1

E1695--04

1E2

E1696--04

Error state of Immobilizer (no fuel release)

1E3

E1697--03

Energizing time exceeds limit of overrun monitoring

1E4

E1698--03

Plausibility error in engine speed check

1E5

E1699--03

1E5

E1699--04

1E6

E1700--03

1E6

E1700--04

1E7

E1701--03

1E7

E1701--04

1E8

E1702--03

1E8

E1702--04

1E9

E1703--03

Supply voltage CJ940 upper limit

1EA

E1704--04

Supply voltage CJ940 lower limit

1EB

E1705--02

1EB

E1705--03

1EB

E1705--04

1EB

E1705--12

1EC

E1706--12

Runup test is set to disable misfire detection during runup test

1ED

E1707--03

Fault path for Runup test

Short circuit to Batt or Ground, no load, excess. temp. for high side power stage Shortt circuit Sh i it tto B Batt tt or G Ground, d no lload, d excess. temp. t f low for l side id power stage

12V sensor supply voltage Sensor supply voltage 1 Sensor supply voltage 2 Sensor supply voltage 3

Atmospheric Pressure Sensor

Particulate Trap 1F1

E1708--12

2F1

E1709--03

2F1

E1709--04

1F2

E1710--02

1F2

E1710--03

1F2

E1710--04

1F2

E1710--12

1F3

E1711--03

1F3

E1711--04

1F4

E1712--03

1F4

E1712--04

Part. filter differential pressure sensor not plausible Part filter differential pressure sensor Part.filter

Particulate filter lamp

Part filter pre temperature sensor Part.filter Flow resistance monitoring

55-13

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Iveco DTC

Combine Fault Code

1F5

E1713--03

Differential pressure above limit

1F6

E1714--12

Dynamics of differential pressure signal not plausible

1F7

E1715--03

1F7

E1715--04

1F7

E1715--12

1F8

E1716--12

Pressure sensor frozen so signal not plausible

1F9

E1717--12

Hose line defect so signal not plausible

1FA

E1718--12

Pressure sensor blocked so signal not plausible

1FB

E1719--03

Permanent regeneration

1FC

E1720--03

1FC

E1720--04

1FC

E1720--12

1FD

E1721--12

1FE

E1722--03

1FE

E1722--04

1FE

E1722--12

1FF

E1723--03

Number of locked regenerations

2FF

E1724--03

Regeneration demand number 2

3FF

E1725--03

Regeneration demand number 3

Iveco DTC

Combine Fault Code

225

E1734--03

Afterrun not completed

232

E1735--12

Coolant Temperature Test failure

17F

E1736--02

17F

E1736--03

17F

E1736--12

39E

E1737--03

Torque Limitation due to Turbo Charger Protection

49E

E1738--03

Torque Limitation due to Engine Protection

69E

E1739--03

Torque Limitation due to Fuel Quantity Limitation

2C6

E1740--02

2C6

E1740--03

3C8

E1741--02

3C8

E1741--03

Failure Description, Cursor (CR)

Differential pressure p signal g

First exhaust gas g temperature p monitoring g General temperature not plausible Second exhaust g gas temperature p monitoring g

Failure Description, Cursor (CR), v91 and above

Injection j Quantity y Adjustment j failure

CAN Message timeout inactive TSC1--PE TSC1 PE CAN Message timeout inactive TSC1--VE TSC1 VE

55-14

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1559-02 -- Coolant Temperature Sensor Context: The Engine Control Unit (ECU) generated an error from a fault associated with the Coolant Temperature Sensor (CTS). This error could result from a signal out of range or a signal that is either erratic or intermittant. When the ECU determines that the CTS temperature value is not valid, it will substitute another value to be used. In case of a defective CTS during engine warmup, a default coolant temperature value is derived from the ramp of the currently logged sensor data. If an error would occur during normal engine operation, the oil temperature is used as the default value. If the oil temperature sensor is defective, 85 °C (185 °F) is substituted as the default value. Cause: The CTS sensor B-44 signal to the ECU is either erratic or intermittant. Possible failure modes: 1. Faulty CTS sensor B-44. 2. Faulty electrical wiring or intermittant connection between CTS sensor B-44 and ECU. 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove CTS sensor connector X373 and inspect housing body/latch, pins and wiring harness for damage. Also, inspect connector portion of the CTS sensor B-44. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. B. If no damage is determined, proceed to step 2. 2. Operation: Check Open Circuit Supply Voltage for CTS Sensor B-44. Vehicle Status: Key On Engine Off. Remove X373 connector from CTS sensor B-44 and check for (DC) voltage outlined in the table below. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X373 (Pin 1) (+)

X373 (Pin 2) (--)

Approx. 5 volts (DC)

A. If 5 volts (DC) is present, proceed to step 4. B. If 5 volts (DC) is not present, proceed to step 3.

55-15

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 3. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity tests between connectors X373 and X516 on engine sensor harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X373. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when making continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X373 (Pin: 1)

X516 (Pin: 15)

Approx. 0 -- 0.10 ohms

2. Continuity

X373 (Pin: 2)

X516 (Pin: 26)

Approx. 0 -- 0.10 ohms

3. Short Circuit

X516 (Pin: 15)

X516 (Pin: 32)

Open Circuit

4. Short Circuit

X516 (Pin: 15)

X516 (Pin: 33)

Open Circuit

5. Short Circuit

X516 (Pin: 15)

X516 (Pin: 26)

Open Circuit

A. If continuity/shorts test is successful, go to step 4. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Operation: CTS Sensor B-44 Test Vehicle Status: Key Off Engine Off. Remove X373 connector and test resistance of CTS sensor B-44 using the table of resistance vs. temp. below. Approximate the temperature when performing test. CTS sensor B-44 failures are typically at the extreme ends of the table or off the table entirely. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the sensor. Coolant Temperature

Resistance Value

--20 °C (--4 °F)

10.5 kOhm

0 °C (32 °F)

7500 ohms

20 °C (68 °F)

4200 ohms

40 °C (104 °F)

980 ohms

60 °C (140 °F)

780 ohms

80 °C (176 °F)

500 ohms

100 °C (212 °F)

280 ohms

120 °C (248 °F)

97 ohms

A. If the resistance measurement does not approximately match the table, replace the sensor. B. If the resistance measurement does approximately match the table, proceed to step 5.

55-16

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 5. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing x193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing x193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for 12 volts and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

A. If the voltages and ground paths are correct and the CTS sensor B-44 was not replaced on a prior diagnostic of this type, replace the sensor. B. If the voltages and ground paths are correct and the CTS sensor B-44 was replaced on a prior diagnostic of this type, reinitialize the ECU as if it was blank (new) and load the appropriate dataset. C. If the voltages and ground paths are correct and the ECU was reinitialized on a prior diagnostic of this type, replace the ECU. D. If the voltages and ground paths are not correct, refer to schematic Frame 2 and 29 and determine root cause of power or continuity problem(s).

55-17

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1559-03 -- Coolant Temperature Sensor Context: The Engine Control Unit (ECU) generated an error from a fault associated with the Coolant Temperature Sensor (CTS). This error could result from a signal out of range or a signal that is either erratic or intermittant. When the ECU determines that the CTS temperature value is not valid, it will substitute another value to be used. In case of a defective CTS during engine warmup, a default coolant temperature value is derived from the ramp of the currently logged sensor data. If an error would occur during normal engine operation, the oil temperature is used as the default value. If the oil temperature sensor is defective, 85 °C (185 °F) is substituted as the default value. Cause: The CTS sensor B-44 signal to the ECU is out of range of the upper threshold limit. Possible failure modes: 1. Faulty CTS sensor B-44. 2. Faulty electrical wiring, short to HIGH (B+) or open circuit condition. 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove CTS sensor connector X373 and inspect housing body/latch, pins and wiring harness for damage. Also, inspect connector portion of the CTS sensor B-44. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace CTS sensor B-44 if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Check Open Circuit Supply Voltage for CTS Sensor B-44. Vehicle Status: Key On Engine Off. Remove X373 connector from CTS sensor B-44 and check for (DC) voltage outlined in the table below. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

1. Voltage

X373 (Pin: 1)

X516 (Pin: 2) (--) Approx. 5 volts (DC)

A. If 5 volts (DC) is present, proceed to step 4. B. If 5 volts (DC) is not present, proceed to step 3.

55-18

Expected Results

From

Expected Results

1. Continuity

X373 (Pin: 1)

X516 (Pin: 15)

Approx. 0 -- 0.10 ohms

2. Continuity

X373 (Pin: 2)

X516 (Pin: 26)

Approx. 0 -- 0.10 ohms

3. Short Circuit

X516 (Pin: 15)

X516 (Pin: 32)

Open Circuit

4. Short Circuit

X516 (Pin: 15)

X516 (Pin: 33)

Open Circuit

5. Short Circuit

X516 (Pin: 15)

X516 (Pin: 26)

Open Circuit

A. If continuity/shorts test is successful, go to step 4. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Operation: CTS Sensor B-44 Test Vehicle Status: Key Off Engine Off. Remove connector X373 and test resistance of CTS sensor B-44 using the table of resistance vs. temp. below. Approximate the temperature when performing test. CTS sensor B-44 failures are typically at the extreme ends of the table or off the table entirely. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the sensor. Coolant Temperature

Resistance Value

--20 °C (--4 °F)

10.5 kOhm

0 °C (32 °F)

7500 ohms

20 °C (68 °F)

4200 ohms

40 °C (104 °F)

980 ohms

60 °C (140 °F)

780 ohms

80 °C (176 °F)

500 ohms

100 °C (212 °F)

280 ohms

120 °C (248 °F)

97 ohms

A. If the resistance measurement does not approximately match the table, replace the sensor. B. If the resistance measurement does approximately match the table, proceed to step 5.

55-19

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 5. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for 12 volts and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-20

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1559-04 -- Coolant Temperature Sensor Context: The Engine Control Unit (ECU) generated an error from a fault associated with the Coolant Temperature Sensor (CTS). This error could result from a signal out of range or a signal that is either erratic or intermittant. When the ECU determines that the CTS temperature value is not valid, it will substitute another value to be used. In case of a defective CTS during engine warmup, a default coolant temperature value is derived from the ramp of the currently logged sensor data. If an error would occur during normal engine operation, the oil temperature is used as the default value. If the oil temperature sensor is defective, 85 °C (185 °F) is substituted as the default value. Cause: The CTS Sensor B-44 signal to the ECU is out of range of the lower threshold limit. Possible failure modes: 1. Faulty CTS sensor B-44. 2. Faulty electrical wiring or short to LOW (ground). 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove CTS sensor connector X373 and inspect housing body/latch, pins and wiring harness for damage. Also, inspect connector portion of the CTS sensor B-44. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace CTS sensor B-44 if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Check Open Circuit Supply Voltage for CTS Sensor B-44. Vehicle Status: Key On Engine Off. Remove X373 connector from CTS sensor B-44 and check for (DC) voltage outlined in the table below. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X373 (Pin 1) (+)

X373 (Pin 2) (--)

Approx. 5 volts (DC)

A. If 5 volts (DC) is present, proceed to step 4. B. If 5 volts (DC) is not present, proceed to step 3.

55-21

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 3. Operation: Check for Faulty Wiring. Vehicle Status: Key Off Engine Off. Remove and perform continuity tests between connectors X373 and X516 on engine sensor harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the sensor connector X373. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when making continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X373 (Pin: 1)

X516 (Pin: 15)

Approx. 0 -- 0.10 ohms

2. Continuity

X373 (Pin: 2)

X516 (Pin: 26)

Approx. 0 -- 0.10 ohms

3. Short Circuit

X516 (Pin: 15)

X516 (Pin: 32)

Open Circuit

4. Short Circuit

X516 (Pin: 15)

X516 (Pin: 33)

Open Circuit

5. Short Circuit

X516 (Pin: 15)

X516 (Pin: 26)

Open Circuit

A. If continuity test is successful, proceed to step 4. B. If continuity test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Operation: CTS Sensor B-44 Test Vehicle Status: Key Off Engine Off. Remove X373 connector and test resistance of CTS sensor B-44 using the table of resistance vs. temp. below. Approximate the temperature when performing test. CTS sensor B-44 failures are typically at the extreme ends of the table or off the table entirely. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the sensor. Coolant Temperature

Resistance Value

--20 °C (--4 °F)

10.5 kOhm

0 °C (32 °F)

7500 ohms

20 °C (68 °F)

4200 ohms

40 °C (104 °F)

980 ohms

60 °C (140 °F)

780 ohms

80 °C (176 °F)

500 ohms

100 °C (212 °F)

280 ohms

120 °C (248 °F)

97 ohms

A. If the resistance measurement does not approximately match the table, replace the sensor. B. If the resistance measurement does approximately match the table, proceed to step 5.

55-22

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-23

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1559-12 -- Coolant Temperature Sensor Context: The Engine Control Unit (ECU) generated an error from a fault associated with the Coolant Temperature Sensor (CTS). This error could result from a signal out of range or a signal that is either erratic or intermittant. When the ECU determines that the CTS temperature value is not valid, it will substitute another value to be used. In case of a defective CTS during engine warmup, a default coolant temperature value is derived from the ramp of the currently logged sensor data. If an error would occur during normal engine operation, the oil temperature is used as the default value. If the Oil Temperature Sensor (OTS) is defective, 85 °C (185 °F) is substituted as the default value. Cause: The ECU is attempting to use the value from the Oil Temperature Sensor (OTS) B-75 as a substitute for the coolant temperature. The oil temperature value is invalid. Possible failure modes: 1. Faulty OTS sensor B-75 or related electrical wiring/connectors. 2. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Check for related fault codes. Check for any fault codes associated with the OTS sensor B-75. Typically these fault codes will be in either the E1566-xx or E1567-xx range. A. If no OTS sensor B-75 fault codes are found, proceed to step 2. B. If any OTS sensor B-75 fault codes are found, follow the troubleshooting procedures related to the fault, and perform the necessary repair(s). 2. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for 12 volts and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the digital multimeter (DMM) to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

A. If the voltages and ground paths are correct, reinitialize the ECU as if it was blank (new) and load the appropriate dataset. B. If the ECU was reinitialized on a prior diagnostic of this type and the fault still exists, replace the ECU. C. If the voltages and ground paths are not correct, refer to schematic Frame 2 and 29 and determine root cause of power or continuity problem(s).

55-24

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1560-12 -- Coolant Temperature Sensor Dynamic Test Context: The Engine Control Unit (ECU) generated a fault when monitoring the temperature rise of the engine coolant temperature during a warm-up cycle. During the monitoring process, the start temp and the current coolant temp are compared against a warm-up cycle curve in the ECU. The fault is generated after a timer expires and the coolant temperature does not match the warm-up cycle curve. This test is carried out once per driving cycle and is stopped when the engine is in after-run mode. Cause: The ECU has determined that the rise in coolant temperature is lower than expected during the engine warm-up cycle. Possible failure modes: 1. Faulty or inaccurate Coolant Temperature Sensor (CTS) B-44. 2. Faulty wiring (high resistance). 3. Very low ambient temperature. 4. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Check Operating Temperature. Check whether engine is being operated under low ambient temperatures. A. If low ambient temperatures exist, cover up a portion of the radiator (20-25%) to accelerate the warm-up cycle. B. If low ambient temperatures do not exist, proceed to step 2. 2. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove CTS sensor connector X373 and inspect housing body/latch, pins and wiring harness for damage. Also, inspect connector portion of the CTS sensor B-44. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace CTS sensor B-44 if damaged. B. If no damage is determined, proceed to step 3. 3. Operation: Check Open Circuit Supply Voltage for CTS Sensor B-44. Vehicle Status: Key On Engine Off. Remove X373 connector from CTS sensor B-44 and check for (DC) voltage outlined in the table below. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X373 (Pin 1 (+)

X373 (Pin 2) (--)

Approx. 5 volts (DC)

A. If 5 volts (DC) is present, proceed to step 5. B. If 5 volts (DC) is not present, proceed to step 4.

55-25

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 4. Operation: Check for Faulty Wiring. Vehicle Status: Key Off Engine Off. Remove and perform continuity tests between connectors X373 and X516 on engine sensor harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the sensor connector X373. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when making continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X373 (Pin: 1)

X516 (Pin: 15)

Approx. 0 -- 0.10 ohms

2. Continuity

X373 (Pin: 2)

X516 (Pin: 26)

Approx. 0 -- 0.10 ohms

3. Short Circuit

X516 (Pin: 15)

X516 (Pin: 32)

Open Circuit

4. Short Circuit

X516 (Pin: 15)

X516 (Pin: 33)

Open Circuit

5. Short Circuit

X516 (Pin: 15)

X516 (Pin: 26)

Open Circuit

A. If continuity test is successful, proceed to step 5. B. If continuity test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 5. Operation: CTS Sensor B-44 Test Vehicle Status: Key Off Engine Off. Remove X373 connector and test resistance of CTS sensor B-44 using the table of resistance vs. temp. below. Approximate the temperature when performing test. CTS B-44 failures are typically at the extreme ends of the table or off the table entirely. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the sensor. Coolant Temperature

Resistance Value

--20 °C (--4 °F)

10.5 kOhm

0 °C (32 °F)

7500 ohms

20 °C (68 °F)

4200 ohms

40 °C (104 °F)

980 ohms

60 °C (140 °F)

780 ohms

80 °C (176 °F)

500 ohms

100 °C (212 °F)

280 ohms

120 °C (248 °F)

97 ohms

A. If the resistance measurement does not approximately match the table, replace the sensor. B. If the resistance measurement does approximately match the table, proceed to step 6.

55-26

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 6. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for 12 volts and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-27

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

55-28

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0 L

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

10.3L ENGINE FRAME--4

A-01 = ENGINE CONTROL UNIT B-05 = ENGINE FLYWHEEL RPM B-07 = ENGINE CAMSHAFT RPM B-36 = FUEL TEMP

B-41 = AIR TEMP/BOOST PRESS B-44 = COOLANT TEMP B-75 = OIL TEMP/PRESS

55-29

L-34 = FUEL ACTUATOR 1 (CYL 1) L-35 = FUEL ACTUATOR 2 (CYL 4) L-36 = FUEL ACTUATOR 3 (CYL 2) L-37 = FUEL ACTUATOR 4 (CYL 6)

L-38 = FUEL ACTUATOR 5 (CYL 3) L-39 = FUEL ACTUATOR 6 (CYL 5)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-30

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1561-02 -- Boost Temp Signal NOTE: This diagnostic procedure references the integrated Boost Pressure Sensor/Boost Temperature Sensor (BPS/BTS). Since the temperature portion of the sensor is only being referenced, it will be referred to as the BTS sensor. Context: The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Temperature Sensor (BTS). This error could result from a signal out of range or a signal that is either erratic or intermittant. When the ECU determines that the BTS sensor value is not valid, it will substitute a default value of 29.96 °C (86 °F). Cause: The Boost Temperature Sensor (BTS) B-23 signal to the ECU is either erratic or intermittant. Possible failure modes: 1. Faulty BTS sensor B-23. 2. Faulty electrical wiring, or intermittant connection between BTS sensor B-23 and ECU. 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove BTS sensor connector X371 and inspect housing body/latch, pins and wiring harness for damage. Also, inspect connector portion of the BTS sensor. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace BTS sensor B-23 if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Check Open Circuit Voltages for BTS Sensor B-23. Vehicle Status: Key On Engine Off. Remove X371 connector from BTS sensor B-23 and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X371 (Pin 3)

X371 (Pin 1)

Approx. 5 volts

2. Voltage

X371 (Pin 2)

X371 (Pin 1)

Approx. 5 volts

3. Voltage

X371 (Pin 4)

X371 (Pin 1)

Approx. 5.4 volts

A. If the voltage test sequence is successful, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 3.

55-31

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 3. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity/shorts tests between connectors X371 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X371. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when making continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X371 (Pin: 1)

X516 (Pin: 25)

Approx. 0 -- 0.10 ohms

2. Continuity

X371 (Pin: 2)

X516 (Pin: 36)

Approx. 0 -- 0.10 ohms

3. Continuity

X371 (Pin: 3)

X516 (Pin: 33)

Approx. 0 -- 0.10 ohms

4. Continuity

X371 (Pin: 4)

X516 (Pin: 34)

Approx. 0 -- 0.10 ohms

5. Shorts

X516 (Pin: 36)

X516 (Pin: 25, 34, 33)

Open Circuit

6. Shorts

X516 (Pin: 25)

X516 (Pin: 34, 33)

Open Circuit

7. Shorts

X516 (Pin: 34)

X516 (Pin: 33)

Open Circuit

A. If continuity/shorts test is successful, go to step 5. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Operation: BTS Sensor B-23 Test Vehicle Status: Key Off Engine Off. Remove the BPS sensor connector X371 and remove the sensor from the engine intake manifold. Allow the sensor to cool to ambient temperature for several minutes, and then test sensor resistance across pins 2 and 3, using the table of resistance vs. temperature below. Approximate the ambient air temperature when performing the test. BPS sensor B-23 failures are typically at the extreme ends of the table or off the table entirely. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the contacts on the BPS sensor B-23 (pins 2 and 3).

55-32

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Temperature

Resistance Nominal Value

Resistance Min/Max Range

--40 °C (-40 °F)

48153 ohms

45301 -- 51006 ohms

--35 °C (-31 °F)

35763 ohms

33703 -- 37823 ohms

--30 °C (-22 °F)

26854 ohms

25350 -- 28359 ohms

--25 °C (-13 °F)

20376 ohms

19265 -- 21487 ohms

--20 °C (-4 °F)

15614 ohms

14785 -- 16443 ohms

--15 °C (5 °F)

12078 ohms

11453 -- 12702 ohms

--10 °C (14 °F)

9426 ohms

8951 -- 9901 ohms

--5 °C (23 °F)

7419 ohms

7055 -- 7783 ohms

0 °C (32 °F)

5887 ohms

5605 -- 6168 ohms

5 °C (41 °F)

4707 ohms

4487 -- 4926 ohms

10 °C (50 °F)

3791 ohms

3618 -- 3964 ohms

15 °C (59 °F)

3075 ohms

2939 -- 3211 ohms

20 °C (68 °F)

2511 ohms

2402 -- 2619 ohms

25 °C (77 °F)

2063 ohms

1976 -- 2150 ohms

30 °C (86 °F)

1715 ohms

1645 -- 1786 ohms

35 °C (95 °F)

1432 ohms

1374 -- 1490 ohms

40 °C (104 °F)

1199 ohms

1152 -- 1247 ohms

45 °C (113 °F)

1009 ohms

970 -- 1047 ohms

50 °C (122 °F)

851 ohms

819 -- 883 ohms

55 °C (131 °F)

721 ohms

694 -- 747 ohms

60 °C (140 °F)

612 ohms

590 -- 634 ohms

65 °C (149 °F)

522 ohms

503 -- 540 ohms

70 °C (158 °F)

446 ohms

431 -- 462 ohms

75 °C (167 °F)

383 ohms

370 -- 396 ohms

80 °C (176 °F)

329 ohms

319 -- 340 ohms

85 °C (185 °F)

284 ohms

275 -- 293 ohms

90 °C (194 °F)

246 ohms

238 -- 254 ohms

95 °C (203 °F)

214 ohms

207 -- 220 ohms

100 °C (212 °F)

186 ohms

180 -- 192 ohms

105 °C (221 °F)

162 ohms

157 -- 167 ohms

110 °C (230 °F)

142 ohms

138 -- 147 ohms

115 °C (239 °F)

125 ohms

121 -- 129 ohms

120 °C (248 °F)

110 ohms

106 -- 113 ohms

125 °C (257 °F)

97 ohms

93 -- 100 ohms

130 °C (266 °F)

85 ohms

83 -- 88 ohms

A. If the resistance measurement does not approximately match the table, replace the sensor. B. If the resistance measurement does approximately match the table, proceed to step 5.

55-33

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 5. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

A. If the voltages and ground paths are correct and the BTS Sensor B-23 was not replaced on a prior diagnostic of this type, replace the sensor. B. If the voltages and ground paths are correct and the BTS Sensor B-23 was replaced on a prior diagnostic of this type, reinitialize the ECU as if it was blank (new) and load the appropriate dataset. C. If the voltages and ground paths are correct and the ECU was reinitialized on a prior diagnostic of this type, replace the ECU. D. If the voltages and ground paths are not correct, refer to schematic Frame 2 and 29 and determine root cause of power or continuity problem(s).

55-34

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1561-03 -- Boost Temp Signal NOTE: This diagnostic procedure references the integrated Boost Pressure Sensor/Boost Temperature Sensor (BPS/BTS). Since the temperature portion of the sensor is only being referenced, it will be referred to as the BTS sensor. Context: The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Temperature Sensor (BTS). This error could result from a signal out of range or a signal that is either erratic or intermittant. When the ECU determines that the BTS temperature value is not valid, it will substitute a default value of 29.96 °C (86 °F). Cause: The Boost Temperature Sensor (BTS) B-23 signal to the ECU is out of range of the upper threshold limit. Possible failure modes: 1. Faulty BTS sensor B-23. 2. Faulty electrical wiring, signal short to HIGH (B+) or open circuit condition. 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove BTS sensor connector X371 and inspect housing body/latch, pins and wiring harness for damage. Also, inspect connector portion of the BTS sensor. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace BTS sensor B-23 if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Check Open Circuit Voltages for BTS Sensor B-23. Vehicle Status: Key On Engine Off. Remove X371 connector from BTS sensor B-23 and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X371 (Pin 3)

X371 (Pin 1)

Approx. 5 volts

2. Voltage

X371 (Pin 2)

X371 (Pin 1)

Approx. 5 volts

3. Voltage

X371 (Pin 4)

X371 (Pin 1)

Approx. 5.4 volts

A. If the voltage test sequence is successful, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 3.

55-35

From

Expected Results

1. Continuity

X371 (Pin: 1)

X516 (Pin: 25)

Approx. 0 -- 0.10 ohms

2. Continuity

X371 (Pin: 2)

X516 (Pin: 36)

Approx. 0 -- 0.10 ohms

3. Continuity

X371 (Pin: 3)

X516 (Pin: 33)

Approx. 0 -- 0.10 ohms

4. Continuity

X371 (Pin: 4)

X516 (Pin: 34)

Approx. 0 -- 0.10 ohms

5. Shorts

X516 (Pin: 36)

X516 (Pin: 25, 34, 33)

Open Circuit

6. Shorts

X516 (Pin: 25)

X516 (Pin: 34, 33)

Open Circuit

7. Shorts

X516 (Pin: 34)

X516 (Pin: 33)

Open Circuit

55-36

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Temperature

Resistance Nominal Value

Resistance Min/Max Range

--40 °C (--40 °F)

48153 ohms

45301 -- 51006 ohms

--35 °C (--31 °F)

35763 ohms

33703 -- 37823 ohms

--30 °C (--22 °F)

26854 ohms

25350 -- 28359 ohms

--25 °C (--13 °F)

20376 ohms

19265 -- 21487 ohms

--20 °C (--4 °F)

15614 ohms

14785 -- 16443 ohms

--15 °C (5 °F)

12078 ohms

11453 -- 12702 ohms

--10 °C (14 °F)

9426 ohms

8951 -- 9901 ohms

--5 °C (23 °F)

7419 ohms

7055 -- 7783 ohms

0 °C (32 °F)

5887 ohms

5605 -- 6168 ohms

5 °C (41 °F)

4707 ohms

4487 -- 4926 ohms

10 °C (50 °F)

3791 ohms

3618 -- 3964 ohms

15 °C (59 °F)

3075 ohms

2939 -- 3211 ohms

20 °C (68 °F)

2511 ohms

2402 -- 2619 ohms

25 °C (77 °F)

2063 ohms

1976 -- 2150 ohms

30 °C (86 °F)

1715 ohms

1645 -- 1786 ohms

35 °C (95 °F)

1432 ohms

1374 -- 1490 ohms

40 °C (104 °F)

1199 ohms

1152 -- 1247 ohms

45 °C (113 °F)

1009 ohms

970 -- 1047 ohms

50 °C (122 °F)

851 ohms

819 -- 883 ohms

55 °C (131 °F)

721 ohms

694 -- 747 ohms

60 °C (140 °F)

612 ohms

590 -- 634 ohms

65 °C (149 °F)

522 ohms

503 -- 540 ohms

70 °C (158 °F)

446 ohms

431 -- 462 ohms

75 °C (167 °F)

383 ohms

370 -- 396 ohms

80 °C (176 °F)

329 ohms

319 -- 340 ohms

85 °C (185 °F)

284 ohms

275 -- 293 ohms

90 °C (194 °F)

246 ohms

238 -- 254 ohms

95 °C (203 °F)

214 ohms

207 -- 220 ohms

100 °C (212 °F)

186 ohms

180 -- 192 ohms

105 °C (221 °F)

162 ohms

157 -- 167 ohms

110 °C (230 °F)

142 ohms

138 -- 147 ohms

115 °C (239 °F)

125 ohms

121 -- 129 ohms

120 °C (248 °F)

110 ohms

106 -- 113 ohms

125 °C (257 °F)

97 ohms

93 -- 100 ohms

130 °C (266 °F)

85 ohms

83 -- 88 ohms

A. If the resistance measurement does not approximately match the table, replace the sensor. B. If the resistance measurement does approximately match the table, proceed to step 5.

55-37

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 5. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-38

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1561-04 -- Boost Temp Signal NOTE: This diagnostic procedure references the integrated Boost Pressure Sensor/Boost Temperature Sensor (BPS/BTS). Since the temperature portion of the sensor is only being referenced, it will be referred to as the BTS sensor. Context: The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Temperature Sensor (BTS). This error could result from a signal out of range or a signal that is either erratic or intermittant. When the ECU determines that the BTS temperature value is not valid, it will substitute a default value of 29.96 °C (86 °F). Cause: The Boost Temperature Sensor (BTS) B-23 signal to the ECU is out of range of the lower threshold limit. Possible failure modes: 1. Faulty BTS sensor B-23. 2. Faulty electrical wiring, signal short to LOW (ground). 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove BTS sensor connector X371 and inspect housing body/latch, pins and wiring harness for damage. Also, inspect connector portion of the BTS sensor. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace BTS sensor B-23 if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Check Open Circuit Voltages for BTS Sensor B-23. Vehicle Status: Key On Engine Off. Remove X371 connector from BTS sensor B-23 and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X371 (Pin 3)

X371 (Pin 1)

Approx. 5 volts

2. Voltage

X371 (Pin 2)

X371 (Pin 1)

Approx. 5 volts

3. Voltage

X371 (Pin 4)

X371 (Pin 1)

Approx. 5.4 volts

A. If the voltage test sequence is successful, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 3.

55-39

From

Expected Results

1. Continuity

X371 (Pin: 1)

X516 (Pin: 25)

Approx. 0 -- 0.10 ohms

2. Continuity

X371 (Pin: 2)

X516 (Pin: 36)

Approx. 0 -- 0.10 ohms

3. Continuity

X371 (Pin: 3)

X516 (Pin: 33)

Approx. 0 -- 0.10 ohms

4. Continuity

X371 (Pin: 4)

X516 (Pin: 34)

Approx. 0 -- 0.10 ohms

5. Shorts

X516 (Pin: 36)

X516 (Pin: 25, 34, 33)

Open Circuit

6. Shorts

X516 (Pin: 25)

X516 (Pin: 34, 33)

Open Circuit

7. Shorts

X516 (Pin: 34)

X516 (Pin: 33)

Open Circuit

55-40

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Temperature

Resistance Nominal Value

Resistance Min/Max Range

--40 °C (--40 °F)

48153 ohms

45301 -- 51006 ohms

--35 °C (--31 °F)

35763 ohms

33703 -- 37823 ohms

--30 °C (--22 °F)

26854 ohms

25350 -- 28359 ohms

--25 °C (--13 °F)

20376 ohms

19265 -- 21487 ohms

--20 °C (--4 °F)

15614 ohms

14785 -- 16443 ohms

--15 °C (5 °F)

12078 ohms

11453 -- 12702 ohms

--10 °C (14 °F)

9426 ohms

8951 -- 9901 ohms

--5 °C (23 °F)

7419 ohms

7055 -- 7783 ohms

0 °C (32 °F)

5887 ohms

5605 -- 6168 ohms

5 °C (41 °F)

4707 ohms

4487 -- 4926 ohms

10 °C (50 °F)

3791 ohms

3618 -- 3964 ohms

15 °C (59 °F)

3075 ohms

2939 -- 3211 ohms

20 °C (68 °F)

2511 ohms

2402 -- 2619 ohms

25 °C (77 °F)

2063 ohms

1976 -- 2150 ohms

30 °C (86 °F)

1715 ohms

1645 -- 1786 ohms

35 °C (95 °F)

1432 ohms

1374 -- 1490 ohms

40 °C (104 °F)

1199 ohms

1152 -- 1247 ohms

45 °C (113 °F)

1009 ohms

970 -- 1047 ohms

50 °C (122 °F)

851 ohms

819 -- 883 ohms

55 °C (131 °F)

721 ohms

694 -- 747 ohms

60 °C (140 °F)

612 ohms

590 -- 634 ohms

65 °C (149 °F)

522 ohms

503 -- 540 ohms

70 °C (158 °F)

446 ohms

431 -- 462 ohms

75 °C (167 °F)

383 ohms

370 -- 396 ohms

80 °C (176 °F)

329 ohms

319 -- 340 ohms

85 °C (185 °F)

284 ohms

275 -- 293 ohms

90 °C (194 °F)

246 ohms

238 -- 254 ohms

95 °C (203 °F)

214 ohms

207 -- 220 ohms

100 °C (212 °F)

186 ohms

180 -- 192 ohms

105 °C (221 °F)

162 ohms

157 -- 167 ohms

110 °C (230 °F)

142 ohms

138 -- 147 ohms

115 °C (239 °F)

125 ohms

121 -- 129 ohms

120 °C (248 °F)

110 ohms

106 -- 113 ohms

125 °C (257 °F)

97 ohms

93 -- 100 ohms

130 °C (266 °F)

85 ohms

83 -- 88 ohms

A. If the resistance measurement does not approximately match the table, replace the sensor. B. If the resistance measurement does approximately match the table, proceed to step 5.

55-41

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 5. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-42

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

55-43

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0 L

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

10.3L ENGINE FRAME--4

A-01 = ENGINE CONTROL UNIT B-05 = ENGINE FLYWHEEL RPM B-07 = ENGINE CAMSHAFT RPM B-36 = FUEL TEMP

B-41 = AIR TEMP/BOOST PRESS B-44 = COOLANT TEMP B-75 = OIL TEMP/PRESS

55-44

L-34 = FUEL ACTUATOR 1 (CYL 1) L-35 = FUEL ACTUATOR 2 (CYL 4) L-36 = FUEL ACTUATOR 3 (CYL 2) L-37 = FUEL ACTUATOR 4 (CYL 6)

L-38 = FUEL ACTUATOR 5 (CYL 3) L-39 = FUEL ACTUATOR 6 (CYL 5)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-45

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1562-02 -- Boost Pressure Sensor NOTE: This diagnostic procedure references the integrated Boost Pressure Sensor/Boost Temperature Sensor (BPS/BTS). Since the pressure portion of the sensor is only being referenced, it will be referred to as the BPS sensor. Context: The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Pressure Sensor (BPS). This error could result from a signal out of range or a signal that is either erratic or intermittant. When the ECU determines that the BPS pressure value is not valid, it will substitute a default value of 270 kPa (39 psi). Cause: The Boost Pressure Sensor (BPS) B-23 signal to the ECU is either erratic or intermittant. Possible failure modes: 1. Faulty BPS sensor B-23. 2. Faulty electrical wiring or intermittant connection between BPS sensor B-23 and ECU. 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove BPS sensor connector X371 and inspect housing body/latch, pins and wiring harness for damage. Also, inspect connector portion of the BPS sensor B-23. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace BPS sensor B-23 if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Check Open Circuit Voltages for BPS Sensor B-23. Vehicle Status: Key On Engine Off. Remove X371 connector from BPS sensor B-23 and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X371 (Pin 3)

X371 (Pin 1)

Approx. 5 volts

2. Voltage

X371 (Pin 2)

X371 (Pin 1)

Approx. 5 volts

3. Voltage

X371 (Pin 4)

X371 (Pin 1)

Approx. 5.4 volts

A. If the voltage test sequence is successful, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 3.

55-46

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 3. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity/shorts tests between connectors X371 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X371. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the DMM to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when making continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X371 (Pin: 1)

X516 (Pin: 25)

Approx. 0 -- 0.10 ohms

2. Continuity

X371 (Pin: 2)

X516 (Pin: 36)

Approx. 0 -- 0.10 ohms

3. Continuity

X371 (Pin: 3)

X516 (Pin: 33)

Approx. 0 -- 0.10 ohms

4. Continuity

X371 (Pin: 4)

X516 (Pin: 34)

Approx. 0 -- 0.10 ohms

5. Shorts

X516 (Pin: 36)

X516 (Pin: 25, 34, 33)

Open Circuit

6. Shorts

X516 (Pin: 25)

X516 (Pin: 34, 33)

Open Circuit

7. Shorts

X516 (Pin: 34)

X516 (Pin: 33)

Open Circuit

A. If continuity/shorts test is successful, go to step 4. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

A. If the voltages and ground paths are correct and the BPS Sensor B-23 was not replaced on a prior diagnostic of this type, replace the sensor. B. If the voltages and ground paths are correct and the BPS Sensor B-23 was replaced on a prior diagnostic of this type, reinitialize the ECU as if it was blank (new) and load the appropriate dataset. C. If the voltages and ground paths are correct and the ECU was reinitialized on a prior diagnostic of this type, replace the ECU. D. If the voltages and ground paths are not correct, refer to schematic Frame 2 and 29 and determine root cause of power or continuity problem(s).

55-47

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1562-03 -- Boost Pressure Sensor NOTE: This diagnostic procedure references the integrated Boost Pressure Sensor/Boost Temperature Sensor (BPS/BTS). Since the pressure portion of the sensor is only being referenced, it will be referred to as the BPS sensor. Context: The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Pressure Sensor (BPS). This error could result from a signal out of range or a signal that is either erratic or intermittant. When the ECU determines that the BPS pressure value is not valid, it will substitute a default value of 270 kPa (39 psi). Cause: The Boost Pressure Sensor (BPS) B-23 signal to the ECU is out of range of the upper threshold limit. Possible failure modes: 1. Faulty BPS sensor B-23. 2. Faulty electrical wiring, short to HIGH (B+) or open circuit condition. 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove BPS sensor connector X371 and inspect housing body/latch, pins and wiring harness for damage. Also, inspect connector portion of the BPS sensor B-23. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace BPS sensor B-23 if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Check Open Circuit Voltages for BPS Sensor B-23. Vehicle Status: Key On Engine Off. Remove X371 connector from BPS sensor B-23 and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X371 (Pin 3)

X371 (Pin 1)

Approx. 5 volts

2. Voltage

X371 (Pin 2)

X371 (Pin 1)

Approx. 5 volts

3. Voltage

X371 (Pin 4)

X371 (Pin 1)

Approx. 5.4 volts

A. If the voltage test sequence is successful, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 3.

55-48

From

Expected Results

1. Continuity

X371 (Pin: 1)

X516 (Pin: 25)

Approx. 0 -- 0.10 ohms

2. Continuity

X371 (Pin: 2)

X516 (Pin: 36)

Approx. 0 -- 0.10 ohms

3. Continuity

X371 (Pin: 3)

X516 (Pin: 33)

Approx. 0 -- 0.10 ohms

4. Continuity

X371 (Pin: 4)

X516 (Pin: 34)

Approx. 0 -- 0.10 ohms

5. Shorts

X516 (Pin: 36)

X516 (Pin: 25, 34, 33)

Open Circuit

6. Shorts

X516 (Pin: 25)

X516 (Pin: 34, 33)

Open Circuit

7. Shorts

X516 (Pin: 34)

X516 (Pin: 33)

Open Circuit

A. If continuity/shorts test is successful, go to step 4. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-49

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1562-04 -- Boost Pressure Sensor NOTE: This diagnostic procedure references the integrated Boost Pressure Sensor/Boost Temperature Sensor (BPS/BTS). Since the pressure portion of the sensor is only being referenced, it will be referred to as the BPS sensor. Context: The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Pressure Sensor (BPS). This error could result from a signal out of range or a signal that is either erratic or intermittant. When the ECU determines that the BPS pressure value is not valid, it will substitute a default value of 270 kPa (39 psi). Cause: The Boost Pressure Sensor (BPS) B-23 signal to the ECU is out of range of the lower threshold limit. Possible failure modes: 1. Faulty BPS sensor B-23. 2. Faulty electrical wiring or short to LOW (ground). 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove BPS sensor connector X371 and inspect housing body/latch, pins and wiring harness for damage. Also, inspect connector portion of the BPS sensor B-23. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace BPS sensor B-23 if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Check Open Circuit Voltages for BPS Sensor B-23. Vehicle Status: Key On Engine Off. Remove X371 connector from BPS sensor B-23 and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X371 (Pin 3)

X371 (Pin 1)

Approx. 5 volts

2. Voltage

X371 (Pin 2)

X371 (Pin 1)

Approx. 5 volts

3. Voltage

X371 (Pin 4)

X371 (Pin 1)

Approx. 5.4 volts

A. If the voltage test sequence is successful, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 3.

55-50

From

Expected Results

1. Continuity

X371 (Pin: 1)

X516 (Pin: 25)

Approx. 0 -- 0.10 ohms

2. Continuity

X371 (Pin: 2)

X516 (Pin: 36)

Approx. 0 -- 0.10 ohms

3. Continuity

X371 (Pin: 3)

X516 (Pin: 33)

Approx. 0 -- 0.10 ohms

4. Continuity

X371 (Pin: 4)

X516 (Pin: 34)

Approx. 0 -- 0.10 ohms

5. Shorts

X516 (Pin: 36)

X516 (Pin: 25, 34, 33)

Open Circuit

6. Shorts

X516 (Pin: 25)

X516 (Pin: 34, 33)

Open Circuit

7. Shorts

X516 (Pin: 34)

X516 (Pin: 33)

Open Circuit

A. If continuity/shorts test is successful, go to step 4. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-51

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1562-12 -- Boost Pressure Sensor NOTE: This diagnostic procedure references the integrated Boost Pressure Sensor/Boost Temperature Sensor (BPS/BTS). Since the pressure portion of the sensor is only being referenced, it will be referred to as the BPS sensor. Context: The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Pressure Sensor (BPS). This error could result from a signal out of range or a signal that is either erratic or intermittant. When the ECU determines that the BPS pressure value is not valid, it will substitute a default value of 270 kPa (2.7 bar). Cause: The Boost Pressure Sensor (BPS) B-23 and the Absolute Pressure Sensor (APS) do not agree on engine startup. Possible failure modes: 1. Faulty BPS sensor B-23. 2. Faulty electrical wiring. 3. Faulty ECU with integrated APS sensor, ECU supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove BPS sensor connector X371 and inspect housing body/latch, pins and wiring harness for damage. Also, inspect connector portion of the BPS sensor B-23. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace BPS sensor B-23 if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Check Open Circuit Voltages for BPS Sensor B-23. Vehicle Status: Key On Engine Off. Remove X371 connector from BPS sensor B-23 and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X371 (Pin 3)

X371 (Pin 1)

Approx. 5 volts

2. Voltage

X371 (Pin 2)

X371 (Pin 1)

Approx. 5 volts

3. Voltage

X371 (Pin 4)

X371 (Pin 1)

Approx. 5.4 volts

A. If the voltage test sequence is successful, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 3.

55-52

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 3. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity/shorts tests between connectors X371 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X371. Also, use the 0.43 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when making continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X371 (Pin: 1)

X516 (Pin: 25)

Approx. 0 -- 0.10 ohms

2. Continuity

X371 (Pin: 2)

X516 (Pin: 36)

Approx. 0 -- 0.10 ohms

3. Continuity

X371 (Pin: 3)

X516 (Pin: 33)

Approx. 0 -- 0.10 ohms

4. Continuity

X371 (Pin: 4)

X516 (Pin: 34)

Approx. 0 -- 0.10 ohms

5. Shorts

X516 (Pin: 36)

X516 (Pin: 25, 34, 33)

Open Circuit

6. Shorts

X516 (Pin: 25)

X516 (Pin: 34, 33)

Open Circuit

7. Shorts

X516 (Pin: 34)

X516 (Pin: 33)

Open Circuit

A. If continuity/shorts test is successful, go to step 4. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.43 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-53

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

55-54

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0 L

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

10.3L ENGINE FRAME--4

A-01 = ENGINE CONTROL UNIT B-05 = ENGINE FLYWHEEL RPM B-07 = ENGINE CAMSHAFT RPM B-36 = FUEL TEMP

B-41 = AIR TEMP/BOOST PRESS B-44 = COOLANT TEMP B-75 = OIL TEMP/PRESS

55-55

L-34 = FUEL ACTUATOR 1 (CYL 1) L-35 = FUEL ACTUATOR 2 (CYL 4) L-36 = FUEL ACTUATOR 3 (CYL 2) L-37 = FUEL ACTUATOR 4 (CYL 6)

L-38 = FUEL ACTUATOR 5 (CYL 3) L-39 = FUEL ACTUATOR 6 (CYL 5)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-56

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1563-03 -- Fuel Temp Signal Context: The Engine Control Unit (ECU) generated a fault associated with Fuel Temperature Sensor (FTS). This error typically results from a signal that is out of range. When the ECU determines that the FTS temperature value is invalid, it will substitute the current “Coolant Temperature” value, or in the case of a defective Coolant Temperature Sensor (CTS), the value 19.96 °C (67.9 °F) will be substituted. Cause: The Fuel Temperature Sensor (FTS) B-36 signal to the ECU is out of range of the upper threshold limit. Possible failure modes: 1. Faulty FTS sensor B-36. 2. Faulty electrical wiring, short to HIGH (B+) or open circuit condition. 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove FTS sensor connector X372 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the FTS sensor B-36. A. If a problem is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace FTS sensor B-36 if damaged. B. If no problems are determined, proceed to step 2. 2. Operation: Check Supply Voltage for FTS Sensor B-36. Vehicle Status: Key On Engine Off. Remove X372 connector from FTS sensor B-36 and check for (DC) voltage outlined in the table below. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X372 (Pin 1)

X372 (Pin 2)

Approx. 5 volts

A. If the voltage test is successful, proceed to step 4. B. If the voltage test is not successful, proceed to step 3.

55-57

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 3. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity tests between connectors X372 and X516 on engine sensor harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X372. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X372 (Pin: 1)

X516 (Pin: 35)

Approx. 0 -- 0.10 ohms

2. Continuity

X372 (Pin: 2)

X516 (Pin: 18)

Approx. 0 -- 0.10 ohms

3. Short Circuit

X516 (Pin: 35)

X516 (Pin: 32)

Open Circuit

4. Short Circuit

X516 (Pin: 35)

X516 (Pin: 33)

Open Circuit

A. If continuity/shorts test is successful, go to step 4. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Operation: FTS Sensor B-36 Test Vehicle Status: Key Off Engine Off. Remove FTS connector X372 and test resistance of FTS sensor B-36 using the table of resistance vs. temp. below. Approximate the fuel temperature when performing test. FTS B-36 failures are typically at the extreme ends of the table or off the table entirely. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the sensor. Fuel Temperature

Resistance Value

--20 °C (--4 °F)

10.5 kOhm

0 °C (32 °F)

7500 ohms

20 °C (68 °F)

4200 ohms

40 °C (104 °F)

980 ohms

60 °C (140 °F)

780 ohms

80 °C (176 °F)

500 ohms

100 °C (212 °F)

280 ohms

120 °C (248 °F)

97 ohms

A. If the resistance measurement does not approximately match the table, replace the sensor. B. If the resistance measurement does approximately match the table, proceed to step 5.

55-58

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 5. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

A. If the voltages and ground paths are correct and the FTS Sensor B-36 was not replaced on a prior diagnostic of this type, replace the sensor. B. If the voltages and ground paths are correct and the FTS Sensor B-36 was replaced on a prior diagnostic of this type, reinitialize the ECU as if it was blank (new) and load the appropriate dataset. C. If the voltages and ground paths are correct and the ECU was reinitialized on a prior diagnostic of this type, replace the ECU. D. If the voltages and ground paths are not correct, refer to schematic Frame 2 and 29 and determine root cause of power or continuity problem(s).

55-59

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1563-04 -- Fuel Temp Sensor Context: The Engine Control Unit (ECU) generated a fault associated with Fuel Temperature Sensor (FTS). This error typically results from a signal that is out of range. When the ECU determines that the FTS temperature value is invalid, it will substitute the current “Coolant Temperature” value, or in the case of a defective Coolant Temp Sensor (CTS), the value 19.96 °C (67.9 °F) will be substituted. Cause: The Fuel Temperature Sensor (FTS) B-36 signal to the ECU is out of range of the lower threshold limit. Possible failure modes: 1. Faulty FTS sensor B-36. 2. Faulty electrical wiring or short to LOW (ground). 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove FTS sensor connector X372 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the FTS sensor B-36. A. If a problem is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace FTS sensor B-36 if damaged. B. If no problems are determined, proceed to step 2. 2. Operation: Check Supply Voltage for FTS Sensor B-36. Vehicle Status: Key On Engine Off. Remove X372 connector from FTS sensor B-36 and check for (DC) voltage outlined in the table below. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X372 (Pin 1)

X372 (Pin 2)

Approx. 5 volts

A. If the voltage test is successful, proceed to step 4. B. If the voltage test is not successful, proceed to step 3.

55-60

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 3. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity tests between connectors X372 and X516 on engine sensor harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X372. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X372 (Pin: 1)

X516 (Pin: 35)

Approx. 0 -- 0.10 ohms

2. Continuity

X372 (Pin: 2)

X516 (Pin: 18)

Approx. 0 -- 0.10 ohms

3. Short Circuit

X516 (Pin: 35)

X516 (Pin: 32)

Open Circuit

4. Short Circuit

X516 (Pin: 35)

X516 (Pin: 33)

Open Circuit

A. If continuity/shorts test is successful, go to step 4. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Operation: FTS Sensor B-36 Test Vehicle Status: Key Off Engine Off. Remove FTS connector X372 and test resistance of FTS sensor B-36 using the table of resistance vs. temp. below. Approximate the fuel temperature when performing test. FTS sensor B-36 failures are typically at the extreme ends of the table or off the table entirely. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the sensor. Fuel Temperature

Resistance Value

--20 °C (--4 °F)

10.5 kOhm

0 °C (32 °F)

7500 ohms

20 °C (68 °F)

4200 ohms

40 °C (104 °F)

980 ohms

60 °C (140 °F)

780 ohms

80 °C (176 °F)

500 ohms

100 °C (212 °F)

280 ohms

120 °C (248 °F)

97 ohms

A. If the resistance measurement does not approximately match the table, replace the sensor. B. If the resistance measurement does approximately match the table, proceed to step 5.

55-61

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 5. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-62

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

55-63

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0 L

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

10.3L ENGINE FRAME--4

A-01 = ENGINE CONTROL UNIT B-05 = ENGINE FLYWHEEL RPM B-07 = ENGINE CAMSHAFT RPM B-36 = FUEL TEMP

B-41 = AIR TEMP/BOOST PRESS B-44 = COOLANT TEMP B-75 = OIL TEMP/PRESS

55-64

L-34 = FUEL ACTUATOR 1 (CYL 1) L-35 = FUEL ACTUATOR 2 (CYL 4) L-36 = FUEL ACTUATOR 3 (CYL 2) L-37 = FUEL ACTUATOR 4 (CYL 6)

L-38 = FUEL ACTUATOR 5 (CYL 3) L-39 = FUEL ACTUATOR 6 (CYL 5)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-65

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1564-02 -- Oil Pressure Sensor NOTE: This diagnostic procedure references the integrated Oil Pressure Sensor/Oil Temperature Sensor (OPS/OTS). Since the pressure portion of the sensor is only being referenced, it will be referred to as the OPS sensor. Context: The Engine Control Unit (ECU) generated a fault associated with the Oil Pressure Sensor (OPS). This error could result from a signal out of range or a plausibility check (oil pressure too high). The plausibility check is only started if these conditions have been met: 1) no detected sensor power supply ( 5 volts DC) errors, 2) no detected Analog to Digital Converter (ADC) signal errors. Cause: The Oil Pressure Sensor (OPS) B-75 signal to the ECU is either erratic or intermittant. Possible failure modes: 1. Faulty OPS sensor B-75. 2. Faulty electrical wiring or intermittant connection between OPS sensor B-75 and ECU. 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove OPS sensor connector X517 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the OPS sensor B-75. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace OPS sensor B-75 if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Check Open Circuit Voltages for OPS Sensor B-75. Vehicle Status: Key On Engine Off. Remove X517 connector from the OPS sensor B-75 and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X517 (Pin 3)

X517 (Pin 1)

Approx. 5 volts

2. Voltage

X517 (Pin 2)

X517 (Pin 1)

Approx. 5 volts

3. Voltage

X517 (Pin 4)

X517 (Pin 1)

Approx. 5.4 volts

A. If the voltage test sequence is successful, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 3.

55-66

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 3. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. 4. Remove and perform continuity tests between connectors X517 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X517. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X517 (Pin: 1)

X516 (Pin: 24)

Approx. 0 -- 0.10 ohms

2. Continuity

X517 (Pin: 2)

X516 (Pin: 28)

Approx. 0 -- 0.10 ohms

3. Continuity

X517 (Pin: 3)

X516 (Pin: 32)

Approx. 0 -- 0.10 ohms

4. Continuity

X517 (Pin: 4)

X516 (Pin: 27)

Approx. 0 -- 0.10 ohms

5. Short Circuit

X516 (Pin: 28)

X516 (Pin: 25, 34, 33)

Open Circuit

6. Short Circuit

X516 (Pin: 24)

X516 (Pin: 34, 33)

Open Circuit

7. Short Circuit

X516 (Pin: 27)

X516 (Pin: 33)

Open Circuit

A. If continuity/shorts test is successful, go to step 4. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 5. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

A. If the voltages and ground paths are correct and the OPS Sensor B-75 was not replaced on a prior diagnostic of this type, replace the sensor. B. If the voltages and ground paths are correct and the OPS Sensor B-75 was replaced on a prior diagnostic of this type, reinitialize the ECU as if it was blank (new) and load the appropriate dataset. C. If the voltages and ground paths are correct and the ECU was reinitialized on a prior diagnostic of this type, replace the ECU. D. If the voltages and ground paths are not correct, refer to schematic Frame 2 and 29 and determine root cause of power or continuity problem(s).

55-67

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1564-03 -- Oil Pressure Sensor NOTE: This diagnostic procedure references the integrated Oil Pressure Sensor/Oil Temperature Sensor (OPS/OTS). Since the pressure portion of the sensor is only being referenced, it will be referred to as the OPS sensor. Context: The Engine Control Unit (ECU) generated a fault associated with the Oil Pressure Sensor (OPS). This error could result from a signal out of range or a plausibility check (oil pressure too high). The plausibility check is only started if these conditions have been met: 1) no detected sensor power supply (+5vDC) errors, 2) no detected Analog to Digital Converter (ADC) signal errors. Cause: The Oil Pressure Sensor (OPS) B-75 signal to the ECU is out of range of the upper threshold limit. Possible failure modes: 1. Faulty OPS sensor B-75. 2. Faulty electrical wiring, signal short to HIGH (B+) or open circuit condition. 3. Faulty ECU, supply voltages or grounds. 4. Faulty engine lubrication system. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove OPS sensor connector X517 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the OPS sensor B-75. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace OPS sensor B-75 if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Check Open Circuit Voltages for OPS Sensor B-75. Vehicle Status: Key On Engine Off. Remove X517 connector from the OPS sensor B-75 and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X517 (Pin 3)

X517 (Pin 1)

Approx. 5 volts

2. Voltage

X517 (Pin 2)

X517 (Pin 1)

Approx. 5 volts

3. Voltage

X517 (Pin 4)

X517 (Pin 1)

Approx. 5.4 volts

A. If the voltage test sequence is successful, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 3.

55-68

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 3. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity tests between connectors X517 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X517. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X517 (Pin: 1)

X516 (Pin: 24)

Approx. 0 -- 0.10 ohms

2. Continuity

X517 (Pin: 2)

X516 (Pin: 28)

Approx. 0 -- 0.10 ohms

3. Continuity

X517 (Pin: 3)

X516 (Pin: 32)

Approx. 0 -- 0.10 ohms

4. Continuity

X517 (Pin: 4)

X516 (Pin: 27)

Approx. 0 -- 0.10 ohms

5. Short Circuit

X516 (Pin: 28)

X516 (Pin: 24, 27, 32)

Open Circuit

6. Short Circuit

X516 (Pin: 24)

X516 (Pin: 27, 32)

Open Circuit

7. Short Circuit

X516 (Pin: 27)

X516 (Pin: 32)

Open Circuit

A. If continuity/shorts test is successful, go to step 4. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Operation: Check Engine Oil Pressure Vehicle Status: Key Off Engine Off (test preparation) Vehicle Status: Key On Engine On (during test) Follow the procedure in the Engine Repair Manual for testing the pressure of the engine oil lubrication system. A. If the oil pressure test is successful, proceed to step 5. B. If the oil pressure test is not successful, refer to the Engine Repair Manual to diagnose, troubleshoot and repair the low oil pressure fault condition.

55-69

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 5. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts (DC)

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-70

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1564-04 -- Oil Pressure Sensor NOTE: This diagnostic procedure references the integrated Oil Pressure Sensor/Oil Temperature Sensor (OPS/OTS). Since the pressure portion of the sensor is only being referenced, it will be referred to as the OPS sensor. Context: The Engine Control Unit (ECU) generated a fault associated with the Oil Pressure Sensor (OPS). This error could result from a signal out of range or a plausibility check (oil pressure too high). The plausibility check is only started if these conditions have been met: 1) no detected sensor power supply ( 5 volts DC) errors, 2) no detected Analog to Digital Converter (ADC) signal errors. Cause: The Oil Pressure Sensor (OPS) B-75 signal to the ECU is out of range of the lower threshold limit. Possible failure modes: 1. Faulty OPS sensor B-75. 2. Faulty electrical wiring or signal short to LOW (ground). 3. Faulty ECU, supply voltages or grounds. 4. Faulty engine lubrication system. 5. Low engine oil level. Solution: 1. Operation: Inspect Electrical Components and Check Engine Oil Level. Vehicle Status: Key Off Engine Off. Electrical: Remove OPS sensor connector X517 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the OPS sensor B-75. Oil Level: Check oil level on dipstick. A. If the engine oil level is low, top off the oil level with the recommended grade of oil specified in the Engine Repair Manual. B. If electrical damage has been determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace OPS sensor B-75 if damaged. C. If no electrical damage has been determined, proceed to step 2.

55-71

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 2. Operation: Check Open Circuit Voltages for OPS Sensor B-75. Vehicle Status: Key On Engine Off. Remove X517 connector from the OPS sensor B-75 and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X517 (Pin 3)

X517 (Pin 1)

Approx. 5 volts

2. Voltage

X517 (Pin 2)

X517 (Pin 1)

Approx. 5 volts

3. Voltage

X517 (Pin 4)

X517 (Pin 1)

Approx. 5.4 volts

A. If the voltage test sequence is successful, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 3. 3. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity tests between connectors X517 and X193 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X517. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X517 (Pin: 1)

X516 (Pin: 24)

Approx. 0 -- 0.10 ohms

2. Continuity

X517 (Pin: 2)

X516 (Pin: 28)

Approx. 0 -- 0.10 ohms

3. Continuity

X517 (Pin: 3)

X516 (Pin: 32)

Approx. 0 -- 0.10 ohms

4. Continuity

X517 (Pin: 4)

X516 (Pin: 27)

Approx. 0 -- 0.10 ohms

5. Short Circuit

X516 (Pin: 28)

X516 (Pin: 24, 27, 32)

Open Circuit

6. Short Circuit

X516 (Pin: 24)

X516 (Pin: 27, 32)

Open Circuit

7. Short Circuit

X516 (Pin: 27)

X516 (Pin: 32)

Open Circuit

A. If continuity/shorts test is successful, go to step 4. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Operation: Check Engine Oil Pressure Vehicle Status: Key Off Engine Off (test preparation) Vehicle Status: Key On Engine On (during test) Follow the procedure in the Engine Repair Manual for testing the pressure of the engine oil lubrication system. A. If the oil pressure test is successful, proceed to step 5. B. If the oil pressure test is not successful, refer to the Engine Repair Manual to diagnose, troubleshoot and repair the low oil pressure fault condition.

55-72

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 5. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-73

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1564-12 -- Oil Pressure Sensor NOTE: This diagnostic procedure references the integrated Oil Pressure Sensor/Oil Temperature Sensor (OPS/OTS). Since the pressure portion of the sensor is only being referenced, it will be referred to as the OPS sensor. Context: The Engine Control Unit (ECU) generated a fault associated with the Oil Pressure Sensor (OPS). This error could result from a signal out of range or a plausibility check (oil pressure too high). The plausibility check is only started if these conditions have been met: 1) no detected sensor power supply ( 5 volts DC) errors, 2) no detected Analog to Digital Converter (ADC) signal errors. Cause: The Oil Pressure Sensor and Oil Temperature Sensor (OPS) B-75 are both operating at the extreme upper portion of signal range. Possible failure modes: 1. Faulty integrated OPS/OTS (integrated) sensor B-75. 2. Faulty electrical wiring. 3. Faulty ECU, supply voltages or grounds. 4. Faulty engine lubrication system. 5. Low engine oil level. Solution: 1. Operation: Inspect Electrical Components and Check Engine Oil Level. Vehicle Status: Key Off Engine Off. Electrical: Remove OPS sensor connector X517 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the OPS sensor B-75. Oil Level: Check oil level on dipstick. A. If the engine oil level is low, top off the oil level with the recommended grade of oil specified in the Engine Repair Manual. B. If electrical damage has been determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace OPS sensor B-75 if damaged. C. If no electrical damage has been determined, proceed to step 2. 2. Operation: Pressure Test of Engine Oil Lubrication System. Vehicle Status: Key Off Engine Off (test preparation) Vehicle Status: Key On Engine On (during test) Follow the procedure in the Engine Repair Manual for pressure testing the engine oil lubrication system. A. If the oil pressure test is successful, proceed to step 3. B. If the oil pressure test is not successful, refer to the Engine Repair Manual to diagnose, troubleshoot and repair the low oil pressure fault.

55-74

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 3. Operation: Check Open Circuit Voltages for OPS Sensor B-75. Vehicle Status: Key On Engine Off. Remove X517 connector from the OPS sensor B-75 and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X517 (Pin 3)

X517 (Pin 1)

Approx. 5 volts

2. Voltage

X517 (Pin 2)

X517 (Pin 1)

Approx. 5 volts

3. Voltage

X517 (Pin 4)

X517 (Pin 1)

Approx. 5.4 volts

A. If the voltage test sequence is successful, proceed to step 5. B. If the voltage test sequence is not successful, proceed to step 4. 4. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity tests between connectors X517 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X517. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X517 (Pin: 1)

X516 (Pin: 24)

Approx. 0 -- 0.10 ohms

2. Continuity

X517 (Pin: 2)

X516 (Pin: 28)

Approx. 0 -- 0.10 ohms

3. Continuity

X517 (Pin: 3)

X516 (Pin: 32)

Approx. 0 -- 0.10 ohms

4. Continuity

X517 (Pin: 4)

X516 (Pin: 27)

Approx. 0 -- 0.10 ohms

5. Shorts

X516 (Pin: 28)

X516 (Pin: 24, 27, 32)

Open Circuit

6. Shorts

X516 (Pin: 24)

X516 (Pin: 27, 32)

Open Circuit

7. Shorts

X516 (Pin: 27)

X516 (Pin: 32)

Open Circuit

A. If continuity/shorts test is successful, go to step 4. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.

55-75

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 5. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts (DC)

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

A. If the voltages and ground paths are correct and the OPS sensor B-75 was not replaced on a prior diagnostic procedure of this type, replace the sensor. B. If the voltages and ground paths are correct and the OPS sensor B-75 was replaced on a prior diagnostic procedure of this type and the sensor mechanical alignment and spacing was verified, reinitialize the ECU as if it was blank (new) and load the appropriate dataset. C. If the voltages and ground paths are correct and the ECU was reinitialized on a prior diagnostic of this type, replace the ECU. D. If the voltages and ground paths are not correct, refer to schematic Frame 2 and 29 and determine root cause of power and/or continuity problem(s).

55-76

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1565-12 -- Oil Pressure Too Low NOTE: This diagnostic procedure references the integrated Oil Pressure Sensor/Oil Temperature Sensor (OPS/OTS). Since the pressure portion of the sensor is only being referenced, it will be referred to as the OPS sensor. Context: The Engine Control Unit (ECU) generated a fault associated with the Oil Pressure Sensor (OPS). This fault is a result of a plausibility check of the engine running extremely low oil pressure. All subsequent engine error states are frozen in case there is a sensor power supply error ( 5 volts DC). The ECU only starts the plausibility check when the following criteria has been met: no sensor supply errors ( 5 volts DC), no ADC signal errors and no errors in CAN message processing. Cause: The oil pressure is operating at the extreme low end of the range of the OPS sensor. Possible failure modes: 1. Faulty OPS sensor B-75. 2. Faulty electrical wiring. 3. Faulty ECU, supply voltages or grounds. 4. Faulty oil lubrication system. 5. Low engine oil level. Solution: 1. Operation: Inspect Electrical Components and Check Engine Oil Level. Vehicle Status: Key Off Engine Off. Electrical: Remove OPS sensor connector X517 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the OPS sensor B-75. Oil Level: Check oil level on dipstick. A. If the engine oil level is low, top off the oil level with the recommended grade of oil specified in the Engine Repair Manual. B. If electrical damage has been determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace OPS sensor B-75 if damaged. C. If no electrical damage has been determined, proceed to step 2. 2. Operation: Pressure Test of Engine Oil Lubrication System. Vehicle Status: Key Off Engine Off (test preparation) Vehicle Status: Key On Engine On (during test) Follow the procedure in the Engine Repair Manual for pressure testing the engine oil lubrication system. A. If the oil pressure test is successful, proceed to step 3. B. If the oil pressure test is not successful, refer to the Engine Repair Manual to diagnose, troubleshoot and repair the low oil pressure fault.

55-77

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 3. Operation: Check Open Circuit Voltages for OPS Sensor. Vehicle Status: Key On Engine Off. Remove X517 connector from OPS sensor B-75 and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X517 (Pin 3)

X517 (Pin 1)

Approx. 5 volts

2. Voltage

X517 (Pin 2)

X517 (Pin 1)

Approx. 5 volts

3. Voltage

X517 (Pin 4)

X517 (Pin 1)

Approx. 5.4 volts

A. If the voltage test sequence is successful, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 4. 4. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity tests between connectors X517 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X517. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X517 (Pin: 1)

X516 (Pin: 24)

Approx. 0 -- 0.10 ohms

2. Continuity

X517 (Pin: 2)

X516 (Pin: 28)

Approx. 0 -- 0.10 ohms

3. Continuity

X517 (Pin: 3)

X516 (Pin: 32)

Approx. 0 -- 0.10 ohms

4. Continuity

X517 (Pin: 4)

X516 (Pin: 27)

Approx. 0 -- 0.10 ohms

5. Short Circuit

X516 (Pin: 28)

X516 (Pin: 25, 27, 32)

Open Circuit

6. Short Circuit

X516 (Pin: 24)

X516 (Pin: 27, 32)

Open Circuit

7. Short Circuit

X516 (Pin: 27)

X516 (Pin: 32)

Open Circuit

A. If continuity/shorts test is successful, go to step 5. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.

55-78

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 5. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts (DC)

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-79

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

55-80

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0 L

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

10.3L ENGINE FRAME--4

A-01 = ENGINE CONTROL UNIT B-05 = ENGINE FLYWHEEL RPM B-07 = ENGINE CAMSHAFT RPM B-36 = FUEL TEMP

B-41 = AIR TEMP/BOOST PRESS B-44 = COOLANT TEMP B-75 = OIL TEMP/PRESS

55-81

L-34 = FUEL ACTUATOR 1 (CYL 1) L-35 = FUEL ACTUATOR 2 (CYL 4) L-36 = FUEL ACTUATOR 3 (CYL 2) L-37 = FUEL ACTUATOR 4 (CYL 6)

L-38 = FUEL ACTUATOR 5 (CYL 3) L-39 = FUEL ACTUATOR 6 (CYL 5)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-82

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1566-02 -- Oil Temp Sensor NOTE: This diagnostic procedure references the integrated Oil Pressure Sensor/Oil Temperature Sensor (OPS/OTS). Since the temperature portion of the sensor is only being referenced, it will be referred to as the OTS sensor. Context: The Engine Control Unit (ECU) generated a fault associated with the Oil Temperature Sensor (OTS). This error could result from a OTS signal out of range, a plausibility check against the Coolant Temperature Sensor (CTS) or CAN message processing. The ECU prohibits any plausibility checking when there are any ADC signal errors on the OTS or CTS sensors. Cause: The Oil Temperature Sensor (OTS) B-75 signal to the ECU is either erratic or intermittant. Possible failure modes: 1. Faulty OTS B-75 sensor. 2. Faulty electrical wiring or intermittant connection between OTS sensor B-75 and ECU. 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove OTS sensor connector X517 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the OTS sensor B-75. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace OTS sensor B-75 if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Check Open Circuit Voltages for OTS Sensor B-75. Vehicle Status: Key On Engine Off. Remove X517 connector from OTS sensor B-75 and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X517 (Pin 3)

X517 (Pin 1)

Approx. 5 volts (DC)

2. Voltage

X517 (Pin 2)

X517 (Pin 1)

Approx. 5 volts (DC)

3. Voltage

X517 (Pin 4)

X517 (Pin 1)

Approx. 5.4 volts (DC)

A. If the voltage test is successful and the OTS sensor B-75 was replaced on a prior diagnostic procedure of this nature and the problem still exists, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 3.

55-83

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 3. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity tests between connectors X517 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X517. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X517 (Pin: 1)

X516 (Pin: 24)

Approx. 0 -- 0.10 ohms

2. Continuity

X517 (Pin: 2)

X516 (Pin: 28)

Approx. 0 -- 0.10 ohms

3. Continuity

X517 (Pin: 3)

X516 (Pin: 32)

Approx. 0 -- 0.10 ohms

4. Continuity

X517 (Pin: 4)

X516 (Pin: 27)

Approx. 0 -- 0.10 ohms

5. Short Circuit

X516 (Pin: 28)

X516 (Pin: 24, 27, 32)

Open Circuit

6. Short Circuit

X516 (Pin: 24)

X516 (Pin: 27, 32)

Open Circuit

7. Short Circuit

X516 (Pin: 27)

X516 (Pin: 32)

Open Circuit

A. If continuity/shorts test is successful, go to step 4. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts (DC)

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

A. If the voltages and ground paths are correct and the OTS Sensor B-75 was not replaced on a prior diagnostic of this type, replace the sensor. B. If the voltages and ground paths are correct and the OTS Sensor B-75 was replaced on a prior diagnostic of this type, reinitialize the ECU as if it was blank (new) and load the appropriate dataset. C. If the voltages and ground paths are correct and the ECU was reinitialized on a prior diagnostic of this type, replace the ECU. D. If the voltages and ground paths are not correct, refer to schematic Frame 2 and 29 and determine root cause of power or continuity problem(s).

55-84

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1566-03 -- Oil Temp Sensor NOTE: This diagnostic procedure references the integrated Oil Pressure Sensor/Oil Temperature Sensor (OPS/OTS). Since the temperature portion of the sensor is only being referenced, it will be referred to as the OTS sensor. Context: The Engine Control Unit (ECU) generated a fault associated with the Oil Temperature Sensor (OTS). This error could result from a OTS signal out of range, a plausibility check against the Coolant Temperature Sensor (CTS) or CAN message processing. The ECU prohibits any plausibility checking when there are any ADC signal errors on the OTS or CTS sensors. Cause: The Oil Temperature Sensor (OTS) B-75 signal to the ECU is out of range of the upper threshold limit. Possible failure modes: 1. Faulty OTS sensor B-75 2. Faulty electrical wiring, signal short to HIGH (B+) or open circuit condition. 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove OTS sensor connector X517 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the OTS sensor B-75. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace OTS sensor B-75 if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Check Open Circuit Voltages for OTS Sensor B-75. Vehicle Status: Key On Engine Off. Remove X517 connector from OTS sensor B-75 and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X517 (Pin 3)

X517 (Pin 1)

Approx. 5 volts (DC)

2. Voltage

X517 (Pin 2)

X517 (Pin 1)

Approx. 5 volts (DC)

3. Voltage

X517 (Pin 4)

X517 (Pin 1)

Approx. 5.4 volts (DC)

A. If the voltage test is successful, proceed to step 4. B. If the voltage test is not successful, proceed to step 3.

55-85

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 3. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity tests between connectors X517 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X517. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X517 (Pin: 1)

X516 (Pin: 24)

Approx. 0 -- 0.10 ohms

2. Continuity

X517 (Pin: 2)

X516 (Pin: 28)

Approx. 0 -- 0.10 ohms

3. Continuity

X517 (Pin: 3)

X516 (Pin: 32)

Approx. 0 -- 0.10 ohms

4. Continuity

X517 (Pin: 4)

X516 (Pin: 27)

Approx. 0 -- 0.10 ohms

5. Short Circuit

X516 (Pin: 28)

X516 (Pin: 24, 27, 32)

Open Circuit

6. Short Circuit

X516 (Pin: 24)

X516 (Pin: 27, 32)

Open Circuit

7. Short Circuit

X516 (Pin: 27)

X516 (Pin: 32)

Open Circuit

A. If continuity/shorts test is successful, go to step 4. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts (DC)

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-86

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1566-04 -- Oil Temp Sensor NOTE: This diagnostic procedure references the integrated Oil Pressure Sensor/Oil Temperature Sensor (OPS/OTS). Since the temperature portion of the sensor is only being referenced, it will be referred to as the OTS sensor. Context: The Engine Control Unit (ECU) generated a fault associated with the Oil Temperature Sensor (OTS). This error could result from a OTS signal out of range, a plausibility check against the Coolant Temperature Sensor (CTS) or CAN message processing. The ECU prohibits any plausibility checking when there are any ADC signal errors on the OTS or CTS sensors. Cause: The Oil Temperature Sensor (OTS) B-75 signal to the ECU is out of range of the lower threshold limit. Possible failure modes: 1. Faulty OTS sensor B-75. 2. Faulty electrical wiring or signal short to LOW (ground). 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove OTS sensor connector B-75 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the OTS sensor B-75. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace OTS sensor if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Check Open Circuit Voltages for OTS Sensor B-75. Vehicle Status: Key On Engine Off. Remove X517 connector from OPS/OTS sensor and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X517 (Pin 3)

X517 (Pin 1)

Approx. 5 volts (DC)

2. Voltage

X517 (Pin 2)

X517 (Pin 1)

Approx. 5 volts (DC)

3. Voltage

X517 (Pin 4)

X517 (Pin 1)

Approx. 5.4 volts (DC)

A. If the voltage test is successful, proceed to step 4. B. If the voltage test is not successful, proceed to step 3.

55-87

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 3. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity tests between connectors X517 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X517. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X517 (Pin: 1)

X516 (Pin: 24)

Approx. 0 -- 0.10 ohms

2. Continuity

X517 (Pin: 2)

X516 (Pin: 28)

Approx. 0 -- 0.10 ohms

3. Continuity

X517 (Pin: 3)

X516 (Pin: 32)

Approx. 0 -- 0.10 ohms

4. Continuity

X517 (Pin: 4)

X516 (Pin: 27)

Approx. 0 -- 0.10 ohms

5. Short Circuit

X516 (Pin: 28)

X516 (Pin: 24, 27, 32)

Open Circuit

6. Short Circuit

X516 (Pin: 24)

X516 (Pin: 27, 32)

Open Circuit

7. Short Circuit

X516 (Pin: 27)

X516 (Pin: 32)

Open Circuit

A. If continuity/shorts test is successful, go to step 4. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 4. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-88

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1566-12 -- Oil Temp Sensor NOTE: This diagnostic procedure references the integrated Oil Pressure Sensor/Oil Temperature Sensor (OPS/OTS). Since the temperature portion of the sensor is only being referenced, it will be referred to as the OTS sensor. Context: The Engine Control Unit (ECU) generated a fault associated with the Oil Temperature Sensor (OTS). This error could result from a OTS signal out of range, a plausibility check against the Coolant Temperature Sensor (CTS) or CAN message processing. The ECU prohibits any plausibility checking when there are any ADC signal errors on the OTS or CTS sensors. Cause: The Oil Temperature Sensor (OTS) B-75 and the CTS B-44 signals to the ECU are out of range with respect to each other. Possible failure modes: 1. Faulty OTS sensor B-75 (inaccurate). 2. Faulty Coolant Temperature Sensor (CTS) B-44 (inaccurate). 3. Faulty electrical wiring, high resistance connections. 4. Faulty ECU, supply voltages or grounds. 5. Faulty oil lubrication or coolant system. Solution: 1. Operation: Check for Coolant Temperature Sensor (CTS) B-44 Faults. Check for fault code(s) related to the CTS B-44 sensor. They will be in this series: E1559-xx or E1560-xx. A. If coolant temperature fault codes exist, diagnose, troubleshoot and perform the necessary repairs to clear the fault(s). B. If coolant temperature fault code(s) do not exist, proceed to step 2. 2. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove OTS sensor connector X517 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the OTS sensor B-75. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace OTS sensor B-75 if damaged. B. If no damage is determined, proceed to step 3.

55-89

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 3. Operation: Check Open Circuit Voltages for OTS Sensor B-75. Vehicle Status: Key On Engine Off. Remove X517 connector from OTS sensor B-75 and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X517 (Pin 3)

X517 (Pin 1)

Approx. 5 volts (DC)

2. Voltage

X517 (Pin 2)

X517 (Pin 1)

Approx. 5 volts (DC)

3. Voltage

X517 (Pin 4)

X517 (Pin 1)

Approx. 5.4 volts (DC)

A. If the voltage test sequence is successful, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 5. 4. Operation: OTS Sensor B-75 Test Vehicle Status: Key Off Engine Off. Remove X517 connector and test resistance of OTS sensor B-75 using the table of resistance vs. temp. below. Approximate the engine oil temperature when performing test. OTS sensor B-75 failures are typically at the extreme ends of the table or off the table entirely. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor. Use a multimeter between pins 1 and 2. Engine Oil Temperature

Resistance Value (between pins 1 and 2)

--40 °C (--40 °F)

70 kOhm

--20 °C (--4 °F)

25 kOhm

0 °C (32 °F)

7.5 kOhm

20 °C (68 °F)

4.5 kOhm

40 °C (104 °F)

1.5 kOhm

60 °C (140 °F)

750 ohms

80 °C (176 °F)

550 ohms

100 °C (212 °F)

320 ohms

120 °C (248 °F)

130 ohms

A. If the resistance measurement does not approximately match the table, replace the sensor. B. If the resistance measurement does approximately match the table, proceed to step 5.

55-90

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 5. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity tests between connectors X517 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X517. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X517 (Pin: 1)

X516 (Pin: 24)

Approx. 0 -- 0.10 ohms

2. Continuity

X517 (Pin: 2)

X516 (Pin: 28)

Approx. 0 -- 0.10 ohms

3. Continuity

X517 (Pin: 3)

X516 (Pin: 32)

Approx. 0 -- 0.10 ohms

4. Continuity

X517 (Pin: 4)

X516 (Pin: 27)

Approx. 0 -- 0.10 ohms

5. Short Circuit

X516 (Pin: 28)

X516 (Pin: 24, 27, 32)

Open Circuit

6. Short Circuit

X516 (Pin: 24)

X516 (Pin: 27, 32)

Open Circuit

7. Short Circuit

X516 (Pin: 27)

X516 (Pin: 32)

Open Circuit

A. If continuity/shorts test is successful, go to step 6. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 6. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts (DC)

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-91

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1567-12 -- Oil Temperature Above Normal NOTE: This diagnostic procedure references the integrated Oil Pressure Sensor/Oil Temperature Sensor (OPS/OTS). Since the temperature portion of the sensor is only being referenced, it will be referred to as the OTS sensor. Context: The Engine Control Unit (ECU) generated a fault associated with the Oil Temperature Sensor (OTS) B-75. This error resulted from a plausibility check against the oil temperature being too high. The ECU will inhibit the plausibility check when there are ADC errors on the OTS sensor B-75 signal. Cause: The Oil Temperature Sensor (OTS) B-75 circuit is reporting an abnormally high oil temperature to the ECU. Possible failure modes: 1. Faulty OTS sensor B-75. 2. Faulty electrical wiring and/or connections. 3. Faulty ECU, supply voltages or grounds. 4. Faulty oil lubrication or coolant system. Solution: 1. Operation: Check for Coolant System Faults. Check for fault codes related to the Coolant Temperature Sensor (CTS) sensor B-44. They will be in this series: E1559-xx or E1560-xx. Also, check the coolant level. A faulty coolant system that is operating above normal temperatures could cause a high oil temperature since the engine has an integrated oil/coolant heat exchanger. A. If coolant level is low, top off the coolant level with the recommended coolant listed in the Engine Repair Manual. B. If coolant temperature fault codes exist, diagnose, troubleshoot and perform the necessary repairs to clear the fault(s). C. If coolant temperature fault codes do not exist, proceed to step 2. 2. Operation: Check for Oil Pressure Faults. Check for fault codes related to the Oil Pressure Sensor (OPS) B-75. They will be in this series: E1564-xx or E1565-xx. Also, check the engine oil level on the sump dipstick. A low pressure oil delivery system, could result in high oil temperatures. A. If the oil level is low, top off the oil level with the recommended oil described in the Engine Repair Manual. B. If oil pressure fault code(s) exist, diagnose, troubleshoot and perform the necessary repairs to clear the fault(s). C. If oil pressure fault code(s) do not exist, proceed to step 3. 3. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove OTS sensor connector X517 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the OTS sensor B-75. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace OTS sensor B-75 if damaged. B. If no damage is determined, proceed to step 4.

55-92

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 4. Operation: Check Open Circuit Voltages for OTS sensor B-75. Vehicle Status: Key On Engine Off. Remove X517 connector from OTS sensor B-75 and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X517 (Pin 3)

X517 (Pin 1)

Approx. 5 volts

2. Voltage

X517 (Pin 2)

X517 (Pin 1)

Approx. 5 volts

3. Voltage

X517 (Pin 4)

X517 (Pin 1)

Approx. 5.4 volts

A. If the voltage test sequence is successful, proceed to step 5. B. If the voltage test sequence is not successful, proceed to step 6. 5. Operation: OTS sensor B-75 Test Vehicle Status: Key Off Engine Off. Remove X517 connector and test resistance of OTS sensor B-75 using the table of resistance vs. temp. below. Approximate the engine oil temperature when performing test. OTS sensor B-75 failures are typically at the extreme ends of the table or off the table entirely. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor. Use a multimeter between pins 1 and 2. Engine Oil Temperature

Resistance Value (between pins 1 and 2)

--40 °C (--40 °F)

70 kOhm

--20 °C (--4 °F)

25 kOhm

0 °C (32 °F)

7.5 kOhm

20 °C (68 °F)

4.5 kOhm

40 °C (104 °F)

1.5 kOhm

60 °C (140 °F)

750 ohms

80 °C (176 °F)

550 ohms

100 °C (212 °F)

320 ohms

120 °C (248 °F)

130 ohms

A. If the resistance measurement does not approximately match the table, replace the sensor. B. If the resistance measurement does approximately match the table, proceed to step 6.

55-93

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 6. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity tests between connectors X517 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Air Press/Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X517. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X517 (Pin: 1)

X516 (Pin: 24)

Approx. 0 -- 0.10 ohms

2. Continuity

X517 (Pin: 2)

X516 (Pin: 28)

Approx. 0 -- 0.10 ohms

3. Continuity

X517 (Pin: 3)

X516 (Pin: 32)

Approx. 0 -- 0.10 ohms

4. Continuity

X517 (Pin: 4)

X516 (Pin: 27)

Approx. 0 -- 0.10 ohms

5. Short Circuit

X516 (Pin: 28)

X516 (Pin: 24, 27, 32)

Open Circuit

6. Short Circuit

X516 (Pin: 24)

X516 (Pin: 27, 32)

Open Circuit

7. Short Circuit

X516 (Pin: 27)

X516 (Pin: 32)

Open Circuit

A. If continuity/shorts test is successful, go to step 7. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 7. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts (DC)

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-94

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

55-95

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0 L

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

10.3L ENGINE FRAME--4

A-01 = ENGINE CONTROL UNIT B-05 = ENGINE FLYWHEEL RPM B-07 = ENGINE CAMSHAFT RPM B-36 = FUEL TEMP

B-41 = AIR TEMP/BOOST PRESS B-44 = COOLANT TEMP B-75 = OIL TEMP/PRESS

55-96

L-34 = FUEL ACTUATOR 1 (CYL 1) L-35 = FUEL ACTUATOR 2 (CYL 4) L-36 = FUEL ACTUATOR 3 (CYL 2) L-37 = FUEL ACTUATOR 4 (CYL 6)

L-38 = FUEL ACTUATOR 5 (CYL 3) L-39 = FUEL ACTUATOR 6 (CYL 5)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-97

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1569-12 -- Coolant Temperature Sensor Absolute Test Context: The Engine Control Unit (ECU) generated a fault when monitoring the temperature rise of the engine coolant temperature during a warm-up cycle. During the monitoring process, the start temp and the current coolant temp are compared against a warm-up cycle curve in the ECU. The fault is generated after a timer expires and the coolant temperature does not reach the minimum threshold. This test is carried out once per driving cycle and is stopped when the engine is in after-run mode. Cause: The ECU has determined that the rise in coolant temperature is lower than expected during the engine warm-up cycle. Possible failure modes: 1. Faulty or inaccurate Coolant Temperature Sensor (CTS). 2. Faulty wiring (high resistance). 3. Very low ambient temperature. Solution: 1. Operation: Check Engine Operating Conditions. Determine whether engine is being operated under extremely low ambient temperatures. A. If low ambient temperatures exist, cover up a portion of the radiator (20-25%) to accelerate the warm-up cycle. B. If low ambient temperatures do not exist, proceed to step 2. 2. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove CTS sensor connector X373 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the CTS sensor B-44. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace CTS sensor B-44 if damaged. B. If no damage is determined, proceed to step 3. 3. Operation: Check Open Circuit Voltages for CTS Sensor B-44 Vehicle Status: Key On Engine Off. Remove X373 connector from CTS sensor B-44 and check for voltages (DC) between connector pins outlined in the table below. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. Test Type

From

Expected Results

1. Voltage

X373 (Pin 1) (+)

X373 (Pin 2) (--)

Approx. 5 volts (DC)

A. If the voltage test sequence is successful, proceed to step 4. B. If the voltage test sequence is not successful, proceed to step 5.

55-98

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 4. Operation: CTS Sensor B-44 Test Vehicle Status: Key Off Engine Off. Remove X373 connector and test resistance of CTS sensor B-44 (between pins 1 and 2) using the table of resistance vs. temp. below. Approximate the temperature when performing test. CTS sensor B-44 failures are typically at the extreme ends of the table or off the table entirely. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the sensor. Coolant Temperature

Resistance Value

--20 °C (--4 °F)

10.5 kOhm

0 °C (32 °F)

7500 ohms

20 °C (68 °F)

4200 ohms

40 °C (104 °F)

980 ohms

60 °C (140 °F)

780 ohms

80 °C (176 °F)

500 ohms

100 °C (212 °F)

280 ohms

120 °C (248 °F)

97 ohms

A. If the resistance measurement does not approximately match the table, replace the sensor. B. If the resistance measurement does approximately match the table, proceed to step 5. 5. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity tests between connectors X373 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X373. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to connector X516. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X373 (Pin: 1)

X516 (Pin: 15)

Approx. 0 -- 0.10 ohms

2. Continuity

X373 (Pin: 2)

X516 (Pin: 26)

Approx. 0 -- 0.10 ohms

3. Short Circuit

X516 (Pin: 15)

X516 (Pin: 26)

Open Circuit

A. If continuity/shorts test is successful, go to step 6. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.

55-99

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 6. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove connector X193 from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to connector X193. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-100

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

55-101

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0 L

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

10.3L ENGINE FRAME--4

A-01 = ENGINE CONTROL UNIT B-05 = ENGINE FLYWHEEL RPM B-07 = ENGINE CAMSHAFT RPM B-36 = FUEL TEMP

B-41 = AIR TEMP/BOOST PRESS B-44 = COOLANT TEMP B-75 = OIL TEMP/PRESS

55-102

L-34 = FUEL ACTUATOR 1 (CYL 1) L-35 = FUEL ACTUATOR 2 (CYL 4) L-36 = FUEL ACTUATOR 3 (CYL 2) L-37 = FUEL ACTUATOR 4 (CYL 6)

L-38 = FUEL ACTUATOR 5 (CYL 3) L-39 = FUEL ACTUATOR 6 (CYL 5)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-103

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1570-03 -- Crankshaft Sensor Failure Context: The Engine Control Unit (ECU) has reported an error with the monitoring of the Crankshaft Position (CKP) sensor. If the engine has a defective CKP sensor it can run off the Camshaft Position (CMP) sensor. This is referred to as BACKUP mode. Diagnostics of the FMI=3 failures is only active if terminal 40 is on (KEY ON) and no errors are reported in the sensor supply voltage. For the FMI=4 failures, additional conditions for active diagnostics are included, such as the engine must be in startup mode and the engine speed must be above 450 RPM. Cause: The ECU has determined that there is no signal coming in from the CKP sensor and the engine is now in BACKUP mode. Possible failure modes: 1. Faulty CKP sensor B-05. 2. Faulty electrical wiring and/or connections. 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove CKP sensor connector X519 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the CKP sensor B-05. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace CKP sensor B-05 if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Resistance Check for Faulty CKP sensor B-05. Vehicle Status: Key Off Engine Off Remove CKP sensor connector X519 and connect the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the sensor terminals. See test table below. Test Type

From

Results (Min)

Results (Max)

1. Resistance

B-05 (Pin 1)

750 ohms

A. If the resistance test does not fall in the specified range, replace CKP sensor B-05. B. If the resistance test does fall in the specified range, proceed to step 3. 3. Operation: Check Output of CKP Sensor B-05. Vehicle Status: Key Off Engine Off (test setup) Vehicle Status: Key On Engine On (during test) Remove CKP sensor connector X519 and make the following electrical tests in the table below. There will be (2) types of tests (in-line and single ended) that will need to be performed which use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185. Reference the descriptions below to make the proper electrical connections for each test type. Single Ended Test Lead Connection Test (Standalone CKP Sensor B-05 Test): Remove CKP sensor connector X519 and connect the above mentioned special test lead to the CKP sensor B-05. Start the engine and measure the (AC) voltage using a multimeter across the breakout alligator clips from the test leads. Use the test table below to determine the measurement results.

55-104

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 In-Line Test Lead Connection Test: Remove CKP sensor connector X519 and connect the above mentioned special test lead in-line with the sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during the connection process. Start the engine and measure the (AC) voltage using a multimeter across the breakout alligator clips from the test leads. Use the test table below to determine the measurement results. NOTE: The engine will be running off the Camshaft Position (CMP) sensor B-07 during the single ended test, if it isn’t already (based on the fault code type). The engine can also be very hard to start when running exclusively off the CMP sensor B-07. The ECU needs to see a few revolutions of the camshaft to be able to use this information to start the engine. The CKP sensor B-05 and the CMP sensor B-07 are exactly the same. These sensors may be swapped in this diagnostic procedure to determine the functionality of the CKP sensor B-05. A new set of error codes may be generated by the ECU if the sensors are swapped. Test Type

From

Expected Results

1. Voltage (AC) -- Single ended connection at low rpm (1000 -- 1100 rpm)

CKP sensor B-05 (Pin 1)

CKP sensor B-05 (Pin 2)

Approx. 16 -- 18 volts (AC)

2. Voltage (AC) -- Single ended connection at high rpm (2000 -- 2200 rpm)

CKP sensor B-05 (Pin 1)

CKP sensor B-05 (Pin 2)

Approx. 32 -- 34 volts (AC)

3. Voltage (AC) -- In-line connection at low rpm (1000 -- 1100 rpm)

CKP sensor B-05 (Pin 1)

CKP sensor B-05 (Pin 2)

Approx. 10 -- 12 volts (AC)

4. Voltage (AC) -- In-line connection at high rpm (2000 -- 2200 rpm)

CKP sensor B-05 (Pin 1)

CKP sensor B-05 (Pin 2)

Approx. 14 -- 17 volts (AC)

55-105

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 4. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity tests between connectors X519 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X519. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X519 (Pin: 1)

X516 (Pin: 23)

Approx. 0 -- 0.10 ohms

2. Continuity

X519 (Pin: 2)

X516 (Pin: 19)

Approx. 0 -- 0.10 ohms

3. Short Circuit

X516 (Pin: 23)

X516 (Pin: 19)

Open Circuit

A. If continuity/shorts test is successful, go to step 5. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness. 5. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts (DC)

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

A. If the voltages and ground paths are correct and the CKP sensor B-05 was not replaced on a prior diagnostic procedure of this type, replace the sensor. B. If the voltages and ground paths are correct and the CKP sensor B-05 was replaced on a prior diagnostic procedure of this type and the sensor mechanical alignment and spacing was verified, reinitialize the ECU as if it was blank (new) and load the appropriate dataset. C. If the voltages and ground paths are correct and the ECU was reinitialized on a prior diagnostic of this type, replace the ECU. D. If the voltages and ground paths are not correct, refer to schematic Frame 2 and 29 and determine root cause of power and/or continuity problem(s).

55-106

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1570-04 -- Crankshaft Sensor Failure Context: The Engine Control Unit (ECU) has reported an error with the monitoring of the Crankshaft Position (CKP) sensor. If the engine has a defective CKP sensor it can run off the Camshaft Position (CMP) sensor. This is referred to as BACKUP mode. Diagnostics of the FMI=3 failures is only active if terminal 40 is on (KEY ON) and no errors are reported in the sensor supply voltage. For the FMI=4 failures, additional conditions for active diagnostics are included, such as the engine must be in startup mode and the engine speed must be above 450 RPM. Cause: The ECU has determined that there are errors in the signal coming in from the CKP sensor. Possible failure modes: 1. Faulty CKP sensor B-05. 2. Faulty electrical wiring and/or connections. 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove CKP sensor connector X519 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the CKP sensor B-05. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace CKP sensor B-05 if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Resistance Check for Faulty CKP sensor B-05. Vehicle Status: Key Off Engine Off Remove CKP sensor connector X519 and connect the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the sensor terminals. See test table below. Test Type

From

1. Resistance X519 (Pin 1)

Results (Min)

Results (Max)

X519 (Pin 2)

750 ohms

1000 ohms

55-107

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 In-Line Test Lead Connection Test: Remove CKP sensor connector X519 and connect the above mentioned special test lead in-line with the sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during the connection process. Start the engine and measure the (AC) voltage using a multimeter across the breakout alligator clips from the test leads. Use the test table below to determine the measurement results. NOTE: The engine will be running off the Camshaft Position (CMP) sensor B-07 during this test. The engine can also be very hard to start when the CKP sensor B-05 is disconnected. The ECU needs to see a few revolutions of the camshaft to be able to use this information to start the engine. Another starting technique would be to have the CKP sensor B-05 connected in-line with the engine wiring harness with the special test lead (Tier II NEF Diagnostic Repair Kit), start the engine and then disconnect the test lead from the wiring harness. The CKP sensor B-05 and the CMP sensor B-07 are exactly the same. These sensors may be swapped in this diagnostic procedure to determine the functionality of the CKP sensor B-05. A new set of error codes may be generated by the ECU if sensors are swapped. Test Type

From

Expected Results

1. Voltage (AC) -- Single ended connection at low rpm (1000 -- 1100 rpm)

CKP sensor B-05 (Pin 1)

CKP sensor B-05 (Pin 2)

Approx. 16 -- 18 volts (AC)

2. Voltage (AC) -- Single ended connection at high rpm (2000 -- 2200 rpm)

CKP sensor B-05 (Pin 1)

CKP sensor B-05 (Pin 2)

Approx. 32 -- 34 volts (AC)

3. Voltage (AC) -- In-line connection at low rpm (1000 -- 1100 rpm)

CKP sensor B-05 (Pin 1)

CKP sensor B-05 (Pin 2)

Approx. 10 -- 12 volts (AC)

4. Voltage (AC) -- In-line connection at high rpm (2000 -- 2200 rpm)

CKP sensor B-05 (Pin 1)

CKP sensor B-05 (Pin 2)

Approx. 14 -- 17 volts (AC)

55-108

From

Expected Results

1. Continuity

X519 (Pin: 1)

X516 (Pin: 23)

Approx. 0 -- 0.10 ohms

2. Continuity

X519 (Pin: 2)

X516 (Pin: 19)

Approx. 0 -- 0.10 ohms

3. Shorts

X516 (Pin: 23)

X516 (Pin: 19)

Open Circuit

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts (DC)

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

55-109

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

55-110

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0 L

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

10.3L ENGINE FRAME--4

A-01 = ENGINE CONTROL UNIT B-05 = ENGINE FLYWHEEL RPM B-07 = ENGINE CAMSHAFT RPM B-36 = FUEL TEMP

B-41 = AIR TEMP/BOOST PRESS B-44 = COOLANT TEMP B-75 = OIL TEMP/PRESS

55-111

L-34 = FUEL ACTUATOR 1 (CYL 1) L-35 = FUEL ACTUATOR 2 (CYL 4) L-36 = FUEL ACTUATOR 3 (CYL 2) L-37 = FUEL ACTUATOR 4 (CYL 6)

L-38 = FUEL ACTUATOR 5 (CYL 3) L-39 = FUEL ACTUATOR 6 (CYL 5)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1571-04 -- Running With Camshaft Sensor Only Context: The Engine Control Unit (ECU) has reported an error with the monitoring of the Crankshaft Position (CKP) sensor. In the case of a defective CKP sensor the engine can also be run alone with the Camshaft Position (CMP) sensor in a BACKUP mode. This operation, however, imposes a lot of restrictions on the system since the precise position of the crankshaft can only be roughly estimated by the camshaft information. In case the engine enters this BACKUP operation due to a crankshaft sensor error the fault path at hand is set. Cause: The ECU has determined that there are errors in the signal coming in from the CKP sensor and has entered into BACKUP mode. The engine is only running on the CMP sensor. Possible failure modes: 1. Faulty CKP sensor B-05. 2. Faulty electrical wiring and/or connections. 3. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove CKP sensor connector X519 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the CKP sensor B-05. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace CKP sensor B-05 if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Resistance Check for Faulty CKP sensor B-05. Vehicle Status: Key Off Engine Off Remove CKP sensor connector X519 and connect the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the sensor terminals. See test table below. Test Type

From

1. Resistance X519 (Pin 1)

Results (Min)

Results (Max)

X519 (Pin 2)

750 ohms

1000 ohms

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 In-Line Test Lead Connection Test: Remove CKP sensor connector X519 and connect the above mentioned special test lead in-line with the sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during the connection process. Start the engine and measure the (AC) voltage using a multimeter across the breakout alligator clips from the test leads. Use the test table below to determine the measurement results. NOTE: The engine will be running off the Camshaft Position (CMP) sensor B-07 during this test. The engine can also be very hard to start when the CKP sensor B-05 is disconnected. The ECU needs to see a few revolutions of the camshaft to be able to use this information to start the engine. Another starting technique would be to have the CKP sensor B-05 connected in-line with the engine wiring harness with the special test lead (Tier II NEF Diagnostic Repair Kit), start the engine and then disconnect the test lead from the wiring harness. The CKP sensor B-05 and the CMP sensor B-07 are exactly the same. These sensors may be swapped in this diagnostic procedure to determine the functionality of the CKP sensor B-05. A new set of error codes may be generated by the ECU if sensors are swapped. Test Type

From

Expected Results

1. Voltage (AC) -- Single ended connection at low rpm (1000 -- 1100 rpm)

CKP sensor B-05 (Pin 1)

CKP sensor B-05 (Pin 2)

Approx. 16 -- 18 volts (AC)

2. Voltage (AC) -- Single ended connection at high rpm (2000 -- 2200 rpm)

CKP sensor B-05 (Pin 1)

CKP sensor B-05 (Pin 2)

Approx. 32 -- 34 volts (AC)

3. Voltage (AC) -- In-line connection at low rpm (1000 -- 1100 rpm)

CKP sensor B-05 (Pin 1)

CKP sensor B-05 (Pin 2)

Approx. 10 -- 12 volts (AC)

4. Voltage (AC) -- In-line connection at high rpm (2000 -- 2200 rpm)

CKP sensor B-05 (Pin 1)

CKP sensor B-05 (Pin 2)

Approx. 14 -- 17 volts (AC)

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From

Expected Results

1. Continuity

X519 (Pin: 1)

X516 (Pin: 23)

Approx. 0 -- 0.10 ohms

2. Continuity

X519 (Pin: 2)

X516 (Pin: 19)

Approx. 0 -- 0.10 ohms

3. Shorts

X516 (Pin: 23)

X516 (Pin: 19)

Open Circuit

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts (DC)

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1572-03 -- Camshaft Sensor Failure Context: The Engine Control Unit (ECU) has reported an error with the monitoring of the Camshaft Position (CMP) sensor. If the engine has a defective CMP sensor it can run off the Crankshaft Position (CKP) sensor. Diagnostics is active if terminal 40 (Key On) is on, the current engine speed is above 50 RPM, no error in the Crankshaft Position (CKP) sensor is present and the sensor supply voltage ( 5 volts DC) is not defective. Cause: The ECU has determined that there is no signal coming in from the CMP sensor. Possible failure modes: 1. Faulty CMP sensor B-07. 2. CMP sensor B-07 is not mechanically installed correctly. 3. Faulty electrical wiring and/or connections. 4. Faulty ECU, supply voltages or grounds. Solution: 1. Operation: Electrical Inspection. Vehicle Status: Key Off Engine Off. Remove CMP sensor connector X518 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect connector portion of the CMP sensor B-07. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace CMP sensor B-07 if damaged. B. If no damage is determined, proceed to step 2. 2. Operation: Resistance Check for Faulty CMP sensor B-07. Vehicle Status: Key Off Engine Off Remove CMP sensor connector X518 and connect the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the sensor terminals. See test table below. Test Type

From

1. Resistance X518 (Pin 1)

Results (Min)

Results (Max)

X518 (Pin 2)

750 ohms

1000 ohms

A. If the resistance test does not fall in the specified range, replace CMP sensor B-07. B. If the resistance test does fall in the specified range, proceed to step 3. 3. Operation: Check Output of CMP Sensor B-07. Vehicle Status: Key Off Engine Off (test setup) Vehicle Status: Key On Engine On (during test) Remove CMP sensor connector X518 and make the following electrical tests in the table below. There will be (2) types of tests (in-line and single ended) that will need to be performed which use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185. Reference the descriptions below to make the proper electrical connections for each test type. Single Ended Test Lead Connection Test (Standalone CMP Sensor B-07 Test): Remove CMP sensor connector X518 and connect the above mentioned special test lead to the CMP sensor B-07. Start the engine and measure the (AC) voltage using a multimeter across the breakout alligator clips from the test leads. Use the test table below to determine the measurement results.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 In-Line Test Lead Connection Test: Remove CMP sensor connector X518 and connect the above mentioned special test lead in-line with the sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during the connection process. Start the engine and measure the (AC) voltage using a multimeter across the breakout alligator clips from the test leads. Use the test table below to determine the measurement results. NOTE: The engine will be running off the Crankshaft Position (CKP) sensor B-05 during this test. The CMP sensor B-07 and the CKP sensor B-05 are exactly the same. These sensors may be swapped in this diagnostic procedure to determine the functionality of the CMP sensor B-07. A new set of error codes may be generated by the ECU if sensors are swapped. Test Type

From

Expected Results

1. Voltage (AC) -- Single ended connection at low rpm (1000 -- 1100 rpm)

CMP sensor B-07 (Pin 1)

CMP sensor B-07 (Pin 2)

Approx. 2 -- 3 volts (AC)

2. Voltage (AC) -- Single ended connection at high rpm (2000 -- 2200 rpm)

CMP sensor B-07 (Pin 1)

CMP sensor B-07 (Pin 2)

Approx. 4 -- 6 volts (AC)

3. Voltage (AC) -- In-line connection at low rpm (1000 -- 1100 rpm)

CMP sensor B-07 (Pin 1)

CMP sensor B-07 (Pin 2)

Approx. 1.5 -- 2.8 volts (AC)

4. Voltage (AC) -- In-line connection at high rpm (2000 -- 2200 rpm)

CMP sensor B-07 (Pin 1)

CMP sensor B-07 (Pin 2)

Approx. 3 -- 4.5 volts (AC)

A. If the voltage test was successful, proceed to step 5. B. If the voltage test was not successful for any of the single ended connections, replace the sensor. C. If the voltages encountered during testing are low and the sensor was replaced on a prior diagnostic of this type, proceed to check sensor mechanical alignment and tooth spacing referenced in the Engine Repair Manual. D. If the voltage test was successful for the single ended connections and not for any of the in-line connections, proceed to step 4. 4. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity tests between connectors X518 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X518. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the DMM to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X518 (Pin: 1)

X516 (Pin: 10)

Approx. 0 -- 0.10 ohms

2. Continuity

X518 (Pin: 2)

X516 (Pin: 9)

Approx. 0 -- 0.10 ohms

3. Short Circuit

X516 (Pin: 10)

X516 (Pin: 9)

Open Circuit

A. If continuity/shorts test is successful, go to step 5. B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 5. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off. Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts (DC)

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

A. If the voltages and ground paths are correct and the CMP B-07 sensor was not replaced on a prior diagnostic procedure of this type, replace the sensor. B. If the voltages and ground paths are correct and the CMP sensor B-07 was replaced on a prior diagnostic procedure of this type and the sensor mechanical alignment and spacing was verified, reinitialize the ECU as if it was blank (new) and load the appropriate dataset. C. If the voltages and ground paths are correct and the ECU was reinitialized on a prior diagnostic of this type, replace the ECU. D. If the voltages and ground paths are not correct, refer to schematic Frame 2 and 29 and determine root cause of power and/or continuity problem(s).

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1572-04 -- Camshaft Sensor Failure Context: The Engine Control Unit (ECU) has reported an error with the monitoring of the Camshaft Position (CMP) sensor. If the engine has a defective CMP sensor it can run off the Crankshaft Position (CKP) sensor. Diagnostics is active if terminal 40 (Key On) is on, the current engine speed is above 50 RPM, no error in the Crankshaft Position (CKP) sensor is present and the sensor supply voltage ( 5 volts DC) is not defective. Cause: The ECU has determined that there is a plausibility error between the phasing of the CKP and the CMP signals. The signal from the CMP sensor is either intermittant or does not exist. Possible failure modes: 1. Faulty CMP sensor B-07. 2. CMP sensor is not mechanically installed correctly. 3. Faulty electrical wiring and/or connections. 4. Faulty ECU, supply voltages or ground. Solution: 1. Operation: Electrical and Sensor Mounting Inspection. Vehicle Status: Key Off Engine Off. Remove CMP sensor connector X518 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect the connector portion and mechanical mounting of the CMP sensor B-07. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace CMP sensor B-07 if damaged. B. If the sensor is not mounted correctly (loose, not seated properly, etc.), remount the sensor taking special care to make sure it is properly seated (flush with sealing surface) and fastened. Use the Engine Repair Manual for a reference if necessary. C. If no damage is determined, proceed to step 2. 2. Operation: Resistance Check for Faulty CMP sensor B-07. Vehicle Status: Key Off Engine Off Remove CMP sensor connector X518 and connect the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the sensor terminals. See test table below. Test Type

From

1. Resistance X518 (Pin 1)

Results (Min)

Results (Max)

X518 (Pin 2)

750 ohms

1000 ohms

55-119

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Single Ended Test Lead Connection Test (Standalone CMP Sensor B-07 Test): Remove CMP sensor connector X518 and connect the above mentioned special test lead to the CMP sensor B-07. Start the engine and measure the (AC) voltage using a multimeter across the breakout alligator clips from the test leads. Use the test table below to determine the measurement results. In-Line Test Lead Connection Test: Remove CMP sensor connector X518 and connect the above mentioned special test lead in-line with the sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during the connection process. Start the engine and measure the (AC) voltage using a multimeter across the breakout alligator clips from the test leads. Use the test table below to determine the measurement results. NOTE: The engine will be running off the Crankshaft Position (CKP) sensor B-05 during this test. The CMP sensor B-07 and the CKP sensor B-05 are exactly the same. These sensors may be swapped in this diagnostic procedure to determine the functionality of the CMP sensor B-07. A new set of error codes may be generated by the ECU if sensors are swapped. Test Type

From

Expected Results

1. Voltage (AC) -- Single ended connection at low rpm (1000 -- 1100 rpm)

CMP sensor B-07 (Pin 1)

CMP sensor B-07 (Pin 2)

Approx. 2 -- 3 volts (AC)

2. Voltage (AC) -- Single ended connection at high rpm (2000 -- 2200 rpm)

CMP sensor B-07 (Pin 1)

CMP sensor B-07 (Pin 2)

Approx. 4 -- 6 volts (AC)

3. Voltage (AC) -- In-line connection at low rpm (1000 -- 1100 rpm)

CMP sensor B-07 (Pin 1)

CMP sensor B-07 (Pin 2)

Approx. 1.5 -- 2.8 volts (AC)

4. Voltage (AC) -- In-line connection at high rpm (2000 -- 2200 rpm)

CMP sensor B-07 (Pin 1)

CMP sensor B-07 (Pin 2)

Approx. 3 -- 4.5 volts (AC)

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 4. Operation: Check for Faulty Wiring. Vehicle status: Key Off Engine Off. Remove and perform continuity tests between connectors X518 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X518. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

X518 (Pin: 1)

X516 (Pin: 10)

Approx. 0 -- 0.10 ohms

2. Continuity

X518 (Pin: 2)

X516 (Pin: 9)

Approx. 0 -- 0.10 ohms

3. Short Circuit

X516 (Pin: 10)

X516 (Pin: 9)

Open Circuit

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts (DC)

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

FAULT CODE E1573-03 -- Offset Between Camshaft and Crankshaft Context: The Engine Control Unit (ECU) has reported an error with the phase relationship between the Crankshaft Position (CKP) sensor and the Camshaft Position (CMP) sensor. The engine will alternatively use a redundant angular system which is based on the CKP sensor. Diagnostics is active under these conditions: 1) terminal 40 (Key On) is active, 2) current engine speed is above 50 RPM, 3) no error is reported for the Crankshaft Position (CKP) sensor and 4) sensor supply voltage ( 5 volts DC) is not defective. Cause: The ECU has determined that there is a phase relationship error between the CKP and the CMP sensor. Possible failure modes: 1. Faulty CMP B-07 or CKP sensor B-05. 2. CMP B-07 or CKP sensor B-05 are not mechanically installed correctly. 3. Faulty electrical wiring and/or connections. 4. Faulty ECU, supply voltages or ground. Solution: 1. Operation: Electrical and Sensor Mounting Inspection. Vehicle Status: Key Off Engine Off. Remove CMP and CKP sensor connectors X518/X519 and inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect the connector portion and mechanical mounting (seating) of the CMP and CKP sensors B-07/B-05. A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a good and sound electrical connection. Replace CMP or CKP sensor B-07/B-05 if damaged. B. If any of the sensors are not mounted correctly (loose, not seated properly, etc.), remount the sensors taking special care to make sure it is properly seated (flush with sealing surface) and fastened. Use the Engine Repair Manual for a reference if necessary. C. If no damage is determined, proceed to step 2. 2. Operation: Resistance Test for CMP sensor B-07. Vehicle Status: Key Off Engine Off Remove CMP sensor connector X518 and connect the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the sensor terminals. See test table below. Test Type

From

Results (Min)

1. Resistance CMP Sensor CMP Sensor 750 ohms B-07 (Pin 1) B-07 (Pin 2)

Results (Max) 1000 ohms

A. If the resistance test does not fall in the specified range, replace CMP sensor B-07. B. If the resistance test does fall in the specified range, proceed to step 3.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 3. Operation: Resistance Test for CKP sensor B-05. Vehicle Status: Key Off Engine Off Remove CKP sensor connector X519 and connect the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the sensor terminals. See test table below. Test Type

From

1. Resistance B-05 (Pin 1)

Results (Min)

Results (Max)

B-05 (Pin 2)

750 ohms

1000 ohms

A. If the resistance test does not fall in the specified range, replace CKP sensor B-05. B. If the resistance test does fall in the specified range, proceed to step 4. 4. Operation: Check CKP Sensor B-05 Output Voltage and Harness Wiring. Perform both (2) electrical tests defined below: 4-1. AC output voltage test for CKP sensor B-05 Vehicle Status: Key Off Engine Off (test setup) Vehicle Status: Key On Engine On (during test) NOTE: When performing this electrical test, use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185. Remove CKP sensor connector X519 and connect the Coolant/Fuel Temp Sensor test lead in-line with the sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during the connection process. Start the engine and measure the (AC) voltage using a multimeter across the breakout alligator clips from the Coolant/Fuel Temp Sensor test lead. Use the table below to determine test parameters and the measurement results. Test Type

From

Expected Results

1. Voltage (AC) -- In-line connection at low rpm (1000 -- 1100 rpm)

CKP sensor B-05 (Pin 1)

CKP sensor B-05 (Pin 2)

Approx. 10 -- 12 volts (AC)

2. Voltage (AC) -- In-line connection at high rpm (2000 -- 2200 rpm)

CKP sensor B-05 (Pin 1)

CKP sensor B-05 (Pin 2)

Approx. 14 -- 17 volts (AC)

4-2. Harness wiring continuity/shorts electrical test (CKP Sensor B-05). Vehicle status: Key Off Engine Off.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Remove and perform continuity tests between connectors X519 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector X519. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital mulutimeter (DMM) to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

CKP Sensor Connector X519 (Pin: 1)

ECU Connector X516 (Pin: 23)

Approx. 0 -- 0.1 ohms

2. Continuity

CKP Sensor Connector X519 (Pin: 2)

ECU Connector X516 (Pin: 19)

Approx. 0 -- 0.1 ohms

3. Shorts

ECU Connector X516 (Pin: 23)

ECU Connector X516 (Pin: 19)

Open Circuit

A. If both electrical tests are successful, proceed to step 7. B. If harness wiring continuity/shorts test was not successful, find and repair the damaged sections(s) of the wiring harness. C. If the voltage test was not successful and the continuity/shorts test was successful, proceed to step 5. 5. Operation: CKP Sensor Alignment. Vehicle Status: Key Off Engine Off. Use the technical information in the Engine Repair Manual to check proper mechanical alignment and tooth spacing of the CKP sensor B-05. The spacing between the trigger teeth and the sensor is critical for proper voltage output. Make sure that the sensor is seated properly (flush with mounting flange). After the sensor alignment is complete, check to see if this fault code has cleared. A. If this fault code is still present and has not cleared, proceed to step 6. 6. Operation: Replace CKP Sensor. Vehicle Status: Key Off Engine Off. If needed, use the technical information in the Engine Repair Manual to replace the CKP sensor B-05. Make sure that the proper mechanical alignment and tooth spacing is correct. The spacing between the trigger teeth and the sensor is critical for proper voltage output. Make sure that the sensor is seated properly (flush with mounting flange). After the sensor alignment is complete, check to see if this fault code has cleared. A. If this fault code is still present and has not cleared, proceed to step 13. 7. Operation: Check CMP Sensor B-07 Output Voltage and Harness Wiring. Perform both (2) electrical tests defined below: A. AC output voltage test for CMP sensor B-07: Vehicle Status: Key Off Engine Off (test setup) Vehicle Status: Key On Engine On (during test) NOTE: When performing this electrical test, use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit 380040185.

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SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Remove CMP sensor connector X518 and connect the Coolant/Fuel Temp Sensor test lead in-line with the sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during the connection process. Start the engine and measure the (AC) voltage using a multimeter across the breakout alligator clips from the Coolant/Fuel Temp Sensor test lead. Use the table below to determine test parameters and the measurement results. Test Type

From

Expected Results

1. Voltage (AC) -- In-line connection at low rpm (1000 -- 1100 rpm)

CMP sensor B-07 (Pin 1)

CMP sensor B-07(Pin 2)

Approx. 1.5 -- 2.8 (AC)

2. Voltage (AC) -- In-line connection at high rpm (2000 -- 2200 rpm)

CMP sensor B-07(Pin 1)

CMP sensor B-07 (Pin 2)

Approx. 3 -- 4.5 volts (AC)

B. Harness wiring continuity/shorts electrical test (CMP Sensor B-07). Vehicle Status: Key Off Engine Off. Remove and perform continuity tests between connectors X518 and X516 on engine wiring harness. Flex harness during test to check for any intermittant operation. Use the test lead labeled “Coolant/Fuel Temp Sensor” from the Tier II (NEF) Diagnostic Repair Kit #380040185 to be able to access the pins on the sensor connector X518. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the DMM to the X516 connector. Make sure the DMM’s test lead resistance is taken into account when taking continuity measurements. See test table below. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Continuity

CMP Sensor Connector X518 (Pin: 1)

ECU Connector X516 (Pin: 10)

Approx. 0 -- 0.1 ohms

2. Continuity

CMP Sensor Connector X518 (Pin: 2)

ECU Connector X516 (Pin: 9)

Approx. 0 -- 0.1 ohms

3. Short Circuit

ECU Connector X516 (Pin: 10)

ECU Connector X516 (Pin: 9)

Open Circuit

A. If both electrical tests are successful, proceed to step 10. B. If harness wiring continuity/shorts test was not unsuccessful, find and repair the damaged sections(s) of the wiring harness. C. If the voltage test was not successful and the continuity/shorts test was successful, proceed to step 8. 8. Operation: CMP Sensor Alignment. Vehicle Status: Key Off Engine Off. Use the technical information in the Engine Repair Manual to check proper mechanical alignment and tooth spacing of the CMP sensor B-07. The spacing between the trigger teeth and the sensor is critical for proper voltage output. Make sure that the sensor is seated properly (flush with mounting flange). After the sensor alignment is complete, check to see if this fault code has cleared. A. If this fault code is still present and has not cleared, proceed to step 9.

55-125

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 9. Operation: Replace CMP Sensor B-07. Vehicle Status: Key Off Engine Off. If needed, use the technical information in the Engine Repair Manual to replace the CMP sensor B-07. Make sure that the proper mechanical alignment and tooth spacing is correct. The spacing between the trigger teeth and the sensor is critical for proper voltage output. Make sure that the sensor is seated properly (flush with mounting flange). After the sensor alignment is complete, check to see if this fault code has cleared. A. If this fault code is still present and has not cleared, proceed to step 13. 10. Operation: Replace CKP Sensor B-05. Vehicle Status: Key Off Engine Off. If needed, use the technical information in the Engine Repair Manual to replace the CKP sensor B-05. Make sure that the proper mechanical alignment and tooth spacing is correct. The spacing between the trigger teeth and the sensor is critical for proper voltage output. Make sure that the sensor is seated properly (flush with mounting flange). After the sensor alignment is complete, check to see if this fault code has cleared. A. If this fault code is still present and has not cleared, proceed to step 11. 11. Operation: Swap the New CKP Sensor B-05 with the Old CMP Sensor B-07. Vehicle Status: Key Off Engine Off. If needed, use the technical information in the Engine Repair Manual to swap the new CKP sensor B-05 with the old CMP sensor B-07. Make sure that the proper mechanical alignment and tooth spacing is correct for both sensors. The spacing between the trigger teeth and the sensor is critical for proper voltage output. Make sure that the sensors are seated properly (flush with mounting flange). After the sensor alignment is complete, check to see if this fault code has cleared. A. If this fault code still exists, proceed to step 12. 12. Operation: Replace Old CMP Sensor B-07. Vehicle Status: Key Off Engine Off. If needed, use the technical information in the Engine Repair Manual to replace the old CMP sensor B-07. When this is complete, both CKP B-05 and CMP sensors B-07 will have been replaced. Make sure that the proper mechanical alignment and tooth spacing is correct. The spacing between the trigger teeth and the sensor is critical for proper voltage output. Make sure that the sensor is seated properly (flush with mounting flange). After the sensor alignment is complete, check to see if this fault code has cleared. A. If this fault code still exists, proceed to step 13. 13. Operation: Check for ECU Voltages and Ground Continuity. Vehicle Status (when removing X193 connector): Key Off Engine Off. Vehicle Status (when performing test): Key On Engine Off. Vehicle Status (when replacing X193 connector): Key Off Engine Off.

55-126

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24 Using schematic Frame 2 and 29 for a reference, remove X193 connector from the ECU and check for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the X193 connector. Make sure the DMM’s test lead resistance is taken into account when making any continuity measurements. IMPORTANT NOTE: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when removing and replacing main ECU connectors if this is not followed. Test Type

From

Expected Results

1. Voltage

X193 (Pin 2, 3, 8, 9, 40)

Ground (engine block)

Approx. 12 volts (DC)

2. Continuity

X193 (Pin 5, 6, 10, 11)

Ground (engine block)

Approx. 0 -- 0.10 ohms

A. If the voltages and ground paths are correct, proceed to step 14. B. If the voltages and ground paths are not correct, refer to schematic Frame 2 and 29 and determine root cause of power and/or continuity problem(s). 14. Operation: ReInitialize the ECU. Vehicle Status: Key On Engine Off. Using the EST service tool, reinitialize the ECU and load the appropriate dataset for this engine type. A call will have to be made to CNH TSS to get an authorization code for the ECU initialization download. Check to see if the fault code has cleared. A. If the fault code did not clear, replace the ECU.

55-127

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

STARTING FRAME--2

A-01 = IVECO ECU A-16 = CUMMINS ECU B-59 = WATER IN FUEL SENSOR F-01 = ECU POWER FUSE

F-26 = STARTING FUSE G-01 = ALTERNATOR K-15 = STARTING RELAY K-23 = NEUTRAL START RELAY

55-128

K-39 = GRID HEATER RELAY R-09 = ENGINE GRID HEATER

IVECO 10 L

CUMMINS 9.0 L

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

10.3L ENGINE FRAME--4

A-01 = ENGINE CONTROL UNIT B-05 = ENGINE FLYWHEEL RPM B-07 = ENGINE CAMSHAFT RPM B-36 = FUEL TEMP

B-41 = AIR TEMP/BOOST PRESS B-44 = COOLANT TEMP B-75 = OIL TEMP/PRESS

55-129

L-34 = FUEL ACTUATOR 1 (CYL 1) L-35 = FUEL ACTUATOR 2 (CYL 4) L-36 = FUEL ACTUATOR 3 (CYL 2) L-37 = FUEL ACTUATOR 4 (CYL 6)

L-38 = FUEL ACTUATOR 5 (CYL 3) L-39 = FUEL ACTUATOR 6 (CYL 5)

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 24

F-38 = KEY SWITCH FUSE F-39 = MEMORY (KAPWR) J-10 = DIAGNOSTIC OUTLET S-02 = KEY SWITCH

A-01 = ENGINE CONTROL UNIT

DISTRIBUTION FRAME--29

55-130

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 25

SECTION 55 - ELECTRICAL SYSTEMS Chapter 25 - CNH 9.0L Engine Fault Codes CONTENTS Section

Description

Page

55-1

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 25 INTRODUCTION

The following table lists the engine fault codes that may be displayed to the operator, along with the corresponding ECU fault code, which is a different fault number. The table is provided for reference only; the INSITE software has the most current information available for diagnosing engine concerns.

The CNH 9.0L engine ECU does fault monitoring for the engine electrical system, and will advise the combine electrical system if faults occur. In order to diagnose these engine faults, it will be necessary to connect the electronic service tool (EST) to the combine, and use the INSITE® software to directly communicate with the ECU. The INSITE software contains the diagnostic procedures for resolving these faults.

55-2

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 25 CNH 9.0L ENGINE FAULTS Description

Display Fault Code

FMI

1792

None

241

None

242

None

131

None

132

None

147

None

148

None

287

None

1242

Medium

268

Medium

2215

Medium

2216

None

418

None

428

Medium

429

Medium

135

Wheel--based Vehicle Speed Accelerator Pedal Position

1793

Fuel Delivery Pressure

1794

Water in Fuel Indicator

1795

Engine Oil Pressure

1796

Boost Pressure

1797

Turbocharger 1 Speed

1798

Intake Manifold #1 Temperature

1799

Barometric Pressure

1800

Engine Coolant Temperature

1801

55-3

Priority

Insite Fault Code

Medium

141

Medium

143

High

415

Medium

435

Medium

122

Medium

123

Medium

433

Medium

2973

Medium

595

Medium

687

Medium

2345

Medium

153

Medium

154

High

155

Low

2964

Medium

221

Medium

222

Medium

295

Medium

144

Medium

145

Medium

146

High

151

Medium

334

Low

2963

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 25 Description

Display Fault Code

FMI

Priority

Insite Fault Code

Coolant Level

1802

None

195

None

196

None

235

High

449

Medium

451

Injector Metering Rail 1 Pressure

1803

Alternate Potential (Voltage)

1804

Electrical Potential (Voltage)

1805

Ambient Air Temperature

1806

Engine Speed

1807

Medium

452

Medium

553

Medium

554

Medium

559

Medium

596

Medium

597

High

598

Medium

441

Medium

442

Medium

249

Medium

256

High

234

Medium

689

Low

2321

Real Time Clock Power Interrupt

1808

Low

319

OEM Temperature

1809

Medium

293

Medium

294

None

431

None

432

None

551

Medium

238

Medium

523

Medium

2185

Medium

2186

Accelerator Pedal Low Idle Switch

1810

System Diagnostic Code # 1

1811

System Diagnostic Code # 2

1812

High

115

Power Supply

1813

Medium

434

Low

1117

High

111

Medium

343

Medium

351

Medium

341

Medium

2217

Controller #1

1814

Calibration Memory

1815

Fuel Control Valve #1

1816

Medium

2311

SAE J1939 Datalink

1817

Medium

285

Medium

286

55-4

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 25 Description

Display Fault Code

FMI

Priority

Insite Fault Code

1818

Medium

2384

Medium

2385

Variable Geometry Turbocharger External Speed Input

1819

Medium

237

Fan Clutch Output Device Driver

1820

Medium

245

Medium

2377

Medium

322

Medium

1139

Medium

331

Medium

1141

Medium

324

Medium

1142

Medium

332

Medium

1143

Medium

323

Medium

1144

Medium

325

Medium

1145

Medium

584

Medium

585

Medium

2557

Medium

2558

Injector Cylinder #01

1821

Injector Cylinder #02

1822

Injector Cylinder #03

1823

Injector Cylinder #04

1824

Injector Cylinder #05

1825

Injector Cylinder #06

1826

Starter Solenoid Lockout Relay Driver Circuit

1827

Auxiliary PWM Driver #1

1828

Auxiliary Equipment Sensor Input

1829

Medium

779

Engine Speed Sensor #2

1830

Medium

731

Medium

753

Medium

778

Low

2322

Medium

2555

Medium

2556

None

133

None

134

None

288

Medium

284

Medium

387

Medium

443

Medium

2362

Medium

2366

Medium

2363

Medium

2367

Medium

2265

Medium

2266

Inlet Air Heater Driver # 1

1831

Remote Accelerator

1832

Internal Sensor Voltage Supply

1833

Engine Compression Brake Output # 1

1834

Engine Compression Brake Output # 2

1835

Electric Lift Pump for Engine Fuel

1836

55-5

SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 25 Description

Display Fault Code

FMI

Priority

Insite Fault Code

1837

Medium

352

Medium

386

Medium

187

Medium

227

Medium

691

Medium

692

Medium

271

Medium

272

Medium

275

Medium

281

5 Volts DC Supply #1 5 Volts DC Supply #2

1838

Turbocharger #1 Compressor Inlet Temperature

1839

Fuel Pump Pressurizing Assy. #1

1840

Multiple Unit Synchronization Switch

1841

Medium

497

Engine Oil Change Interval

1842

Low

649

Auxiliary Pressure Sensor Input #2 Circuit

1843

Medium

297

Medium

298

None

1239

None

1241

1844

Turbocharger Compressor Outlet Temperature (Calculated)

1845

Low

2347

Turbocharger Turbine Inlet Temperature (Calculated)

1846

Low

2346

55-6

SECTION 60 - PRODUCT FEEDING - CHAPTER 1

SECTION 60 - PRODUCT FEEDING Chapter 1 - Feeder House CONTENTS Section

60-1

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 SPECIFICATIONS CR9040

CR9060

CR9070

FEEDER

Number of chains

Chain type

CA557; hard chrome plated pins

Number of slats

Slat type

S slat

Driveline, fixed

3HB belt mainshaft to feeder jackshaft, 4HB belt to header jackshaft, RC-80 chain to feeder pivot shaft

Driveline, variable

3HB belt mainshaft to variable drive, HQ belt, hydraulically shifted variable driver to torque sensing sheave on feeder drive jackshaft, 4HB belt to header jackshaft, RC-80 chain to feeder pivot shaft

Cross shaft speed, fixed drive

750 rpm

Cross shaft speed, variable drive

523 to 746 rpm

Feeder jack shaft speed, fixed drive

576 rpm

Feeder jack shaft speed, variable drive

402 to 574 rpm

Primary drive belt tensioner spring length

130 mm (5.12 in)

Secondary drive belt tensioner spring length

108 mm (4.25 in)

Feeder chain tensioner spring length

91 mm (3.6 in)

Feeder clutch

Hydraulic multi-plate

Header Lift cylinders, dia.

70 mm (2.75 in)

Reverser System

Hydraulic, bi-directional

Stone Ejection System

Automatic Stone Detection (ASD) system with floor sensors

Floor plates

solid or perforated

60-2

SECTION 60 - PRODUCT FEEDING - CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON-METERS (FOOT POUNDS) FOR NORMAL ASSEMBLY APPLICATIONS

METRIC NON-FLANGED HARDWARE AND LOCKNUTS CLASS 5.8

CLASS 8.8

CLASS 10.9

PLATED W/ZnCr

UNPLATED

PLATED W/ZnCr

LOCKNUT CL.8 W/CL8.8 BOLT

2.6 (23)*

3.4 (30)*

3.7 (33)*

4.8 (42)*

2.3 (20)*

7.6 (67)*

8.9 (79)*

12 (102)*

13 (115)*

17 (150)*

7.8 (69)*

14 (124)*

18 (159)*

22 (195)*

28 (248)*

31 (274)*

40 (354)*

19 (169)*

M10

28 (21)

36 (27)

43 (32)

56 (41)

61 (45)

79 (58)

38 (28)

M12

49 (36)

63 (46)

75 (55)

97 (72)

107 (79)

138 (102)

66 (49)

M16

121 (89)

158 (117)

186 (137)

240 (177)

266 (196)

344 (254)

164 (121)

M20

237 (175)

307 (226)

375 (277)

485 (358)

519 (383)

671 (495)

330 (243)

M24

411 (303)

531 (392)

648 (478)

839 (619)

897 (662)

1160 (855)

572 (422)

NOMINAL SIZE

UNPLATED

PLATED W/ZnCr

1.7 (15)*

2.2 (19)*

5.8 (51)*

UNPLATED

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION HEX CAP SCREW AND CARRIAGE BOLTS CLASSES 5.6 AND UP MANUFACTURER’S IDENTIFICATION

PROPERTY CLASS

HEX NUTS AND LOCKNUTS CLASSES 05 AND UP MANUFACTURER’S IDENTIFICATION

86529681 REV F 5.1

PROPERTY CLASS

CLOCK MARKING

60-3

SECTION 60 - PRODUCT FEEDING - CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON-METERS (FOOT POUNDS) FOR NORMAL ASSEMBLY APPLICATIONS

INCH NON-FLANGED HARDWARE AND LOCKNUTS SAE GRADE 2 NOMINAL UNPLATED SIZE or PLATED SILVER 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

6.2 (55)* 13 (115)* 23 (17) 37 (27) 57 (42) 81 (60) 112 (83) 198 (146) 193 (142) 289 (213)

SAE GRADE 5

PLATED W/ZnCr

SAE GRADE 8

PLATED W/ZnCr

GOLD

UNPLATED or PLATED SILVER

8.1 (72)* 17 (149)* 30 (22) 47 (35) 73 (54) 104 (77) 145 (107) 256 (189) 248 (183) 373 (275)

9.7 (86)* 20 (178)* 35 (26) 57 (42) 87 (64) 125 (92) 174 (128) 306 (226) 495 (365) 742 (547)

13 (112)* 26 (229)* 46 (34) 73 (54) 113 (83) 163 (120) 224 (165) 397 (293) 641 (473) 960 (708)

GOLD

UNPLATED or PLATED SILVER

LOCKNUTS

PLATED W/ZnCr GOLD

GR.B w/GR5 BOLT

GR.C w/GR8 BOLT

NOMINAL SIZE

12.2 (109)* 25 (220)* 44 (33) 71 (53) 108 (80) 156 (115) 215 (159) 383 (282) 617 (455) 924 (681)

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION CAP SCREWS AND CARRIAGE BOLTS

SAE GRADE 2

SAE GRADE 5

SAE GRADE 8 REGULAR NUTS

SAE GRADE 5 HEX NUTS

SAE GRADE 8 HEX NUTS

LOCKNUTS

GRADE IDENTIFICATION

GRADE A NO NOTCHES

GRADE A NO MARKS

GRADE B ONE CIRCUMFERENTIAL NOTCH

GRADE B THREE MARKS

GRADE C TWO CIRCUMFERENTIAL NOTCHES

GRADE C SIX MARKS MARKS NEED NOT BE LOCATED AT CORNERS

86529681 REV F 5.2

GRADE A NO MARK GRADE B LETTER B GRADE C LETTER C GRADE IDENTIFICATION

60-4

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 SPECIAL BOLT TORQUES Feeder Feeder Chain Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N⋅m (35 ft-lb) Feeder Chain Slat Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N⋅m (35 ft-lb) Lower Cradle Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 N⋅m (145 ft-lb)

60-5

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 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.

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

TUBING SIZE OD mm In.

THREAD SIZE

TORQUE FOOT NEWTON POUNDS METERS Min. Max. Min. Max.

O-RING BOSS PLUGS ADJUSTABLE FITTING LOCKNUTS, SWIVEL JIC - 37° SEATS TORQUE NEWTON FOOT METERS POUNDS Min. Max. Min. Max.

6.4

1/4

7/16-20

5 6

7.9 9.5

5/16 3/8

1/2-20 9/16-18

16 29

20 33

12 21

15 24

14 20

20 27

10 15

15 20

8 10

12.7 15.9

1/2 5/8

3/4-18 7/8-14

47 72

54 79

35 53

40 53

34 47

41 54

25 35

30 40

12 14

19.1 22.2

3/4 7/8

1-1/16-12 1-3/16-12

104 122

111 136

77 90

82 100

81 95

95 109

60 70

70 80

25.4

1-5/16-12

149

163

110

120

108

122

20 24

31.8 38.1

1-1/4 1-1/2

1-5/8-12 1-7/8-12

190 217

204 237

140 160

150 175

129 163

158 190

95 120

115 140

50.8

2-1/2-12

305

325

225

240

339

407

250

300

solvent or Loctite cleaner and apply hydraulic sealant Loctite no. 569 to the 37° flare and the threads.

These torques are not recommended for tubes of 12.7 mm (0.5 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.

Install fitting and torque to specified torque, loosen fitting and retorque to specifications.

Before installing and torquing 37° flared fittings, clean the face of the flare and threads with a clean

60-6

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 PIPE THREAD FITTING TORQUE Before installing and tightening pipe fittings, clean the threads with a clean solvent or Loctite cleaner and apply sealant Loctite no. 567 for all fittings including stainless steel or no. 565 for most metal fittings. For high filtration/zero contamination systems use no. 545.

THREAD SIZE

TORQUE (MAXIMUM)

1/8″ - 27

13 N⋅m (10 ft-Ib)

1/4″ - 18

16 N⋅m (12 ft-Ib)

3/8″ - 14

22 N⋅m (16 ft-Ib)

1/2″ - 14

41 N⋅m (30 ft-lb)

3/4″ - 14

54 N⋅m (40 ft-Ib)

INSTALLATION OF ORFS (O-RING FLAT FACED) FITTINGS When installing ORFS fittings thoroughly clean both flat surfaces of the fitting, 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. IMPORTANT: 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.

50011183

IMPORTANT: Always use genuine New Holland 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.

60-7

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 DESCRIPTION OF OPERATION

WARNING Anytime the combine feeder house is being serviced or adjusted, ALWAYS stop the combine engine, engage the parking brake, remove the key from the ignition and engage the feeder safety lock, 1. Failure to comply could result in serious injury or death. The feeder house is located at the front of the combine and is used to mount and drive various headers. The CR Combine feeders are available in 1.02 m (40 in) and 1.27 m (50 in) widths, depending upon the model of the combine.

86060925

1 3

The feeder chain, located inside the feeder house, transports crop from the header to the rotors in the combine. The feeder chain turns on the front drum, which helps to guide the chain. The front drum is located at the face plate on the front of the feeder house. Polyethylene rollers and wear strips inside the feeder house also help to guide the feeder chain as well as provide a surface for the chain to move on, so the chain does not wear into the feeder house. The feeder chain is driven by the pivot shaft, which runs through the rear of the feeder house. The pivot shaft also serves as a pivot point for the feeder house. The pivot shaft is driven by feeder drive chains, located on the right side of the feeder house. The feeder drive chains are driven by the secondary drive belt, located on the left side of the feeder house. A jack shaft, located at the front of the feeder house, transfers power from the secondary drive belt to the drive chains on the right side of the feeder house. The feeder house is raised and lowered by two hydraulic cylinders mounted to the front of the feeder house and to the combine front axle. An optional lateral float cylinder can be attached to the left side of the feeder house and cradle. The lateral float cylinder allows the header to adjust lateral position on the feeder house. This adjustment is in relation to the slope of the terrain the header is travelling over.

60-8

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 OVERHAUL FEEDER HOUSE The feeder house can be removed from the combine as a complete unit to gain access to the threshing rotors or other components located behind the feeder house. Most components on the feeder house can be serviced or replaced without removing the feeder house with the exception of the pivot shaft. Removal NOTE: The secondary drive belt does not need to be removed from the feeder house to be able to remove the feeder house from the combine. 4. Remove the upper drive belt shield. Loosen the adjusting nut, 1, for the secondary feeder drive belt tensioner. Remove the belt, 2, from the feeder clutch and idler.

2 1 10021019

4 5. Remove the side shields, 1, from the left side of the feeder house. 6. Remove the side shields (not shown) from the right side of the feeder house.

86060925

5 NOTE: Hydraulic fluid will drain from the hydraulic lines once they have been disconnected. Have a suitable container ready to catch the draining fluid.

7. Disconnect the hydraulic lines, 1, which connect to the valve stack on the left side of the feeder house. Route the lines out of the feeder house.

8. Label the wiring harness connections for the feeder wiring harness. Disconnect the wiring harness connectors, 2, and route the wiring harness out of the feeder house. 10021116

60-9

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 DANGER The feeder house weighs approximately 1225 -1315 kg (2700 -- 2900 lb), depending on the size of the feeder house. Be sure to use a tractor in good working order with proper ballasting and a minimum hitch capacity of 2500 kg (5511 lb) at approximately 1 m (3.3 ft) above the ground. Severe personal injury or damage to equipment may occur when removing the feeder house if the proper equipment or procedure is not used. Failure to comply will result in serious injury or death.

1 10021117

9. The feeder house is equipped with connection points, 1, for a tractor three-point hitch. Use a tractor with a three-point hitch minimum capacity of 2500 kg (5511 lb) and proper ballasting. 10. Lower the feeder house to the lowest possible position to still be able to connect the tractor’s three-point hitch to the feeder. Place jack stands with a minimum capacity of 9072 kg (10 ton) under the feeder house. 11. Connect the three-point hitch to the feeder house. Secure the connection points with hitch pins or hairpin clips. Raise the tractor three-point hitch slightly so the weight of the feeder house is supported by the tractor. Be sure the parking brake for the tractor is engaged.

WARNING Illustration shows lift cylinder retaining pins from under the feeder house. NEVER disconnect or connect lift cylinders while under the feeder house. Be sure the area under and around the feeder house is clear before disconnecting the lift cylinders from the feeder house. Failure to comply could result in serious injury or death. 12. Working from the side of the feeder house, remove the cotter pins securing the front retaining pin, 1, for each lift cylinder in the feeder house. Remove each pin and lower the lift cylinders to the ground.

60-10

1 10021114

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 13. Remove the feeder house retaining pin, 1, and pivot shaft bracket, 2, from the each side of the combine. Each retaining pin is held in place by a hitch pin, 3. 14. Once the retaining pins and brackets have been removed, the feeder house is no longer attached to the combine. SLOWLY pull the feeder away from the combine. Have an assistant make sure that no components remain attached to the combine.

1 3 2 40021742

9 Installation 1. Before installing the feeder house onto the combine, generously lubricate the pivot points on the combine frame and pivot shaft.

DANGER The feeder house weighs approximately 1225 -1315 kg (2700 -- 2900 lb), depending on the size of the feeder house. Use care when installing the feeder house to the combine. Failure to comply will result in serious injury or death. 2. With the feeder attached to the tractor three-point hitch, install the feeder back to the front of the combine. Have an assistant make sure the feeder position arm, 1, is properly located on the nylon roller, 2, as the feeder house is being installed.

1 10022478

2 10

3. Grease and install the pivot shaft bracket, 2, and retaining pin, 1, for each side of the feeder house. Install the hitch pin, 3, into each retaining pin.

1 3 2 40021742

60-11

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 WARNING Illustration shows lift cylinder retaining pins from under the feeder house. NEVER disconnect or connect lift cylinders while under the feeder house. Be sure the area under and around the feeder house is clear before disconnecting the lift cylinders from the feeder house. Failure to comply could result in serious injury or death. 4. Working from the side of the feeder house, raise each lift cylinder up to the feeder house and install the front retaining pin, 1, for each lift cylinder in the feeder house. Secure the retaining pins in the feeder frame with cotter pins.

1 10021114

WARNING DO NOT disconnect the center link if the feeder house has not been secured to the combine at the pivot shaft and lift cylinders. Failure to comply could result in serious injury or death.

5. If possible, use the tractor three-point hitch to raise the feeder high enough to engage the feeder safety lock. The center link, 1, may need to be temporarily disconnected to be able to raise the feeder high enough to engage the safety lock. 6. If the feeder safety lock cannot be engaged, lower the feeder house completely.

10021117

DANGER Serious injury or death may occur if the feeder house falls and there are no jack stands in place under the feeder house. Failure to comply will result in serious injury or death. 7. Place jack stands with a minimum capacity of 9000 kg (10 ton) under the feeder house face plate. 8. Route the hydraulic lines, 1, which connect to the valve stack on the left side of the feeder house up to the valve stack. Connect the hydraulic lines, 1, to the proper locations.

9. Route the wiring harness up to the feeder house. Connect each wiring harness connector, 2, to the proper connection, as labeled during removal.

10021116

60-12

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 10. Install the feeder secondary drive belt, 2, onto the feeder drive clutch and tensioner. Tighten the tensioner nut, 1, so the tensioner spring lines up with the gauge, 3. The proper spring length should be approximately 108 mm (4.25 in). Install the upper guard for the secondary drive belt. 11. Install the side covers back onto the feeder house.

WARNING The weight of the feeder house MUST be removed from the tractor three-point hitch BEFORE disconnecting the hitch from the feeder house. Failure to comply could result in serious injury or death.

1 10021019

12. Be sure the weight of the feeder house is removed from the tractor three-point hitch and placed on the jack stands. Disconnect the hitch from the feeder house.

FEEDER DRIVE CHAINS The two feeder drive chains are located on the right side of the combine feeder house. The front chain is driven by the header drive jack shaft and is connected to an idler sprocket that turns the rear chain. The rear chain drives the pivot shaft. Each chain is connected by a master link and can be disconnected by removing this link. Removal 1. Remove the side shields, 1, from the right side of the feeder house.

20026238

60-13

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 2. Rotate the drive chain to be removed until the master link is easily accessible. 3. Release tension on the on the chain to be removed by loosening the nut, 1, for the chain idler sprocket.

1 10021070

17 4. Remove the retaining clip, 1, and master link, 2, from the chain and remove the chain from the feeder house.

1 2

10021071

18 Installation NOTE: If offset links are used in the chain, install the chain with the narrow end of the links in the normal direction of travel, clockwise rotation, as viewed from the right side of the feeder house. 1. Before installation, clean the chain in a suitable solvent and inspect the links for damage or excessive wear. Lubricate the chain with New Holland Hypoide 90 oil. 2. Place the drive chain onto the sprockets in the same route as removed. Connect the ends of the chain together using the master link as previously removed. 3. Adjust idler, 1, to obtain 9.7 -- 15.7 mm (3/8 -- 5/8 in) sag at the center of the longest length of chain, 2. NOTE: The forward chain contains an offset link that can be removed, if the chain has stretched, in order to adjust the chain sag to specifications.

60-14

2 2 1

1 10021070

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 4. Install the side shields, 1, onto the right side of the feeder house.

20026238

FEEDER CHAIN The feeder chain transports the incoming crop from the header, through the feeder house and to the rotors in the combine. The feeder chain is driven by the pivot shaft and loops around the front drum in the feeder house. If damaged or worn, the serrated slats on the feeder chain can be replaced without removing the chain. Removal 1. Remove guide plates, 1, from the front of the feeder house. 2. Rotate the feeder chain until the removable offset links for each chain are easily accessible.

56063458

21 3. Relieve tension on the feeder chain by loosening the nut, 1, on the tensioner bolt.

10021074

60-15

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 4. Remove the nut from an offset link connecting bolt on each of the feeder chains.

50021222

CAUTION The chain is heavy and will pull away from the front drum as the pins are removed. Use care to keep hair, fingers and clothing away from the chain during removal. Failure to comply may result in minor or moderate injury. 5. Remove the bolt, 1, from each chain.

1 10021073

CAUTION The chain weighs approximately 88.5 kg (195 lb) use care when removing the chain from the feeder house. Failure to comply may result in minor or moderate injury. 6. Rotate the feeder jack shaft, 1, to help feed the chain from the feeder house.

1 10021070

60-16

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 Installation 1. Before installation, clean the chain in a suitable solvent and inspect the links and serrated slats for damage or excessive wear. Replace any damaged or worn parts. If any slats are replaced, torque the retaining bolts to a minimum of 47 N⋅m (35 ft-lb). Lubricate the chain with New Holland Hypoide 90 oil.

10021075

26 2. To aid in installation, attach rope or twine to each leading slat of the feeder chain. The leading slats have the serrated portion of the slat to the front, in the direction of travel. Make the rope long enough to go through the front of the feeder house, around the pivot shaft, and out of the feeder house.

56063459

WARNING If lowering the feeder house, make sure the area below and around the feeder house is clear before lowering. Failure to comply could result in serious injury or death. 3. Route the feeder chain through the bottom of the feeder house and around the pivot shaft. Be sure the chain is properly oriented before installation. Disconnect the rear feeder drive chain so the pivot shaft is able to rotate freely. If necessary, completely lower the feeder house to gain access to the feeder chain through the top of the feeder.

60-17

20021143

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 NOTE: Have an assistant help hold the feeder chain when installing the connecting bolts into the feeder chain. 4. Install the connecting bolts, 1, into each chain using a suitable hammer and punch. 5. Install the locknuts onto each of the chain connecting bolts. Torque the nuts to a minimum of 47 N⋅m (35 ft-lb).

50021222

29 6. Adjust the feeder chain tensioner by tightening the nut, 1, on the tensioner for each side. Tighten the nut until the end of the tensioner spring lines up with the metal gauge, 2, for each tensioner. The spring length should be approximately 91 mm (3.6 in). If the adjuster bracket, 3, bottoms out on the spacer, 4, before the end of the tensioner spring lines up with the metal gauge, 2, a link must be removed from each chain.

2 10021074

30 7. Install the front guide plates, 1, onto the combine feeder house.

56063458

60-18

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 FRONT DRUM The front drum is located at the front of the feeder house. The drum rotates with the feeder chain and helps the feeder chain to draw crop into the feeder house. The front drum also is used to adjust tension on the feeder chain. Removal 1. Remove the front guide plates, 1, from the front of the feeder house.

56063458

32 2. Disconnect the feeder chain using the procedure described previously in this chapter. Position the feeder chain out of the way of the front drum.

10021073

33 3. Loosen the cam adjusting bolt, 1, for the front drum. Turn the cam, 2, to the lowest position. 4. Remove the retaining bolt, 3, for the cam stop, 4, from each side of the feeder house. Remove the cam stop from each side. The front drum may need to be raised a small amount to allow the cam stops to be removed.

2 10021074

1 34

60-19

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 5. Use wooden chocks to keep the front drum from rolling out of the feeder house.

56063706

35 6. Remove the nut, 1, bolt, and spacer that the arms for the front drum pivot on from each side of the feeder house.

10021079

WARNING The front drum assembly weighs approximately 75 kg (166 lb). Use care when removing the assembly from the combine feeder house. Failure to comply could result in serious injury or death. 7. Position a forklift with a pallet in front of the feeder house opening or using the help of an assistant, remove the front drum assembly, 1, from the feeder house.

1 56063697

60-20

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 Replacing the Bearings NOTE: The bearing and housing are only available as an assembly component for replacement. 1. Use a paint marker or other suitable marking device to denote the right side, “R”, of the drum. The right side of the drum can be determined by what side the flare, is on the guide for the feeder chain. The flare should be right of center on the drum when looking at the drum from the rear, facing what would be the normal direction of combine travel.

R 56063698

38 NOTE: The left and right arms for the front drum are different.

2. Remove the M8 x 70 bolt, 1, securing left arm to the front drum shaft. Slide the left arm off the drum shaft.

56063705

39 3. Slide the right arm, 1, off the drum shaft. Remove the shims, 2, from the drum shaft.

56063701

60-21

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 4. Loosen the set screw on each lock collar, 1. Use a suitable hammer and punch to loosen the lock collars. Slide the lock collars off the shaft.

56063704

41 5. Pull the drum shaft, 1, from the drum. A punch, 2, inserted through the shaft can help to remove the shaft from the drum.

1 56063703

42 6. Remove the six M10 locknuts and washers, 1, and washers which secure each bearing housing, 2, to the drum. Remove the housings from drum.

7. Inspect the bearings and bearing housing assemblies for damage or excessive wear. Check the bearings for smooth movement and seal damage. Replace any damaged or worn assembly.

NOTE: The bearing and housing are only available as an assembly component for replacement.

1 56063702

60-22

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 8. Slide the drum shaft, 1, into the front drum. Be sure the left end of the shaft is at the left side of the drum. The left side of the drum shaft has a through hole drilled for the arm retaining bolt to be installed. Apply a light coat of grease to the ends of the shaft. 9. Slide a bearing assembly, 3, onto the shaft. Apply Loctite 242/243 to the threaded studs, 2. Secure the assembly to the front drum using six M10 locknuts and washers removed during disassembly.

3 56063700

44 10. Center the shaft in the drum using a caliper or other suitable measuring device. The distance from the end of the shaft to the front of the bearing housing on each side should be 70.5 ± 1 mm (2.78 ± 0.040 in).

56063699

45 11. Once the shaft is centered in the front drum, lock the shaft in place with the lock collars, 1. Use care not to disturb the position of the shaft in the drum while installing the lock collars.

56063704

60-23

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 12. Slide the left arm, 2, onto the left end of the drum shaft. The left side of the drum shaft has a through hole drilled for the bolt, 1, to be installed. Install the M8 x 70 bolt and lock nut through the arm and shaft.

56063705

47 13. Install the shims, 2, onto the right end of the drum shaft. Be sure to install the same number of shims that were removed during disassembly. Slide the right arm, 1, onto the drum shaft.

56063701

48 14. Check the distance, A, between the “outside” of the arms. The distance for CR9040 and CR9060 models should be 989.6 ± 1.5 mm (39.0 ± 0.06 in). The distance for the CR9070 model should be 1249.6 ± 1.5 mm (49.2 ± 0.6 in.). If the distance is not within specifications, add or remove shims between the right side arm and lock collar as necessary.

R 56063698

60-24

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 Installation

WARNING The front drum assembly weighs approximately 75 kg (166 lb). Use care when installing the assembly into the combine feeder house. Failure to comply could result in serious injury or death. 1. Raise and install the front drum assembly up to the feeder house using a forklift with a pallet or the help of an assistant.

1 56063697

50 2. Use wooden chocks to keep the front drum from rolling out of the feeder house.

56063706

51 3. Inspect the spacers that the front drum arms rest on. Replace the spacers if they are worn or damaged. Install the carriage bolt and spacer for the rear of each feeder drum arm. Secure the bolt for each arm with the lock nut, 1, and washer, 2.

10021079

60-25

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 4. Install the carriage bolt, 1, through each drum arm and through the side of the feeder house. Install the cam stop, 2, onto each bolt and secure using the lock nut and washer.

5. Adjust each cam, 3, to the desired position and tighten the bolt, 4, which keeps the cam from changing position.

10021074

53 6. Connect the feeder chain, 1, using the procedure for feeder chain installation, described earlier in this chapter.

7. Install the front guide plates, 2, to the front of the feeder house.

56063458

60-26

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 POLYETHYLENE STRIPS Three sets of three polyethylene wear strips, 1, are utilized in the feeder house to prevent the feeder chain from damaging the feeder house frame. Two sets of the wear strips are accessible through the stone door and are attached to the feeder frame or skid plate. The other set of strips can be accessed through the panel on the top of the feeder house and are mounted to the feeder frame. The strips are easily replaced by removing the socket head screws which secure the strips to the feeder frame.

1 20021042

LATERAL FLOAT HYDRAULIC CYLINDER The lateral float hydraulic cylinder is attached to the left side of the feeder house and cradle. The lateral float cylinder is a double acting cylinder that allows the header to adjust lateral position on the feeder house. This adjustment is in relation to the slope of the terrain the header is travelling over. Removal

NOTE: Hydraulic fluid will leak from the hydraulic lines and cylinder when the lines are disconnected.

1. Identify and remove the two hydraulic lines, 1, for the lateral float cylinder.

2. Remove the potentiometer rod, 2, for the lateral float cylinder. The bend in the top of the rod will need to be straightened to allow removal. Remove the pin, 3, securing the top of the hydraulic cylinder to the cradle. 3. Remove the bottom pin, 4, securing the bottom of the hydraulic cylinder to the face plate. The bottom pin is held in place by a cotter pin.

60-27

10021098

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 Installation

1. Place the hydraulic cylinder up to the feeder house. Install the bottom retaining pin, 4, into the face plate and hydraulic cylinder. Secure the retaining pin in the face plate using a suitable cotter pin. 2. Install the top retaining pin, 3, into the cradle and the hydraulic cylinder. Be sure the holes in the pin are aligned with the holes in the cradle. Install the potentiometer rod, 2, into the retaining pin. Bend the potentiometer rod back to the original position.

1 4 10021098

3. Connect the hydraulic lines, 1, to the hydraulic cylinder. Be sure to connect the lines to the proper location.

CRADLE The cradle is mounted to the front of the feeder house on the feeder face plate and serves mainly as the mounting point for various headers designed to attach to the CR combine. The cradle can be tilted laterally by the optional lateral float cylinder, which is mounted on the left side of the cradle and feeder house. This allows the header and combine to move over uneven terrain easier. A mechanical adjuster is also available. Removal

1. Using 10 x 40 mm grade 8 bolts, secure lifting eyes (OEM # 4129), 1, to the holes in each side of the cradle front lip.

10021096

58 2. Connect a chain or strap to the lifting eyes and support the weight of the cradle using a forklift or overhead hoist.

10021097

60-28

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 3. Remove the pin, 2, retaining the header leveling turnbuckle, 1, to the cradle. The pin is secured in the cradle with a cotter pin.

4. If equipped with hydraulic lateral float, remove the potentiometer rod, 1. The bend in the top of the rod will need to be straightened to allow removal. Remove the pin, 2, securing the top of the hydraulic cylinder to the cradle.

1 3

5. Disconnect the wiring harness, 3, for the header from the holder on the cradle. 20021130

60 FEEDER EQUIPPED WITH LEVELING TURNBUCKLE

2 1 3

10021098

61 FEEDER EQUIPPED WITH HYDRAULIC LATERAL FLOAT

6. On each side of the cradle, 1, remove the M16 locknut, 5, washer, 4, spacer, 3, and the M16 x 120 carriage bolt, 2, securing the cradle to the feeder house face plate, 6.

8 7

6 5

66063463

3 4 62

60-29

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 NOTE: Make sure the weight of the cradle is supported before removing the center pin from the cradle. 7. Remove the two M16 x 45 cap screws and washers securing the center pin, 1, in the cradle. Remove the pin from the cradle.

1 56063457

63 8. Lift the cradle up and away from the feeder house using the forklift or overhead hoist. NOTE: The wear strips, 7 and 8, in Figure 62, may drop off when the cradle is removed. They are trap secured between the cradle and feeder face plate.

10021101

64 Installation

1. Before installing the cradle onto the feeder house, inspect the bushings, 1, for the cradle’s center pin, located at the top of the feeder house face plate. Replace the bushings if worn or damaged excessively. Lubricate the bushings with lithium grease before installing the cradle.

10021102

60-30

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 2. Inspect the black polyethylene wear strips, 1 and 2, that are trapped between the cradle back and face plate. Replace as needed. Wear strip 1, runs along the bottom inside face of the cradle, and a wear strip, 2, is mounted on the left-hand and right-hand inside face of the cradle. Wear strip, 1, can be temporarily held in place when mounting the cradle, by using a few strips of thin tape e.g., electrical tape. Do not use an adhesive or sealant compound to hold the strips in place. Wear strip, 2, is held in place when properly mounted on the on the collar, 3, on the cradle back.

1 2 66063463

3. Inspect the poly-glass wear bars, 1, on the feeder face plate for excessive wear or damage. Replace the wear bars as necessary by removing the three counter-sunk hex socket screws, 2. Remove the wear bar, capture and retain the shim pack. Install the new poly-glass wear bar with the original shim pack. Apply Loctite 242/243 to the three counter-sunk hex socket screws and install. Torque the screws to 36 N⋅m (26 ft-lb). Mount the cradle.

56070060

NOTE: When the cradle is installed with new wear bars the back of the cradle to wear bar clearance should be 0 – 1 mm (0 – 0.0393 in). The factory set-up is as follows:

A B

4. First, install the wear bar, 1, and support, 2, with no shims to obtain thickness measurement, B. Temporarily mount the cradle, as described in the steps that follow without securing it. Ensure the cradle back is flush against the wear bar, 1, and then measure distance between the cradle back and the feeder face plate, A. The shim thickness to be inserted at, 3, is calculated as (A – B + 3 mm (7/64 in)). Remove the cradle, remove the screws, assemble the shim pack with the wear bar and support. Apply Loctite 242/243 to the three counter-sunk hex socket screws and install. Torque the screws to 36 N⋅m (26 ft-lb). Complete the cradle installation as follows: Apply New Holland Ambra GR9 multi-purpose grease to the wear bars same area of movement on the cradle back before installing the cradle onto the feeder house.

60-31

66063462

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 5. Use the forklift or over head hoist to place the cradle onto the feeder house. Be sure the cradle is seated properly on the face plate of the feeder house.

10021101

69 6. Align the hole in the feeder face plate with the hole in the cradle and install the center pin, 1, into the cradle and face plate. Secure the pin using the two mounting bolts, 2.

2 1 56063457

70 7. Ensure the wear strips, 3 and 6, are installed and properly positioned.

Insert an M16 x 120 carriage bolt, 2, through the cradle, 1, wear strip, 3. Install the spacer, 4, and ensure it is positioned in the slot of the wear strip. Check for proper alignment of the spacer, 5, in the slot on the front of the face plate, 5 (see Important below, Figure 72).

2 3 66063463

4 5 71

60-32

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 IMPORTANT: The spacer, 1, should never touch the slot in the face plate to prevent binding when the cradle tilts from side to side. There should be a minimum clearance at (A) and (B) of 2 mm (3/32 in). There is no adjustment for this clearance, but serves as an indicator to ensure correct mounting, parts, and no deformation to the cradle. Contact requires further investigation.

A 1

B 66063460

72 8. Install the washer, 1 (see Note below, Figure 74). Install, tighten, and torque lock nut, 2, to 164 N⋅m (120 ft-lb).

66063463

1 73

NOTE: The washer, 2, may have been manufactured by a punch-press operation resulting in a slightly convex (rounded) face. This type of washer must be assembled with the convex (rounded) face, 3, against the spacer, 1.

3 66063463

60-33

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 9. Grease and install the pin, 2, retaining the header leveling turnbuckle, 1, to the cradle. Secure the pin in the cradle with a cotter pin.

10. If equipped with hydraulic lateral float, grease and install the pin, 2, securing the top of the hydraulic cylinder to the cradle. Install the potentiometer rod, 1, for the for the lateral float cylinder. The top of the rod will need to be bent back to the original position as before the rod was removed. 11. Connect the wiring harness, 3, for the header to the holder on the cradle.

1 3

20021130

75 FEEDER EQUIPPED WITH LEVELING TURNBUCKLE

2 1 3

10021098

76 FEEDER EQUIPPED WITH HYDRAULIC LATERAL FLOAT

12. Remove the chain or lifting strap from the lifting eyes, 1. Remove the lifting eyes from the cradle.

10021096

60-34

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 FACE PLATE The face plate is located behind the cradle on the feeder house. The face plate allows the cradle to be tilted forward or back. This adjustment allows for different headers and tires to be used on the combine. Removal NOTE: The bottom sensor plate does not need to be disconnected from the feeder house wiring harness. 1. Remove the mounting hardware for the bottom sensor plate, 1, and position the plate back away from the front face plate. Refer to the bottom sensor plate removal procedure described in Chapter 3 of this section.

56063458

78 2. Remove the cradle, 1, from the feeder house using the procedure described previously in this chapter.

1 10021101

60-35

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 3. Remove the pin, 1, securing the bottom of lateral float cylinder or leveling turnbuckle to the face plate. Position the cylinder away from the face plate.

1 2

4. If equipped, remove the two bolts securing the lateral float potentiometer, 2, to the face plate. Position the potentiometer out of the way. 5. Remove the two bolts securing the hydraulic quick release bracket, 3, to the face plate.

3 1 10021103

80 6. Remove the cotter pin, 1, which retains the pivot pin, 2, in the feeder house. Remove pivot pin, 2, from the feeder house. If necessary, LOOSEN the nine bolts which secure each side of the face plate to the feeder house frame to facilitate removal of the pivot pins.

10021107

WARNING

Be sure the face plate is properly supported before removing the face plate mounting bolts. Use care when removing the mounting bolts, the face plate may move or shift. Failure to comply could result in serious injury or death. 7. Connect chains or lifting straps to the face plate and support the weight of the face plate with a forklift or overhead hoist. Support the face plate at a minimum of three-points, such as the locations the cradle mounts at. 8. Remove the pin, 1, from the eyebolt for the face plate angle adjustment. A cotter pin must be removed from the pin before removing the eyebolt pin. 9. Note the tilt angle of the face plate and remove the nine mounting bolts, 2, from each side of the face plate. Move the face plate away from the feeder house.

60-36

10021106

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 Installation

1. Install the face plate up to the feeder house. Locate the face plate to the same location as removed and install the nine bolts, 2, into each side of the face plate. Make sure the holes, 3, for the pivot pins are aligned before tightening the mounting bolts.

2. Grease and install the pin, 1, for each face plate angle eyebolt. Secure the pins in the feeder house using cotter pins.

3 10021106

83 3. Grease and install the pivot pins, 1, into the face plate and feeder house frame. The pins should be installed so that the cotter pin holes in the pivot pins and face plate are aligned. Secure each pivot pin with a cotter pin, 2.

10021107

84 4. Grease and install the pin, 1, securing the bottom of lateral float cylinder or leveling turnbuckle to the face plate.

1 2

5. If equipped, install the two bolts securing the lateral float potentiometer, 2, to the face plate. 6. Install the two bolts securing the hydraulic quick release bracket, 3, to the face plate.

3 1 10021103

60-37

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 7. Install the cradle, 1, from the feeder house using the procedure described previously in this chapter.

1 10021101

86 8. Install the bottom sensor plate, 1, using the procedure described in Chapter 3 of this section.

56063458

1 87

FEEDER FLOOR The feeder house floor consists of several removable wear plates and panels which mount to feeder frame cross beams. The feeder floor can be divided into two portions, front and rear. The front portion is two wear plates and a panel in front of the stone door. The rear portion is two wear plates, a center panel and an angle plate to the rear of the stone door.

FRONT FLOOR Replacement 1. Raise the feeder house and engage the feeder safety lock. Place jack stands under the front of the feeder house for additional support.

2. Lower the stone door using the procedure described in Chapter 3 of this section. 3. Raise the stone door off the stops, 1, using a jack stand. Allow room to access bolts on the rear wear plate. 10021090

60-38

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 4. Loosen the four mounting bolts, 2, that secure the front sensor plate, 1, to the feeder house.

20021066

89 5. Raise the feeder drum to the highest position using the height adjustment cam, 1, each side of the feeder house. This will allow better access to the feeder floor from inside the feeder house.

10021074

90 NOTE: The front drum and feeder chain have been removed for illustration purposes.

6. Remove the five bolts which secure the rearmost wear plate, 1, to the feeder house frame.

7. Remove the three bolts, 2, which secure the front wear plate to the feeder house frame.

10021091

60-39

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 8. Remove the five bolts, 1, securing each wear plate to the center panel, 2. NOTE: The stone door will need to be raised on the jack stand to give clearance for removal of the center floor panel.

3 2

9. Remove the three bolts, 3, securing the center panel to the each side of the feeder house. Lower the center panel out of the feeder house.

10. Once the center panel is removed, the wear plates can be removed. 10021092

92 11. Place the new wear plates at their proper locations in the feeder house. Be sure the front wear plate is positioned under the front sensor plate. 12. Install the center panel, 1, into the feeder house. Temporarily hold the panel in place by installing the three mounting bolts, 2, in each side of the panel and feeder house. Do not tighten the bolts yet.

2 1

10021092

93 13. Align the bolt holes for the wear plates and the center panel and install the five bolts, 1, into the front and rear wear plates and center panel. Install the stops, 2, for the stone door when installing the bolts in the rear of the panel. Do not tighten the bolts yet.

2 1

10021092

60-40

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 14. Align the height of the center panel so the panel is equal to the height of the wear plates. Make sure the bolts holes for the wear plates are aligned with the holes in the feeder frame. Tighten the sixteen bolts that secure the panel and wear plates to the feeder house frame.

15. Install the five bolts for the rearmost wear plate, 1, and the three bolts, 2, for the front wear plate affords.

10021091

95 16. Run a bead of RTV silicone sealant in the center panel corner seams, 1.

10021092

96 17. Tighten the four nuts to the countersunk hex socket screws, 2, that secure the front sensor plate, 1, to the feeder house.

20021066

60-41

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 18. Lower the feeder drum by the adjustment cam, 1, to the required current operational setting.

10021074

REAR FLOOR Replacement 1. Lower the stone door using the procedure described in Chapter 3 of this section.

10021090

99 2. Remove the stone ejection system actuating cylinder, 1, using the procedure described in Chapter 3 of this section. Position the cylinder out of the way.

3. Remove the nuts, 2, which secure each side of the latching bracket to the feeder house frame. Remove the bracket from the feeder frame.

20021037

2 100

60-42

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 NOTE: Illustration shows feeder chain removed from feeder house.

4. Remove the nine bolts, 1, which secure the front most wear plate, 2, to the feeder house frame. Remove the wear plate from the feeder house.

10021093

101 5. Remove the sixteen bolts, 1, which secure each side of the rear center panel, 2, to the feeder house frame. Lower the panel from the feeder house.

10021094

102 6. Remove the five screws which secure the rear wear plate, 1, to the feeder house frame. Remove the wear plate from the feeder house. The rear angle plate, 2, will also be removed with the wear plate.

1 10021095

103

60-43

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 NOTE: Illustrations show feeder chain removed from feeder house.

7. Place the rear wear plate, 2, on the feeder house frame. Place the rear angle plate, 3, under the feeder frame, aligning the holes in the angle plate with the holes in the wear plate. Install the five retaining screws through the top of the wear plate and into the angle plate. 8. Place a 6 mm (0.250 in) bead of RTV silicone sealant along the edge, 1, where the angle plate, 3, and wear plate, 2, meet.

2 10021095

104 NOTE: When installing the center panel, be sure to install the rear actuating cylinder bracket, 3, on the rear side.

9. Install the rear center panel, 2, into the feeder house frame. Align the bolt holes in the panel with the bolt holes in the feeder house frame and install the sixteen bolts, 1.

10021094

105 10. Place a bead of RTV silicone sealant in each corner gap, 1, of the center panel. Fill each corner gap in with sealant.

10021094

106

60-44

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 11. Install the front most wear plate, 2, of the rear feeder house floor. Secure the wear plate to the feeder house using the nine retaining bolts, 1.

10021093

107 12. Install the latching bracket, 3, into the feeder frame. Be sure the radiuses of the latches face up. Install the nuts, 2, on the adjusting studs.

13. Install the stone ejection system actuating cylinder, 1, using the procedure described in Chapter 3 of this section.

14. Adjust the actuating cylinder and spring tension on the latching bracket using the procedure described in Chapter 3 of this section.

20021037

2 108

60-45

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 HYDRAULIC LIFT CYLINDERS The feeder house is raised and lowered by two hydraulic lift cylinders mounted to each side of the front of the feeder house and to the combine front axle. These cylinders are the single acting type, using hydraulic fluid to extend the cylinder and the weight of the feeder house to retract the cylinder. Removal

WARNING The feeder house MUST be properly supported when servicing or removing the hydraulic lift cylinders. Failure to comply could result in serious injury or death.

CAUTION Each lift cylinder weighs approximately 52 kg (115 lb), empty. Use care when handling the cylinders. Failure to comply may result in minor or moderate injury. 1. Place jack stands with a minimum capacity of at least 9000 kg (10 ton) at the front of the feeder house. Adjust the height of the jack stands so they support the weight of the feeder house. If the left cylinder will be removed, disengage the feeder safety lock, 1, and support the feeder house with the jack stands.

1 10021112

109 NOTE: When disconnecting the hydraulic line for the lift cylinder, hydraulic fluid will drain from the line and the cylinder. Have a suitable container to collect the fluid that drains from the cylinder. 2. Disconnect and cap the hydraulic line, 1, for the cylinder that is to be removed. 3. Remove the cotter pin which retains the rear pin, 2, for the lift cylinder in the front axle of the combine. Remove the pin and carefully lower the rear of the hydraulic cylinder to the ground.

1 2

10021113

110

60-46

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 4. Remove the cotter pins which secure the front pin, 1, for the lift cylinder in the feeder house frame. Remove the front pin and carefully lower the lift cylinder to the ground.

1 10021114

111 Disassembly

NOTE: When servicing the feeder lift cylinder, be sure the area is clean and free from dirt and other contaminants. 1. Place the lift cylinder on a flat surface. To keep the cylinder from rotating, place a metal rod through the barrel eye. 2. Using a suitable spanner wrench, turn the cylinder head, 1, off the lift cylinder barrel. Slide the cylinder head off the cylinder rod. 20021132

112 3. Slide the piston rod out of the barrel. Have a suitable container ready to collect any hydraulic fluid in the cylinder barrel.

20021138

113

60-47

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 4. Remove and discard the O-ring, 1, on the cylinder barrel.

20021133

114 5. Remove the piston ring, 1, from the piston rod.

20021134

115 6. Use an O-ring pick to remove all internal O-rings, wipers and seals, 1, from the cylinder head. Discard the parts removed from the head.

20021135

116

60-48

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 Inspection 1. Inspect the piston rod for any pitting, scoring, cracks, excessive wear or any other damage. 2. Check for uniformity of the diameter over the length of the piston rod. Measure the diameter at several different points along the length of the rod. At each point, measure the diameter three times approximately 120-degrees apart.

20021139

117 3. Inspect the lift cylinder barrel for pitting, scoring, cracks, excessive wear or any other damage. 4. Use a suitable bore gauge to check the bore of cylinder barrel. Check the inner diameter of the cylinder several times at different points in the depth of the bore.

20021140

118 5. Inspect the cylinder head internally for pitting, scoring, cracks, excessive wear or any other damage. Inspect the valleys and grooves for the seals and O-rings. There must be no corrosion, wear, or damage present for a proper seal.

20021141

119

60-49

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 Assembly

1. Install new O-rings, seals, and wipers into the cylinder head. The middle seal, 1, sits inside an O-ring in the cylinder head.

20021136

120 2. Install a new piston ring, 1, onto the piston rod.

20021134

121 3. Install a new O-ring, 1, onto the cylinder barrel.

20021133

122

60-50

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 4. Install the piston into the cylinder barrel.

20021138

123 5. Slide the cylinder head, 1, over the piston. Thread the head onto the barrel and tighten with a suitable spanner wrench.

20021137

124 Installation

CAUTION Each lift cylinder weighs approximately 52 kg (115 lb), empty. Use care when handling the cylinders. Failure to comply may result in minor to moderate injury. 1. Lift the front of the lift cylinder up to the feeder house frame. If the lift cylinder being installed is the left cylinder, install the feeder safety lock, 2. Install the retaining pin, 1, into the frame and cylinder. Secure the retaining pin with a cotter pin.

10021114

125

60-51

SECTION 60 - PRODUCT FEEDING - CHAPTER 1 2. Raise the rear of the lift cylinder up to the combine front axle. Install the retaining pin, 2, into the axle and cylinder. Secure the retaining pin with a cotter pin. 3. Connect the hydraulic line, 1, to the lift cylinder.

1 2

10021113

126

WARNING Be sure the area below and around the feeder house is clear before raising or lowering the feeder house. Failure to comply could result in serious injury or death. 4. Start the combine engine and raise the feeder house. Have an assistant remove the jack stands from underneath the feeder house. 5. Cycle the feeder house up and down several times to remove air from the lift cylinders.

10021112

127

60-52

SECTION 60 - PRODUCT FEEDING - CHAPTER 2

SECTION 60 - PRODUCT FEEDING Chapter 2 - Feeder Drives CONTENTS Section

Description

Page

Special Bolt Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Primary Feeder Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Replacement (Fixed Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Replacement (Variable Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Variable Sheave Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Variable Drive Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Variable Drive Sheave Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Torque Sensing Drive Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Cross Shaft and Bearing Replacement (Fixed Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Cross Shaft And Bearing Replacement (Variable Drive) . . . . . . . . . . . . . . . . . . . . . . . . 38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

60-1

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 Section

Description

Page

60-2

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 SPECIAL BOLT TORQUES Feeder Drive Variable Drive Sheave Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 -- 106 N⋅m (61 -- 78 ft-lb) Fixed Drive Sheave Retaining Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425 -- 525 N⋅m (313 -- 387 ft-lb) Torque Sensing Drive Sheave Retaining Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425 -- 525 N⋅m (313 -- 387 ft-lb) Torque Sensing Drive Sheave Hub Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 85 -- 105 N⋅m (63 -- 77 ft-lb) Torque Sensing Drive Sheave Cam Ring Mounting Bolts . . . . . . . . . . . . . . . . . . . . . 85 -- 105 N⋅m (63 -- 77 ft-lb) Torque Sensing Drive Sheave Cam Ring Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 -- 78 N⋅m (51 -- 57 ft-lb) Cross Shaft Mounting Plate Mounting Bolts (Fixed Drive) . . . . . . . . . . . . . . . . . . . . . 85 -- 105 N⋅m (63 -- 77 ft-lb) Cross Shaft Bearing Assembly Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 -- 105 N⋅m (63 -- 77 ft-lb) Feeder Clutch Retaining Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 -- 190 N⋅m (125 -- 140 ft-lb) Feeder Clutch Front Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 -- 90 N⋅m (64 -- 66 ft-lb) Feeder Clutch Hydraulic Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 -- 27 N⋅m (64 -- 66 ft-lb) Pivot Shaft Sprocket Lock Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 -- 68 N⋅m (40 -- 50 ft-lb) Pivot Shaft Anti-Wrap Shield (to Bushings Only) Mounting Screws . . . . . . . . 6892 -- 8022 N⋅mm (61 -- 71 in-lb) Feeder Secondary Drive Jackshaft Sheave Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 N⋅m (118 ft-lb) Jackshaft Bearing Housing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 -- 262 N⋅m (150 -- 193 ft-lb) Reverser Motor Gear Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 -- 30 N⋅m (18 -- 22 ft-lb) Reverser Motor Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 -- 106 N⋅m (61 -- 78 ft-lb) Feeder Chain Idler Sprocket Set Screws and Jam Nuts . . . . . . . . . . . . . . . . . . . . . . . 49 -- 60 N⋅m (36 -- 44 ft-lb) Jackshaft Chain Sprocket Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 -- 75 N⋅m (50 -- 55 ft-lb)

60-3

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 SPECIAL TOOLS 228.6 mm (9 in) 152.4 mm (6 in) 34.9 mm (1-3/8 in)

127.0 mm (5 in) 34.9 mm (1-3/8 in) 19.0mm (3/4 in)

14.2 mm DIA. (9/16 in)

20.6mm DIA. (13/16 in)

14.2 mm DIA. (9/16 in)

38.0 mm (1-1/2 in)

12.7 mm (1/2 in)

114.3 mm (4-1/2 in)

12.7 mm (1/2 in)

38.0 mm (1-1/2 in)

1 Torque Sensing Drive Sheave Removal Tool* *(Manufacture as shown)

60-4

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 Torque Sensing Hub Remover #380000735 For removal of the torque sensing drive sheave.

20033109

2 Locknut Wrench #FNH00088* For removal of the feeder/header drive clutch cross shaft locknut. *This tool is a New Holland drive train special tool.

50030182

3 Feeder Slip Clutch Tool (Manufacture if Required) Manufacture a special tool made of a 25 mm (1 in) diameter bar that is approximately 1321 mm (52 in) long. Weld one end to a standard 1-3/8 in 6 point U joint, which will attach the feeder jackshaft. Weld a heavy flat washer at a point approximately 1219 mm (48 in) from the center line of the yoke.

19993128

60-5

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 DESCRIPTION OF OPERATION

WARNING Anytime the combine feeder house is being serviced or adjusted, always stop the combine engine, engage the parking brake, remove the key from the ignition and engage the feeder safety lock, 1. Failure to follow this warning may result in serious injury or death. The CR Combines are equipped with feeder houses in 1.02 m (40 in) and 1.27 m (50 in) widths, depending upon the model of the combine. With the thresher clutch engaged, a belt from the engine gearbox on the left side of the combine drives the main cross shaft. The cross shaft drives a sheave on the opposite (right) side of the combine. This sheave drives the primary drive belt which transfers power to the primary feeder cross shaft via a fixed drive sheave or through an optional variable speed arrangement. The primary feeder cross shaft then transfers power to the feeder/header engagement clutch, located on the opposite (left) side of the combine.

86060925

1 5

Hydraulic pressure applied to the feeder clutch causes the clutch to engage. The clutch drives the secondary drive belt, which is routed to a sheave attached to the left side of the header jackshaft, located at the front of the feeder house. A reverser motor and gearbox attached to the right side of the jackshaft will rotate the feeder and header in the reverse direction to clear jams caused by slugs or foreign material entering the feeder. A sprocket installed on the right side of the header jackshaft drives the feeder drive chains. These chains are connected in series and route power to the feeder slip clutch that is attached to the upper pivot shaft. The upper pivot shaft drives the feeder chain and front drum to move crop from the auger header to the threshing rotors.

60-6

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 OVERHAUL PRIMARY FEEDER DRIVE BELT Replacement (Fixed Drive) Use the following procedure to replace the drive belt for the primary header drive. 1. Engage the combine parking brake and remove the key from the combine ignition switch. 2. Raise the right side shield. Before removing the drive belt, note the path the belt takes around the sheaves and pulleys. 3. Relieve belt tension by loosening the adjusting nut, 1, for the belt tensioner idler. Loosen the nut until the belt, 2, can be removed from the sheaves.

4. Remove the rotor drive belt, 3, using the procedure described in Section 66, Chapter 3. 5. Once the rotor drive belt has been removed, the primary header drive belt can be removed.

6. Install the header drive belt onto the sheaves and idlers in the same orientation as removed.

7. Install the rotor drive belt using the procedure described in Section 66, Chapter 3.

10021005

8. Adjust the tension of the drive belt using the adjusting nut, 1, on the belt tensioner idler. Adjust the tension so that the spring, 2, is the same length as the gauge plate, 3. The spring length should be approximately 130 mm (5.1 in).

3 2 10021006

60-7

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 Replacement (Variable Drive) 1. Remove the drive belt, 1, for the variable drive system using the procedure described later in this chapter.

2. Remove the drive belt, 3, for the rotor gearbox, using the procedure described in Section 66, Chapter 3 of the CR combine repair manual. 3. Loosen the adjusting nut, 2, for the primary drive belt tensioner. The primary drive belt, 4, can then be removed from the combine.

4. Inspect the belt for signs of wear or any other damage. Replace the belt if worn or damaged.

10021193

1 8

5. Route the belt, 4, around the sheaves and tensioner in the same orientation as removed. 6. Install the drive belt, 3, for the rotor gear box. Use the procedure described in Section 66, Chapter 3 of the repair manual. 7. Install the drive belt, 1, for the variable drive system using the procedure described later in this chapter. 8. Adjust the tension of the drive belt using the adjusting nut, 1, on the belt tensioner idler. Adjust the tension so that the spring, 2, is the same length as the gauge plate, 3. The spring length should be approximately 130 mm (5.1 in).

3 2 10021006

VARIABLE SHEAVE DRIVE BELT Replacement If the combine is equipped with a variable speed feeder drive, use the following procedure to replace the drive belt. 1. Remove the six M10 x 40 bolts with lock washers, 1, which secure the hydraulic cylinder, 2, to the variable drive sheave. Slide the cylinder out of the sheave. Use care not to lose any shims on the cylinder. The shims are fitted between the sheave and the cylinder mounting flange.

10021129

2. Support the hydraulic cylinder out of the way.

60-8

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 3. Use a paint marker or other suitable marking tool to place an aligning mark, 1, on the outer sheave half and the sheave hub. 4. Remove the cross pin, 2, by removing one 0.38 x 1.00 bolt, lock washer, and washer from one end of the cross pin. Slide the cross pin out of the sheave.

10021194

11 5. Place a socket, 1, or a suitable piece of steel between the outer sheave half and hub of the torque sensing drive. This will prevent the sheave halves from coming together when the belt is removed.

1 10021200

12 6. Slide the outer sheave half off the hub and remove the drive belt, 1. 7. Inspect the belt for cracks, excessive wear or other damage. Replace as necessary. 8. Install the belt onto the torque sensing sheave.

10021195

1 13

60-9

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 9. Lubricate the sheave hub and outer sheave half with lithium grease. Install the outer sheave half onto the hub. Use the aligning marks, 1, made in step 3 when installing the sheave half onto the hub. 10. Install the cross pin into the variable drive sheave. Secure the cross pin in the sheave with the washer, lock washer, and retaining bolt, 2.

Torque the cross pin retaining bolts to 47 -- 61 N⋅m (35 -- 45 ft-lb). 10021194

14 11. Install the hydraulic cylinder, 2, with any shims into the sheave. Install the six M10 x 40 retaining bolts with lock washers, 1, into the sheave and tighten in a crossing pattern. Torque the six M10 x 40 retaining bolts in a crossing pattern to 47 -- 61 N⋅m (34 -- 45 ft-lb). 12. Remove the socket or steel rod used to keep the torque sensing sheave halves separated.

1 10021129

VARIABLE DRIVE SHEAVE Removal

NOTE: Overhaul of the hydraulic cylinder, 2, is covered later in this chapter. 1. Remove the six M10 x 40 bolts with lock washers, 1, which secure the hydraulic cylinder, 2, to the variable drive sheave. Slide the cylinder out of the sheave. Use care not to lose any shims on the cylinder. The shims are fitted between the sheave and the cylinder mounting flange.

10021193

2. Support the hydraulic cylinder out of the way. 3. Loosen the belt tensioner adjusting nut, 3, for the feeder primary drive belt, 4.

60-10

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 4. Use a paint marker or other suitable marking tool to place aligning marks, 1, on the outer sheave half and the sheave hub. 5. Remove the cross pin by removing one bolt, lock washer, and washer from one end of the cross pin. Slide the cross pin out of the sheave.

10021194

17 6. Place a socket, 1, or a suitable piece of steel between the outer sheave half and hub of the torque sensing drive sheave. This will prevent the sheave halves from coming together when the belt is removed.

1 10021200

18 7. Slide the outer sheave half off the hub. Position the variable sheave drive belt, 1, out of the way.

8. Slide the primary feeder drive belt, 2, off the sheave and position the belt out of the way.

10021195

1 19

60-11

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 9. Install the outer sheave half back onto the hub, using the aligning marks, 1, made previously.

10. Install the cross pin back into the sheave halves. Secure the cross pin in the sheave with the washer, lock washer, and 0.38 x 1.00 retaining bolt, 2. Do not torque. 11. Disconnect the remote grease fitting line (not shown) from the sheave.

10021196

12. Wrap a lifting strap around the inside of the two sheave halves. Route the strap around the frame of the combine and tie the strap off so the weight of the sheave will be supported when the sheave is unbolted from the combine.

WARNING Use care not to damage the refrigerant lines when removing the bolts which secure the variable drive sheave to the combine frame. Serious injury may occur if the lines are punctured and refrigerant is allowed to escape. Failure to comply could result in serious injury or death. NOTE: The refrigerant lines for the cab air conditioning run through the frame where the upper three mounting bolts for the drive sheave are. The lines are wrapped in sheathing and must be carefully pulled away from the frame to allow access the top three bolts. DO NOT use a sharp object to pull the lines away from the frame. The wire ties that are used to secure the lines may be cut to allow for additional slack in the lines to access the bolts. 13. Remove the six M12 x 30 bolts (only three are shown) with lock washers, 1, which secure the sheave to the combine frame. Have an assistant lower the sheave to ground using the lifting strap while guiding the sheave to the ground.

10021197

60-12

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 Disassembly 1. Before disassembly, remove crop residue and grease from the variable drive sheave using a suitable solvent.

2. Remove cross pin, 1, from the variable drive sheave by removing one 0.38 x 1.00 bolt, lock washer, and washer from one end of the cross pin. Slide the outer sheave half, 2, off the hub. 20021175

22 3. Remove the six M12 x 40 bolts, 1, which secure the inner sheave half, 2, to the hub assembly, 3. Tap the sheave half off the hub using a suitable mallet. Use care not to damage the sheave.

1 2

20021167

23 4. Remove the three M6 x 20 bolts, 1, which secure the bearing cover, 2, to the hub. Remove the cover from the hub.

2 1

20021168

60-13

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 NOTE: If the bearings will be reused, make note of the location of each bearing so they will installed into their original position during assembly. 5. Clean the bearing grease out of the hub assembly.

6. Remove the M16 x 40 bearing retaining bolt, 1, and washer, 2, from the hub shaft.

20021169

25 7. Place the hub assembly in a hydraulic press. The bearing housing, 1, which bolts to the combine, must be supported as shown. Push the hub shaft, 2, out of the bearing housing using the press. Be sure the hub shaft will not fall when pressed out of the housing.

1 2

20021170

26 8. Remove the rear bearing, 1, and spacer, 2, from the bearing housing.

20021174

60-14

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 9. Remove the four M6 x 20 bolts with lock washers, 1, which retain the front bearing plate, 2, to the housing. Remove the bearing plate and the bearing, 3.

1 1

2 20021171

28 NOTE: If the bearings are being replaced, the races must also be removed and replaced. Never replace bearings without replacing the races.

10. Using ice placed inside a plastic bag, chill the outer bearing races, 1, for a minimum of 15 minutes. Make sure the ice makes good contact with the bearing races. 11. Once the races are chilled, place the bearing housing in a vice and tap out the races using a suitable hammer and punch. If the bearings and races will be reused, place each race with the respective bearing so the race can be installed in same location as removed.

20021172

12. Slide the spacer, 1, out of the bearing housing. Remove the lock ring, 2.

2 20021173

60-15

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 Inspection 1. Clean all components using a suitable solvent and allow to dry. 2. Remove and discard the two seals, 1, (only one is shown) from the outer sheave half. Lubricate and install new seals into the sheave half. 3. Inspect the sheave halves for cracks, grooving or other damage. Check the splines inside the outer sheave half for damage or excessive wear. Replace components as necessary.

4. Inspect the bearings for excessive lateral play or rough movement. Inspect the races for grooves, pitting or excessive wear. Replace the bearings and races if necessary. 5. Inspect the hub shaft and bearing housing for damage or wear. Replace as necessary.

50021159

Assembly 1. Install the lock ring, 2, into the bearing housing. Apply a light coating of lithium grease to the spacer, 1, and slide the spacer into the bearing housing. The spacer goes in from the flange side of the housing and has a groove which fits over the lock ring.

2 20021173

32 2. Chill the bearing races with ice for a minimum of 15 minutes. Dry any water from the races before installation. Using a suitable bearing/seal driver, install the races into the bearing housing. Install the race for the mounting flange side first.

20021176

60-16

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 3. Pack the outside bearing, 3, with lithium grease and install the bearing into the bearing housing. Install the front bearing plate, 2, onto the housing and secure using the four M6 x 20 retaining bolts with lock washers, 1.

1 1

Tighten to standard torque.

20021171

34 4. Lightly lubricate and place the bearing spacer, 1, into the bearing housing. 5. Pack the remaining bearing, 2, with lithium grease and place the bearing into the bearing housing.

20021174

35 6. Place the hub shaft, 1, in a hydraulic press, supporting the shaft as shown. Place the bearing housing, 2, on top of the hub shaft. IMPORTANT: Be sure to press against the inner race of the rear bearing when installing the bearing housing onto the hub shaft. Damage may occur to the bearing if the inner race is not used. 7. Press the bearing housing onto the hub shaft, using a tube to press against the inner race of the rear bearing. Remove the assembly from the press.

2 1

20021177

60-17

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 8. Install the M16 x 40 bolt, 1, and washer, 2, into the end of the hub shaft assembly. Torque the bolt to 233 -- 262 N⋅m (172 -- 193 ft-lb). Check to make sure the bearings rotate smoothly. If the bearings do not rotate smoothly, check assembly of the bearing housing and hub shaft.

20021169

37 9. Install the bearing cover, 2, onto the hub assembly. Install the three M6 x 20 retaining bolts with lock washers, 1, which secure the bearing cover to the hub and tighten to standard torque.

10. Fill the bearing housing with lithium grease using the grease fitting, 3.

20021168

38 11. Install the inner sheave half, 2, onto the hub assembly, 3, and secure using the six M12 x 40 mounting bolts, 1. Torque the bolts in a crossing pattern to 82 -- 106 N⋅m (61 -- 78 ft-lb).

1 2

20021167

60-18

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 12. Thoroughly lubricate the inside bore of the outer sheave half, 1, with lithium grease. Be sure to fill the grooves in the bore with grease. Coat the hub shaft with a layer of lithium grease.

13. Slide the outer sheave half, 1, onto the hub shaft, using the aligning marks made during disassembly. 14. Slide the cross pin, 2, through the sheave halves and secure using the 0.38 x 1.00 retaining bolt, lock washer, and washer removed from the end of the pin. 20021175

Do not torque cross pin bolt at this time.

40 Installation

WARNING The variable drive sheave weighs approximately 73 kg (161 lb). Use care when handling the sheave, otherwise personal injury may occur. Failure to comply could result in serious injury or death. 1. Have an assistant raise the sheave up to the combine using the lifting strap looped around the center of the two sheave halves. Guide the sheave up to the combine frame and install the six M12 x 30 bolts with lock washers, 1, (only three are shown) which secure the sheave to the frame. Torque the bolts to 82 -- 106 N⋅m (61 -- 78 ft-lb) in a crossing pattern.

10021197

2. Position the air conditioning refrigerant lines back into the combine frame rail. Replace any wire ties which were cut during sheave removal. 3. Remove the lifting strap, 2, from the sheave. 4. Remove one cross pin retaining bolt and washers, and the cross pin, 1, from the sheave and slide the outer sheave half off the hub.

1 2

10021196

60-19

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 5. Install the primary feeder drive belt, 1, onto the rear sheave half. 6. Place the variable sheave drive belt, 2, onto the hub shaft.

10021195

43 7. Slide the outer sheave half onto the hub using the aligning marks, 1, made during removal. Install the cross pin, 2, into the sheave and secure the pin using the 0.38 x 1.00 bolt, lock washers and washer removed. Torque to 47 -- 61 N⋅m (35 -- 45 ft-lb).

10021194

44 NOTE: Be sure to place the same number of shims on the hydraulic cylinder when installing the cylinder onto the variable drive sheave.

8. Install the hydraulic cylinder, 2, into the variable drive sheave. Secure the cylinder to the sheave using the six mounting bolts, 1, tightening the bolts in a crossing pattern. 9. Tighten the adjusting nut, 4, for the primary feeder drive belt, 3, until the spring is even with the spring gauge on the tensioner. The spring length should be approximately 130 mm (5.1 in). 10. Remove the socket or steel rod used to keep the torque sensing sheave halves separated.

60-20

10021193

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 VARIABLE DRIVE SHEAVE HYDRAULIC CYLINDER Removal NOTE: Hydraulic fluid may drain from the hydraulic line when removed have a suitable container ready to catch any fluid which drains from the line. 1. Disconnect the hydraulic line fitting, 1, from the hydraulic cylinder. Position the line out of the way. 2. Remove the six M10 x 40 bolts with lock washers, 2, which secure the hydraulic cylinder to the variable drive sheave. Pull the cylinder out of the sheave, using care not to lose any shims. The shims are fitted between the sheave and the cylinder mounting flange.

1 10021129

Disassembly 1. Remove the shims, 1, from the hydraulic cylinder. Count the number of shims removed from the cylinder so if any shims are lost or need replaced, the same amount can be installed between the cylinder and the sheave.

20021178

47 2. Carefully clamp the cylinder mounting flange in a vice. Remove the three 0.31 x 0.625 bolts with lock washers, 1, which secure the retaining plate, 2, for the rotating union, 3.

2 1 1

3 20021179

60-21

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 3. Remove the cylinder from the vice and separate the cylinder from the mounting flange, 2, by removing the snap ring, 1. Slide the mounting flange off the cylinder.

1 20021180

49 4. Slide the rotating union, 1, out of the hydraulic cylinder. Remove the snap ring, 2, retaining the fitting portion of the union. The fitting portion can then be removed from the rotating union.

20021181

50 5. Remove the bronze floating seal, 1, the O-ring, 2, the aluminum seal guide, 3, and spring, 4, from the rotating union housing, 5.

3 20021183

60-22

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 IMPORTANT: DO NOT place the sliding surface of the piston rod in the vice, as any surface blemishes on the rod will cause the cylinder to function improperly. DO NOT over tighten the vice.

6. Place the end of the piston rod, 1, in a soft jaw vice, tightening the jaws enough to secure the rod. Pull the cylinder, 2, off the rod. Remove the piston rod from the vice.

2 20021184

52 7. Remove the orifice, 1, from each end of the piston rod.

20021185

53 Inspection 1. Thoroughly clean all parts using a suitable solvent and allow to dry.

2. Remove and discard the oil seals, 1, from the cylinder, 2. Replace the oil seals with new seals lubricated with clean hydraulic fluid. 3. Inspect the cylinder bore and outer diameter for signs of wear, corrosion, or any other damage.

2 20021186

60-23

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 4. Remove and discard the O-rings, 1, on the rotating union housing, 2.

5. Discard the O-ring, 3, for the floating seal, 4.

6. Inspect the housing, floating seal, 4, and fitting, 5, for excessive wear or other damage. 7. Inspect the bearings on the fitting for smooth movement or excessive lateral play. Replace the rotating union if the bearings are damaged or worn.

WARNING Always wear eye protection when using compressed air. Serious injury may occur if care is not taken.

2 6

20021187

8. Inspect the holes in the orifices, 6, to make sure they are not clogged. Use only compressed air to clean the orifices. IMPORTANT: DO NOT use any type of drill or wire to clean the orifice holes, as this will increase the diameter of the holes. 9. Inspect the piston rod for corrosion or any other damage. The hydraulic cylinder will not function properly if the rod is damaged. Replace the piston rod as necessary. 10. Measure the outer diameter of the piston rod in several places along the length of the rod. The diameter of the rod should be 44.4119 -- 44.4500 mm (1.7485 -- 1.7500 in). Replace the piston if the diameter is below specifications.

20021188

56 Assembly 1. Lubricate new O-rings, 1, with petroleum jelly and install onto the union housing, 2.

2. Lubricate the spring, 3, seal guide, 4, O-ring, 5, and floating bronze seal, 6, with new hydraulic fluid. Install the components into the union housing, 2, in the order shown in the illustration. When installing the bronze seal, 6, make sure the long portion of the seal is installed into the housing first and the tabs in seal are aligned with the pins in the housing.

5 20021183

60-24

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 3. Secure the fitting portion, 1, of the rotating union, 2, with the small snap ring, 3.

1 3

2 20021181

58 4. Install an orifice, 1, into each end of the piston rod.

20021185

59 5. Lubricate the piston rod, 1, with clean hydraulic fluid and install the piston rod into the cylinder, 2.

2 20021189

60-25

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 6. Install the rotating union, 1, into the hydraulic cylinder, 2.

2 20021182

61 7. Place the mounting flange, 2, on top of the cylinder. Install the snap ring, 1, to secure flange to the cylinder.

1 20021180

62 8. Carefully clamp the cylinder mounting flange in a vice. Install the three 0.31 x 0.625 bolts with lock washers, 1, which secure the retaining plate, 2, for the rotating union, 3.

Torque to 22 -- 28 N⋅m (16 -- 21 ft-lb).

1 1

3 20021179

60-26

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 9. Install the shims, 1, onto the hydraulic cylinder. Be sure the same number of shims are installed on the cylinder.

20021178

64 Installation 1. Install the hydraulic cylinder into the variable drive sheave. Secure the cylinder with the six M10 x 40 retaining bolts with lock washers, 2. Tighten the bolts in a crossing pattern and torque to 47 -- 61 N⋅m (35 -- 45 ft-lb). 2. Install the hydraulic line, 1, onto the rotating union. 3. Start the combine and cycle the hydraulic cylinder several times to fill the cylinder and bleed air out.

10021129

TORQUE SENSING DRIVE SHEAVE The torque sensing drive sheave is a self adjusting sheave that drives the cross shaft. The torque sensing sheave is driven by the variable drive sheave by a belt. The torque sensing sheave uses two spring loaded sheave halves on a hub to sense when the drive belt is slipping. If slippage occurs on the outer sheave half (rotor drive half), the inner sheave (driven half) will tighten to stop the slippage. The torque sensing drive also adjusts to the speed the variable drive sheave is set at. The torque sensing sheave will spread apart the higher the speed the variable drive sheave is set to.

Removal 1. Remove the drive belt, 1, using the procedure described previously in this chapter.

10021129

60-27

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 2. Remove the M20 x 45 center bolt, 1, and flat washer from the torque sensing drive sheave. Install a 20 mm x 110 bolt and the flat washer into the cross shaft. This will allow the sheave to be pulled off the tapered splines, but keep the sheave from falling.

3. Remove two 0.50 x 2.0 hub bolts with lock washers, 2, at 180-degrees apart.

2 10021198

WARNING The torque sensing drive sheave weighs approximately 70 kg (155 lb). To prevent personal injury or equipment damage, use care when handling the sheave. Failure to comply could result in serious injury or death.

2 4 3

IMPORTANT: Make sure that the M12 threaded rod is threaded into the torque sensing drive completely so the threads in the drive do not become stripped out. 4. Wrap a lifting strap, 4, around the sheave and tie the strap off so the weight of the sheave is supported. Be sure the sheave will not be able to slip out of the lifting strap when the sheave is removed from the cross shaft. 5. Manufacture the torque sensing drive removal tool as shown in the Special Tools portion of this manual. Install the tool, 1, using two 200 mm (7.875 in) lengths of M12 threaded rod, 2, with a nut and flat washer on each piece of rod. Place a 50 mm (2 in) length of steel rod, 3, or suitable socket against the center of the bolt. 6. Turn the two nuts on the M12 threaded rod evenly until the sheave loosens on the tapered splines. 7. Once the sheave is loose on the cross shaft, remove the tool, 1 and threaded rods, 2. 8. Remove the center bolt from the cross shaft. Have an assistant lower the sheave to the ground while guiding the sheave off the cross shaft and away from the combine.

60-28

1 2 10021199

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 Disassembly

WARNING Use extreme caution and follow procedures exactly when disassembling the torque sensing drive. The large spring in the drive is under a lot of tension and may cause serious injury or death if the spring release is not controlled. 1. Use tool 380000735 to relieve the spring pressure of the torque sensing drive sheave. 2. Disassemble the torque sensing hub removal tool by removing the tool body, 1, from the threaded rod, 2, and also removing the thrust washer, 3, and centering washer, 4. The smaller diameter of the centering washer is positioned on the threaded rod against the tool body and the thrust washer is positioned on the threaded rod against the larger diameter of the centering washer.

20033104

4 69

3. Secure the tool to the sheave by inserting the threaded rod of the remover tool through the center of the sheave. Ensure that the mounting flanges, 1, of the removal tool are aligned and engaged with the edges of the spring cam, 2, before tightening the threaded rod to the tool body of the hub remover tool, 3.

1 20033112

70 4. Tighten the threaded rod, 1, fully against the thrust washer, 2, and centering washer, 3, using a 22 mm socket wrench until the pressure is released from the snap ring and the snap ring can be removed.

2 1 20033106

60-29

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 5. Remove the snap ring, 1, using the snap ring pliers, 2. The snap ring should lift off from beneath the top of the hub removal tool, 3.

2 3

20033111

WARNING Keep hands and clothing away from the spring and sheave halves when releasing the spring. The sheave halves will rotate as the threaded rod of the remover tool is being loosened. Failure to comply could result in serious injury or death. 6. Slowly loosen the threaded rod with the socket wrench to release the spring pressure. Tap the cam lightly with a rubber mallet or similar-type tool if the cam hub does not slide on the shaft as the threaded rod is loosened. As the spring cam disengages the rollers, the torsional pressure of the spring will release and the sheave halves will rotate. 7. Loosen the remainder of the threaded rod from the upper portion of the remover tool and remove the tool from the sheave.

60-30

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 Inspection 1. Separate the sheave halves. Clean each part of the torque sensing drive using a suitable cleaner. Inspect each portion of the sheave for excessive wear or damage. Inspect the splines on the hub and the splines in the spring cam. Replace any components that are worn or damaged. 2. The hub, 1, can be replaced by removing the four remaining (six total) bolts which retain the hub to the outer sheave half, 2. Install the new hub and torque the mounting bolts to 95 -- 123 N⋅m (70 -90 ft-lb). If the hub will not be removed, install the two bolts removed for the sheave removal tool.

50021163

3. Remove and discard the two seals, 1, (only one is shown) from the inner sheave half. Lubricate new seals with lithium grease and install into the sheave half so the open side of both seals will face the rear of the sheave when assembled and installed on the combine. Refer to the illustration inset.

50021201

4. Inspect the bearings, 2, on the cam ring. Replace the bearings if they do not turn freely or have excessive play. When installing bearings, torque the bearings to 68 -- 78 N⋅m (51 -- 53 ft-lb).

1 2

5. The cam ring, 3, can be replaced by removing the six mounting bolts from the inner sheave half, 4. Install the new cam ring and secure using the mounting bolts. Torque the mounting bolts to 82 -- 106 N⋅m (61 -- 78 ft-lb). 6. Generously coat the splines and sliding surfaces of the hub and sheave halves with lithium grease. Be sure the grooves in the bore of the inner sheave half are filled with grease. Lubricate the cam bearings with lithium grease.

50021164

Assembly

1. Slide the sheave halves together. 2. Install the spring onto the rear sheave halve. Install the spring tab into the rear of the inner sheave half. Install the spring tab into the hole that is NOT marked with an “R”, 1. If the marking is not legible, use the left side hole when the sheave is viewed from the end with two holes at the top.

60-31

50021165

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 3. Install the spring cam, 1, onto the spring. Be sure the spring tab is locked into the cam.

50021166

76 4. Install the spring cam onto the hub shaft, mating against the spring, and being sure to lock the spring into the spring tab on the cam.

5. Install the hub tool, 1. Before installing the removal tool, slide the snap ring over the shaft of the tool for easy installation later. Slowly start to compress the tool using a ratchet wrench. Just before the splines on the hub shaft mate with the splines on the cam, rotate the inner sheave half until the cam roller, 2, is in line with the ramp on the cam, 3. 6. Start to compress the spring slowly, making sure that everything is mating properly. Watch the cam and cam rollers, also watch the hub shaft and cam splines for correct mating. Sometimes the cam may bind on the splines slightly, use a heavy rubber dead blow hammer to tap around the cam while compressing the spring, this will help resolve the binding.

3 2

20033105

7. Once this is achieved, fully compress the spring until the snap ring groove is visible.

WARNING Be sure the snap ring is fully seated in the hub groove; otherwise, the spring will force the cam off once the tool is removed, possibly causing severe personal injury or death. 8. Install the snap ring, 1, onto the outer sheave hub using a suitable pair of snap ring pliers. Ensure that the snap ring is fully seated in the hub groove. 9. Remove the hub remover tool from the torque sensing drive sheave by loosening the threaded rod with a socket wrench and removing the two washers.

60-32

20033108

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 Installation

CAUTION

The torque sensing drive sheave weighs approximately 70 kg (155 lb). To prevent personal injury or equipment damage, use care when handling the sheave. 1. Loop a lifting strap around the torque sensing drive sheave. Be sure the sheave will not slip out of the strap as the sheave is being raised up to the cross shaft. Wrap the strap around the combine frame and have an assistant raise the sheave up to the cross shaft. Guide the sheave up to the cross shaft while the sheave is being raised. 2. Install a 20 mm x 90 bolt and the large flat washer into the cross shaft. Tighten the bolt so the sheave seats on the cross shaft. Remove the 20 mm x 90 bolt and install the original center bolt, 1, and flat washer into the cross shaft. Torque the bolt to 425 -- 525 N⋅m (313 -- 387 ft-lb). 3. If not installed at inspection, install the two hub bolts, 2, and torque to 95 -- 123 N⋅m (70 -- 90 ft-lb). 4. Install the drive belt, 1, using the procedure described previously in this chapter. The torque sensing drive sheave may need to be separated to allow the belt to be installed. Use a suitable prying tool to separate the sheave halves, if necessary.

2 10021198

10021129

CROSS SHAFT AND BEARING REPLACEMENT (FIXED DRIVE) Removal

WARNING The feeder/header drive clutch weighs approximately 43 kg (94 lb); use care when removing the clutch from the combine. Failure to comply could result in serious injury or death. 1. Remove the feeder/header drive clutch, 1, from the left side of the cross shaft using the procedure described later in this chapter.

10021007

60-33

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 2. Remove the primary feeder drive belt from the fixed drive sheave, 2, using the procedure described in this chapter.

3. Insert a pry bar or steel rod into one of the holes in the sheave, 2, to prevent the sheave from rotating. 4. Remove the M20 x 50 bolt and washer, 1, securing the sheave to the cross shaft.

1 10021008

82 5. Use a large gear puller, 1, and a metal spacer, 2, to remove the sheave, 3, from the cross shaft.

3 1

2 10021009

83 6. Remove the key, 4, from the cross shaft. Remove the four M12 x 30 bolts, 1, which secure the right bearing retaining plate, 2, to the combine frame. Slide the bearing and plate off the cross shaft, 3.

2 1 10021010

60-34

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 7. Remove the four M12 x 40 bolts, 1, which secure the left bearing retaining plate, 2, to the combine frame.

1 1 2 10021011

85 8. Slide the cross shaft, 1, out of combine from the left side.

10021012

86 9. Clamp the bearing plate from the right side of the combine in a vice. Remove the bearing by prying down on the bearing, 1, until the bearing is 90 degrees from the normal position. The bearing will now slide out of the bearing housing, 2, sideways.

10. Inspect the bearing and housing for damage or excessive wear. Replace the components as necessary.

10021013

60-35

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 11. Loosen the setscrew in the locking collar, 1, on the left side of the cross shaft. Remove the locking collar, 1, by using a hammer and suitable punch rotate the collar counter-clockwise. 12. Slide the bearing, 2, and housing, 3, for the left side off the cross shaft. Remove the bearing by prying down on the bearing until the bearing is 90 degrees from the normal position in the bearing housing. The bearing will now slide out of the bearing housing sideways. 13. Inspect the bearing and housing for damage or excessive wear. Replace the components as necessary.

3 1 4

2 10021014

14. Inspect the cross shaft for damage or excessive wear. Check for cracks, damaged threads and worn bearing surfaces. Replace the shaft as necessary. Replace the two O-rings, 4, for the feeder clutch. Installation NOTE: Apply a light coat of Loctite anti-seize when installing the bearing into the bearing housing.

1. Install the left side bearing, 1, into the bearing housing, 2, in the same manner as removed. Install the bearing and housing onto the left side of the cross shaft. Do not install the locking collar at this time. 2. Install the cross shaft into the combine from the left side.

10021032

89 3. Install the left bearing housing, 2, to the combine frame using the four M12 x 40 mounting bolts, 1. Make sure each bolt is secured with a lock washer and nut, but do not tighten the bolts at this time. Coat the protruding portion of the cross shaft with Loctite anti-seize compound.

1 1 2 10021015

60-36

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 4. Install the bearing for the right side of the cross shaft into the bearing housing in the same manner as removed. Install the right bearing plate, 2, onto the combine frame and cross shaft, 3. Secure the plate using the four M12 x 30 bolts, 1. Torque the four bolts, 1, to 85 -- 105 N⋅m (63 -77 ft-lb). Install the key, 4, into the slot on the cross shaft. Coat the protruding portion of the cross shaft with Loctite anti-seize compound.

2 1 10021010

91 5. Align the keyway in the primary drive sheave, 1, with the key on the cross shaft. Place the sheave onto the cross shaft.

6. Thread a 6 inch length of 20 MM x 2.5 threaded rod, 2, into the cross shaft and thread a nut and washer onto the rod. Draw the sheave onto the cross shaft by turning the nut clockwise until the sheave is fully seated on the shaft.

10021033

92 7. Remove the threaded rod and install the M20 x 50 bolt and washer, which secures the sheave to the cross shaft. Torque the bolt to 425 -- 525 N⋅m (313 -- 387 ft-lb).

1 10021008

60-37

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 8. Make sure the sheave on the right side of the combine is pushed in towards combine frame as far as possible.

2 3

9. Torque the four M12 x 40 bolts, 1, for the left bearing assembly to 82 -- 105 N⋅m (63 -- 77 ft-lb). 10. Install the locking collar, 3, onto the cross shaft, 2, and use a hammer and suitable punch to lock the collar onto the shaft. Tighten the setscrew in the locking collar. 11. Install the key (not shown) into the slot on the left side of the cross shaft.

1 10021016

94 12. Install the feeder/header drive clutch, 1, onto the left side of the combine using the procedure described later in this chapter. Reference Feeder/Header -- Drive Clutch -- Installation. 13. Install the drive belt for the primary feeder drive onto the right side of the combine.

10021007

CROSS SHAFT AND BEARING REPLACEMENT (VARIABLE DRIVE) Removal

10021007

60-38

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 2. Remove the torque sensing drive sheave, 1, using the procedure described previously in this chapter.

10021129

97 3. Loosen the set screw on the right side bearing lock collar, 1. Use a suitable hammer and punch to loosen the lock collar on the bearing. Slide the collar off the cross shaft.

50021202

98 4. Remove the four M12 x 40 bolts, 1, which secure the left side bearing housing, 2, to the combine frame.

1 1 2 10021011

60-39

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 5. Slide the cross shaft, 1, out of the left side of the combine.

10021012

100 6. Remove the four M12 nuts and lock washers, 1, which secure the right side bearing housing, 2, to the combine frame. Remove the bearing housing.

1 2

1 50021203

101 7. Loosen the setscrew in the locking collar, 1, on the left side of the cross shaft. Remove the locking collar, 1, by using a hammer and suitable punch rotate the collar counter-clockwise. 8. Slide the bearing assembly, 3, for the left side off the cross shaft. Clamp the assembly in a vice. Remove the bearing, 2, by prying down on the bearing until the bearing is 90-degrees from the normal position in the bearing housing. The bearing will now slide out of the bearing housing sideways. 9. Remove and inspect the right bearing housing in the same manner. Inspect the bearings and housings for damage or excessive wear. Replace the components as necessary. 10. Inspect the cross shaft for damage or excessive wear. Check for cracks, damaged threads or splines and worn bearing surfaces. Replace the shaft as necessary. Replace the two O-rings, 4, for the feeder clutch. Inspect the keyway and key for the left side of the cross shaft. Replace the key if damaged.

60-40

3 1 4

2 10021014

102

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 Installation NOTE: Apply a light coat of Loctite anti-seize compound when installing the bearing into the bearing housing.

10021032

103 2. Secure the bearing assembly, 2, for the right side of the cross shaft to the combine frame using the four M12 x 40 mounting bolts, lock washers and M12 nuts, 1. Torque to 85 -- 105 N⋅m (63 -- 77 ft-lb).

1 2

1 50021203

104 3. Slide the cross shaft, 1, into the combine through the left side of the combine. Insert the cross shaft through the right side bearing assembly.

10021012

105

60-41

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 4. Secure the left bearing assembly, 2, to the combine frame using the four M12 x 40 mounting bolts, 1, lock washers and nuts. Torque the four bolts, 1, for the left bearing assembly to 82 -- 105 N⋅m (63 -- 77 ft-lb). Slide the locking collar, 3, onto the cross shaft, but do not lock at this time.

1 1 2 10021011

106 5. Slide the right side locking collar, 1, onto the cross shaft. Do not lock the collar at this time.

292.6 mm (11.52 in)

6. Position the cross shaft in the bearing assemblies by measuring the distance from the RIGHT end of the shaft to the right side of the combine frame. The distance should be 292.6 mm (11.52 in).

50021205

107 7. Once the cross shaft, 1, is properly positioned, lock the lock collars, 2, onto the bearing assembly on each side of the combine using a suitable hammer and punch. Tighten the set screw in each lock collar once the collar is locked on the bearing assembly and shaft. Use care not to move the cross shaft laterally when installing the lock collars. 8. Check the distance from the RIGHT end of the cross shaft to the bearing mounting plate on the combine frame. The distance should be 292.6 mm (11.52 in). See Figure 107. If the distance is not as specified, remove the lock collars and adjust the cross shaft position as necessary.

60-42

2 10021016

108

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 WARNING The feeder/header drive clutch weighs approximately 43 kg (94 lb); use care when removing the clutch from the combine. Failure to comply could result in serious injury or death.

9. Install the feeder/header drive clutch, 1, onto the left side of the cross shaft using the procedure described later in this chapter. Reference; Feeder/Header Drive Clutch -- Installation. 10021007

109 10. Install the torque sensing drive sheave, 1, using the procedure described previously in this chapter. Reference -- Torque Sensing Drive Sheave; Installation.

10021129

110

60-43

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 FEEDER/HEADER DRIVE CLUTCH Feeder/Header Drive Clutch -- Cross Section View

7 4

9 8

10 13

3 2

1 17

19 66063465

18 111

Feeder/Header Drive Clutch -- Cross Section 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Bolt, M12 x 50 (Cylinder) Cylinder Oil Seal Piston Oil Seal Spacer Washer Housing Spring Washers, Diaphragm Clutch Pack (5 Separator Discs, 4 Friction Discs) Backing Disc Retaining Ring

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

60-44

Pulley Washer, Flat Screw, Hex Socket (M12 x 30 10.9) Spring, Disc Retaining Rings Retaining Ring Cross Shaft Bearings, Ball Type Bushing O-ring Hub

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 Feeder/Header Drive Clutch -- Exploded View

20 19

13 15

12 11 9 10

10 9 10 9

6 5

4 3 2

66063466

1 112

*(Clutch cross shaft -- not shown) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Bolt, M12 x 50 (Cylinder) Cylinder Oil Seal Oil Seal Piston Hub Spacer Washer Spring Washers, Diaphragm Separator Discs (5) Friction Discs (4)

60-45

Backing Disc Retaining Ring Housing Pulley Screw Washer, Flat Hex Socket (M12 x 30 10.9) O-ring Bearings, Ball Type Spring, Disc Retaining Ring Bushing Retaining Ring

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 The feeder/header drive clutch is located on the left side of the combine under the side shield. The feeder clutch is hydraulically activated and is operated by a switch in the cab. Removal NOTE: The feeder clutch does not need to be removed from the combine to gain access to the clutch friction plates. 1. Engage the combine parking brake and remove the key from the combine ignition switch. Raise the combine left side shield. 2. Remove secondary drive belt guard, 1.

1 20026245

113 3. Remove the hydraulic supply line, 1, from the combine. Remove the entire line, including the coupling, 2. Plug the hydraulic line at the combine frame to avoid contamination.

2 1

10021007

114 4. Bend the lock tab from the washer, 2, away from the lock nut, 1, securing the clutch to the cross shaft.

2 1

10021017

115

60-46

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 5. Using special tool #FNH00088, 1, remove the lock nut from the cross shaft.

10021018

116 6. Loosen the adjusting nut, 1, for secondary feeder drive belt tensioner, 2. 7. Remove the belt from the feeder clutch sheave.

2 1 10021019

117

WARNING The feeder clutch weighs approximately 43 kg (94 lb). Have an assistant help remove the feeder clutch from the combine. Failure to comply could result in serious injury or death. 8. Install a large two or three arm gear puller, 1, and a metal disc, 2, onto the feeder clutch sheave. Carefully remove the clutch from the cross shaft using the gear puller.

1 2 10021020

118

60-47

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 Disassembly IMPORTANT: Use care not to contaminate the feeder/header drive clutch when performing service or rebuilding. Service the clutch in a clean area, free from dirt and debris.

1. Remove the four M12 x 50 bolts, 1, from the front of the clutch.

10021021

119 2. Thread two 12 mm bolts, 1, into the two small holes on the front of the clutch. Turn the bolts in evenly so the front of the clutch pushes away from the sheave. Lift the front cover of the clutch from the clutch body (sheave).

10021022

120 3. Remove the beveled washer, 1, and shim, 2, from the front cover.

10021023

1 121

60-48

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 4. Remove the beveled washer, 1, and clutch discs, 2, and separator plates, 3, from the clutch assembly.

1 2

10021024

3 122

5. Remove the backing plate, 1, from the clutch assembly.

10021025

123 6. If damaged or worn, remove the large snap ring, 1, from the clutch hub. This snap ring supports the backing plate.

1 10021026

124

60-49

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 7. Turn the clutch assembly over and remove the snap ring, 1, from the rear of the clutch hub.

10021027

125 8. Place the clutch assembly in a press. Using a suitable driver, 2, carefully press the clutch hub out of the clutch body (sheave), 1.

2 1

10021028

126 9. Remove the spring washers, 1, and the bearing spacer, 2, from the splined clutch hub.

10021029

1 127

60-50

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 10. Use a spacer, 1, and a gear or bearing puller, 2, to remove the bearing, 3, from the clutch hub.

1 3 10021030

128 11. Remove the two snap rings, 1, from the clutch body (sheave). Use a suitable bearing driver to remove the bearing, 2, in the clutch sheave.

12. Remove and discard the O-ring, 3, in the clutch sheave.

10021031

129 Inspection NOTE: Cross shaft is shown removed from the combine for illustration purposes. 1. Remove and discard the O-rings, 1, from the cross shaft. Lubricate new O-rings with petroleum jelly and install the new O-rings onto the cross shaft.

2. Clean all clutch components using a suitable solvent. Allow the clutch components to air dry. 3. Inspect all clutch components for excessive wear and damage. Check the splines on the clutch hub, the clutch body (sheave) and the front cover. Replace any worn or damaged components. 4. If the hub or pulley requires replacement, the pulley can be removed from the hub by removing six M12 x 30 socket head screws with flat washers. When assembling torque the screws to 120 -- 134 N⋅m (89 -- 98 ft-lb).

60-51

10021014

130

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 5. Inspect the clutch discs and separator plates for excessive wear, discoloration, or any other damage. Use a micrometer or a caliper to measure the thickness of the clutch discs and separator plates. Take measurements from several points on each to check for abnormal wear and service limits. 6. Lay each separator plate and clutch disc on a known flat surface and inspect for warpage. Replace any warped components. 7. Inspect the bearings for the clutch. The bearings should rotate smoothly and should not have any play. The bearings are factory sealed and lubricated, if the seal is damaged, replace the bearing.

10021034

131

8. The front cover can be separated from the front hub to replace the two oil seals. Refer to Figure 111. 9. Lubricate all parts with new hydraulic fluid before assembly. Assembly 1. Press the outer bearing, 2, into the clutch body (sheave) using a suitable bearing driver. Press on the outer race of the bearing only when installing this bearing. 2. Install the two snap rings, 1, into the clutch body. 3. Lubricate and install a new O-ring, 3.

10021031

132 4. Install the inner bearing, 1, onto the clutch hub using a suitable bearing driver. Press on the inner race of the bearing only when installing the bearing onto the hub.

5. Install the four spring washers, 2, and the bearing spacer, 3, onto the splined clutch hub.

10021029

1 133

60-52

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 6. Place the clutch assembly, 1, in a press. Using a suitable driver, 2, carefully press the clutch hub into the clutch body (sheave) until the bearing on the hub bottoms out against the snap ring in the clutch body.

2 1

10021035

134 7. Turn the clutch assembly over and install the snap ring, 1, onto the rear of the clutch hub assembly.

10021027

135 8. If removed, install the large snap ring, 1, into the clutch assembly. This snap ring supports the backing plate. Install the backing plate on top of the snap ring. The portion of the backing plate with the groove should face the separator plates and clutch discs.

1 10021026

136

60-53

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 NOTE: The beveled washer, 1, should be installed so the outer edge rests against the clutch hub.

9. Install the beveled washer, 1, and clutch discs, 2, and separator plates, 3, into the clutch assembly. Install a separator plate against the backing plate and then alternate between clutch discs and separator plates. There are five separator plates and four clutch discs.

10021024

3 137

NOTE: The beveled washer should be installed so the outer edge of the washer rests against the shim.

10. Install the beveled washer, 1, and shim, 2, onto the front clutch cover. Use a thin coating of petroleum jelly to hold the shim and washer to the cover during installation.

10021023

138 NOTE: The clutch hub may need to be rotated in order for the bolt holes in the clutch cover to line up with the bolt holes in the clutch hub. 11. Install the front clutch cover onto the clutch body (sheave). Be sure the four bolt holes in the cover are aligned with the four bolt holes in the clutch hub. 12. Thread the four M12 x 50 bolts, 1, that secure the cover onto the body into the four bolt holes in the clutch cover. Draw the bolts down evenly to draw the cover into the clutch body (sheave). Torque the bolts to 86 N⋅m (64 ft-lb).

10021021

139

60-54

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 Installation

CAUTION The feeder clutch weighs approximately 43 kg (94 lb). Have an assistant help install the feeder clutch into the combine. 1. Coat the cross shaft with Loctite anti-seize compound before placing the clutch onto the cross shaft. 2. Align the key hole in the clutch hub with the key on the cross shaft and install the clutch onto the cross shaft.

1 2 10021036

140

3. Use a 8 inch length of 3/8″-24 threaded rod, 1, a 3/8″-24 nut, a large flat washer, and a large socket, 2, or a piece of pipe to draw the clutch onto the cross shaft. The socket or pipe must be large enough to fit around the cross shaft without damaging the threads of the cross shaft. 4. Install the secondary feeder drive belt, 1, onto the feeder clutch. Tighten the adjusting nut, 2, for secondary feeder drive belt tensioner, 3, until the spring in the tensioner is even with the gauge plate. The proper spring length should be approximately 108 mm (4.25 in).

2 10021019

141 5. Place the tabbed lock washer onto the cross shaft and thread the lock nut on the shaft. 6. Using special tool # FNH00088, 1, torque the lock nut to 170 -- 190 N⋅m (125 -- 140 ft-lb).

10021018

142

60-55

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 7. Bend a lock tab from the washer, 2, into a notch in the lock nut, 1, so the lock nut will not loosen.

2 1

10021017

143 8. Coat the threads on the coupling, 2, with Loctite 567 PST pipe sealant. Torque the coupling to 23 -- 27 N⋅m (16 -- 20 ft-lb).

Attach the hydraulic supply line, 1, at the combine frame and to the coupling, 2.

10021007

144 9. Install the secondary drive belt cover, 1.

1 20026245

145

60-56

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 SECONDARY DRIVE BELT 1

Removal 1. Remove left side shields, 1. Set the shields on top of the feeder. 2. Remove the secondary drive belt shield, 2.

10021115

2 146

3. Remove the lower drive belt guard, 1, from the feeder.

20026244

147 4. Remove the upper secondary drive belt guard, 1. NOTE: Completely removing the adjusting nut is not necessary.

5. Loosen the belt tensioner adjusting nut, 2.

1 20026245

148

60-57

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 6. Remove the belt, 1, from the combine.

20016286

149 Installation 1. Route the secondary drive belt around the feeder clutch, 1, and under the belt tensioner, 2.

1 2

20016286

150 2. Route the other end of the belt around the header jackshaft drive sheave, 1. 3. Install lower belt guard, 2.

20026244

151

60-58

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 4. Install secondary drive belt guard, 1. 5. Tighten the belt tensioning idler at 2 so that the spring is the length of the gauge. The proper spring length should be approximately 108 mm (4.25 in).

1 20026245

152 6. Install the secondary drive belt shield, 2.

7. Install the left side shields, 1.

10021115

2 153

FEEDER REVERSER GEARBOX Removal 1. Remove the right side shields, 1, from the feeder house. Set the shields on top of the feeder.

20026238

154

60-59

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 2. Remove the front chain drive guard, 1, from the feeder.

3. Position the chain, 2, to make the master link accessible. Remove the master link and chain. Store the drive chain in a clean dry place.

20026239

155 4. Loosen the sprocket set screws, 1, from the shaft. Attach a puller, 2, and remove the sprocket from the header jackshaft, 3.

1 3

2 20026240

156 5. Lift the sprocket key, 1, from the shaft.

6. Loosen set screw, 2. Using a punch and hammer, rotate the lock collar, 3, to disengage the collar and bearing from the shaft.

1 20026241

157

60-60

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 7. Using emery cloth, clean the accessible areas of the shaft of dirt and set screw nicks.

8. Position the reverser engagement motor in mid travel to relieve pressure on cap screw, 1. 9. Remove cap screw, 1.

20026242

158 10. Remove the left side, 1, and secondary drive belt shields, 2. Set the shields on top of the feeder.

20026243

159 11. Remove the front drive belt guard, 1, from the feeder.

20026244

160

60-61

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 12. Loosen the secondary drive belt tensioning idler at 1. NOTE: Completely removing the adjusting nut is not necessary. 13. Remove the belt from the header jackshaft drive sheave.

20026245

161 14. Remove cap screw and lock nut, 1.

NOTE: If the position of the sheave, 2, on the shaft is not marked, installing the sheave so that the locking cap screw will be in line with the groove in the shaft will be difficult.

15. Mark the position of the sheave in relation to the shaft. 16. Install a puller, 3, onto the sheave, 2. Pull the sheave from the header jackshaft.

3 20026246

162 NOTE: The set screw is staked in two places and may be difficult to remove.

17. Loosen set screw, 1. Using a punch and hammer, rotate the lock collar, 2, to disengage the bearing from the shaft.

18. Remove the retaining nuts, 3. Pull the bearing from the header jackshaft.

2 56063455

163

60-62

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 19. Detach electrical connectors, 1, from the feeder house wiring harness. 20. Disconnect hydraulic supply and return lines, 2. Plug the hydraulic lines and cap the motor ports. Remove the two upstream clamps holding the lines to the feeder.

21. Turn off the retaining nuts, 3.

20026248

2 164

22. Turn out the cap screws located in cavities, 1. NOTE: Depending on the condition of the shaft, removing the bearing, 2, may be difficult. The bearing may be removed with a puller or cut from the shaft. If cutting the bearing, exercise care not to damage or otherwise mark the shaft.

23. Remove bearing, 2, from the header jackshaft. 24. Slide the header jackshaft toward the left side of the feeder, until the right end of the jackshaft clears the frame. Lower the assembly to the ground.

2 20026249

165 Disassembly

1. Remove the actuator, 1, from the reverser assembly by removing the bolt, 2. The actuator and hex bushing may then be removed from the clutch fork.

2 50016254

166

60-63

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 2. Remove the nut and washer, 1, securing the fork, 2, to the shaft. Slide the fork off the shaft. Drive out the roll pin, 3, and slide the shaft out of the reverser housing. Keep track of the shims, 4, used on each end of the shaft for reassembly. NOTE: The shaft is under mild spring pressure. Use caution when removing the roll pin.

50016253

2 167

3. Loosen the lock collars, 1, securing the bearing and gear to the header drive shaft. Slide the shaft, 2, out of the gear, 3, and reverser housing bearing, 4.

10014614

168 4. Remove the lock collars, 1, and gear, 2, from the reverser housing.

10014615

169

60-64

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 5. The bearing, 1, in the reverser housing may be removed by turning the bearing sideways in the housing, and sliding it out through the loading slots in the housing.

50016251

170 6. Remove the bearing in the gear by removing the snap ring, 1, and drive the bearing out of the gear. When installing a new bearing, ensure that the locking flange on the bearing is facing out on the snap ring side of the gear.

10014617

171 7. Remove the hydraulic motor, 1, from the reverser housing. Holes are provided in the housing to provide access to the motor mounting bolts.

50016250

172

60-65

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 8. Remove the gear, 1, from the motor by using softjawed pliers to hold the gear while loosening the bolt, 2, from the end of the motor shaft. Remove the bolt, lock washer and large flat washer. Slide the gear off the motor shaft.

Inspection 1. Inspect both bearings. Replace if any wear or damage to the seals is noticed. 2. Inspect the gear teeth for chipping, cracks or galling. Replace if any damage is found. 3. Inspect the engaging surface of the gear and clutch jaws. Replace if excessive wear or rounding of the corners is found. Inspect the shaft and clutch jaw splines for excessive wear or galling. Replace both parts if damage is found.

60-66

10014619

173

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 Assembly

C 3

5 10

D 9

66063452

174 1. 2. 3. 4. 5.

Hydraulic motor Bearing, gear Gear, drive Bearing, housing Shims (clutch engaged clearance)

6. 7. 8. 9. 10.

Spring Lock collar, housing bearing Lock collar, gear bearing Gear, driven Shims (clutch released clearance)

Dimension A: 405 -- 407 mm (15-15/16 -- 16 in) Dimension B: 0.5 ± 1mm (0.020 in ± 0.040 in) Dimension C (clutch engaged clearance): 0.5mm -- 1.5mm (0.020 -- 0.060 in) Dimension D (clutch released clearance): 10 -- 12 mm (3/8 -- 1/2 in)

60-67

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 1. Remove all paint, rust or corrosion from the gear and motor shaft, and install the gear, 1, on the motor shaft by sliding it over the key. Install the bolt, 2, lock washer and flat washer, and tighten securely. IMPORTANT: Do not use a hammer to drive the gear onto the motor shaft, or the motor will be damaged. The gear should be a slip fit on the motor shaft and key.

10014619

175 2. Slide the clutch jaw, 1, onto the header drive shaft until it is engaged on the splined area of the shaft.

56063453

176 3. Insert the gear, 1, into the reverser housing with the jaws on the gear facing away from the reverser housing bearing. While sliding the header drive shaft, 2, through the gear and housing, carefully fit the locking collars, 3, over the shaft.

NOTE: Ensure that the locking collars are properly oriented for each bearing.

56063454

177

60-68

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 4. Position the reverser housing on the shaft so that it is positioned 405 -- 407 mm (15-15/16 -- 16 in) from the end of the shaft to the bearing, A. Install the locking collar, 1, on the reverser housing bearing to secure the housing in this position. NOTE: Tighten the lock collar counter-clockwise as viewed from the end of the shaft.

50016258

178 5. Attach the hydraulic motor and gear assembly, 1, to the reverser housing. Position the reverser housing so that it is perpendicular to the shaft. Slide the gear, 2, on the shaft until it is aligned to the hydraulic motor gear, 3, within 0.5 ± 1mm (0.020 ± 0.040 in). Install the locking collar, 4, on the gear bearing to secure it in this position.

NOTE: Tighten the lock collar counter-clockwise as viewed from the end of the shaft.

10014614

179 6. Preassemble the shaft, 1, by installing the roll pin, 2, and slide the shims, 3, and spring over the shaft.

10014623

180

60-69

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 7. Slide the shaft through the housing, and install the fork, 1, over the shaft and into the groove on the clutch jaw, 2. Install the nut and washer, 3, to secure the fork to the shaft. Use a large clamp or spring compressor to shift the shaft and fork against the spring until the spring is completely coil-bound. Push the clutch jaw against the fork so that it is tight at 4, and measure the clearance between the clutch and gear jaws. The clearance should be 10 -- 12 mm (3/8 -- 1/2 in). Adjust this clearance by adding or removing shims at 5.

1 3 5

50016256

10 -- 12 mm (3/8 -- 1/2 in)

181 8. Remove the nut and washer, 1, and remove the fork. Install the shims, 2, and roll pin, 3, on the shaft. NOTE: The clamp or spring compressor must be used to partially compress the spring in order to allow installation of roll pin, 3. Reinstall the fork, nut and washer, and remove the clamp or spring compressor. Pull the clutch jaw against the fork so that it is tight at 4, and measure the clearance between the clutch and gear jaws. The clearance should be 0.5 mm -- 1.5 mm (0.020 -- 0.060 in). Adjust this clearance by adding or removing shims at 2.

0.5 -- 1.5 mm (0.020 -- 0.060 in)

50016255

182 9. Attach the actuator, 1, to the fork by inserting the actuator and hex bushing through the fork, and installing the bolt and locknut, 2. Loosen the bolt securing the J-hook, 3, to the reverser housing, as this will be adjusted after the header drive shaft is reinstalled on the straw elevator.

2 50016254

3 183

60-70

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 Installation 1. Orient the header jackshaft with the gearbox assembly on the right side. Insert the left end of the jackshaft through the shaft hole in the frame. Slide the right end through the right side frame. Push the gearbox against the inside frame of the feeder until the gearbox is flush. 2. Apply a light coating of grease over the non-painted areas of the jackshaft.

1 56063467

184 3. Apply a light coating of grease to the inside of the left side bearing. 4. Slide the bearing onto the left end of the jackshaft. Orient the bearing so that the plugged grease hole, 1, is on the bottom.

20016284

185 NOTE: To gain access to the right jackshaft bearing flange hardware, push the shaft about six inches toward the left side of the frame, if necessary. This will allow easier access to the flange hardware at 1.

20016285

186

60-71

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 5. Apply a light coating of lithium grease to the inside of the bearing.

6. Slide the bearing, 1, onto the right end of the jackshaft.

NOTE: Do not tighten the hardware at this time. 7. Install the hardware, 2, to hold the bearing onto the frame.

2 20026249

187 8. Secure the gearbox assembly to the frame with cap screws and nuts, 1. 9. Connect hydraulic supply and return lines, 2, to the reverser motor. Install the two upstream pipe brackets.

10. Attach electrical connectors, 3. Apply wire ties as required to hold the wires and connectors securely away from the rotating jackshaft.

20026248

2 188

11. Secure the bearing for the left side to the frame with four M16 x 50 bolts, lock washers and M16 nuts, 1.

Torque the hardware to 204 -- 262 N⋅m (150 -- 193 ft-lb).

12. Shift the jackshaft to the left side of the feeder. NOTE: If the shaft is not moved to the left most position, the locking bolt will not slide through the clamp in the jackshaft sheave. 13. Set the locking collar into place. Using a punch and hammer, secure the bearing to the shaft by turning the collar in the normal direction of rotation. Tighten set screw, 2. 14. Stake the set screw to the collar in two places 180 degrees apart.

60-72

56063455

189

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 15. Secure the right side bearing in place by tightening the hardware.

16. Set the locking collar into place. Using a punch and hammer, secure the bearing to the shaft by turning the collar in the direction of rotation. Tighten set screw, 1. 17. Apply a light coating of grease on the key. Place the key, 2, into the shaft.

2 20026241

190 18. Apply a light coating of grease to the inside surface of the sprocket. Slide the sprocket, 1, onto the right end of the jackshaft. Adjust the position of the sprocket to obtain 167.6 mm (6-9/16 in) from the side of the feeder to the centerline of the sprocket.

167.6 mm (6-9/16 in)

20016287

191 19. Tighten the set screws. Secure the set screws into place with jam nuts, 1.

20. Install cap screw and nut, 2, to attach the reverser engagement motor to the frame.

2 20026259

192

60-73

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 NOTE: If offset links are used, install the chain with the narrow end of the links in the direction of travel.

21. Route the chain, 1, around the sprocket. Connect the ends of the chain together using the master link previously removed. 22. Adjust idler, 2, to obtain 9.7 -- 15.7 mm (3/8 -- 5/8 in) sag at the center of the longest length of chain.

23. Install the front chain drive guard, 3.

20026239

193 24. Install the right side feeder shields, 1.

20026238

194 25. Using the alignment mark made during removal as a guide, slide the sheave onto the end of the jackshaft.

26. Install the locking cap screw and nut, 1. Torque to 160 N⋅m (118 ft-lb).

20026260

195

60-74

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 27. Route the secondary drive belt, 1, over the sheave. Tighten the tensioning idler until the top of the spring is even with the end of the spring length gauge.

28. Install the front drive belt guard, 2.

20026244

196 29. Install the secondary drive belt shield, 1, and left side shield, 2.

20026243

197

FEEDER REVERSER MOTOR Removal 1. Remove the right side shields, 1, from the feeder house. Place the shields on top of the feeder.

2. Detach the front chain drive guard, 2, from the feeder.

20026238

198

60-75

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 3. Disconnect hydraulic supply and return lines, 1. Plug the hydraulic lines and cap the motor ports. Remove the two upstream clamps holding the lines to the feeder.

20026248

199 NOTE: During removal, allow the lock washers to fall through the bottom of the reverser gearbox. Retain the nuts inside the socket being used until fully withdrawn from the cavity. 4. Remove the retaining nuts and lock washers located inside the cavities, 1.

1 20020100

200 5. Remove the hydraulic motor, 1, from the reverser gearbox.

20020101

201

60-76

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 Disassembly The reverser motor is not serviceable. If the motor is found to be defective, the entire unit must be replaced. The drive gear, 1, on the reverser motor must be replaced if inspection points listed are present. See Inspection below.

Inspection Inspect the gear teeth for chipping, cracks or galling. Replace if any damage is found. Remove the gear, 1, from the motor by using soft jawed pliers to hold the gear while loosening the bolt, 2, from the end of the motor shaft. Remove the bolt, lock washer and large flat washer. Slide the gear off the motor shaft.

10014619

202

Assembly IMPORTANT: Do not use a hammer to drive the gear onto the motor shaft, or the motor will be damaged. The gear should be a slip fit on the motor shaft and key.

Remove all paint, rust or corrosion from the gear and motor shaft, and install the gear, 1, on the motor shaft by sliding the gear over the key. Install the bolt, 2, lock washer and flat washer, and tighten securely.

Torque to 24 -- 30 N⋅m (18 -- 22 ft-lb). 10014619

203 Installation

1. Orient the reverser motor so the hydraulic fittings are toward the bottom. Install the motor into the gearbox.

20020101

204

60-77

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 NOTE: For ease of installation of the reverser motor, insert the M12 x 40 bolts through cavities, 1, as this is easier. Install the locknuts on the motor side of the bolts. 2. Secure the reverser motor to the gearbox with M12 x 40 bolts at cavities, 1. Torque to 82 -- 106 N⋅m (61 -- 78 ft-lb).

1 20020100

205 3. Connect hydraulic supply and return lines, 1, to the reverser motor. Install the two upstream pipe brackets.

20026248

1 206

4. Attach the front chain drive guard, 1, to the feeder. 5. Install the feeder side shields, 2.

1 2

20026238

207

60-78

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 FEEDER CHAIN IDLER Removal 1. Remove the feeder side shields, 1, from the right side of the feeder house Place the shields on top of the feeder.

20026238

208 2. Position the front drive chain, 1, so the master link is accessible. Release chain tension by loosening the tensioner bolt, 3, and remove the master link and chain. Store the drive chain in a clean, dry place.

2 1 3

3. Position the rear drive chain, 2, to make the master link accessible. Release chain tension by loosening the tensioner bolt, 3, and remove the master link and allow the chain to hang freely.

3 10021070

209 4. Loosen the inside and outside lock collar set screw, 1, (outside lock collar shown). Using a punch and hammer, disengage both lock collars from the shaft. 5. Turn off the bearing flange nuts, 2, from the inside and outside bearing assemblies.

20026262

1 210

60-79

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 NOTE: Hold the bearing assembly that is on the inside of the idler mount as the shaft is being removed.

6. Pull the shaft, sprocket and outside bearing, 1, from the idler mount.

20026263

211 Disassembly 1. Unlock and completely remove the two sprocket set screws, 1.

2. Push the idler shaft from the sprocket. Remove the key from the idler shaft. Inspection 1. Inspect the sprocket for cracked, broken or worn teeth. 2. Inspect the shaft for wear and scoring. 3. Inspect the bearings for smooth movement and play. Replace any bearing that does not turn smoothly or has excessive play.

20026264

212

Assembly 1. Apply a light coating of grease to the shaft, inner bore of the sprocket and key.

2. Set the key into place on the shaft. Insert the shaft into the sprocket until the groove lines up with the set screw holes. 3. Turn in the two set screws, 1, and secure them in place with the jam nuts. Torque both the setscrew and jam nut to 49 -- 60 N⋅m (36 -- 44 ft-lb). 4. Slide the outside lock collar, 2, onto the shaft with the locking end toward the bearing side of the shaft. 5. Set the bearing and flange assembly, 3, in place oriented so the bearing will mate with the lock collar.

60-80

20026263

2 213

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 NOTE: Do not tighten bearing hardware at this time. 6. Install the inside bearing flange assembly, 1, in the idler mount with the locking portion of the bearing positioned out.

7. Thread the flange nuts, 2, on the bolts until finger tight.

20026265

214 8. Slide the sprocket assembly into the inside bearing. 9. Install the three carriage bolts and nuts, 1, and tighten only until finger tight.

20026266

215 10. Adjust the position of the idler shaft to obtain 122.5 -- 126.5 mm (4-13/16 -- 4-15/16 in) from the side of feeder to the centerline of the inner sprocket.

122.5 -- 126.5 mm (4-13/16 -- 4-15/16 in)

11. Tighten the inside and outside bearing hardware. 12. Check the position of the shaft in relation to the side of the feeder. Adjust as required to maintain 122.5 -- 126.5 mm (4-13/16 -- 4-15/16 in).

50016288

216

60-81

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 13. Install the inside and outside locking collars on the bearings to secure the shaft into position. Tighten the locking collars in the direction of rotation. Secure the collars in place with the set screws, 1.

20026262

217 14. Route the rear drive chain, 1, around the sprocket. Connect the ends of the chain together using the master link previously removed.

15. Adjust tensioning sprocket, 2, to obtain 9.7 -- 15.7 mm (3/8 -- 5/8 in) of sag at the center of the longest length of chain.

20026267

218 16. Route the front drive chain, 1, around the sprocket. Connect the ends of the chain together using the master link previously removed.

17. Adjust tensioning sprocket, 2, to obtain 9.7 -- 15.7 mm (3/8 -- 5/8 in) of sag at the center of the longest length of chain.

20026239

219

60-82

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 18. Install the feeder side shields, 1.

20026238

220

SLIP CLUTCH Removal 1. Lower the feeder house to the lowest position. NOTE: If the feeder house is not at the lowest point of travel, the top slip clutch guard will be difficult to remove. 2. Remove the feeder side shields, 1, from the right side of the feeder house. Place the shields on top of the feeder.

20026238

221 3. Position the chain, 1, to make the master link accessible. Relieve chain tension and remove the master link. 4. Remove the three cap screws and nuts, 2, and remove the guard, 3, from the feeder house.

2 1 3 20016268

222

60-83

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 5. Remove two cap screws and nuts at 1, along the bottom of the slip clutch guard 2. Remove three cap screws and nuts, 3, along the side of the guard. Remove the guard from the feeder house.

1 20016269

223 6. Remove the two cap screws and nuts, 1, and lift shield, 2, from the feeder house.

20016270

224 7. Lift the chain, 1, from the slip clutch sprocket and store in a clean, dry place.

56063474

225

60-84

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 8. Insert a 4 x 6″ wood block, 1, into the lower area of the feeder opening. Rotate the front drum to lodge the wood in place.

20016274

226 NOTE: The nut, 1, has left hand threads. NOTE: Be sure not to lose any shims when removing the slip clutch spring.

9. Remove nut, 1. Slide the spring, 2, and shims (not shown) from the slip clutch assembly.

20016275

227 10. Slide the outer hub, 1, and clutch jaw, 2, off the pivot shaft.

20016276

2 228

60-85

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 11. Pull the sprocket and jaw assembly, 1, from the pivot shaft while holding the splined bushing, 2, in place with a screwdriver or other appropriate tool.

20016277

229 12. Slide the washer, 1, and splined bushing, 2, from the shaft.

20016278

230 Inspection 1. Inspect the two clutch plates for wear. When mated together, the plates must contact each tooth at 1, before bottoming out at the root of the tooth. If contact is made at 2, before 1, the clutch plates must be replaced as a set.

2 10007659

231

60-86

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 2. Inspect the sprocket, 1, for cracks, broken or worn teeth. Inspect the center bushing, 2, for excessive or uneven wear.

20016279

232 3. Inspect the splined hub, 1, for cracks and deformation. Inspect the internal spline, 2, for missing or worn teeth.

2 1

20016280

233 4. Inspect the adjusting nut, 1, for cracks.

5. Inspect the spring, 2, for cracks and discoloration due to excessive heat.

56063473

234

60-87

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 6. Inspect the splined bushing, 1, for cracks and discoloration from excessive heat. Inspect the internal spline, 2, for missing or worn teeth. 7. Inspect the washer, 3, for cracks and discoloration from excessive heat.

2 1

8. Replace any damaged or worn components as necessary.

20016282

235 Assembly

1. Apply a light coating of grease to the spline shaft, 1, spline bushing, 2, and washer, 3. Slide the splined bushing and washer onto the shaft.

20016278

3 236

2. Apply a light coating of grease on the sprocket bushing, 1. Set the sprocket, 2, into place on the splined bushing. 3. Apply a light coating of grease to the jaws of the slip clutch plate, 3. Install the inside clutch plate onto the sprocket.

3 1 2

20016277

237

60-88

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 4. Apply a light coating of grease to the jaws of the outer slip clutch plate, 1. Install the inside clutch plate onto the hub, 2. 5. Set the assembly onto the shaft.

20016276

238 NOTE: The nut, 2, has left-hand threads. Prior model years included a right-hand threaded jam nut installed on the end of the shaft, 3. The jam nut is not required for assembly.

6. Set the shims (not shown) and the spring, 1, into place. Install nut, 2, until the nut bottoms out against the shoulder of the pivot shaft. Torque to 320 -- 380 N⋅m (236 -- 280 ft-lb).

3 20016275

239 7. Route the rear chain, 1, around the sprocket. Connect the ends of the chain together using the master link previously removed.

8. Adjust the tensioner sprocket to obtain 9.7 -- 15.7 mm (3/8 -- 5/8 in) of sag at the center of the longest length of chain. 9. Install the front chain in the same using steps 8 and 9.

56063474

240

60-89

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 10. Insert a 4 x 6″ wood block, 1, into the lower area of the feeder opening. Rotate the drum to lodge the wood in place.

11. Loosen the secondary drive belt tensioner allowing the jackshaft sheave to rotate freely.

20016274

241 12. Manufacture a special tool made of a 25 mm (1 in) diameter bar that is approximately 1321 mm (52 in) long. Weld one end to a standard 1-3/8 in six point U-joint, which will attach the feeder jackshaft. Weld a heavy flat washer at a point approximately 1219 mm (48 in) from the center line of the yoke.

1219 mm (48 in)

13. Attach the special tool, 1, to the header jackshaft at 2. Make sure the 4 x 6 inch wooden block, 4, is lodged in the feeder house opening. 14. Attach a spring scale, 3, to the special tool. 15. Pull on the spring scale. Be sure to pull at a right angle to the special tool. Note the pounds of pull required to slip the clutch. NOTE: The pounds of pull are based on using the special tool with the spring scale attached 1219 mm (48 in) from the header jackshaft. If the special tool is not used, the amount of torque required to cause the clutch to slip should be 753 -- 807 N⋅ m (555 -- 595 ft-lb) at the jackshaft. 16. The amount of pull applied to the spring scale should be 65 ± 2.3 kg (144 ± 5 lbs) to equal the specified setting of 753 -- 807 N⋅m (555 -- 595 ft-lb) at the jackshaft. If the clutch slips at a lower setting, add shims between the spring and the clutch plate. If the clutch slips at a higher setting, loosen the adjusting nut, 1, one or two flats. 17. Repeat steps 14 through 17 to ensure the clutch torque setting falls between the specified range. 18. Tighten the secondary feeder drive belt.

60-90

19993128

4 242

56063474

243

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 19. Secure upper half of the slip clutch guard, 1, to the feeder house using cap screws, washers and nuts, 2.

20016270

244 20. Secure lower half of the guard, 1, to the feeder house using cap screws, washers and nuts at 2 and 3.

1 2

20016269

245 21. Secure the outer portion of the guard, 1, to the feeder house using cap screws, washers and nuts at 2.

1 20016268

246

60-91

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 22. Install feeder house side shields, 1. 23. Remove the wood block from the feeder house opening.

20026238

247

PIVOT SHAFT The pivot shaft is located in the rear of the feeder house and is used to drive the feeder chain. The pivot shaft also serves as the pivot point for the feeder house. The pivot shaft is driven by the feeder drive chains on the right side of the feeder house. The slip clutch is attached to the right side of the pivot shaft. Removal 1. Remove the feeder house using the procedure described in Chapter 1 of this section of the repair manual.

10021117

248 2. Remove the feeder slip clutch, 1, using the procedure described previously in this chapter of the repair manual.

56063474

249

60-92

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 3. Rotate the feeder jack shaft so the feeder chain connecting bolts are at the pivot shaft. Disconnect the feeder chain at the pivot shaft using the procedure described in Chapter 1 of this section of the repair manual.

20021144

250 4. Remove the M10 x 25 bolt with lock washer, 1, which retains the sensor target disc, 2, for the feeder speed to the pivot shaft. 5. Loosen the set screw, 3, for the left side bearing lock collar. Use a suitable hammer and punch to loosen the collar. Remove the lock collar from the right side using the same procedure.

3 2 1

10021118

251 6. Remove the two sets of anti-wrap shields, 1.

Remove the twelve 0.25 x 0.75 hex socket cap screws (six screws per set of shields), 2, which secure the two halves of the shields together.

2 1

Remove the eight 0.25 x 0.75 hex socket cap screws (four screws per set of shields), 3, which secure the halves of each shield to the nylon shield bushings. NOTE: The twelve screws securing the anti-wrap shield halves together are assembled with Loctite 242/243 thread lock compound. To assist removal, gently heat the screws if necessary. DO NOT heat the eight screws that secure the shield halves to the nylon bushings.

60-93

56063469

3 252

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 7. Rotate the pivot shaft so that a retaining bolt, 1, for each of the feeder chain sprockets is visible. For ease of assembly, mark the position (left, center, right) of each sprocket on the shaft with a paint marker or other suitable marking tool. Place a mark on a retaining bolt for each sprocket. This is so the pivot shaft will be assembled and installed in the same orientation as removed from the feeder house. 8. Loosen the two retaining bolts for each sprocket. The sprockets will be able to slide on the pivot shaft freely.

1 56063471

253 9. Slide the end sprockets away from each bearing assembly, 1. Remove the nuts, 2, from the 10 bolts which secure each bearing assembly to the feeder house. The bolts securing the anti-wrap tabs, 3, may need to be removed to access all the nuts.

56063472

2 254

NOTE: The right bearing assembly contains a spacer. 10. Remove the bearing assembly, 1, from each side of the pivot shaft.

10021122

255

60-94

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 11. Slide the pivot shaft, 1, out of the feeder house, removing each sprocket and shield bushing, 2, from the shaft.

2 1 10021123

256 12. Remove each bearing, 1, from the housing by finding the release slots, 2, in the bearing housing and rotating the bearing 90-degrees in the housing to those slots. The bearing can then be removed from the housing.

Inspection 1. Inspect the shaft for damaged or worn splines. Check for any damage or wear on the shaft. Replace as necessary. 2. Inspect each feeder chain sprocket for damage or excessive wear. Replace damaged or worn sprockets. 3. Inspect the shaft bearings for smooth movement and play. Replace any bearing that does not turn smoothly or has excessive play. 4. Inspect the bearing housings for damage or cracks. The feeder house pivots on the bearing housings; check for wear or damage where the feeder pivots on the housing. Replace the housings as needed. 5. Inspect the nylon shield bushings for excessive wear or damage. Replace the bushings as necessary.

60-95

2 10021124

257

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 Installation NOTE: Be sure the portion of the bearing, 1, that the lock collar locks on faces out when installing the bearing in the housing.

1. Install each bearing into the bearing housing at the release slots, 2. Pry the bearing 90-degrees up or down so the bearing is locked in place in the housing. Apply a coating of grease to the inner race of the bearing.

2 10021124

258 NOTE: When installing the pivot shaft, be sure the splined side of the shaft is at the right side of the feeder house. Make sure the slots in the anti-wrap flanges, 1, are aligned with the anti-wrap tabs in the feeder housing. 2. Slide the pivot shaft into the feeder house, installing the anti-wrap flanges, 1, the sprockets, 2, and the nylon shield bushings, 3. Use the markings made during removal to install the shaft and sprockets properly.

3 1 10021123

259 3. Install the spacer and right bearing assembly, 1, onto the pivot shaft. Secure the bearing assembly using the ten M12 x 50 conuntersunk screws, lock washer and M12 nuts.

Torque to 136 -- 150 N⋅m (100 -- 111 ft-lb). Install the left bearing assembly. Position the pivot shaft by pulling the shaft to the right side of the feeder house until the shaft bottoms out against the bearing race.

10021127

260

60-96

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 4. Refer to the illustration to verify that the pivot shaft is properly located inside the feeder housing. The end of the right side of the pivot shaft should protrude 267.9 mm (10.54 in), A, from the side of the feeder house wall.

A 20021125

261 5. Once the pivot shaft is aligned, install the lock collar, 1, onto each side of the pivot shaft. Use a suitable hammer and punch to lock the collar in place. Tighten the set screw for each collar. 6. Check to make sure the shaft remained properly aligned in the feeder house.

1 10021126

262 7. Use the paint markings made during removal to locate the sprockets to their original position on the pivot shaft. There should be 435.8 ± 1 mm (17.16 ± 0.04 in), B, Figure 261 between each sprocket. Once the sprockets are aligned on the pivot shaft, tighten the two lock bolts, 1, securing each sprocket to the shaft. Torque the lock bolts to 54 -- 68 N⋅m (40 -- 50 ft-lb). 8. Rotate the pivot shaft by hand. The shaft should rotate freely on the bearings. Check bearing installation or sprocket installation if the shaft does not rotate freely.

1 56063471

263

60-97

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 NOTE: Install the anti-wrap shields together as shown in the illustration so the welded nuts for the screws are on the inside of the shields.

56063468

264 9. Install the anti-wrap shields, 1, onto the shield bushings on the pivot shaft.

Apply Loctite 242/243 to the twelve 0.25 x 0.75 hex socket cap screws, install and tighten. Torque the screws to 7 N⋅m (5 ft-lb). Be sure the shields are able to rotate around the pivot shaft. If the shields do not rotate freely, make sure the sprockets are properly aligned.

56063469

265 10. Install the sensor target drive, 2, for the feeder speed sensor to the left side of the pivot shaft using the retaining M10 x 25 bolt with lock washer, 1. Torque to 49 -- 60 N⋅m (36 -- 44 ft-lb).

2 1

10021118

266

60-98

SECTION 60 - PRODUCT FEEDING - CHAPTER 2 11. Install the feeder slip clutch, 1, using the procedure described previously in this chapter of the repair manual.

56063474

267 12. Connect the feeder chain using the procedure described in Chapter 1 of this section of the repair manual.

20021144

268 NOTE: Be sure to apply grease to the feeder house pivot points. 13. Install the feeder house using the procedure described in Chapter 1 of this section of the repair manual.

10021117

269

60-99

SECTION 60 - PRODUCT FEEDING - CHAPTER 2

60-100

SECTION 60 - PRODUCT FEEDING - CHAPTER 3

SECTION 60 - PRODUCT FEEDING Chapter 3 - Stone Ejection System CONTENTS Section

Description

Page

60-1

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 DESCRIPTION OF OPERATION

WARNING ALWAYS stop the combine engine, engage the parking brake, remove the key from the ignition and engage the feeder safety lock, 1, anytime the combine feeder house is being serviced or adjusted. Failure to comply could result in serious injury or death. The CR Combine feeder is equipped with a New Holland Advanced Stone Protection (ASP™) system that is designed to protect the combine feeder and rotors from damage if a large stone enters the feeder. This system is operated automatically by electronic sensors mounted in the feeder house. If the sensors detect that a stone has entered the feeder, a hydraulically operated cylinder will unlatch a door in the bottom of the feeder house. The door will swing down, allowing the stone to exit the feeder, saving the combine from damage. This stone door is externally connected to an inner panel in the feeder house that also swings downward as the bottom door opens. This inner panel is called the skid plate and is designed to help deflect the incoming stone out of the bottom stone door. If the stone ejection system is activated, an alarm will alert the operator of the system activation. The stone door will raise and latch and skid plate will raise when the feeder is raised off the ground. Theory of operation and troubleshooting of the electronic stone ejection system control is described in “Section 55 -- Electrical Systems; Chapter 11 -- Feeder Systems; Advanced Stone Protection (ASP) System” of the “CR Combine Repair Manual”. An overview of operation and sensitivity settings are described in the CR9000 Series Operator’s Manual; Section 3 -- Field and Site Operation.

86060925

1 1

60-2

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 OVERHAUL BOTTOM SENSOR PLATE The bottom sensor plate, 1, for the stone ejection system is located below the front drum and behind the face plate in the feeder house. If a rock enters the feeder house and strikes this plate, the sensors in this plate will send a signal to the control module and the module will activate the hydraulic cylinder for stone door.

2 1

Adjustment and Inspection Where the Advanced Stone Protection (ASP™) sensitivity is an issue, especially in corn, check the following adjustments and settings. •

Ensure that the rubber isolation strips on the bottom sensor plate are in place (glued) on all four edges (end strips are not as critical). Ensure that there is no metal to metal contact between the sensor plate and feeder frame.

•

Ensure that the sensor plate has not shifted to one side, allowing it to contact the side of the feeder. Look for and remove any small pieces of stone that may have become wedged between the sensor and the side sheet.

•

Ensure that the rubber grommets, for the front set screws of the sensor plate, are in place.

•

Check for a loose feeder chain. Adjust to operator’s manual specifications.

•

Ensure that the rubber stop blocks, on the feeder drum supports, are in place and in good condition.

•

Check sensors for isolation or wire harness problems.

56063458

NOTE: Correctly set, it is usually possible to operate in corn at a sensitivity level of 20 to 30. Removal NOTE: The sensors attached to the plate can be removed without removing the sensor plate. 1. Remove the four M6 x 16 carriage bolts which secure each of the guide plates, 2, to the front of the cradle.

60-3

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 NOTE: Illustration shows the bottom of the feeder house.

2. Loosen the bolt, 1, on each side of the feeder house. 3. Disconnect the feeder wiring harness from connectors, 2, for the two sensors. The connectors are held together by a wire clip. Cut any wire ties needed to free the connectors.

20021064

1 3

4. Remove the four nuts and lock washers, 1, and M8 x 25 countersunk hex socket screws retaining the sensor plate in the feeder house. The countersunk screws can be accessed through the front opening in the feeder house and the nuts can be accessed through the opening between the feeder faceplate and feeder frame.

20021066

4 5. Remove the sensor plate from the feeder house by pushing the plate, 1, up and towards the rear of the combine and then lifting and pulling the plate out of the front of the feeder house.

20021067

60-4

SECTION 60 - PRODUCT FEEDING - CHAPTER 3

66063475

6 Apply Terostat MS-9360 Black sealing paste to the rubber strip in the pattern shown, 3. The paste should be applied within 5 mm (3/16 -- 3/64 in), D, of the edge of the strip.

Installation NOTE: Proper installation of the sensor plates is critical to correct operation of the stone traps. The sensor plate must be isolated from the rest of the feeder; that is, no metal to metal contact.

Apply the strips to the sensor plate as shown. The front strip is set back from the front edge 1 -- 5 mm (3/64 -- 3/16 in), B.

1. Before installing the sensor plate, 1, check the condition of the rubber isolation strips, 2, on the plate. Replace any pieces that are worn excessively or damaged.

The sides and rear strips must overhang the edge of the sensor plate. Overhang the sides, 2 -- 6 mm (5/46 -- 15/64 in), A, and the rear, 4 -- 10 mm (5/32 -- 25/64 in), C.

To replace or reattach loose strips; clean all sealing paste residue from the sensor plate with Loctite 7070 cleaning solvent.

Minimum drying time is eight (8) hours.

60-5

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 2. Install the plate into the feeder house as removed. Feed the connectors for the sensors through the holes in the feeder house frame when installing the sensor plate. Make sure the front of the plate fits in the feeder house properly.

20021067

7 3. Thread the two bolts, 1, which secure the front of the plate in the feeder house into the rubber isolators in the sensor plate. Tighten the nuts on the bolts to secure the bolts in the feeder house.

4. Make sure the bottom mounting plates, 2, are properly aligned with the sensor plate.

5. Connect the sensor connectors, 3, to the feeder wiring harness. Replace any wire ties cut during removal.

20021064

1 8

6. Secure the sensor plate, 1, to the brackets in the feeder house using the four M8 x 25 countersunk hex screws and nuts, 2. Be sure to use lock washers on each bolt.

20021066

60-6

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 7. Install the guide plates, 1, onto the feeder cradle. Secure the guide plates using the four M6 x 16 carriage bolts, lock washers, and nuts for each plate.

56063458

60-7

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 STONE EJECTION SYSTEM ACTUATING CYLINDER The stone ejection system actuating cylinder is located towards the rear of the feeder house floor. The ejection system cylinder is a hydraulically activated double-acting cylinder. Removal

WARNING ALWAYS stop the combine engine, engage the parking brake, remove the key from the ignition and engage the feeder safety lock anytime the combine feeder house is being serviced or adjusted. Block the combine wheels to prevent movement. NEVER be under the feeder house while the combine is running or attempting to lower the stone door. Failure to comply could result in serious injury or death. 1. With the feeder completely lowered, disconnect the stone door cable, 1, from the combine by removing the attaching pin, 2. 2. Raise the feeder completely and engage the feeder safety lock.

2 1 20021041

WARNING Make sure the area beneath the feeder is clear before lowering the stone door. Failure to comply could result in serious injury or death.

3. Start the combine engine and engage the threshing and feeder clutches. Press the quick stop button, 1. This will cause the stone door to open. 4. Shut the combine engine OFF, make sure the parking brake is engaged and the key is removed from the ignition.

86060942

60-8

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 5. To ensure proper installation, label the hydraulic lines, 1, for the actuating cylinder. Remove the hydraulic lines connected to the cylinder. Plug the hose ends and cylinder ports.

6. Remove the two pins, 2, which secure the hydraulic cylinder to the side feeder house. Remove the cylinder from the feeder.

20021037

13 Installation 1. Install the actuating cylinder onto the feeder. Secure the cylinder to the feeder using the two pins, 1.

2. If necessary, adjust the clevis, 2, Figures 13 and 14. The radius edges of the latches, 3, Figures 13 and 14, must be even with the outer edge of the channel, 4, Figures 13 and 14, when the cylinder is fully retracted; see Figure 14. The range of movement is approximately 25.4 mm (1.0 in). If the edges of the latches protrude from the channel after the cylinder is fully retracted, the stone door may not drop. If the cylinder retracts the latches too far, the latches will jam as the cylinder tries to extend.

1 2

5 3

4 20021037

3. The tension spring studs, 5, Figures 13 and 14, should be evenly adjusted to 13 mm (0.512 in), A, so the hydraulic cylinder will pull the latching bracket straight out when activated.

4. Install the hydraulic lines, 6, Figure 14, to the cylinder, using the labels made during removal for proper installation.

20021038

60-9

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 STONE DOOR The stone door is located on the bottom of the feeder house. This door opens to eject stones and crop when sensors in the feeder detect a rock entering the feeder. The stone door is closed by a cable and linkage connected to the feeder and the combine. When the feeder is raised, the cable, which is connected to the combine, pulls on the linkage that is connected to the stone door. The door closes and a proximity sensor tells the control module to close the valve for the stone ejection system actuating cylinder, latching the door shut. Opening the Stone Door

WARNING Always stop the combine engine, engage the parking brake, remove the key from the ignition and engage the feeder safety lock anytime the combine feeder house is being serviced or adjusted. Block the combine wheels to prevent movement. NEVER be under the feeder house while the combine is running or attempting to lower the stone door. Failure to comply could result in serious injury or death.

WARNING The stone door should never be opened from underneath the feeder. ALWAYS use the emergency stop button in the combine cab to open the stone door. Failure to comply could result in serious injury or death. NOTE: The stone door seals can be replaced without removing the door from the combine feeder house. 1. With the feeder completely lowered, disconnect the stone door cable, 1, from the combine by removing the attaching pin, 2, in the front axle. 2. Raise the feeder completely and engage the feeder safety lock.

2 1 20021041

60-10

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 WARNING Make sure the area beneath the feeder is clear before lowering the stone door. The stone door weighs approximately 57 kg (125 lb). To avoid bodily injury, use care when handling the door. Failure to comply could result in serious injury or death. 3. Start the combine engine and engage the threshing and feeder clutches. Press the quick stop button, 1. This will cause the stone door to lower.

4. Shut the combine engine OFF, make sure the parking brake is engaged and the key is removed from the ignition.

86060942

17 Removal and Bearing Replacement NOTE: The seals around the stone door an can be replaced without removing the door from the feeder house. NOTE: The following procedure is the suggested method for bearing replacement. 1. Open the stone door using the procedure described in this chapter of the repair manual. 2. Place jack stands with a minimum capacity of 9000 kg (10 ton) under the front of the feeder house. 3. Support the stone door with forklift and skid or a suitable jack and blocks. Place a block, 1, on the skid to support the front portion of the stone door, 2.

2 1 20021055

60-11

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 4. Loosen the setscrew on the right side bearing lock collar, 1. Use a suitable hammer and punch to rotate the collar counterclockwise (loosen) and remove the collar from the stone door.

20021056

19 5. Remove the four M12 nuts, lock washers, and M12 x 30 carriage bolts, 1, which secure each of the bearing retainers, 2, to the feeder house.

1 1

20021057

20 6. Remove the bearing, 1, and bearing flanges, 2, from the stone door.

20021058

60-12

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 7. Remove the side shields from the left side of the feeder house.

8. Loosen the left locking collar, 1, using a hammer and punch to rotate the collar counterclockwise. 9. Remove the M12 x 40 bolt, 2, which attaches the linkage for the skid plate to the linkage arm on the stone door.

10. Remove the M12 nuts and lock washers from the four M12 x 30 carriage bolts, 3, which secure the housing for the left bearing to the feeder house.

2 20021059

22 11. Lower the stone door away from the feeder house several inches.

12. Remove the linkage arm, 1, from the stone door by loosening the M10 jam nuts and the two set screws, 2. 13. Slide the outer bearing flange, 3, off the stone door.

20021060

23 14. Remove the key, 1, from the shaft extension on the door. 15. Remove the bearing lock collar, 2, and the bearing, 3, from the shaft extension.

20021061

60-13

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 CAUTION

The stone door weighs approximately 57 kg (125 lb). To avoid bodily injury, use care when handling the door. Failure to comply could result in minor or moderate injury. 16. To pull the stone door, 1, away from the feeder, use the help of an assistant to rotate the door on the skid. Lower the door between the feeder hydraulic lift cylinders, 2.

2 20021063

25 Seal Replacement NOTE: The stone door seals can be replaced without removing the door from the combine feeder house. 1. Replace the seals around the stone door if they are damaged or excessively worn. The seals can be replaced by removing the retaining nuts, bolts and plates from the door.

20021052

26 2. Replace the seals and secure using the retaining plates and screws. Do not tighten the retaining screws until the seals have been adjusted to the door opening in the feeder house. Adjust the seals so the distance between the seal and the door opening in the feeder house is approximately 0 -- 1 mm (0 -- 0.040 in), A.

A 20021054

60-14

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 Installation 1. Before installing the stone door, inspect the bearings the door swings on. The bearings should spin freely and have no play. Replace bearings that are damaged or worn. Coat the shaft extensions on the stone door with Loctite anti-seize compound. 2. Install the bearing, 1, and flanges, 2, for the left side of the stone door onto the shaft extensions.

3. Slide the bearing locking collar, 3, on the left side of the stone door. Do not tighten the locking collar yet. 4. Install the key (not shown) into the keyway in the shaft extension. 5. Install the skid plate linkage arm, 4, onto the stone door, but do not tighten the arm down yet.

3 20021060

28 6. Raise the stone door up to the feeder house. Make sure the door is properly aligned to the slots in the feeder house before raising the door to the feeder.

7. Install the bearing and bearing flanges, 2, for right side of the stone door. Secure each side of the door to the feeder house using the four M12 x 30 bolts, 1, for each side. Torque the M12 nuts with lock washers to 97 N⋅m (72 ft-lb). Do not lock the collars for the bearings at this point.

1 1

20021057

29 8. Center the stone door in the feeder house so there is approximately 4.8 mm (3/16 in), A, of space between the door and the feeder house frame on each side.

20021054

60-15

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 9. Once the stone door is centered in the feeder house, lock the bearing collars for each side in place on the stone door bearings. To lock the collars, 1, use a suitable hammer and punch to rotate the collar clockwise on the bearing. Tighten the setscrew once the collar is locked in place.

20021062

31 10. Attach the skid plate linkage, 1, to the linkage arm, 2, using the attaching M12 x 40 bolt, 3, and hardware. Make sure the linkage does not bind, and then tighten the two square setscrews, 4, that secure the linkage arm to the stone door. Torque the setscrews, 4, to 49 -- 60 N⋅m (36 --44 ft-lb). Tighten and torque the jam nut, 5, to 49 -- 60 N⋅m (36 -- 44 ft-lb).

1 3

20021059

32 11. Lower the feeder house and attach the stone door cable, 1, to the combine using the attaching pin, 2. 12. Test the stone door for proper operation. If the door does not raise all the way to latch when the feeder house is raised, tighten the slack in the cable by turning the eye bolt, 3, into the clevis. Turn the eyebolt in only enough for the stone door to close and latch properly.

2 1

20021041

60-16

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 SKID PLATE (INNER PANEL) The skid plate is designed to help expel rocks and crop out of the feeder house through the stone door. The skid plate is located inside the feeder house. The skid plate is attached to the stone door by external linkage and will swing downward when the stone door opens. The three polyethylene wear strips, 1, screwed to the skid plate can be replaced without having to remove the plate from the feeder house. Replace the strips if excessively worn or damaged as follows:

1 20021042

Remove three M8 x 16 flat head machine screws from each wear strip being replaced.

Replace the wear strip, install the screws, and then tighten and torque to 6214 -- 7344 N⋅mm (55 -- 65 in-lb). Removal 1. Open the stone door using the procedure described in this chapter of the repair manual.

2. If not previously done, remove the left front shield from the feeder house. 3. Remove the M12 x 40 bolt with spacer, washer, and locknut, 1, which connects the stone door linkage to the skid plate linkage, 2.

4. Remove the four M12 x 25 carriage bolts, 3, which secure the retaining plate to the feeder house.

3 20021039

35 5. Drive the hex shaft, 1, out of the right side retainer plate, 2, using a suitable hammer and drift.

20021043

60-17

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 NOTE: The spacers and shims for the right side of the skid plate will fall when the hex shaft is removed from the feeder. Use care not to lose these parts.

6. Pull the hex shaft, 1, out the right side of the feeder house. NOTE: It is not necessary to remove the linkage arm, 2, unless servicing the shaft an linkage arm assembly.

20021044

37 7. The skid plate, 1, can then be turned and pulled out of the feeder house through the feeder chain and stone door opening.

20021045

38 Installation NOTE: Steps 1 -- 3 are only necessary if the linkage arm was removed. Coat the hex shaft hexagonal section with Loctite anti-seize compound in either case. 1. Before installing the hex shaft, coat the hexagonal portion of the shaft with Loctite anti-seize compound. Lubricate the bore of the retaining plate, 2, with Molykote G-n Paste. Lubricate the bore of the linkage arm, 1, with Loctite anti-seize compound. 2. Install the two spacers, 4, and the two shims, 3, onto the left side of the shaft. 3. Install the retaining plate, 2, and the linkage arm, 1, onto the hex shaft. Secure the linkage arm to the hex shaft using the retaining bolt.

60-18

20021046

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 4. Install the skid plate, 1, into the feeder house as removed. Make sure the polyethylene wear strips face down and the skid plate is behind (towards the rear of the combine) the pivot point.

20021045

40 5. Remove the four M12 nuts, lock washers and M12 x 25 bolts, 1, which secure the hex shaft retaining plate, 2, to the right side of the feeder house.

1 1

2 20021048

60-19

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 6. Using an assistant’s help, align the skid plate with the hex shaft, 1. The shaft and plate are aligned when the bolt hole, 3, in the hex shaft is 90 degrees from the flat portion of the skid plate, 2. Have the assistant slide the hex shaft, 1, into feeder house when the shaft and skid plate are aligned properly.

20021044

3 2

20021047

43 7. Install the two spacers, 1, and then the two shims, 2, onto the right side of the hex shaft.

20021049

60-20

SECTION 60 - PRODUCT FEEDING - CHAPTER 3 8. Lubricate the bore of the retaining plate, 1, with Molykote G-n Past, and then install onto the right side of the hex shaft. Secure the plate with the four M12 x 25 bolts, lock washers, and M12 nuts, 2. Do not tighten the nuts at this time.

2 2

1 20021048

45 9. Secure the left retaining plate to the feeder house using the four lock washers and M12 nuts, 3. Torque the nuts to 97 N⋅m (72 ft-lb). Torque the nuts for the right retaining plate to 97 N⋅m (72 ft-lb). 10. Check that the skid plate moves freely in the feeder house. Connect the stone door linkage to the linkage arm, 2. Use the M12 x 40 bolt, 1, lock nut, spacer and washers to secure the linkage to the arm.

3 20021039

46 11. Check the alignment of the skid plate in the feeder house and the stone door linkage. There should be 10 mm (0.40 in), A, on either side of the skid plate.

12. If the linkage between the stone door and the skid plate is not aligned, check the distance between the feeder house wall and the center of the linkage arm bolt hole. The distance should be 96.6 mm (3.8 in) ± 1 mm (0.040 in), B. If the measurement is not within specifications, check for the proper amount and position of shims and spacers on both sides of the hex shaft.

B 96.6 mm

20021050

60-21

SECTION 60 - PRODUCT FEEDING - CHAPTER 3

60-22

SECTION 66 - THRESHING - CHAPTER 1

SECTION 66 - THRESHING Chapter 1 - Rotor Chamber CONTENTS Section

Description

Page

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Front Infeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Concave Wear Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Rotor Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Concave Adjusting Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Concave Adjustment Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Concave Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Separator Grates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

66-1

SECTION 66 - THRESHING - CHAPTER 1 DESCRIPTION OF OPERATION This chapter is divided into three portions; the rotor infeed, concaves and separator grates. The rotor infeed consists of the rotor covers, the infeed and wear plates and their supports. These pieces are designed to help the rotors process crop. The infeed and wear plates are removed and replaced when the pieces are worn from use and/or become damaged by foreign materials.

40025287

1 The concaves are located at the front of the rotor tubes and extend the full length of the rotor rasp bars. The clearance between the concaves and the rasp bars is remotely adjustable from the combine cab to suit crop conditions. Extensions are secured with bolts to the concave frames and offer further adjustment to suit crop conditions. Several types of concaves are available to suit different types of crops. Refer to the CR operator’s manual for descriptions of concaves.

10021769

2 The separator grates are located behind the concaves and extend to the discharge beater grate. There are three equally sized separators on each side of the rotor and these separators can be removed for access to the rear portion of the rotor. The separator grates are not adjustable; however, there are two types of grates which are suited for different types of crops. Refer to the CR operator’s manual for descriptions of the separator grates.

10021791

66-2

SECTION 66 - THRESHING - CHAPTER 1 OVERHAUL FRONT INFEED Removal NOTE: Remove feeder assembly as described in Section 60, Chapter 1 of this manual.

1. Lower and remove the concaves, 1, from the combine using the directions described in the CR operator’s manual. NOTE: Concave and extension assemblies weigh approximately 54 kg (120 lb). Assistance may be required when removing the concave assembly.

10021775

4 NOTE: The rotor and bearing plate have been removed for illustrative purposes. The rotors and bearing plate DO NOT need to be removed to remove the front infeed components.

2. Remove the infeed side casting, 1, by removing the two bolts on both the side and bottom of each casting. The side bolts (only one shown), 2, and the rear bottom bolts (only one shown) are accessible through the concave area and the front bolt for each casting is accessible under the feed plate assembly.

3 4

1 40025287

3. Remove the infeed center casting, 3, by removing the three bottom mounting bolts. The front mounting bolt is accessible from under the feed plate, 4. The two rear bolts are located at the center of the concave area.

4. Remove the infeed wear plates, 5.

1 2

20025288

66-3

SECTION 66 - THRESHING - CHAPTER 1 5. Remove an auger lug, 1, from each rotor. If the combine is equipped with a two-speed gearbox, place the gearbox in the neutral position and rotate the rotors so the portion of the rotor where the lug was removed is at the top portion of the side plate. If the combine is not equipped with the two-speed gearbox, the rotors must be rotated so the portion of the rotor where the lug was removed lines up with upper portion of the side wear plate.

1 40025292

7 6. Remove the two front bolts, 1, which secure each side wear plate to combine frame.

40025290

8 7. Remove the two upper bolts, 1, which secure the side wear plates to the rotor cover. The front bolt, 2, can also be removed to ease removal of the wear plate.

8. Remove the side plates by breaking the RTV silicone sealant bead and pulling the side plates out through the concave area.

40025289

66-4

SECTION 66 - THRESHING - CHAPTER 1 NOTE: There are three mounting bolts for each side of the feedplate weld assembly. Only two are shown in the illustration. The two shown are in front of the concave area, the third is accessible at the concave area.

9. Remove the feedplate weld assembly, 1, by removing the six mounting bolts, 2, which secure the plate assembly to the combine frame. Remove the feedplate from the combine.

2 20025291

10 Installation

1. Install the feedplate weld assembly, 1, into the combine. The leading edges of the assembly are the bases for the welded triangular plates. Secure the assembly to the combine frame using the six bolts, 2.

2 20025291

11 2. Place the side plates into position through the concave area. Make sure the rotors are positioned properly to allow this. 3. Install the two front bolts, 1, which secure each side plate to combine frame.

4. Run a bead of silicone sealant along the leading edge of the wear plates.

40025290

66-5

SECTION 66 - THRESHING - CHAPTER 1 5. Install the two upper bolts, 1, which secure the side wear plates to the rotor cover. Align the wear plates with the rotor tubes and tighten the bolts.

1 2

40025289

13 6. Install the front auger lugs, 1, removed from each rotor using the three mounting bolts and nuts for each lug.

1 40025292

66-6

SECTION 66 - THRESHING - CHAPTER 1 NOTE: The bearing plate and rotor have been removed for illustrative purposes.

7. Install the infeed center casting, 2, onto the feedplate weld assembly. Make sure that the groove in the rear of the center casting is engaged with the center concave adjusting plate, 4. Install the three bolts that secure the center casting to the feedplate. The two rear bolts are accessible through the concave area and the front bolt is accessible at the front of the feedplate.

2 1 40025287

15 8. Install the side castings, 1, onto the front feedplate assembly through the concave area. Secure the castings to the feedplate and frame using the four mounting bolts, 3.

1 3

20025288

16 9. Install the concaves, 1, into the combine using the directions described in the CR operator’s manual.

10021775

66-7

SECTION 66 - THRESHING - CHAPTER 1 10. Install the combine feeder house using the procedure described in Section 60, Chapter 1 of this manual.

20021040

CONCAVE WEAR PLATE Removal NOTE: The front rotor cover and rotor are removed for illustrative purposes.

1. Remove the seven bolts, 2, securing the wear plate weld assembly, 1, to the combine frame.

40025287

19 NOTE: The top bolts, 2, are used to sandwich the wear plate between the frame and the rotor covers. Additional bolts along this seam may need to be loosened because the wear plate is sandwiched between the frame and the top covers.

2 40025293

66-8

SECTION 66 - THRESHING - CHAPTER 1 NOTE: Assistance is needed in removing the wear plates. 2. Using prying bars, 1, raise the rotor covers to allow the top of the wear plates to slide out between the covers and the combine frame. Remove the wear plates, while rotating the rotor as necessary to ease removal.

40025294

21 NOTE: The front rotor cover and rotor have been removed for illustrative purposes.

3. Remove the separator wear plates, 1, from each rotor tube by removing the 11 bolts (six are shown), 2, which secure each plate to the combine frame. The top portion of the plate is secured between the rotor covers, 3, and the combine frame. The lower portion of the wear plate is secured between the combine frame and the separator grates, 4.

40025287

4 40025295

66-9

SECTION 66 - THRESHING - CHAPTER 1 4. Remove each wear plate, 1, from the combine through the concave area. If necessary, rotate the rotors or remove a rotor blade, 2, to allow the plate to be removed.

1 2

40025296

24 Installation NOTE: Be sure the rear wear plates are properly oriented before installing them into the rotor tubes. The wider mounting surface should be in the upper position. 1. Place a rear wear plate, 1, into the rotor tube. If necessary, rotate the rotor to ease positioning. Once the wear plate is positioned, install the rotor blade, 2, if removed. If rotor blades are removed, ensure that the blades are installed in the same position.

1 2

3 40025296

2. Position the top of the wear plate between the rotor cover and combine frame and position the bottom of the wear plate between the combine frame and the separator grates, 3.

3. Install the bolts, 1, which secure the rear wear plate in the rotor tube. DO NOT tighten the bolts at this time.

40025295

66-10

SECTION 66 - THRESHING - CHAPTER 1 NOTE: The front rotor cover and rotor have been removed for illustrative purposes.

4. Place the front wear plate weld assembly, 4, into the rotor tube. The upper lip of the wear plate is fitted between the rotor cover and combine frame. 5. Install the seven bolts, 5, which secure the front wear plate weld assembly to the combine frame. DO NOT tighten the bolts at this time. 6. Move the rear wear plate, 1, so the upper and lower edges of the plate are even with the rotor cover, 2 and the separator grates, 3. Once the plate is even, tighten the 11 bolts that secure the plate in the rotor tube.

1 4 3 40025287

7. Move the front wear plate weld assembly, 4, so the upper and lower edges are even with the rear wear plate and the separator grates, 3.

8. Once the wear plates are positioned properly, tighten the mounting bolts that secure each plate to the combine frame. 9. Repeat this procedure for the opposite rotor chamber.

5 40025293

ROTOR COVERS Removal There are two large covers and one small cover for each of the combine rotors. Use the following procedure to remove the rotor covers. 1. The rotors, 1, must be removed to allow enough clearance for the covers to be removed. Using the procedure described in Section 66, Chapter 2, remove the rotors from the combine. NOTE: This only applies to the 22-inch rotor. The 17-inch rotor does not have to be removed to remove the rotor covers.

66-11

1 10025278

SECTION 66 - THRESHING - CHAPTER 1 2. Remove the rear access panel in the combine grain tank.

3. Remove the two small front access panels, 1, in the combine grain tank.

20025297

20030359

31 4. Remove the bolts that secure the front portion of the rotor covers and seam plate of the combine frame. The front rotor covers are rotated down into the rotor tube and are removed from the front of the combine. NOTE: This only applies with the 22-inch rotors. The rotor covers for the 17-inch rotor should slide straight forward and out of the rotor chamber.

66-12

SECTION 66 - THRESHING - CHAPTER 1 5. Remove the bolts for the rear left and right rotor covers, 1, and the seam cover (or seal) plates, 2. These bolts can be accessed through the rear grain tank access panel. The small upper rearmost covers, 3, can also be removed from the frame.

6. Once the covers are unbolted, they can be lowered into the rotor tube and removed through the front of the combine, just as the front covers were removed. 10025284

1 32

Installation 1. Slide the rear rotor cover for the left and right rotors up the corresponding rotor tube. Secure the rear covers, 1, onto the frame using the mounting bolts. Do not install the upper covers or joining plates at this time.

1 40030344

33 2. Install the left and right front covers onto their corresponding rotor tube. Secure the covers to the combine frame using the mounting bolts. Be sure to install the joining plate where the front cover and rear cover meet.

20030359

66-13

SECTION 66 - THRESHING - CHAPTER 1 NOTE: There are two large covers and one small cover for each of the combine rotors. Use the following procedure to remove the rotor covers. 3. Using the procedure described in Section 66, Chapter 2, install the rotors, 1, into the combine.

1 10025278

35 4. Install the rear access panel in the combine grain tank.

5. Install the two small front access panels, 1, in the combine grain tank.

20025297

CONCAVE ADJUSTING MOTOR Removal 1. Park the combine on a flat surface and engage the parking brake. Remove the key from the ignition.

2. Remove the rear grain tank access panel.

3. Use a wrench to rotate the hexagonal hub, 1, which connects the adjusting motor, 2, to the threaded adjusting rod until the bottom groove pin, 3, can be removed easily. 4. Use a suitable hammer and punch to drive the lower groove pin out of the coupler and motor shaft. 5. Slide the motor out of the hub and disconnect the motor wiring harness connection, 4, for the motor.

66-14

2 20030345

SECTION 66 - THRESHING - CHAPTER 1 Inspection

NOTE: If the motor is suspected of being faulty, the unit should be connected to a 12-volt power supply and tested for proper operation. 1. Clean any dirt or debris from the motor using a suitable solvent. 2. Using a 12-volt power source, such as a battery, 1, connect the battery terminals to the terminals in the motor wiring harness connector, 2. If the positive (+) red cable is connected to the positive terminal of the battery and the negative (--) cable is connected to the black or yellow terminal of the battery, the output shaft, 3, should turn clockwise (when looking at the output shaft from the motor side). Reversing the terminals should cause the motor output shaft to rotate counterclockwise. The output shaft should rotate in either direction at 17 ± 2 rpm with no load.

20030346

3. If the output shaft does not rotate, rotate smoothly or turn fast enough, the motor must be replaced. The motor is not serviceable and must be replaced as an entire unit.

Installation 1. Coat the output shaft of the adjusting motor, 2, with LoctiteR anti-seize compound. Insert the adjusting motor output shaft into the hexagonal coupler, 1. 2. Align the through hole in the motor output shaft with the holes in the coupler. Drive the groove pin, 3, into the coupler and output shaft using a hammer and punch. 3. Connect the motor wiring harness connector, 4, to the combine wiring harness. 4. Check the motor for proper operation and that the concaves adjust properly. 5. Replace the rear grain tank access cover.

66-15

3 2 20030345

SECTION 66 - THRESHING - CHAPTER 1 CONCAVE ADJUSTMENT LINKAGE Removal

20030360

40 1. Park the combine on a flat surface and engage the parking brake. Lower the concaves to their lowest position. Remove the key from the combine ignition switch. 2. Remove the concaves from the combine. Refer to the operator’s manual for the concave removal procedure. 3. Place a flat board, 1, across the combine frame at the concave area. Use wooden blocks to support the concave center plate, 2.

40030348

41 4. Remove the rear grain tank access panel.

5. Remove the concave adjusting motor using the procedure described earlier in this chapter.

6. Remove pin, 6. Remove the two limiting nuts, 4, from the top of the threaded rod. Unscrew the threaded rod from the adjusting nut, 5.

7. Remove the upper groove pin, 1, from the hexagonal coupler and threaded rod, 2. Slide the coupler, 3, and thrust washer off. 8. Remove the threaded rod out of the front rod support, using care not to lose the thrust washer.

6 1 20020347

3 42

66-16

SECTION 66 - THRESHING - CHAPTER 1 9. Disconnect the small linkage rod, 1, for the concave potentiometer.

10. Remove the shear bolt, 2, securing the arm, 3, for the linkage rod to the rear linkage arm, 4.

11. Remove a cotter pin from either side of the large pin, 5, that secures the rear linkage arm. Use care not to lose the shims on the pin. Drive the pin out of the center beam channel using a hammer and punch.

40030349

43 12. Remove the front grain tank access covers, 1.

20025297

44 13. Remove the lower linkage pin, 1, from each of the front linkage arms.

40030350

66-17

SECTION 66 - THRESHING - CHAPTER 1 14. Remove the two bolts securing each of the hub assemblies, 1, to the center plate.

40030351

CAUTION The center plate is awkward and heavy. Use care when removing the center plate from the combine. Assistance may be required when removing this plate. NOTE: Use a paint marker or other marking device to mark the center plate to indicate its front. NOTE: The rotor was removed for illustrative purposes. 40030348

15. Remove the wooden blocks from underneath the center plate and lower the center plate out of the rotor tube frame.

16. Remove the large pivot pin, 1, which goes through each of the linkage arms, 2. Use care not to lose any of the washers from the pins during removal.

40030350

66-18

SECTION 66 - THRESHING - CHAPTER 1 17. Remove the pins, 1, which secure the linkage rod to each of the linkage arms, 2. Slide the adjusting rod out the front of the combine.

18. To remove the linkage arms, disconnect the grease lines, 3, from each of the arms at the grease fitting.

1 40030352

49 Inspection 1. Clean all parts using a suitable solvent and allow the parts to dry.

2. Inspect the parts for damage such as cracks, bends, or wear. Inspect the threads in the threaded rod for damage. Replace any parts that are damaged. 3. Inspect the condition of the rubber dust seal, 1, for the center plate. Replace the seal if it is torn, damaged or excessively worn. 20030354

66-19

SECTION 66 - THRESHING - CHAPTER 1 Installation 1. Adjust the front portion of the linkage rod, 1, so the initial distance between the front arm mounting holes is 584 mm (23.0 in), center to center. To adjust the rod, loosen the lock nut, 2, and turn the adjuster, 3, clockwise or counterclockwise, as needed.

20030353

51 (584) 50

20030361

52 2. Install the linkage rod, 1, into the combine. Make sure the adjustable end of the rod is at the front of the combine.

3. Attach the rod to each of the linkage arms, 2, using the pins removed during disassembly. The pins must be installed in the same orientation as removed, with the head of the pin on the left side of the linkage rod.

2 40030352

66-20

SECTION 66 - THRESHING - CHAPTER 1 NOTE: Make sure there is an equal amount of shims on each side of the pivot pin when installing the pin into the arm.

NOTE: Apply a coating of lithium grease to each pin during installation. 4. Align each of the linkage arms, 3, with the ears on the concave center channel and install the arm pivot pin, 2, for each of the arms. Make sure there is an equal amount of shims, 4, on each side of the pivot pin when installing the pin into the arm.

4 2

40030350

5. If the arms were removed from the combine, install the grease line for each arm. Be sure to use the grease fittings located above the right drive tire to lubricate the arms once the linkage is installed.

6. Install each of the lower linkage pins, 1, through the front and rear of the center plate assembly. Place a washer on each of the pins and secure using a cotter pin. NOTE: Apply a coating of lithium grease to the pins and the inner bores of the arms during installation.

7. Align the linkage arms, 3, 4, with the rotor tube center channel. Install the large pin, 5, making sure there is an equal amount of shims on each side of the pin. Secure the large pin using a cotter pin.

8. Install the bolt, 2, securing the arm, 3, for the front linkage rod to the rear linkage arm, 4. 9. Connect the small linkage rod, 1, for the concave potentiometer.

40030349

55 NOTE: Apply a coating of lithium grease to the threaded rod before installation.

4 5

10. Turn the threaded rod, 2, into the adjusting nut, 5. Install the two limiting nuts, 4, onto the top of the threaded rod. Jam the nuts so they cannot turn on the threaded rod.

11. Place the thrust washer on the front of the threaded rod and place the rod into the front rod support. 12. Place the remaining thrust washer onto the threaded rod. Slide the coupler, 3, onto the threaded rod and install the groove pins, 1 and 6.

66-21

6 1 20020347

3 56

SECTION 66 - THRESHING - CHAPTER 1 13. Install the concave adjusting motor, 1, using the procedure described earlier in this chapter. 14. Check the movement of the concave adjustment linkage by turning the combine ignition switch to the “ON” position and using the adjusting switch on the control console.

15. If the limiting nuts, 2, were moved, they must be adjusted so the concaves will not get any closer than 2 mm (0.080 in) to the rotors. Once the limiting nuts are adjusted properly, jam the nuts so they will not move on the threaded rod.

1 20030345

57 NOTE: The rotor has been removed from the combine for illustrative purposes. 16. Install the center plate, 1, into the combine, using the mark made during removal as a reference to properly orient the plate. The front edge of the plate is identified by measuring the distance between the center of the mounting holes to the edge of the plate. The distance at the front of the plate is 50 mm (2.0 in). 17. Position a board, 2, across the combine frame and use a wooden block(s), 3, to support the center plate in the rotor tube frame.

3 1

40030348

58 (584) 50

20030361

66-22

SECTION 66 - THRESHING - CHAPTER 1 18. Install the two bolts securing each of the hub assemblies, 1, to the center plate. The portion of each assembly with the hub eye goes through the left side of the center plate.

40030351

60 19. Install the concaves, 1, into the combine, using the procedure described in the CR operator’s manual.

10021775

61 20. Using the procedure described in this chapter, check the adjustment of the concaves. The distance between the concave and the rotor from the front to the rear of the concave must be equal. When the distance is not equal, the center plate must be adjusted. This adjustment is located at the front of the long linkage rod. To adjust the rod, 1, loosen the lock nut, 2, and turn the adjuster, 3, clockwise or counterclockwise, as needed. Extending the rod lowers the front of the center plate and retracting the rod raises the front of the center plate.

40030355

66-23

SECTION 66 - THRESHING - CHAPTER 1 CONCAVE FRAME Adjustment The rotor concaves must be adjusted so that they are centered laterally beneath each of the rotors. Concave adjustment is the same for combines equipped with 17-inch rotors and combines equipped with 22-inch rotors. The left and right rotor clearances are adjusted independently of each other. NOTE: This procedure is only required if the concaves are no longer centered in relationship to the rotor. Concaves are centered from the factory and should only need adjusting if the concave adjustment plates have changed position by a large overload to the concaves and latches.

10021777

NOTE: The concave extension must be removed before adjustment is made to the concaves. 1. Turn the combine ignition key to the “ON” position. Use the concave clearance switch, 1, on the right side console to raise the concaves to the highest position (closest to the rotors). 2. Remove the concave covers from the side of the combine frame. 3. A measuring gage is necessary to measure the distance between the rotor and the concave. Using wire and/or steel stock, manufacture the tool as described for the appropriate combine: •

•

17-Inch Rotors: A piece of square stock that is 5 mm (.187 in) thick should be used. Bend the stock or weld a piece of curved wire to the END of the stock so that the gage can be placed between the rotor and the concave. 22-Inch Rotors: A piece of stock that is 6 mm (.25 in) thick should be used. Bend the stock or weld a piece of curved wire to the END of the stock so that the gage can be placed between the rotor and the concave.

66-24

50030357

SECTION 66 - THRESHING - CHAPTER 1 NOTE: A 17-inch rotor is shown. The 22-inch rotor is similar. 4. Using the measuring gage, check the clearance between the rotor rasp bar and the concave rub bar, at 1, that is closest to the center of the combine at three points (front, center, rear) along the length of the concave. Perform this measurement for both rotors, rotating the rotors as necessary so the rasp bar(s) is at the centermost rub bar. If the clearance between the concave and rotor (front to back) varies more than 2 mm (.078 in), proceed to step 10.

1 20030356

65 NOTE: Have an assistant inside the combine cab help with adjusting the concave clearance switch (referenced previously) while the other person checks the dimension between the concave and the rotor with the measuring gage.

5. Loosen the center nut, 1, on both adjusters. Ensure that the other four bolts on each adjuster remain tight. 6. Adjust the concave in or out by loosening or tightening the draw nut, 2, on each side of the concave cover to obtain the gage clearance at the first and last rub bars of the rotor. Several attempts will normally be needed before the proper dimension is achieved.

2 50033123

7. When the proper clearance is achieved, tighten both center nuts. 8. Replace the concave extension. 9. Replace the concave cover, 1.

50033124

66-25

SECTION 66 - THRESHING - CHAPTER 1 10. If the concave clearance from front to rear is greater than the tolerances allow, the linkage rod, 1, must be adjusted. To adjust the rod, loosen the lock nut, 2, and turn the adjuster, 3, clockwise or counterclockwise, as needed. Extending the rod lowers the front of the center plate (more clearance) and retracting the rod raises the front of the center plate (less clearance). 11. Repeat steps 4 thru 6 if the linkage rod required adjustment. 12. Check the concaves and concave adjusting linkage for proper operation.

40030355

13. Install the concave side covers onto the combine frame.

SEPARATOR GRATES Removal NOTE: There are three separator grates on each side of the combine. Before removing the front and center grates, the returns deflector along the side of the combine should be removed. The rotor loss sensor must be removed when removing the rear grate. NOTE: When removing the attaching hardware, the separator grates, which weigh approximately 50 lb., must be supported with either a hand or support bar during removal.

1 2

3 3

1. Remove the separator grate access cover, 1, on each side of the combine by loosening its handles, 2, and rotating the clips, 3, downward. Grip the cover by its handle and remove the cover by pulling it straight out. 50020166

2. Remove the two bolts and nuts and washers, 1, that secure the rotor loss sensor assembly, 2, and move it out of the way for better access to the rear grates.

50054008

66-26

SECTION 66 - THRESHING - CHAPTER 1 3. If removing the front and center sections on left and right sides of the combine, remove the two cap screws, 1, nuts and washers that secure the returns deflectors, 2, and remove both deflectors.

1 2 50020156

71 NOTE: The front rotor cover and rotor were removed for illustrative purposes. 4. Remove the front bolt, 1, and rear bolt (not shown) which help to secure the front and rear separator grates. Remove the bolts that are located between the adjacent grates (not shown) but within the same location as the bolt indicated.

1 40025287

66-27

SECTION 66 - THRESHING - CHAPTER 1 5. Remove the cap screws, 1, that secure the separator grates to the frame. Ensure that each grate is supported by hand or with a support bar during its removal.

40025295

73 6. Lower the separator grate, 1, onto plywood or heavy plastic plate. Rock the center of separator grate off of center divider plate and remove.

7. Check all separator grates for damage or wear and replace if necessary. Installation 1. Install the separator grates in the reverse order in which they were disassembled.

50020158

66-28

SECTION 66 - THRESHING - CHAPTER 2

SECTION 66 - THRESHING Chapter 2 - Rotors CONTENTS Section

Description

Page

66-1

SECTION 66 - THRESHING - CHAPTER 2 DESCRIPTION OF OPERATION

20021767

1 between the rotor and concaves several times. This allows for more efficient and complete threshing to reduce the risk of crop loss.

The CR combines are equipped with two different size rotors. The CR9040 and the CR9060 are equipped with two 17-inch diameter rotors, while the CR9070 is equipped with two 22-inch diameter rotors. The rotors are driven by the rotor gearboxes, covered in Chapter 3 of this section of the CR repair manual.

Any remaining grain and crop residue is transported to the rear half of the rotor where the rotor transport blades and separator grates separate the remaining grain from the crop residue by centrifugal force.

Both sizes of rotors incorporate augers at the front of the rotor to transport crop material to the threshing area. Replaceable rasp bars are at the front portion of each rotor, behind the auger. Rasp bars thresh the crop against the concaves. Replaceable transport blades are at the rear portion of the rotor to force the crop material against the separator grates. Rotors may also have “fingers” installed at the rear portion of the rotor. These fingers are helpful in separating grain in long, wet straw conditions such as a rice crop.

Grain drops through the concaves and separator grates onto the grain pan where the grain is cleaned. Any material remaining in the rotor chamber is conveyed out the back of the rotor and to the discharge beater. The rotor speed and concave clearance--distance between the rotors and concave are adjustable and should be altered accordingly to crop and conditions. Improper rotor speed and/or concave clearance can result in poor threshing performance. If either rotor speed or concave clearance is incorrect, under threshing, over-threshing and/or grain damage could occur.

The rotors are designed to rub the crop against the concave rub bars and concave wires. The movement of crop rearward is controlled so the crop passes

66-2

SECTION 66 - THRESHING - CHAPTER 2 TIGHTENING TORQUES Tightening torque

Description

N⋅m

ft-lbs

Auger Flight

34 -- 37

24 -- 27

Front Rotor Flange

54 -- 60

40.1 -- 44.4

217 -- 240

160 -- 177

Rotor Blades

31 -- 35

21 -- 24

Counter Weight

27 -- 30

20.2 -- 22.3

Outer Drive Coupler -- 17″ Rotor

95 -- 105

70 -- 77

Outer Drive Coupler -- 22″ Rotor

235 -- 260

173 -- 192

Rasp Bars

66-3

SECTION 66 - THRESHING - CHAPTER 2 OVERHAUL RASP BAR Replace NOTE: Rasp bars may be replaced with the rotor installed in the combine, or with the rotor removed. 1. If the rotor is installed in the combine, remove the concaves, as described in the Operator’s manual, or lower the concaves, and remove the upper extension from the concave frame. 10021778

2 2. Remove the bolts, 1, retaining the rasp bar to be replaced. Carefully remove the rasp bar from the rotor, using care to retain any shims installed between the rasp bar and mount. The shims must be reinstalled in the same location with the new rasp bar. Install the new rasp bar, using the original shims in the same locations, and secure using two new bolts. Torque the bolts to 217--240 Nm (160--177 ft-lbs).

IMPORTANT: Be sure to thread the rasp bar bolts into the rasp bar holder a minimum of four complete turns, by hand, before installing a wrench. Failure to have the bolts properly threaded into the rasp bar holder may result in damage to the holder.

86060071

3. Rotate the rotor, and replace the opposing rasp bar on the rotor, using the same process described above. IMPORTANT: The rasp bars must be replaced as a balanced set to maintain rotor balance. Replace the rasp bars as a set of two 180 degrees apart on 17 inch diameter rotors (CR9040, CR9060), or as a set of three 120 degrees apart on 22 inch diameter rotors (CR9070). 4. Reinstall the concave and concave extension. NOTE: If the rasp bars are properly replaced as matching sets, and the original shims are reused in the same locations, it should not be necessary to rebalance the rotor, or to shim the rasp bars to obtain the correct rotor diameter.

66-4

SECTION 66 - THRESHING - CHAPTER 2 Shimming If all rasp bars are being replaced, or if the original shims are not reused, the rasp bars must be shimmed to the same radius to ensure proper threshing performance of the rotor. This shimming may be done with the rotor installed in the combine, or with the rotor removed.

1 2

1. If the rotor is installed in the combine, remove the concave extension from the concave frame by removing the two capscrews, 1, and lifting the extension off the lower pins, 2. Use the concave position switch in the cab to fully raise the concaves.

10021780

2. Use the outer rub bar, 1, on the concave as a reference to reshim the rasp bars correctly. Use shims to set all rasp bars to the same clearance to the concave rub bar.

1 20033128

5 3. If the rotor is removed from the combine, the rasp bars may be shimmed while the rotor is set up on jack stands for balancing. Clamp a straight edge to a jack stand, and position it at 62 mm (2--1/2 inches) from the rotor tube. Ensure the straight edge is parallel to the rotor tube. Use shims under the rasp bars to set all rasp bars to the same clearance to the straight edge. IMPORTANT: The rasp bars should be shimmed before completing the rotor balancing. The rasp bar shimming should also be rechecked when the rotor is reinstalled in the combine, using the method described in step 2 above.

20033119

66-5

SECTION 66 - THRESHING - CHAPTER 2 ROTOR Removal

WARNING Anytime the combine feeder house is being serviced or adjusted, ALWAYS stop the combine engine, engage the parking brake, remove the key from the ignition and engage the feeder safety lock, 1. Failure to follow this warning may result in serious injury or death. 1. Remove the combine feeder house using the procedure described in Section 60, Chapter 1 of the CR combine repair manual.

86060925

1 7

2. Remove the separator grate access doors from each side of the combine.

CAUTION BOTH rotors MUST BE secured in the combine, otherwise personal injury or machine damage may occur. Be sure the bolt that secures each rotor in the combine is grade 10.9 hardware or better and at least 140 mm long.

3. Use a high strength (grade 10.9 or better) M16 x 140 mm bolt, 1, to secure each rotor in the combine. Thread the bolt into one of the threaded holes in the rotor at the separator grates. Be sure the bolt is threaded completely into the rotor and the upper portion of the bolt is resting against the separator grate.

10025266

4. Remove the snap ring, 1, securing the feeder position arm, 2, to the combine frame. Disconnect the linkage, 3, and remove the arm.

10025267

66-6

SECTION 66 - THRESHING - CHAPTER 2 5. Disconnect the rotor speed sensor, 1, from the combine wiring harness, 2. Position the wiring harness out of the way.

6. Remove the bolt retaining the rotor speed sensor pickup, 3, to the left rotor.

10025268

3 10

7. Remove the bearing collar, 1, from the front of each rotor by first loosening the setscrew in each collar. Use a suitable hammer and punch to tap the collar in the direction opposite of rotation until loosened.

10025269

11 NOTE: The wiring harness does not have to be removed when removing the two rotors. Use care when removing the rotor to ensure that the wiring harness is not damaged. Secure excess wire harness with wire ties as needed.

10025271

66-7

SECTION 66 - THRESHING - CHAPTER 2 NOTE: There are shims located between the front bearing plate and each rotor. Use care not to lose any shims when removing the front bearing plate.

8. Remove mounting bolts for the front bearing plate, 1, and the two front covers, 2. There are two hidden bolts located behind the bearing plate in the middle of the rotor chambers.

9. Carefully pry the bearing plate off the combine frame. Assistance is required when removing the front cover. 10025273

13 10. Remove the shims, 1, from each rotor. Place the shims for each rotor in a separate storage container such as a plastic bag and label the bag. Use care not to lose any of the shims.

1 2

11. Remove the six bolts that secure the front rotor flange, 2, to the rotor(s) being removed. Tap the flange of the rotor using a soft mallet or dead blow hammer to help in its removal.

10025274

14 NOTE: The rotor removal tool consists of the rotor assembly handling bracket, a rear support and a rotor adapter (not shown). The rear support slides into the handling bracket to help support the rotor when it is being removed and inserted into the combine.

12. Loosen and remove the hardware that secures the rotor rear support, 1, (tool #380000916) to the rotor assembly handling bracket, 2, (tool #380000806) and remove the upright from the rear support slide rail.

4 2 10030055

13. Insert the blades of a forklift into the two slots, 3, on the bottom of the rotor assembly handling bracket.

14. Secure the rotor assembly handling bracket to the forklift using chains that are secured by wrapping the chains around the bars, 4, of the handling bracket. This ensures that the removal tool will not slide off the forklift.

66-8

SECTION 66 - THRESHING - CHAPTER 2 WARNING

Be sure to use grade 10.9 or higher hardware to attach the rotor support adapter (tool #380001139) to the front of the rotor. Using bolts that are rated lower than grade 10.9 may cause the rotor(s) to disengage when removed from the combine, causing personal injury or death.

15. Insert the rotor adapter, 1, into the end of the rotor assembly handling bracket. Use the forklift to align the rotor adapter on the removal tool with the rotor, 2, that is being removed.

10025277

16. Install six M10 x 50 mm minimum grade 10.9 bolts, 3, through the rotor support adapter and into the rotor. Tighten the bolts evenly so the rotor is attached firmly to the rotor’s mounting flange.

WARNING The rotors are heavy! Be sure that rotor is properly attached to the rotor removal tool before removing it from the combine. Injury or death may occur from falling rotors if the rotor is not properly secured to the rotor removal tool. DO NOT remove the rotor from the combine without supporting the rear of the rotor with the rear support assembly. Stay clear of the rotor during its removal from the combine. NOTE: An assistant should help to drive the forklift and/or to help guide the rotor out of the combine.

10025278

1 17

NOTE: The retaining bolt that was installed in step No. 3 to secure the rotor must be removed before the rotor is removed from the combine. 17. Using the help of an assistant, remove the rotor from the combine. For every few inches the rotor is removed from the front of the combine, the rotor must be lowered a few inches using the forklift. 18. Install the rotor rear support, 1, once the rotor has been removed enough from the combine to allow extension of the rear support slide rail. Extend the slide rail and insert pin through frame and rail and reinstall upright. Use care not to damage the cab platform with the rotor. The rotor may need to be rotated and/or twisted as it is removed to avoid interferences. 19. Repeat previous steps if the remaining rotor is being removed.

66-9

SECTION 66 - THRESHING - CHAPTER 2 Inspection 1. Inspect the front auger extension and auger lugs, 1, of the rotor for damage or excessive wear. Replace any parts that are worn or damaged.

1 2

2. Inspect the rasp bars, 2, for damage or excessive wear. Replace rasp bars as a matched set, if damaged. 3. Inspect the rotor body for dents, cracks, and wear from foreign objects. Repair or replace the rotor as necessary. 4. Inspect the rotor blades, 3, for damage or excessive wear. Replace the blades as necessary.

50033125

5. If the rotor is equipped with fingers, inspect the fingers, 4, for damage or wear. Replace as necessary. Check the fingers for tightness. Apply LoctiteR 271 to any fingers that are loose. 6. Inspect the front bearing shaft for the rotor. Check for scoring, pitting or any other damage or excessive wear to the shaft. Replace as necessary.

10025280

19 7. Inspect the rotor bearings, 1, in the front bearing plate to ensure smooth rotation and no lateral play. Replace the complete bearing and housing assembly, 2, if any deficiency is found with the bearing rotation or lateral stability. IMPORTANT: Do not attempt to replace the bearing only. The housing and bearing assembly are assembled and tested to meet critical specifications. Failure to comply may cause serious damage to the combine. 8. Inspect the front bearing plate for damage or wear. Check the seals on the plate and combine frame. Replace the plate or seals if damaged.

66-10

1 2

10025279

SECTION 66 - THRESHING - CHAPTER 2 9. Inspect the outer drive coupler, 1, of the rotor gearbox coupling for damage or excessive wear. Replace the coupler if the teeth are damaged or worn. If the outer drive coupler is worn, be sure to check the wear of the inner coupler located on the rotor gearbox.

10025281

21 Balancing To ensure proper, vibration-free operation, each rotor is balanced by setting it upon two jack stands, 1. A rotor rear balancing adapter and two sets of bearings are used to balance the rotor. The rotors must be balanced when repairs have been made to the rotor body, such as repairs due to foreign object damage or if the front auger portion of the rotor has been repaired.

Use the following procedure to balance the rotors: 20033119

22 1. While the rotor is still mounted on the rotor removal tool, remove the outer drive coupler, 1, from the rear of the rotor by removing the eight coupler mounting bolts, 2.

2 20033115

66-11

SECTION 66 - THRESHING - CHAPTER 2 NOTE: The rotor rear balancing adapter, 1, (#380000916) is designed for either a 17-in. diameter rotor or a 22-in. diameter rotor. The smaller diameter, 2, of the rotor rear balancing adapter faces outwards from the rear of the rotor when balancing 22-inch diameter rotors. Eight M16 x 40 mm bolts are used to secure the adapter in the 22-inch diameter rotor during balancing. The bearings, 3, are inserted over the flange of the rear balancing adapter.

20033116

24 NOTE: The larger diameter of the rotor rear balancing adapter faces outwards from the rear of the rotor when the adapter is being used for balancing 17-inch rotors. The adapter is secured to the 17-inch diameter rotor using six M12 x 40 mm bolts in the holes, 1, in the inner bolt circle.

20033121

25 2. After determining what size rotor is being balanced, install the rotor rear balancing adapter, 1, onto the rear of the rotor. Insert the bolts, 2, to secure the tool to the rotor. Slide one bearing assembly, 3, onto the sleeve of the rotor rear balancing adapter.

3 1 2

20033117

66-12

SECTION 66 - THRESHING - CHAPTER 2 3. Install the other bearing assembly, 1, over the front rotor shaft, 2.

2 20033120

DANGER Be sure the area around the rotor is free from people and obstacles. Rotors are very heavy and can inflict severe injury or death if they are not handled properly. 4. Use a fork lift or overhead hoist and lifting straps to set the rotor onto a set of jack stands that have a V-groove, 1, in the center of the support. Make sure the bearings, 2, are positioned in the center of this groove and that the rotor turns easily on the bearings without striking the jack stands, 3. Place the rear jack stand as close to the rear of the rotor as possible.

1 3 20033118

NOTE: The rotor should turn freely on the bearings. If the rotor does not turn freely, the tool bearing(s) may be damaged and have to be replaced. 5. Once the rotor is positioned on the two jack stands, 1, spin the rotor slowly several times, noting where the rotor stops after each spin. If the rotor stops at approximately the same point after each spin, the rotor is out of balance.

20033122

66-13

SECTION 66 - THRESHING - CHAPTER 2 6. If the rotor needs to be balanced, add rotor weights, 1, to the rear of the rotor. Torque the rotor weight bolts to 27 -- 30 N⋅m (20.2 -- 22.3 ft-lbs). The weight is added to the opposite (top) side of the rotor from the point where the rotor stopped. No more than 10 weights are added to the rear of the rotor. If more weight is necessary, weld weights to the front of the rotor. The shape of the weight may vary from the illustration, but the weight must not be any thicker than 13 mm (0.5 in.).

20033127

30 Installation

WARNING Be sure to use the proper grade of hardware, 1, to attach the rotor removal tool to the rotor. Using bolts that are rated lower than grade 10.9 in the rotor support adapter may cause the rotor(s) to disengage when inserting it into the combine, causing possible personal injury or death. 1. If the rotor was removed from the rotor removal tool, use a forklift or overhead hoist to lift and attach the rotor to the removal tool. Be sure the bolts that secure the rotor support adapter, 2, to the rotor, 3, are tightened evenly so the rotor is firmly attached to the tool’s mounting flange. 2. Insert the forklift into the two slots in the bottom of the rotor removal tool. Secure the forklift to the rotor removal tool by wrapping chains around the bars of the removal tool and connecting them to the forklift.

66-14

3 10025277

2 31

SECTION 66 - THRESHING - CHAPTER 2 3. Remove the access panel in the combine grain tank.

4. Remove the upper rotor cover, 1, for the rotor(s) being installed. This will provide visual help aligning the rotor with the rotor gearbox. 5. If the combine is equipped with two speed rotor gearboxes, place them in the neutral gear position

10025284

WARNING The rotors are heavy! Be sure that rotor is properly attached to the rotor removal tool, 1, before removing it from the combine. Injury or death may occur from falling rotors if the rotors are not properly secured to the rotor removal tool. DO NOT remove the rotor from the combine without supporting the rear of the rotor with the rear support assembly. Stay clear of the rotor during removal from the combine. NOTE: An assistant should drive the forklift or guide the rotor into the combine. 6. Carefully raise the rotor up and into the combine. The rotor must be stepped into the combine, the same as during its removal. For every few inches the rotor is installed into the combine, the rotor must be raised accordingly.

66-15

10025278

1 33

SECTION 66 - THRESHING - CHAPTER 2 7. Before the outer rotor gearbox coupler is engaged, rotate the rotor until the rotor is or will be properly timed with the opposite rotor. •

17-Inch-Diameter Rotors: The rotors must be positioned so one rasp bar, 1, of the right rotor is entering the grated area of the concave, 2, while one rasp bar, 3, of the left rotor is exiting the grated area. This alignment is approximately 90 degrees apart.

20033128

34 •

22-Inch-Diameter Rotors: The leading edge, 1, of one auger flight extension on the right rotor, when installed, should be positioned so the edge is parallel with the bottom of the front bearing plate, 2. The left rotor should be positioned so the leading edge, 3, of an auger flight extension is rotated 60 degrees counterclockwise from the leading edge of the right rotor that is aligned with the front bearing plate.

8. Once the rotors are in the timed position, install the rotor the rest of the way into the combine. The outer gearbox coupling on the rotor must be engaged with the inner gearbox coupling on the rotor gearbox.

1 20033131

10. Remove the rotor removal tool.

66-16

3 35

9. Once the rotor is positioned properly in the combine, install the bolt, 1, used to secure the rotor. Use a high strength (grade 10.9 or better) M16 x 140 mm bolt to secure the rotor in the combine. Thread the bolt into one of the threaded holes in the rotor at the separator grates. Be sure the bolt is threaded completely into the rotor and the upper portion of the bolt is resting against the separator grate. 11. If the remaining rotor was already removed from the combine, follow steps 1 through 10 to install the remaining rotor.

10025266

SECTION 66 - THRESHING - CHAPTER 2 12. Install the front rotor stub shaft, 1, and secure using the six mounting bolts. Torque to 54 -- 60 N⋅m (40.1 -- 44.4 ft-lbs).

2 1

13. Place the shims, 2, onto each rotor. Make sure to use the same number of shims that were removed from each rotor. If the rotor needs to be shimmed because the shims were lost or destroyed, or the rotor was changed, proceed to step 14. If the shimming does not need to be adjusted, proceed to step 19.

10025274

37 NOTE: A 17-inch diameter rotor is shown; the 22-inch diameter rotor is similar. 14. To calculate proper shimming for the rotors, install the front bearing plate, 1, with the shims, 2, removed, onto the rotors and combine frame. Secure the plate using the mounting bolts removed previously. Be sure to tighten all mounting bolts. Remove the M16 x 140 mm bolt, installed in step 9, that secures each rotor in the combine. 15. With each rotor pushed as far to the rear in the combine rotor chamber as possible, place a lock collar backward onto each rotor flange and lock into place. Once the collar is installed, pull the rotors as far forward in the rotor tube as possible.

2 1

20033130

16. Measure the distance between each collar. This distance will be the amount of shimming required. The shims, 1, are 0.7 mm (0.0275 in.) thick. There must be no more than 5 mm (0.20 in.), 2, between the front auger extension, 4, and the back of the stripper on the front bearing plate, 3.

20033129

2 39

66-17

SECTION 66 - THRESHING - CHAPTER 2 17. Once the proper shimming has been determined, install the high strength bolts, 1, again which were used to secure each of the rotors in the rotor tubes. Ensure that the bolts are threaded fully into each rotor. 18. Remove the front bearing plate and install the shims as calculated in step 16.

10025266

40 19. Place the front bearing plate, 1, onto the rotors and combine frame. Secure the plate using the bolts removed previously. Install the two center bolts that are located behind the plate between the rotors.

NOTE: Make sure the seals for the front covers are in good condition. Replace the seals if necessary. 20. Install the two front covers, 2, onto the bearing plate and combine frame and secure them with the mounting bolts removed previously. Be sure to install the wire harness hanger for the rotor speed sensor.

3 10025273

21. Install the bottom infeed plate, 3, onto the combine frame and secure using the mounting bolts. 22. Install the bearing collar, 1, onto the front of each rotor by placing the collar over the bearing and the rotor flange and rotating the collar in the direction of rotation using a suitable hammer and punch. Tighten the set screw, 2, in each collar to lock the collar on the front collar shaft.

2 1

10025269

66-18

SECTION 66 - THRESHING - CHAPTER 2 23. Install the rotor speed sensor pick up, 1, onto the left rotor flange. Secure the pickup with the mounting bolt, 2.

24. Connect the sensor wire connector, 3, to the combine wiring harness. Be sure to route the harness through the hanger bolted to the front bearing plate.

10025268

43 25. Install the feeder position arm, 2, onto the combine frame. Connect the linkage, 3, to the arm. Secure the arm with the snap ring, 1.

10025267

66-19

SECTION 66 - THRESHING - CHAPTER 2 26. Remove the bolt, 1, used to retain each rotor during installation and disassembly.

10025266

45 27. Install the combine feeder house using the procedure described in Section 60, Chapter 1 of the CR combine repair manual.

86060925

66-20

SECTION 66 - THRESHING - CHAPTER 3

SECTION 66 -- THRESHING Chapter 3 -- Main Threshing Drives CONTENTS Section

Description

Page

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Drive Belt (Engine Gearbox Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Main Cross Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Rotor Variable Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Rotor Variable Drive Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Rotor Variable Drive Sheave Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Torque Sensing Drive Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Rotor Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

66-1

SECTION 66 - THRESHING - CHAPTER 3 Section

Description

Page

Right Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Left Rotor Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

66-2

SECTION 66 - THRESHING - CHAPTER 3 SPECIAL TOOLS Torque Sensing Drive Sheave Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manufacture as shown* *This tool is also used on the TR model combine

228.6 mm (9 in) 152.4 mm (6 in) 34.9 mm (1-3/8 in)

127.0 mm (5 in) 34.9 mm (1-3/8 in) 19.0mm (3/4 in)

14.2 mm DIA. (9/16 in)

20.6mm DIA. (13/16 in)

14.2 mm DIA. (9/16 in)

38.0 mm (1-1/2 in)

12.7 mm (1/2 in)

114.3 mm (4-1/2 in)

12.7 mm (1/2 in)

38.0 mm (1-1/2 in)

1 Torque Sensing Drive Sheave Removal Tool

66-3

SECTION 66 - THRESHING - CHAPTER 3 Torque Sensing Drive Disassembly Tool (Manual Press Type) Tool No. 380000735

20033109

2 Tool #380000660 - Modified chisel The modified chisel shown should be used to disengage the locknuts installed on various components in the gearbox. An unmodified tool will not have the capability to pull the indentation from the shaft slot, and will make removal more difficult. If a tool similar to the one shown is not available, carefully cut the locknut free of the shaft. Any damage to the shaft threads caused by this operation must be repaired prior to installation of the new locknut. 20021288

3 Nut Spanner Wrench (65 mm) Special Tool No. 380000807 Used for disassembly and assembly of the drive and input shafts.

50030182

66-4

SECTION 66 - THRESHING - CHAPTER 3 Nut Spanner Wrench (60 mm) Special Tool No. FNH00089

20034311

DESCRIPTION OF OPERATION controls the rotor speed. Two different variable drive sheaves are available, a low speed and a high speed. A belt then transfers power from the variable drive sheave to a torque-sensing drive sheave. The torque sensing drive sheave is a two part sheave that senses torque between the engine and rotors and loosens or tightens against the belt, depending upon the torque being applied. The more torque that is applied, the tighter the drive sheave grips the belt. From the torque sensing sheave, power is transferred directly to the right rotor gearbox. The right gear box is a dual speed gearbox, and is standard for the CR. The right gearbox transfers power to the right rotor and the left rotor gearbox. The left gearbox is a single speed gearbox, with the speed of right gearbox controlling the speed of the left.

The combine rotors are driven by the engine through a series of sheaves, belts, shafts and gearboxes. The speed at which the rotors turn is changed by a variable drive sheave and a two-speed rotor gearbox. The variable drive sheave is controlled from the cab of the combine and the rotor gearbox speed is switched directly at the gearbox via mechanical linkage. Power from the engine is transferred to the rotors through a clutch in the engine gearbox, which will turn a sheave on the engine gearbox when the clutch is engaged. The sheave drives a belt which turns a sheave that is connected to a cross shaft. The cross shaft transfers power to the right side of the combine to a variable speed drive sheave. The variable drive sheave uses a hydraulic cylinder to move the halves of the sheave further apart or closer together. This

66-5

SECTION 66 - THRESHING - CHAPTER 3 OVERHAUL DRIVE BELT (ENGINE GEARBOX SIDE) The drive belt on the engine gearbox side is driven by a clutch in the gearbox that turns a sheave on which the belt rides. The belt then turns a sheave mounted to the cross shaft. Removal

1. If the optional straw chopper is installed, loosen the adjusting nut, 1, for the straw chopper drive belt tensioner, 2. Slide the belt, 3, off the engine gear box sheave.

20021294

4 2. Loosen the adjusting nut for the drive belt tensioner, 1. Slide the drive belt, 2, off the engine gearbox sheave and cross shaft sheave.

Installation 1. Install the belt, 1, onto the engine gearbox sheave. Route the belt around the tensioner and onto the cross shaft sheave. 2. Tighten the adjusting nut for the drive belt tensioner, 2, until the washer at the end of the spring is even with the end of the indicator.

1 40021145

5 3. Install the straw chopper drive belt, 3, onto the engine gearbox drive sheave. Tighten the adjusting nut, 1, for the straw chopper belt tensioner, 2, until the end of the spring is even with the end of the indicator, 4.

20021294

66-6

SECTION 66 - THRESHING - CHAPTER 3 MAIN CROSS SHAFT The main cross shaft transfers power to drive the rotors from the left side of the combine to the right side of the combine. A standard sheave is attached to the left side of the cross shaft. The variable drive sheave is attached to the right side of the cross shaft. Removal 1. Remove the variable drive sheave, 1, using the procedure described later in this chapter.

1 40021149

7 2. Remove the main drive belt, 1, and the beater drive belt, 2, from the engine gearbox side of the combine. 3. Remove the unloading drive belt, 3, for clearance.

1 2 40021145

8 4. Remove the two nuts, 1, from the cross shaft which secure the sheave on the left side of the combine to the cross shaft. Remove the washer, 2, behind the two nuts.

1 40021146

66-7

SECTION 66 - THRESHING - CHAPTER 3 5. Install a large puller, 1, onto the sheave and cross shaft. The arms of the puller are placed at the center of the pulley. Use the puller to remove the sheave from the cross shaft.

40021147

10 6. Remove the key, 1, from the cross shaft. 7. Disconnect the fitting, 2, for the grease line from the bearing retainer plate, 4.

8. Remove the two bolts, 3, from the side of the bearing retainer plate.

2 1

40021148

11 NOTE: The bolts for each bearing mounting plate can be reached easier from the rear access panel in the combine grain tank. The bolts can also be removed from the side of the combine, if access is not possible through the grain tank.

9. Remove the four bolts, 1, securing the left side bearing plate to the combine frame. 10. Remove the two bolts, 2, which secure the bracket for the hydraulic fluid accumulator to the bearing plate. Position the accumulator away from cross shaft.

40021150

2 12

66-8

SECTION 66 - THRESHING - CHAPTER 3 11. Disconnect the fitting, 2, for the grease line from the right side bearing retainer.

12. Remove the four bolts, 1, securing the right side bearing retainer to the combine frame. The cross shaft is now free from the combine frame.

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CAUTION The cross shaft weighs approximately 75 kg (166 lb) An assistant should help when removing the cross shaft from the combine. Failure to comply may result in minor or moderate injury. 13. Remove the cross shaft from the left side of the combine.

40021152

14 Bearing Replacement Disassembling Bearing Assembly NOTE: When disassembling the bearing assemblies, be sure to note where each component belongs for ease of assembly. The bearing assembly for each side is different. NOTE: The bearing plates attach to each bearing assembly differently. Be sure to note how each plate attaches to the bearing assembly. 1. Remove the bearing plates that secure each side of the shaft to the combine. Remove the key from the left end of the main shaft.

2. Install a split bearing puller, 1, over the bearing assembly, 2, of the non-splined (left) end of the shaft. Draw the bearing assembly off the shaft by using the puller.

1 40021207

66-9

SECTION 66 - THRESHING - CHAPTER 3 3. Install the bearing puller or a two or three arm puller, 1, as shown, onto the bearing assembly, 2, of the splined (right) end of the main shaft. Use the puller to remove the bearing assembly.

40021208

16 Inspecting Bearing 1. Remove and discard the seals, 1, from the bearing assemblies.

40021209

17 2. Remove the spacers, shims and bearings from each bearing assembly. Remove grease from the all parts. Clean the parts in a suitable solvent and allow them to dry. 3. Inspect the bearings for each side of the main shaft for free movement, excessive lateral play, or damage. Inspect the bearing races in the bearing housing for signs of wear or damage. Replace as necessary. ALWAYS replace the bearings, races and shims as a matched set. 4. Inspect the spacers and shims for signs of excessive wear or damage. Replace the spacers as necessary. The shims and internal spacer are part of the bearing assembly set, which come with the proper amount of shims with the spacers, races and bearings.

66-10

40021210

SECTION 66 - THRESHING - CHAPTER 3 5. Inspect the main shaft for cracks, bends, fatigue or other signs of excessive wear or damage. Check the splines for wear. Repair or replace the shaft as necessary.

40021211

19 Assembling Bearing Assembly

NOTE: Right bearing housing is shown; the left housing is similar. 1. If removed, install the center spacer ring, 1, in the bearing housing. When installing the spacer, be sure the opening in the spacer is aligned with the hole for the grease fitting, otherwise the bearing may not be able to be properly lubricated. 2. If removed, install the outer bearing races in the bearing housings. To help installation, chill the bearings in ice before driving the races into the housing. Be sure to keep track of what bearing belongs with each race.

40021215

3. Pack the bearings for the right side of the main shaft with high-quality lithium grease. Install the inner bearing into the bearing housing. Be sure to install the bearing into the side of the bearing housing that will face to the inside of the combine when the shaft is installed. The grease fitting threads into the inside portion of the bearing housing. 4. Place a new bearing seal, 1, in the inner side of the bearing housing. Use a large piece of wood and a suitable mallet or a seal driver to install the seal into the housing. The seal should be installed evenly with the lip of the bearing housing.

66-11

1 40021216

SECTION 66 - THRESHING - CHAPTER 3 5. Flip the bearing assembly over. Lubricate the shims and inner spacer with lithium grease. Place the spacer and shims, 1, onto the inner race of the previously installed bearing. Install the remaining bearing, 2, into bearing housing.

6. Install the bearing seal for the outside of the right bearing housing using a large wooden block and a suitable mallet or a seal driver. 7. Install the spacers in each end of the bearing assembly. The right bearing housing has a thick spacer on the inside and a thin spacer on the outside. Spacers for the left side bearing housing are the same size.

1 40021217

8. Repeat the preceding steps to assemble the left side bearing assembly. 9. A tool for pressing the bearing assemblies onto the main shaft can be fabricated out of steel tubing. The first part, 1, of the tool should be a minimum of 305 mm (12.0 in) long with an outer diameter of 83 mm (3.25 in) and inner diameter of 70 mm (2.75 in). The washer, 4, that retains the sheave to the left side of the main shaft, is also used. 10. The second part, 2, of the tool, is needed to press the LEFT bearing assembly onto the main shaft. This part will thread onto the left side of the shaft. Two M30 x 1.5 nuts (P/N 100034) are welded together and a standard M20 x 2.50 nut must be welded to one end. A length of M20 x 2.50 threaded rod, 3, with a minimum length of 381 mm (15.0 in) is also required.

1 3

40021218

IMPORTANT: The right bearing assembly has a groove, 4, around the outside of the bearing housing. Use this groove to distinguish the left and right bearing assemblies. When installing the right bearing assembly onto the main shaft, be sure the grease fitting, 2, will face to the inside of the main shaft. 11. Coat the right end of the main shaft with LoctiteR anti-seize compound. Slide the right bearing assembly, 1, onto the main shaft and use the bearing press tool, 3, to press the right bearing assembly onto the shaft. Make sure to seat completely the assembly onto the shaft.

66-12

2 3 40021219

SECTION 66 - THRESHING - CHAPTER 3 IMPORTANT: Be sure the grease fitting for the left bearing assembly will face out when installing the assembly onto the main shaft.

12. Coat the left side of the main shaft with LoctiteR anti-seize compound. Slide the left bearing assembly, 1, onto the main shaft. 13. Thread the second part of the tool, 2, onto the left end of the main shaft. 14. Install the bearing press tool, 3, onto the left end of the main shaft and press the left bearing assembly onto the shaft. Be sure the bearing assembly is fully seated on the main shaft.

40021220

15. Remove the bearing installation tools. 16. Install the bearing plates, 1, to each bearing assembly as removed. The mounting surfaces of the plates should face in towards the center of the combine. Bolt the retaining brackets, 2, to each mounting plate. The left bearing plate uses one bracket on the outside front and the right side uses one on the outside front and two on the inside.

2 1

17. Install the grease fittings into each bearing assembly.

2 20021328

26 Installation

CAUTION The main cross shaft weighs approximately 75 kg (166 lb). An assistant(s) should help when installing the main shaft from the combine. Failure to comply may result in minor or moderate injury. 1. Install the main cross shaft into the combine from the left side. Be sure the splined end of the shaft will be on the right side of the combine.

40021152

66-13

SECTION 66 - THRESHING - CHAPTER 3 2. Install the four bolts, 1, which secure the left side bearing retaining plate to the combine frame. 3. Install the two bolts, 2, which secure the hydraulic fluid accumulator to the bearing plate.

40021150

28 4. Install the four bolts, 1, which secure the right side of the cross shaft to the combine frame.

5. Attach the grease line, 2, to the fitting on the bearing assembly.

1 40021151

29 6. Coat the right end of the main shaft with anti-seize compound. Install the variable drive sheave, 1, onto the main shaft. Use the installation procedure described later in this chapter.

1 40021149

66-14

SECTION 66 - THRESHING - CHAPTER 3 7. Connect the grease line, 1, to the fitting on the left bearing assembly. 8. Coat the outer portion of the main shaft and the shaft key with anti-seize compound. Install the key, 2, into the keyway in the main shaft.

2 20021295

31 9. Slide the sheave onto the left end of the main shaft. Install the washer, 1, and one of the 30 x 1.5 nuts, 2, onto the shaft. Use the inner nut to draw the sheave onto the shaft. Torque the nut to 200 N⋅m (148 ft-lb). Install the outer nut, 3, onto the main shaft and torque the nut to 300 N⋅m (222 ft-lb).

3 2 40021146

32 10. Install the unloading drive belt, 1. 11. Install the beater drive belt, 2, onto the beater sheave and the main shaft sheave. 12. Install the main drive belt, 3, onto the engine gearbox and main shaft sheave.

13. Adjust the belt tensioner (not shown) to the correct tension by tightening the nut for the tensioner spring. Tighten the nut until the spring is the same length as the indicator.

3 2 40021145

66-15

SECTION 66 - THRESHING - CHAPTER 3 ROTOR VARIABLE DRIVE BELT Replacement 1. If possible, run the variable drive to the high-speed position.

2. Insert a 40 x 90 mm (2 by 4-in) wood block, 1, between the inner and outer portion of the torque sensing sheave. This is to keep the inner and outer sheaves from coming together once the belt is removed. 3. If the variable drive cannot be run to the high-speed position, the torque sensing sheave must be pried apart using a suitable pry bar or spreading tool. NOTE: Hydraulic fluid will drain from the hydraulic cylinder and line. Use a suitable container to catch any fluid that drains from the cylinder or line.

40021153

4. Disconnect the hydraulic line, 1, from the cylinder. 5. Use a pry bar to separate the outer and inner portions of the sheave as much as possible. The belt, 2, can then be removed from the sheaves. 6. Install the belt onto the variable drive sheave and then working the belt onto the torque sensing sheave.

2 40021149

7. Install the hydraulic line for the cylinder in the variable drive sheave.

ROTOR VARIABLE DRIVE SHEAVE

Removal 1. Remove the variable drive sheave belt, 1, as described previously. 2. Remove the primary feeder drive belt, 2, from the drive sheave by loosening the tensioner adjusting nut, 3.

1 3 10021005

66-16

SECTION 66 - THRESHING - CHAPTER 3 3. Remove the six bolts, 1, which secure the hydraulic cylinder to the sheave support hub. Slide the cylinder out of the hub.

4. Remove the cross pin, 2, which bisects the sheave.

1 2 40021154

37 5. Place aligning marks, 1, on the inner and outer sheaves with a paint marker or other marking device. This is to ensure that the sheave is assembled in the same manner if the sheave halves are separated.

6. Loosen the bolt, 2, which secures the sheave to the main cross shaft, five complete turns.

40021155

66-17

SECTION 66 - THRESHING - CHAPTER 3 WARNING

The variable drive sheave weighs approximately 73 kg (161 lb). Use care when handling the sheave, otherwise personal injury may occur. 7. Place a lifting strap around the center of the variable drive sheave. Secure the strap to a lifting hoist or part of the combine so the weight of the sheave will be supported when removed from the main cross shaft. 8. Place a piece of pipe or rod, 2, into the center of the sheave so the pipe rests against the washer. The pipe should be approximately 267 mm (10.5 in) long.

40021156

NOTE: The tool used to remove the torque sensing sheave is used to pull the variable drive sheave. 9. Install a puller, 1, onto the sheave, using the M10 x 1.5 tapped bolt holes in end of the sheave support hub. Tighten the bolts until the sheave becomes loose on the tapered splines of the main cross shaft. 10. Remove the puller from the sheave. 11. Remove the center bolt from the sheave and install the cross pin back into the sheave halves.

CAUTION When sliding the sheave off the cross shaft, the sheave halves will tend to separate. Hold or clamp both halves together when removing and lowering the sheave. 12. Slide the sheave off the cross shaft and guide the sheave out of the combine while an assistant lowers the sheave. Inspection 1. Separate the sheave halves by removing the cross pin and lifting the outer sheave off the inner sheave. The inner sheave portion, 1, can be removed from the sheave support hub, 2, by removing the six mounting bolts, 3. 2. Inspect the sheave halves for excess wear or damage such as cracks or grooves. Replace as necessary. 3. Inspect the splines of the shaft for damage or wear. Inspect the shaft for excessive wear or damage. Replace the shaft as necessary.

40021157

66-18

SECTION 66 - THRESHING - CHAPTER 3 4. Remove and discard the O-ring, 1, from the outer sheave half. Lubricate and replace the O-ring. 5. Lubricate generously with AMBRA GR 75 MD grease the inner splines and sliding bores of the outer sheave half and the splines of the sheave support hub.

6. Coat the splines of the cross shaft with AMBRA GR 75 MD grease.

50021159

41 Installation

WARNING The variable drive sheave weighs approximately 73 kg (161 lb). Use care when handling the sheave. Failure to comply could result in serious injury or death.

1. Install the sheave halves together, aligning the markings made during removal. Temporarily install the cross pin, 1, into the sheave halves. 2. Place lifting strap, 2, around the inside of the sheave halves.

40021158

CAUTION When lifting and installing the sheave onto the cross shaft, the sheave halves will tend to separate. Hold or clamp both halves together when raising and installing the sheave. 3. Install the variable drive sheave onto the main cross shaft, using the help of an assistant to raise the sheave. 4. With the sheave on the cross shaft, remove the cross pin. Install the large retaining bolt, 1, and washer, 2, into the cross shaft. 5. Draw the sheave down onto the cross shaft using the M20 x 45 retaining bolt. Torque the bolt to 412--529 N⋅m (304--390 ft-lb).

2 40021155

66-19

SECTION 66 - THRESHING - CHAPTER 3 6. Install the cross pin, 2, into the sheave. Install one spacer washer, one flat washer, one lock washer and one 3/8 x 1 cap screw on one end, and one flat washer, lock washer and 3/8 x 1 cap screw on the other end. Tighten both to 47--61 N⋅m (35--45 ft-lb). 7. Install the hydraulic cylinder into the variable drive sheave. Install the six retaining bolts, 1, into the cylinder and sheave, tightening the bolts one or two turns in a crossing pattern until the cylinder is seated in the hub. Tighten to 47--61 N⋅m (35--45 ft-lb).

1 2 40021154

44 8. Install the primary feeder drive belt, 2. Tighten the tensioner adjusting nut, 3, until the spring is even with the gauge on the tensioner. The spring length should be approximately 130 mm (5.12 in) long.

9. Install the variable drive belt, 1, using the procedure described earlier in this chapter.

1 3 10021005

ROTOR VARIABLE DRIVE SHEAVE HYDRAULIC CYLINDER

Removal NOTE: Hydraulic fluid will drain from the hydraulic cylinder and line. Use a suitable container to catch any fluid which drains from the cylinder or line.

1. Disconnect the hydraulic line fitting, 1, from the hydraulic cylinder. Position the line out of the way. 2. Remove the six bolts, 2, which secure the hydraulic cylinder to the variable drive sheave. Pull the cylinder out of the sheave, using care not to lose any shims. The shims are fitted between the sheave and the cylinder mounting flange.

66-20

40021149

SECTION 66 - THRESHING - CHAPTER 3 Disassembly

1. Remove the shims, 1, from the hydraulic cylinder. Count the number of shims removed from the cylinder so if any shims are lost or need replaced, the same amount can be installed between the cylinder and the sheave.

20021178

47 2. Carefully clamp the cylinder mounting flange in a vice. Remove the three bolts, 1, which secure the retaining plate, 2, for the rotating union, 3.

20021179

48 3. Remove the cylinder from the vice and separate the cylinder from the mounting flange, 2, by removing the snap ring, 1. Slide the mounting flange off the cylinder.

1 20021180

66-21

SECTION 66 - THRESHING - CHAPTER 3 4. Slide the rotating union, 1, out of the hydraulic cylinder. Remove the snap ring, 2, retaining the fitting portion of the union.

2 20021181

50 5. Remove the bronze floating seal, 1, the O-ring, 2, the aluminum seal guide, 3, and spring, 4, from the rotating union housing, 5.

20021183

51 IMPORTANT: DO NOT place the sliding surface of the piston rod in the vice, as any surface blemishes on the rod will cause the cylinder to function improperly. DO NOT over tighten the vice.

6. Place the end of the piston rod, 1, in a soft jaw vice, tightening the jaws enough to secure the rod. Pull the cylinder, 2, off the rod. Remove the piston rod from the vice.

2 20021184

66-22

SECTION 66 - THRESHING - CHAPTER 3 7. Remove the orifice, 1, from each end of the piston rod.

20021185

53 Inspection

1. Thoroughly clean all parts using a suitable solvent and allow the parts to dry. 2. Remove and discard the oil seals, 1, from the cylinder, 2. Replace the oil seals with new seals lubricated with clean hydraulic fluid. 3. Inspect the cylinder bore and outer diameter for signs of wear, corrosion, or any other damage.

20021186

54 4. Remove and discard the O-rings, 1, on the rotating union housing, 2.

5. Discard the O-ring, 3, for the floating seal, 4.

WARNING Always wear eye protection when using compressed air. Serious injury may occur if care is not taken. 8. Inspect the holes in the orifices, 6, to make sure they are not clogged. Use compressed air to clean the orifices. DO NOT use any type of drill or wire to clean the orifice holes, as this will increase the diameter of the holes.

66-23

1 20021187

5 6 55

SECTION 66 - THRESHING - CHAPTER 3 9. Inspect the piston rod for corrosion or any other damage. The hydraulic cylinder will not function properly if the rod is damaged. Replace the piston rod as necessary. 10. Measure the outer diameter in several places along the length of the piston rod. The diameter of the rod should be 44.4119 – 44.4500 mm (1.7485 -- 1.7500 in). Replace the piston if the diameter is below specifications.

20021188

56 Assembly 1. Lubricate new O-rings, 1, with petroleum jelly and install onto the union housing, 2. 2. Lubricate the spring, 3, seal guide, 4, O-ring, 5, and floating bronze seal, 6, with new hydraulic fluid. Install the components into the union housing, 2, in the order shown in the illustration. When installing the bronze seal, 6, make sure the long portion of the seal is installed into the housing first and the tabs in seal are aligned with the pins in the housing.

1 20021183

57 3. Secure the fitting portion, 1, of the rotating union, 2, with the small snap ring, 3.

1 3

20021181

66-24

SECTION 66 - THRESHING - CHAPTER 3 4. Install an orifice, 1, into each end of the piston rod.

20021185

59 5. Lubricate the piston rod, 1, with clean hydraulic fluid and install the piston rod into the cylinder, 2.

2 20021189

60 6. Install the rotating union, 1, into the hydraulic cylinder, 2.

20021182

66-25

SECTION 66 - THRESHING - CHAPTER 3 7. Place the mounting flange, 2, on top of the cylinder. Install the snap ring, 1, to secure flange to the cylinder.

1 20021180

62 8. Carefully clamp the cylinder mounting flange in a vice. Install the three 5/16 x 5/8 cap screws, 1, and lock washers which secure the retaining plate, 2, for the rotating union, 3, and tighten to 22--28 N⋅m (16--21 ft-lb).

3 20021179

63 9. Install the shims,1, onto the hydraulic cylinder. Be sure the same number of shims is installed on the cylinder as were removed.

20021178

66-26

SECTION 66 - THRESHING - CHAPTER 3 Installation 1. Install the hydraulic cylinder into the variable drive sheave. Secure the cylinder with the six retaining bolts, 2. Tighten the bolts in a crossing pattern to 47--61 N⋅m (35--45 ft-lb).

2. Install the hydraulic line, 1, onto the rotating union.

40021149

65 3. Make sure the area around the combine is free from people and objects. Start the combine engine.

4. Engage the threshing mechanism switch, 1. 5. Cycle the speed of the variable rotor drive sheave using the rotor speed switch, 2. This bleeds hydraulic fluid into the variable drive sheave hydraulic cylinder.

86060926

66 6. With the threshing mechanism engaged, set the variable rotor speed to the lowest setting. 7. Use the IntelliViewII/IntelliView Plus II screen to check that the variable drive sheave hydraulic cylinder is shimmed properly. Go to a “Run” screen that has rotor speed displayed. 8. With the rotor variable drive sheave set to the lowest speed, set the rotor speed to 557 ± 5 rpm.

56063224

66-27

SECTION 66 - THRESHING - CHAPTER 3 9. If the rotor speed is not as specified, remove the hydraulic cylinder from the variable drive sheave and add or remove shims. The shims, 1, are located between the cylinder and the sheave hub. Each shim is .76 mm (0.030 in) thick. To increase minimum shaft speed, decrease the amount of shims. To decrease minimum shaft speed, add shims.

10. Install the hydraulic cylinder into the variable drive sheave. Check the minimum rotor speed after changing the amount of shimming. 20021178

TORQUE SENSING DRIVE SHEAVE

The torque sensing drive sheave is a self-adjusting sheave that drives the right rotor gearbox. The torque sensing sheave is driven by the variable drive sheave by a belt. The torque sensing sheave uses two spring-loaded sheave halves on a hub to sense when the drive belt is slipping. If slippage occurs on the outer sheave half (rotor drive half), the inner sheave (driven half) will tighten to stop the slippage. The torque sensing drive also adjusts to the speed the variable drive sheave is set. The torque sensing sheave will spread apart the higher the speed to which the variable drive sheave is set. Removal 1. Remove the drive rotor drive belt, 1, using the procedure described earlier in this chapter.

1 40021149

69 2. For clearance, remove the drive belt, 1, for the clean grain elevator.

3. Remove the center retaining bolt, 2, and washer in the torque sensing sheave. IMPORTANT: It is important that a washer is inserted behind the bolt, as this prevents the torque sensing sheave from falling off the shaft on which the sheave is mounted.

4. Install an M20 x 110 bolt and the washer removed in step 3 into the torque sensing sheave.

1 40021160

66-28

SECTION 66 - THRESHING - CHAPTER 3 CAUTION The torque sensing drive sheave weighs approximately 70 kg (155 lb). To prevent personal injury or equipment damage, use care when handling the sheave. Failure to comply may result in minor or moderate injury. IMPORTANT: Make sure that the M12 threaded rod is threaded completely into the torque sensing drive so the threads in the drive do not become stripped out. 5. Install a lifting strap around the sheave and then tie the strap to a solid object to support the weight of the sheave. 6. Acquire the torque sensing drive remover tool as shown in the Special Tools section of this chapter. Install the tool, 1, using two 200 mm (7-7/8 in) lengths of M12 threaded rod with a nut, 2, and flat washer on each piece of rod. Place a 50 mm (2 in) length of steel rod, 3, or suitable socket against the center of the bolt.

7. Turn the two nuts on the M12 threaded rod evenly until the sheave loosens on the tapered splines. 10021161

71 8. Remove the torque sensing hub removal tool from the torque sensing drive. 9. Be sure the sheave, 1, is properly supported and remove the center bolt from the shaft on which the sheave is mounted. 10. Using the help of an assistant, lower the torque sensing drive sheave using the lifting strap, 2. Guide the sheave out of the combine as the sheave is lowered.

2 1 10021162

66-29

SECTION 66 - THRESHING - CHAPTER 3 Disassembly

WARNING Use extreme caution and follow procedures exactly when disassembling the torque sensing drive. The large spring in the drive is under high tension and may cause serious injury or death if the spring release is not controlled. Failure to comply could result in serious injury or death. 1. Use tool 380000735 to relieve the spring pressure of the torque sensing drive sheave. 2. Disassemble the torque sensing hub remover tool by removing the tool body, 1, from the threaded rod with mounted nut, 2, the thrust washer, 3, and the centering washer, 4. The smaller diameter of the centering washer is positioned on the threaded rod against the tool body and the thrust washer is positioned on the threaded rod against the larger diameter of the centering washer.

20033104

4 73

3. Secure the tool to the sheave by inserting the threaded rod of the remover tool through the center of the sheave. Ensure that the mounting flanges, 1, of the remover tool are aligned and engaged with the edges of the spring cam, 2, before tightening the threaded rod into the tool body of the hub remover tool, 3.

20033105

74 4. Tighten the threaded rod, 1, fully against the thrust washer, 2, and washer, 3, using a 22 mm socket wrench until the pressure is released from the snap ring and the snap ring can be removed.

3 2

1 20033106

66-30

SECTION 66 - THRESHING - CHAPTER 3 5. Remove the snap ring, 1, using the snap ring pliers, 2. The snap ring should lift off from beneath the tool body of the hub remover tool, 3.

WARNING

Keep hands and clothing away from the spring and sheave halves when releasing the spring. The sheave halves will rotate as the threaded rod of the remover tool is being loosened. Failure to comply could result in serious injury or death. 6. Slowly loosen the threaded rod with the socket wrench to release the spring pressure. Tap the cam lightly with a rubber mallet or similar-type tool if the cam hub does not slide on the shaft as the threaded rod is loosened. As the spring cam disengages the rollers, the torsional pressure of the spring will release and the sheave halves will rotate. 7. Loosen the remainder of the threaded rod from the tool body of the remover tool and remove the tool from the sheave.

3 20033107

Inspection 1. Separate the sheave halves. Clean each part of the torque sensing drive using a suitable cleaner. Inspect each portion of the sheave for excessive wear or damage. Inspect the splines on the hub and the splines in the spring cam. Replace any components that are either worn or damaged.

2. Replace the hub, if necessary, by removing the six bolts, 1, which retain the hub to the outer sheave half. Install the new hub and torque the mounting bolts to 19--123 N⋅m (70--90 ft-lb). 50021163

77 3. Remove and discard the two seals, 1, from the inner sheave half. Lubricate new seals with lithium grease and install into the sheave half so the open side of both seals will face the rear of the sheave when assembled and installed on the combine. Refer to the illustration inset. 4. Inspect the bearings, 2, on the cam ring. Replace the bearings if they do not turn freely or have excessive play. When installing bearings, torque the bearings to 68--78 N⋅m (50--58 ft-lb). 5. The cam ring can be replaced by removing the six mounting bolts, 3, from the inner sheave half. Install the new cam ring and secure using the mounting bolts. Torque the mounting bolts to 82--106 N⋅m (60--78 ft-lb). 6. Generously coat the splines and sliding surfaces of the hub and sheave halves with AMBRA GR 9 multi-purpose grease. Be sure the grooves in the bore of the inner sheave half are filled with grease. Lubricate the two cam bearing lube fittings with grease as well.

66-31

50021164

SECTION 66 - THRESHING - CHAPTER 3 Assembly

WARNING

Use extreme caution and follow procedures exactly when assembling the torque sensing drive. The large spring in the drive is under extreme tension and may cause serious injury or death if the spring compression is not controlled. NOTE: Make sure the grease fitting in the inner sheave half is aligned with a window on the outer sheave half when assembling the sheave. 50021165

1. Slide the sheave halves together.

2. Install the spring onto the rear sheave half. Install the spring tab into the rear of the inner sheave half by installing the spring tab into the hole marked with an “R”, 1. If this marking is not legible, use the right hole (clockwise direction) when viewing the sheave from the end with the two holes at the top. 3. Install the spring cam onto the hub shaft, mating against the spring, and being sure to lock the spring into the spring tab on the cam. 4. Install the hub tool, 1. Before installing the removal tool, slide the snap ring over the shaft of the tool for easy installation later. Slowly start to compress the tool using a ratchet wrench. Just before the splines on the hub shaft mate with the splines on the cam, rotate the inner sheave half until the cam roller, 2, is in line with the ramp on the cam, 3. 5. Start to compress the spring slowly, making sure that everything is mating properly. Watch the cam and cam rollers, also watch the hub shaft and cam splines for correct mating. Sometimes the cam may bind on the splines slightly, use a heavy rubber dead blow hammer to tap around the cam while compressing the spring, this will help resolve the binding.

3 2

20033105

6. Once this is achieved, fully compress the spring until the snap ring groove is visible.

WARNING Be sure the snap ring is fully seated in the hub groove; otherwise, the spring will force the cam off once the tool is removed, possibly causing severe personal injury or death. 7. Install the snap ring, 1, onto the outer sheave hub using a suitable pair of snap ring pliers. Ensure that the snap ring is fully seated in the hub groove. 8. Remove the hub remover tool from the torque sensing drive sheave by loosening the threaded rod with a socket wrench and removing the two washers.

66-32

20033108

SECTION 66 - THRESHING - CHAPTER 3 Installation

CAUTION

The torque sensing drive sheave weighs approximately 70 kg (155 lb). To prevent personal injury or equipment damage, use care when handling the sheave.

1. Coat the rotor gearbox input shaft, 3, with AMBRA GR75 MD grease. 2. Raise the sheave, 1, up to the rotor gearbox input shaft using a lifting strap, 2. Have an assistant help raise the sheave as the sheave is being guided onto the gearbox shaft.

1 10021162

3. Install the M20 x 45 bolt, 2, with the lock washer and flat washer into the gearbox shaft. Draw the sheave onto the gearbox shaft with the bolt. Torque the bolt to 412 -- 529 N⋅m (304 -- 390 ft-lb). 4. Install the drive belt, 1, for the clean grain elevator.

2 1 40021160

83 5. Install the drive rotor drive belt, 1, using the procedure described earlier in this chapter.

1 40021149

66-33

SECTION 66 - THRESHING - CHAPTER 3 ROTOR GEARBOXES CR combines are equipped with dual speed rotor gearboxes. The right gearbox is driven by the torque sensing drive sheave. The left gearbox is driven by the right gearbox, and is connected to the right gearbox by a central coupling, 1. The right gearbox switches and controls the speed of both the right and left gearbox.

1 66071494

RIGHT GEARBOX Removal 1. Turn the combine ignition switch to the “ON” position. Use the switch on the right console to close the upper sieve, then turn the ignition switch to the “OFF” position. Remove the grain tank access panel and the straw hood access panel from the combine. This allows access to the rotor gearbox. Place a suitable piece of plywood on upper sieve to prevent any damage. 2. Remove the torque sensing sheave, 1, from the right rotor gearbox, 2. Use the procedure described earlier in this chapter.

1 10021162

NOTE: The rotor gearbox coupler can be accessed through the graintank access panel or through the straw hood access panel.

3. Disconnect the right rotor gearbox from the left by removing the six bolts from the gearbox coupler, 1.

66071493

66-34

SECTION 66 - THRESHING - CHAPTER 3 4. Remove the top rotor cover for the right rotor. Wrap a chain or lifting strap around the rotor. Support the rear of the rotor by hooking the chain or tying the strap off to framework above the rotor.

40021228

88 5. If equipped, disconnect the linkage for the gear range selector, 1, from the right gearbox.

6. Remove the lower three bolts, 2, which secure the bottom of the rotor gearbox to the combine frame.

40021225

2 89

CAUTION

The rotor gearbox weighs approximately 121 kg (266 lb) Use care when handling the gearbox, otherwise severe personal injury may occur. Use the help of an assistant to remove the gearbox from the combine. 7. Place a wood block for support under the bottom of the right gearbox. NOTE: There may be shims between the top gearbox mounting points and the combine frame. Be sure to note the number and location of these shims when removing the gearbox. 8. Remove the three bolts, 1, securing the top of the rotor gearbox to the combine frame. Using the help of an assistant(s), carefully remove the gearbox from the rear of the combine.

66-35

40021229

SECTION 66 - THRESHING - CHAPTER 3

20021243

66-36

SECTION 66 - THRESHING - CHAPTER 3 Disassembly (Dual Speed) NOTE: References to directions (left, right, top, bottom) are referenced as if the gearbox is installed in the machine, facing the normal direction of travel.

1. Drain the gear oil from the gearbox into a suitable container. Remove the fill plug from the gearbox case. 2. Remove the snap ring, 3, from the splined output shaft. 3. Remove the six bolts, 2, which secure the range selector, 1, to the gearbox. Pry the range selector off the gearbox.

20021258

4. Remove the eight hex socket bolts, 1, which secure the two gearbox halves together. Two bolts are located inside the gearbox housing.

NOTE: The gearbox halves will be referred to as the drive gearbox and the range gearbox. 5. Separate the gearbox halves from each other.

20021259

93 6. Remove the eight bolts, 1, which secure the rear cover of the drive gearbox half to the case. Pry the cover off the case.

20021282

66-37

SECTION 66 - THRESHING - CHAPTER 3 IMPORTANT: Use care not to damage the gearbox case or shaft when removing oil seal. 7. Remove the oil seal, 1, from the left (output) side of the drive gearbox. Discard the seal.

40021234

95 8. Remove the snap ring, 1, from the left side of the drive gearbox using suitable snap ring pliers.

40021235

1 96

IMPORTANT: Use care not to lose any shims that are behind the snap ring.

9. Remove the shims, 1, located behind the snap ring removed in the previous step. Note the amount and thickness of the shims.

40021236

66-38

SECTION 66 - THRESHING - CHAPTER 3 10. Using a suitable pair of snap ring pliers, remove the external snap ring, 1, from the right (input) side of the shaft. 11. Using a suitable pair of snap ring pliers, remove the internal snap ring, 2, from the gearbox case.

IMPORTANT: Use care not to lose any shims that are behind the snap ring. 12. Remove any shims located behind the snap ring. Note the amount and thickness of the shims. 20021260

98 NOTE: When pressing the input shaft out of the drive gearbox, be sure to hold the shaft or keep the shaft from falling during pressing.

13. Place the gearbox in a press and press on the long splined end of the input shaft, 1. To prevent damage, be sure to catch the bearing, race, pinion gear and spacer as the input shaft is being removed from the case.

40021237

99 IMPORTANT: Use extreme care when bending the tabs of the stake nut away from the output shaft. DO NOT damage the threads on the output shaft. 14. Using special tool number OTC 380000660 (inset), bend the stakes in the stake nut away from keyways in the output shaft. Insert the tool into each keyway and use a hammer to strike the tool, bending the stakes away from the keyway.

40021238

100

66-39

SECTION 66 - THRESHING - CHAPTER 3 15. Remove the stake nut, 1, using New Holland special tool #FNH00089 (inset). Discard the stake nut.

1 40021238

101 IMPORTANT: Be sure the output shaft is properly supported (so not to drop) while pressing the shaft out of the drive gearbox. Use care not to lose the shims when the shaft is removed. Note the number of shims when removing the output shaft.

16. Place the gearbox in a press. With the gearbox case properly supported, press the output shaft, 1, out of the gearbox. Remove the crown gear and bearing from the gearbox. 40021240

102 17. The bearing, 1, is removed from the shaft using a bearing puller, allowing for removal of the seal, 2, and the seal cover, 3, at that time. Discard the seal.

18. The drive coupler, 4, for the rotor is removed by removing the retaining bolt and pressing the shaft out of the coupler.

40021241

2 103

66-40

SECTION 66 - THRESHING - CHAPTER 3 19. Remove the plug, 1, from the range gearbox. Use care not to damage the gearbox case or shaft. The oil seal, 2, will be removed when the input shaft is removed from the gearbox case.

20021261

1 104

20. Slide the range coupler, 1, from the input shaft.

20021262

105 21. Using special tool number OTC 380000660 (inset), bend the stakes in the stake nut away from keyways in the input shaft. Insert the tool into each keyway and use a hammer to strike the tool, bending the stakes away from the keyway.

20021266

106

66-41

SECTION 66 - THRESHING - CHAPTER 3 22. Use special tool # 380000807 to remove the stake nut from the input shaft.

20021266

107 IMPORTANT: When pressing the shaft out of the range gearbox, be sure to catch the shaft, races and bearings to avoid damage to the components. 23. Place the range gearbox in a press. Press the input shaft, 1, out of the gearbox.

24. Remove the large reduction gear and bearing assembly from the range gearbox case.

20021267

108 25. Remove the snap ring, 1, from the input shaft. Remove the gear, 2, from the shaft. To remove the bearing, 3, remove the snap ring (not shown) behind the gear. Use a bearing puller or press to remove the bearing.

2 1

20021268

109

66-42

SECTION 66 - THRESHING - CHAPTER 3 26. Remove the snap ring, 1, which secures the reduction gearset and gear reduction shaft in the gearbox case. NOTE: Be sure to note the thickness and number of shims removed from the gearbox case.

27. Remove any shims located behind the snap ring removed in the previous step. Use care not to lose the shims.

20021263

110 28. Connect a slide hammer to the gear reduction shaft, 1, using the 10 mm x 1.5 threaded hole in the center of the shaft. Using the slide hammer, extract the gear reduction shaft from the gearbox case.

20021269

111 NOTE: Be sure to note the location of each gear, spacer and bearing in the range gearbox case. 29. Remove the gears and spacer from the gearbox case.

20021270

112

66-43

SECTION 66 - THRESHING - CHAPTER 3 30. Disassemble the range selector linkage by removing the stake nut, 1, from the selector and pressing the selector portion, 2, of the linkage out of the cover plate, 3.

31. If necessary, use a bearing puller to remove the selector bearing from the linkage.

3 20021264

2 113

Inspection (Dual Speed)

1. Remove silicone sealant from the gearbox cases and covers. Clean all parts in a suitable solvent and allow the parts to dry. Inspect the breather on the drive gearbox cover for proper operation. Replace as necessary. 2. Inspect the shaft bearings for excessive wear or damage. Make sure all bearings rotate freely and there is not excessive play. Inspect the races removed from the gearbox cases and races, 1, that remain in the cases for damage or wear. The races that are remaining in the cases are removed using a bearing driver or slide hammer. Replace bearings and races as a set, if necessary.

66-44

1 40021242

114

SECTION 66 - THRESHING - CHAPTER 3 3. Inspect the pinion gear and crown gear for chips or cracks. Check for any damage or excessive wear. Replace any damaged or worn gears. 4. Inspect the range gears for chips or cracks. Check for any damage or excessive wear. Replace any damaged or worn gears. 5. Inspect the input and output shafts for damage, excessive runout, and wear. Check for damaged splines. Replace as necessary. 6. Inspect the gearbox cases for cracks, wear, or any other damage. Replace as necessary.

1 20021271

115 7. Inspect the roller bearing/gear assembly. Check to make sure the rollers turn freely and smoothly. Check for excessive play in the bearing. Inspect the gear for damaged or worn teeth. The bearing race, 1, must be carefully cut out of the gear to replace either component. A retaining ring in the center of the gear holds the bearing race and rollers in place.

20021285

116

66-45

SECTION 66 - THRESHING - CHAPTER 3 Assembly (Dual Speed)

20021243

117

66-46

SECTION 66 - THRESHING - CHAPTER 3 NOTE: Replacement oil seals and a new stake nut for the drive and range gearbox halves are required to assemble the gearbox. 1. If any outer bearing races, 1, 2, in the drive gearbox case were removed, install the races at this time. Chill the races in ice or a freezer and install the races using a suitable driver. Be sure the bearing races for output shaft are fully seated in the gearbox case. The left side race, 2, for the input shaft should be installed so the inside end of the race is protruding into the case approximately 1 mm (0.040 in).

1 40021242

118 2. Check the input shaft endplay and rolling torque before the crown gear and output shaft are installed.

NOTE: Be sure the pinion gear and bearing are installed on the input shaft properly.

3. Slide the input shaft, 1, into the right side of the gearbox case. Slide the pinion gear, 2, spacer, 3, and the left bearing, 4, onto the shaft when installing the shaft into the case.

20021272

119 NOTE: Install the same number of shims removed. 4. Place the shims, 1, against the left side bearing race. Install the snap ring, 2, into the groove in the left side of the gearbox case, making sure the shims are properly located before snapping the ring in place.

1 2

40021245

120

66-47

SECTION 66 - THRESHING - CHAPTER 3 5. Place the drive gearbox in a press. Carefully press the input shaft, 1, into the case until the bearing, spacer and pinion gear, 2, are properly seated on the shaft. This will also seat the left side bearing race and shims against the snap ring.

2 40021246

121 IMPORTANT: When installing the right bearing race in the drive gearbox case, be sure the race is square to the case. Use only enough pressure to seat the race. This will avoid damaging the bearing race or gearbox case.

6. Thoroughly chill the right side bearing race, 1, in ice or in a freezer. Carefully align the race squarely in the drive gearbox case and use a press to seat the race against the right bearing. 40021247

122 NOTE: Install the same number of shims that were removed. 7. Remove the gearbox from the press and place the shims removed from the right side of the gearbox against the right bearing race.

8. Install the snap ring, 1, for the right side of the input shaft, making sure the shims are properly located before snapping the ring in place.

20021260

123

66-48

SECTION 66 - THRESHING - CHAPTER 3 9. Using a plastic mallet or dead blow hammer, strike the internal splined end of the input shaft. This is to seat the left side bearing race and shims against the snap ring.

20021273

124 10. Using a dial indicator, measure the input shaft end play. The shaft end play should be 0.05 mm (0.002 in). Use a torque meter to measure the input shaft rolling torque. Rolling torque should be 2 kg⋅cm (2 in-lb). If end play or rolling torque are not as specified, repeat step # 9. If they are still not as specified, shim(s) must be added or removed from the right side (side opposite of pinion gear) of the gearbox. Shims are available in thicknesses 0.3 mm (0.012 in), 0.35 mm (0.014 in), 0.4 mm (0.016 in), 0.5 mm (0.020 in) and 2 mm (0.079). 20021274

125 IMPORTANT: Make sure not to lose shims when removing them from the gearbox case. Note the number of shims, as the same number of shims will be used when reinstalling the input shaft.

11. Once the proper rolling torque and end play have been achieved, remove the snap ring and shim(s) from the left side of the gearbox case. NOTE: When pressing the input shaft out of the gearbox, be sure to hold the shaft or keep the shaft from falling during pressing. 12. Place the gearbox in a press and remove the input shaft, 1, by pressing on the splined end of the shaft. Be sure to catch the bearing, race, pinion gear and spacer as the input shaft is being removed from the case.

66-49

20021237

126

SECTION 66 - THRESHING - CHAPTER 3 13. Install the outer bearing onto the output shaft using a suitable bearing driver or press so the tapered end of the bearing will face towards the center of the gearbox. Be sure to press on the inner bearing race only and not the bearing cage or rollers. 14. Install the shaft into the gearbox case and place the gearbox in a press. The gearbox will need to be balanced on the output shaft, 1. Press the inner bearing onto the output shaft until the bearing is fully seated on the shaft and in the outer race. 15. Remove the gearbox from the press. Using a suitable mallet or dead blow hammer, strike both ends of the output shaft. This is to ensure the bearings and races are properly seated.

1 40021250

127

NOTE: Be sure to install the same number of shims as removed. 16. Place the shims and the crown gear onto the output shaft. 17. Coat the threads of the output shaft with LoctiteR 270. Thread and tighten a new stake nut onto the output shaft to hold the assembly in place. Use special tool FNH00089. DO NOT stake the nut at this time. 20021251

128 18. Use a torque meter to check rolling resistance of the output shaft. Rolling resistance should be 1 -- 3 kg⋅cm (1 -- 3 in-lb). 19. If rolling torque is not as specified, loosen or tighten the stake nut as necessary. 20. Repeat steps 3 through 9 to install the input shaft back into the gear box case.

40021252

129

66-50

SECTION 66 - THRESHING - CHAPTER 3 21. To check gear contact pattern, apply gear marking paste or Prussian blue onto four or five teeth of the crown gear. NOTE: There should be NO LOAD placed on the gears while checking contact pattern. 22. Slowly rotate the left side of the input shaft counter-clockwise until a contact pattern appears on the other teeth of the crown gear. Rotate the input shaft clockwise until the marking paste makes a pattern on the opposite side of the crown gear teeth.

20021275

130 23. Check the contact pattern the marking paste creates on the drive side of the crown gear teeth. Looking at the tooth in the twelve o’clock position on the crown gear, the right side of the tooth is the drive side. Compare the contact pattern on the drive side of teeth with the illustration. •

•

For combines equipped with 22 inch rotors, measurement “A” should be 3.9 mm (0.15 in). Measurement “B” should be 15.5 mm (0.61 in). For combines equipped with 17 inch rotors, measurement “A” should be 4.4 mm (0.17 in). Measurement “B” should be 17.4 mm (0.69 in). The pattern on the opposite side of the teeth should be similar to the drive side.

24. Use a dial indicator to check gear backlash. Set the teeth contact on the gears to the non-drive side by turning the input shaft at 1, clockwise. Zero the indicator on one of the pinion gear tooth faces, then rotate the output shaft counter-clockwise until the gears contact the drive side of the teeth. Make sure the input shaft does not rotate, as this will give a false reading.

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131

25. Compare the measurement with the following: •

•

For combines equipped with 22 inch rotors, backlash should be 0.13 -- 0.35 mm (0.005 -0.014 in). For combines equipped with 17 inch rotors, backlash should be 0.16 -- 0.42 mm (0.006 -0.017 in).

66-51

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132

SECTION 66 - THRESHING - CHAPTER 3 IMPORTANT: If it is necessary to add or remove shims, rolling torque will have to be checked and adjusted. 26. If necessary, adjust the contact pattern and backlash by adding or removing shims. Generally, If backlash requires adjustment, add or remove shims to the output shaft (crown gear). If the contact pattern needs moved, add or subtract shims from the input shaft (pinion gear). Shims are available in thicknesses 0.1 mm (0.004 in), 0.15 mm (0.006 in), 0.3 mm (0.012 in) and 0.5 mm (0.020 in). Use the following chart to determine where to add or subtract shims. Gear Contact Pattern

Proper Contact

High Contact

Low Contact

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133

Measured Backlash

Adjustment

Low on crown gear

Tight, needs to be increased

Pinion out

Low on crown gear

Loose, needs to be decreased

Pinion out, crown gear in

High on crown gear

Tight, needs to be increased

Crown gear out

High on crown gear

Loose, needs to be decreased

Crown gear out, pinion in

Correct

Tight, needs to be increased

Crown gear out

Correct

Loose, needs to be decreased

Crown gear in

NOTE: Input shaft and gears not shown for illustration purposes.

27. Once the proper backlash and contact pattern have been set, lock the stake nut, 1, onto the output shaft by staking the nut at the slots, 2, in the output shaft.

1 40021238

134 28. Lubricate a new output shaft oil seal with gear oil or petroleum jelly. Using a suitable seal driver, install the new oil seal, 1, over the input shaft and into the gearbox case. The seal should be recessed into the case approximately 1 mm (0.040 in).

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135

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SECTION 66 - THRESHING - CHAPTER 3 29. Lubricate a new output shaft oil seal with gear oil or petroleum jelly. Using a suitable seal driver, install the new oil seal, 1, over the output shaft and into the gearbox case. The seal should be recessed into the case approximately 10 mm (0.40 in).

30. Install the steel environmental seal, 2 (inset), over the oil seal.

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136 31. Install the snap ring (not shown) and rotor drive coupler, 1, on the output shaft. Apply LoctiteR 271t adhesive to internal threads of shaft and install M12 x 45 flange head class 10.9 bolt and washer, 2, if 22 inch rotors. For 17 inch rotors, install M12 x 70 flange head class 10.9 bolt and conical spacer. Torque to 150--165 N⋅m (111--122 ft-lb). 32. Install the external snap ring, 3, on the short splined end of the input shaft.

3 2

20021277

137 IMPORTANT: The rear cover must be oriented so the breather, 1, on the cover is upright when the gearbox is installed in the combine. 33. Place a 3 mm (1/8 inch) bead of LoctiteR RTV sealant on the mounting surface of the rear cover. Install the cover, with the breather, 1, up, and secure using the eight mounting bolts, 2. Torque the bolts in a crossing pattern to 24 -- 31 N⋅m (18 -- 23 ft-lb).

2 20021282

138

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SECTION 66 - THRESHING - CHAPTER 3 IMPORTANT: The side cover must be oriented so the sight glass, 1, on the cover is at the bottom of the gearbox when installed in the combine. 34. Place a 3 mm (1/8 in) bead of LoctiteR RTV sealant on the mounting surface of the side cover. Install the cover, with the sight glass, 1, down, and secure using the eight mounting bolts, 2. Torque the bolts in a crossing pattern to 61 -- 79 ft-lb.

1 40021232

139 35. If removed from the range gearbox case, chill the bearing races in a freezer or ice for 15 minutes. Install the races in their proper position in the gearbox case using a suitable driver. 36. Place the inner bearing for the gear reduction shaft in the race, 1.

1 20021271

140 NOTE: Install the small reduction gear so that the recess in the gear will face the inner shaft bearing.

37. Install the large reduction gear, the spacer, and the small reduction gear, 1, into the range gearbox case.

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141

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SECTION 66 - THRESHING - CHAPTER 3 NOTE: When installing the gear reduction shaft, strike the shaft only. DO NOT strike the bearing race. 38. Install the gear reduction shaft, 1, into the gearbox case. Using a suitable driver on the shaft only, drive the gear reduction shaft into the race of the inner bearing. Be sure the shaft is fully seated in the bearing and gearbox case.

1 20021278

142 39. Chill the outer bearing race in a freezer or ice for 15 minutes. Use a suitable driver and hammer to install the race into the gearbox case. Be sure the race is fully installed in the gearbox.

20021279

143 NOTE: Start with the same amount of shimming removed from the range gearbox. 40. Install the shim(s), 1, and the snap ring, 2, for the gear reduction shaft.

2 20021263

144

66-55

SECTION 66 - THRESHING - CHAPTER 3 41. Connect a slide hammer to the gear reduction shaft, 1. Use the slide hammer to pull the shaft out to ensure the outer bearing race and shim(s) are properly seated against the snap ring.

20021269

145 42. Check the rolling torque of the gear reduction shaft using a torque meter. The rolling torque should be between 5 -- 9 kg⋅cm (4.3 -- 7.8 in-lb). If the rolling resistance is not as specified, remove the snap ring from the gear reduction shaft and add or remove shims as necessary to obtain the correct rolling torque. Be sure to connect the slide hammer and pull the gear reduction shaft bearing race and shims out against the snap ring before checking rolling torque. 20021280

146 43. If removed, install the bearing (not shown, behind race) and outer race, 1, onto the shaft. The bearing should be installed so the top of the cone faces the small splined end of the shaft.

2 3

44. Install the inner snap ring (not shown), the gear, 2, and the outer snap ring, 3, onto the shaft.

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147

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SECTION 66 - THRESHING - CHAPTER 3 45. Install the input shaft, 1, into the gearbox case using a press. The outer bearing race, 2, will be pressed into the gearbox case by the bearing.

1 2

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148 NOTE: The bottom of the input shaft must be supported when pressing the gearbox internals onto the input shaft. 46. Install the bearing, 1, onto the input shaft using a press and suitable driver. Be sure to fully seat the bearing in the race. Install the thrust washer, 2, onto the input shaft. NOTE: The gear and bearing assembly must be oriented so the internal teeth (not the shaft splines) of the gear will be able to mesh with the range coupler when installed.

2 20031251

149 47. Press the gear and bearing assembly onto the input shaft using a press and bearing driver, 3. Be sure to fully seat the bearing assembly in the gearbox case.

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150

66-57

SECTION 66 - THRESHING - CHAPTER 3 48. Coat the threads of the input shaft with LoctiteR 270 or 271™ Install the stake nut, 1, using the special tool #380000807. Tighten the nut, but DO NOT stake the nut at this time.

20021266

151 49. Strike each end of the shaft with a suitable mallet or dead blow hammer. This ensures the races and bearings are properly seated. 50. Check the rolling torque of the input shaft using a torque meter. The rolling torque should be 14 -- 21 kg⋅cm (12.2 -- 18.2 in-lb). If preload is not as specified, tighten or loosen the stake nut as required. 51. Once proper rolling torque has been achieved, stake the nut at the slots on the input shaft using a hammer and punch. 20021283

152 52. Using a suitable seal driver, install a new oil seal, 1, 1 mm (0.040 in) into the range gearbox housing.

53. Using a suitable driver, install a new cap, 2, into the range gearbox housing.

20021261

2 153

66-58

SECTION 66 - THRESHING - CHAPTER 3 54. Slide the range coupler, 1, onto the input shaft. Be sure the coupler is installed so the gear teeth will mesh with the gear and bearing assembly, 2, inside the gearbox case. 55. Apply a 3 mm (1/8 inch) bead of silicone RTV sealant to the range gearbox at the mating surface, 3, for the drive gearbox.

1 2

56. Apply a 3 mm (1/8 inch) bead of silicone RTV sealant to the drive gearbox at the mating surface for the range gearbox.

3 20021262

154 57. Join the drive gearbox half with the range gearbox half. Install the eight (8) retaining bolts, 1, which secure the halves together. Two mounting bolts are installed inside the gearbox case. Torque the retaining bolts in a crossing pattern to 140 -- 180 N⋅m (103 -- 133 ft-lb).

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155

66-59

SECTION 66 - THRESHING - CHAPTER 3 58. Using a new O-ring lubricated with petroleum jelly, assemble the range selector linkage by pressing the selector linkage, 1, into the cover plate, 2.

59. Install the stake nut, 3, onto the selector linkage. Torque the nut to 9 --10 kg⋅cm (8 -- 9 ft-lb). Once the proper adjustment is reached, lock the nut by staking at the grooves in the linkage arm.

1 20021264

2 156

IMPORTANT: Be sure the bearing on the range selector properly engages the range coupler in the gearbox.

60. Place a 3 mm bead of silicone RTV sealant on the drive gearbox case where the surface mates to the range selector, 1. Install the four top bolts, 2, for the range selector and torque to 24 -- 32 N⋅m (18 -- 23 ft-lb). 61. Coat the two detent plate bolts, 4, with LoctiteR 271. Install the range detent plate, 3, and the retaining bolts and torque to 24 -- 32 N⋅m (18 -- 23 ft-lb).

20021258

3 157

62. Install the external snap ring, 5, onto the shaft. 63. Move the range selector to all positions to ensure that the gearbox properly changes ranges. 64. Fill the gearbox with 3.8 L (4.0 qt) of AMBRA Hypoide 90 or Hypoide 90 LS gear oil.

66-60

SECTION 66 - THRESHING - CHAPTER 3 Installation

1. Clean left output shaft splines and apply LoctiteR Primer T™. Apply LoctiteR 680™ or 638™ to shaft splines and to coupler hub splines. Install coupler hub against snap ring. Apply AMBRA GR 75 MD grease to external drive lugs of inner coupling half and to inner drive lugs of outer coupling half. Assemble outer on inner.

CAUTION The rotor gearbox weighs approximately 121 kg (266 lb). Use care when handling the gearbox, otherwise severe personal injury may occur. Use the help of an assistant to remove the gearbox from the combine. Failure to comply may result in minor or moderate injury.

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158

IMPORTANT: If the rotors are timed, do not rotate the rotor to install the gearbox. Rotate the gearbox output shaft. 2. Using the help of an assistant, raise the rotor gearbox up to the combine frame. 3. Make sure all coupler components for the right gearbox are on the gearbox shaft at this time. 4. Use a wood block to help support the gearbox. Using the block or a prying bar, engage the gearbox output shaft into the rotor. Thread the three bolts, 1, securing the top of the rotor gearbox to the combine frame, placing any shims removed previously between the gearbox and the combine frame. The shims prevent binding from occurring at the gearbox coupler. 5. Thread the bottom three gearbox mounting bolts, 2, into the gearbox and combine frame. Torque all six mounting bolts to 94 -- 106 N⋅m (69 -- 78 ft-lb).

6. Connect the gear range linkage, 1, to the gearbox and install cotter pins.

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2 159

66-61

SECTION 66 - THRESHING - CHAPTER 3 7. If necessary, time the rotors so they are in phase. Refer to the rotor timing procedure in Chapter 1 of this manual.

1 2

IMPORTANT: As coupler is assembled, it is important to check alignment of gearbox shafts to reduce wear in coupler. Shim as required under mounting feet of both gearboxes to align. Check coupler alignment using a straight edge at three places 120° apart on the outer couplings, 2. With the coupler spacer plate, 1, in place between the right and left outer couplers, install six M12 x 100 cap screws, hand washers at both ends, and nuts. Tighten to 94--106 N⋅m (69--78 ft-lb).

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160

8. Remove the chain or lifting strap from around the rotor. Install the upper rotor cover onto the combine frame. Make sure the gearbox coupler will not bind by rotating the rotors. Adjust right gearbox shimming if necessary.

40021228

161 9. Install the torque sensing sheave, 1, to the right rotor gearbox input shaft, 2, using the installation procedure described earlier in this chapter.

1 10021162

162

66-62

SECTION 66 - THRESHING - CHAPTER 3 LEFT ROTOR GEARBOX Removal 1. Remove the grain tank access panel and the straw hood access panel from the combine. This allows access to the rotor gearbox. Place a suitable piece of plywood on upper sieve to prevent any damage. 2. Remove the upper rotor cover for the right rotor. Wrap a chain or lifting strap, 1, around the rotor. Support the rear of the rotor by hooking the chain or tying the strap off to framework above the rotor.

20021299

163 3. Disconnect the left rotor gearbox from the right by removing the six bolts from the gearbox coupler, 1.

66071493

164 4. Remove the two lower bolts, 1, which secure the bottom of the left rotor gearbox to the combine.

40021226

165

66-63

SECTION 66 - THRESHING - CHAPTER 3 CAUTION The left rotor gearbox weighs approximately 62 kg (136 lb) wet. Use the help of an assistant(s) to remove the gearbox from the combine. Failure to comply may result in minor or moderate injury.

5. Place a wooden block under the rotor gearbox for support. Remove the two remaining bolts (not visible), 1, securing the top of the gearbox to the combine. 6. Use the help of an assistant to remove the gearbox from the combine.

40021227

166 Disassembly NOTE: References to directions (left, right, top, bottom) are referenced as if the gearbox is installed in the machine, facing the normal direction of travel. 1. Drain the gear oil from the gearbox into a suitable container. Remove the fill plug from the gearbox case. 2. Remove the snap ring from the spline input shaft. 3. Remove the eight bolts securing the rear cover, 1, to the gearbox. Use a suitable mallet to break the cover loose.

40021231

167 4. Remove the eight bolts securing the side cover, 1, to the gearbox. Use a suitable mallet to break the cover loose.

40021232

168

66-64

SECTION 66 - THRESHING - CHAPTER 3 IMPORTANT: Use care not to loose any shims. Note the amount of shims removed, and their location. 5. Use snap ring pliers to remove the snap ring, 1, in the left side of the case.

1 40021233

169 IMPORTANT: Use care not to damage the gearbox case or input shaft when removing oil seal. 6. Remove the oil seal, 1, from the right side of the gearbox. Discard the seal.

40021234

170 7. Remove the snap ring, 1, from the right side of the gearbox using suitable snap ring pliers.

40021235

1 171

66-65

SECTION 66 - THRESHING - CHAPTER 3 IMPORTANT: Use care not to loose any shims that happen to be behind the snap ring.

8. Remove the shims, 1, located behind the snap ring removed in the previous step. Note the amount and thickness of the shims.

40021236

172 NOTE: When pressing the input shaft out of the gearbox, be sure to hold the shaft or keep the shaft from falling during pressing.

9. Place the gearbox in a press and press on the splined end of the input shaft, 1. Be sure to catch the bearing, race, pinion gear and spacer as the input shaft is being removed from the case.

40021237

173 IMPORTANT: Use extreme care when bending the tabs of the stake nut away from the output shaft. DO NOT damage the threads on the output shaft.

10. Using special tool number OTC 380000660 (inset), bend the stakes in the stake nut away from keyways, 1, in the input shaft. Insert the tool into each keyway and use a hammer to strike the tool, bending the stakes away from the keyway.

40021238

174

66-66

SECTION 66 - THRESHING - CHAPTER 3 11. Remove the stake nut, 1, using New Holland special tool #FNH00089 (inset). Discard the stake nut.

1 40021238

175 IMPORTANT: Be sure the output shaft is properly supported (so not to drop) while pressing the shaft out of the gearbox. Use care not to lose the shims as the shaft is being removed. Note the number of shims when removing the output shaft.

12. Place the gearbox in a press. With the gearbox case properly supported, press the output shaft, 1, out of the gearbox. Remove the crown gear and bearing from the gearbox. 40021240

176 13. The bearing, 1, can be removed from the shaft using a bearing puller, allowing for removal of the seal, 2, and the seal cover, 3, at that time. Discard the seal.

14. The drive gear, 4, for the rotor can be removed by removing the retaining bolt and pressing the shaft out of the gear.

40021241

2 177

66-67

SECTION 66 - THRESHING - CHAPTER 3 Inspection

1. Remove silicone sealant from the gearbox case and covers. Clean all parts in a suitable solvent and allow to dry. Inspect the breather on the drive gearbox cover for proper operation. Replace as necessary. 2. Inspect all of the bearings for excessive wear or damage. Make sure all bearings rotate freely and there is no excessive play. Inspect the races removed from the gearbox case and races that remain in the case, 1, for damage or wear. The races that are remaining in the case can be removed using a bearing driver. Replace bearings and races as a set, if necessary. 3. Inspect the pinion gear and crown gear for chips or cracks. Check for any damage or excessive wear. Replace any damaged or worn gears. 4. Inspect the input and output shafts for damage, excessive runout, or wear. Check for damaged splines. Replace as necessary. 5. Inspect the gearbox case for cracks, wear, or any other damage. Replace as necessary.

66-68

1 40021242

178

SECTION 66 - THRESHING - CHAPTER 3 Assembly

20021298

179

66-69

SECTION 66 - THRESHING - CHAPTER 3 NOTE: Replacement oil seals and a new stake nut will be required to assemble the gearbox.

1. If any outer bearing races, 1, 2, in the gearbox case were removed, install the races at this time. Chill the races in ice or a freezer and install the races using a suitable driver. Be sure the bearing races for output shaft are fully seated in the gearbox case. The right side race, 2, for the input shaft should be installed so the inside end of the race is protruding into the case approximately 1 mm (0.040 in).

2 40021242

180 2. Before the crown gear and output shaft can be installed, the input shaft endplay and rolling torque must be checked.

NOTE: Be sure the pinion gear and bearing are installed on the input shaft properly. 3. Slide the input shaft, 1, into the left side of the gearbox case. Slide the pinion gear, 2, spacer, 3, and the right bearing, 4, onto the shaft when installing the shaft into the case. NOTE: Spacer, 3, is used only in gearboxes of combines equipped with 22 inch rotors.

20021272

181 NOTE: Install the same number of shims removed. 4. Place the shims, 1, against the right side bearing race, Install the snap ring, 2, into the groove in the right side of the gearbox case, making sure the shims are properly located before snapping the ring in place.

1 2

40021245

182

66-70

SECTION 66 - THRESHING - CHAPTER 3 5. Place the gearbox in a press. Carefully press the input shaft, 1, into the case until the right bearing, spacer and pinion gear, 2, are properly seated on the shaft. This will also seat the right side bearing race and shims against the snap ring.

2 40021246

183 IMPORTANT: When installing the left bearing race in the gearbox case, be sure the race is square to the case. This will avoid damaging the bearing race or gearbox case.

6. Thoroughly chill the left side bearing race, 1, in ice or in a freezer. Carefully align the race squarely in the gearbox case and use a press to seat the race against the left bearing.

40021247

184 NOTE: Install the same number of shims removed. 7. Remove the gearbox from the press and place the shims, 2, removed from the right side of the gearbox against the right bearing race. 8. Install the snap ring, 1, for the right side of the input shaft, making sure the shims are properly located before snapping the ring in place.

40021233

185

66-71

SECTION 66 - THRESHING - CHAPTER 3 9. Take a plastic mallet or dead blow hammer and strike the splined end of the input shaft. This is to seat the left side bearing race and shims against the snap ring.

40021248

186 10. Use a dial indicator to measure the input shaft end play. The shaft end play should be 0.05 mm (0.002 in). Use a torque meter to measure the input shaft rolling torque. Rolling torque should be 2 kg⋅cm (2 in-lb). If end play or rolling torque are not as specified, repeat step # 9. If they are still not as specified, shim(s) must be added or removed from the left side (opposite of pinion gear) of the gearbox. Shims are available in thicknesses 0.3 mm (0.012 in), 0.35 mm (0.014 in), 0.4 mm (0.016 in), 0.5 mm (0.020 in) and 2 mm (0.079 in). 40021249

187 IMPORTANT: Make sure not to lose shims when removing them from the gearbox case. Note the number of shims, as the same number of shims will be used when reinstalling the input shaft. 11. Once the proper rolling torque and end play have been achieved, remove the snap ring and shim(s) from the left side of the gearbox case. NOTE: When pressing the input shaft out of the gearbox, be sure to hold the shaft or keep the shaft from falling during pressing. 12. Place the gearbox in a press and remove the input shaft by pressing on the splined end of the shaft. Be sure to catch the bearing, race, pinion gear and spacer as the input shaft is being removed from the case.

66-72

40021237

188

SECTION 66 - THRESHING - CHAPTER 3 13. Install the outer bearing onto the output shaft using a suitable bearing driver or press so the tapered end of the bearing will face towards the center of the gearbox. Be sure to press on the inner bearing race only. 14. Install the shaft into the gearbox case and place the gearbox in a press. The gearbox will need to be balanced on the output shaft, 1. Press the inner bearing onto the output shaft until the bearing is fully seated on the shaft and in the outer race. 15. Remove the gearbox from the press. Using a suitable mallet or dead blow hammer, strike both ends of the output shaft. This is to ensure the bearings and races are properly seated.

1 40021250

189

NOTE: Be sure to install the same number of shims as removed. 16. Place the shims and the crown gear onto the output shaft. 17. Coat the threads of the output shaft with LoctiteR 270 or 271™. Thread and tighten a new stake nut onto the output shaft to hold the assembly in place. Use special tool FNH00089. DO NOT stake the nut at this time. 20021251

190 18. Use a torque meter to check rolling resistance of the output shaft. Rolling resistance should be 1 -- 3 kg⋅cm (1 -- 3 in-lb). 19. If rolling torque is not as specified, loosen or tighten the stake nut as necessary. 20. Repeat steps 3 through 9 to install the input shaft back into the gear box case.

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191

66-73

SECTION 66 - THRESHING - CHAPTER 3 21. To check gear contact pattern, apply gear marking paste or Prussian blue onto four or five teeth of the crown gear. NOTE: There should be NO LOAD placed on the gears while checking contact pattern. 22. Slowly rotate the right side of the input shaft clockwise until a contact pattern appears on the other teeth of the crown gear. Rotate the input shaft counter-clockwise until the marking paste makes a pattern on the opposite side of the crown gear teeth.

40021253

192 23. Check the contact pattern the marking paste creates on the drive side of the crown gear teeth. Looking at the tooth in the twelve o’clock position on the crown gear, the left side of the tooth is the drive side. Compare the contact pattern on the drive side of teeth with the illustration. •

•

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193

24. Use a dial indicator to check gear backlash. Set the teeth contact on the gears is on the non-drive side by turning the input shaft counter-clockwise. Zero the indicator on one of the pinion gear tooth faces, then rotate the output shaft counter-clockwise until the gears contact the drive side of the teeth. Make sure the input shaft does not rotate, as this will give a false reading. 25. Compare the measurement with the following: •

•

For combines equipped with 22 inch rotors, backlash should be 0.13 -- 0.35 mm (0.005 -0.014 in). For combines equipped with 17 inch rotors, backlash should be 0.16 -- 0.42 mm (0.006 -0.017 in).

66-74

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194

SECTION 66 - THRESHING - CHAPTER 3 IMPORTANT: If shims are added or removed for the output or input shaft, rolling torque will have to be checked and adjusted. 26. If necessary, adjust the contact pattern and backlash by adding or removing shims. Generally, If backlash requires adjustment, add or remove shims to the output shaft (crown gear). If the contact pattern needs moved, add or subtract shims from the input shaft (pinion gear). Shims are available in thicknesses 0.1 mm (0.004 in), 0.15 mm (0.006 in), 0.3 mm (0.012 in) and 0.5 mm (0.020 in). Use the following chart to determine where to add or subtract shims. Gear Contact Pattern

Proper Contact

High Contact

Low Contact

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195

Measured Backlash

Adjustment

Low on crown gear

Tight, needs to be increased

Pinion out

Low on crown gear

Loose, needs to be decreased

Pinion out, crown gear in

High on crown gear

Tight, needs to be increased

Crown gear out

High on crown gear

Loose, needs to be decreased

Crown gear out, pinion in

Correct

Tight, needs to be increased

Crown gear out

Correct

Loose, needs to be decreased

Crown gear in

NOTE: Input shaft and pinion gear not shown for illustration purposes.

27. Once the proper backlash and contact pattern have been set, lock the stake nut, 1, onto the output shaft by staking the nut at the keyways, 2, in the output shaft.

1 40021238

196 28. Lubricate a new output shaft oil seal with gear oil or petroleum jelly. Using a suitable seal driver, install the new oil seal, 1, over the input shaft and into the gearbox case. The seal should be recessed into the case approximately 1 mm (0.040 in).

40021234

197

66-75

30. Install the metal environmental seal, 2 (inset), over the oil seal. 31. Coat shaft splines with AMBRA GR 75 MD grease.

40021255

198 32. Coat rotor drive coupler, 1, splines with AMBRA GR 75 MD grease. 33. Install the snap ring (not shown), and the rotor drive coupler, 1. Apply LoctiteR 271™ to threads tapped in end of shaft and install M12 class 10.9 flange head bolt with flat washer (if 22 inch rotors) or conical spacer (if 17 inch rotors). Torque to 150--165 N⋅m (111--112 ft-lb).

1 2

40021256

199 IMPORTANT: The rear cover must be oriented so the breather, 1, on the cover is upright when the gearbox is installed in the combine.

34. Place a 3 mm (1/8 inch) bead of LoctiteR RTV sealant on the mounting surface of the rear cover. Install the cover, with the breather, 1, up, and secure using the eight mounting bolts, 2. Torque the bolts in a crossing pattern to 24 -- 31 N⋅m (18 -- 23 ft-lb).

40021231

200

66-76

SECTION 66 - THRESHING - CHAPTER 3 IMPORTANT: The side cover must be oriented so the sight glass, 1, on the cover is at the bottom of the gearbox when installed in the combine. 35. Place a 3 mm (1/8 in) bead of LoctiteR RTV sealant on the mounting surface of the side cover. Install the cover, with the sight glass, 1, down, and secure using the eight mounting bolts, 2. Torque the bolts in a crossing pattern to 61 -- 79 ft-lb. 36. Fill the gearbox with 2.9 L (3.0 qt) of AMBRA Hypoide 90 or Hypoide 90 LS gear oil.

1 40021232

201 Installation 1. Clean input shaft splines and apply LoctiteR Primer T™. Apply LoctiteR 680™ or 638™ to shaft splines and to coupler hub splines. Install coupler hub against snap ring. Apply AMBRA GR 75 MD grease to external drive lugs of inner coupling half and to inner drive lugs of outer coupling half. Assemble outer on inner.

CAUTION The left rotor gearbox weighs approximately 62 kg (136 lb) wet. Use the help of an assistant (s) to remove the gearbox from the combine.

40021227

202 IMPORTANT: If the rotors are timed, do not rotate the rotor to install the gearbox. Rotate the gearbox input shaft. 2. Using the help of an assistant, raise the rotor gearbox up to the combine frame. 3. Use a wood block to help support the gearbox. Install the two bolts, 1, securing the top of the rotor gearbox to the combine frame. 4. Install the two lower bolts, 1, which secure the bottom of the left rotor gearbox to the combine. Torque the four mounting bolts to 94 -- 106 N⋅m (69 -- 78 ft-lb).

40021226

203

66-77

SECTION 66 - THRESHING - CHAPTER 3 5. If necessary, time the rotors so they are in phase. Refer to the rotor timing procedure in Chapter 1 of this manual.

IMPORTANT: As coupler is assembled, it is important to check alignment of gearbox shafts to reduce wear in coupler. Shim as required under mounting feet of both gearboxes to align. Check coupler alignment using a straight edge at three places 120° apart on the outer couplings, 2. 6. With the coupler spacer plate, 1, in place between the right and left outer couplers, install six M12 x 100 cap screws, hand washers at both ends, and nuts. Tighten to 94--106 N⋅m (69--78 ft-lb).

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204

7. Remove the lifting strap or chain from the rotor and install the upper rotor cover.

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205

66-78

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1

SECTION 72 -- DISCHARGE BEATER Chapter 1 -- Discharge Beater CONTENTS Section

Description

Page

72-1

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1 SPECIFICATIONS Discharge Beater Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 paddle with replaceable blades Number of replaceable blades . . . . . . . . . . . . . . . 20 (CR9040, CR9060) 24 (CR9070) Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2HB belt from main shaft Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 rpm Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1295 -- 1298 mm (51 -- 51-1/8 in) (CR9040, CR9060) 1555 -- 1558 mm (61-7/32 -- 61-5/16 in) (CR9070) Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398.5 -- 401.5 mm (15-11/16 -- 15-3/4 in) Beater Grate Grate Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1309 -- 1311 mm (51-1/2 -- 51-9/16 in) (CR9040, CR9060) 1569 -- 1571 mm (61-3/4 -- 61-13/16 in) (CR9070) Wrap Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 degrees Grate Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perforated sheet Number of perforations . . . . . . . . . . . . . . . . . . . . . 260 (5 rows of 52) (CR9040, CR9060) 310 (5 rows of 62) (CR9070) Opening size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 mm x 40 mm (9/16 in x 1-9/16 in) Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . At rear suspension point

72-2

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1 INTRODUCTION 1. Stiff stems or stalks spear through the grate and plug the upper sieve.

The CR 9000 combines are equipped with a discharge beater which propels the material from the rotors out the rear of the combine. The discharge beater grate allows for separation of any grain which may be left in the straw after it leaves the rotors. The discharge beater is belt driven from the main shaft and rotates at a constant speed of 800 rpm. The discharge beater grate is adjustable for extreme crop conditions.

2. Dry, brittle straw crops when excess chaff and fine stems fall through the grate and overload the cleaning area. 3. The crop is damp or green weeds are present which make the crop difficult to throw out the rear of the combine. The covers provide a smooth surface for the crop to pass over.

A full-length beater grate cover is available for all models. Install the beater grate cover when operating in the following conditions:

NOTE: The beater grate cover is recommended for use in Soybeans and most corn varieties.

SPECIAL TOOLS OEM6210 -- 3/4 in drive Adjustable Spanner Wrench (2 in -- 4-3/4 in O.D.). Used for removal and installation of two gland nuts on the right-hand side beater shaft bearing.

86072857

72-3

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1 OVERHAUL NOTE: Most service procedures will require an assistant for hardware and component removal and installation, as one person will have to work from inside the strawhood and the second from the outside, or together to lift heavy components.

DISCHARGE BEATER GRATE

WARNING The beater grate is heavy, approximately 55 kg (122 lb). The grate’s width and location may make handling and support difficult. Always use appropriate and adequate support materials or devices. Failure to comply could result in serious injury or death. Removal 1. Fully close the upper sieve.

2. Unplug the Rotor Loss Detector, 1, from the main wire harness.

3. Remove cable ties and pull Rotor Loss Detector wire harness to the inside of the combine, through the grommet hole, at, 2. (Right-hand side shown in Figure 2).

56070017

2 4. Inside the combine, route the wire harness, 1, out of the way of the discharge beater grate, 2.

5. Repeat steps 2, 3, and 4 for the Rotor Loss Detector on the other side of the combine.

6. Remove the cleaning shoe light, 3, by removing the cap screws, washers and nuts.

7. Support the front of the discharge beater grate, remove an M12 nut and lock washer at each end of the grate and then remove the M12 x 35 cap screws, 4.

NOTE: There is a spacer between the discharge beater grate and the side of the combine.

56070018

8. Lower the front of the discharge beater grate onto the upper sieve.

72-4

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1 9. Support the rear of the discharge beater grate and remove M20 locknuts, 1, from the lever pin bolt that extends outward through the rear of the beater grate, the frame, and the slat, 2, on both sides of the machine.

56070013

4 10. Remove the M8 x 20 carriage bolt, washer and lock nut, 1, from the seal plate, 3, at each end. 11. Remove the lever pin bolt, 2, at each end and then lower the discharge beater grate and slide it out the rear of the combine.

3 2

Installation

WARNING

The beater grate is heavy, approximately 55 kg (122 lb). The grate’s width and location may make handling and support difficult. Always use appropriate and adequate support materials or devices. Failure to comply could result in serious injury or death.

10023044

1. Slide the discharge beater grate into position from the rear of the combine. 2. Lift the rear of the discharge beater grate into position and install lever pin bolt, 2. NOTE: Due to the tight clearance, it may be necessary to slide the seal plate, 3, in after the beater grate is lifted into position. 3. Install an M8 x 20 carriage bolt, washer and locknut, 1. Tighten nut to take end play from carriage bolt. Do not torque. 4. Tighten locknut, 1, to remove end play from lever pin bolt. Do not torque.

56070013

72-5

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1 5. Lift the front of the discharge beater grate into position. 6. Place spacer, 1, between the combine frame and the discharge beater grate and install cap screw, 2, lock washer and nut.

7. Route the rotor loss detector wire harness through the side of the combine at 3, and plug in to main wire harness. Secure rotor loss detector wire harness with cable ties.

8. Repeat steps 6 and 7 on the other side of the combine.

10023042

9. Install the cleaning shoe light, 4, using the cap screws, washers and nuts.

Adjustment Adjust the beater grate position so there is a clearance, A, of 8.5 -- 11.5 mm (0.34 -- 0.45 in) between the end of the beater blades and a grate at the exit of the beater grate.

66070019

8 Adjust as follows: 1. To raise the grate, back off jam nut, 1, and adjust nut, 2. 2. To lower the grate, back off jam nut 2, and adjust nut, 1. 3. Retighten jam nut.

1 2 56070014

72-6

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1 DISCHARGE BEATER DRIVES Replacement

1. Loosen idler, 1, and remove the main drive belt, 2, from the sheave, 3.

2 40021145

10 2. Loosen idlers and remove the shoe drive belt, 1, and then the beater drive belt, 2. 3. Inspect the belt for cracks, tears or other indications of excessive wear or damage. Replace the belt if necessary.

4. Install the beater drive belt, 2, and then the shoe drive belt, 1. 5. Tighten the shoe drive belt idler to the spring gage indicator.

6. Tighten the beater drive idler to the spring gage indicator.

56070012

7. Install the main drive belt, 2, Figure 10, and tighten the idler to the spring gage indicator.

DISCHARGE BEATER

WARNING

Removal

1. Loosen idlers and remove the shoe drive belt, 1, and the beater drive belt, 2.

56070012

2. Remove the M10 x 30 cap screw with lock washer and flat washer, 3, and remove the sheave, 4. 3. Clean any dirt and corrosion from the exposed shaft area.

72-7

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1 4. Loosen the two M8 nuts and M8 x 30 cap screws, 1, and remove sheave, 2. 5. Clean any dirt and corrosion from the exposed shaft area.

1 56070011

13 6. Remove the lock collar, 1.

56070010

14 7. Loosen idler at, 1, and then remove the grain elevator intermediate drive belt, 2.

2 56070015

72-8

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1 8. Remove the four M12 x 50 cap screws, 1.

1 1

56070016

9. Support the rear of the discharge beater grate and remove the M20 locknuts, 1, from the lever pin bolt that extends outward through the rear of the heater grate, the frame and the slat, 2, on both sides of the machine.

56070013

17 10. Remove the M8 x 20 carriage bolt, washer and locknut, 2, from the seal plate, 3, at each end. 11. Remove the lever pin bolt, 1, at each end of the grate and then lower the rear of the discharge beater grate.

2 10023044

3 18

72-9

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1 12. Remove the cap plugs from the clamp bolt access holes, 1, on both sides of the discharge beater. 13. Loosen the clamp bolts, 2, on both sides of the discharge beater.

2 1 10023050

19 14. Support the weight of the discharge beater using boards, 1, or straps. 15. Drive the discharge beater shaft out of the right side of the combine. 16. Remove the discharge beater out the rear of the combine.

10023051

20 17. Clean and inspect the discharge beater shaft brush seals located between the beater bearings and the side walls on either side of the combine. 18. The brush seals can be inspected from inside the strawhood and/or removed for replacement or inspection by removing three M6 flange nuts, 1, and then removing the seal plate, 2.

19. Replace the brush seals if full of grease and dirt, and/or the bristles are worn or deformed as to no longer contact and brush the shaft during operation. 56070020

2 21

72-10

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1 Installation

1. Place the discharge beater in the combine. NOTE: The beater blades, 1, are tapered on one side. When installing the discharge beater, make sure the tapered side of the blades are on the leading edge of the discharge beater.

10023052

2. Slide the shaft in from the right side of the combine and through the beater clamps on both sides of the discharge beater, and out through the bearing on the left side of the combine. 3. Align the key on the shaft with the keyway in the right end of the discharge beater. 4. Install the four M12 x 50 cap screws, 1, and secure with lock washers and nuts. 5. Tighten and torque to 85 -- 105 N⋅m (63 -- 77 ft-lb).

1 1

56070016

23 6. Install the lock collar, 1.

1 56070010

72-11

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1 7. Center the discharge beater, 1, between the sidesheets, 2.

8. Ensure the key, 3, is installed opposite of the clamp hardware, 4.

20023053

25 9. Tighten the clamp bolts, 2, on both sides of the discharge beater. 10. Insert the cap plugs into the clamp bolt access holes, 1.

2 1 10023050

26 11. Lift the rear of the discharge beater grate into position and install lever pin bolt, 1.

NOTE: Due to the tight clearance, it may be necessary to slide the seal plate, 2, in after the beater grate is lifted into position.

12. Install an M8 x 20 carriage bolt, washer and lock nut, 3. Tighten nut to take end play from carriage bolt. Do not torque.

3 10023044

72-12

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1 13. Tighten locknut, 1, to remove end play from lever pin bolt. Do not torque. 14. Ensure there is a clearance of 8.5 -- 11.5 mm (0.34 -- 0.45 in) between the end of the beater blades and the beater grate. Adjust as necessary as described in “Discharge Beater Grate -Adjustment” in this section.

56070013

28 15. Install the grain elevator Intermediate drive belt, 1, and tighten idler to the spring gage indicator.

2 56070015

29 16. Coat the shaft with anti-seize compound and install sheave, 2. Tighten and torque the two M8 x 30 cap screws with nuts, 1, to 25 -- 30 N⋅m (19 -- 22 ft-lb). Lock the cap screws in place with the nuts and torque to 25 -- 30 N⋅m (19 -- 22 ft-lb).

1 56070011

72-13

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1 17. Coat the shaft with anti-seize compound, install the key and install sheave, 4. Secure in place with assembled M10 x 30 cap screw, lock washer, and flat washer, 3. Tighten to standard torque.

3 2

18. Install the shoe drive belt, 1, and the beater drive belt, 2. 19. Tighten the shoe drive belt idler to the spring gage indicator. 20. Tighten the beater drive idler to the spring gage indicator. 21. Clean excess anti-seize lubricant from the exposed shaft areas between the bearing sheave, and the two sheaves. Protect the shaft by spray application of Grafloscon CA--Plus spray.

BEATER BLADE

4 1 56070012

Replacement 1. Remove the four M10 x 25 carriage bolts, lock washers and nuts, 1. 2. Remove the beater blade, 2. 3. Install the new beater blade, 2, and secure with the four M10 x 25 carriage bolts, lock washers and nuts, 1. 4. Tighten and torque the M10 nuts to 50 -- 66 N⋅m (37 -- 48 ft-lb).

10023054

72-14

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1 BEATER BEARINGS

Replacement Left-hand side 1. Remove the drive belts and sheaves as described in Discharge Beater – Removal.

2. Clean dirt and corrosion from the shaft.

3. Remove the lock collar, 1. 4. Remove four M12 x 45 bolts, 2, with lock washers and nuts, and then slide the bearing housing from the shaft.

56070010

NOTE: The bearing alone is not a replaceable component; the bearing and housing are replaced as a single component.

5. Remove the grease fitting, 3, from the housing and install it on the replacement bearing housing oriented forward, as shown. 6. Lubricate the bearing inner diameter with Loctite 767 anti-seize compound. Slide the bearing on the shaft and orient with the grease fitting downward and pointed forward. 7. Install the four M12 x 45 bolts, 2. Secure with the lock washers and nuts. Tighten and torque to 85 – 105 N⋅m (63 – 77 ft-lb). 8. Install and adjust the sheaves and belts as described in Discharge Beater – Installation. 9. Purge grease the bearing before operation with New Holland Ambra GR9 Multi--purpose Grease. Clean excess grease from bearing and fitting. Right-hand side

1. Loosen the idler at, 1, and then remove the grain elevator drive belt, 2. 2. Remove the M16 x 45 cap screw, lock washer and large hardened washer, 3, securing the sheave, 4, to the beater shaft.

3. Pull the sheave, 4, from the beater shaft.

56070015

72-15

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1 4. Clean dirt and corrosion from the shaft, 4. 5. Use special tool OEM6210 (Adjustable Spanner Wrench), Figure 36, to loosen and remove the two bearing gland nuts, 2.

4 1 1

NOTE: The bearing nuts are torqued to 217 – 244 N⋅m (160 – 180 ft-lb) and have shallow notches for the spanner tool to grasp. Ensure the tool is well fitted for the removal procedure as to not damage the bearing nut or incur sudden slippage of the tool from the nut. 6. Remove four M12 x 45 bolts, 1, with lock washers and nuts, and then slide the bearing housing from the shaft.

56070020

3 35

NOTE: The bearing alone is not a replaceable component; the bearing and housing are replaced as a single component. 7. Remove the grease fitting, 3, from the housing and install it on the replacement bearing housing oriented forward, as shown. 8. Lubricate the bearing inner diameter with Loctite 767 anti-seize compound. Slide the bearing on the shaft and orient with the grease fitting downward and pointed forward. 9. Install the four M12 x 45 bolts. Secure with the lock washers and nuts. Tighten and torque to 85 – 105 N⋅m (63 – 77 ft-lb).

72-16

86072857

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1 10. Install the first of two gland nuts, 1, onto the shaft. Use special tool OEM6210 (Adjustable Spanner Wrench), Figure 36, to tighten and torque the first gland nut to 217 -- 244 N⋅m (160 -- 180 ft-lb).

IMPORTANT: Adjust the torque range as required for the offset from center distance of the spanner wrench drive position and the length of the torque wrench being used. Strike the end of the beater shaft twice with a soft-faced dead-blow mallet. Check and retorque the nut again to 217 -- 244 N⋅m (160 -- 180 ft-lb), adjusted per note above.

86072858

Install the second gland nut to serve as a jam nut. Tighten the second nut against the first nut securely, but do not attempt to torque to the above specification for the first nut.

11. Purge grease the bearing before operation with New Holland Ambra GR9 Multi-purpose Grease. Clean excess grease from bearing and fitting. 12. Apply Loctite 767 anti-seize compound to the sheave inner diameter, install the shaft key and sheave.

13. Secure the sheave, 4, with the M16 x 45 cap screw, lock washer, and hardened washer, 3. 14. Protect the exposed shaft between the bearing and sheave, by spray application of Grafloscon CA--Plus spray. Ensure shaft is clean before application.

15. Install the drive belt, 2, and adjust the drive belt tension at the idler adjustment rod, 1, to the spring gauge indicator.

56070015

72-17

SECTION 72 -- DISCHARGE BEATER -- CHAPTER 1

72-18

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1

SECTION 74 - CLEANING SYSTEMS Chapter 1 - Cleaning Shoe Frame CONTENTS Section

Description

Page

74-1

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 Section

Description

Page

74-2

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 SPECIFICATIONS CLEANING SHOE Frame Width

1580 mm (62-3/16 in)

Cleaning Shoe Type

Self leveling

Drive

1HC belt

Upper Shaker Shoe Shaft Speed

270 rpm

Horizontal Stroke

56 mm (2.2 in)

Throwing Angle, front

36 degrees

Throwing Angle, rear

36 degrees

Grain Pan width

1580 mm (62-3/16 in)

Grain Pan length

1650 mm (65 in)

Grain Pan + rake surface

2.178 sq. m (3376 sq in.)

Pre-sieve width

1580 mm (62-3/16 in)

Pre-sieve length

901 mm (35-1/2 in)

Pre-sieve area (with rake)

1.424 sq. m (2207 sq in.)

Upper sieve width

2 x 790 mm (2 x 31 in)

Upper sieve length

1445 mm (56-7/8 in)

Upper sieve area

2.284 sq. m (3540 sq. in)

Upper sieve grate surface

0.237 sq. m (367 sq. in)

Upper sieve wire finger surface

0.253 sq. m (392 sq. in)

Lower Shaker Shoe Horizontal Stroke

45 mm (1-3/4 in)

Throwing Angle

15 degrees

Lower sieve length

1445 mm (56-7/8 in)

Lower sieve width

2 x 790 mm (2 x 31 in)

Lower sieve area

2.284 sq. m (3540 sq. in)

Total sieve area under wind control

6.25 sq. m (9687 sq. in)

74-3

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON-METERS (FOOT POUNDS) FOR NORMAL ASSEMBLY APPLICATIONS

METRIC NON-FLANGED HARDWARE AND LOCKNUTS CLASS 5.8

CLASS 8.8

CLASS 10.9

PLATED W/ZnCr

UNPLATED

PLATED W/ZnCr

LOCKNUT CL.8 W/CL8.8 BOLT

2.6 (23)*

3.4 (30)*

3.7 (33)*

4.8 (42)*

2.3 (20)*

7.6 (67)*

8.9 (79)*

12 (102)*

13 (115)*

17 (150)*

7.8 (69)*

14 (124)*

18 (159)*

22 (195)*

28 (248)*

31 (274)*

40 (354)*

19 (169)*

M10

28 (21)

36 (27)

43 (32)

56 (41)

61 (45)

79 (58)

38 (28)

M12

49 (36)

63 (46)

75 (55)

97 (72)

107 (79)

138 (102)

66 (49)

M16

121 (89)

158 (117)

186 (137)

240 (177)

266 (196)

344 (254)

164 (121)

M20

237 (175)

307 (226)

375 (277)

485 (358)

519 (383)

671 (495)

330 (243)

M24

411 (303)

531 (392)

648 (478)

839 (619)

897 (662)

1160 (855)

572 (422)

NOMINAL SIZE

UNPLATED

PLATED W/ZnCr

1.7 (15)*

2.2 (19)*

5.8 (51)*

UNPLATED

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION HEX CAP SCREW AND CARRIAGE BOLTS CLASSES 5.6 AND UP MANUFACTURER’S IDENTIFICATION

PROPERTY CLASS

HEX NUTS AND LOCKNUTS CLASSES 05 AND UP MANUFACTURER’S IDENTIFICATION

86529681 REV F 5.1

PROPERTY CLASS

CLOCK MARKING

74-4

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON-METERS (FOOT POUNDS) FOR NORMAL ASSEMBLY APPLICATIONS

INCH NON-FLANGED HARDWARE AND LOCKNUTS SAE GRADE 2 NOMINAL UNPLATED SIZE or PLATED SILVER 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

6.2 (55)* 13 (115)* 23 (17) 37 (27) 57 (42) 81 (60) 112 (83) 198 (146) 193 (142) 289 (213)

SAE GRADE 5

PLATED W/ZnCr

SAE GRADE 8

PLATED W/ZnCr

GOLD

UNPLATED or PLATED SILVER

8.1 (72)* 17 (149)* 30 (22) 47 (35) 73 (54) 104 (77) 145 (107) 256 (189) 248 (183) 373 (275)

9.7 (86)* 20 (178)* 35 (26) 57 (42) 87 (64) 125 (92) 174 (128) 306 (226) 495 (365) 742 (547)

13 (112)* 26 (229)* 46 (34) 73 (54) 113 (83) 163 (120) 224 (165) 397 (293) 641 (473) 960 (708)

GOLD

UNPLATED or PLATED SILVER

LOCKNUTS

PLATED W/ZnCr GOLD

GR.B w/GR5 BOLT

GR.C w/GR8 BOLT

NOMINAL SIZE

12.2 (109)* 25 (220)* 44 (33) 71 (53) 108 (80) 156 (115) 215 (159) 383 (282) 617 (455) 924 (681)

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION CAP SCREWS AND CARRIAGE BOLTS

SAE GRADE 2

SAE GRADE 5

SAE GRADE 8 REGULAR NUTS

SAE GRADE 5 HEX NUTS

SAE GRADE 8 HEX NUTS

LOCKNUTS

GRADE IDENTIFICATION

GRADE A NO NOTCHES

GRADE A NO MARKS

GRADE B ONE CIRCUMFERENTIAL NOTCH

GRADE B THREE MARKS

GRADE C TWO CIRCUMFERENTIAL NOTCHES

GRADE C SIX MARKS MARKS NEED NOT BE LOCATED AT CORNERS

86529681 REV F 5.2

GRADE A NO MARK GRADE B LETTER B GRADE C LETTER C GRADE IDENTIFICATION

74-5

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 DESCRIPTION OF OPERATION The air coming from the main blow opening of the cleaning fan blows the chaff over the upper sieve out of the machine, while the grain, unthreshed heads and small volumes of chaff fall onto the lower sieve. In addition, the grain separated by the pre-sieve is guided by the small grain pan to the lower sieve. The installation of a pre-sieve considerably increases the cleaning shoe capacity as the main separation of grain and chaff occurs at both finger grates. The lower sieve, or cleaning sieve, provides the final cleaning operation. Grain that passes through the cleaning sieve is carried over the grain plate to the clean grain cross auger. Unthreshed heads which do not fall through the lower sieve are transported by the returns auger to the tailings processor for rethreshing. The processor discharges the processed tailings on the upper sieve for cleaning.

The grain and chaff on the grain pan are transported to the rear by the reciprocating action of the cleaning shoe. An electrical actuator ensures that the cleaning shoe automatically remains horizontal in the transverse axis of the machine, even when operating on side slopes up to 15%. This innovation increases the capacity of the cleaning shoe considerably when operating in hilly conditions. The cleaning shoe is composed of an upper shoe and a lower shoe which move in opposite directions. A first separation takes place on the grain pan as the lighter chaff forms the top layer and the heavier grain the bottom layer. The material falls through the finger grate installed at the rear of the grain pan, onto the pre-sieve. The air coming from the secondary blow opening of the cleaning fan blows the chaff over the pre-sieve so that grain with a reasonably high degree of cleanliness falls through the presieve. This action will be repeated a second time between the pre-sieve and upper sieve.

74-6

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1

20013967

1 grain pan to move back and forth during normal operation of the system. The rear of the grain pan is connected to the upper cleaning shoe. An adjustment is provided on the right side of the pan allowing the shoe and the pan to be set square with each other.

The cleaning shoe assembly is constructed of six major parts. The Cleaning Shoe Frame, 1 All components that make up the cleaning shoe are connected to the frame. The frame attaches to the combine at the front through a pivot pin in the center. The rear of the frame rests on a sealed roller bearing mounted to the combine. Plastic rollers at the back corners, hold the lateral position of the frame inside the combine while allowing the cleaning shoe assembly to rotate.

The Upper Cleaning Shoe, 3 The upper cleaning shoe is attached at the front with drive arms, and at the rear with two support arms. Three sieves are secured to the upper shoe. A lever at the right rear corner manually positions the pre-sieve, mounted on the front part of the shoe. The two remaining sieves may be positioned remotely from the cab and are mounted side-by-side on the back portion of the upper shoe. A rocker arm connects the upper and lower shoe to move them in opposite directions during normal operation.

The Grain Pan, 2 The grain pan is forward of the upper cleaning shoe. The front of the pan attaches to the cleaning shoe frame with two support arms. The arms provide a semi-rigid connection to the shoe frame enabling the

74-7

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1

5 6

A 4

20013967

2 on both sides of the combine. The neutral position of the shoe assembly is obtained by setting the keyway of the eccentric shaft at angle A to the drive arm. Anytime a rubber bushing is replaced, the arm must be in the neutral position prior to tightening the clamp. Angle A is 90°.

The Lower Cleaning Shoe, 4 The lower cleaning shoe is connected to the frame and upper cleaning shoe at the front with the rocker arm. Two support arms fasten the lower shoe to the frame while allowing back and forth motion as the shoe is driven by the rocker arm. Two sieves are mounted side-by-side on the lower shoe and positioned remotely from the cab.

The Rocker Arm, 6 Two rocker arms provide the pivot point for the back and forth motion of the upper and lower cleaning shoe. The left arm is attached to the shoe frame at a fixed point, the right arm is adjustable fore and aft so that the timing of the drive arms will match.

The Drive Arm, 5 The rotating cams of the eccentric shaft move the drive arms in a back and forth motion. Two drive arms attach the upper cleaning shoe to the eccentric shaft

74-8

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 OVERHAUL UPPER CLEANING SHOE Removal 1. Remove any crop residue components, such as the straw chopper or chaff spreader, using procedures described in Section 88 of the Repair manual. 2. Remove the cleaning shoe fan, 1, from the combine using the procedure described later in this section.

1 63060827

3 3. Unplug the grain sensing pad electrical connector. Turn off four locknuts, 1. Lift the sensing pad, 2, from the combine.

1 20013945

4 4. Disengage the adjusting arms at 1 from the left and right sieves. NOTE: The sieves are shown removed to better illustrate the attaching mechanism.

1 20013958

74-9

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 5. Turn out three cap screws, 1, and slide the upper sieves, 2, from the combine.

1 50013943

6 6. Disengage the adjusting arms from the left and right sieves at 1, (left side shown). 7. Turn out three cap screws, 2, and slide the lower sieves from the combine. Turn out two cap screws, 3. Remove the pre-sieve from the combine.

3 2

50013944

1 7

8. Remove cap screws and clamps, 1, from the grain pan. Turn off nuts, 2, and push the cap screws out toward the outside of the combine. Raise the back end of the grain pan, 3, and tie it up securely.

2 50013946

74-10

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 9. Disconnect the leveling frame, 1, from the positioning motor, 2, by removing pin, 3.

2 10052220

9 10. Insert two or three wood blocks, 1, under the upper cleaning shoe frame.

NOTE: The blocks are used to support the upper cleaning shoe when the drive and connecting arms are removed.

50013947

10 11. Rotate the leveling frame to make the right side accessible. Turn out cap screws, 1, and remove the drive arm bushing cap, 2, from the right drive arm. Turn out cap screws, 3, and remove the connecting arm bushing cap. Rotate the leveling frame to make the left side accessible. Remove the left side drive and connecting arm bushing caps.

50013948

74-11

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 12. Turn out cap screws, 1, several turns. Apply blows using a mallet to the head of the cap screws to force the bushings and pins from the upper shoe frame. Continue until the pins can be removed from the frame.

13. At this point, the front of the cleaning shoe is supported by the wood blocks, 2, previously set in place.

20013950

12 14. Rotate the leveling frame to make the right side accessible. Turn out the cap screws from the upper shoe frame right support arm bushing cap, 1. Remove the support arm, 2. 15. Rotate the leveling frame to make the left side accessible. Turn out the cap screws from the upper shoe frame left support arm bushing cap.

2 1

20013949

CAUTION

The upper cleaning shoe frame is heavy and awkward. The rake is still attached to the grain pan. Exercise extreme caution while removing the cleaning shoe frame. Severe personal injury can result while removing the upper shoe frame. 16. Use the help of several assistants to remove the upper cleaning shoe frame from the combine. 17. With all points disconnected, lift and pull the upper cleaning shoe frame, 1, from the machine.

50013951

74-12

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 Installation 1. Install the grain pan, using the procedure described later in this section, if it had been removed.

2. Install the lower cleaning shoe, using the procedure described later in this section, if it had been removed. 3. Attach the leveling frame positioning motor, 2, to the leveling frame, 1, using pin, 3.

2 10052220

CAUTION

The upper cleaning shoe frame is heavy and awkward. The rake is still attached to the grain pan. Exercise extreme caution while installing the cleaning shoe frame. Severe personal injury can result while installing the upper shoe frame. 4. Use the help of several assistants to set the upper cleaning shoe frame into place. 5. Lift and pull the upper cleaning shoe frame, 1, into the machine.

50013951

16 6. Insert two or three wood blocks, 1, under the upper cleaning shoe frame.

NOTE: The blocks are used to support the upper cleaning shoe while attaching the drive and connecting arms.

50013947

74-13

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 7. Set the pin and bushing assemblies in the upper shoe frame. Turn in the four cap screws and lock washers, 1. Torque the cap screws to 150 -- 170 N⋅m (111 -- 125 ft-lb). 8. Disengage the leveling frame from the positioning motor.

20013950

18 9. Rotate the leveling frame to make the right side accessible. Lift the shoe as necessary and install the arm clamps, 1, onto the bushings.

NOTE: A spacer is to be installed between the drive arm and clamp at 2. 10. Rotate the leveling frame to make the left side accessible. Repeat this procedure for the left side.

11. Do not tighten the hardware until instructed. 50013948

19 NOTE: The correct orientation of the support arm is: the end with the smaller distance between the bushing and arm surface is attached to the shoe at the top, 1. The end with the larger distance between the bushing and arm surface is attached to the frame at 2.

12. Lift the shoe as required and install the support arm. 13. Rotate the leveling frame to make the right side accessible. Repeat this procedure for the right side. 14. Do not tighten the hardware until instructed.

20013949

2 20

74-14

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 15. Turn the eccentric drive shaft until the drive arm is on the lowest leg of travel. Position the shaft key and center line of the drive arm perpendicular (90 degree angle) to each other. This is known as the neutral position. 16. Lock or hold the shaft in the neutral position until instructed to release it. 17. Adjust the horizontal position of the upper cleaning shoe until it is centered within 3 mm (1/8 in) of the leveling frame and lower shoe. 18. Tighten the hardware for the drive and rocker arms.

90°

20013967

21 19. Lift or lower the back end of the upper cleaning shoe until a 36 degree angle is obtained on the rear support arm, at A.

20. Tighten the hardware for the rear support arm. 21. Lift or lower the back end of the lower cleaning shoe until a 15 degree angle is obtained on the rear support arm. 22. Tighten the hardware for the rear support arm.

20013967

74-15

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 23. Connect the leveling frame, 1, to the positioning motor, 2, using pin, 3.

2 10052220

23 24. Install cap screws, two washers and a locknut at 1, on both sides of the grain pan, 2.

25. Do not tighten the hardware until instructed to do so.

1 50013946

24 26. Release the lock on the eccentric shaft. Rotate the shaft until the grain pan is at it’s front dead point. Adjust the right side of the pan until a vertical distance of 12 -- 16 mm (0.472 -- 0.630 in) is obtained between the tab on the leveling frame at 1, and the forward most point of the grain pan, 2.

27. Tighten all grain pan hardware. 12 -- 16 mm (0.472 -- 0.630 in) 40015724

1 25

74-16

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 28. Install the cap screws and clamps, 1, on both sides of the grain pan.

50013946

26 29. The sieves with welded tabs, 1, are manufactured to be installed on the left side of the shoes.

40015723

27 30. Slide the pre-sieve into position on the upper cleaning shoe and secure with two cap screws and lock washers, 1.

31. Slide the appropriate sieves onto the lower shoe. Secure the sieves into place using the previously removed hardware, 2.

32. Attach the positioning mechanism, 3.

50013944

3 28

74-17

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 33. Slide the appropriate sieves onto the upper shoe. Secure the sieves into place using the previously removed hardware, 1. 34. Attach the positioning mechanism.

1 50013943

29 35. Set the grain sensing pad, 1, into position and secure using the four locknuts, 2, previously removed. Plug in the sensing pad electrical connector.

2 20013945

30 36. Install the cleaning shoe fan, 1, into the combine in accordance with the appropriate section. 37. Install any crop residue components removed using the procedures described in Section 88.

1 63060827

74-18

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 GRAIN PAN Removal

1. Remove the upper cleaning shoe using the procedure described previously in this manual. 2. Lower the grain pan, 1, onto several wood blocks, 2. 3. Rotate the leveling frame as necessary to make the grain pan support arms accessible. Turn out the cap screws from the grain pan left and right support arm upper bushing caps, 3.

50013952

CAUTION The grain pan is heavy and awkward. The rake is still attached to the grain pan. Exercise extreme caution while removing the pan. Severe personal injury can result while removing the grain pan.

4. Use the help of several assistants to remove the grain pan from the combine. 5. With all points disconnected, lift and pull the grain pan, 1, from the machine. 50013953

33 Installation

CAUTION The grain pan is heavy and awkward. The rake is still attached to the grain pan. Exercise extreme caution while installing the pan. Severe personal injury can result while installing the grain pan. 1. Use the help of several assistants to install the grain pan. 2. Orient the grain pan so that the rake is toward the rear. Install the pan into the combine.

50013953

74-19

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 3. Rotate the leveling frame as necessary to make the grain pan support arms accessible. Attach the grain pan, 1, to the forward support arms, 2.

4. Do not tighten the hardware. 5. Lift the back end of the pan up and insert wood blocks, 3.

50013952

LOWER CLEANING SHOE 3

Removal NOTE: It is not necessary to remove the grain pan in order to get the lower cleaning shoe from the combine.

1 2

1. Remove the upper cleaning shoe using the procedure described earlier in this chapter. 2. Unplug the electrical connector, 1. Remove the two cap screws and nuts, 2. Take the sieve positioning motor, 3, from the lower shoe and store in a suitable location.

20013954

36 3. Position several wood blocks, 1, under the lower cleaning shoe, 2. Remove five cap screws and nuts, 3, from both sides to detach the lower shoe from the connecting arm, 4.

50013955

1 37

74-20

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 4. Remove the lower support arm bushing caps, 1, from both sides of the lower shoe. Remove all of the brace hardware, 2. Carefully lift the lower shoe and pull the brace from the machine on both sides.

20013956

1 38

CAUTION The cleaning shoe is heavy and awkward. Exercise extreme caution while removing the cleaning shoe. Severe personal injury can result while removing the lower cleaning shoe.

5. Use the help of several assistants to remove the lower cleaning shoe from the combine. 6. With all points disconnected, lift and pull the lower cleaning shoe, 1, from the machine. 20013957

39 Installation

CAUTION The cleaning shoe is heavy and awkward. Exercise extreme caution while installing the cleaning shoe. Severe personal injury can result while installing the lower cleaning shoe.

1. Use the help of several assistants to install the lower cleaning shoe. 2. Set the lower cleaning shoe, 1, into position in the combine.

50015725

74-21

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 3. Attach the braces on both sides using previously removed hardware at 1. Tighten this hardware. 4. Install the support arm bushing caps, 2, on both sides. Do not tighten this hardware.

20013956

41 5. Attach the lower grain pan, 1, to the connecting arm, 2, using previously removed hardware at 3, on both sides. Tighten this hardware to standard torque.

50013955

42 6. Attach the sieve positioning motor, 1, at 2, with the previously removed hardware.

7. Plug in the motor electrical connector, 3.

NOTE: All models.

8. Adjust the horizontal position of the lower cleaning shoe until it is centered within 3.18 mm (1/8″) of the leveling frame.

20013954

74-22

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 CLEANING SHOE SUPPORT ARM BUSHINGS

Removal 1. The upper cleaning shoe uses two movable support arms to attach the shoe to the frame. The support arms, 1, are located toward the rear of the combine, close to the lower shoe support arms, 2.

2. The two grain pan support arms are located toward the front end of the combine. 3. The lower cleaning shoe uses two support arms, 2, to attach the shoe to the frame.

20013949

4. All six support arms are similar in construction, only one set of removal instructions is given. NOTE: Lower cleaning shoe support arm removal is shown, the others are similar. 5. Disconnect the support arm, 1, by removing clamps and hardware at 2. NOTE: Depending on the support arm being removed, it may be necessary to rotate the leveling frame to obtain access to the clamping hardware. Disengage the shoe positioning motor and rotate the frame as required.

1 2

20013949

45 6. Remove the snap rings, 1, and washers, 2, from the support arm.

NOTE: The upper shoe support arms do not have washers and snaps rings.

2 20013963

74-23

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 7. Remove the bushings, 1, from the support arm by pressing or cutting them from the journals.

20013959

47 Inspection 1. Inspect the supports for wear or damage. 2. Upper shoe support arm journals, 1, are to be 18.87 -- 19.00 mm (0.743 -- 0.748 in). Journals with diameters less than that specified should be replaced.

20013962

48 3. Grain pan support arm journals, 1, are to be 18.87 -- 19.00 mm (0.743 -- 0.748 in). Journals with diameters less than that specified should be replaced.

20013961

74-24

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 4. Lower shoe support arm journals, 1, are to be 17.89 -- 18 mm (0.704 -- 0.709 in). Journals with diameters less than that specified should be replaced.

20015692

50 Installation NOTE: Depending on the support arm being repaired, a specific distance is required between the bottom of the bushing and surface of the support arm. The following steps describe this measurement for the particular support arm being repaired.

1. Press on the new bushings, 1.

20013960

51 For grain pan support arm: Maintain a distance of 4 -- 6 mm (5/32 -- 1/4 in) between the bottom of the bushing and the surface of the support arm.

4 -- 6 mm (5/32 -- 1/4 in) 20013961

74-25

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 For lower shoe support arm: Maintain a distance of 8 -- 10 mm (5/16 -- 13/32 in) between the bottom of the bushing and the surface of the support arm.

8 -- 10 mm (5/16 -- 13/32 in) 20015692

53 For the upper shoe support arm, shoe connection, 1: Maintain a distance of 4 -- 6 mm (5/32 -- 1/4 in) between the bottom of the bushing and surface of the support arm.

18 -- 20 mm (23/32 -- 25/32 in)

For the upper shoe support arm, frame connection, 2: Maintain a distance of 18 -- 20 mm (23/32 -- 25/32 in) between the bottom of the bushing and surface of the support arm.

4 -- 6 mm (5/32 -- 1/4 in)

20013962

54 2. Set the washers, 1, into place on the journals. Install the snap rings, 2, to secure the washers on the support arms.

NOTE: The upper shoe support arms do not have washers and snap rings.

1 20013963

74-26

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 3. Attach the support arm, 1, using the hardware and clamps, 2, previously removed. Rotate the leveling frame as required to gain access to the support arm attachment points. Do not tighten the hardware until instructed to do so. NOTE: Anytime a rubber bushing is replaced, the drive arm must be in the neutral position prior to tightening the clamp.

1 2

20013949

56 4. Position the drive arms so that the keyway is at angle A to the arm, this is known as the neutral position. Angle A = 90°. Tighten the bushing clamp hardware while holding the drive arm in the neutral position.

20013967

57 5. If the leveling frame positioning motor had been disconnected, attach the motor, 1, to the frame, 2.

1 10052220

74-27

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 CONNECTING ARM PIVOT BUSHINGS

Removal 1. Unplug the grain sensing pad electrical connector. Turn off four locknuts, 1. Lift the sensing pad, 2, from the combine.

1 20013945

59 2. Disengage the adjusting arms at 1 from the left and right sieves. NOTE: The sieves are shown removed to better illustrate the attaching mechanism.

1 20013958

60 3. Turn out three cap screws, 1, and slide the upper sieves, 2, from the combine.

1 50013943

74-28

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 4. Disengage the adjusting arms from the left and right sieves at 1, (left side shown). NOTE: All models. 5. Turn out three cap screws, 2, and slide the lower sieves from the combine.

6. Place jacks under the cleaning shoe on the side to be repaired. Support the weight of the shoe with the jacks.

50013944

1 62

CAUTION Turning out the three cap screws, 1, will detach the cleaning shoe assembly from the supporting frame. Personal injury can result if the cleaning shoe is not properly supported.

7. Carefully turn out the three cap screws, 1, from the rocker arm pivot.

40015719

63 NOTE: This step is applicable to the right side only.

8. Mark both ends of the plate, 1, so that it can be put back into its original position. Loosen the inside jam nut, 2. Turn out the adjusting cap screw, 3.

40015720

74-29

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 NOTE: Right side shown. Left side is similar. 9. Turn out four cap screws and lock washers, 1. Lift the plate from the frame.

40015720

65 10. Using a press, remove the steel-cased rubber bushing, 1, from the rocker arm pivot pin, 2. Press the rocker arm mounting flange, 3, from the bushing.

40015721

3 66

Inspection 1. Inspect the journal, 1, for wear or damage. The diameter of the journal is to be 28.064 -- 28.085 mm (1.105 -- 1.106 in). Journals with diameters less than that specified should be replaced.

40015722

74-30

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 Installation 1. Press the rocker arm mounting flange, 1, onto a new metal-cased rubber bushing, 2, until the bottom of the flange is 5.5 -- 6.5 mm (7/32 -- 1/4 in) from the bottom of the center metal insert of the bushing. Pivot pin, 3, is installed in a later step.

5.5 -- 6.5 mm (7/32 -- 1/4 in)

40015722

68 2. Orient the flange bushing assembly so that the rocker arm will be at a 78 degree angle when attached.

78 degrees

NOTE: The left side is shown, the right side will be opposite.

40015721

69 3. Press the flange bushing assembly, 1, onto the pivot pin, 2, until the top of the flange is 35 -- 37 mm (1-3/8 -- 1-7/16 in) from the top of the mounting plate.

1 2

40015722

35 -- 37 mm (1-3/8 -- 1-7/16 in)

74-31

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 NOTE: Right side shown. Left side is similar. 4. Set the pivot plate against the frame. 5. If installing the left pivot plate, secure the plate using four previously removed cap screws and lock washers, 1.

6. If installing the right pivot plate, tighten the hardware only enough to hold the plate steady.

40015720

71 NOTE: Right side shown.

7. Turn in adjusting cap screw, 1, until it is seated tight in the plate, 2. Set the plate into its previously known position by turning nuts, 3 and 4. Tighten all hardware.

3 40015720

CAUTION The shoes are being supported by jacks. Personal injury can result if the cleaning shoe is not properly supported.

1 8. Install the previously removed cap screws and lock washers, 1, to attach the rocker arm without disturbing the flange-bushing assembly on its pivot. 9. Remove the jacks that were supporting the cleaning shoe.

40015719

74-32

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 10. The sieves with welded tabs, 1, are manufactured to be installed on the left side of the shoes.

40015723

74 11. Slide the appropriate sieves onto the lower shoe. Secure the sieves into place using the previously removed hardware, 1. 12. Attach the positioning mechanism, 2.

50013944

75 13. Slide the appropriate sieves onto the upper shoe. Secure the sieves into place using the previously removed hardware, 1. 14. Attach the positioning mechanism.

1 50013943

74-33

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 15. Set the grain sensing pad, 1, into position and secure using the four locknuts, 2, previously removed. Plug in the sensing pad electrical connector.

2 20013945

DRIVE AND UPPER CONNECTING ARM BUSHING

Removal 1. Unplug the grain sensing pad electrical connector. Turn off four locknuts, 1. Lift the sensing pad, 2, from the combine.

1 20013945

78 2. Disengage the adjusting arms at 1, from the left and right sieves. NOTE: The sieves are shown removed to better illustrate the attaching mechanism.

1 20013958

74-34

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 3. Turn out three cap screws, 1, and slide the upper sieves, 2, from the combine.

1 50013943

80 4. Disengage the adjusting arms from the left and right sieves at 1, (left side shown). NOTE: All models. 5. Turn out three cap screws, 2, and slide the lower sieves from the combine.

50013944

81 6. Disengage the leveling frame, 1, from the positioning motor, 2, by removing pin, 3.

2 10052220

74-35

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 7. Rotate the leveling frame to make the appropriate side accessible. Turn out cap screws, 1 or 2, and remove the bushing cap from the arm.

50013948

83 8. Turn out the appropriate cap screw, 1, several turns. Apply blows using a mallet to the head of the cap screw to force the bushing and pin from the upper shoe frame. Continue until the pin can be removed from the frame.

40015719

84 9. Press the bushing, 1, from the pin, 2.

2 40015726

74-36

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 Inspection 1. Inspect the journal, 1, for wear or damage. The diameter of the journal is to be 28.064 -- 28.085 mm (1.105 -- 1.106 in). Journals with diameters less than that specified should be replaced.

1 40015727

86 Installation 1. Press the new bushing, 1, onto the pin, 2, until the center metal insert of the bushing is flush ± 0.5 mm (0.020 in) with the top of the pin.

0 ± .5 mm (0 ± 0.020 in)

1 40015727

87 2. Install the bushing assembly with the previously removed cap screw at 1. Torque the cap screw to 150 -- 170 N⋅m (111 -- 125 ft-lb).

40015719

74-37

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 3. Rotate the leveling frame to make the appropriate side accessible. Install the arm clamp, 1, onto the bushing.

4. Do not tighten the hardware until instructed. NOTE: A spacer is to be installed between the drive arm and clamp at 2.

2 50013948

89 5. Turn the eccentric drive shaft until the drive arm is on the lowest leg of travel. Position the shaft key and center line of the drive arm at angle A (90 degree angle) to each other. This is known as the neutral position.

20013967

90 6. Lock or hold the shaft in the neutral position at coupling, 1, if gearbox is in place, or at coupling, 2, if gearbox is removed, until instructed to release it.

7. Tighten the hardware for the drive or connecting arm bushing caps. 8. Release the lock or hold from the eccentric drive shaft.

1 20013195

74-38

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 9. The sieves with welded tabs, 1, are manufactured to be installed on the left side of the shoes.

40015723

92 10. Slide the appropriate sieves onto the lower shoe. Secure the sieves into place using the previously removed hardware, 1. 11. Attach the positioning mechanism, 2.

50013944

93 12. Slide the appropriate sieves onto the upper shoe. Secure the sieves into place using the previously removed hardware, 1. 13. Attach the positioning mechanism.

1 50013943

74-39

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 14. Set the grain sensing pad, 1, into position and secure using the four locknuts, 2, previously removed. Plug in the sensing pad electrical connector.

2 20013945

LOWER CONNECTING ARM BUSHINGS

Removal 1. Unplug the grain sensing pad electrical connector. Turn off four locknuts, 1. Lift the sensing pad, 2, from the combine.

1 20013945

96 2. Disengage the adjusting arms at 1, from the left and right sieves. NOTE: The sieves are shown removed to better illustrate the attaching mechanism.

1 20013958

74-40

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 3. Turn out three cap screws, 1, and slide the upper sieves, 2, from the combine.

1 50013943

98 4. Disengage the adjusting arms from the left and right sieves at 1, (left side shown). NOTE: All models. 5. Turn out three cap screws, 2, and slide the lower sieves from the combine.

6. Place jacks under the cleaning shoe on the side to be repaired. Support the weight of the shoe with the jacks. 50013944

1 99

CAUTION Turning out the five cap screws, 1 or 2, will detach the lower cleaning shoe from the supporting frame. Personal injury can result if the cleaning shoe is not properly supported.

7. Carefully turn out the five cap screws at 1 or 2. NOTE: Additional items may be shown removed to better illustrate this step. 50015725

100

74-41

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 8. Turn out two cap screws, 1. Remove the lower connecting arm bushing cap, 2, and mounting plate, 3, from the right side of the combine. Repeat for the left side.

3 2

1 40015728

101 9. Using a press, remove the steel cased rubber bushing, 1, from the mounting plate journal, 2.

2 1

50052166

102 Inspection 1. Inspect the journal, 1, for wear or damage. The diameter of the journal is to be 28.064 -- 28.085 mm (1.105 -- 1.106 in). Journals with diameters less than that specified should be replaced.

40015729

103

74-42

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 Installation 1. Press the new bushing, 1, onto the journal, 2, until the bottom of the center metal insert is 22 -24 mm (7/8 -- 15/16 in) from the surface of the mounting plate.

1 40015729

22 -- 24 mm (7/8 - 15/16 in)

104 2. Attach the mounting plate, 1, to the lower cleaning shoe with the previously removed hardware.

3. Install bushing cap, 2, on both sides of the combine. Do not tighten the hardware.

40015728

105 4. Turn the eccentric drive shaft until the drive arm is on the lowest leg of travel. Position the shaft key and center line of the drive arm at angle A (90 degree angle) to each other. This is known as the neutral position. Tighten the bushing clamp hardware while holding the drive arm in the neutral position. 5. Release the drive arm from the neutral position.

20013967

106

74-43

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 6. The sieves with welded tabs, 1, are manufactured to be installed on the left side of the shoes.

40015723

107 7. Slide the appropriate sieves onto the lower shoe. Secure the sieves into place using the previously removed hardware, 1. 8. Attach the positioning mechanism, 2.

50013944

108 9. Slide the appropriate sieves onto the upper shoe. Secure the sieves into place using the previously removed hardware, 1. 10. Attach the positioning mechanism.

1 50013943

109

74-44

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 11. Set the grain sensing pad, 1, into position and secure using the four locknuts, 2, previously removed. Plug in the sensing pad electrical connector.

2 20013945

110

CLEANING SHOE SEALS

All cleaning shoe seals can be replaced without removing the shoe frames. Sieves may have to be removed to gain access to some of the seals. When replacing the seals, use the same type and size rivet that was removed. The upper cleaning shoe frame has three seals and two guards. Two seals are located on the left and right sides of the frame at 1. The remaining rubber seal is attached at the rear, 2.

2 50013951

111 1. The two guards, 1, are located at the front left and right corners of the shoe frame.

40015730

112

74-45

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 2. The lower cleaning shoe has three seals attached to it. Two seals, 1, are installed inside channels on the left and right sides of the shoe. These seals are specially cut and must be installed with the cutouts at the forward end of the frame. The rear seal, 2, is attached to the back of the shoe.

2 50015725

113 3. The two grain pan seals, 1, are installed on the left and right sides.

20013953

114

LEVELING FRAME - PIVOT BUSHING Removal

1. Remove the cleaning fan from the combine. See “Cleaning Fan - Removal” in this section. 2. Use two suitable floor jacks, 1, and blocks, 2, to support the leveling frame, 3, on the left and right sides of the frame.

20015181

1 115

74-46

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 3. Loosen and remove the locknut, 1, and washers, 2, from the pivot shaft.

1 2 20015183

116 4. Use a hammer and an aluminum drift to drive the pivot shaft, 1, from the leveling frame, 2, and combine frame, 3.

20015184

117 5. Raise the floor jacks evenly to allow the leveling frame, 1, to be positioned above the combine frame, 2, just enough to allow bushing removal.

1 2

20015185

118

74-47

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 6. Remove the shim washer, 1, positioned between the leveling frame, 2, and combine frame, 3.

1 2

20015187

119 7. Remove the two bushings, 1, from the leveling frame, 2.

20015186

120 Inspection 1. Clean all parts in a suitable solvent and allow to air dry. 2. Inspect the pivot shaft for wear or damage. Repair or replace as necessary. 3. Inspect the leveling frame and combine frame pivot housings for wear or damage. Repair or replace as necessary. Installation 1. Install two new bushings, 1, into the pivot bore, 2, of the leveling frame.

1 2

20015188

121

74-48

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 2. Insert the shim washer, 1, between the leveling frame and combine frame.

20015187

122 3. Lower the floor jacks to align the pivot bores in the leveling frame, 1, and combine frame, 2. 4.

Insert 50 grams (1.75 oz.) of Loctite® Moly Paste

grease in the pivot bore, 3.

5. Coat the pivot shaft, 4, with same grease.

6. Insert the pivot shaft, 4, through the pivot bore, 3.

3 20015184

123 7. Install the washers, 1, and locknut, 2, onto the pivot shaft. Tighten the nut securely.

2 1 20015183

124

74-49

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 8. Adjust the locknut, 1, to gain 0.1 -- 0.6 mm (0.004 -- 0.023 in) clearance between the two washers.

0.1 mm (0.004 in)

1 20015189

125 9. Lower the floor jacks, 1. Remove the wood blocks, 2. 10. Install the cleaning fan. See “Cleaning Fan Installation” in this section.

20015181

1 126

LEVELING FRAME - REAR ROLLER

Removal 1. Loosen and remove the cap screws, 1, and washers securing the roller assembly to the leveling frame, 2.

20015190

127

74-50

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 2. Remove the roller assembly, 1, from the leveling frame, 2.

1 20015192

128 Disassembly 1. Remove the snap ring, 1, from the roller shaft, 2.

2 1

20015193

129 2. Remove the two washers, 1, from the roller shaft, 2.

20015194

130

74-51

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 3. Remove the roller, 1, from the roller shaft, 2.

20015195

131 Inspection 1. Wash all parts in a suitable solvent and allow to air dry. 2. Inspect roller shaft for wear, burrs, nicks or other damage. Replace as necessary. Assembly 1. Install a new roller, 1, onto the roller shaft, 2.

2 1

20015196

132 2. Install two washers, 1, onto the roller shaft, 2.

20015194

133

74-52

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 3. Install the snap ring, 1, onto the roller shaft, 2, to secure the roller assembly.

1 20015197

134 Installation 1. Install the roller assembly, 1, onto the leveling frame, 2, with the slotted hole positioned at the bottom mounting location.

1 20015192

135 2. Secure the roller assembly with the cap screws, 1, and washers. Leave cap screws hand tight until adjustment is completed.

20015190

136

74-53

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 Adjustment NOTE: The leveling frame must be centered in the lower combine frame to properly adjust both cleaning shoe rollers.

1. Measure the distance between the lower combine frame, 1, and leveling frame, 2, on both sides of the combine. 2. Position the leveling frame until both measurements are equal. This will center the leveling frame in the lower combine frame. 3. With the leveling frame centered, move both rollers out against the rolling surface, 3, on the lower combine frame, 1. IMPORTANT: Maximum combined roller clearance must not exceed 3.5 mm (0.138 in).

20015198

137

4. Pivot the roller assembly to obtain 1 mm (0.039 in) clearance between the roller, 1, and the rolling surface, 2. Repeat for the opposite side. 1 mm (0.039 in)

1 26015199

138 5. Tighten the cap screws, 1, securely on the roller assemblies. 6. Recheck the clearance of each roller. IMPORTANT: At least one roller must be free to turn at all times in any position or orientation of the cleaning shoe. Roller clearance must be increased if both rollers are tight. Do not exceed the maximum combined clearance of 3.5 mm (0.138 in).

20015190

139

74-54

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 LEVELING FRAME - REAR PIVOT BEARING Removal 1. Support the cleaning shoe with suitable floor jacks under the leveling frame on both sides of the combine.

20015200

140 2. Remove the two mounting bolts and two cap screws, 1, from the rear pivot bearing shaft, 2.

2 1

20015191

141 3. Remove the rear pivot bearing assembly, 1, from the lower combine frame, 2.

2 20015201

142

74-55

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 Disassembly 1. Remove the snap ring, 1, from the bearing shaft, 2.

20015202

143 2. Remove the two washers, 1, from the bearing shaft, 2.

20015203

144 3. Press the bearing shaft, 1, from the bearing, 2.

20015204

145

74-56

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 Inspection 1. Wash all parts in a suitable solvent and allow to air dry. 2. Rotate bearing by hand to check for roughness or binding. Replace as necessary. 3. Inspect roller shaft for wear, burrs, nicks or other damage. Replace as necessary. Assembly 1. Press a new sealed bearing, 1, onto the bearing shaft, 2.

20015205

146 2. Install two washers, 1, onto the bearing shaft, 2.

20015203

147 3. Install the snap ring, 1, onto the bearing shaft, 2, to secure the pivot bearing assembly.

20015202

148

74-57

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 1 Installation 1. Install the rear pivot bearing assembly, 1, onto the lower combine frame, 2.

2 20015201

149 2. Install the two mounting bolts and two cap screws, 1, through the rear pivot bearing shaft, 2, into the lower combine frame. Tighten the hardware securely.

2 1

20015191

150 3. Lower and remove the floor jacks from both sides of the combine.

20015200

151

74-58

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2

SECTION 74 - CLEANING SYSTEMS Chapter 2 - Cleaning Shoe Drive CONTENTS Section

Description

Page

74-1

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 SPECIFICATIONS Upper Gearbox Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-degree right angle Lubricant-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH AMBRA GR-9 Multi-Purpose Grease Lubricant-Amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 960 ml (32.5 oz.) (Fill gearbox with specified grease until grease exits the breather on the gearbox housing.) Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 -- 0.6 mm (0.0039 -- 0.0236 in) Rolling Torque (Input) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 -- 0.4 N⋅m (1.6 -- 3.5 in-lb) Rolling Torque (Output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 3 N⋅m (13 -- 26 in-lb) Lower Gearbox Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 degree right angle Lubricant - Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH AMBRA GR-9 Multi-Purpose Grease Lubricant - Amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 660 ml (22.3 oz.) (Fill gearbox with specified grease until grease exits the breather on the gearbox housing.) Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 -- 0.6 mm (0.0039 -- 0.0236 in) Backlash Shims (Thickness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 -- 0.5 mm (0.0079 -- 0.0197 in) Rolling Torque (Input) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 -- 0.4 N⋅m (1.6 -- 3.5 in-lb) Rolling Torque (Output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 -- 3 N⋅m (13 -- 26 in-lb)

SPECIAL TORQUES Use standard torque chart for all tightening torque specifications unless otherwise specified.

74-2

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 DESCRIPTION OF OPERATION rod is mounted to the left and right side of the eccentric shaft on a press fit eccentric bearing assembly. The eccentric shaft turns with power supplied by the gearbox, rotating the eccentric bearings, in turn rotating the connecting rods. The connecting rods are attached to the cleaning shoe with bushings and bushing caps. When the connecting rods turn on the eccentric shaft, the cleaning shoe moves in time with the eccentric assembly, moving the cleaning shoe back and forth.

The cleaning shoe drive is driven from a pulley on the discharge beater shaft, through a belt, to a safety clutch located on the input shaft of the cleaning shoe drive lower gearbox. Power is transmitted from the output shaft of the lower gearbox through an extendable drive shaft connected to the input shaft of the cleaning shoe drive upper gearbox. Power is transmitted from the output shaft of the upper gearbox, through a flexible coupling connecting the upper gearbox to the eccentric shaft. A connecting

74-3

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 OVERHAUL UPPER GEARBOX

Removal 1. Loosen and remove the three bolts and nuts, 1, from the drive shaft coupling, 2. Separate the coupling.

20013195

1 2. Loosen and remove the three nuts and washers, 1, on the elastic coupling, 2.

2 1

20015004

2 3. Loosen and remove the three gearbox mounting bolts, 1.

4. Remove the gearbox, 2, and elastic coupling from the eccentric shaft.

NOTE: Use care not to lose the spacer washers between the elastic coupling and mounting block.

20015005

74-4

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 Repair The cleaning shoe upper gearbox consists of two case halves, each containing a shaft, gear, shims and bearings. The repair text will show Disassembly, Inspection and Assembly for each half of the gearbox. The gearbox case halves will be designated as Input and Output. Disassembly of Input Half

1. Loosen and remove the six retaining bolts, 1, from the gearbox case, 2. Observe the length of the gearbox retaining bolts during disassembly. 2. Separate the gearbox case halves. Remove the grease from each case half.

20014973

4 3. Remove the shims, 1, between the case halves, 2 and 3.

1 2 3

20015003

5 4. Loosen and remove the four bolts, 1, securing the end cap, 2, to the gearbox case.

5. Remove the end cap, 2, from the gearbox case.

20014974

74-5

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 6. Remove the shims, 1, from the gearbox case, 2.

2 1

20014975

7 7. Remove the snap ring, 1, from the groove on the input shaft, 2.

20014976

8 8. Drive the input shaft, 1, in the direction shown until both end bearings, 2, are free from the case.

2 20014977

74-6

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 9. Remove the small bearing, 1, gear, 2, collar, 3, snap rings, 4, spacer, 5, and large bearing, 6, from the input shaft, 7.

20014978

10 10. Remove the input shaft, 1, from the gearbox case, 2.

1 2

20014979

11 11. Remove and discard the input shaft seal, 1, from the gearbox case, 2.

20014980

74-7

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 12. Remove the snap ring, 1, from the gearbox case, 2.

1 20014981

13 13. Remove the shim, 1, from the gearbox case, 2.

1 20014982

14 14. If the bearings are to be replaced, carefully remove the large bearing race, 1, from the gearbox case, 2.

NOTE: Bearing and bearing race must be replaced as a set if replacement is necessary.

20014983

74-8

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 15. If the bearings are to be replaced, carefully remove the small bearing race, 1, from the gearbox case, 2.

NOTE: Bearing and bearing race must be replaced as a set if replacement is necessary.

20014984

16 Inspecting Input Half 1. Clean all parts in a suitable solvent and allow to air dry. 2. Inspect the input shaft for wear or damage. Repair or replace as necessary. 3. Rotate the bearings by hand to check for roughness or binding. Replace as necessary. 4. Inspect each bearing race for pitting, signs of wear or damage. Replace as necessary. NOTE: Bearing and bearing race must be replaced as a set if replacement is necessary. 5. Inspect the input shaft gear for wear, chips or other damage. Replace as necessary. Assembly of Input Half 1. If bearings are to be replaced, install the small bearing race, 1, into the gearbox case, 2.

1 2

20014984

74-9

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 2. Install the large bearing snap ring, 1, into the groove in the gearbox case, 2.

2 20014985

18 3. Install the shim, 1, into the gearbox case, 2, on the inside of the snap ring, 3.

2 20014986

19 4. If bearings are to be replaced, install the large bearing race, 1, into the gearbox case, 2.

20014987

2 20

74-10

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 5. Install a new input shaft seal, 1, into the gearbox case, 2.

6. Lubricate the ID of the new seal with NH AMBRA GR-9 Multi-Purpose Grease.

20014980

21 7. Lubricate the input shaft, 1, with NH AMBRA GR-9 Multi-Purpose Grease and install part way into the gearbox case, 2.

1 2

20014979

22 8. Pack the large bearing, 1, and small bearing, 2, with NH AMBRA GR-9 Multi-Purpose Grease.

9. Install the large bearing, 1, collar, 3, snap rings, 4, large collar, 5, gear, 6, and small bearing, 2, onto the input shaft, 7.

20014978

74-11

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 10. Seat the large bearing, 1, and small collar, 2, into the gearbox case. 11. Install the snap ring, 3, into the groove on the input shaft to retain the collar and bearing.

NOTE: Be sure the bearing and collar are seated in the bearing race as well as against the snap ring.

20014976

24 12. Install the end cap shims, 1, into the gearbox case, 2.

2 1

20014975

25 13. Install the end cap, 1, onto the gearbox case and secure with the four mounting bolts, 2.

14. Use a pull scale to check the rolling torque of the assembled input shaft. 15. The rolling torque reading on the pull scale should be 0.18 -- 0.4 N⋅m (1.6 -- 3.5 in-lb).

16. Adjust the rolling torque by adding or removing shims under the end cap. 17. When the correct rolling torque is established, remove the end cap, place a 1/8 inch bead of RTV gasket sealer to the mating surface of the end cap. 18. Re-install the end cap and secure with the four mounting bolts. Tighten the bolts securely.

74-12

20014974

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 Disassembling of Output Half

1. Bend the locking washer tab, 1, flat. 2. Loosen and remove the nut, 2, from the output shaft.

1 20014988

27 3. Remove the locking washer, 1, from the output shaft, 2.

1 2

20014989

28 4. Remove the spacer, 1, from the output shaft, 2.

20014990

74-13

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 5. Lift the output gear, 1, from the output shaft, 2.

20014991

30 6. Drive the output shaft, 1, from the gearbox case, 2.

20014992

31 7. Remove the large bearing, 1, from the gearbox case, 2

1 2

20014993

74-14

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 8. Use a suitable puller to remove the small bearing, 1, from the output shaft, 2.

20014994

33 9. Remove and discard the output shaft seal, 1.

20014995

34 10. If the bearings are to be replaced, carefully remove each bearing race, 1, from the gearbox case, 2.

NOTE: Bearing and bearing race must be replaced as a set if replacement is necessary.

20014996

74-15

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 Inspecting of Output Half 1. Clean all parts in a suitable solvent and allow to air dry. 2. Inspect the output shaft for wear or damage. Repair or replace as necessary. 3. Rotate the bearings by hand to check for roughness or binding. Replace as necessary. 4. Inspect each bearing race for pitting, signs of wear or damage. Replace as necessary. NOTE: Bearing and bearing race must be replaced as a set if replacement is necessary. 5. Inspect the output shaft gear for wear, chips or other damage. Replace as necessary. Assembly of Output Half 1. Pack the small bearing, 1, with NH AMBRA GR-9 Multi-Purpose Grease and install into the gearbox case, 2.

20014997

36 2. Install a new output shaft seal, 1, into the gearbox case, 2.

3. Lubricate the ID of the shaft seal, 1, with NH AMBRA GR-9 Multi-Purpose Grease.

20014998

74-16

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 4. Use a press, 1, to install the output shaft, 2, into the gearbox case, 3. Press the shaft until fully seated in the bearing.

2 3

20014999

38 5. Fill the cavity, 1, in the gearbox case with 40 ml (1.35 oz.) of NH AMBRA GR-9 Multi-Purpose Grease.

20015000

39 6. Pack the large bearing, 1, with NH AMBRA GR-9 Multi-Purpose Grease and install on the output shaft, 2.

20015001

74-17

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 7. Install the output gear, 1, onto the output shaft, 2.

20014991

41 8. Install the spacer, 1, onto the output shaft, 2.

20014990

42 9. Install the locking washer, 1, onto the output shaft, 2.

1 2

20014989

74-18

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 10. Install the nut, 1, onto the output shaft, 2.

11. Use a torque wrench to tighten the nut, 1, to obtain 1.5 -- 3 N⋅m (13 -- 26 in-lb) of rolling torque.

20015002

44 12. When the proper rolling torque has been set, bend the locking washer, 1, to secure the nut, 2.

1 20014988

45 13. Install the shims, 1, onto the gearbox case, 2 or 3.

14. Check and adjust backlash. See “Upper Gearbox Adjustment - Backlash” in this chapter. 15. Apply a 1/8 inch bead of RTV gasket eliminator to the mating surfaces of both case halves.

2 3

20015003

74-19

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 16. Install the six mounting bolts, 1, to assemble the two halves of the gearbox, 2.

NOTE: Be sure to use the correct length bolts in the proper position when assembling the gearbox case halves. 17. Tighten the six mounting bolts, 1, securely.

20014973

1 47

74-20

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 Adjusting Backlash 1. Clamp the output shaft, 1, in a vise. 2. Check the backlash of gears, 2 and 3, as follows: 3. Measure the maximum, angular, displacement, A, of sheave, B, by measuring the distance, C. The distance, C, should be 0.1 -- 0.6 mm (0.0039 -- 0.0236 in.). 4. If distance, C, is not within 0.1 -- 0.6 mm (0.0039 -- 0.0236 in.), add or remove shims, 4, to obtain the correct backlash. Repeat step 3. 5. With the backlash correctly adjusted, and with the gearbox bolted together, use a grease gun to fill the gearbox through the grease nipple on the end cap, with NH AMBRA GR-9 Multi-Purpose Grease until the grease exits the breather.

B A

1 2

20015003

4 48

74-21

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 Installation 1. Install the gearbox, 1, and connect the elastic coupling onto the eccentric shaft. 2. Install and tighten the three gearbox mounting bolts, 2.

20015005

49 3. Install and tighten the three nuts and washers, 1, on the elastic coupling, 2. Torque the nuts to 61 N⋅m (45 ft-lb).

2 1

20015004

50 4. Connect the drive shaft coupling, 1, to the gearbox, 2. Install and tighten the three bolts and nuts, 3.

20013195

74-22

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 5. Install the returns drive belts, 1.

6. Tighten the nut, 2, on the returns drive belt adjuster, 3, until the washer, 4, is even with the adjustment guide plate, 5.

2 3 5 4

50013193

52 7. Install the cleaning shoe drive belt, 1.

8. Tighten the nut, 2, on the cleaning shoe drive belt adjuster, 3, until the washer, 4, is even with the adjustment guide plate, 5.

3 1 4

20013194

74-23

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 LOWER GEARBOX

Removal

1. Loosen the nut, 1, on the cleaning shoe drive belt adjuster, 2. 2. Remove the belt, 3.

20013194

54 3. Loosen the nut, 1, on the returns drive belt adjuster, 2. 4. Remove the belts, 3.

50013193

55 5. Loosen and remove the three bolts and nuts, 1, from the drive shaft coupling, 2. Separate the coupling.

40015045

74-24

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 6. Loosen and remove the bolt, 1, and washer, 2, from the drive sheave, 3.

3 2

40015046

57 7. Use a suitable puller, 1, to remove the drive sheave, 2, from the input shaft.

2 1

40015047

58 8. Remove the key, 1, from the tapered end of the input shaft, 2. 9. Drive both roll pins, 3, from the slip clutch, 4, and input shaft, 2.

3 1

4 40015048

2 59

74-25

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 10. Remove the slip clutch, 1, from the input shaft, 2.

2 40015049

60 11. Remove the retaining ring, 1, from the idler arm, 2.

1 2

40015050

61 12. Remove the spacer, 1, from the idler arm, 2.

40015051

74-26

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 13. Remove the cotter pin, 1, washer, 2, and adjustment rod, 3, from the idler arm, 4.

4 2 1 40015052

63 14. Remove the idler arm assembly, 1, from the gearbox, 2.

40015053

1 64

15. Loosen and remove the two upper retaining bolts, 1, from the gearbox.

40015054

74-27

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 16. Loosen and remove the four lower retaining bolts, 1, from the gearbox.

17. Remove the lower gearbox from the mounting brackets.

40015055

66 Repair The cleaning shoe lower gearbox consists of two case halves, each containing a shaft, gear, shims and bearings. The repair text will show Disassembly, Inspection and Assembly for each half of the gearbox. The gearbox case halves will be designated as Input and Output. Disassembling of Output Half 1. Loosen and remove the four retaining bolts, 1, from the gearbox case, 2.

40015006

67 2. Separate the gearbox case halves. Remove the grease from each case half.

40015007

74-28

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 3. Remove the shims, 1, between the case halves, 2 and 3.

40015008

69 4. Loosen and remove the four bolts, 1, securing the end cap, 2, to the gearbox case.

1 40015009

70 5. Remove the end cap, 1, and shims, 2, from the gearbox case, 3.

3 2

40015010

74-29

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 6. Remove the snap ring, 1, from the groove on the output shaft, 2.

1 40015011

72 7. Drive the output shaft, 1, in the direction shown until both end bearings, 2 and 3, are free from the case.

8. Remove the small bearing, 2, gear, 4, snap rings, 5, collar, 6, and large bearing, 3, from the output shaft, 1.

2 6

40015012

4 73

9. Remove the output shaft, 1, from the gearbox case, 2.

2 1

40015013

74-30

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 10. Remove and discard the output shaft seal, 1, from the gearbox case, 2.

1 40015014

75 11. Remove the snap ring, 1, from the gearbox case, 2.

1 40015015

76 12. Remove the shims, 1, from the gearbox case, 2.

40015016

1 77

74-31

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 13. If the bearings are to be replaced, carefully remove the large bearing race, 1, from the gearbox case, 2.

2 1

NOTE: Bearing and bearing race must be replaced as a set if replacement is necessary.

40015017

78 14. If the bearings are to be replaced, carefully remove the small bearing race, 1, from the gearbox case, 2

2 1

NOTE: Bearing and bearing race must be replaced as a set if replacement is necessary.

40015018

79 Inspecting of the Output Half 1. Clean all parts in a suitable solvent and allow to air dry. 2. Inspect the output shaft for wear or damage. Repair or replace as necessary. 3. Rotate the bearings by hand to check for roughness or binding. Replace as necessary. 4. Inspect each bearing race for pitting, signs of wear or damage. Replace as necessary. NOTE: Bearing and bearing race must be replaced as a set if replacement is necessary. 5. Inspect the output shaft gear for wear, chips or other damage. Replace as necessary.

74-32

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 Assembling of Output Half

1. If bearings are to be replaced, install the small bearing race, 1, into the gearbox case, 2.

40015018

80 2. Install the large bearing snap ring, 1, into the groove in the gearbox case, 2.

40015019

81 3. Install the shims, 1, into the gearbox case, 2, on the inside of the snap ring, 3.

40015020

3 82

74-33

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 4. If bearings are to be replaced, install the large bearing race, 1, into the gearbox case, 2.

1 2

40015021

83 5. Install a new output shaft seal, 1, into the gearbox case, 2.

6. Lubricate the ID of the new seal with NH AMBRA GR-9 Multi-Purpose Grease.

1 40015022

84 7. Lubricate the output shaft, 1, with NH AMBRA GR-9 Multi-Purpose Grease and install part way into the gearbox case, 2.

40015023

74-34

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 8. Pack the large bearing, 1, and small bearing, 2, with NH AMBRA GR-9 Multi-Purpose Grease.

9. Install the large bearing, 1, collar, 3, snap rings, 4, gear, 5, and small bearing, 2, onto the output shaft, 6.

1 40015024

86 10. Seat the large bearing, 1, and collar, 2, into the gearbox case.

11. Install the snap ring, 3, into the groove on the output shaft to retain the collar and bearing.

2 1

NOTE: Be sure the bearing and collar are seated in the bearing race as well as against the snap ring.

40015025

87 12. Install the end cap shims, 1, into the gearbox case, 2.

40015026

74-35

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 13. Install the end cap, 1, onto the gearbox case and secure with the four mounting bolts, 2.

14. Use a pull scale to check the rolling torque of the assembled output shaft. 15. The rolling torque reading on the pull scale should be 0.18 -- 0.4 N⋅m (1.6 -- 3.5 in-lb). 16. Adjust the rolling torque by adding or removing shims under the end cap. 17. When the correct rolling torque is established, remove the end cap, place a 1/8 inch bead of RTV gasket sealer to the mating surface of the end cap.

40015027

18. Re-install the end cap and secure with the four mounting bolts. Tighten the bolts securely. Disassembling the Input Half 1. Use the special tool, 1, to unstake the stake nut, 2, from the input shaft. 2. Loosen and remove the nut, 2, from the input shaft.

40015028

90 3. Remove the input gear, 1, from the input shaft, 2.

2 1

40015029

74-36

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 4. Press the input shaft, 1, from the gearbox case, 2.

40015030

92 5. Remove the bearing, 1, from the gearbox case, 2.

2 1

40015031

93 6. Remove and discard the input shaft seal, 1.

40015032

74-37

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 7. Remove the input shaft, 1, from the gearbox case, 2. Remove the bearing, 3, from the shaft.

40015033

95 8. If the bearings are to be replaced, carefully remove each bearing race, 1, from the gearbox case, 2.

NOTE: Bearing and bearing race must be replaced as a set if replacement is necessary.

1 40015034

96 Inspecting the Input Half 1. Clean all parts in a suitable solvent and allow to air dry. 2. Inspect the input shaft for wear or damage. Repair or replace as necessary. 3. Rotate the bearings by hand to check for roughness or binding. Replace as necessary. 4. Inspect each bearing race for pitting, signs of wear or damage. Replace as necessary. NOTE: Bearing and bearing race must be replaced as a set if replacement is necessary. 5. Inspect the input shaft gear for wear, chips or other damage. Replace as necessary.

74-38

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 Assembling the Input Half 1. Pack the bearing, 1, with NH AMBRA GR-9 Multi-Purpose Grease and install into the gearbox case, 2.

1 2

40015035

97 2. Install a new input shaft seal, 1, into the gearbox case, 2. 3. Lubricate the ID of the shaft seal, 1, with NH AMBRA GR-9 Multi-Purpose Grease.

2 1

40015036

98 4. Use a press, 1, to install the input shaft, 2, into the gearbox case, 3. Press the shaft until fully seated in the bearing.

1 2

3 40015037

74-39

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 5. Fill the cavity, 1, in the gearbox case with 60 ml (2.0 oz.) of NH AMBRA GR-9 Multi-Purpose Grease.

40015038

100 6. Pack the bearing, 1, with NH AMBRA GR-9 Multi-Purpose Grease and install on the input shaft, 2.

40015039

101 7. Install the input gear, 1, onto the input shaft, 2.

40015040

102

74-40

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 8. Install a new stake nut, 1, onto the input shaft, 2. 9. Tighten the stake nut, 1, to seat the bearing.

10. Loosen the stake nut and retighten to achieve the proper rolling torque. 11. Use a torque wrench to tighten the nut, 1, to obtain 1.5 -- 3 N⋅m (13 -- 26 in-lb) of rolling torque. 12. When the rolling torque is set properly, use a punch and a hammer to stake the nut, 1, at the slot on the input shaft.

2 40015041

103 13. Install the shims, 1, onto the gearbox case, 2.

1 2

40015042

104 14. Place the two gearbox halves together, making sure to position the mounting holes, 1, on the input case, opposite of the grease fitting, 2, on the output case. 15. Install the four mounting bolts, 3.

16. Tighten the four mounting bolts, 3, securely.

17. Check and adjust backlash. See “Lower Gearbox Adjustment - Backlash” in this chapter.

3 40015043

105

74-41

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 Adjusting Backlash 1. Clamp the input shaft, 1, in a vise. 2. Check the backlash of gears, 2 and 3, as follows: 3. Measure the maximum, angular, displacement, A, of sheave, B, by measuring the distance, C. The distance, C, should be 0.1 -- 0.6 mm (0.0039 -- 0.0236 in.).

4. If distance, C, is not within 0.1 -- 0.6 mm, add or remove shims, 4, to obtain the correct backlash. Repeat step 3. 5. With the backlash correctly adjusted, and with the gearbox bolted together, use a grease gun to fill the gearbox through the grease nipple, with NH AMBRA GR-9 Multi-Purpose Grease until the grease exits the breather.

B A

C B 4 2 1

3 20015044

106

74-42

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 Installation

1. Install the gearbox onto the mounting brackets. 2. Install the two upper gearbox mounting bolts, 1. Do not tighten at this time.

40015054

107 3. Install the four lower gearbox mounting bolts, 1. Do not tighten at this time.

40015055

108 4. Lubricate the bushing, 1, on the idler arm, 2, with NH AMBRA GR-9 Multi-Purpose Grease. 5. Install the idler arm, 2, onto the gearbox, 3.

2 1

40015053

3 109

74-43

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 6. Install the adjustment rod, 1, into the idler arm, 2, and secure with the flat washer, 3, and a new cotter pin, 4.

3 4 40015052

110 7. Install the spacer, 1, into the idler arm, 2.

40015051

111 8. Install the retaining ring, 1, into the idler arm, 2.

1 2

40015050

112

74-44

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 9. Grease the ID of the slip clutch, 1, with NH AMBRA GR-9 Multi-Purpose Grease and install onto the input shaft, 2, making sure to align the roll pin holes.

2 40015049

113 10. Install the key, 1, into the tapered end of the input shaft, 2. 11. Install both roll pins, 3, through the slip clutch, 4, and input shaft, 2. 12. Align the slip clutch pulley with the returns cross auger pulley by moving the lower gearbox in or out on the mounting brackets. When alignment is satisfactory, tighten the gearbox mounting bolts securely.

3 1

4 2

40015048

114 13. Install the drive sheave, 1, onto the input shaft and secure with the flat washer, 2, and bolt, 3. Tighten the bolt securely.

1 2

40015046

3 115

74-45

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 14. Connect the drive shaft coupling, 1, to the gearbox, 2. Install and tighten the three bolts and nuts, 3.

40015045

116 15. Install the returns drive belts, 1.

16. Tighten the nut, 2, on the returns drive belt adjuster, 3, until the washer, 4, is even with the adjustment guide plate, 5.

2 3 5 4

50013193

117 17. Install the cleaning shoe drive belt, 1.

18. Tighten the nut, 2, on the cleaning shoe drive belt adjuster, 3, until the washer, 4, is even with the adjustment guide plate, 5.

3 1 4

20013194

118

74-46

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 ECCENTRIC SHAFT Removal 1. Remove the cleaning shoe drive upper gearbox. (See “Upper Gearbox - Removal” in this section.) 2. Remove the variator drive sheave and cleaning fan belt. (See Cleaning Fan section, “Mechanical Variator - Removal” or “Cleaning Fan Motor Removal”.) 3. Loosen and remove the two connecting rod small end bolts, 1, on the left side. Repeat for the right side.

4. Loosen and remove the nut, 2, and washer, 3, on right and left side.

20013196

119 5. Use a suitable puller, 1, to remove the connecting rod, 2, and eccentric block, 3, as an assembly from the right side of the eccentric shaft.

2 3

20013197

120 6. Use a suitable puller, 1, to remove the connecting rod, 2, eccentric block and collar plate, 3, as an assembly from the left side of the eccentric shaft.

1 20013198

121

74-47

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 7. Loosen and remove the four bolts, 1, securing the left-hand bearing housing, 2, to the frame.

20013199

122 8. Loosen and remove the four bolts, 1, securing the right-hand bearing housing, 2, to the frame.

9. Remove the parallel key, 3, from the eccentric shaft.

1 3 20013200

123 10. Use two M16 bolts, 1, in the threaded holes of the right-hand bearing housing, 2, to remove the bearing and housing from the shaft.

1 2

20013201

124

74-48

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 11. Pull the eccentric shaft, 1, part way out of the left-hand side of the frame.

20013202

125 12. Remove the right-hand connecting rod, 1, and bearing housing, 2, from the eccentric shaft.

13. Pull the eccentric shaft out of the combine from the left-hand side.

20013203

126 Inspection 1. Clean all parts in a suitable solvent and allow to air dry. 2. Inspect the eccentric shaft for excessive wear or damage. Repair or replace as necessary. 3. Rotate all bearings by hand and check for roughness or binding. Replace bearings as necessary. Installation

1. Install the eccentric shaft, 1, from the left-hand side, part way through the frame on the right-hand side of the combine.

20013202

127

74-49

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 2. Install the right-hand bearing housing and bearing, 1, onto the eccentric shaft, 2.

1 2

20013204

128 3. Temporarily place the right-hand connecting rod, 1, on the eccentric shaft, 2.

4. Push the eccentric shaft the rest of the way through the frame.

2 20013203

129 5. Install the four mounting bolts, 1, securing the left-hand bearing housing, 2, to the frame. Tighten the bolts securely.

20013199

130

74-50

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 6. Install the four mounting bolts, 1, securing the right-hand bearing housing, 2, to the frame. Tighten the bolts securely.

IMPORTANT: Be sure to install the chamfer side of the parallel key in the eccentric shaft. 7. Install the parallel key, 3, into the eccentric shaft.

1 3 20013200

131 IMPORTANT: Connecting rods must be assembled with no axial or longitudinal stress. 8. Position the right-hand connecting rod, 1, onto the eccentric shaft, 2, aligning the key way with the parallel key. Push the connecting rod onto the shaft until the eccentric block is fully seated on the shaft.

1 90°

9. Rotate the eccentric shaft until the key slot, 3, in the eccentric block is perpendicular to the axis of the connecting rod.

20013205

132 IMPORTANT: It is critical that the eccentric block key slot is perpendicular to the axis of the connecting rod when installing and tightening the connecting rod small end bolts. 10. Install the small end connecting rod bolts, 1, and nuts through the bearing caps, 2, and connecting rod, 3. Tighten the bolts and nuts to 95 N⋅m (70 ft-lb) minimum torque.

1 3

20013206

133

74-51

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 2 IMPORTANT: Be sure to install the chamfer side of the parallel key in the eccentric shaft. 11. If removed, install the parallel key, 1, into the eccentric shaft, 2, on the left-hand side of the combine.

20013199

134 IMPORTANT: Connecting rods must be assembled with no axial or longitudinal stress. 12. Position the left-hand connecting rod, 1, and gearbox collar, 2, onto the eccentric shaft, aligning the key way with the parallel key. Push the connecting rod onto the shaft until the eccentric block is fully seated on the shaft. 13. Rotate the eccentric shaft until the key slot in the eccentric block is perpendicular to the axis of the connecting rod, and. Loctite®

14. Apply 242 to threads. Install two washers, 3, and nut, 4, onto the eccentric shaft. 15. Tighten the nut to 100 N⋅m (73.8 ft-lb). IMPORTANT: It is critical that the eccentric block key slot is perpendicular to the axis of the connecting rod when installing and tightening the connecting rod small end bolts. 16. Install the small end bolts, 5, and nuts through the bearing caps, 6, and connecting rod, 1. Tighten the bolts and nuts to 95 N⋅m (70 ft-lb) minimum torque. 17. Install the cleaning shoe drive upper gearbox. (See “Cleaning Shoe - Upper Gearbox Installation” in this section.)

74-52

6 5

4 20013196

135

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3

SECTION 74 - CLEANING SYSTEMS Chapter 3 - Cleaning Fan and Drives CONTENTS Section

Description

Page

74-1

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 SPECIFICATIONS CR9040, CR9060, CR9070 CLEANING FAN

Drive

Hydraulic Drive -- Closed Loop Circuit

Speed, Standard Variator

275 rpm to 1100 rpm

Speed, Fan Speed Reducer

Speed Control

Electro Hydraulic

Read Out

Intelliview™ II

Number of Blades

74-2

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 DESCRIPTION OF OPERATION The cleaning fan drive is a closed loop hydraulic circuit. The loop consists of a hydraulic gear pump driven through the hydrostatic pump, a solenoid-operated control valve and a hydraulic motor. This drive can maintain a constant fan speed, regardless of changing engine speed due to loading. This allows an efficient air blast to be maintained in the cleaning system.

10051858

74-3

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 TROUBLESHOOTING PROBLEM

POSSIBLE CAUSE

REMEDY

Cleaning fan is not turning at the 1. Fan blades are encountering 1. Grease or replace worn or proper speed. an obstruction. damaged parts. 2. Target or sensor on fan shaft 2. Stop engine and cleaning fan, faulty. clear obstruction. 3. Replace or adjust sensor and target. Unit is noisy.

1. Fan shaft bearings are dry, 1. worn, or damaged. 2. 2. Fan blades out of adjustment, bent or broken.

Grease or replace bearings. Adjust, repair or replace fan blades. See Cleaning Fan section for adjustment.

3. Shafts or bearings, worn or 3. Repair or replace worn or damaged parts. damaged. 4. Hydraulic motor shaft and fan 4. Align the motor and fan shaft within the bracket slots. shaft out of alignment. Cleaning fan vibrates during opera- 1. Fan shaft bearings dry, worn, 1. Replace worn, damaged or tion. damaged or broken. broken bearings. 2. Drive shaft worn, damaged or 2. Repair or replace shaft. bent. 3. Replace hydraulic motor cou3. Faulty coupler on hydraulic pler. motor.

74-4

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 OVERHAUL HYDRAULIC DRIVE Pump -- Remove 1. Loosen and remove the suction and discharge hoses from the pump, 1. Using string or other means support the hoses up in the air and cap the ends using the appropriate plugs to prevent any contamination into the system.

86060561

2 2. Remove the two 1/2″ x 1-1/4″ cap screws, 1, and washers securing the pump.

1 10051777

3 3. Using a pry bar gently persuade the pump apart from under the flanges, 1, evenly.

1 10051773

74-5

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 Pump -- Install 1. Lubricate the O-ring using a thin film of clean hydraulic fluid. Install the O-ring onto the mounting flange, 1, of the pump.

1 10051773

5 2. Install the pump, 1, into the machine allowing the shaft splines to align correctly. Position the pump so that the suction port, 2, (larger port) is to the rear of the machine. Install the two 1/2″ x 1-1/4″ cap screws and washers, 3, to secure the pump. Torque the two cap screws to 98 -- 122 N⋅m (72 -- 90 ft-lb).

1 3

10051777

3 6

3. Install the pump suction port connector to the suction port of the pump. Torque to 115 -- 163 N⋅m (85 -- 120 ft-lb). Connect the pump suction line to the suction port connector. Torque hose connection to 110 -- 120 N⋅m ( 81 -- 88 ft-lb).

86060561

74-6

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 4. Install the pump discharge port connector to the discharge port of the pump. Torque the connector to 75 -- 108 N⋅m (55 -- 80 ft-lb). Connect the discharge line to the connector. Torque hose connection to 90 -- 95 N⋅m (65 -- 70 ft-lb).

86060561

8 Motor -- Remove NOTE: Drain the hydraulic reservoir disconnecting any lines in the circuit.

before

1. Using a paint pen or marker label (upper/lower) the two lines, 1, and connectors, 2, attached to the motor. This will ensure the correct routing when the lines are re-installed.

2 1 10051783

9 2. Disconnect the two lines, 1, from the motor. Cap the lines using the proper plugs to prevent any contamination from entering the hydraulic circuit.

1 10051783

74-7

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 3. Remove the four M10 x 45 mm bolts, flat washers, lock washers, and nuts, 1, securing the motor, 2, to the motor bracket, 3. Using a pry bar, gently slide back the keyed motor shaft from the coupler.

2 10051858

11 Motor -- Install 1. Install the key on the motor shaft (inspect key for wear, replace with new key if necessary). Slide the motor shaft into the shaft coupler. Secure the motor, 1, to the motor bracket using four M10 x 45 mm bolts, flat washers, lock washers, and nuts, 2. Be sure the motor and fan shafts are aligned before tightening the bolts. Adjust the motor and motor bracket if necessary to align the shafts. Tighten the hardware.

2 2

1 10051858

12 2. Check the sensor, 1, to be sure the adjustment has not changed. The sensor should be 1--2 mm from the nine-lobe flange target.

10051858

74-8

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 3. Connect the upper and lower hoses, 1, to the motor following the proper routing as indicated when removed. Torque the fittings to 90 -- 95 N⋅m (65 -- 70 ft-lb). Orient the 90-degree elbow fittings approximately 20 degrees outboard from the machine to allow a more natural hose routing. Torque the upper fitting to 75 -- 108 N⋅m (55 -- 77 ft-lb). Torque lower fitting to 163 -- 224 N⋅m (120 -- 165 ft-lb).

4. Fill the hydraulic reservoir.

1 10051783

14 Valve Block -- Remove NOTE: Drain the hydraulic reservoir disconnecting any lines in the circuit.

before

1. Using a paint pen or marker, mark the hose end to the connector, 1, before being removed. This will allow for correct hose routing when lines are installed.

10051849

15 2. Disconnect all the lines, 1, from the valve block. Cap all the lines using the proper plug to prevent any contamination from entering the hydraulic circuit.

1 1 1

10051845

74-9

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 3. Disconnect the electrical connection, 1, from the solenoid on the valve block.

10051779

17 4. Remove the one M8 x 120 mm bolt, lock washer, and nut, 1, securing the hose clamp, 2, to the valve block.

1 2 10051779

18 5. Remove the two M10 x 25 mm cap screws, lock washers, and nuts, 1, securing the valve assembly, 2, to the frame.

10051779

74-10

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 6. To remove the bracket from the valve assembly, remove the remaining three M8 x 120 mm bolts, lock washers, and nuts.

2 10053972

Valve Block -- Install 1. If the mounting plate, 1, had been removed from the valve assembly, install it now using the four M8 x 120 mm bolts, lock washers, and nuts, 2. Do not tighten the bolts at this time.

1 10053972

21 2. Orient the valve assembly so the solenoid, 1, is facing the front of the machine. Mount the valve assembly to the frame of the machine using two M10 x 25 mm cap screws, lock washers, and nuts, 2. Torque the two M10 x 25 mm cap screws to 56 N⋅m (41 ft-lb).

NOTE: The valve mounting bracket should be centered in the mounting slots.

10051779

74-11

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 3. Remove the outer right corner M8 x 120 mm bolt, 1, from the valve assembly, and install the hose clamp, 2, and bolt, 1. Torque all four M8 x 120 mm bolts on the valve assembly to 28 N⋅m (248 in-lb.).

1 2 10051779

23 4. Install the three lines, 1, to the valve assembly, and torque all hydraulic line fittings to 90 -- 95 N⋅m (65 -- 70 ft-lb).

5. Refill the hydraulic reservoir.

10051779

74-12

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 CLEANING FAN ASSEMBLY

Removal 1. Loosen and remove the nuts and bolts, 1, securing the fan shield, 2, to the right side of the combine. Remove the shield from the combine.

20013153

25 2. Loosen and remove the carriage bolts and nuts, 1, securing the upper fan shield, 2, to the left side of the combine. Loosen the two mounting bolts, 3. Remove the upper fan shield from the combine.

1 3

20013154

26 3. Loosen and remove the nuts and bolts, 1, securing the lower fan shield, 2, to the left side of the combine. Remove the shield from the combine.

20013155

74-13

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 CAUTION The fan guard is heavy. Use a suitable means of support, such as a floor jack, below the fan guard when removing the hardware from the mounting brackets. Failure to comply may result in minor or moderate injury.

4. Loosen and remove the nuts and bolts, 1, from the rear, fan guard bracket, 2, on the left side of the cleaning fan. Repeat for the opposite side.

2 20013156

28 5. Loosen and remove the bolts, 1, from the front, fan guard bracket, 2, on the left side of the cleaning fan. Repeat for the opposite side.

2 1

20013157

29 6. Lower the floor jack, 1, and fan guard, 2. Remove the fan guard from under the cleaning fan assembly.

63060824

74-14

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 7. Loosen and remove the two nuts and bolts, 1, securing the fan shaft bearing assembly to the frame. Repeat for the opposite side. 8. Lower the fan and fan shaft assembly, allowing the assembly to rest in the fan housing.

63060825

1 31

9. Loosen and remove the nuts, 1, securing the fan housing, 2, and support bracket, 3, to the corner brace, 4. Repeat for the opposite side.

4 1

20013160

2 32

CAUTION 1

The fan housing is heavy and awkward. Use extreme care when lowering the housing from the cleaning shoe frame. Failure to comply may result in minor or moderate injury. 10. Place a suitable floor jack under the left and right sides of the fan housing. With the fan housing supported, loosen and remove the four mounting nuts and bolts, 1, from the right side of the cleaning shoe frame, 2, and fan housing. Repeat for the left side.

63060826

11. Lower the fan housing and remove from under the combine.

74-15

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 Inspection 1. Clean the fan housing with a suitable cleaner and dry thoroughly. 2. Inspect the fan housing for wear or damage. Repair or replace worn or damaged parts. 3. Inspect the canvas seals on the fan housing for cracks, tears, wear, or other damage. Replace worn or damaged canvas seals using the procedure described later in this chapter. 4. Inspect deflectors for wear or damage. Repair or replace worn or damaged deflectors. Installation

CAUTION

The fan housing is heavy and awkward. Use extreme care during installation onto the cleaning shoe frame. Failure to comply may result in minor or moderate injury. 1. Place a suitable floor jack under the left and right sides of the fan housing. With the fan housing securely supported, raise the fan housing into the mounting position in the cleaning shoe frame, 2. 2. Align the mounting holes. Install and tighten the four mounting nuts and bolts, 1, from the right side of the cleaning shoe frame, 2, and fan housing. Repeat for the left side.

63060826

NOTE: Use an alignment punch to align the mounting holes on the fan housing with the mounting holes in the cleaning shoe frame. 3. Install and tighten the nuts, 1, securing the fan housing, 2, and support bracket, 3, to the corner brace, 4. Repeat for the opposite side.

4 1

20013160

2 35

74-16

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 4. Raise the fan and fan shaft into the mounting position. 5. Align the mounting holes and install the two bolts and nuts, 1, to secure the fan shaft bearing assembly to the frame. Do not tighten the nuts at this point. 6. Install the two bolts and nuts to secure the fan shaft bearing assembly to the frame on the opposite side. Tighten securely, the nuts on both sides of the fan shaft bearing assemblies.

63060825

CAUTION The fan guard is heavy. Use a suitable means of support, such as a floor jack, below the fan guard during installation of the guard to the cleaning shoe frame. Failure to comply may result in minor or moderate injury. 7. Place a floor jack, 1, under the fan guard, 2, and raise the guard into the mounting position.

63060824

37 8. Install the two mounting bolts, 1, through the front, fan guard bracket, 2, and frame on the left side of the cleaning fan. Repeat for the opposite side.

2 1

20013157

74-17

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 9. Install the two mounting bolts and nuts, 1, through the rear, fan guard bracket, 2, and frame on the left side of the cleaning fan. Repeat for the opposite side.

10. Tighten all of the fan guard mounting bolts and nuts securely.

2 20013156

39 11. Install the lower fan shield, 1, onto the combine and secure with the bolts and nuts, 2. Tighten the hardware securely.

20013155

40 12. Install the upper fan shield, 1, to the left side of the combine. Install and tighten the carriage bolts and nuts, 2, securely. Tighten the two mounting bolts, 3.

2 3 1 20013154

74-18

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 13. Install the fan shield, 1, on the right side of the combine. Install and tighten the bolts and nuts, 2.

20013153

CANVAS SEALS

Overhaul The canvas seals, 1, on the cleaning fan housing should be inspected for distortion, wear and/or damage when the cleaning fan housing is removed from the combine. If distortion, wear or damage is found, the seals need to be replaced. The procedure to remove and install the canvas seals follows. 1. Remove the cleaning fan housing from the combine. (See “Cleaning Fan - Removal”, earlier in this section.)

63060822

43 IMPORTANT: Note the mounting position of the horizontal seals during removal. The seals must be installed on the same side of the flange they were removed from.

2. Use a sharp chisel and a hammer to remove the rivets, 1, from the canvas seal, 2. Repeat for the remaining rivets. 3. Clean the mounting surface on the cleaning fan housing and position a new canvas seal, 2, on the housing, aligning the mounting holes. 20013149

74-19

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 4. Use a pop-rivet tool, 1, to install new rivets in the mounting holes of the seal, 2, and the housing.

5. Repeat the procedure for the remaining seals being replaced on the fan housing.

1 20013150

45 6. Use a sharp chisel and a hammer to remove the rivets, 1, on the housing edge seals, 2. 7. Clean the mounting surface on the cleaning fan housing and position a new edge seal, 2, on the housing, aligning the mounting holes.

1 2

20013151

46 8. Use a pop-rivet tool, 1, to install new rivets in the mounting holes of the seal, 2, and housing.

63060823

74-20

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 DEFLECTOR PLATE ADJUSTMENT After the cleaning fan housing is installed in the combine, the position of the deflector plates must be checked. Use the tables provided for adjustment information. Model

CR9040, CR9060

354 mm (13.94 in)

356 mm (14.02 in)

68 mm (2.68 in)

42 mm (1.65 in)

10 mm (0.39 in)

CR9070, CR9080

514 mm (20.25 in)

538 mm (21.18 in)

68 mm (2.68 in)

42 mm (1.65 in)

10 mm (0.39 in)

1. Loosen the deflector plate mounting bolt, 1, and adjustment bolt, 2, on both sides of the fan housing.

2 1

20013147

48 2. Position the deflector plate to correspond with the correct measurements for the specific machine shown in the table, and tighten the adjustment bolt and mounting bolt. 3. Re-check the measurement. If the measurement is correct, tighten the adjustment bolt and mounting bolt on the opposite side. 4. Follow the same procedure for adjustment of the short deflectors, as referenced in the table as X1 and X2. 20015611

20015610

74-21

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 CLEANING FAN SHAFT Removal

1. Loosen and remove the nuts and bolts, 1, securing the fan shield, 2, to the right side of the combine. Remove the shield from the combine.

2. For hydraulic drive fans, see “Hydraulic Drive Motor -- Remove”.

20013153

51 3. Loosen and remove the carriage bolts and nuts, 1, and cap screws, 3, securing the upper fan shield, 2, to the left side of the combine. Remove the upper fan shield from the combine.

1 3

20013154

52 4. Loosen and remove the nuts and bolts, 1, securing the lower fan shield, 2, to the left side of the combine. Remove the shield from the combine.

20013155

74-22

5. Loosen and remove the nuts and bolts, 1, from the rear, fan guard bracket, 2, on the left side of the cleaning fan. Repeat for the opposite side.

2 20013156

54 6. Loosen and remove the bolts, 1, from the front, fan guard bracket, 2, on the left side of the cleaning fan. Repeat for the opposite side.

2 1

20013157

55 7. Lower the floor jack, 1, and fan guard, 2. Remove the fan guard from under the cleaning fan assembly.

63060824

74-23

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 8. Loosen and remove the bolts and nuts, 1, the self tapping screws, 2, and remove the lower plate of the cleaning fan housing to gain access to the fan.

1 2 1 63060827

57 9. Loosen the locknut, 1, and locking screw, 2, on each of the three fan collars, 3.

3 20013166

58 10. Support the fan from the bottom, through the opening of the removed lower plate in the housing.

20013167

74-24

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 11. Use puller to remove hub, 1, from shaft.

1 66060833

60 12. Loosen the set screw, 1, on the right hand bearing lock collar, 2. Use a punch and a hammer to strike the collar in a counterclockwise direction, to loosen the collar from the shaft. Remove the lock collar. Remove two capscrews, nuts and lock washers, 3.

63060828

2 61

13. Loosen the set screw on the left side, bearing lock collar, 1. Use a punch and a hammer to strike the collar in a counterclockwise direction, to loosen the collar from the shaft. Remove the lock collar.

20013169

1 62

74-25

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 14. Remove the bearing, 1, from the right-hand end of the fan shaft, 2.

63060829

1 63

15. Loosen and remove the nuts, 1, and the bearing, 2, from the left-hand end of the fan shaft.

16. Remove the paint from the fan shaft to ease removal.

2 20013173

64 17. Carefully pull the fan shaft, 1, from the right side of the fan.

NOTE: A small amount of oil or grease may be applied to the fan shaft to ease removal from the fan.

63060830

65 Inspection 1. Clean all parts in a suitable solvent and allow to air dry. 2. Inspect the fan shaft for nicks, burrs, or other damage. Repair or replace if necessary. 3. Inspect the bearings for smooth operation. If bearing rotation is rough or tight, replace with new bearings.

74-26

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 Installation 1. Install the fan shaft, 1, through the three fan collars, from the right side of the fan.

63060830

66 2. Install the left side bearing, 1, onto the fan shaft. Install and tighten the nuts, 2, on the bearing retainer.

1 20013173

67 3. Install the lock collar, 1, onto the bearing, 2, but do not tighten at this time.

20013169

74-27

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 4. Install the right side bearing, 1, onto the fan shaft, 2.

63060829

69 5. Position shaft so that dimension A from the inside surface of the frame, 1, to the outer shoulder of the fan shaft, 2, is 25.5 ± 1 mm (1 ± 1/32 in).

2 66060832

70 6. Install the bearing retainer, 1, and re-check the measurement. Tighten the retainer bolts and nuts, 2, securely.

7. Install the RH bearing lock collar, 3, onto the bearing. Use the punch and hammer in a clockwise direction, to tighten the lock collar, 3, onto the bearing. Tighten the set screw, 4, on the lock collar.

2 1 63060828

3 71

74-28

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 8. Use a punch and hammer, in a counterclockwise direction, to tighten the left-hand bearing lock collar, 1, onto the bearing, 2. Tighten the set screw in the set collar.

1 20013169

72 9. Install 8 x 7 x32 mm key, 1, in fan shaft keyslot. 10. Install hub, 2, with nine teeth on shaft all the way to shoulder. NOTE: Hub fit on shaft is an interference fit and must be driven on. Use an assistant to hold a metal backup against left end of shaft and drive hub on with a dead-blow mallet.

1 2

66060833

73 11. Install elastic coupling, 1, to hub, 2, and three-lobed hub, 3, to coupling, 1, using six M10 x 40 cap screws and nuts, and twelve lock washers.

12. Install motor per “Hydraulic Drive -- Motor -Install” elsewhere in this chapter.

1 3

66060834

74-29

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 13. Remove the supports from beneath the fan.

20013167

75 14. Tighten the locking screw, 1, and the locknut, 2, on each of the three fan collars, 3.

3 20013166

76 15. Install the lower plate onto the cleaning fan housing, and secure with the bolts and nuts, 1, and self tapping screws, 2. Tighten all mounting hardware securely.

1 2 1 63060827

74-30

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 CAUTION The fan guard is heavy. Use a suitable means of support, such as a floor jack, below the fan guard during installation of the guard to the cleaning shoe frame. Failure to comply may result in minor or moderate injury. 16. Place a floor jack, 1, under the fan guard, 2, and raise the guard into the mounting position.

63060824

78 17. Install the two mounting bolts, 1, through the front fan guard bracket, 2, and frame on the left side of the cleaning fan. Repeat for the opposite side.

2 1

20013157

79 18. Install the two mounting bolts and nuts, 1, through the rear fan guard bracket, 2, and frame on the left side of the cleaning fan. Repeat for the opposite side.

19. Tighten all of the fan guard mounting bolts and nuts securely.

2 20013156

74-31

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 3 20. Install the lower fan shield, 1, onto the combine and secure with the bolts and nuts, 2. Tighten the hardware securely.

20013155

81 21. Install the upper fan shield, 1, to the left side of the combine. Install and tighten the carriage bolts and nuts, 2, securely. Tighten the two mounting bolts, 3. 22. Install drive motor, see “Hydraulic Drive Motor -Install” elsewhere in this chapter.

2 3 1 20013154

82 23. Install the fan shield, 1, on the right side of the combine and secure with the bolts and nuts, 2. Tighten all mounting hardware securely.

20013153

74-32

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4

SECTION 74 - CLEANING SYSTEMS Chapter 4 - Returns System CONTENTS Section

Description

Page

74-1

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 OVERHAUL LEFT RETURNS AUGER Removal 1. Loosen the nut, 1, on the returns drive belt adjuster, 2.

2. Remove the belts, 3.

2 20013193

1 3. Loosen the nut, 1, on the cleaning shoe drive belt adjuster, 2.

4. Remove the belt, 3.

20013194

2 5. Loosen and remove the bolt, 1, and washer, 2, from the drive sheave, 3.

3 2 1

40015046

74-2

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 6. Use a suitable puller, 1, to remove the drive sheave, 2, from the input shaft.

40015047

4 7.

Remove the key, 1, from the tapered end of the input shaft, 2.

8. Drive both roll pins, 3, from the slip clutch, 4, and input shaft, 2.

3 1

40015048

5 9. Remove the slip clutch, 1, from the input shaft.

40015049

74-3

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 10. Remove the retaining ring, 1, from the idler arm, 2.

40015050

7 11. Remove the spacer, 1, from the idler arm, 2.

2 1

40015051

8 12. Remove the cotter pin, 1, washer, 2, and adjustment rod, 3, from the idler arm, 4.

2 3 4 1 40015052

74-4

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 13. Remove the idler arm assembly, 1, from the gearbox, 2.

40015053

10 14. Remove the brackets, 1, retaining the main hydraulic lines, 2, for the combine drive system. Position the lines out of the way.

50021206

11 15. Loosen and remove the bolts, 1, from the drain valve retaining brackets, 2. 16. Remove the bracket with the hoses attached and position the assembly out of the way of the auger tube.

1 2

40015057

74-5

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 17. Remove the bolts, 1, securing the support rail, 2. Remove the support rail from the combine.

40015058

13 18. Cut the plastic wire ties, 1, and disconnect the paddle sensor connector, 2.

40015059

14 19. Loosen and remove the four nuts, 1, and washers, (two in front, two in rear), securing the auger tube to the cross auger housing.

40015060

74-6

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 20. Loosen and remove the two bolts, and nuts, 1, securing the cradle support to the cross auger housing.

40015061

16 21. Loosen and remove the bolt, 1, from the paddle end of the auger housing.

40015062

17 22. Loosen and remove the three bolts and nuts, 1, from the paddle end of the auger housing.

2 1

23. Remove the mounting hardware, 2, from the support, 3. Remove the support, 3, from the combine. 24. Remove the auger from the combine.

3 40015063

74-7

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 Installation 1. Place the auger into the mounting position on the combine. 2. Secure the cradle support to the cross auger housing with the two nuts and bolts, 1. Leave the bolts hand tight at this time.

40015061

19 3. Install the bolt, 1, into the head end of the auger tube. Leave the bolt hand tight at this time.

40015062

20 4. Install the three bolts and nuts, 1, into the head end of the auger tube. Leave the bolts hand tight at this time.

5. Install the support, 2, and secure with the mounting hardware, 3. Tighten the hardware securely.

2 40015063

74-8

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 6. Install and tighten the four washers and nuts, 1, to secure the auger tube to the mounting brackets.

7. Securely tighten all mounting hardware previously left hand tight.

40015060

22 8. Connect the paddle sensor wire connector, 1, and secure the wire with plastic wire ties, 2.

40015059

23 9. Install the brackets, 1, securing the main hydraulic lines, 2, for the combine drive system.

50021206

74-9

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 10. Install the support rail, 1, and secure with the bolts, 2. Tighten the bolts securely.

11. Lineup the gearbox sheave, 3, to the cross auger sheave, 4, using a straight edge.

12. Remove or install shim washers as necessary on both sides of the gearbox sheave to achieve proper alignment. [Maximum deviation - 2 mm (0.08 in)].

2 3 40015058

25 13. Install the drain valve retaining bracket, 1, and secure with the bolts, 2.

14. Secure the bottom bracket, 3, with bolts and nuts, 4. Tighten all hardware securely.

4 3 40015057

26 15. Lubricate the bushing, 1, on the idler arm, 2, with NH AMBRA GR-9 Multi-Purpose Grease. 16. Install the idler arm, 2, onto the gearbox, 3.

1 40015053

74-10

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 17. Install the adjustment rod, 1, into the idler arm, 2, and secure with the flat washer, 3, and a new cotter pin, 4.

1 2 4

40015052

28 18. Install the spacer, 1, into the idler arm, 2.

2 1

40015051

29 19. Install the retaining ring, 1, into the idler arm, 2.

40015050

74-11

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 20. Grease the ID of the slip clutch, 1, with NH AMBRA GR-9 Multi-Purpose Grease and install onto the input shaft, making sure to align the roll pin holes.

40015049

31 21. Install the key, 1, into the tapered end of the input shaft, 2. 22. Install both roll pins, 3, through the slip clutch, 4, and input shaft, 2.

23. Align the slip clutch pulley with the returns cross auger pulley by moving the lower gearbox in or out on the mounting brackets. When alignment is satisfactory, tighten the gearbox mounting bolts securely.

2 40015048

32 24. Install the drive sheave, 1, onto the input shaft and secure with the flat washer, 2, and bolt, 3. Tighten the bolt securely.

1 2 3

40015046

74-12

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 25. Install the return auger drive belts, 1. Tighten the nut, 2, on the returns drive belt adjuster, 3, until the washer is even with the adjustment guide plate.

2 1

3 20013193

34 26. Install the cleaning shoe drive belt, 1. 27. Tighten the nut, 2, on the cleaning shoe drive belt adjuster, 3, until the washer is even with the adjustment guide plate.

2 3

20013194

RIGHT RETURNS AUGER (IF EQUIPPED)

Removal 1. Turn the three 1/4-turn fasteners, 1, to disengage them from the support braces. Lift off the belt guard, 2.

1 20013916

74-13

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 2. Turn off the adjusting nut, 1, from the belt tensioner. Slide the washer, spring gauge, spring and lower nylon bushing from the adjusting rod. Remove drive belts, 2.

1 2

20013917

37 3. Remove cap screws and nuts at 1.

20013919

38 4. Remove five cap screws and nuts, 1, from the cross auger end of the return auger.

20013920

74-14

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 5. Turn out cap screws, 1, and lift off the belt guard support brace, 2.

2 20013918

40 6. Remove the four cap screws and nut, 1, securing the support, 2, in place.

20013921

41 7. Unplug the speed sensor connector, 1. Remove the two remaining cap screws, 2, and lift the auger out.

1 2 20013921

74-15

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 Installation 1. Slide the right returns auger, 1, into position behind the clean grain elevator. During installation, ensure the adjusting rod, 2, is inserted into the mounting frame, 3.

3 2

2. Lineup the gearbox sheave to the cross auger sheave using a straight edge. 3. Remove or install shim washers as necessary on both sides of the gearbox sheave to achieve proper alignment. [Maximum deviation - 2 mm (0.08 in)].

20013920

43 4. Attach the discharge end of the auger to the combine with cap screws and nuts, 1. Do not tighten the hardware.

5. Plug in the speed sensor connector, 2.

20013921

44 6. Install the support, 1, using four cap screws and nuts, 2.

2 2

1 20013921

74-16

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 7. Attach the drive end of the returns auger to the cross auger chute at 1, with cap screws and nuts.

20013920

46 8. Install the two cap screws and nuts, 1. 9. Tighten all returns auger hardware.

20013919

47 10. Attach the belt guard support brace, 1, to the returns auger with two cap screws, 2.

20013918

74-17

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 11. Slide the nylon bushing, 1, spring gauge, 2, spring, 3, washer, 4, onto the adjusting rod. Turn on the adjusting nut, 5.

4 5 3 2 1

20013922

49 12. Install the drive belts, 1. Tighten the adjusting nut, 2, until the washer is even with the top of the spring gauge.

2 1

20013917

50 13. Attach the belt guard, 1, to the combine. Turn the three 1/4-turn fasteners, 2, one-quarter turn to engage them to the support braces.

2 20013916

74-18

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 GEARBOX Removal NOTE: Left-hand side shown. Use same procedure for the right-hand gearbox removal. 1. Remove the snap ring, 1, and washers, 2, from the input shaft.

1 40015064

52 2. Use a suitable puller to remove the pulley, 1.

1 40015065

53 3. Remove the key, 1, and washers, 2, from the input shaft.

2 40015066

74-19

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 4. Loosen and remove the four nuts, 1, securing the access cover, 2,to the auger tube.

1 40015100

55 5. Drive the double roll pin, 1, from the gearbox output shaft and auger shaft.

40015067

56 6. Loosen and remove the six retaining bolts, 1, from the auger tube, 2, and gearbox, 3.

20015068

74-20

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 7. Remove the cradle support, 1, from the auger tube.

1 20015069

58 8. Remove the gearbox, 1, from the auger tube.

1 20015070

59 Disassembly

Output NOTE: The returns auger gearbox consists of two case halves, each containing a shaft, gear, shims and bearings. The repair text will show Disassembly, Inspection and Assembly for each half of the gearbox. The gearbox case halves will be designated as Input and Output. 1. Loosen and remove the four bolts, 1, in the gearbox housing. 20015071

1 60

74-21

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 IMPORTANT: Observe the orientation of the six auger tube mounting holes during separation of the gearbox halves. This is important during installation of the gearbox onto the auger. 2. Separate the gearbox halves from each other.

20015072

61 3. Use a suitable puller to remove the output gear, 1, from the output shaft, 2.

20015073

62 4.

Remove the key, 1, from the output shaft, 2.

2 1

20015074

74-22

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 5. Drive or press the output shaft, 1, out of the gearbox case in the direction of the arrow. 6. Remove the cap, 2, from the output shaft, 1.

20015075

64 7. Remove the snap ring, 1, from the gearbox case.

20015076

65 8. Remove the two bearings, 1, from the gearbox case.

20015077

74-23

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 9. Remove the second snap ring, 1, from the gearbox case.

20015078

67 10. Remove and discard the seal, 1, from the gearbox case.

20015079

68 Inspection 1. Clean all parts in a suitable solvent and allow to air dry. 2. Do not use compressed air to dry bearings as damage could result. 3. Rotate bearings by hand to check for roughness or binding. Replace as necessary. 4. Inspect the output shaft and gearbox, for wear, chips, nicks, burrs and signs of heat discoloration. Repair or replace as necessary. 5. Inspect the gearbox case for cracks. Repair or replace as necessary.

74-24

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 Assembly Output 1. Install the inner snap ring, 1, into the groove in the gearbox case.

20015080

69 2. Turn the gearbox case over.

3. Pack the two bearings with NH AMBRA GR-9 Multi-Purpose Grease. 4. Install the bearings, 1, into the gearbox case. 5. Tap the bearings lightly until seated against the snap ring.

20015081

70 6. Install the outer snap ring, 1, into the groove in the gearbox case.

7. Place NH AMBRA GR-9 Multi-Purpose Grease above the bearing in the gearbox case.

20015082

74-25

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 8. Install a new seal, 1, into the gearbox case. 9. Lightly grease the ID of the new seal with NH AMBRA GR-9 Multi-Purpose Grease.

20015079

72 10. Fill the cavity above the seal with NH AMBRA GR-9 Multi-Purpose Grease and install the cap, 1, until seated in the gearbox case.

20015083

73 11. Install the output shaft, 1, through the cap, seal and bearings.

12. Tap or press the shaft until seated on the bearings.

20015084

74-26

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 13. Use a center punch to stake the output shaft, 1. This is necessary to lock the gear onto the shaft when installed.

20015085

75 14. Insert the key, 1, into the key slot on the output shaft.

20015086

76 15. Tap or press the gear, 1, onto the output shaft until seated against the bearing.

20015087

74-27

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 Disassembly Input 1. Remove the snap ring, 1, from the end of the gearbox case.

20015088

78 2. Remove the shim, 1, from the gearbox case.

1 20015089

79 3.

Drive the input shaft, 1, out of the gearbox case in the direction of the arrow.

20015090

74-28

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 4. Remove the gear, 1, from the gearbox case.

20015091

81 5. Remove the bearing, 1, and metal seal, 2, from the input shaft.

20015092

82 6. Remove the bearing, 1, and metal seal, 2, from the gearbox case.

2 1 20015093

74-29

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 Inspection 1. Clean all parts in a suitable solvent and allow to air dry. 2. Do not use compressed air to dry bearings as damage could result. 3. Rotate bearings by hand to check for roughness or binding. Replace as necessary. 4. Inspect the input shaft and gearbox, for wear, chips, nicks, burrs and signs of heat discoloration. Repair or replace as necessary. 5. Inspect the gearbox case for cracks. Repair or replace as necessary. Assembly Input

1. Install the metal seal, 1, and sealed bearing, 2, onto the end of the input shaft.

2 20015094

84 2. Place the gear, 1, into the gearbox case.

20015095

74-30

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 3. Insert the input shaft, 1, through the gearbox case and gear.

4. Seat the gear over the key in the shaft and against the inside of the gearbox case.

5. Insert the metal seal, 2, over the shaft and into the gearbox case.

20015096

86 6. Install the sealed bearing, 1, over the input shaft and into the gearbox case.

20015097

87 7. Install the output half, 1, of the gearbox onto the input gearbox case and secure with the four bolts, 2.

1 2

8. Tighten the bolts securely.

20015098

74-31

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 9. Install the shims, 1, and snap ring, 2, into the gearbox case.

1 20015099

89 10. Check the backlash measurement.

11. Clamp the output shaft, 1, in a vise. 12. Position a dial indicator, 2, as shown.

13. Insert the key, 3, into the key slot on the input shaft.

14. The backlash should be 0.0254 -- 0.1780 mm (0.001 -- 0.007 in) as measured at the key on the input shaft. 15. Add or remove shims until the desired backlash measurement is achieved.

50015101

16. Fill the gearbox with 500 ml (17 fl. oz.) of NH AMBRA GR-9 Multi-Purpose Grease or until grease exits the gearbox case.

Installation 1. Install the gearbox, 1, onto the auger shaft, 2, aligning the roll pin holes.

2. Install the double roll pins, 3, through the auger shaft and gearbox output shaft.

20015067

1 91

74-32

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 3. Position the gearbox in the auger tube so the orientation of the grease fitting, 1, and gearbox input shaft, 2, are correct depending the gearbox being used as a left-hand or right-hand mount.

NOTE: To change the returns auger gearbox from left-hand to right-hand or right-hand to left-hand, the grease fitting and plug must be reversed. The gearbox can then be mounted in the proper orientation. 4. Install and tighten securely the five mounting bolts, 3.

20015068

92 5. Install the cradle support, 1, and secure with the mounting bolt, 2.

1 20015069

93 6. Install the access cover, 1, onto the auger tube and secure with the four nuts and washers, 2.

2 40015100

74-33

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 7. Install the washers, 1, and key, 2, into the key slot on the input shaft.

1 40015066

95 8. Install the drive pulley, 1, onto the input shaft and secure with large washers, 2, small washer, 3, and snap ring, 4.

NOTE: The gearbox drive pulley will need to be aligned with the returns cross auger pulley upon installation of the returns auger. Add or remove the washers shown in step 7 and step 8 to adjust alignment.

4 40015064

3 96

74-34

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 RETURNS AUGER SAFETY CLUTCH Removal 1. Loosen the nut, 1, on the cleaning shoe drive belt adjuster, 2. 2. Remove the belt, 3.

1 3

20013194

97 3. Loosen the nut, 1, on the returns drive belt adjuster, 2.

4. Remove the belt, 3.

20013193

98 5. Loosen and remove the bolt, 1, and washer, 2, from the drive sheave, 3.

3 2 1

40015046

74-35

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 6. Use a suitable puller, 1, to remove the drive sheave, 2, from the input shaft.

40015047

1 100

7. Remove the key, 1, from the tapered end of the input shaft, 2. 8. Drive both roll pins, 3, from the safety clutch, 4, and input shaft, 2.

3 1

2 40015048

101 9. Remove the safety clutch, 1, from the input shaft, 2.

40015049

2 102

74-36

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 Verify Clutch Slip Torque Inspect the clutch assembly for discolored paint. If the paint on the clutch housing is burned or blackened, replacement may be necessary. The heat which caused the discoloration will also have caused internal parts to loose their hardness. Clamp the slip clutch in a vice. NOTE: Ensure the vise is attached to a heavy bench or is secured to the floor. Insert a short metal bar with a socket welded on one end, and a hole drilled in the middle that will mate with the holes in the slip clutch.

50015716

103

Slide a rod through the hole in the slip clutch and metal bar as shown. Use a torque wrench attached to the socket. The clutch should slip at 225 -- 275 N⋅m (166 -- 203 ft-lb). If the actual slip torque is out of range, disassemble the clutch and add or remove springs as required. Perform this procedure until a satisfactory slip torque is obtained. Returns Auger Safety Clutch Disassembly NOTE: Leave the sheave attached to the safety clutch until instructed to remove it. 1. Remove the retaining ring, 1, from the safety clutch.

20013902

104 2. Lift the spacer ring, 1, from the safety clutch.

20013903

105

74-37

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 3. Carefully pull the nylon ring, 1, from the safety clutch.

20013904

106

CAUTION Ensure that the boards or other suitable items are thin enough so that the springs and pins are maintained inside the bucket as the inside of the clutch is driven out. 4. Set two boards or other suitable items over a bucket. Place the assembly over the bucket.

20013905

107

CAUTION The slip clutch springs and pins are under extreme pressure. Use care when driving the pin cylinder out of the housing to prevent serious injury. 5. Drive the pin cylinder out of the clutch housing. The pins and springs will be expelled from the cylinder and held inside the bucket.

20013906

108

74-38

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 6. Set the sheave and housing in a vise. Remove the sleeve, 1, if it is to be replaced.

7. Turn out the six cap screws, 2, to separate the sheave from the clutch housing.

20013907

109 Inspection Clean and dry all parts in a suitable cleaning solvent.

Inspect all internal parts for wear, damage or discoloration from heat. Replace any worn damaged, or discolored parts.

Inspect the clutch housing, 1, for wear. Replace the housing when the corners are rounded and grooves are present where the pins press against the housing. Inspect the pin pockets of the pin cylinder, 2, for burrs. Remove all burrs which could restrict pin movement.

20013908

110

Inspect the springs for heat discoloration and cracks. Inspect the pins for wear, cracks, discoloration and height. The measured height of the pins should not be less than 15.5 mm (0.61 in). Returns Auger Safety Clutch Assembly 1. Secure the sheave, 1, in a vise. Attach the clutch housing to the sheave using six M8 x 25 cap screws, 2, and lock washers. Install a new bushing, 3, if it had been removed.

20013907

111

74-39

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 2. Set the assembly on a table with the inside of the housing pointing up. Apply a liberal coating of grease to the inside surface of the housing.

20013909

112 3. Apply a liberal coating of grease to the pockets of the pin cylinder.

20013910

113 4. Insert the springs into the pin cylinder. NOTE: There will be fewer inner springs than outer springs. Space the double springs equally around the cylinder.

20013911

114

74-40

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 5. Insert the pins into the cylinder with the ridges positioned vertically.

20013912

115 6. Set the pin cylinder assembly in a piston ring compressor so that a screw driver or other suitable tool can hold the cylinder secure while tightening the compressor.

20013913

116 7. Tighten the ring compressor until the edges of the pins will clear the inside of the clutch housing. Line the pins up with the housing and lightly tap the cylinder into place. Insert the cylinder until it bottoms out against the housing.

20013914

117

74-41

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 8. Insert the nylon ring, 1, into the housing.

20013915

118 9. Insert the metal ring, 1, into the housing.

20013903

119 10. Install the snap ring, 1, into the housing.

1 20013902

120

74-42

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 Returns Auger Safety Clutch Installation 1. Grease the ID of the safety clutch, 1, with NH AMBRA GR-9 Multi-Purpose Grease, and install onto the input shaft, 2, making sure to align the roll pin holes.

2 40015049

121 2. Install the key, 1, into the tapered end of the input shaft, 2. 3. Install both roll pins, 3, through the safety clutch, 4, and input shaft, 2.

3 1

2 40015048

122 4. Install the drive sheave, 1, onto the input shaft and secure with the flat washer, 2, lock washer and M12 x 35 cap screw, 3. Tighten the bolt securely.

1 2 3

40015046

123

74-43

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 5. Install the cleaning shoe drive belt, 1. 6. Tighten the nut, 2, on the cleaning shoe drive belt adjuster until the washer is even with the spring gauge, 3.

2 3

20013194

124 7. Install the returns drive belts, 1. 8. Tighten the nut, 2, on the returns drive belt adjuster until the washer is even with the spring gauge.

20013193

2 125

74-44

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 RETURNS AUGER BEARING REPLACEMENT

Right Auger Bearing Replacement 1. Remove the access door from the side of the auger discharge.

2. Turn off cap screw, 1, and remove the speed sensor cam, 2.

40013923

126 3. Loosen set screw, 1. Disengage the bearing lock collar, 2. 4. Remove nuts and carriage bolts, 3. Hang the speed sensor, 4, so that it is out of the way.

4 1 2 40013924

127 5. Lift the bearing and retainers, 1, from the shaft.

40013925

128

74-45

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 6. Slide the new bearing and retainers onto the shaft with the locking end of the bearing toward the end of the shaft.

40013926

129 7. Secure the bearing assembly to the auger housing using two carriage bolts, nuts, and lock washers, 1, with the speed sensor, 2, mounted at the top.

8. Set the lock collar, 3, onto the end of the bearing. Engage the collar with a hammer and punch opposite the direction of rotation. Tighten the set screw, 4.

4 3 40013924

130 9. Attach the speed sensor cam, 1, to the end of the shaft using cap screw and lock washer, 2.

10. Install the access door.

40013923

131

74-46

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 Left Auger Bearing Replacement 1. Remove the access door from the side of the auger discharge. Loosen set screw, 1. Disengage the bearing lock collar, 2.

1 3 3

2. Remove nuts and carriage bolts, 3. Pull the bearing from the auger shaft.

2 40013927

132 3. Slide the new bearing and retainers onto the shaft with the locking end of the bearing toward the end of the shaft.

400139128

133 4. Secure the bearing assembly to the auger housing using two carriage bolts, nuts, and lock washers, 1.

40013929

134

74-47

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 5. Set the lock collar, 1, onto the end of the bearing. Engage the collar with a hammer and punch in the direction of rotation. Tighten the set screw, 2.

1 40013927

135 6. Rotate the auger until a paddle is lined up with the flow sensor. Verify the gap, 1, between the sensor and paddle is 1 - 3 mm (0.039 - 0.118″). Adjust the position of the paddle as necessary to obtain the required dimension. Perform this step for both paddles.

7. Install the access door.

40013930

136 Right Auger Paddle Replacement (If Equipped) 1. Remove the access door from the side of the auger discharge. Turn out cap screws, 1, and lift the paddle from the auger.

2. Set the new paddle in place and secure to the auger shaft using two cap screws and lock washers. 3. Rotate the auger and check for interference. Adjust the paddle as necessary. 40013931

137

74-48

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 Left Auger Paddle Replacement 1. Remove the access door from the side of the auger discharge. Turn out cap screws, 1, and lift the paddle from the auger. 2. Set the new paddle in place and secure to the auger shaft using two cap screws and lock washers. 3. Rotate the auger until the paddle is lined up with the flow sensor. Set the gap, 2, between the sensor and paddle to 1 -- 3 mm (0.039 -- 0.118 in). Adjust the position of the paddle as necessary to obtain the required dimension.

40013932

138 Returns Auger Shaft Replacement 1. Remove the left or right returns auger in accordance with the appropriate section.

40013933

139 NOTE: Right side shown, left side is similar. 2. Remove the discharge paddles, 1.

40013931

140

74-49

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 3. Remove the access cover from the auger. Punch out the double roll pin, 1, securing the gearbox shaft to the auger, 2.

20015067

141 NOTE: The drive sheave is shown removed. It is not necessary to remove the sheave. 4. Turn out the six cap screws, 1, holding the gearbox to the auger housing. Remove the gearbox from the housing.

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142 NOTE: Left side shown, right side is similar.

5. Loosen the locking collar set screw, 1. Using a hammer and punch, disengage the locking collar, 2. Remove the cap screws and nuts, 3, and slide the bearing assembly from the shaft.

3 3

2 40013927

143

74-50

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 6. Slide the old auger shaft, 1, from the housing, 2. Insert the new auger shaft into the housing.

40013934

144 7. Orient the gearbox, 1, with the input shaft to the side as shown. Secure the gearbox to the housing with six cap screws, 2.

NOTE: The left side auger is shown. Installation of the gearbox on a right side returns auger is similar. The gearbox input shaft will be on the opposite side.

20015068

145 8. Line the holes up between the auger shaft, 1, and gearbox output shaft. Drive the double roll pin, 2, into the shafts with the gaps of the roll pins oriented 180 degrees apart.

20015067

146

74-51

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 9. Slide the bearing onto the end of the auger shaft with the locking end of the bearing toward the end of the shaft. Secure the bearing assembly to the housing using two cap screws, nuts and lock washers, 1.

3 1 1

10. Set the lock collar, 2, onto the end of the bearing. Engage the collar with a hammer and punch opposite the direction of rotation. Tighten the set screw, 3.

2 40013927

147 11. Set the paddles in place and secure to the auger shaft using two cap screws and lock washers, 1.

Left return auger paddles only: Rotate the auger until the paddle is lined up with the flow sensor. Set the gap, 2, between the sensor and paddle to 1 -- 3 mm (0.039 -- 0.118 in). Adjust the position of the paddle as necessary to obtain the required dimension.

40013932

148 Right return auger paddles only: Set the paddles, 1, in place and secure to the auger shaft using two cap screws and lock washers, 2.

Rotate the auger and check for interference. Adjust the paddle as necessary.

40013931

149

74-52

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4 12. Install the left or right returns auger using the procedure described earlier in this section.

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150

74-53

SECTION 74 -- CLEANING SYSTEMS -- CHAPTER 4

74-54

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1

SECTION 80 -- GRAIN STORAGE Chapter 1 -- Clean Grain Transport CONTENTS Section

Description

Page

80-1

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 OVERHAUL CLEAN GRAIN CROSS AUGER Clean Grain Cross Auger -- Exploded View

1. 2. 3.

Clean grain cross auger Sprocket Bearing

4. 5. 6.

80-2

Grain elevator chain Key Spring pin

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 Removal To remove the clean grain cross auger, proceed as follows: 1. Open cover, 1.

2 2. Loosen adjustment nut, 1, to release the tension on the grain elevator intermediate shaft drive belt.

10020117

3 3. Rotate the elevator chain until the coupler links are accessible on the bottom sprocket. 4. Release the chain tension with nuts, 1, and 2, at the rear of the grain elevator.

80-3

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 5. To disconnect the chain, remove cotter pins, 2, to remove coupler link, 1. To prevent from slipping out of the grain elevator chain, fit a rope on both ends of the chain.

5 6. Remove the spring pin of the sprocket, 1.

6 7. Remove three M10 nuts (with lock washers, if installed), 1, to remove cover, 2.

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80-4

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 8. Remove lock collar, 1.

9. Loosen three M10 nuts and lock washers, 2, and then remove the bearing flange and M10 x 40 carriage bolts.

1 8 10. Disconnect the senior connector, 3. Remove two M8 x 12 bolts and lock washers, 2, to remove cover, 1, at the left-hand side.

9 11. Remove the M10 x 20 bolt, lock washer, and flat washer, 1, and then remove the sensor target disc, 2.

2 40033202

80-5

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 12. Loosen the mid nut to remove cover, 2. 13. Remove lock collar, 3. 14. Loosen two M10 nuts and lock washers, 1, and then remove the bearing flange.

1 11

15. Pull the auger, 1, outward to remove it through the long key hole, 2, at the left-hand side.

1 12 16. Turn the auger, 1, counterclockwise outward through the elongated keyhole. 17. Remove the sprocket at the right-hand side.

1 13

80-6

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 Installation 1. Install the auger, 1, from the left-hand side. Insert the auger flighting into the elongated keyhole, 2, and then rotate the auger clockwise until it is partway into the lower elevator.

1 14 2. Install sprocket, 1, key, 7, and spring pin, 2, (right-hand end). Insert three M10 x 40 carriage bolts, 6, outward through the elevator housing. 3. As the auger is advanced fully to the right, install right-hand side bearing and flanges, 3, with lock washers and M10 nuts. Tighten the cap nuts. (Do not tighten lock collar, 4). NOTE: Lubricate the spherical outer ring with New Holland Ambra Hi-Temp Grease and lubricate the inner ring of the bearing and the lock collar with Loctite® 767 anti-seize grease.

4. Adjust the auger so that sprocket, 1, is in the middle of the elevator frame.

5. Tighten lock collar, 4, in clockwise direction. 6. Install cover, 5, and secure with M10 nuts and (lock washers, if previously installed, not required). 7. Insert two M10 x 20 carriage bolts outward through the left side housing for the bearing flanges. Install the bearing and flanges. Tighten the left-end nuts, 1, with lock washers and M10 nuts. NOTE: Lubricate the spherical outer ring with New Holland Ambra Hi-Temp Grease and lubricate the inner ring of the bearing and the lock collar with Loctite® 767 anti-seize grease. 8. Install and tighten lock collar, 3.

9. Install and secure cover, 2, with lock washer and M10 nut.

1 16

80-7

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 10. Install the sensor target disc, 1, and secure with the M10 x 20 bolt, 2, flat washer, and lock washer.

1 40033202

17 11. Install the sensor cover, 1, with two M8 x 12 bolts and lock washers, 3, and then connect the wires, 2.

NOTE: Turn the target disc inboard if clearance between target legs and the access cover, 4, is less than 2 mm (0.079 in).

1 3

3 4

18 12. Connect the grain elevator chain, with coupler links, 1. 13. Install cotter pins, 2, to secure the coupler links. NOTE: Insert the cotter pins in the direction of travel. See Figure 19.

80-8

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 14. Tighten the grain elevator chain tension with nuts, 1 and 2. NOTE: The tension is correct when the chain can be moved axially across the lower sprocket by hand.

20 15. Install and adjust the grain elevator intermediate shaft drive belt tension with nut, 1. Adjust to the specified length per the indicator plate on the adjustment rod.

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21 16. Close the bottom of the grain elevator with the cover, 1.

80-9

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 GRAIN ELEVATOR Removal To remove the grain elevator, proceed as follows:

1. Remove the right-hand forward side shielding, 1, as described in Section 90 -- Platform, Cab, Bodywork, Decals; Chapter 2 -- Shielding; Side Shield -- Removal. 2. Access the upper right-hand side shielding, 2, using an appropriate ladder or lift. Remove the shielding, 2.

56063417

23 3. Loosen bolts, 1, and remove shielding, 2. 4. Remove bolt, 3.

1 2

24 5. Disconnect the wires, 1, of the moisture sensor, if installed. 6. Remove the clean grain cross auger. Refer to “Clean Grain Cross Auger -- Removal” of this chapter.

10020120

80-10

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 7. Loosen the bolts to remove clean grain cross auger tube halves, 1.

26 8. Remove cover, 1.

27 9. Disconnect the wires of grain flow sensor, 1, and remove bubble-up tube sensor, 2, if installed.

2 28

80-11

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 10. Remove bolt, 1, to open bubble-up tube, 2.

29 11. Loosen two bolts, 1, and remove the upper bubble-up tube completely.

1 30 12. Loosen the bolts to remove seal, 1, completely.

80-12

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 WARNING

The grain elevator weighs approximately 260 kg (595 lb). Use a hoist and supporting devices capable of supporting this weight. Failure to comply could result in serious injury or death. 13. Support the elevator weight, approximately 260 kg (575 lb), with a hoist attached to an appropriate lifting tool, e.g., a bale (as shown, 1), or chain that passes through the lifting hole at, 2.

2 32 14. If a bail type tool is used, ensure it passes completely through the left hole and is secured with an appropriate device or hardware, e.g., a linchpin, 1, as shown.

33 15. Remove two bolts, 1, at the front of the grain elevator.

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80-13

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 16. Remove two bolts, 2, at the back of the grain elevator.

10020122

35 17. Remove bolts, 1, of the supports at the bottom of the grain elevator.

18. Remove the grain elevator completely.

80-14

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 Installation 1. Bring the grain elevator into its position, using an adequate lifting device. Insert the bubble-up tube into the grain tank opening.

37 2. Install two bolts, 1, loosely at the front of the grain elevator.

10020121

38 3. Install two bolts, 1, loosely at the back of the grain elevator.

10020122

80-15

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 4. Install the supports and tighten bolts, 1. 5. Tighten the front and back bolts, 1, installed and shown in Figures 38 and 39.

40 6. Install clean grain cross auger tube halves, 1, with the legs about horizontal. Move the tube halves as much as possible into the grain elevator opening and tighten the bolts until all the gap is removed.

41 7. Connect the wires of the moisture sensor, if installed. 8. Remove the hoist and lifting tools. 9. Install the clean grain cross auger, refer to “Clean Grain Cross Auger -- Installation”. 10. Install seal, 1, and tighten the bolts.

80-16

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 11. Connect the wires of grain flow sensor 1, and install bubble-sensor, 2.

2 43 12. Install the upper bubble-up tube with two bolts, 1.

1 44 13. Install bolt, 2, to connect the draw bar of upper bubble-up tube, 3, if grain tank extensions installed. 14. Adjust the draw bar by loosening nuts, 1, (only with the grain tank extensions completely open) until the gap between the two bubble-up tube is completely removed.

80-17

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 15. Install cover, 1.

46 16. Install bolt, 3. 17. Install shielding, 2, and tighten bolts, 1.

1 2

47 18. Install the upper shielding, 2.

19. Install the side shield, 1, as described in Section 90 -- Platform, Cab, Bodywork, Decals; Chapter 2 -- Shielding; Side Shield -- Installation.

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80-18

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 GRAIN ELEVATOR CHAIN Removal To remove the grain elevator chain, proceed as follows: 1. Open cover, 1.

49 2. Loosen adjustment nut, 1, to release the tension on the grain elevator intermediate shaft drive belt.

10020117

50 3. Rotate the elevator chain until the coupler links are accessible on the bottom sprocket. 4. Loosen the grain elevator chain with nuts, 1 and 2.

80-19

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 5. Remove cotter pins, 2, to disconnect coupler link, 1.

52 6. If removing the chain for service, attach a rope to both ends of the chain to ensure ability to reinstall chain depending on the direction the chain rolls out of the housing. If removing the chain for replacement, orient the new chain as the old, and then connect two chains with a connector link and secure. As the old chain is turned out, the new chain will be guided into place.

53 7. Turn the old chain out.

80-20

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 Installation 1. Use the rope to install the old chain after service.

2. Disconnect the rope or the old chain, if installing a new chain. IMPORTANT: Ensure the chain is installed in the direction shown in Figure 55. 3. Connect the chain with coupler link, 1. 4. Install cotter pins, 2, in the direction of travel to secure the coupler link. NOTE: Insert the cotter pins in the direction of travel. See Figure 55.

5. The chain tension can be adjusted with nuts, 1 and 2, at the side of the grain elevator. NOTE: The tension is correct when the chain can be moved axially across the lower sprocket by hand.

56 6. Adjust the intermediate shaft drive belt tension with nut, 1. Adjust to the specified length per the indicator plate on the adjustment rod.

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80-21

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 7. Close the bottom of the grain elevator with cover, 1.

GRAIN ELEVATOR UPPER SHAFT Grain Elevator Upper Shaft -- Exploded View

59 1. 2. 3. 4.

Upper shaft Sprocket Bearing Sprocket

5. 6. 7.

80-22

Key Spring pin Elevator chain

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 Removal To remove the upper shaft of the grain elevator, proceed as follows: 1. Remove the grain elevator chain, refer to “Grain Elevator Chain -- Removal”, described earlier in this Section. 2. Remove cover, 1.

60 3. Remove spring, 1, to remove grain elevator drive chain, 2.

2 1

80-23

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 4. Remove the upper shielding, 1, to have access at the top of the grain elevator, using a ladder.

56063418

62 5. Remove all bolts, 1, securing the top plate, and then remove elevator top plate, 2.

63 6. To remove the driven sprocket of the upper shaft is it necessary to adjust the grain elevator head in the upper position, using nut, 1.

80-24

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 7. Remove spring pin, 1, of the sprocket.

65 8. Remove an M10 x 25 bolt, 1, lock washer and flat washer, 2.

66 9. Remove sprocket, 1, using a puller (or using the holes in the sprocket with a special puller).

80-25

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 10. Remove key, 1, lock collar, 2.

11. Loosen three nuts, 3.

1 68

12. Loosen the Allen screw and remove lock collar, 1. 13. Loosen three nuts, 2, and remove the bearing flange.

69 14. Remove the upper shaft.

80-26

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 Installation 1. Install the upper shaft. 2. Install the bearing flange on both sides and tighten the nuts. NOTE: Lubricate bearing with New Holland Ambra Hi-Temp Grease on the spherical outer ring. NOTE: Lubricate inner ring of the bearing and set collar with Loctite 767 anti-seize grease. 3. Install spring pin, 1, of the sprocket.

71 4. Adjust sprocket, 1, in the middle of the elevator frame and tighten the Allen screws of lock collar, 2, on both sides.

5. Install key, 3, and sprocket, 4.

6. Install washers, 5, and tighten the sprocket with bolt, 6.

6 5 72 7. Lower the grain elevator head in the standard position, with nut, 1.

8. Install the grain elevator chain, refer to “Grain Elevator Chain -- Installation” earlier in this chapter.

80-27

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 9. Install grain elevator drive chain, 2, and tighten them with spring, 1.

2 1

74 10. Install the elevator top plate with the bolts. IMPORTANT: First tighten bolts, 1, then bolts, 2, 3, etc.

75 11. Install the upper shielding, 1.

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80-28

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 12. Install cover, 1.

77 Adjustment The functionality of the grain flow sensor is affected by the play between the grain elevator paddles and the top of the grain elevator. The top shaft of the clean grain elevator can be shifted up and down independent of the top of the elevator adjusting the distance with the sprocket.

To adjust proceed as follows: 1. Release grain elevator chain with nuts, 1 and 2.

78 2. Loosen adjustment nut, 1, to release the tension on the grain elevator intermediate shaft drive belt.

10020117

80-29

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 3. Remove cover, 1.

80 4. Remove the upper shielding, 1, to have access at the top of the grain elevator, using a ladder.

56063418

81 5. Remove all bolts, 1, securing the top plate to remove elevator top plate, 2.

80-30

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 6. Check now distance X between the paddles and top of clean grain elevator (using a small plate instead of cover, 2, Figure 82). At the top left and right side of the grain elevator the distance between paddle tip in its vertical position with the top edge of the elevator housing may be not larger than 3 mm (0.125 in) but not smaller than 1 mm (0.04 in). (Turn the sprocket by hand to bring the paddle in this position.)

83 7. Loosen two bolts, 1, and nut, 2, on both sides of the grain elevator. 8. Adjust distance X, Figure 83, with nuts, 3. 9. After adjusting, tighten bolts, 1, and nut, 2, on both sides.

84 10. Install elevator top plate and tighten the bolts. IMPORTANT: First tighten bolts, 1, then bolts 2, 3, etc.

80-31

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 11. Install the upper shielding, 1.

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86 12. Install cover, 1.

87 13. Adjust the grain elevator chain with nuts, 1 and 2, at the rear of the grain elevator.

80-32

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 14. Adjust the grain elevator intermediate shaft drive belt tension with nut, 1. Adjust to the specified length per the indicator plate on the adjustment rod.

10020117

GRAIN FLOW SENSOR PLATE Adjustment To adjust the sensor plate, proceed as follows: 1. Remove cover, 1.

90 2. Remove the upper shielding, 1, to have access at the top of the grain elevator, using a ladder.

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80-33

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 3. Remove all bolts, 1, securing the top plate to remove elevator top plate, 2.

92 4. Install special assembly gauge, 1, with the four bolts.

NOTE: To make a special assembly gauge, refer to Figure 94.

80-34

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1

94 A B C D E F G

= 260 mm (10-1/4 in) = 142 mm (5-19/32 in) = 192 mm (7-9/16 in) = 23.5 mm (59/64 in) = 213 mm (8-3/8 in) = 8 mm (5/16 in) = 23 mm (15/16 in)

H I K V W R

5. Release nuts, 1, and nuts, 2, on both sides. 6. Adjust sensor support, 4, with bolts, 3, evenly on both sides until the measurement chute Y = 1 -- 3 mm (3/64 -- 1/8 in) from the special assembly gauge. See Figure 93.

=105 mm (4-1/8 in) = 1 mm (3/64 in) = 252 mm (9-15/16 in) = 7 x 16 mm (1/4 in x 5/8 in) = 7 mm (1/4 in) = 600 mm (23-5/8 in)

7. After adjusting tighten nuts, 2, and nuts, 1. 8. Remove the special assembly gauge.

80-35

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 9. Install the elevator top plate and tighten the bolts. IMPORTANT: First tighten bolts, 1, then bolt, 2, 3 etc.

96 10. Install the upper shielding, 1.

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97 11. Install the cover, 1, in the grain tank.

80-36

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 MOISTURE SENSOR Adjustment The moisture sensor measures grain that is falling out of the clean grain elevator into a small bin of the by-pass unit. The moisture content of the grain in this bin is sensed by the moisture sensor at the back of the by-pass unit. The level of grain in the bin is controlled by a level sensor, which is located at the top of the bin and an auger at the bottom of the bin. In order to have a good moisture reading the moisture sensor fin must always be clean and covered totally by grain. In other words, the bin always has to contain a minimum amount of grain. The sensitivity of the level sensor can be adjusted. If the level sensor is set too sensitive then the auger will start turning too early and not enough grain will be available in the sensor chamber to have a good moisture reading. As a result you will see the moisture value on the cab display monitor fluctuating a lot and suddenly drop to a low level. If the level sensor is set not sensitive enough the bin will always contain the same grain resulting in a practical constant moisture reading all over the field. NOTE: Although the level sensor sensitivity is set correct it is possible that due to material blockage (pieces of corn cobs) in front of the level sensor will also cause the auger to turn continuously when the threshing is on. This situation can be recognized when the moisture readings are abnormally low or largely fluctuating. Therefore, before changing the sensitivity of the level sensor, remove the moisture sensor and then look into the bin. In the top of the bin a white circle (= level sensor head surface) must be visible without being covered by dirt or crop residues. Remove any material accumulated in front of the level sensor. Reinstall the moisture sensor. If the moisture reading is still fluctuating or the electrical motor keeps on turning all the time then it is advised to change the sensitivity of the level sensor.

80-37

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 Sensitivity Set IMPORTANT: Before adjusting the sensitivity, check first if the moisture sensor fin and the level sensor are clean. Refer to Operator’s Manual, Section 4 -- Grain Storage -- “Moisture Sensor”. To set the sensitivity of the level sensor, proceed as follows: 1. Pull two pins, 1, out to remove the auger.

1 100 2. Pullout the auger, 1.

101 3. Remove all the grain out of auger chamber, 1.

NOTE: No grain may be in front of the level sensor otherwise the sensitivity setting will be biased.

102

80-38

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 4. Loosen two wing nuts, 1, to remove sensor fin, 2.

103 5. Key switch “On”, engine not running. Set the cab display monitor to display the Bypass Unit Full Sensor voltage using diagnostic mode.

6. Remove two nuts, 1, to remove side plate, 2.

10020123

104 7. The optical level sensor, a 25.4 mm (1.0 in) diameter plastic cylinder, becomes visible. At the back of the sensor there is a small screw, 1.

Turn the small adjustment screw (on the backside of the sensor), clockwise (CW) until the voltage just switches to something less than 2.5 volts. When the screw is turned the voltage level will jump between two values, one value above 2.5 volts and one value below 2.5 volts. Turn the adjustment screw four full revolutions counterclockwise (CCW) from this point. Reassemble the cover. 105

80-39

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 8. Install the side plate, 1, and tighten the nuts, 2.

10020123

106 9. Install the sensor fin, 1, and tighten the wing nuts, 2.

107 10. Insert the auger, 1.

108

80-40

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 11. Install two pins, 1.

1 109

BUBBLE-UP GEARBOX Bubble-up Gearbox -- Exploded View

110 1. 2. 3. 4. 5. 6. 7. 8.

Bearing, Tapered Roller Type Spacer Bearing, Tapered Roller Type Retaining ring Shim Spacer Spacer Shim

9. 10. 11. 12. 13. 14. 15. 16.

80-41

Retaining ring Oil seal Hub Washer Bolt, M12 x 25 Key Shaft Plug, Oil

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 Removal 1. Open the grain tank extensions (if installed).

2. Remove bolt, 1, to open bubble-up tube, 2.

111 3. Loosen two bolts, 1, and remove the sensor. 4. Remove the lower bubble-up auger.

1 112 5. Loosen the idler sprocket, 1, to remove the chain. 6. Remove cover, 2.

113

80-42

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 7. Remove four M10 nuts, lock washers, and M10 x 30 bolts, 1, to remove the bubble-up gearbox.

114 Installation 1. Install the bubble-up gearbox with four M10 x 30 carriage bolts, lock washers, and nuts, and then tighten nuts, 1, to standard torque.

115 2. Install cover, 2. 3. Install the chain and adjust tension with idler sprocket, 1.

116

80-43

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 4. Guide the auger into the lower bubble-up tube and make sure the auger bottom fits over the gearbox output shaft. 5. Install two bolts, 1, of the bearing support with the sensor.

1 117 6. Install the draw bar to upper bubble-up tube, 3, and tighten bolt, 2. 7. Adjust the draw bar by loosening nuts, 1, (only with the grain tank extensions completely open) until the gap between the two bubble-up tube is completely removed. IMPORTANT: Check if the ball joints of the draw bar are positioned in line.

118 Disassembly NOTE: During disassembly, keep track of location and number of all shim packs. Use the same shim packs during reassembly. To disassemble the bubble-gearbox, proceed as follows: 1. Remove the bubble-up gearbox, refer to “BubbleUp Gearbox -- Removal” of this chapter. 2. Remove M12 x 25 bolt, 3, and washer, 1.

3. Remove hub, 2, using a special puller.

119

80-44

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 4. Remove M12 x 30 bolt, 1, lock washer and washer, 2. 5. Remove sprocket, 3, using a puller.

120 6. Remove key, 2, on both sides.

7. Remove oil seal, 1. Discard oil seal.

NOTE: Oil seal, 10, will be damaged when it is removed.

121 8. Remove retaining ring, 3, and the shims.

9. Remove retaining ring, 2.

3 4

10. Remove shims, 5, and spacer, 1. 11. To remove pre-assembled shaft, 4, install the sprocket or the hub with the bolt to pull out the shaft.

1 2 3 4 ZDA3530A

5 122

80-45

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 12. Remove bearing, 3, and spacer, 2. 13. Remove bearing, 1. Carefully take away the inner ring with a bearing puller, make sure not to damage the shaft.

123 14. Take out spacer, 1, and shims, 2.

124

80-46

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 Assembly 1. Install bearing, 1, on the shafts.

125 2. Install spacer, 3, and bearing, 2, on the shaft.

3. Install the shims and retaining ring, 1.

2 3 126 4. In order to set the two bearings, 1 and 2, hit the ends with a soft-faced mallet shaft on both, and then rotate the bearings two full revolutions to seat the bearing rollers. 5. Check the preload on the bearings with a torque meter. This preload (individually) should cause a rolling torque of 1200 -- 2000 N⋅mm (11 -- 17 in-lb).

Set the shimming in case the preload is not between the tolerance range shown. 6. Apply a bluing compound to the gear teeth of both shafts. 127

80-47

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 7. Install original shim packs, 1, and spacer, 2.

128 8. Install the pre-assembled shafts partially in, by only pushing on the outer ring of the bearings. Check if the preload of these pinions is still between the range shown. This preload (assembly) should be 1200 -- 2000 N⋅mm (11 -- 17 in-lb).

129 9. On the output shaft, install the spacer, 4, outer shim pack, 5, and retaining ring, 6. Add shims at 5 as required to ensure there is no clearance (zero endplay) between the spacer and retaining ring. On the input shaft, install the spacer, 3, outer shim pack, 1, and retaining ring, 2. Add shims at 1 as required to ensure there is no clearance (zero endplay) between the shaft assembly and the retaining ring. 10. While holding the output shaft to apply a light load to it, rotate the input shaft clockwise several revolutions, as viewed from the end of the shaft. This will seat the bearing rollers, and will also mark the gear contact pattern in the bluing compound on the gear teeth. 11. Check the gear backlash. The back lash should be between 0.11 and 0.3 mm (0.004 -- 0.012 in). Remove the input shaft from the gearbox, and check the gear contact pattern on the gears; the contact pattern should be 40% central-toe, as shown in Figure 131.

80-48

3 2

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1 130

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1

OUTPUT

INPUT LOW ON INPUT HIGH ON OUTPUT

NORMAL 40% CENTRAL-TOE

HIGH ON INPUT LOW ON OUTPUT

20014634

131 Adjusting Backlash The shaft that is moved to adjust the backlash depends on whether the backlash needs to be increased or decreased, and on the gear contact pattern observed. Refer to the following chart to determine the adjustment required. Gear Contact Pattern

Backlash Measured

Adjust:

High on input, low on output

Input out, output in equally

Low on input, high on output

Output out, input in equally

High on input, low on output

Tight; increase backlash

Input shaft out

High on input, low on output

Loose; decrease backlash

Input shaft out, output shaft in

Low on input, high on output

Tight; increase backlash

Output shaft out

Low on input, high on output

Loose; decrease backlash

Output shaft out, input shaft in

Correct, 40% central-toe

Tight; increase backlash

Move both shafts out an equal amount

Correct, 40% central-toe

Loose; decrease backlash

Move both shafts in an equal amount

80-49

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 To adjust backlash, move shims from one end of the appropriate shaft to the other. To move a shaft out of the gearbox, remove shims from 1 or 4, and add shims at 2 or 3. To move a shaft into the gearbox, remove shims from 2 or 3, and add shims at 1 or 4.

2 1

IMPORTANT: When moving both shafts to correct both an incorrect gear contact pattern and a loose backlash condition, move the one shaft out in 0.05 mm (0.002 in ) increments while moving the other shaft in using 0.1 mm (0.004 in) increments. Shifting one shaft 0.1 mm (0.004 in) will change the backlash between the gears approximately 0.05 mm (0.002 in). To shift the shaft 0.1 mm (0.004 in) inwards, remove a 0.4 mm or 0.5 mm (0.016 or 0.020 in) shim at 6, and substitute the next size smaller shim [0.3 mm or 0.4 mm (0.012 or 0.016 in)]. Then remove a 0.3 mm or 0.4 mm (0.012 or 0.016 in) shim from 7, and install the next size bigger shim [0.4 mm or 0.5 mm (0.016 or 0.020 in)]. Use the opposite procedure to move the shaft outwards. Shims are available in the following sizes: 0.3 mm (0.012 in) 0.35 mm (0.014 in) 0.4 mm (0.016 in) 0.5 mm (0.020 in) 1.0 mm (0.039 in)

80-50

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SECTION 80 -- GRAIN STORAGE -- CHAPTER 1

OUTPUT

INPUT

NORMAL 40% CENTRAL-TOE

LOW ON INPUT HIGH ON OUTPUT

HIGH ON INPUT LOW ON OUTPUT

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133

Inspecting Gear Contact Pattern After the backlash has been correctly adjusted, re-apply bluing compound to the gears, and re-install them in the gearbox. While holding the output (double tapered roller bearing) shaft to apply a light load to it, rotate the input (tapered roller and ball bearing) shaft clockwise several revolutions, as viewed from the end of the shaft. This will seat the bearing rollers, and will also mark the gear contact pattern in the bluing compound on the gear teeth. If the gear contact pattern is not correct, both shafts must be moved AN EQUAL AMOUNT in order to correct the contact pattern, as follows: If contact pattern is:

Move shafts as follows:

High on input, low on output

Input shaft out, output shaft in

Low on input, high on output

Output shaft out, input shaft in

80-51

Use the same procedure as described in “Adjusting Backlash” to move the shafts in or out. After adjusting the shafts, recheck the backlash to ensure it has not changed. Continue to apply bluing compound to check and adjust gear contact pattern until it is correct.

SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 12. Install new oil seal, 1. Ensure the lip seals are not damaged when installing. Install keys, 2.

134 13. Install sprocket, 3, and washer, 2. Tighten bolt, 1.

135 14. Install hub, 2, and washer, 1, and bolt, 3. Tighten and torque to 83 -- 106 N⋅m (61 -- 78 ft-lb).

15. Fill the gearbox with 0.25 L (8.5 fl oz) of New Holland Ambra Hypoide 90 gear oil.

136

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SECTION 80 -- GRAIN STORAGE -- CHAPTER 2

SECTION 80 -- GRAIN STORAGE Chapter 2 -- Unloading System CONTENTS Section

Description

Page

80-1

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 OVERHAUL UNLOADING DRIVE BELT Removal To remove the unloading drive belt, proceed as follows: 1. Loosen nut, 1, to release the unloading drive belt.

1 2. To release unloading drive chain, loosen the tensioner arm adjustment nut, 1.

10030884

2 3. Remove four M10 x 30 mm bolts, 1, Belleville lock washers, and nuts.

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80-2

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 4. Rotate the bearing plate, 1, forward. (View is from behind the V-pulley.) 5. Remove unloading drive belt, 2.

56063439

4 Installation To install, proceed as follows: 1. Install a new belt, 2.

2. Rotate the bearing plate, 1, and align four holes to the frame.

56063439

5 3. Install and tighten four M10 x 30 mm bolts with Belleville lock washers, and then secure with Belleville lock washers and M10 nuts, 1.

1 1

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80-3

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 4. Adjust tension of the unloading drive belt. Tighten nut, 3, until spring, 1, equals the length of the indicator plate, 2.

7 5. Adjust the unloading drive chain. Apply NH AMBRA GR9 multi-purpose grease to the face of the tensioner support bracket, 1.

6. Tighten nut, 2, until spring, 3, equals the length of the indicator plate, 4.

7. Ensure the tensioner slides freely along the tensioner bracket, 1.

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4 8

80-4

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 UNLOADING INTERMEDIATE SHAFT

Unloading Intermediate Shaft -- Exploded View

5 3 4

6 7

11 12 13 14

8 1 10 9

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9 1. 2. 3. 4. 5. 6. 7.

Hardware Set (M10 x 25 carriage bolt, Belleville lock washer, M10 nut), Bearing Flange Bearing Flanges (inner set) Ball Bearing -- 72 mm (2-13/16 in) diameter (inner) V-pulley, Intermediate Shaft Belt, Unloading Drive Hardware Set (M10 x 30 Cap Screw Hex Head, and M10 nut) Intermediate Shaft

8. 9. 10. 11. 12. 13. 14.

Square Keys (10 x 8 x 50) Hardware Set (M12 x 30 carriage bolt, Belleville lock washer, M12 nut), Bearing Flange Bearing Flanges (outer set) Ball Bearing -- 80 mm (3-3/32 in) diameter (outer) Washer (71.5 mm [2-13/16 in]) Sprocket Assembly Retaining Ring

Sprocket Shearbolt -- Replace The unloading system drive is protected by a shearbolt, 1. The shearbolt should be torqued to 20 -- 26 N⋅m (15 -- 19 ft-lb).

Spare shearbolts, 2, are located on the bearing plate above the sprocket. NOTE: If repetitive failures occur, adjust cross auger covers down.

1 86063610

80-5

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 Removal To remove, proceed as follows: 1. Loosen nut, 1, to release the unloading drive belt.

11 2. Loosen nut, 1, and remove the unloading drive chain from sprocket, 2.

12 3. Loosen the Allen screw, unlock and remove lock collar, 3, of the back bearing. 4. Disassemble the bearing flanges from the bearing plate, 1. Remove three M10 nuts and Belleville lock washers, 2, and then remove the M10 x 25 mm carriage bolts from the bearing flanges.

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80-6

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 5. Loosen Allen screw, 1, and move lock collar, 2, off the front bearing. 6. Remove four M12 x 30 carriage bolts, 3, on the outer bearing plate. 7. Remove the complete shaft.

14 8. Remove the retaining ring, 3, the sprocket, 1, with shaft keys, and large washer, 2. NOTE: Sprocket removal is necessary in order to allow for torque wrench application to the outer bearing flange nuts during installation. 9. As required, disassemble, clean, service, and assemble the intermediate shaft components. Reference Figure 9; Unloading Intermediate Shaft -- Exploded View.

IMPORTANT: When assembling the intermediate shaft, the shaft must be clean and corrosion free. Apply anti-seize lubricant to the inside diameter of the V-pulley and sprocket hubs, the ball bearings, and to the outside diameter of the shaft where these components are installed. Treat the exposed outer diameter of the shaft (middle and ends) with an anti-corrosion spray, e.g., Grafloscon CA Plus.

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3 15

80-7

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 Installation 1. Lift the assembled shaft into position to the inner and outer bearing plates with the unloading drive belt installed around the shaft.

2. Assemble the outer bearing flanges, 6, to the inside of the outer bearing plate, 5. Install four M12 x 30 carriage bolts, 4, outward, as shown, and secure with Belleville lock washers and M12 nuts. 3. Assemble the inner bearing flanges, 3, to the outside of the inner bearing plate, 1. Install three M10 x 25 carriage bolts, 2, inward, and then secure with Belleville lock washers, and M10 nuts.

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6 16

4. Tighten and torque the outer bearing flange M12 nuts, 2, to 80 -- 105 N⋅m (63 -- 77 ft-lb).

5. Tighten and torque the inner bearing flange M10 nuts, 1, to 49 -- 60 N⋅m (36 -- 44 ft-lb). 6. Align sprocket, 3, to the other sprockets of the chain drive assembly before locking the bearing lock collars, 4. Setting, A = 64.9 mm (2-9/16 in), between the outer bearing plate and the outer sprocket face.

7. Install and lock both lock collars onto the bearings, and then tighten the Allen screws.

66070058

17 8. Apply anti-seize lubricant to the ID of the sprocket hub and to the OD of the shaft. Install the large washer, 2, shaft keys and sprocket, 1, and retaining ring, 3.

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3 18

80-8

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 9. Align V-pulley, 1, of the intermediate shaft in line with V-pulley, 2, of the engine gearbox. 10. Secure the V-pulley settings; tighten and torque the M10 x 30 cap screw to 54 -- 60 N⋅m (41 -- 44 ft-lb), and then tighten and torque the M10 jam nut to the same specification. Reference items 4 and 6 in Figure 9, see Unloading Intermediate Shaft -- Exploded View.

19 11. Install the unloading drive belt. 12. Tighten nut, 3, until spring, 1, equals the length of the indicator plate, 2.

80-9

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 DRIVE SYSTEM UNLOADING GEARBOX Drive System Unloading Gearbox -- Exploded View

8 7

9 12

6 5 3

11 4

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21 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Housing, Unloading Gearbox Input Shaft Assembly Plug, Oil Filler Shaft, Output Retaining Ring (exterior) Bearing, Tapered Roller (60 mm OD) Shim Cover Seal, Rubber Screw, M8 x 16 Hex Socket Cap

11. 12. 13. 14. 15. 16. 17. 18. 19.

80-10

Cover Cover, Access (right-hand side) Plug, Oil Level Bevel Gear Plug, Oil Drain Bearing, Tapered Roller Type (90 mm OD) Shim Retaining Ring (interior) Cap

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 NOTE: Do this job with minimum two persons. NOTE: The weight of the gearbox is about 40 kg (88 lb). NOTE: When removing the gearbox, there is no risk of the vertical unloading auger coming out with the gearbox or suddenly dropping after the gearbox is removed. The auger must be physically turned out of the tube. Removal To remove, proceed as follows:

1. Loosen nut, 2, and remove drive chain, 1, of the unloading gearbox sprocket. 2. If removing gearbox for disassembly service, remove the oil drain plug, 4, and drain oil into suitable container. Dispose of used oil. 3. Remove six M12 nuts and Belleville lock washers, 3, and then remove the gearbox.

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3 4 22

Disassembly NOTE: During disassembly keep track of location and number of all shim packs. Use the same shim packs during re-assembly. To disassemble the unloading gearbox, proceed as follows: 1. Remove the unloading gearbox, refer to “Unloading Drive Gearbox -- Removal” of this chapter. 2. Drain the oil of the gearbox. 3. Remove eight M8 x 20 bolts, 1, and take away cover, 2.

80-11

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 4. Remove the M12 x 35 bolt, 1, and washer, 2. 5. Pull off sprocket, 3.

24 6. Remove two keys, 1, and washer, 2. 7. Remove oil seal, 3, using a screw driver. Discard oil seal. NOTE: Oil seal, 3, will be damaged when it is removed.

1 25 8. Remove retaining ring, 2, spacer, 3, and shims, 4. 9. Pull out shaft, 1, together with the bearings. 10. Remove shims, 5, from the housing.

80-12

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 11. Remove retaining ring, 2, and shims, 3. 12. Remove bearing, 4, and spacer, 5. 13. Remove bearing, 6. Carefully take away the inner race with a screw driver, making sure not to damage the shaft. 14. Remove the M10 x 30 flange bolt, 8, and blade, 7.

27 15. Remove the M12 x 30 bolt, 1, and washer, 2. 16. Take away sprocket, 3.

28 17. Remove retaining ring, 1. 18. Remove four M8 x 16 hex socket cap screws, 2.

80-13

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 19. Pull out shaft, 1, together with cover, 2, and bearing, 3.

30 20. Remove cover, 1, from the shaft.

21. Remove seal, 2.

22. Remove the shims between cover, 1, and bearing, 3. 23. Remove bearing, 3, from the shaft.

31 24. Remove crown wheel, 1, from the housing.

80-14

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 25. Remove bearing, 1, from the crown wheel.

33 26. Remove cap seal, 1.

34 27. Remove retaining ring, 1, shims, 2, and bearing outer ring, 3.

80-15

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 Assembly

36 Assembled Output Shaft, Unloading Gearbox -- Cross Section View 1. 2. 3. 4. 5. 6.

Shims Cover Shaft, Output Seal, Rubber Screw, M8 x 16 Hex Socket Cap Bearing, Tapered Roller Type (60 mm OD)

7. 8. 9. 10. 11.

Bevel Gear Bearing, Tapered Roller Type (90 mm OD) Cap Retaining Ring (interior) Shims

To assemble the output shaft, proceed as follows: 1. Install retaining ring, 10, original shim packs, 11, and bearing cup of bearing, 8. 2. Install bearing cone at, 8, on bevel gear, 7. 3. Apply a bluing compound to the gear teeth of the bevel gear, 7, and then install gear with bearing into the gearbox housing. 4. Install bearing cone at, 6, on output shaft, 3, and assemble the shaft in the gearbox housing. 5. Install bearing cup at, 6, and shims, 1.

6. Install cover, 2, with four M8 x 16 hex socket cap screws, 5, and then tighten to a torque of 25 to 32 N⋅m (19 -- 24 ft-lb). 7. In order to set the two bearings, 6 and 8, hit the shaft on both ends with a soft-faced mallet, and then rotate the shaft two full revolutions to seat the bearing rollers. 8. Check the preload on the bearings with a torque meter. This preload should cause a rolling torque of 339 -- 791 N⋅mm (3 -- 7 in-lb). 9. Set shimming, 1, in case the preload is not between the tolerance range shown.

80-16

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2

37 Input Shaft, Unloading Gearbox -- Cross Section View 1. 2. 3. 4.

Input shaft Retaining ring Shims Bearing, Tapered Roller (90 mm OD)

5. 6. 7. 8.

Spacer Bearing, Tapered Roller (90 mm OD) Plate Bolt, M10 x 30 Flange

To pre-assemble the input shaft, proceed as follows: 1. Install the bearing cone, of 6, on input shaft, 1, pushing the inner race. 2. Install the bearing cup, of 6, and spacer, 5.

6. Check the preload on the bearings with a torque meter. This preload should cause a rolling torque of 791 -- 1243 N⋅mm (7 -- 11 in-lb). 7. Set shimming, 3, in case the preload is not between the tolerance range shown.

3. Install the bearing cup, and then cone, of 4. 4. Install shims, 3, and retaining ring, 2. 5. Hold up the assembly and hit the input shaft on both ends with a soft-faced mallet in order to set bearings, 4 and 6, and then rotate the bearing two full revolutions to seat the bearing rollers.

80-17

8. Apply Loctite 243 to the M10 x 30 flange bolt, 8, and then install the bolt and blade, 7. 9. Tighten the flange bolt, 8, to a torque of 15 N⋅m (11 ft-lb).

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 5 6

7 38 Assembled Input Shaft, Unloading Gearbox -- Cross Section View 1. 2.

Pre-assembled input shaft Retaining ring

3. 4.

To assemble the pre-assembled input shaft in the gearbox, proceed as follows: 1. Install original shim pack, 5, in the housing. 2. Apply a bluing compound to the gear teeth of the input shaft, and install the pre-assembled input shaft partially into the gearbox housing, by only pushing the outer ring of the bearing. 3. Check if the pre-load of the input shaft is still between the tolerance range shown. 4. Install the pre-assembled input shaft completely. 5. Install shims, 4, and spacer, 3. Install retaining ring, 2, so that there is no clearance between the retaining ring and spacer, 3.

80-18

Spacer Shims

6. While holding the output shaft to apply a light load to it, rotate the input shaft counterclockwise several revolutions, as viewed from the end of the shaft. This will seat the bearing rollers, and will also mark the gear contact pattern in the bluing compound on the gear teeth. 7. Check the gear backlash. The backlash should be between 0.12 -- 0.32 mm (0.005 -- 0.0013 in). Remove the input shaft from the gearbox, and check the gear contact pattern on the gears; the contact pattern should be 40% central-toe, as shown in Figure 39. 8. If the gear backlash is not between the tolerance range shown, or if the contact pattern is not located properly, the gearbox will need to be reshimmed.

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 Backlash Adjustment To adjust backlash, move shims from one end of the output shaft to the other. To increase backlash, remove shims from 7, and add shims at 6, Figure 38. To decrease backlash, remove shims from 6, and add shims at 7, Figure 38. Shifting the output shaft 0.1 mm (0.004 in) will change the backlash between the gears approximately 0.05 mm (0.002 in). NOTE: The shims used at 6 and 7 are different diameters. Keep track of the shims used, so that the shaft preload adjustment does not change. The shims used on the output shaft are available in 0.3 , 0.35 , 0.4 , and 0.5 mm (0.012 , 0.014 , 0.016 and 0.020 in) thicknesses.

20014628

To shift the shaft 0.1 mm (0.004 in) inwards [to decrease backlash], remove a 0.4 or 0.5 mm (0.016 or 0.020 in) shim at 6, and substitute the next size smaller shim [0.3 or 0.4 mm (0.012 or 0.016 in)]. Then remove a 0.3 or 0.4 mm (0.012 or 0.016 in) shim from 7, and install the next size bigger shim [0.4 or 0.5 mm (0.016 or 0.020 in)]. Use the opposite procedure to increase backlash. Gear Contact Pattern To adjust the gear contact pattern, move shims from one end of the input shaft to the other, to reposition the pinion gear. If the contact pattern is low (towards the root of the tooth) on the pinion, and high (towards the top of the tooth) on the crown wheel, remove shims from 5 and add them at 4, Figure 38, to move the pinion further into mesh with the crown wheel.

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40 If the contact pattern is high on the pinion, and low on the crown wheel, remove shims from 4 and add them at 5, Figure 47, to move the pinion out of mesh with the crown wheel. The shims used between the input shaft bearings and the housing are the same on both ends, and are available in 0.3, 0.35, 0.4 and 0.5 mm (0.012, 0.014, 0.016 and 0.020 in) thicknesses. To shift the input shaft 0.1 mm (0.004 in) inwards [to increase mesh], remove a 0.4 or 0.5 mm (0.016 or 0.020 in) shim from 5 and install it at 4, and move the next size smaller shim [0.3 or 0.4 mm (0.012 or 0.016 in)] from 4 to 5. Use the opposite of this process to move the pinion out of mesh. Repeat steps 6 and 7 as necessary until the backlash and gear contact patterns are correct.

80-19

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SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 9. Install oil seal, 3. 10. Install washer, 2, and two keys, 1.

1 42 11. Install sprocket, 3. 12. Apply Loctite 243 to the M12 x 35 bolt, 1, and then install the bolt with washer, 2. Tighten and torque the bolt to 82 -- 106 N⋅m (60 -- 78 ft-lb).

43 13. Install seal, 3. 14. Apply Dow RTV780 (or equivalent) sealing compound and install cover, 2. 15. Apply Loctite 243 to the eight M8 x 20 bolts, 1, and the install and torque to 24 -- 32 N⋅m (18 -- 24 ft-lb).

80-20

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 16. Install oil seal, 1, in the cover. Apply sealing compound and install cover, 2. Install retaining ring, 3, on the shaft. NOTE: Apply some grease on the shaft and the seal before installation.

3 1 2

45 17. Install sprocket, 3. 18. Apply Loctite 243 to the M12 x 30 bolt, 1, and then install the bolt with washer, 2. Tighten and torque the bolt to 82 -- 106 N⋅m (60 -- 78 ft-lb). 19. Fill the gearbox with 0.6 L (20 oz) of New Holland Hypoide 90 gear oil. IMPORTANT: As this gearbox is not mounted horizontally, check the oil level after assembly on the combine.

80-21

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 Installation 1. Ensure the vertical auger is fully engaged to the toothed hub of the unloading (elbow) gearbox. Remove the access cover, 1, for inspection, and then reinstall the cover.

47 2. Rotate the toothed hub on the unloading gearbox to properly align the large tooth of the gearbox to the large tooth of the auger hub sleeve. Mount the gearbox, 1, ensuring the engagement of the hub to the auger. Apply Loctite 243 to the six M12 x 30 carriage bolts installed downward and secure the gearbox with lock washers and nuts, 2. Tighten and torque the M12 nuts to 82 -- 106 N⋅m (60 -- 78 ft-lb).

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2 1 48

80-22

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 DRIVE SYSTEM UNLOADING TUBE GEARBOX Drive System Unloading Tube Gearbox -- Exploded View

1 2 6 9

4 2

12 3

3 5 8

10 12

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49 1. 2. 3. 4. 5. 6. 7.

Shaft -- Input/Output Shim Kit Retaining Ring Bearing, Tapered Roller Spacer Bearing, Ball Type Retaining Ring

8. 9. 10. 11. 12. 13.

80-23

Shim Kit Shim -- 3 mm (0.118 in) Shim -- 1 mm (0.039 in) Retaining Ring Oil Seal Washer, Seal Protective

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 Removal To remove the unloading gearbox, proceed as follows: 1. First remove the unloading tube and the vertical unloading auger and the unloading tube. Refer to “Unloading Auger -- Vertical Auger -- Removal” and “Unloading Auger -- Unloading Tube and Auger -- Removal” of this chapter. 2. Remove the single M8 x 20 mm cap screw and spring washer, 2, and capture the large washer, 1, that is between the gearbox arm and the inside of the elbow tube. 3. Remove two M8 x 20 mm cap screws, spring washers, and large washers, 3.

66063426

50 4. Remove the unloading tube gearbox.

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80-24

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 Disassembly NOTE: During disassembly, keep track of location and number of all shim packs. Use the same shim packs during re-assembly. To disassemble the gearbox, proceed as follows: On both sides: 1. Remove the unloading tube drive gearbox, refer to “Unloading Drive Gearbox Removal/Installation” of this chapter. 2. Remove retaining ring, 1, and washer, 2.

3. Remove sprocket, 3. 4. Remove retaining ring, 1, and 3.

5. Remove washer, 2.

3 53 6. Remove oil seal, 1, using a screw driver. Discard oil seal.

1 2

NOTE: Oil seal will be damaged when it is removed. 7. Remove retaining ring, 2, shims, 3, retaining ring, 4, shims, 5, and spacer, 6.

4 5

3 2 56063430

1 54

80-25

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 8. To remove the pre-assembled shaft, install toothed hub, 1, with retaining ring, 2, to pull the shaft from the housing. IMPORTANT: The bearing configuration is different on the two shafts. Mark the gearbox housing to indicate which end the shaft with one ball bearing and one tapered roller bearing is installed in.

55 9. Remove input and output inner bearing shims, 1 and 2.

1 56063433

56 Assembly The assembly steps: •

Preassemble input/output shafts

•

Assemble shafts into housing

•

Adjusting backlash and contact pattern

•

Oil fill gearbox

Preassemble Input/Output Shafts 1. To pre-assemble the shafts, proceed as follows: Press the inner race, 1, of the tapered roller bearing onto shaft, 2. Use a piece of tubing sized to press only on the inner race.

ZDA3545

80-26

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 2. Onto the input shaft, A, slide the bearing cup, 2, and then strike the gear end of the shaft at, 1, with a soft faced mallet to seat the bearing. Assemble the 5.0 mm (0.1968 in) spacer, 3, roller bearing, 4, shim pack (shims less than 1 mm [0.039 in]), 5, shim (3 mm [0.118 in]), 6, and retaining ring, 7. Check the input shaft combination bearing preload with a torque meter. The rolling torque for input shaft is 226 – 678 N⋅mm (2 – 6 in-lb). Adjust and maintain the bearing preload by adjusting the shim set, 5. An available shim pack set contains the following thicknesses: 0.1 mm (0.004 in) 0.15 mm (0.006 in) 0.3 mm (0.012 in) 0.5 mm (0.020 in)

1 2 3

4 5 7

6 A

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3. Onto the output shaft, B, slide the bearing cup, 1, the 5.0 mm (0.1968 in) spacer, 2, taper roller bearing cup, 3, and then press on the bearing cone, 4.

Install a 2 -- 3 mm (0.0787 -- 0.1181 in) shim set, 6, spacer, 7, and retaining ring, 8.

Strike the both ends of the output shaft with a soft faced mallet to seat the bearings. Check the output shaft taper roller bearings preload with a torque meter. The rolling torque for output shaft is 904 – 1356 N⋅mm (8 – 12 in-lb). Adjust and maintain the bearing preload by adjusting the shim set, 6. An available shim pack set contains the following thicknesses: 0.1 mm (0.004 in) 0.15 mm (0.006 in) 0.3 mm (0.012 in) 0.5 mm (0.020 in) 4. Apply bluing compound to the teeth of both gears. 5. To assemble the pre-assembled shafts in the gearbox, proceed as follows: Install the original inner shim packs, 1 and 2, in the housing. Install the pre-assembled shafts completely, by pushing only on the outer races of the bearings. Check if the preload of these shafts is still within the ranges shown. IMPORTANT: Make sure the input shaft with the tapered roller bearing and ball bearing is installed in the correct end of the housing (toward the vertical auger) as previously marked. Rib, A, is the output end with two tapered bearings.

80-27

2 56063434

A 59

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 6. On the output (double tapered roller bearing) shaft, 7, install the spacer, 4, outer shim pack, 5, and retaining ring, 6. Add shims at, 2, as required to ensure there is no clearance (zero end play) between the spacer and retaining ring. On the input (tapered roller and ball bearing) shaft, 1, install the outer shim pack, 3, and retaining ring, 2. Add shims at, 6, as required to ensure there is no clearance (zero end play) between the shaft assembly and the retaining ring.

7 6

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60 Assemble Shafts into Housing 7. While holding the output shaft, 2, to apply a light resistance to it, rotate the input shaft, 1, clockwise several revolutions, as viewed from the end of the shaft. This will seat the bearing rollers, and will also mark the gear contact pattern in the bluing compound on the gear teeth. Check the gear backlash. The backlash should be between 0.2 -- 0.5 mm (0.008 -- 0.020 in) measured at 47.25 mm (1.86 in) pitch radius. Remove the input shaft, 1, from the gearbox, and check the gear contact pattern. It should be 40 % central-toe, as indicated by, A, in Figure 63.

1 56063430

61 Adjusting Backlash and Contact Pattern 8. The shaft that is moved to adjust the backlash depends on whether the backlash needs to be increased or decreased, and upon the gear tooth contact pattern observed.

1 2

The contact should be as represented at (A). If contact pattern shows as at (B) the input shaft is in too far and the output shaft is out too far. If it is as in (C), the input shaft is out too far and the output shaft is in too far. Refer to the following chart to determine the adjustment required. To adjust backlash, move shims from one end of the appropriate shaft to the other. To move a shaft out of the gearbox, remove shims from, 1 or 4, and add shims at, 2, or, 3.

80-28

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SECTION 80 -- GRAIN STORAGE -- CHAPTER 2

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63 Contact Pattern Reference -- Cross Section View

Gear Contact Pattern

Backlash Measured

Adjust:

High on input, low on output

Input out, output in equally

Low on input, high on output

Output out, input in equally

High on input, low on output

Tight; increase backlash

Input shaft out

High on input, low on output

Loose; decrease backlash

Input shaft out, output shaft in

Low on input, high on output

Tight; increase backlash

Output shaft out

Low on input, high on output

Loose; decrease backlash

Output shaft out, Input shaft in

Correct, 40% central-toe

Tight; increase backlash

Move both shafts out an equal amount

Correct, 40% central-toe

Loose; decrease backlash

Move both shafts out an equal amount

IMPORTANT: When moving both shafts to correct both an incorrect gear contact pattern and a loose backlash, move the one shaft out in 0.05 mm (0.002 in) increments while moving the other shaft in using 0.1 mm (0.004 in) increments.

80-29

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 9. Shifting one shaft 0.1 mm (0.004 in) will change the backlash between the gears approximately 0.05 mm (0.002 in) Shims are available in the following sizes for the 100 mm (3.94 in) housing bore: 0.3 mm (0.012 in) 0.35 mm (0.014 in) 0.4 mm (0.016 in) 0.5 mm (0.020 in) After the backlash has been properly adjusted, reapply bluing compound to the gears, and reinstall them in the gearbox. While holding the output shaft (furthest away from the hole plug) to apply a light load to it, rotate the input shaft (ball bearing visible) clockwise several revolutions, as viewed from the end of the shaft. This will seat the rollers, and also will mark the contact pattern in the bluing compound on the gear teeth. If the gear contact pattern is not correct, both shafts must be moved an equal amount in order to correct the contact pattern, as follows: If the contact pattern is high on input gear tooth and low on output, move input shaft out and output shaft in. If the contact pattern is low on input gear tooth and high on output, move output shaft out and input shaft in. Use the procedure described in the beginning of Adjusting Backlash and Contact Pattern to move the shafts in or out. After adjusting the shafts, recheck the backlash to ensure it has not changed. Continue to apply bluing compound to check and adjust gear pattern until it is correct.

80-30

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 10. Fill the area around the bearings with NEW HOLLAND AMBRA HI-TEMP GREASE, and install the seal, 1, seal plate, 2, and retaining ring, 3, on each shaft. Install the retaining rings, 4, that locate the sprockets.

3 4

1 2 1

2 4

56063430

64 11. Install the toothed hubs, 1, onto the splined input and output shafts. Center the large, 2, tooth of each hub on the housing center line that passes through the casting stiffening rib, 3. NOTE: The centerline of each installed hub large tooth must align within 10-degrees of each other.

2 3

56063432

65 12. Secure the toothed hub, 3. Install washer, 2, and retaining ring, 1, on both shafts.

ZDA3548

80-31

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 Oil Fill Gearbox 13. Identify output shaft end of box with stiffener rib, 1, and set this shaft horizontal. Remove plug, 2, and fill box with approximately 0.43 L (14.5 oz) of NEW HOLLAND HYPOIDE 90 GEAR LUBE. Fluid level, 3, is correct when it touches bottom of plug. Tighten plug to 30 N⋅m (22 ft-lb).

IMPORTANT: Make sure sealing washer is in place on plug.

1 66063431

67 Installation 1. Orient and install the gearbox, with both toothed drive hubs assembled to the gearbox, into the elbow unloading tube with the single bolt arm to the right-hand side of the unload tube.

56063427

68 2. Install the gearbox right-hand side hardware (M12 x 30 bolt and spring washer), 1, and then visually check the centerline rib, 3, on the gearbox to the centerline seam, 4, of the elbow tube.

Center the gearbox, if required, by removing the right side hardware (M12 x 30 bolt and spring washer), 1. Insert or remove a spacer washer(s), 2, between the right end of the gearbox and the inner wall of elbow tube, and then install the M12 x 30 and spring washer, 1. When the gearbox is centered, install the left-hand side hardware (M12 x 30 bolt, spring washer, and oversize washer), 5. Tighten and torque the gearbox hardware, 1 and 5, to 82 -- 106 N⋅m (60 -- 78 ft-lb).

80-32

66063426

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 UNLOADING AUGER -- VERTICAL AUGER Removal To remove the auger proceed as follows: 1. Remove the unloading gearbox as described in “Drive System Unload Gearbox -- Removal” of this chapter. 2. Turn out vertical auger, 1, to remove it.

70 NOTE: In some configurations it will be necessary to remove the left traction wheel.

71 Installation To install the vertical auger, proceed as follows: 1. Open cover, 1.

80-33

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 2. Bring the vertical unloading auger with end, 1, first in to the tube.

56063425

73 3. Turn in the vertical auger. IMPORTANT: Make sure the auger sprocket fits over the gearbox sprocket. 4. Install the unloading drive gearbox. Refer to “Unloading Drive Gearbox -- Removal/Installation” of this chapter. 5. Close cover, 1, Figure 72. 6. Install the left-hand side traction wheel if removed. 74

80-34

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 UNLOADING AUGER -- CROSS AUGER Cross Auger -- Exploded View

11 10

9 12

5 2 1 8

7 66063438

6 75

1. 2. 3. 4. 5. 6.

Sprocket Hardware Set (bolt w/small and large washers) Front Sprocket (38T) Rear Sprocket (43T) Shim Washers Bearing Flanges (72 mm I.D.), Left Side Bearing, Left Side (72 mm O.D. w/o lock collar)

7. 8. 9. 10. 11. 12.

Spacer (concave) Cross Auger, Rear Cross Auger, Front Bearing Plate Bearing Flanges (62 mm I.D.), Right Side Bearing, Right Side (62 mm O.D.)

Removal 1. Disengage and remove the grain tank cross auger covers, 1. Open the combine left and right-hand side access doors.

2. Identify the cross auger chain drive components on the left-hand side of the combine. To remove the front cross auger proceed to step 3. To remove the rear cross auger proceed to step 4. 10021837

80-35

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2

3 2 1

56063436

77 Cross Auger Chain Drive Components 1. 2. 3.

Front Auger Sprocket (38T) Drive Chain Rear Auger Sprocket (43T)

4. 5. 6.

Chain Drive Sprocket Tension Arm/Idler Sprocket Chain Tension Adjustment Nut

3. To remove the front auger sprocket; lock the chain rotation by inserting a suitable bolt, 1, between the idler sprocket, 2, teeth and drive chain at the bottom side of the tensioner arm sprocket bracket, 3.

Proceed to step 5.

10030885

1 78

80-36

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 4. To remove the rear auger sprocket; lock the chain rotation by inserting a suitable bolt, 1, between the idler sprocket, 2, teeth and drive chain at the top side of the tensioner arm sprocket bracket, 3.

1 10030877

79 5. Loosen, do not remove, one or both cross auger sprocket bolts (M12 x 30), 1, as required.

Remove the bolt, used for locking the chain rotation, from between the idler sprocket and chain.

56063436

80 6. Loosen the tensioner arm adjustment nut, 1.

10030884

80-37

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 7. Loosen the adjustment nut, 1, to provide enough slack to remove the chain from the cross auger sprocket(s). Do not remove the adjustment nut, 1, as to disassemble the tensioner arm, 2.

2 1 10030879

82 8. Remove the drive chain, 2, from the front auger sprocket, 1, and the rear auger sprocket, 3, as required. Do not remove the entire chain from the remaining sprockets of the drive system.

56063436

83 9. Remove the bolt, small washer, and large washer set, 1, for the front or rear sprocket, as required.

Remove the front sprocket, 2, and/or the rear sprocket, 3, as required, using a sprocket/gear puller. Remove the shaft key, 4. Remove any shim washers, 5, noting the quantity for the front auger and rear auger, if removing both. NOTE: The illustrated quantity of shim washers, 5, is not specific to any or all units. Shim quantity is, as required, to meet the sprocket alignment tolerance specifications in the install procedure.

80-38

5 10012174

4 2

1 84

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 10. Remove the corresponding bearing plate, 1, on the right-hand side of the grain tank.

Remove the six bolts, lock washers, and nuts, 2. NOTE: It is not necessary to remove the bearing flanges and bearings, 3, in order to remove the augers. Bearing flanges and bearings, 3, need only to be removed if replacing an auger or the bearing.

66063437

3 85

11. Pull the complete bearing plate/auger assembly, 1, from the grain tank.

1 66063443

86 12. Inspect the left-hand end of the auger shaft, 1, for the auger shaft washer, 2. The inner diameter of the washer, 3, is designed to mate with the shaft end base, 4.

If the washer, 2, is not present on the shaft, inspect the grain tank and/or the left-hand side bearing flange. Retain the washer for the install procedure.

60051109

80-39

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 Installation 1. First, if a right-hand side cross auger bearing is removed or is being replaced; to a clean bearing and clean bearing flanges apply a coating NH AMBRA GR9 Multi-Purpose Grease to the inner bearing race surface. 2. Assemble the bearing between the flanges, and then assemble the flanges to the bearing plate with the M10 x 30 bolts extending outward through the bearing plate. Secure with lock washers and nuts and tighten. 3. Slide the assembled bearing plate onto the auger shaft. Do not secure bearing with lock collar at this time. 4. Identify the front auger, 1, or rear auger, 2, for installation. The front auger, 1, has a left-hand spiral. The rear auger, 2, has a right-hand spiral.

2 60051117

88 5. Partially install the auger in the grain tank with one full turn of auger flighting extending on the right-hand side.

66063443

80-40

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 6. From inside the grain tank, install the auger shaft washer, 1, on the auger shaft, 2. Orient the shaft washer with the inside diameter shape, 3, that mates to the shaft base, 4.

Lubricate the auger shaft base, 4, and the bearing spherical outer race and bore of the inner race with NH AMBRA GR9 Multi-purpose Grease. Slide the auger shaft through bearing until the shaft and washer is in full contact with the bearing. NOTE: Do not install a locking collar on the left-hand side bearings.

60051109

7. On the right-hand side, orient the bearing plate, 1, with the two closely spaced holes, 2, to the lower rear (seven o’clock) position.

Install the six bearing plate bolts outwards from inside the grain tank in the pattern shown, and secure with lock washers and nuts, 3.

Tighten the hardware. NOTE: The front and rear bearing plate/auger assemblies can be differentiated by the bolt patterns of the bearing plate, 1. Notice that for both bearing plates, 1, two closely spaced holes, 2, (A & B), are oriented to the lower rear side of the tank at the seven o’clock position.

2A 2B

66063437

The rear auger bearing plate, 2A, has a clockwise pattern, from the six o’clock position, of: bolt, bolt, hole. The front auger bearing plate, 2B has a clockwise pattern from the six o’clock position of: bolt, hole, bolt. 8. Push on the end of the auger shaft, 2, to ensure full contact of the opposite end with the drive side (left-hand) bearing. 9. Install the lock collar, 1, on the bearing, locking the collar clockwise on the front auger bearing, and counterclockwise on the rear auger bearing. Tighten the Allen screw. 10. Right-hand side shielding.

completed;

close the

56063444

80-41

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 11. Slide the 38T front sprocket, 1, and/or the 43T rear sprocket, 2, on the corresponding auger shaft. Ensure the auger shaft is against the bearing (inside) and the sprocket is against the bearing (outside).

Check the alignment of sprocket being installed to be within 1.5 mm (1/16 in) to the tensioner idler sprocket, 3. Adjust the tolerance by installing shim washers, 4, as required, between the bearing and the sprocket. When adjusted within tolerance, remove the sprocket and install the 50 mm (1.97 in) long shaft key, 5.

5 4

60051118

NOTE: Each shim is 1.5 mm (0.06 in) thickness. Align the sprocket onto the auger shaft with the shaft key. With a rubber mallet, tap the sprocket face to seat the sprocket against the bearing and shims. Install the bolt, small washer, and large washer hardware, 6. Recheck the tolerance, adjust if needed, and then hand-tighten the hardware. NOTE: NO bearing lock collar is installed on the left side auger shaft bearings. Ensure the installed sprocket(s) is tight against the sprocket shimming washers on the left-hand side. 12. Install the unloading drive chain, 1, along the path shown.

56063436

80-42

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 13. Apply NH AMBRA GR9 Multi-Purpose Grease to the face of the tensioner support bracket, 1.

Tighten the tension adjustment nut, 2, so that the end of the spring, 3, aligns, as shown, to the length indicator, 4.

Ensure the tensioner slides freely along the tensioner bracket, 1.

2 4

10030884

95 14. To secure the front grain tank cross auger sprocket; lock the chain rotation by inserting a suitable bolt, 1, between the idler sprocket, 2, teeth and drive chain at the top side of the tensioner arm sprocket bracket, 3.

Torque the front sprocket bolt to 82 -- 106 N⋅m (60 -- 78 ft-lb).

1 10030877

80-43

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 15. To secure the rear grain tank cross auger sprocket; lock the chain rotation by inserting a suitable bolt, 1, between the idler sprocket, 2, teeth and drive chain at the bottom side of the tensioner arm sprocket bracket, 3.

Torque the rear sprocket bolt to 82 -- 106 N⋅m (60 -- 78 ft-lb).

10030885

97 16. Install the cross auger covers. Adjust height as needed. Close and secure the left-hand side access panel. Perform an operational test of the cross auger drive.

10021837

80-44

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 UNLOADING TUBE AUGER -- UNLOADING TUBE AND AUGER Unloading Tube Auger -- Exploded View

1 4 5 2

3 6 9

7 8

12 66063435

14 13 99

1. 2. 3. 4. 5. 6. 7. 8.

Bolts, M16 x 80, 10.9 (adjusting plate) Adjusting plate Adjusting nuts, M12 Spout, unloading Tube, unloading (auger) Hardware set (M12 x 40 bolt, hardened washers, M12 nut) Toothed drive hub, washer, and retaining ring Spacer washer (as required for centering gearbox)

9. 10. 11. 12. 13. 14. 15. 16.

80-45

Bolt (M12 x 30) and spring washer Cover, access (right-hand side) Gearbox, unloading (elbow) Elbow tube, unloading Bolt (M12 x 30), spring and oversize washers Cover, access (left-hand side) Auger Support

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 Removal

WARNING The unloading tube is heavy; weighing approximately 340 – 480+kg (750 – 900+ lb) for the 18 ft and 21 ft lengths. Use a minimum of two lifting slings separated with a minimum 2.4 m (8 ft) wide spreader bar to maintain the slings in position. Failure to comply could result in the unloading tube becoming unbalanced, suddenly dropping, and further result in serious injury or death. 1. Swing the unloading tube outward to allow for access to the 19 sets of hardware, 3, that joins the unloading tube and the unloading elbow.

3 56063424

100 2. Use an adequate lifting device and sling support system as described in the “WARNING” above to support the unloading tube.

10020202

101

80-46

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 3. To remove access cover, 1, loosen (do not remove) the M8 nuts, 4, and then slide the cover upward to clear the hardware from the keyhole slots in the elbow tube.

4. Disconnect the unloading tube light electrical connector, 1. 5. Remove nineteen sets of M12 x 40 bolts, hardened washers and nuts, 3, to disconnect the unloading tube from the elbow. 6. Carefully pull the unloading tube in the support sling away from the elbow which will separate the unloading auger hub from the unloading gearbox toothed hub in the elbow.

3 1 4 56063424

102

7. Lower the unloading tube, support and stabilize it on a level work surface. 8. Loosen the two large hose clamps, 2, and then pull the unloading spout, 1, from the end of the unloading tube.

9. At the auger bearing, 3, loosen the bearing collar Allen screw, unlock the collar and remove. If required, bearing can be removed for replacement and/or auger can be extracted from the opposite end of the unloading tube. NOTE: It is possible to access the auger bearing through the unloading spout opening without removing the spout from the tube, it may be necessary to remove the internal deflector, 5, after removing the two machine screws and washers, 4, on both sides of the spout.

103

Installation 1. If removed, insert the unloading auger, 2, into the unloading tube, 5. Guide the outer end of the auger shaft through the bearing. Do not install the bearing lock collar or unloading spout, if removed, at this time.

80-47

2 1

2. Using the recommended sling support for the unloading tube, lift the tube into alignment with the elbow tube. 3. Identify the single large tooth, 4, on the auger hub sleeve, 1, and item 1, Figure 105, on the unloading gearbox toothed hub, item 2, Figure 105. Orient the auger hub sleeve to align with the gearbox toothed hub.

66063422

56063421

5 104

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 4. Join the auger and gearbox, and then orient the square hole, item 3, Figure 104 of the unloading tube to align with the square hole, 4, on the elbow tube, 3, Figure 105.

4 1 3 2 56063420

105 5. Install the nineteen M12 x 40 bolts with hardened washers forward through the unloading tube and elbow tube flanges, 3. Secure with hardened washers and M12 nuts. Tighten the nuts to standard torque.

2 3

6. Install the access cover, 2. Tighten the cover hardware, 4. 7. Connect the electrical connector, 1, for the unloading tube light. 8. Remove the support sling and equipment from the unloading tube.

1 4 56063424

106 9. At the discharge end of the unloading tube, push the unloading auger forward to ensure full engagement with the gearbox hub.

10. Install the bearing lock collar; lock the collar and tighten the Allen screw. 11. If access to the bearing was through the unloading spout, 1, install the deflector, 5, with the four washers and machine screws, 4. If the unloading spout was completely removed, install as follows in the next step.

4 66063422

5 107

80-48

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 12. Mount the unloading spout, 1, with two hose clamps, 2, onto the discharge end of the unloading tube. Slide the spout over the ring, 3, on the tube, and then align the slot in the spout with the alignment plate on the bottom of the tube at, 4.

13. Tighten the hose clamps, 2.

14. Swing the unloading tube inward to return it to the support.

4 66063423

108 15. Check and measure the gap, X, between the unloading tube, 1, and the support, 2. The gap, X, should equal 5 – 9 mm (7/32 – 11/32 in). Adjust to specifications as described in Support Adjustment that follows.

56063449

109 Support Adjustment 1. To adjust the gap required between the unloading tube and the support to 5 – 9 mm (7/32 – 11/32 in), first, loosen (do not remove) the six M16 x 80 cap screws, 1, in the rail, 2, above the unloading tube, 3.

1 2

2. Climb to the rear platform and enter the grain tank. Move to the front left side.

3 56063419

110

80-49

SECTION 80 -- GRAIN STORAGE -- CHAPTER 2 3. Locate the threaded adjustment rod on the underside of the front left side of the grain tank frame. 4. Loosen the M12 jam nut at, 1. To increase the gap, tighten the secondary adjustment nut; to reduce the gap loosen the nut to obtain the 5 – 9 mm (7/32 – 11/32 in) gap, and then tighten the jam nut.

1 ZDA3581A

111 5. Tighten and torque the six M16 x 80 cap screws to 261 – 334 N⋅m (193 – 246 ft-lb).

56063419

112

80-50

SECTION 88 -- ACCESSORIES -- CHAPTER 1

SECTION 88 -- ACCESSORIES Chapter 1 -- Straw Chopper CONTENTS Section

Description

Page

88-1

SECTION 88 -- ACCESSORIES -- CHAPTER 1 SPECIFICATIONS Straw chopper type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hood-mounted Rotor speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1585 rpm (LO) 3100 rpm (HI) Number of knife rows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Number of knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 (CR9020, CR9040, CR9060) 68 (CR9070) Number of counterknives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 (CR9020, CR9040, CR9060) 33 (CR9070) Swath path deflector divider plate adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual or remote

88-2

SECTION 88 -- ACCESSORIES -- CHAPTER 1 GENERAL The optional straw chopper, located at the rear of the combine, is belt driven from the main shaft. The sheaves are configured to offer two different rotor speeds, depending upon the belt installation position. The straw chopper consists of a main rotor containing a series of knives that rotate, chopping the straw delivered from the rear of the combine between the rotor knives, and a series of fixed counter knives. As the straw is chopped into small debris, it is discharged through an adjustable swath path deflector, located at the rear of the straw chopper. The counter knives are adjustable according to the type and size of the grain being harvested. The straw chopper also includes a chop/drop baffle plate to select the path of the straw as it leaves the combine. The straw can be directed through the straw chopper, or bypassed and discharged onto the chaff spreader, or the straw can be dropped in a swath.

88-3

SECTION 88 -- ACCESSORIES -- CHAPTER 1 OVERHAUL SECONDARY DRIVE BELT Removal 1. Remove the belt shield, 1.

1 86066352

1 2. Release the pulley handle, 1, to remove tension on the chopper rear drive belt.

1 86066353

2 3. Remove the belt, 1, from the chopper sheave, 2.

2 86066354

88-4

SECTION 88 -- ACCESSORIES -- CHAPTER 1 4. Remove the belt, 1, from the idler pulley, 2, and the intermediate drive sheave, 3.

4 3

Inspection 1. Inspect the belt for cracks, tears or other indications of excessive wear or damage.

2. Inspect sheaves for binding, wobble or other indications of excessive wear or damage. 3. Replace or repair any parts found to have excessive wear or damage.

2 20023056

Installation 1. For low rpm operation, route the belt, 1, over the idler pulley, 2, and onto the smaller diameter intermediate drive sheave, 3.

2. For high rpm operation, route the belt, 1, over the idler pulley, 2, and onto the larger diameter intermediate drive sheave, 4. 3. For low rpm operation, install the belt, 3, on the larger diameter chopper sheave, 1.

4. For high rpm operation, install the belt, 3, on the smaller diameter chopper sheave, 2.

2 3

86066355

5 5. Latch the pulley handle, 1, to provide tension on the chopper rear drive belt.

1 86066353

88-5

SECTION 88 -- ACCESSORIES -- CHAPTER 1 6. The drive belt spring tensioning rod, 1, has a two settings spring gage indicator, 2, to adjust the belt tension for high rpm or low rpm chopper operation.

1 2

86066356

7 7. Tighten or loosen the adjustment nut, 1, to align the top of the spring at the washer, 2, to the appropriate speed setting for the installed belt to sheave arrangement: •

Slow (turtle symbol, 3) -- belt on the small outer intermediate drive sheave and the large outer chopper sheave.

•

Fast (rabbit symbol, 4) -- belt on the large inner intermediate drive sheave and the small inner chopper sheave.

86066357

8 8. Install the belt shield, 1.

1 86066352

88-6

SECTION 88 -- ACCESSORIES -- CHAPTER 1 PRIMARY DRIVE BELT Removal 1. Remove the belt shield, 1.

1 86066352

10 2. Loosen the idler tensioning adjustment nut, 1, and remove belt, 2.

Inspection 3. Inspect the belt for cracks, tears or other indications of excessive wear or damage.

4. Inspect sheaves for binding, wobble or other indications of excessive wear or damage. 5. Replace or repair any parts found to have excessive wear or damage.

20023058

Installation 1. Install the chopper front drive belt, 2, and adjust the belt tension to the spring gage indicator, 1.

2. Install the front shield, 1, Figure 10.

88-7

SECTION 88 -- ACCESSORIES -- CHAPTER 1 CHOPPER KNIVES Replacement

NOTE: The straw chopper knives must be replaced in pairs on opposite sides of the straw chopper rotor with new mounting hardware to ensure the proper balance of the rotor. IMPORTANT: Always replace both straw chopper knives on each mount to prevent imbalance of the rotor assembly.

1. Loosen and remove the bolt, lock nut, flat washers and spacers, 1, securing the knife to the mount. Discard the mounting hardware and old knives.

19986014

2. Repeat step 1 for the nearest opposing knife mount, 2. 3. Install the washer, 1, knife, 2, and spacer, 3, on the new cap screw, with the small end of the spacer inserted into the knife, 2.

1 4

4. Position the cap screw through the knife mount on the rotor, 4, and install the spacer, 5, with the large end inserted into the mount.

5. Install the remaining knife, washer, and lock nut onto the cap screw.

NOTE: The knife hardware must be assembled with the lock nut located on the drive side of the chopper.

19986015

6. Tighten and torque the lock nut to 90 -- 100 N⋅m (67 -- 73 ft-lb).

7. Repeat steps 3 – 6 for the nearest opposing knife mount.

88-8

SECTION 88 -- ACCESSORIES -- CHAPTER 1 COUNTER KNIVES Removal 1. Loosen the M12 (prevailing torque) locknut, 1, on the left and right-hand sides of the combine, securing the counter knife bar to the chopper body.

86066351

14 2. Use the hand grips, 1, on either side of the knife bar, 4, to slide the counter knife bar to the front of the slot, 2, as shown.

3. Remove the hairpin clip, 4, from the counter knife retaining rod, 5.

1 66063716

15 4. Pull the counter knife retaining rod, 1, out, to release the counter knives. NOTE: Counter knives must be removed one at a time as the retaining rod is pulled out.

1 66063717

88-9

SECTION 88 -- ACCESSORIES -- CHAPTER 1 5. Remove the retaining rod, 1, from the counter knife, 2, and remove the knife from the counter knife bar, 3.

Installation NOTE: Counter knives must be installed one at a time as the retaining rod is pushed in. 1. Starting on the right-hand side of the chopper, slide the counter knife, 2, into the slot on the counter knife bar, 3, and slide the retaining rod, 1, through the counter knife.

66066350

2. Continue the process until all knives are installed and the retaining rod is fully inserted.

3. Install the hairpin clip, 1, through the counter knife retaining rod, 2.

NOTE: Hairpin must be located on the left of the bracket, 3, as shown.

4. Adjust the position of the counter knife bar relative to the type of material to be cut (Refer to the Operator’s Manual; Section 3 -- Field and Site Operation; Residue Handling).

66063716

3 18

5. Check alignment, and then tighten the M12 (prevailing torque) locknut, 1, on the right and left-hand side of the combine, securing the counter knife bar.

86066351

88-10

SECTION 88 -- ACCESSORIES -- CHAPTER 1 SPREADER HOOD

Removal 1. Remove the two M8 x 30 bolts, 1, from the ends of the gas strut, 2. Remove the gas strut, 2, from the left side of the chopper.

2 86066358

20 2. Move the spreader hood height adjustment handle, 1, full forward, as shown, to fully lower the spreader hood. 3. Remove the M10 x 35 bolt, washers, spacer, and nut, 3, from the spreader hood position linkage, 2, on the right side of the chopper.

86066359

21 4. Remove the M10 x 35 bolt, washers, spacer, and lock nut, 1, from the spreader hood position linkage, 2, on the left side of the chopper.

86066360

2 22

88-11

SECTION 88 -- ACCESSORIES -- CHAPTER 1 5. Disconnect the electrical plug, 1, for the remote controlled divider plate actuator, if equipped. 6. Remove the wire clamps, 2, and place the wire harness on top of the spreader hood to avoid damage during removal.

2 20023063

23 7. If spreader hood, 1, is equipped with a windrow skid plate, 2, remove the skid plate as follows, with the aid of an assistant.

86066363

1 24

8. Remove the two sets of mounting hardware (M12 x 35 bolt, bushing, washer, and locknut), 1, on each side of the skid plate. Remove the skid plate.

86066364

88-12

SECTION 88 -- ACCESSORIES -- CHAPTER 1 CAUTION Use a suitable lifting device to remove the spreader hood from the combine to avoid injury or damage. Failure to comply may result in minor or moderate injury. 9. Attach suitable slings or chains to the spreader hood and connect to a suitable lifting device.

10011090

26 10. With the spreader hood safely supported, remove the M12 x 35 bolts, washers, spacers, and nuts, 1, from both sides of the spreader hood.

86066359

27 11. Carefully lower the spreader hood, 1, down and away from the combine. Installation 1. Lift the spreader hood, 1, into position, aligning the mounting holes.

1 40011020

88-13

SECTION 88 -- ACCESSORIES -- CHAPTER 1 2. Insert the M12 x 35 bolt, 1, through the bushing, then the spreader hood and combine frame. Secure in place with the flat washer and locknut. Repeat on opposite side.

3. Insert the M10 x 35 bolt, 2, through the bushing, then the linkage, then the spacer and spreader hood. Secure in place with the flat washer and locknut. Repeat on opposite side. NOTE: Connect the linkage forwardmost hole, as shown; the rearward hole, 3, is for European models only.

86066359

4. Disconnect and remove the lifting device.

5. Connect the electrical plug, 1, for the remote controlled divider plate actuator, if equipped. 6. Route the wire harness and secure in place with the wire clamps, 2.

2 20023063

30 7. Position the cylinder end of the gas strut, 1, to the left side of the chopper body and the piston end of the gas strut, 2, to the linkage. Install the M8 x 30 bolts, washers, and nuts at both ends of the gas strut.

86066358

88-14

SECTION 88 -- ACCESSORIES -- CHAPTER 1 8. If the spreader hood, 1, is equipped with a windrow skid plate, 2, install the skid plate as follows, with the aid of an assistant.

86066363

1 32

9. Lift the skid plate into position, and install on each side, an M12 x 35 bolt and bushing, 1, inward through the skid plate and chopper body. Secure with a flat washer and locknut.

86066364

DIVIDER PLATE

Replacement 1. Remove the nuts and lock washers, 1, from the carriage bolts and remove the divider plate, 2. 2. Install the new divider plate, 2, on the carriage bolts and secure with the lock washers and nuts, 1.

86066361

88-15

SECTION 88 -- ACCESSORIES -- CHAPTER 1 DIVIDER PLATE ACTUATOR Replacement 1. Disconnect the electrical plug, 1, for the remote controlled divider plate actuator.

2. Remove the wire clamps, 2.

20023063

35 3. Remove cap screws and lock nuts, 1. 4. Remove the Remote Controlled Divider Plate Actuator, 2

5. Install the new Remote Controlled Divider Plate Actuator, 2, and secure with cap screws and lock nuts, 1.

10011092

36 6. Connect the electrical plug, 1, for the remote controlled divider plate actuator. 7. Route the wire harness and secure in place with the wire clamps, 2.

1 2

20023063

88-16

SECTION 88 -- ACCESSORIES -- CHAPTER 1 CHOPPER BODY Removal 1. Remove the belt shield, 1. 2. Remove the tension from the rear drive belt and remove the belt as described at the beginning of this chapter in “Secondary Drive Belt -Removal”. 3. Remove the spreader hood as described in “Spreader Hood – Removal” earlier in this section.

86066352

1 38

4. Disconnect the chopper speed sensor connector, 1.

86063721

88-17

SECTION 88 -- ACCESSORIES -- CHAPTER 1 5. Use a forklift and pallet, 1, to support the chopper body, 2.

6. Remove the cap screws, washers and lock nuts, 3, on both sides. 7. Carefully lower the chopper body, 2, away from the combine. Inspection 1. Inspect the chopper body for bent, cracked or damaged sections. 2. Inspect area around mounting holes for cracks or excessive wear.

1 56066362

2 40

Installation 1. Carefully lift the chopper body, 2, into position on the combine. 2. Install cap screws, washers, and lock nuts, 3. 3. Lower the forklift and remove from under the chopper body. 4. Connect the chopper speed sensor connector, 1. 5. Install the rear drive belt and the rear drive belt shield as previously described in this chapter.

86063721

41 6. Latch the pulley handle, 1, to provide tension on the chopper rear drive belt. 7. Adjust the secondary belt tension as previously described in this chapter. 8. Install the spreader hood as described in “Spreader Hood – Installation” earlier in this section.

1 86066353

88-18

SECTION 88 -- ACCESSORIES -- CHAPTER 1 CHOPPER ROTOR Removal 1. Remove the chopper body as described in “Chopper Body -- Removal” earlier in this section. 2. Attach a suitable lifting device, 1, to slings, 2, attached to the rotor shaft, 3. Lift the rotor just enough for support while removing mounting hardware.

1 2 3

10011036

43 3. Remove the four M6 x 16 bolts and lock washers, 1, and remove the rotor speed sensing cover, 2.

2 86063721

44 4. Remove flange head cap screw and lock washer, 1, and remove the rotor speed sensing disc, 2.

56063722

2 45

88-19

SECTION 88 -- ACCESSORIES -- CHAPTER 1 5. Remove the four M12 x 35 bolts and lock washers, 1, and remove the brackets, 2.

2 1

56063723

46 6. Loosen the set screw, 1, and unlock the lock collar, 2. Remove it from the shaft.

2 1

66063713

47 7. Using a puller, remove the bearing/collar assembly, 1, from the rotor shaft. 8. Clean all parts in a suitable solvent and allow to air dry.

9. Remove the spherical bearing from the collar and check for roughness or binding when the bearing is rotated by hand. Replace as necessary. 10. Bearing swivel while in the collar must have slight resistance. If no resistance is observed, replace the spherical bearing. 11. Inspect the collar for cracks, abnormal wear patterns, excessive wear or damage. Replace as necessary.

88-20

66063719

SECTION 88 -- ACCESSORIES -- CHAPTER 1 12. Remove the cap screw, 1, lock washer, and spacer, 2, and remove the sheave, 3.

20023064

49 13. Remove the key, 1, from the rotor shaft, 2.

1 2

66063711

50 14. Remove the four M12 x 35 bolts and lock washers, 1, and remove the bearing/collar assembly, 2.

15. Clean all parts in a suitable solvent and allow to air dry. 16. Inspect the bearing and housing assembly and check for roughness or binding when the bearing is rotated by hand. Replace, as necessary. 17. Bearing swivel while in the collar must have slight resistance. If no resistance is observed, replace the bearing and housing assembly. 18. Inspect the collar for cracks, abnormal wear patterns, excessive wear or damage. Replace the bearing and housing assembly as necessary. NOTE: Bearing and housing can only be replaced as an assembly.

88-21

66063712

SECTION 88 -- ACCESSORIES -- CHAPTER 1 19. Remove the two carriage bolts, washers and nuts, 1, from the anti-wrap plate on both ends of the rotor.

66063715

52 20. Carefully lift the rotor assembly, 1, from the chopper body, 2. Take care not to damage the anti-wrap seal plates, 3, during rotor removal. Inspection 1. Inspect the rotor and hammer knife mounts for cracks, broken welds or damage.

1 3

2. Ensure any installed balancing weights are tight. 3. Inspect rotor shaft for nicks, abnormal wear patterns, excessive wear, or other damage. Replace as necessary.

56063718

4. Use a file and/or emery cloth to dress the rotor shaft, removing any nicks, burrs, or marks. Installation 1. Carefully lower rotor assembly, 1, into the chopper body, 2. Make sure the flat portion of the anti-wrap plates, 3, are at the top of the rotor. Position the anti-wrap plates to align the mounting holes. 2. Insert carriage bolts through the anti-wrap plate and chopper body from inside the chopper body. Secure in place with the washers and nuts, 1. Repeat on opposite side.

66063715

88-22

SECTION 88 -- ACCESSORIES -- CHAPTER 1 3. Install the LH bearing/collar assembly, 1, onto the rotor shaft. Make sure the grease fitting, 2, is in the six o’clock position.

4. Install the four M12 x 35 bolts and lock washers, 3. 5. Pull the rotor to left side against the bearing.

66063712

55 6. Install the RH bearing/collar assembly, 1, onto the rotor shaft, 2. Make sure the grease fitting, 3, is in the six o’clock position.

3 66063714

56 7. Install the chopper speed sensing brackets, 1, and secure the bearing housing to the anti-wrap seal with four M12 x 35 bolts and lock washers, 2.

8. Tighten to standard torque.

56063723

88-23

SECTION 88 -- ACCESSORIES -- CHAPTER 1 9. Ensure rotor is against left bearing and then install the locking collar, 1, onto the rotor shaft. Turn the collar clockwise to tighten the collar

10. Tighten the set screw on the locking collar.

66063720

58 11. Insert the key, 1, into the key slot on the rotor shaft, 2.

1 2

66063711

59 12. Install the chopper drive sheave, 1, onto the shaft. 13. Install the spacer, 2, lock washer and cap screw, 3.

20023064

88-24

SECTION 88 -- ACCESSORIES -- CHAPTER 1 14. Secure the chopper speed sensing disc, 1, in place using the lock washer and flange head cap screw, 2.

2 3

15. Adjust the speed sensor, 3, to a 1 -- 3 mm (0.04 -- 0.12 in) gap between the sensor and the sensor plate.

56063722

61 16. Install the rotor speed sensor shield, 1, using the four M6 x 16 bolts and lock washers, 2.

If disconnected, connect the sensor electrical connector, 3.

2 3

86063721

62 17. Lower the lifting device, 1, and remove the slings, 2.

10011036

88-25

SECTION 88 -- ACCESSORIES -- CHAPTER 1 CHOP/DROP BAFFLE Removal 1. Place the chop/drop baffle in the drop position by pushing forward on the handle and engage it in rear latch position, 1. 2. Remove the cap screws, washers and nuts, 2, from both sides of the baffle and remove the handle.

20023066

64 3. Remove the cap screws, 1, washers and nuts from both sides of the baffle. NOTE: It will be necessary to have a second person assist in removing the nuts because one person cannot reach both sides.

4. Lower the baffle out through the opening between the combine and the straw chopper.

20023065

65 Inspection 1. Inspect baffle, 1, for damage. Replace as necessary.

2. Inspect rubber seal, 2, on both sides of the baffle, 1. Replace if worn or damaged.

20023067

88-26

SECTION 88 -- ACCESSORIES -- CHAPTER 1 Installation 1. Lift the baffle, 1, into position and insert the cap screws, 2, through washers and the support brackets, 3, and through the straw hood, 4, have a second person attach the washers and nuts to the cap screws. Tighten securely.

4 3 2 1 20023065

67 2. Attach the handle to the baffle using the cap screws, washers and nuts, 1.

1 20023066

88-27

SECTION 88 -- ACCESSORIES -- CHAPTER 1

88-28

SECTION 88 -- ACCESSORIES -- CHAPTER 2

SECTION 88 -- ACCESSORIES Chapter 2 -- Chaff/Corn Spreader CONTENTS Section

Description

Page

88-1

SECTION 88 -- ACCESSORIES -- CHAPTER 2 OVERHAUL INTRODUCTION The chaff/corn spreader is used in conjunction with the straw chopper, is a hydraulically driven contra-rotating dual impeller spreader. The spreader operates when the threshing clutch is engaged. Spreader speed is adjustable with a control knob on the hydraulic block. The speed can only be adjusted while the machine is shut down. Chaff exiting the sieves, drops onto the chaff spreader where it is discharged evenly across the full cutting width of the combine. Corn residue can be distributed by the spreader when the straw chopper baffle is in the “drop” position.

66063710

HYDRAULIC BLOCK Removal IMPORTANT: Cap or plug all open hydraulic hose and connector fittings to prevent contamination ingress. NOTE: Capture drain oil from disconnected hoses and lines. Do not reuse oil. Dispose of used oil in accordance with local ordinance. In-feed Roller Equipped 1. Close the speed control valve, 1, on the hydraulic block.

2 1

2. Unplug the solenoid electrical connector, 2.

3. Disconnect the spreader pressure hose, 5, and return hose, 4, from the block fittings.

4. Disconnect the hydraulic block supply and return lines, 6.

4 5

5. Remove the nuts, lock washers and M10 x 130 mm cap screws, 3, and then remove the hydraulic block.

60051033

88-2

SECTION 88 -- ACCESSORIES -- CHAPTER 2 PSD (Positive Straw Discharge) Equipped 1. Close the speed control valve, 1, on the hydraulic block.

2. Unplug the solenoid electrical connector, 2.

3. Disconnect the PSD return hose, 3, drain hose, 5, and, pressure hose, 4, from the block fittings.

6 7

4. Disconnect the spreader return hose, 7, and pressure hose, 8, from the block fittings. 5. Disconnect the hydraulic block supply and return lines, 9.

86063390

6. Remove the nuts, lock washers and M10 x 130 mm cap screws, 4, and then remove the hydraulic block. Component Replacement 1. To replace the solenoid, 1, remove the nut, 2, and slide the solenoid off the valve shaft.

2. Install the new solenoid, 1, and torque the nut, 2, to 5 -- 8 N⋅m (4 -- 6 ft-lb). IMPORTANT: Do not over-torque the solenoid.

40023097

4 3. As necessary, replace the speed control valve, 1, solenoid valve, 2, check valve, 3, and/or relief valve, 4, by unscrewing them from the hydraulic block.

1 2

4 3 40023099

88-3

SECTION 88 -- ACCESSORIES -- CHAPTER 2 4. Make sure the O-rings are in good condition. Coat the O-rings with New Holland Mastertran hydraulic fluid prior to installing the new valve in the hydraulic block.

4 3

40023098

6 Installation

In- feed Roller Equipped 1. Mount the hydraulic block to the combine frame with two M10 x 130 mm cap screws, Belleville lock washers, and nuts. Tighten the hardware.

1 6

2. Connect the spreader pressure hose, 5, and return hose, 4, to the block fittings. Torque return fitting to 60 – 68 N⋅m (44 – 50 ft-lb).

3. Connect the hydraulic block supply and return lines, 6. Torque fittings to 60 – 68 N⋅m (44 – 50 ft-lb).

5 60051033

4. Plug the electrical connector, 2, to the solenoid. 5. Open the speed control valve, 1, and set for operation as required. PSD (Positive Straw Discharge) Equipped 1. Mount the hydraulic block to the combine frame with two M10 x 130 mm cap screws, Belleville lock washers, and nuts. Tighten the hardware.

2. Plug the electrical connector, 2, to the solenoid.

5 6

3. Connect the PSD pressure hose, 4, drain hose, 5, and, return hose, 3, to the block fittings. Torque fittings, 3 and 4, to 60 – 68 N⋅m (44 – 50 ft-lb). Torque the small drain fittings to 24 – 27 N⋅m (18 – 20 ft-lb).

4. Connect the spreader return hose, 7, and pressure hose, 8, to the block fittings. Torque fittings to 60 – 68 N⋅m (44 – 50 ft-lb).

86063390

5. Connect the hydraulic block supply and return lines, 9. Torque fittings to 60 – 68 N⋅m (44 – 50 ft-lb). 6. Open the speed control valve, 1, and set for operation as required

88-4

SECTION 88 -- ACCESSORIES -- CHAPTER 2 SPREADER DISC/BLADE

Removal 1. Ensure the speed control valve, 1, is closed.

86063390

9 2. Lower the wide spreader and lock it into its lowest position.

To remove the disc/blade assemblies for motor removal, the top plate and hub, 1, must be removed to allow the disc/blades, 2, to be angled in order to clear the disc/blade shrouds.

4 1

Remove the M8 x 90 mm locking bolt and flat washer, 3.

Remove the M10 x 20 mm carriage bolts, 4, from the top plate, and then lift the top plate from the disc/blade.

60051043

NOTE: The left and right top plates and discs are not of the same orientation. Keep each assembly set of right and left side components together.

3. With the top plate and hub removed, grasp two of the blades lift and angle the disc/blade to clear the shroud. Adjust frame position as required for removal of the hydraulic motors.

10051022

88-5

SECTION 88 -- ACCESSORIES -- CHAPTER 2 Installation 1. Lower the wide spreader and lock it into its lowest position. Identify the LH, 1, and RH, 2, disc/blade assembly by the orientation of the top leading edge of the blades, 3 and 4. The LH disc/blade assembly rotates clockwise with blade leading edge facing the LH discharge-opening chute of the wide spreader frame. The RH disc/blade assembly rotates counterclockwise with blade leading edge facing the RH discharge-opening chute of the wide spreader frame.

60051043

12 2. To install RH disc/blade assembly, 1, into the spreader frame, 2, grasp two blades oriented at the one o’clock and nine o’clock position as shown. Angle the blade slightly with the one o’clock blade directed to the one o’clock position, 3, of the wrap-around housing. Slide the outer edge, 4, of the disc into the housing opening and guide the disc completely into the housing. Center the disc center-hole over the motor shaft and rest the blade in place.

To install the LH disc/blade assembly into the spreader frame, grasp two blades oriented at the eleven o’clock and three o’clock position. Complete the installation procedure using the same method as for the right side.

10051022

3. Insert the four each M10 x 25 mm carriage bolts, 1, for attaching the top-plate, 2, to the hub, 3 through the top-plate and hub. Secure the top-plate to the hub bolts with the Belleville lock washers and M10 nuts. Tighten the nuts.

Install the assembled hub and top-plate on the motor shaft. Ensure the shaft key is installed.

Rotate the assembled hub and top-plate, so that the arms of top-plate align with blades on the disc and the hub engages the notched center hole of the disc.

5 60051043

NOTE: If the arms do not align with the blades, the top-plate is upside-down and must be reversed.

Fasten the assembled top-plate and hub to the blades by inserting two M10 x 20 mm carriage bolts, 4, for each blade through the top-plate, 2, and blade, 5. Secure each bolt with a Belleville lock washer and M10 nut. Tighten the nuts. Secure each top-plate, hub, and disc/blade assembly to the motor shaft with an M8 x 90 mm locking bolt, 5, and large OD flat washer, 6. Tighten the bolt.

88-6

SECTION 88 -- ACCESSORIES -- CHAPTER 2 HYDRAULIC MOTOR Removal 1. Label, disconnect, and cap the hydraulic hoses, 1.

2 3

Remove and retain the woodruff key, 2. Remove the four cap screws, 3, and remove the motor, 4.

40023094

15 If equipped, remove and retain the cover plate, 2, after removing the four cap screws, 1.

66060036

16 NOTE: Although both motors are the same, the hydraulic connections are different. The left motor uses all three ports, while the right motor has one port plugged. When installing the new motor, make sure the fittings are installed in the same manner as the old motor.

Left

Right

50023095

88-7

SECTION 88 -- ACCESSORIES -- CHAPTER 2 Overhaul Special Tools Required • (Eaten Tool) -- Shaft Pressure Seal Installation Tool #600523 •

(Eaten Tool ) -- Seal Sleeve or Bullet Tool (for 1 in. shaft) -- #600304

•

Torque Wrench -- 34 N⋅m (300 in-lb) capacity

•

Breaker Bar -- 300 -- 400 mm (12 -- 16 in)

•

5/16 in. -- 6 point (E10 Torx Drive) socket

•

Hex Key -- 5 mm (3/16 in)

•

Small flat blade screwdriver (to be modified as described in instructions) -- 150 -- 200 mm x 6 mm (6 -- 8 x 1/4 in)

IMPORTANT: No impact wrench is used. Damage to sockets or rounded screw heads can occur. IMPORTANT: Cleanliness is extremely important when repairing these motors. Work in a clean area. Before removing fittings, clean port areas of motor. Remove woodruff key, 2. Check shaft and key slot, 1. Remove burrs, nicks and sharp edges that may damage a seal.

60051046

A 2

Ensure the work port fittings, 3, are marked to the motor housing as the hoses were to the fittings. This will ensure ease of assembly at installation.

Before disassembly, drain oil from motor. Remove the work port fittings, 3, and plug or drain port fitting, 4, if equipped. Cap fittings to prevent dirt ingress.

Plug ports and thoroughly clean exterior of motor.

60051051

NOTE: Although not all drawings show the motor in a vise, we recommend that you keep the motor in a vise during disassembly. Follow the clamping procedures explained throughout the manual.

1. Place motor in vice and clamp across edge of flange with output shaft down. When clamping, use protective device on vise such as special soft jaws, pieces of hard rubber or wood. IMPORTANT: Do not clamp on side of housing. Excessive clamping pressure on side of housing causes distortion. IMPORTANT: Discard all used seals removed. Do not reuse seals. Replace with new seals. 56050542

88-8

SECTION 88 -- ACCESSORIES -- CHAPTER 2 2. Remove cap screws, 1. Remove end cap, 2. Remove seal, 3 from end cap.

3 56050541

20 3. Remove gerotor section, 1. Remove seal, 2, from gerotor.

2 56050540

21 4. Remove drive shaft, 1. Remove spacer plate, 2. Remove seal, 3, from housing. Remove output shaft, 4, from housing in direction shown.

Remove needle thrust bearing from shaft or housing.

1 3

56050539

88-9

SECTION 88 -- ACCESSORIES -- CHAPTER 2 5. Reposition motor in vise. Clamp across ports as shown, clamping dimension A at both sides of port boss, where A = 13 mm (0.5 in).

IMPORTANT: Do not clamp on side of housing. Excessive clamping pressure on side of housing causes distortion.

56050538

23 6. Remove four cap screws, 1, from mounting flange. These screws are assembled with Loctite® to hold them in place. The screws will require 35 -- 45 N⋅m (300 -- 400 in-lb) of torque to break loose and 11 N⋅m (100 in-lb) torque to remove. IMPORTANT: Do not use impact wrench on screws that have been secured with Loctite. This could result in rounded heads or broken sockets. 7. If torque higher than given above is required to break screws loose, apply heat according to following instructions: When heated, Loctite partially melts. This reduces torque required to remove screw. Use small flame propane torch, 2, to heat small area of housing, 3, where screw enters. IMPORTANT: Be careful not to overheat housing and damage motor. Gradually apply torque to screw with socket wrench as heat is applied for 8 to 10 seconds. As soon as screw breaks loose, remove heat from housing. Continue turning screw until it is completely removed. 8. Carefully remove flange, 4, from housing, 5.

88-10

3 1

56050537

5 24

SECTION 88 -- ACCESSORIES -- CHAPTER 2 The dirt exclusion seal, 1, back-up ring, 2, pressure seal, 4, and O-ring seal, 5, will come off with the flange, 3. Use a seal removal tool, described in the following step to remove the dirt exclusion seal and pressure seal. IMPORTANT: Some motors may have a quad seal and back-up ring in place of the pressure seal, 1. The quad seal and back-up ring are no longer available and are replaced by the pressure seal. They are interchangeable, but some precautions must be taken to insure proper installation. Follow the reassembly instructions.

2 1

3 56050536

9. A seal removal tool is made by modifying a small flat blade screwdriver (150 -- 200 x 6 mm [6 -- 8 x 1/4 in]).

2 1

Bend tip over, 1, and grind end of blade to radius, 2. Remove all burrs. IMPORTANT: Be careful not to scratch seal cavity O.D. This could create a leak path.

56050535

26 10. Using the seal removal tool as shown, work from outer side for both (either) seals. Remove pressure seal, 1, and back-up washer, 2.

Then remove dirt exclusion seal, 3.

56050534

3 27

88-11

SECTION 88 -- ACCESSORIES -- CHAPTER 2 11. A metal plug, 1, one of the three types shown with seal, plugs a machining hole in the housing. It is not necessary to remove plug and replace seal unless leakage occurs around plug. To remove plug, insert 5 mm (0.187 in) hex key, 2, through port opening and push it out. If you remove plug and seal, lubricate new seal and install on plug. Some plugs have two O-ring grooves but require only one O-ring. Install O-ring in groove closest to end of plug. Push plug into housing so plug and housing are flush. Be careful not to damage seal. 12. Check all mating surfaces. Replace any parts with scratches or burrs that could cause leakage or damage. Clean all metal parts in clean solvent. Blow dry with air. Do not wipe parts with cloth or paper towel because lint or other matter could get into the hydraulic system and cause damage. Check around key slot and chamfered area of shaft for burrs, nicks or sharp edges that could damage seals during reassembly. Remove nicks or burrs with a hard smooth stone (such as an Arkansas stone). Do not file or grind motor parts. NOTE: Lubricate all seals with petroleum jelly. Use new seals when reassembling motor. IMPORTANT: Do not stretch seals before installing them.

88-12

56050533

SECTION 88 -- ACCESSORIES -- CHAPTER 2 NOTE: Cleanliness is extremely important in the successful application of Loctite®. Fully cured Loctite resists most solvents, oils, gasoline and kerosene and is not affected by cleaning operations. It is not necessary to remove cured Loctite that is securely bonded in tapped holes; however, any loose particles of cured Loctite should be removed. Before Loctite can be applied, the parts should be cleaned as follows:

a. Wash the housing with solvent to remove oil, grease and debris. Pay particular attention to four tapped holes on flange end. b. Blow dry with compressed air. Clean and dry tapped holes. Discard any screws that have damaged threads or rounded heads. c. Wire brush screw threads to remove cured Loctite and other debris. Discard any screws that have damaged threads or rounded heads.

56050532

d. Wash screws with non-petroleum base solvent. Blow dry with compressed air. 13. Lubricate output shaft with hydraulic oil at areas, 3, then install shaft in housing. IMPORTANT: Do not permit oil to get into the four tapped holes. 14. Install needle thrust bearing, 1, then bearing race, 2, on shaft. Pull shaft partially out of housing. Push all three parts in housing together. The bearing race must rotate freely when in position. 15. Install dirt exclusion seal, 1, in flange, 2, with lip facing out. Carefully press dirt exclusion seal into place using Eaten Seal Installation (seal driver) Tool 600523, 7. 16. Visually check seal seat in mounting flange for scratches or other marks that might damage the pressure seal. Check for cracks in flange that could cause leakage. 17. Install back-up ring, 3, against shoulder in housing. Lubricate I.D. of seal tube, 7, and O.D. of shaft pressure seal with light film of clean petroleum jelly. Align small I.D. end of seal tube, 7, with seal seat in mounting flange. Install pressure seal, 4, in tube with lip of seal face up. Insert seal driver, 5, in tube and firmly push seal to seat with a rotating action. IMPORTANT: After installing seal in flange, remove tool and examine seal condition. If damaged or improperly installed, you must replace it before continuing with reassembly. 18. Install 49 mm (1.937 in) O.D. seal, 6, in flange.

88-13

7 6

56050531

SECTION 88 -- ACCESSORIES -- CHAPTER 2 19. It is recommended to apply a light coat of Loctite® 7649t Primer Nt in tapped holes of housing. Allow primer to air dry for at least 1 minute. Do not force dry with air jet; the primer will blow away. Use of primer is optional. With primer, Loctite curing time is approximately 15 minutes. Without primer, curing time is approximately 6 hours. Apply 3 or 4 drops of Loctite® 242®, 243t or 246t sealant at top of thread for each of four holes in housing. Do not allow parts with Loctite applied to come in contact with any metal parts other than those for assembly. Wipe off excess Loctite from housing face, using a non-petroleum base solvent.

56050530

NOTE: Do not apply Loctite to threads more than 15 minutes before installing screws. If housing stands for more than 15 minutes, repeat application. No additional cleaning or removal of previously applied Loctite is necessary. 20. Before installing flange and seal assembly, 1, over shaft, 2, place protective sleeve or bullet (Eaten tool 600304) over shaft. Then lubricate space between dirt exclusion seal and pressure seal, 3, as well as lips of both seals with petroleum jelly. Install flange while rotating flange slowly while pushing down over shaft. Be careful not to invert or damage seals.

2 1

56050529

32 21. After removing bullet, clamp motor in vise as shown at dimension A, where A = 13 mm (0.5 in). Make sure shaft cannot fall out. Install dry screws and alternately torque them immediately to 28 N⋅m (250 in-lb). If you use primer, allow to cure for 10 to 15 minutes. Without primer, allow 6 hours curing time before subjecting motor to high torque reversals. If you use new screws, make sure they are 22 mm (0.875 in) under head length.

A 56050528

88-14

SECTION 88 -- ACCESSORIES -- CHAPTER 2 22. Reposition motor with gerotor end up, then clamp across ports. Do not clamp on side of housing. IMPORTANT: To aid installation of seals, apply light coat of clean petroleum jelly to seals. Do not stretch seals before installing them in groove. 23. Pour approximately 35 cc of clean hydraulic oil in output shaft cavity.

6 4

5 1 2

24. Install 73 mm (2.875 in) I.D. seal in housing seal groove. Avoid twisting seal. Timing Procedure (Steps 25 - 27) 25. Install drive. Use felt tip marker to mark one drive tooth, 1. Align this tooth with timing dot, 2, on shaft.

56050527

26. Install spacer plate, 3. 27. Install 73 mm (2.875 in) I.D. seal in gerotor seal groove, 4, (this side). Carefully place gerotor on spacer plate, seal side toward spacer plate. Align star points, 5, with line marking drive tooth, 1. 28. Rotate gerotor, 6, to line up with bolt holes. Be careful not to disengage star from drive or disturb gerotor seal. 29. Install another 73 mm (2.875 in) seal, 1, in end cap, 2. Carefully place end cap on gerotor. Install seven 41.1 mm (1.62 in) long cap screws, 3, in end cap.

56050541

88-15

SECTION 88 -- ACCESSORIES -- CHAPTER 2 30. Pre-tighten screws to 7.4 N⋅m [40 in-lb]. Torque screws 27 -- 28 N⋅m [235 -- 250 in-ft] in sequence, as shown.

4 1 6 56050525

36 Install the marked fittings, 2, in their respective motor housing work ports. Torque to 136 -- 149 N⋅m (100 -110 ft-lb).

60051046

A 1

Install the plug or drain fitting, 3. Torque to 48 -- 53 N⋅m (35 -- 39 ft-lb).

Do not remove fitting caps until motor is installed and hoses are ready to connect. Insert woodruff key, 1, for installation.

60051051

88-16

SECTION 88 -- ACCESSORIES -- CHAPTER 2 Installation 1. Install the motor, 1, and secure in place with four cap screws, 2.

3 2

2. Insert woodruff key, 3. If equipped with cover plate, 1, shown in Fig. 39, install the cover plate, and then secure with the four cap screws. 3. Connect the hydraulic lines, 4.

40023094

1 38

66060036

88-17

SECTION 88 -- ACCESSORIES -- CHAPTER 2 CHAFF/CORN SPREADER Removal

In- feed Roller Equipped IMPORTANT: Cap or plug all open hydraulic hose and connector fittings to prevent contamination ingress.

NOTE: Capture drain oil from disconnected hoses and lines. Do not reuse oil. Dispose of used oil in accordance with local ordinance. 1. Close the speed control valve, 1, on the hydraulic block.

2 60051033

2. Disconnect and plug the pressure hose, 2, and the return hose, 3, from the hydraulic block fittings. Cap the hydraulic block fittings. 3. If equipped with an in-feed roller motor, 1, disconnect and plug the pressure hose, 2, and the return hose, 3, from the roller motor, Cap the roller motor fittings. Release the hoses from any clamps or tie wraps securing the hoses to the combine frame.

Proceed with spreader disassembly and frame removal with hydraulic hoses attached.

56063709

41 PSD (Positive Straw Discharge) Equipped IMPORTANT: Cap or plug all open hydraulic hose and connector fittings to prevent contamination ingress.

NOTE: Capture drain oil from disconnected hoses and lines. Do not reuse oil. Dispose of used oil in accordance with local ordinance.

1. Close the speed control valve, 1, on the hydraulic block. 2. Disconnect the spreader pressure hose, 2, and, return hose, 3, from the block fittings.

86063390

88-18

SECTION 88 -- ACCESSORIES -- CHAPTER 2 CAUTION The following steps involve careful release of a high-tension spring load. Use the correct tool and maintain hands-on control through a 180-degrees counterclockwise rotation, releasing of the full tension. Ensure the spreader is in the full UP (horizontal) position to minimize the spring tension, as it loads, during rotation of the spring cage. Failure to comply may result in minor or moderate injury. 3. Locate the spring cage, 1, on the RH side of the spreader.

3 1 10051041

Remove the M12 nut and Belleville lock washer from the M12 x 90 mm cap screw, 3. Do NOT attempt to remove the cap screw at this time. Insert a 1/2-inch drive breaker bar, with the handle upward as show, in the square hole of the spring cage at, 2. Use forward pressure on the breaker bar to rotate the spring cage clockwise and release pressure on the cap screw, 3. Maintain pressure on the breaker bar and remove the cap screws, 3. Continue to maintain pressure on the breaker bar, 1, and then carefully release the spring tension by rotating the breaker bar with the spring cage, 2, through a 180-degree counterclockwise rotation.

Remove the breaker bar and slide the spring cage from the spreader support shaft, 3.

60051056

88-19

SECTION 88 -- ACCESSORIES -- CHAPTER 2 4. For wide frame combines with the spreader mainframe mounting bracket, 1, mounted as shown; remove the two M12 x 30 mm cap screws, 2, with Belleville lock washers.

Proceed with sliding the spreader from the right--hand side bracket as described after the following narrow frame equipped instruction.

86063391

45 5. For narrow frame combines with the mainframe spreader bracket, 1, mounted as shown; remove the two M12 x 30 mm cap screws, 2, with Belleville lock washers.

Slide the spreader adjustable bracket, 3, from the inside of the mainframe bracket, and then continue with the removal of the right--hand side of the spreader.

2 3

86063392

46 6. With a helping assistant, slide the spreader frame, 1, to the left-hand side of the combine thereby sliding the support shaft, 2, from the hole in spreader frame bracket, 3.

1 2

10051038

3 47

88-20

SECTION 88 -- ACCESSORIES -- CHAPTER 2 Installation 1. With helper assistance, lift the Wide Spreader frame, 1, and slide the RH support shaft, 2, through the hole of the RH bracket, 3.

Mount the LH side of the spreader as shown in the following figures for the specific application for wide and narrow combines.

3 10051038

48 2. For wide frame combines, align the spreader with attached mainframe bracket, 1, to the mainframe, and then install two M12 x 30 mm cap screws, 2, with Belleville lock washers. Tighten the hardware. Proceed to Spring and Spring Cage installation.

86063391

49 3. For narrow frame combines, align the spreader with attached adjusting bracket, 3, to the inside of the mounted mainframe bracket, 1, and then install two M12 x 30 mm cap screws, 2, with Belleville lock washers, and nuts.

2 3

86063392

88-21

SECTION 88 -- ACCESSORIES -- CHAPTER 2 Spring and Spring Cage Installation 1. Ensure the Wide Spreader is in the full UP (horizontal) position.

4 2

Insert the springs into spring cage as shown. Note the cage orientation with hole/shaft, 1, to the left and the square hole, 2, to the right. Position the springs within the cage so that the spring hooks, 3, will engage the shaft, 1, when mounted and loading spring tension in following steps. Slide the spring between the plates so that the spring tabs, 4, will align vertically as represented by the arrow, 5.

10051037

2. Install the springs and spring cage on the shaft, as shown. The spring tabs, 1, align to the slot, 2, in the shaft, and the round hole, 3, and square hole, 4, are positioned as shown.

4 3

10051039

CAUTION The following steps involve careful loading of a high-tension spring load to a spring. Use the correct tool and maintain hands-on control through a 180-degrees clockwise rotation when loading and securing the full tension to the springs. Ensure the spreader is in the full UP (horizontal) position to minimize the spring tension as it loads during rotation of the spring cage. 3. With the handle down as shown, insert a 1/2-inch breaker bar, 1, into the square hole (item 4, Fig. 52) in the spring cage, 2. This positioning allows the complete 180-degrees clockwise rotation to load the spring tension.

Rotate the spring cage clockwise and maintain hands-on control of the spring tension with the breaker bar until the cage is secured as outlined in the following steps.

1 10051040

88-22

SECTION 88 -- ACCESSORIES -- CHAPTER 2 4. The hole in the spring cage, 1, when fully rotated will align with slot, 2, in the RH bracket. Insert the bolt, 3, through the hole and the slot as described in the following step.

10051042

54 5. Align the hole in the spring cage, 1, with the slot in the RH bracket, item 2 Fig. 54, and then insert an M12 x 90 mm cap screw hex head bolt, 2, through the spring cage and RH bracket. Secure it with a Belleville lock washer and nut.

Tighten the hardware.

10051041

55 In- feed Roller Equipped 1. If equipped with an in-feed roller motor, 1, connect the return hose, 2, and the pressure hose, 3, from the roller motor. Clamp, wrap tie, or support the hoses as required to prevent damage or operation interference.

3 2

56063709

88-23

SECTION 88 -- ACCESSORIES -- CHAPTER 2 2. Connect the spreader return hose, 2, and pressure hose, 1, to the block fittings. Torque return fitting to 60 – 68 N⋅m (44 – 50 ft-lb).

2 1 60051033

57 PSD (Positive Straw Discharge) Equipped 1. Connect the spreader return hose, 2, and pressure hose, 1, to the block fittings. Torque fittings to 60 – 68 N⋅m (44 – 50 ft-lb).

86063390

88-24

SECTION 88 -- ACCESSORIES -- CHAPTER 3

SECTION 88 - ACCESSORIES Chapter 3 - Positive Straw Discharge (PSD) CONTENTS Section

Description

Page

88-1

SECTION 88 -- ACCESSORIES -- CHAPTER 3 GENERAL The PSD Conveyor, 1, is mounted inside the straw-hood of the combine, above and forward of the chopper. The PSD is hydraulically driven and operates when the threshing clutch is engaged. Its speed is non-adjustable, but may vary during operation dependent of the amount of residue material passing over it.

The PSD conveyor can be serviced while mounted in the unit or can be completely removed for repair or replacement of a major component, e.g., PSD frame. (Crowfoot wrenches may be required to access adjustment linkage components.)

66060048

Each component can feasibly be replaced, if necessary, without disassembling the chopper housing components, e.g., chop/swath and kick back doors, control handles, and windrow forming shield.

3 1

The PSD Conveyor Speed Sensor, 2, is bracket mounted and installed on the left-hand side tension adjustment guide bracket, item 3, of the PSD Conveyor. The electrical connection from the sensor is through the combine side plate. The connecting wire harness is routed to the CCM2 following the main wire harness. If not equipped with the speed sensor, the sensor is available as a stand-alone installation kit. If equipped, the conveyor belt speed is monitored for low speed conditions by a proximity speed sensor. A low speed condition produces a high priority pop-up alarm (A0127), an audible alarm as other shaft speed alarms, and the “Residue” lamp on the SSM is illuminated. The low speed alarm may be a result of belt slippage, requiring tension and tracking adjustment and/or the sensor target out of range, thus requiring a roller and/or sensor clearance adjustment.

20060075

88-2

SECTION 88 -- ACCESSORIES -- CHAPTER 3 OVERHAUL PSD (POSITIVE STRAW DISCHARGE)

Removal Remove the left rear access cover, 1.

86060087

3 Remove the windrow forming shield, 1, and chopper top cover, 2.

1 86060088

4 Remove the cap screws and bushings, 2, nuts and lock washers from both sides of the spreader hood, 1.

Lift the windrow forming shield from the unit. Remove the carriage bolts, 3, nuts and lock washers from both sides of the chopper top cover, 4.

4 2

Lift the chopper cover from the unit.

86060089

1 5

88-3

SECTION 88 -- ACCESSORIES -- CHAPTER 3 Remove the chop/swath door, 1 and kickback door, 2.

NOTE: The chop/swath door is smaller in height than the kickback door, as a reference for assembly. NOTE: Inspect the rubber seals on the ends of each door to be intact and serviceable. Replace as needed, applying an oil resistant sealant to the seal cavity before pressing on.

The kickback door, 2, is removed first. Both doors are positioned vertically for removal. 66060085

6 Pull the detent ring pins, 1, from the chop/swath door handle, A, and the kickback door handle, B.

Remove both handle keepers, 2, each secured by M10 x 20 mm carriage bolts, lock washers, and nuts, 3.

A 2 2 1 86060090

7 Position the kickback door handle, 1, in the two o’clock position shown; this will position the door vertically for removal. Have a second person hold the door while performing the following steps on the right and left-hand sides. Withdraw the handle, 1, and attached hex shaft 2, along with bushing (not shown) from the right end of the kickback door.

1 2

Retain the bushing with the handle. 10040147

88-4

SECTION 88 -- ACCESSORIES -- CHAPTER 3 On the left-hand side, locate the left hex shaft retainer assembly (cover plate, 2, and three spacers, 1). Remove the hardware, 3, and then cover, 2, and spacers, 1.

Pull the hex shaft from the left end of the door. Remove the door from the unit. NOTE: The hex shaft may be able to be extracted by only opening the cover plate without removing all parts described.

3 10041686

Reassemble the spacers, 1, and cover, 2, as shown. Do not tighten hardware at this time.

Repeat the left and right-hand kickback door removal steps above, for removal of the chop/swath door. The door handle, 1, is positioned in the seven o’clock position for removal of the handle and hex shaft, 2. Remove the chop/swath door from the unit.

1 2 10040147

10 If equipped with PSD Conveyor Sensor, locate the electrical connectors on the left side, forward of the PSD motor.

3 2

Disconnect the sensor connector, 2, from the sensor cable connector, 1.

Push the connector receptacle, 2, and grommet, 3, inward through the side plate.

86060049

88-5

SECTION 88 -- ACCESSORIES -- CHAPTER 3 At the PSD motor, 1, on left rear side-plate, without removing the hydraulic hoses, remove the nuts, 2, lock washers, and cap screws from the motor mount bracket.

Suspend the motor and bracket assembly at the side of the unit.

86060091

12 From under the straw-hood, at the PSD conveyor drive shaft, loosen the two setscrews, 1, securing the inner coupler half, 2, with flexible spider, 3, to the shaft.

Slide the inner coupler half, 2, with flexible spider, 3, from the shaft and remove the woodruff key from the shaft.

3 2 66060084

13 From inside the straw-hood, remove the right-hand conical deflector, A, and left-hand deflector, B.

86060041

Remove two M6 x 16 cap screws, 1, nuts, and lock washers. Remove two M10 x 20 cap screws, 2, nuts, and lock washers.

1 A B

86060040

88-6

SECTION 88 -- ACCESSORIES -- CHAPTER 3 From the rear of the combine, use two long wooden boards at least 305 cm (10 ft) to span from the top of the chopper housing to the discharge beater grate.

10041682

15 Raise the support boards up to the conveyor, to support the conveyor unit as the installation hardware on both sides of the unit is removed.

10041685

16 With the right conical deflector, 1, previously removed; remove three M10 x 20 cap screws, 3, nuts, and lock washers securing the conveyor frame to side deflector mount, 2.

IMPORTANT: Ensure support is maintained on the unsecured right side of the conveyor to prevent the weight from deforming or damaging the conveyor frame and left deflector as the left side hardware is removed.

3 86060092

88-7

SECTION 88 -- ACCESSORIES -- CHAPTER 3 With the left conical deflector, 1, previously removed; remove three M10 x 20 cap screws, 3, nuts, and lock washers securing the conveyor frame to side deflector mount, 2.

3 86060093

18 Lower the conveyor onto supports boards. Lower the support boards and rest them on the chopper housing.

10041685

19 Secure the boards at the chopper housing to prevent them from moving rearward while rolling the conveyor assembly down the boards. Roll the conveyor rearward down the boards and lift the conveyor from the boards for service. Service the PSD conveyor as required.

10041684

88-8

SECTION 88 -- ACCESSORIES -- CHAPTER 3 Installation Prior to installing the PSD conveyor in the unit, tension and adjust roller alignment as described in PSD Conveyor Belt; Adjustment. From the rear of the combine, use two long wooden boards at least 305 cm (10 ft) to span from the top of the chopper housing to the discharge beater grate. Secure the boards at the chopper housing to prevent them from moving rearward while rolling the conveyor assembly up the boards. 10041682

21 Place conveyor assembly on boards with the extended drive shaft, 1, to the left rear, and then roll the conveyor assembly up the boards.

10041684

22 When the frame brackets are aligned under the installed side deflectors, lift the conveyor with boards to align the conveyor frame mounting holes to the side deflectors.

10041685

88-9

SECTION 88 -- ACCESSORIES -- CHAPTER 3 Secure the left side of the conveyor to the side deflector, 2, with three M10 x 20 cap screws, 1, nuts, and lock washers.

Install the left-hand conical deflector, 3, to the side deflectors, 2, with the two M10 x 20 cap screws, 4, nuts, and lock washers.

Install the loose end of the rubber seal with two M6 x 16 cap screws, 5, nuts, and lock washers. Do not over-tighten the hardware as to compress or twist the seal. IMPORTANT: Ensure support is maintained on the unsecured right side of the conveyor to prevent the weight from deforming or damaging the conveyor frame and left deflector when the left side hardware is installed.

86060093

Secure the right side of the conveyor to the side deflector, 2, with three M10 x 20 cap screws, 3, nuts, and lock washers.

Install the right-hand conical deflector, 1, to the side deflectors, 2, with the two M10 x 20 cap screws, 4, nuts, and lock washers.

Install the loose end of the rubber seal with two M6 x 16 cap screws, 5, nuts, and lock washers. Do not over-tighten the hardware as to compress or twist the seal.

5 86060092

25 From under the straw-hood, at the PSD conveyor drive shaft, install the woodruff key into the conveyor drive shaft, and then slide on the inner coupler half, 2, with flexible spider, 3.

Do not tighten the setscrews, 1, at this time.

3 2 66060084

88-10

SECTION 88 -- ACCESSORIES -- CHAPTER 3 Lift the motor and bracket assembly, 3, to the mounting location; align the outer and inner coupler halves, and then align the mounting bracket holes.

Mount the motor and bracket assembly, 3, by installing four M10 x 20 mm cap screws outwards through the side plate and mounting bracket. Secure bracket with lock washers and nuts, 2.

Tighten the hardware.

86060091

27 With motor installed, check and set a clearance, A, of 1.5 – 2 mm (0.059 – 0.098 in) between the outer coupler half, 1 and the inner coupler half, 2.

66060083

A 28

Measure clearance with a feeler gauge, 3, selected within the specification range above, and then slide the conveyor shaft coupler half, 2, against the gauge as shown.

First tighten the setscrew over the shaft, and then tighten the setscrew over the shaft key. Torque both set screws, 1, to 17.0 – 18.5 N⋅m (150 – 165 in-lb).

3 10041694

88-11

SECTION 88 -- ACCESSORIES -- CHAPTER 3 If equipped with PSD Conveyor Sensor, push the connector receptacle, 2, outward through the side plate, and then position the grommet, 3, in the side plate hole.

3 2 1

Connect the sensor connector, 2, to the wire harness connector, 1. IMPORTANT: Ensure the connection and the sensor cable is not and will not contact the chopper sheave during operation. 86060049

30 Install the chop/swath door, 1 and kickback door, 2. NOTE: The chop/swath door is smaller in height than the kickback door, as a reference for assembly.

NOTE: Inspect the rubber seals on the ends of each door to be intact and serviceable. Replace as needed, applying an oil resistant sealant to the seal cavity before pressing on.

The chop/swath door, 1, is installed first. Both doors are positioned vertically for installation. Have a second person position and hold each doors vertically as shown, as the hex shafts are inserted in the left-hand, and then right-hand ends of the door panels.

66060085

Insert the chop/swath door into the unit. With the chop/swath door held in position; on the left-hand side, locate the left hex shaft retainer assembly (cover plate, 2, and three spacers, 1).

Insert the hex shaft, 4, into the left end of the door. Remove one set of hardware, 3, to allow the cover plate, 2, to be lowered to retain the hex shaft. Re-install the hardware. Tighten both M10 nuts and torque to 56 N⋅m (41 ft-lb).

10041688

88-12

SECTION 88 -- ACCESSORIES -- CHAPTER 3 The chop/swath door handle, 1, is positioned in the seven o’clock position for installation of the handle and hex shaft, 2. Ensure the bushing is on the hex shaft, and then insert hex shaft into the right end of the door.

1 2 10040147

33 Repeat the left and right-hand chop/swath door installation steps above, for installation of the kickback door. Position the kickback door handle, 1, in the two o’clock position shown when installing.

10040147

34 Install both handle keepers, 2, each secured by M10 x 20 mm carriage bolts, lock washers, and nuts, 3. Position the doors for the desired residue handling, and then insert the detent ring pins, 1, into the chop/swath door handle, A, and the kickback door handle, B.

A 2 2 1 86060090

88-13

SECTION 88 -- ACCESSORIES -- CHAPTER 3 Install the chopper top cover, 1, and windrow forming shield, 2.

2 86060088

36 Lift the chopper top cover onto the unit Install the carriage bolts, 3, nuts and lock washers from both sides of the chopper top cover, 4. Tighten the hardware.

Lift the windrow forming shield onto the unit.

Install the cap screws and bushings, 2, nuts and lock washers from both sides of the spreader hood, 1.

Tighten the hardware. 86060089

1 37

Install the left rear access cover, 1.

Test run the PSD, inspect tracking, and adjust as required. See PSD Conveyor Belt; Adjustment, later in this chapter.

86060087

88-14

SECTION 88 -- ACCESSORIES -- CHAPTER 3 HYDRAULIC MOTOR Removal

WARNING To prevent eye injury, always wear goggles or full face protection before using compressed air or high pressure washers. Failure to comply could result in serious injury or death.

Access the PSD motor, 1, by removing the left rear access cover, 2. IMPORTANT: Cleanliness is extremely important when servicing these motors. Work in a clean area. Before disconnecting hoses, have a selection of hydraulic caps and plugs immediately available, and first, clean the motor ports and surrounding areas.

86060087

Clean the motor, hoses, and surrounding area using pressurized air or water. NOTE: If cleaned with pressurized water, allow the area to thoroughly dry before proceeding to the next step. Using a paint pen or permanent marker, mark the work port hose end fittings, 2, to the port fittings and the port fittings to the port housing to ensure correct assembly and connections after service.

Disconnect the work port hoses, 2. Plug the hoses and cap the fittings.

Disconnect the hydraulic drain hose, 1. Plug the hose and cap the fitting.

Remove the motor mount assembly by removing the nuts, 3, lock washers, and cap screws from the motor mount bracket, 4.

86060091

40 Loosen the set screws, 4, on the outer coupler half, 3, and slide the coupler from the motor shaft.

Remove three M10 x 20 mm cap screws, 1, with lock washers, and then remove the mounting bracket, 2.

1 66060082

2 41

88-15

SECTION 88 -- ACCESSORIES -- CHAPTER 3 Overhaul Special Tools Required • (Eaten Tool) -- Shaft Pressure Seal Installation Tool #600523 •

(Eaten Tool ) -- Seal Sleeve or Bullet Tool (for 1 in. shaft) -- #600304

•

Torque Wrench -- 34 N⋅m (300 in-lb) capacity

•

Breaker Bar -- 300 -- 400 mm (12 -- 16 in)

•

5/16 in. -- 6 point (E10 Torx Driove) socket

•

Hex Key -- 5 mm (3/16 in)

•

Small flat blade screwdriver (to be modified as described in instructions) -- 150 -- 200 mm x 6 mm (6 -- 8 x 1/4 in)

IMPORTANT: No impact wrench is used. Damage to sockets or rounded screw heads can occur. IMPORTANT: Cleanliness is extremely important when repairing these motors. Work in a clean area. Before removing fittings, clean port areas of motor. Remove woodruff key, 1. Check shaft and key slot. Remove burrs, nicks and sharp edges that may damage a seal. Ensure the work port fittings are marked to the motor housing as the hoses were to the fittings. This will ensure ease of assembly at installation.

3 2 1

Before disassembly, drain oil from motor. Remove the work port fittings, 2, and drain port fitting, 3. Cap fittings to prevent dirt ingress. Then plug ports and thoroughly clean exterior of motor.

66060091

NOTE: Although not all drawings show the motor in a vise, we recommend that you keep the motor in a vise during disassembly. Follow the clamping procedures explained throughout the manual. 1. Place motor in vice and clamp across edge of flange with output shaft down. When clamping, use protective device on vise such as special soft jaws, pieces of hard rubber or wood. IMPORTANT: Do not clamp on side of housing. Excessive clamping pressure on side of housing causes distortion. IMPORTANT: Discard all used seals removed. Do not reuse seals. Replace with new seals. 56050542

88-16

SECTION 88 -- ACCESSORIES -- CHAPTER 3 2. Remove cap screws, 1. Remove end cap, 2. Remove seal, 3 from end cap.

3 56050541

44 3. Remove gerotor section, 1. Remove seal, 2, from gerotor.

2 56050540

45 4. Remove drive shaft, 1. Remove spacer plate, 2. Remove seal, 3, from housing. Remove output shaft, 4, from housing in direction shown. Remove needle thrust bearing from shaft or housing.

4 1 3

56050539

88-17

SECTION 88 -- ACCESSORIES -- CHAPTER 3 5. Reposition motor in vise. Clamp across ports as shown, clamping dimension A at both sides of port boss, where A = 13 mm (0.5 in).

IMPORTANT: Do not clamp on side of housing. Excessive clamping pressure on side of housing causes distortion.

56050538

47 6. Remove four cap screws, 1, from mounting flange. These screws are assembled with Loctite® to hold them in place. The screws will require 35 -- 45 N⋅m (300 -- 400 in-lb) of torque to break loose and 11 N⋅m (100 in-lb) torque to remove. IMPORTANT: Do not use impact wrench on screws that have been secured with Loctite. This could result in rounded heads or broken sockets. 7. If torque higher than given above is required to break screws loose, apply heat according to following instructions: When heated, Loctite partially melts. This reduces torque required to remove screw. Use small flame propane torch, 2, to heat small area of housing, 3, where screw enters. IMPORTANT: Be careful not to overheat housing and damage motor. Gradually apply torque to screw with socket wrench as heat is applied for 8 to 10 seconds. As soon as screw breaks loose, remove heat from housing. Continue turning screw until it is completely removed. 8. Carefully remove flange, 4, from housing, 5.

88-18

3 1

56050537

5 48

SECTION 88 -- ACCESSORIES -- CHAPTER 3 The dirt exclusion seal, 1, back-up ring, 2, pressure seal, 4, and O-ring seal, 5, will come off with the flange, 3. Use a seal removal tool, described in the following step to remove the dirt exclusion seal and pressure seal. IMPORTANT: Some motors may have a quad seal and back-up ring in place of the pressure seal, 1. The quad seal and back-up ring are no longer available and are replaced by the pressure seal. They are interchangeable, but some precautions must be taken to insure proper installation. Follow the reassembly instructions.

2 1

3 56050536

9. A seal removal tool is made by modifying a small flat blade screwdriver (150 -- 200 x 6 mm [6 -- 8 x 1/4 in]).

2 1

Bend tip over, 1, and grind end of blade to radius, 2. Remove all burrs. IMPORTANT: Be careful not to scratch seal cavity O.D. This could create a leak path.

56050535

50 10. Using the seal removal tool as shown, work from outer side for both (either) seals. Remove pressure seal, 1, and back-up washer, 2.

Then remove dirt exclusion seal, 3.

56050534

3 51

88-19

SECTION 88 -- ACCESSORIES -- CHAPTER 3 11. A metal plug, 1, one of the three types shown with seal, plugs a machining hole in the housing. It is not necessary to remove plug and replace seal unless leakage occurs around plug. To remove plug, insert 5 mm (0.187 in) hex key, 2, through port opening and push it out. If you remove plug and seal, lubricate new seal and install on plug. Some plugs have two O-ring grooves but require only one O-ring. Install O-ring in groove closest to end of plug. Push plug into housing so plug and housing are flush. Be careful not to damage seal. 12. Check all mating surfaces. Replace any parts with scratches or burrs that could cause leakage or damage. Clean all metal parts in clean solvent. Blow dry with air. Do not wipe parts with cloth or paper towel because lint or other matter could get into the hydraulic system and cause damage. Check around key slot and chamfered area of shaft for burrs, nicks or sharp edges that could damage seals during reassembly. Remove nicks or burrs with a hard smooth stone (such as an Arkansas stone). Do not file or grind motor parts. NOTE: Lubricate all seals with petroleum jelly. Use new seals when reassembling motor. IMPORTANT: Do not stretch seals before installing them.

88-20

56050533

SECTION 88 -- ACCESSORIES -- CHAPTER 3 NOTE: Cleanliness is extremely important in the successful application of Loctite®. Fully cured Loctite resists most solvents, oils, gasoline and kerosene and is not affected by cleaning operations. It is not necessary to remove cured Loctite that is securely bonded in tapped holes; however, any loose particles of cured Loctite should be removed. Before Loctite can be applied, the parts should be cleaned as follows:

56050532

88-21

7 6

56050531

SECTION 88 -- ACCESSORIES -- CHAPTER 3 19. It is recommended to apply a light coat of Loctite® 7649t Primer Nt in tapped holes of housing. Allow primer to air dry for at least 1 minute. Do not force dry with air jet; the primer will blow away. Use of primer is optional. With primer, Loctite curing time is approximately 15 minutes. Without primer, curing time is approximately 6 hours. Apply 3 or 4 drops of Loctite® 242®, 243t or 246t sealant at top of thread for each of four holes in housing. Do not allow parts with Loctite applied to come in contact with any metal parts other than those for assembly. Wipe off excess Loctite from housing face, using a non-petroleum base solvent.

56050530

2 1

56050529

56 21. After removing bullet, clamp motor in vise as shown at dimension A, where A = 13 mm (0.5 in). Make sure shaft cannot fall out. Install dry screws and alternately torque them immediately to 28 N⋅m (250 in-lb). If you use primer, allow to cure for 10 to 15 minutes. Without primer, allow 6 hours curing time before subjecting motor to high torque reversals. If you use new screws, make sure they are 22 mm (0.875 in) under head length.

A 56050528

88-22

SECTION 88 -- ACCESSORIES -- CHAPTER 3 22. Reposition motor with gerotor end up, then clamp across ports. Do not clamp on side of housing. IMPORTANT: To aid installation of seals, apply light coat of clean petroleum jelly to seals. Do not stretch seals before installing them in groove. 23. Pour approximately 35 cc of clean hydraulic oil in output shaft cavity.

6 4

5 1 2

56050527

56050541

88-23

SECTION 88 -- ACCESSORIES -- CHAPTER 3 30. Pre-tighten screws to 7.4 N⋅m [40 in-lb]. Torque screws 27 -- 28 N⋅m [235 -- 250 in-ft] in sequence, as shown.

4 1 6 56050525

60 Install the marked fittings, 2, in their respective motor housing work ports.

Install the 90-degree drain fitting, 3.

Tighten the fittings. Do not remove caps until motor is installed and hoses are ready to connect.

Insert woodruff key, 1, for installation assembly, as follows. 66060091

61 Installation Assemble the motor mounting bracket, 2, to the motor with three M10 x 20 mm cap screws and lock washers, 1.

Ensure the woodruff key is installed in the motor shaft and then slide the outer coupler half, 3, onto the motor shaft. Position the outer coupler half, 3, with a clearance, A, of 8.7 – 10.7 mm (0.343 – 0.421 in) from the bracket, 2. Tighten the setscrews, 4; the setscrew over the shaft first, and then tighten the setscrew over the key. Torque both setscrews to 17.0 – 18.5 N⋅m (150 – 165 in-lb).

88-24

1 66060082

2 62

SECTION 88 -- ACCESSORIES -- CHAPTER 3 Lift the motor and bracket assembly, 4, to the mounting location; align the outer and inner coupler halves, and then align the mounting bracket holes.

Mount the motor and bracket assembly, 4, by installing four M10 x 20 mm cap screws outwards through the side plate and mounting bracket. Secure bracket with lock washers and nuts, 3.

Tighten the hardware.

Connect the work port hoses, 2, to the like marked port fittings. Tighten the connection fittings. Connect the drain hose, 1. Tighten the connection fitting.

86060091

Install the access cover. With motor installed, check and set a clearance, A, of 1.5 – 2 mm (0.059 – 0.098 in) between the outer coupler half, 1 and the inner coupler half, 2.

66060083

A 64

Under the straw-hood, at the rear PSD pulley drive shaft, measure clearance with a feeler gauge, 4. Select a feeler within the specified range above. Insert the feeler between the inner, 2, and outer, 3, coupler halves.

If adjustment is required, loosen the setscrews, 1, slide the conveyor shaft inner coupler against the gauge as shown.

3 4

First tighten the setscrew over the shaft, and then tighten the setscrew over the shaft key. Torque both set screws, 1, to 17.0 – 18.5 N⋅m (150 – 165 in-lb). Test run the PSD, and then inspect for leaks.

88-25

10041694

SECTION 88 -- ACCESSORIES -- CHAPTER 3 PSD SPEED SENSOR

Inspection and Adjustment

3 4

WARNING Do not attempt any inspection or adjustment with the combine running. • Set the parking brake. • Turn off combine. • Remove key. Failure to comply could result in serious injury or death.

5 6 7 86060047

Ensure the belt is tracking properly; the belt V-tongue is running fully in the roller V-groove and not showing signs of edge wear or rubbing on painted surfaces of the frame or striking the sensor. Ensure sensor cable, 1, and sensing head, 3, are intact and in good condition. Ensure the four target plate targets, 5, are not bent or deformed. All must run parallel to the sensor face, 6, within the specifications given for adjustment below. The driven sensor target roller, 4, may have lateral play of 3.175 – 6.35 mm (1/8 – 1/4 in); when checking or adjusting clearance, ensure the roller, 4, is positioned fully to the left side, and adjust clearance as described. If it is determined that sensor low speed alarms are due to the target moving out of range because of lateral play, add one or two shim washers to the right end of the roller shaft to push the roller, 1 (Figure 67) to the left.

Adjust the nuts, 2 (Figure 66) and lock washer on either side of the sensor bracket, 7 (Figure 66), to position the sensor face, indicated by 3 (Figure 67), within 4 -- 6 mm (0.157 – 0.236 in) clearance, A, of the sensor target plate, indicated by 2 (Figure 67).

A 86060046

3 67

88-26

SECTION 88 -- ACCESSORIES -- CHAPTER 3 PSD CONVEYOR BELT

Adjustment

7 8

9 10

86060086

68 Belt slippage requires Components of the tension / tracking adjustment linkage on the left side of the unit as seen from within the straw-hood under the PSD conveyor looking up and forward are as follows: 1. Cotter pin and washer 2. Rocker support 3. Rocker 4. Jam nuts 5. Push rod 6. Quadrant hex (1-1/8 in) 7. Quadrant ratchet 8. Pawl 9. Conveyor frame 10. Conveyor belt Tension the conveyor belt by applying a torque of 68 – 88 N⋅m (50 – 65 lb-ft) to the ratchet quadrant hex, 1, counterclockwise and engage the pawl, 2, in the closest notch of the quadrant.

1 66060058

88-27

SECTION 88 -- ACCESSORIES -- CHAPTER 3 Verify the drive and driven rollers are parallel. Measure the distance between the rollers on both sides of the conveyor. Adjust the distance to be equal at the right-hand side adjustment linkage, shown.

NOTE: Crowfoot wrenches may be required to access the jam nuts, 1, for adjustment. Adjust distance with the double jam nuts, 1, on the tensioning push rod, 2. Run unit several revolutions, shut down combine, remove key, and then check the belt tracking. Further tracking adjustments should be made to the same (right-hand) side by increasing or decreasing the jam nut position on the push rod. Fine adjustment should be only one flat of the nut at a time.

56063241

2 70

Run unit several revolutions, shut down combine, remove key, and then check the belt tracking, repeat procedure as necessary. Replacement Remove the conveyor belt tension at the adjustment linkage on the left-hand side of the PSD frame.

Turn the ratchet quadrant, 1, counterclockwise enough to free the pawl, 2, and then release the pressure from the linkage.

1 66060058

88-28

SECTION 88 -- ACCESSORIES -- CHAPTER 3 Manually rotate the conveyor belt to a position of best access to the connector hardware. Disassemble the belt connector hardware (bolts, connector bars, and locknuts), 1, and remove the belt, 2.

NOTE: When removing the belt from under the side deflectors, use care as to not tear the rubber seal along the bottom of the deflectors. Before installing a new belt, check the belt for square by measuring the diagonals. Ensure the rollers are parallel, by measuring the distance between them to be equal. Adjust as necessary. See PSD Conveyor Belt Adjustment. Install the conveyor belt, 2, with the belt V-tongue, 4, positioned to the left. Wrap the belt around the drive and driven rollers and ensure the belt V-tongue, 4, is positioned in both roller V-grooves, 3. NOTE: Install the conveyor belt with care when feeding the belt under the rubber seals along the deflectors on either side of the PSD frame, as to not tear the seals. Replace torn or damaged seals. Install the belt connecting hardware (bolts, connector bars, and locknuts), 1. Ensure the bolt heads are positioned towards the direction of belt travel. Tighten and torque belt hardware to 3.5 -- 4.5 N⋅m (30 – 40 lb-in). Tension and adjust roller alignment as described in PSD Conveyor Belt Adjustment. Run the PSD several revolutions, shut down combine, remove key, and then check tracking of the new belt. Adjust tracking as described in PSD Conveyor Belt Adjustment. IMPORTANT: A new belt requires frequent (minimum -daily) inspection of tension and tracking until initial belt stretch has been achieved.

88-29

2 66060038

4 3 72

SECTION 88 -- ACCESSORIES -- CHAPTER 3

88-30

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1

SECTION 90 - PLATFORM, CAB, BODYWORK, DECALS Chapter 1 - Cab CONTENTS Section

Description

Page

90-1

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 OVERHAUL CAB SUSPENSION SYSTEM Removal

1. In the cab remove the rubber plugs, 1, on the left and right corners on the floor next to the windshield to expose the front isolator mount hardware.

40044140

1 2. After the rubber plug, 1, is removed, you have access to the bolt head, 2.

40044141

2 3. Remove the two front M16 x 120 bolts, 7, and washer, 6, from the isolators, 1. Remove the rebound washers, 3, and hardware, 4 and 5. Remove the two spacers, 2, from the front isolators. Partially raise the feeder allowing clearance to access the mounts. Support the feeder with jackstands. Place a wood board on top of the feeder, and use a hydraulic bottle jack to lift on the cab floor, also using a wood board to spread force over the cab floor and jack the cab up until the two front isolators can be removed.

7 6

NOTE: An assistant will be needed to help remove the two front bolts from the suspension isolators.

NOTE: Always replace the cab mounts in pairs (front and rear).

IMPORTANT: To ensure safety, cab structure must be supported from an overhead hoist before removing more than one pair (front and rear) of the isolators and hardware.

3 60044153

5 3

90-2

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 4. For the two rear isolators use the same procedure as used on the front by removing the two M16 x 120 bolts, 1, rebound washers, 2, isolators, 3, spacers and hardware. Then proceed by jacking up the cab slightly to remove or replace the isolators.

40044127

4 Installation 1. The cab isolators should be replaced in pairs (front and rear). With the feeder raised in the up position, but with still enough clearance to gain access to the cab mount isolators use a board on the feeder a bottle jack and another board under the cab floor to spread the load, jack up on the cab until there is enough clearance to install the isolators. When the front isolators are in place, install the M16 x 120 with the washer from the inside of the cab down through the isolator.

60044153

5 2. From underneath the cab install the spacer up into the isolator, 3, then add the rebound washer, 2, followed by a an M16 washer and the M16 lock nut, 1.

Torque the nut, 1, to 164 N⋅m (121 ft-lbs).

40044127

90-3

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 3. Repeat steps for the rear cab isolators. NOTE: Rear isolator bolts are located underneath the cab and not in the cab.

1 40044126

AIR RIDE SEAT Removal 1. Detach the two seat control electrical connectors, 1.

1 40015752

8 2. Turn out the three screws, 1, and lift the cushion from the seat frame.

40015753

90-4

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 3. Remove the four allen head cap screws, 1. Lift the seat frame from the combine.

40015754

10 NOTE: Observe the orientation of stop, 1, when removing the right front cap screw.

40015756

11 4. Slide the console and mounting rails, 1, front to back as required to gain access to four cap screws, 2 and 3. Remove cap screws, 2, before cap screws, 3. 5. Set the console on the cab floor so that it is out of the way.

1 2

40015755

90-5

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 6. Remove the plastic cover, 1, now if desired.

7. Turn out cap screws, 2, holding the air ride seat pedestal. Remove the pedestal from the combine.

40015757

13 Installation

1. Set the air ride seat pedestal in place with the operating handle, 1, on the left. Secure the pedestal to the foundation with four cap screws, 2. Install the plastic cover, 3, if it had been removed.

40015757

14 NOTE: Observe the orientation of stop, 1, when installing the right front cap screw.

40015756

90-6

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 2. Position the console and mounting rails, 1, on the seat pedestal. Secure the console to the pedestal with four allen head cap screws, 2 and 3. Install the cap screws at 2 before the cap screws at 3.

1 3

40015755

16 3. Attach the seat frame to the pedestal with four cap screws, 1.

40015754

17 4. Install the seat cushion with three screws, 1.

40015753

90-7

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 5. Attach the two seat control electrical connectors, 1.

1 40015752

SEAT COMPRESSOR/BELLOWS Removal

1. Remove the air ride seat pedestal, 1, in accordance with the Air Ride Seat removal instructions.

40015757

20 2. Remove all plastic plugs, 1, and work the bellows, 2, from the pedestal.

1 40015758

90-8

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 NOTE: Trace the wires from the compressor to ensure the correct connectors are being pulled.

3. Unplug the compressor electrical connectors, 1. 4. Turn out the top bellows attaching cap screw, 2.

40015759

22 5. Remove attaching hardware for the compressor, 1, and bellows, 2.

40015760

23 6. Take the compressor and bellows from the pedestal. Cut cable ties as required to allow the components to be removed.

7. Carefully pull or pry air lines, 1, from the manifold at the bottom of the bellows.

40015761

90-9

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 8. Remove the desired component, compressor, 1, or bellows, 2.

40015762

25 Installation NOTE: Ensure that when replacing air line, 1, the same length is maintained.

1. Attach the compressor, 2, to the bellows, 3, with air line, 1.

1 40015762

26 2. Attach air lines, 1, to the manifold located on the bottom of the bellows.

40015761

90-10

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 3. Set the compressor and bellows in the pedestal with compressor tab, 1, and bellows tab, 2, in their appropriate positions. Secure the components to the bottom of the pedestal with hardware at 3.

4. Coil and apply cable ties to the air lines as required to hold the lines in position and away from any moving parts.

2 40015760

28 5. Turn in the upper bellows cap screw, 1. Attach the compressor power wires to the appropriate connectors at 2.

NOTE: The wires can only be connected one way.

40015759

29 6. Work the bellows, 1, over the pedestal and attach using plastic plugs, 2.

2 40015758

90-11

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 7. Install the air ride seat in accordance with the Installation instructions.

40015753

SEAT SHOCK ABSORBER Removal NOTE: Some illustrations show the pedestal removed from the foundation. It is not necessary to remove the pedestal in order to replace the shock absorber. 1. Detach the two seat control electrical connectors, 1.

1 40015752

32 2. Turn out the three screws, 1, and lift the cushion from the seat frame.

40015753

90-12

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 3. Remove the four allen head cap screws, 1. Lift the seat frame from the combine.

40015754

34 NOTE: Observe the orientation of stop, 1, when removing the right front cap screw.

40015756

35 4. Slide the console and mounting rails, 1, front to back as required to gain access to four cap screws, 2 and 3. Remove cap screws, 2, before cap screws, 3. 5. Set the console on the cab floor so that it is out of the way.

1 2

40015755

90-13

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 6. Remove the plastic cover, 1.

40015757

37 7. Remove all plastic plugs, 1, and work the bellows, 2, from the pedestal.

1 40015758

38 8. Insert a piece of wood, 1, or other blocking material to prevent the pedestal from collapsing during maintenance.

40015763

90-14

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 9. Remove clip, 1, and pin, 2, from the barrel end of the shock absorber, 3.

10. Remove the clip and pin from the rod end. 11. Take the shock absorber from the pedestal.

1 3 40015764

40 Installation 1. Set the shock absorber, 1, into place. 2. Attach the barrel end of the shock absorber with pin, 2, and clip, 3. 3. Attach the rod end of the shock absorber with a pin and clip.

4. Remove the blocking material from the pedestal.

1 40015764

41 5. Work the bellows, 1, over the pedestal and attach using plastic plugs, 2.

2 40015758

90-15

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 6. Install the plastic cover, 1.

40015757

43 NOTE: Observe the orientation of stop, 1, when installing the right front cap screw.

40015756

44 7. Position the console and mounting rails, 1, on the seat pedestal. Secure the console to the pedestal with four allen head cap screws, 2 and 3. Install the cap screws at 2 before the cap screws at 3.

1 3

40015755

90-16

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 8. Attach the seat frame to the pedestal with four cap screws, 1.

40015754

46 9. Install the seat cushion with three screws, 1.

40015753

47 10. Attach the two seat control electrical connectors, 1.

1 40015752

90-17

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 SEAT ADJUSTER Removal

1. Remove the air ride seat pedestal, 1, in accordance with the Air Ride Seat removal instructions.

40015757

49 2. Remove all plastic plugs, 1, and work the bellows, 2, from the pedestal.

1 40015758

50 3. Pull or pry the air lines, 1, attached to the manifold at the bottom of the bellows.

40015765

90-18

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 4. Pull cable, 1, from the plastic sleeve.

40015767

52 5. Rotate the cable around, then down, releasing the keeper from the lever, 1.

6. Pull the electrical connectors, 2, from the micro switch.

1 40015768

53 7. Remove screw, 1. 8. Using a screw driver, push in tabs at 2.

1 40015766

90-19

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 9. Using a finger or a screw driver, push in cable clip, 1.

40015769

55 10. Turn out screw, 1. Push the pin and rubber grommets, 2, from the belt, 3.

11. Remove lock nuts, 4. Pull the adjuster part way from the pedestal.

2 40015770

56 12. Pass the cable, 1, through the opening on the side and remove the cable and keeper from the adjuster. 13. Cut cable ties as required to remove the component from the pedestal.

1 40015771

90-20

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 Installation 1. Attach the appropriate air lines to the adjuster as required.

40015772

58 2. Attach the two air lines, 1, from the adjuster to the manifold at the bottom of the bellows.

40015765

59 3. Pass the cable, 1, through the opening on the side to install the keeper and cable into the adjuster.

1 40015771

90-21

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 4. Pass the pin and grommets, 1, through the looped end of the adjuster strap. Install the pin into the bottom of the pedestal and secure in place with the screw that had been previously removed at 2.

2 1

40015773

61 5. Insert the cable clip, 1, into the slotted hole in the adjuster. Move the cable until the end sits securely in the sleeve of the clip at 2.

6. Install the adjuster into the pedestal so that the studs have passed through the holes, 3.

40015774

62 NOTE: The prongs at 1 must grasp the adjuster securely.

7. Complete the installation of the cable clip with a screw driver if required. 8. Turn in screw at 2, securing the cable clip to the adjuster.

9. Secure the adjuster to the pedestal with lock nuts at 3.

2 40015775

3 63

90-22

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 10. Coil and apply cable ties to the air lines as required to hold the lines in position and away from any moving parts.

11. Work the bellows, 1, over the pedestal and attach using plastic plugs, 2.

2 40015758

64 12. Install the air ride seat in accordance with the Installation instructions.

40015753

WINDSHIELD WIPER MOTOR Removal 1. Turn out the three screws, 1, and let the cover hang from the wiper fluid supply lines.

1 86071381

90-23

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 2. Gently disconnect the wiper fluid jet supply lines, 1. Store the cover in a suitable location.

40015777

67 3. Disconnect the plug, 1, from the windshield wiper motor.

40015778

68 4. Using a flat bladed screw driver or knife, pry the cap screw cover, 1, from the hanger. Turn out the two screws holding the hanger in place. Store the hanger in a suitable location.

40015779

90-24

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 5. Turn out seven screws, 1, from the panel, 2. Allow the panel to hang inside the cab.

2 40015780

70 6. If applicable, remove all components, 1, from the right side panel.

7. Turn out two cap screws, 2. Store the panel in a suitable location.

1 40015781

71 8. Remove the cab climate control, 1, from the left side panel.

9. Turn out two cap screws, 2. Allow the panel to hang in the cab.

1 40015782

90-25

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 10. Pull the courtesy light, 1, from the headliner and disconnect the electrical wires.

40015783

73 11. Turn out two screws, 1, on either end of the sun visor, 2. Lower the visor from the headliner and store in a suitable location.

40015784

74 12. Carefully work the headliner from the cab roof. Allow the headliner to sit on the steering wheel. Adjust the steering wheel as required to stabilize the headliner. NOTE: The headliner cannot be removed from the cab.

40015785

90-26

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 13. Remove the clamping cap screw and nut, 1, from the wiper linkage, 2. Pull the linkage clamp from the wiper motor shaft.

NOTE: Two people are required to properly remove the wiper motor from its mount. 14. Turn out the three mounting cap screws, 3, and take the wiper motor from the machine.

40015786

3 76

Installation

NOTE: Two people are required to properly attach the wiper motor to its mount.

1. Set the wiper motor against its mount on the outside of the combine. Turn in three cap screws and lock washers, 1, to secure the motor. 2. Orient the clamp, 2, to be in line with the linkage, 3. Tighten the clamp with a cap screw, lock washer and nut, 4. 40015786

1 77

3. Push the headliner up into place against the cab roof. Secure the headliner and sun visor, 1, with screws, 2.

40015784

90-27

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 NOTE: Ensure that the power and control wires, 1, for the courtesy lamp have been drawn through the hole in the center of the headliner. 4. Install the courtesy lamp.

40015787

79 5. Set the left panel into place. Secure the panel and headliner to the cab roof using screws, 1. Install the climate control panel at 2.

2 40015782

80 6. Set the right panel into place. Secure the panel and headliner to the cab roof using screws, 1. Install the components, 2, that had been previously removed.

2 40015781

90-28

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 7. Set the rear panel, 1, into place and secure to the headliner and cab roof using seven screws, 2.

1 40015780

82 8. Install the hanger using two screws. Push the cover, 1, into place.

40015779

83 9. Attach the power and control wires, 1, to the windshield wiper motor.

40015778

90-29

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 10. Connect the wiper fluid supply lines, 1, to the jets.

40015777

85 11. Set the cover into place and secure using three screws, 1.

1 86071381

STEERING COLUMN COVER

Removal NOTE: Raise the steering wheel to gain access to the top screws. 1. Turn out seven screws, 1, and pull the two halves of the cover from the steering column.

1 40015795

90-30

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 2. Pull the switches, 1, from the cover halves.

40015796

88 3. Turn off adjusting knob, 1. Capture the spring and sleeve. 4. Remove screws, 2, and take the cover halves from the steering column.

2 2

1 40015797

89 5. With the covers removed, all internal steering column components can be accessed.

40015798

90-31

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 Installation 1. Position the two lower halves of the steering column covers just above the boot so that pins, 1, are inside the covers.

40015798

91 2. Secure the lower covers to the columns using six screws, 1. Slide the sleeve and spring onto the threaded rod and turn on the adjusting knob, 2.

1 1

2 40015797

92 3. Install the switches, 1, into the cover halves.

40015796

90-32

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 NOTE: Raise the steering wheel to gain access to the top screws.

4. Install the upper cover halves using seven screws, 1.

1 40015795

STEERING COLUMN Removal

1. Pull the boot up from the cab floor mat. 2. Detach the two electrical connectors, 1. 3. Turn off the four lock nuts, 2. 4. Remove the steering column from the combine.

1 40015799

2 95

Installation 1. Slide the column onto its mount. 2. Secure the column to the combine with four lock nuts, 1.

3. Attach the two electrical connectors, 2. 4. Secure the boot to the cab floor mat.

2 40015799

1 96

90-33

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 RIGHT HAND CONSOLE

CAUTION Remove key, 1, from ignition before servicing the Right Hand Console. Tilted console top may come in contact with ignition key and cause it to rotate, bend, break off or accidentally start engine.

10024363

97 Removal 1. Remove three socket bolts and washers, 1, from under console.

1 86060926

98 2. Tilt top half of console, 1, upward to service the wiring and controls underneath.

1 10024362

90-34

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1 Installation 1. Replace console to upright position. Attach the console with three previously removed washers and bolts, 1.

1 86060926

100

OUTSIDE CAB ROOF LIGHTS

Replacement 1. Replacement of the cab roof lights is performed by removing cover, 1. Remove the defective bulb and insert a new one. Install the cover to complete replacement.

40015800

101

90-35

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 1

90-36

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2

SECTION 90 - PLATFORM, CAB, BODYWORK, DECALS Chapter 2 - Shielding and Ladders CONTENTS Section

Description

Page

90-1

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 OVERHAUL SIDE SHIELD Removal

NOTE: The left side is shown, the right side is similar. 1. On the left side only, unplug connector, 1, for the under shield work light. Remove wire harness from shield by removing the wire clamps, 2.

2 86071382

1 2. Support the combine side shield open with an appropriate lifting device.

10024364

2 3. Remove the nut and cap screw, 1, and allow the opener, 2, to rest on the ground.

2 1

10024365

90-2

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 4. Remove nut, 1, and disengage cable end from the operating mechanism. Loosen the jam nut, 2.

5. Remove the four cap screws, 3, and take the opener from the combine. Store the opener in a suitable location. 6. Carefully lower the side shield until it is vertical. Remove the lifting gear used to support the side shield.

10012174

4 NOTE: The weight of the combine side shield is approximately 68 kg (150 lbs).

CAUTION The side shield is heavy and awkward. Improper handling of the side shield during removal could cause serious injury.

7. Attach the appropriate lifting equipment to the combine side shield hinges, 1, as shown. Support the weight of the side shield with a tow motor and disengage the hinges. Store the side shield in a suitable location.

10012176

Installation NOTE: The weight of the combine side shield is approximately 68 kg (150 lbs).

CAUTION The side shield is heavy and awkward. Improper handling of the side shield during installation could cause serious injury. 1. Attach the appropriate lifting equipment to the combine side shield hinges and set the side shield into place. Insert the hinge pins and secure them in place using cotter pins.

10012176

90-3

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 2. Using the appropriate lifting equipment, raise the combine side shield until it is open.

3. Secure the opener to the combine using four cap screws, 1, with the cap screws in the mid position of the slotted holes. 4. Connect the operating cable, 2, mechanism and secure with nut, 3.

the

2 3

10012174

7 5. Raise the inside end of the opener and attach it to the combine with a nut and cap screw, 1.

10024365

8 NOTE: Shield height may be adjusted for tire options or operator preference at locations, 1.

10024365

90-4

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 6. Remove the lifting equipment used to hold the side shield open.

7. Adjust the four jam nuts, 1, as necessary to obtain a distance of 30 - 32 mm (1-1/8 - 1-1/4 in) from the top of the latch handle, 2, to the top of the handle, 3. Tighten the jam nuts to maintain this position.

20015731

10 8. On the left side only, route the wire harness and secure in place with wire clamps, 1. Plug connector, 2, into the under shield work light.

9. Place the side shield in the desired position.

1 86071382

11 Gas Strut Replacement NOTE: The left side is shown, the right side is similar. 1. Support the combine side shield open with an appropriate lifting device.

10024364

90-5

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 2. Remove the nut and cap screw, 1, and allow the opener, 2, to rest on the ground.

2 1

10024365

13 3. Remove nut, 1, and disengage cable end from the operating mechanism. Loosen the jam nut at 2.

4. Remove the four cap screws, 3, and take the opener from the combine.

10012174

14 5. Remove clip, 1, from the end of the cable. Loosen jam nuts, 2, and detach the cable from the opener.

6. Remove the spring, 3, from the opener.

2 20015732

1 15

90-6

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 7. Pull the cotter pin, 1, from the pivot, 2.

20015733

16 8. As the pivot, 1, is being withdrawn, set aside each piece.

20015734

17 9. Remove the cotter pin, 1, and withdraw the pivot, 2, from the assembly.

20015735

90-7

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 10. Slide the defective strut, 1, from the assembly.

20015736

19 11. Insert the replacement strut, 1, into the assembly. Slide the pivot, 2, through the end and secure using a washer and cotter pin at 3.

3 20015735

20 12. Place the mounting frame under the rod ends of the struts with the long end, 1, toward the struts.

13. Slide the pivot, 2, through the frame and one rod end. Set the locking lever, 3, next to the first strut and continue to insert the pivot through the frame.

3 20015734

2 21

90-8

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 14. Position the spring mount, 1, and second strut, 2, on the pivot.

20015734

22 15. Set the channel, 1, into place and slide the pivot, 2, the rest of the way in. Secure the pivot with a washer and cotter pin at 3.

20015733

23 16. Attach the cable to the locking lever with pin clip, 1. Turn the jam nuts, 2, until finger tight. Install spring, 3.

2 20015732

1 24

90-9

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 17. Secure the opener to the combine using four cap screws, 1, with the cap screws in the mid position of the slotted holes. 18. Connect the operating cable, 2, mechanism and secure with nut, 3.

the

2 3

10012174

25 19. Raise the inside end of the opener and attach it to the combine with a nut and cap screw, 1.

10024365

26 NOTE: Shield height may be adjusted for tire options or operator preference at locations, 1.

10024365

90-10

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 20. Remove the lifting equipment used to hold the side shield open.

21. Adjust the four jam nuts, 1, as necessary to obtain a distance of 30 - 32 mm (1-1/8 - 1-1/4 in) from the top of the latch handle, 2, to the top of the handle, 3. Tighten the jam nuts to maintain this position.

22. Place the side shield in the desired position.

20015731

REAR LADDER Removal 1. Set the ladder in the up position. Lock the ladder in the up position by using a chain, large hose clamp or other appropriate device at 1.

2. Support the ladder from above with a tow motor or hoist.

10024366

29 NOTE: The ladder shown may not be identical to your particular model.

CAUTION Substantial force is being exerted on the pivot pin by the strut. Personal injury may result if the pin is not removed cautiously. 3. Remove the cotter pin, washer and pivot pin, 1, from the lower strut connection. 20015738

90-11

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 CAUTION The ladder is heavy and awkward. Use the proper equipment to support the ladder while removing the mounting blocks, 1.

2 1 1

4. Remove hardware, 2, and carefully remove the ladder from the combine.

20015739

2 31

Installation

CAUTION The ladder is heavy and awkward. Use the proper equipment to support the ladder while installing the mounting blocks, 1.

1 1

1. Using the proper lifting equipment, set the ladder in place. 2. Secure the ladder in place using mounting blocks, 1, and previously removed hardware, 2. 20015739

2 32

NOTE: The ladder shown may not be identical to your particular model.

CAUTION Substantial force is being exerted by the strut. Personal injury may result if the pin is not installed cautiously. 3. Install the pivot pin, washer and cotter pin at 1. 20015738

90-12

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 4. Remove the chain or other clamping device from 1. 5. Perform the steps in the Rear Ladder Adjustment section.

10024366

34 Rear Ladder Adjustment

1. Set the ladder in the down position. 2. Adjustments to the ladder are to be made using the cap screw/jam nut assemblies at 1.

20015740

35 3. The cap screw/jam nut assemblies are to be adjusted so that the top rung of the ladder, 1, sits squarely and evenly into channel, 2.

4. Tighten all cap screw/jam nut assemblies when all adjustments are complete.

20015741

2 36

90-13

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 5. Shown is a properly adjusted ladder.

20015742

37 Strut Replacement 1. Set the ladder in the up position. Lock the ladder in the up position by using a chain, large hose clamp or other appropriate device at 1.

10024366

38 NOTE: The ladder shown may not be identical to your particular model.

CAUTION Substantial force is being exerted on the pivot pin by the strut. Personal injury may result if the pin is not removed cautiously. 2. Remove the cotter pin, washer and pivot pin, 1, from the lower strut connection. 20015738

90-14

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 3. Remove the cotter pin, washer and pivot pin, 1, from the upper strut connection. Lift the strut, 2, from the combine.

4. Install the new strut to the upper connection with a pivot pin, washer and cotter pin at 1.

20015743

40 NOTE: The ladder shown may not be identical to your particular model.

CAUTION Substantial force is being exerted by the strut. Personal injury may result if the pin is not installed cautiously. 5. Install the pivot pin, washer and cotter pin at 1. 20015738

41 6. Remove the chain or other clamping device from 1.

10024366

90-15

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 FRONT LADDER Removal If necessary pull down on the ladder latch handle, 1, and pivot the ladder to its side position.

1 10031261

43 1. On the left side of the combine, disconnect the position light connector, 1, and auxiliary power connector, 2. Cut all plastic cable tie straps, 3, that hold the wiring harness, 4, to the tie base, 5. 2. Pull the wiring harness through the slots of the ladder platform frame. Record the exact routing of the wiring harness before removing it. 3. Move the wiring harness away from the ladder platform to ensure the platform can be moved without damaging the wiring harness.

86064099

44 4. Loosen the two nuts, 1, on the three plates, 2, beneath the ladder platform, 3, but do not remove the plates.

1 3

10033169

2 45

90-16

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 5. Remove the left half-front panel by first raising the left side panel to gain access. Remove the two bolts, 1, and then the two bolts, 2. Remove the windshield washer fluid container and mounting bracket by removing the two bottomflange mounting bracket bolts, 3, from the platform deck.

1 3

56064100

86064102

46 6. Loosen and remove the two bolts, 1, that secure the left half-front panel to the ladder platform, 2. Loosen the two upper bolts, 3, which secure the brackets to the front left shield. Loosening the four bolts allows the two brackets to “swing” away from the ladder platform so this platform can easily slide away from the platform extension.

86064101

3 86064103

47 7. Remove the M10 x 20 mm bolts, 2, and M10 x 25 mm bolts, 3, lock washers, washers and nuts that secure the ladder platform, 1, to the platform extension.

CAUTION The ladder is heavy and awkward. Exercise care when handling the ladder. Failure to comply could result in serious injury. 8. Using an appropriate lifting device, lift up on ladder slightly and slide ladder platform off the combine.

90-17

3 1 10033169

4 48

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 Installation

CAUTION The ladder is heavy and awkward. Exercise care when handling the ladder. Failure to comply could result in serious injury.

1 4 5

1. Using an appropriate lifting device, align ladder platform arm, 1, with plates, 2, and slide ladder platform into place. 2. Secure the ladder platform, 3, to the platform extension, and the extensions to each other, with M10 x 20 mm bolts, 4, and M10 x 25 mm bolts, 5, lock washers, washers and nuts.

3 2

10033169

3. Tighten the two nuts on each plate, 2. 4. Tighten the two upper bolts, 3, which secure the brackets. Install and tighten the two bolts, 1, that secure the brackets to the ladder platform, 2.

86064101

3 86064103

50 5. Install the windshield washer fluid container and mounting bracket by installing and tightening the two bottom-flange mounting bracket bolts, 3, into the platform deck. Install the left half-front panel by first reinstalling the two face bolts, 2, and then the two bracket bolts, 1.

1 3

56064100

2 86064102

90-18

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 6. Reroute the wiring harness, 4, through the slots of the platform. 7. Connect the harness to the auxiliary power outlet, 2, and to the position light connector, 1. 8. Bundle any excess length of the wiring harness beneath the ladder platform and secure with a cable tie strap, 3, supplied in the kit. Check the lamp assembly for correct operation.

86064099

PLATFORM EXTENSION Removal If necessary pull down on the ladder latch handle, 1, and pivot the ladder to its side position.

1 10031261

53 1. On the left side of the combine, disconnect the position light connector, 1, and auxiliary power connector, 2. Cut all plastic cable tie straps, 3, that hold the wiring harness, 4, to the tie base, 5. 2. Pull the wiring harness through the slots of the ladder platform frame. Record the exact routing of the wiring harness before removing it. 3. Move the wiring harness away from the ladder platform to ensure the platform can be moved without damaging the wiring harness.

86064099

90-19

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 4. Loosen the two nuts, 1, on the three plates, 2, beneath the ladder platform, 3, but do not remove the plates.

1 3

10033169

55 5. Remove the left half-front panel by first raising the left side panel to gain access. Remove the two bolts, 1, and then the two bolts, 2. Remove the windshield washer fluid container and mounting bracket by removing the two bottomflange mounting bracket bolts, 3, from the platform deck.

1 3

56064100

86064102

56 6. Loosen and remove the two bolts, 1, that secure the left half-front panel to the ladder platform, 2. Loosen the two upper bolts, 3, which secure the brackets to the front left shield. Loosening the four bolts allows the two brackets to “swing” away from the ladder platform so this platform can easily slide away from the 150 mm (5-7/8 in) platform extension.

86064101

3 86064103

90-20

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 7. Remove the M10 x 20 mm bolts, 2, and M10 x 25 mm bolts, 3, lock washers, washers and nuts that secure the ladder platform, 1, to the platform extension, or the extensions to each other.

3 2

NOTE: Always remove extension closest to ladder platform. 8. Remove the 250 mm (9-13/16 in) wide platform extension. Lift up on ladder slightly and slide ladder platform back into place. 9. Relocate plates, 4, beneath the platform extension as needed. Secure them by tightening the two nuts on each plate.

1 4

10033169

10. Insert the two M10 x 25 mm bolts, 1, washers and nuts that secure the front left panel bracket to the extensions. Tighten the two upper bolts, 3, which secure the brackets. Tighten the two bolts, 1, that secure the brackets to the ladder platform, 2.

86064101

3 86064103

59 11. Install the windshield washer fluid container and mounting bracket by installing and tightening the two bottom-flange mounting bracket bolts, 3, into the platform deck. Install the left half-front panel by first reinstalling the two face bolts, 2, and then the two bracket bolts, 1.

1 3

56064100

2 86064102

90-21

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 12. Secure the 250 mm (9-13/16 in) platform extension, 1, to the 150 mm (5-7/8 in) extension platform, 2, with M10 x 20 mm bolts, 3, and M10 x 25 mm bolts, 4, washers, lock washers and nuts. Repeat the above to secure the outer extension to the inner extension.

4 1 3

2 10033168

61 13. Reroute the wiring harness, 4, through the slots of the platform. 14. Connect the harness to the auxiliary power outlet, 2, and to the position light connector, 1. 15. Bundle any excess length of the wiring harness beneath the ladder platform and secure with a cable tie strap, 3, supplied in the kit. Check the lamp assembly for correct operation.

86064099

62 16. Install the two safety chains, 1, using two chain links, 2, on the hand rail, and two spring chain links, 3, to the cab.

66062074

90-22

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 17. Make sure safety chain WARNING decal, 1, is attached to the upper chain.

1 87385554

64 Installation If necessary pull down on the ladder latch handle, 1, and pivot the ladder to its side position.

1 10031261

65 1. On the left side of the combine, disconnect the position light connector, 1, and auxiliary power connector, 2. Cut all plastic cable tie straps, 3, that hold the wiring harness, 4, to the tie base, 5. 2. Pull the wiring harness through the slots of the ladder platform frame. Record the exact routing of the wiring harness before removing it. 3. Move the wiring harness away from the ladder platform to ensure the platform can be moved without damaging the wiring harness.

86064099

90-23

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 4. Loosen the two nuts, 1, on the three plates, 2, beneath the ladder platform, 3, but do not remove the plates.

1 3

10033169

67 5. Remove the M10 x 25 mm bolts, washers, lock washers and nuts that secure the ladder platform, 1, to the 150 mm (5-7/8 in) extension platform, 2. Close the cab door.

2 1

20033167

68 6. Remove the left half-front panel by first raising the left side panel to gain access. Remove the two bolts, 1, and then the two bolts, 2. Remove the windshield washer fluid container and mounting bracket by removing the two bottomflange mounting bracket bolts, 3, from the platform deck.

1 3

56064100

2 86064102

90-24

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 7. Loosen and remove the two bolts, 1, that secure the left half-front panel to the ladder platform, 2. Loosen the four upper bolts, 4, which secure the brackets to the front left shield. Loosening the four bolts allows the two brackets to “swing” away from the ladder platform so this platform can easily slide away from the 150 mm (5-7/8 in) platform extension.

86064101

3 86064103

70 8. Lift up on the ladder, 1, slightly while pulling the ladder platform, 2, away from the combine, 3, until there is enough space to install the two 250 mm (9-13/16″) wide platform extensions. Lifting the ladder helps to slide easily the ladder platform away from the stationary 150 mm (5-7/8″) platform extension platform assembly that is bolted to the combine frame. Install the two 250 mm (9-13/16″) platform extensions on top of the arm, 4, and slide the platform extension towards the 150 mm (5-7/8″) platform extension until the two butt together.

1 4

ZDA6833A

71 9. Secure the 250 mm (9-13/16″) platform extension, 1, to the 150 mm (5-7/8″) extension platform, 2, with M10 x 20 mm bolts, 3, and M10 x 25 mm bolts, 4, washers, lock washers and nuts. Repeat the above to secure the outer extension to the inner extension.

4 1 2

10033168

90-25

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 10. Lift up on ladder slightly and slide ladder platform back into place. 11. Secure the ladder platform, 1, to the platform extension, and the extensions to each other, with M10 x 20 mm bolts, 2, and M10 x 25 mm bolts, 3, lock washers, washers and nuts.

3 2

12. Relocate plates, 4, beneath the platform extension as needed. Secure them by tightening the two nuts on each plate.

1 4

10033169

73 13. Install the front handrail, 1, to the outer extension, 2, and secure with two M10 x 30 mm and two M10 x 40 mm bolts, washers, lock washers and nuts.

2 20045833

74 14. Install the rear handrail, 1, to the outer end of the ladder platform using the four M10 x 25 mm bolts, washers, lock washers and nuts, 2.

10033170

90-26

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2 15. Tighten the two upper bolts, 3, which secure the brackets. Install and tighten the two bolts, 1, that secure the brackets to the ladder platform, 2.

86064101

3 86064103

76 16. Install the two safety chains, 1, using two chain links, 2, on the hand rail, and two spring chain links, 3, to the cab.

66062074

77 17. Make sure safety chain WARNING decal, 1, is attached to the upper chain.

1 87385554

90-27

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 2

90-28

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3

SECTION 90 - PLATFORM, CAB, BODYWORK, DECALS Chapter 3 - Blow Off System CONTENTS Section

Description

Page

90-1

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3 SPECIFICATIONS MODELS

CR9070

CR9040 -- CR9060

SUPPLIER

WABCO COMPRESSOR 412 352 008 0

WABCO COMPRESSOR 911-153-010-0

TYPE

Single cylinder flange mounted compressor (gear to gear engagement)

DRIVE GEAR

36 helical teeth

42 helical teeth

OPERATING PRESSURE (MAX)

14 bar (203 psi)

BORE

∅85 (3.35 in)

STROKE

62 (2.44 in)

36 (2.44 in)

SWEPT VOLUME

352 ccm (21.5 cubic inch)

AIR OUTPUT RATING

31.8 m3/hr (18.7 cfm)

TYPE OF OPERATION

NDR -- Normal pressure with unloadervalve (pressure relief valve)

LUBRICATION

UD -- Circulation system lubrication with connection to engine oil pressure.

OPERATING SPEED

3000 rpm (Maximum)

COOLING TYPE

WATER

COOLING FLOW

6 l/min (1.6 gpm)

UNLOADER VALVES

WABCO UNLOADER 975 303 072 0

CUT-OUT PRESSURE

8.3 -- 8.7 bar (120.4 -- 126.2 psi)

OPERATIONAL RANGE

0.7 -- 1.2 bar (10.1 -- 17.4 psi)

TEMPERATURE RANGE

--40° -- 150°C (--72° -- 270°F)

SAFETY VALVE

14 -- 14.3 bar (203 -- 207.4 psi)

AIR RESERVOIR WABCO 60 I

TYPE MAXIMUM OPERATING PRESSURE

10 BAR (145.1 PSI)

MAXIMUM OPERATING TEMPERATURE

100°C (212°F)

MINIMUM OPERATING TEMPERATURE

--50°C (--58°F)

CAPACITY

60 LITERS (15.85 US GALLONS)

90-2

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3

1 2

5 1

WABCO COMPRESSOR (412 352 008 0) FLANGE MOUNT (CR9070) Reference

Port

Port Name

Port Function

Inlet Port

Discharge Port

Expels pressurized air for system

Governor Port

Input from pilot line to allow compressor to idle

8.1

Oil Supply

Supplies compressor with lube oil from engine

8.2

Oil Drain

Allows lube oil to return to engine

9.1

Coolant

Receive coolant from engine

9.2

Coolant

Return coolant to engine

Supplies Compressor with clean intake air

90-3

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3

2 6

66060805

WABCO COMPRESSOR (911-153-010-0) FLANGE -- MOUNT (CR9040, CR9060) Reference

Port

Port Name

Port Function

Air Inlet

Discharge

Expels pressurized air for system

8.1

Oil Supply

Supplies compressor with lube oil from engine

Governor

Input from pilot line to allow compressor to idle

Coolant

Discharges coolant to engine

Coolant

Receives coolant from engine

Supplies compressor with clean air

90-4

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3

1 2

5 3

WABCO UNLOADER VALVE (975 303 072 0) FOR FLANGE MOUNT COMPRESSOR (CR9040 -- CR9060 -- CR9070) Reference

Port

Port Name

Port Function

Inlet

Outlet

Exhaust for compressor idling

Control Port

Auxiliary Supply

Auxiliary port not used in this application

Outlet for control impulse

Signal line to compressor governor port for compressor idle

Pressurized air “in” from compressor Pressurized air “out” to reservoir tank and blow off line quick connect port Discharge exhaust for excess pressure in system Controls valve function for system demand and pressure

90-5

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3 SPECIAL TOOLS 1. Use engine rotating tool 380000732 to rotate engine flywheel.

866060796

90-6

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3 DESCRIPTION OF OPERATION GENERAL

controlled by a sliding leaf valve. When system cut-in pressure is reached, air is exhausted from the unloader port.

The CR Combine blow off system is an optional accessory used to remove crop debris from the machine by using compressed air at high velocities through a hand operated nozzle attached to a length of hose.

4. After unloading, the unloader piston returns the sliding leaf valve to the loaded position. This seals the unloader ports and compression resumes.

The air compressor provides and maintains air under pressure to supply air for the blow-off system. It consists of two major subassemblies: Cylinder head and crankcase/cylinder block.

Air in the circuit is distributed through galvanized steel lines at two locations, one on the engine platform and the other near the air tank reservoir on the left hand side of the unit off of a shield bracket. Both locations are conveniently accessible to reach most areas of the machine, and use quick coupler connections where the supplied hose and hand operated air nozzle can be connected.

The cylinder head contains the inlet, discharge and unloader valving, as well as an integral relief valve. There are two water ports, marked Port 9, an air discharge port, marked Port 2, and an inlet port, marked Port 0. The cylinder head is mounted on the crankcase/cylinder block.

Specific Arrangement -- CR9040, CR9060 The flange mounted compressor is mounted to the housing on the front of the engine in an accessory port below the fuel injection pump. The compressor is driven off of the accessory drive using a direct gear to gear engagement. The compressor is plumbed to utilize resources from the engine such as, pre-filtered air from the engine’s intake manifold cover and engine coolant from water passages in the engine block. Oil for lubrication is also routed into the compressor through a hose from the engine, and returned back to the engine through a case drain in the compressor housing into the accessory drive housing.

The crankcase/cylinder block contains the cylinder bore, piston, bearings, crankshaft, governor port and connecting rod. The compressor is driven by the engine and its crankshaft turns continuously while the engine is running. Compression of air is controlled by the governor and by the compressor’s unloading mechanism. The governor maintains the system air pressure at preset maximum and minimum levels. The governor is mounted apart from the compressor, vertically. The governor port is located on the crankcase of the compressor.

Specific Arrangement -- CR9070 The flange mounted compressor setup is mounted to the housing on the rear of the engine in an accessory port above the starter motor. The compressor is driven off of the accessory drive using a direct gear to gear engagement. The compressor is plumbed to utilize resources from the engine such as, pre-filtered air from the engine’s intake supply and engine coolant from water passages in the engine block. Oil for lubrication is also routed into the compressor through an O-ring sealed port at the compressor mounting flange, and returned back to the engine through a case drain in the compressor housing into the accessory drive housing.

The unloader mechanism controls the air compression cycle. An air compression cycle has three phases: 1. Induction: Air flows from the engine to the compressor, opening an inlet valve in the cylinder head of the compressor. 2. Compression: Air pressure is increased, causing the compressor’s discharge valve to open. 3. Unloading: Air passes from the cylinder to the inlet chamber of the cylinder head via a port

90-7

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3 TROUBLESHOOTING Condition Compressor continuously cycles

No air delivery Low air delivery Low air pressure

Possible Cause

Solution

Governor air leak

Refer to the manufacturer’s manual for governor maintenance and troubleshooting procedures.

Air leak at governorcompressor attachment

Inspect connection for physical damage. Inspect and repair connection.

Excessive reservoir contamination

Drain reservoir.

Discharge line blockage

Check for freeze-up in the discharge line. Check for low spots and eliminate any traps in the discharge line. Inspect and repair compressor discharge port and clear any line restrictions. Check for carbon build-up. If present, make sure cooling lines are not kinked or restricted. If carbon has built up in the discharge line, replace line.

Noisy air compressor

Inlet line kinked or restricted

Inspect the compressor air induction line for kinks and restrictions. Repair or replace as necessary.

Governor malfunction or maladjustment

Check for correct loader/unloader cycles of compressor.

External contamination

Replace broken, defective or dirty air filters. Clean surface of compressor.

Chafed or worn discharge line

Replace faulty sections of discharge line.

Loose or leaking air line connections

Verify all connections are secure. Tighten to vehicle specifications where necessary. Inspect port threads for damage. If damage is extensive, replace cylinder head.

Loose accessory drive gear

Check fit of drive gear. Ensure hub is completely seated and crankshaft nut is tight. Inspect crankshaft for damage -- replace compressor if crankshaft is damaged.

Broken connecting rod or crankshaft

Oil starvation to crank pin or front main bearing.

90-8

Check oil pressure. Verify oil passage is free of obstructions. Make necessary repairs, possibly to include replace compressor.

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3 Condition Compressor leaks g engine coolant

Possible Cause

Solution

Loose fitting

Check fittings at compressor and engine for leaks and verify fittings are correctly torqued.

Cracked coolant port

Replace cylinder head.

Porosity in cylinder head

Replace cylinder head.

Leaking of gasket internal to the cylinder head

Verify cylinder head bolts are correctly torqued. Make necessary adjustments. Inspect gasket for cracks or signs of wear. Replace if necessary. Replace cylinder head.

Compressor head gasket failure

None of the above, but condition persists

Replace compressor.

Discharge line blocked due to freezing or carbon build-up

Check for trap (low spots) in lines. Make necessary repairs. Clear discharge line. Replace line if necessary. Check for carbon build-up. If carbon build-up is present, replace the discharge line.

Frozen or blocked line to governor

Clear blocked line. Replace line if necessary.

Governor malfunction

Repair or replace the governor. Refer to governor manufacturer’s maintenance manual for service information.

Incorrect cylinder head bolt torque, machining defect on cylinder head or block, defective cylinder head gasket

Inspect gasket. Replace if necessary. Verify all bolts are correctly torqued. If problem persists, replace cylinder head.

None of the above, but condition persists

Replace compressor cylinder head assembly.

Compressor leaks oil

Physical damage or internal problems with compressor

Replace the compressor.

Unloader leakage

Possible internal damage, including worn or damaged unloader piston O-ring, porosity in unloader piston bore, loose or leaking seal at unloader piston bore

Replace compressor cylinder head assembly.

Compressor pressury izes coolant system or coolant l lleakage k to compressor inlet

Leaking of gasket internal to the cylinder head

Inspect gasket. Replace if necessary.

Cavitation or corrosion in cylinder head

Replace cylinder head.

Porosity in cylinder head or cylinder head cracked

Replace cylinder head.

None of above, but condition persists

Replace the compressor.

90-9

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3 OVERHAUL CYLINDER HEAD Remove carbon deposits from the discharge cavity and rust and scale from the cooling passages of the cylinder head. Clean carbon and dirt from the inlet and unloader passages. NOTE: Shop air may be used to blow the carbon and dirt deposits from the unloader passages. Should it become necessary to tighten the compressor head bolts, proceed: 1. Tighten the four hex head bolts in sequence (1 – 2 – 3 – 4) to 25 N⋅m (18.4 ft-lb), then a further 90 degrees of rotation of each bolt, again in sequence (1 – 2 – 3 – 4).

66060802

5 Torx®

Torx®

2. Use a T--30 tool to tighten the five head screws in sequence (5 – 6 – 7 – 8 – 9) to 6 N⋅m (4.4 ft-lb), then a further 90 degrees rotation of each screw. INFORMATION: The cylinder head portion of the compressor is replaceable. The crankcase is not replaceable. If the crankcase is damaged or malfunctioning, replace the complete compressor.

66060803

90-10

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3 AIR COMPRESSOR -- CR9070 Removal

1. Remove hose, 1, from fitting, 2, at compressor and from tubing union, 3. 2. Disconnect small tube, 4, from elbow fitting at compressor.

66060807

7 3. Loosen clamp, 1, and remove elbow, 2, from fitting, 3, in compressor.

3 2 1

66060808

8 4. Drain sufficient coolant from engine cooling system to allow removal of coolant lines. Remove the coolant lines, 1 and 2, to the pump.

66060812

2 9

90-11

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3 5. Remove the air compressor pump, 1, from the engine by removing three Socket Head Cap Screws, 2. Make sure to capture seals, 3 and 4, as pump is pulled away from engine.

4 2

66060812

10 Installation 1. Install the drive gear, 1, and washer, 2, to the compressor pump, 3, and torque the nut, 4, to 135 -- 145 N⋅m (100 -- 107 ft-lb).

66060812

11 2. Install O-ring seal, 1, in recess at top of mounting flange with a dab of petroleum jelly. Mount the air compressor pump, 2, to the engine using three M12 x 50 mm Socket Head Cap Screws, 3. Be sure the gears mesh correctly, and the seal, 4, is installed.

4 66060812

3 12

90-12

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3 3. Install the tube, 1, from the rear of the compressor pump, 2, to the engine using hollow bolts, 6, and sealing washers on both sides of banjo fitting. Install the adapter fittings, 3, into the engine block and compressor head using sealing washers, 4. Install the coolant tube, 5, from the top of the compressor pump to the engine.

5 3 2

4 6

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13 4. Install straight fittings, 1 and 2, in rear of compressor head, using Loctite® 542t on threads. Install short hose, 3, to air tube outlet in previous step and connect tube, 5, using two clamps, 4. At compressor end of tube, 5, install elbow, 6, and install elbow on straight fitting, 1, using two more clamps, 4.

2 1 6 4

5. Install two clamps, 7, on existing hardware on front support of platform.

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14 6. Install straight fitting, 1, in M26 threaded air discharge port in end of compressor head using Loctite® 542t on threads. Install hose, 2, to fitting, 1, and install straight fitting, 3, in other end of hose.

7. Tighten all line fittings after all lines are connected and secured in place with clamps 8. Add engine coolant to cooling system per operator’s manual. 9. Start engine to charge system with air. Allow the air system to build pressure to governor cutout. Stop engine and use a soap and water solution at connection points to check for air leaks. Make any necessary repairs.

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SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3 AIR COMPRESSOR – CR9040, CR9060

Removal 1. Drain sufficient coolant from engine cooling system to allow coolant lines to be disconnected from compressor. 2. Remove two clamps, 1, that tie the two coolant tubes together. 3. Disconnect tubes, 2, from fittings. 4. Remove hose, 3, from elbow fitting in compressor. 5. Disconnect hose, 4, from fitting in air discharge port.

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6. Remove clamp, 1, and disconnect rubber elbow, 2, from beaded stem fitting on compressor head. 7. Remove fitting, 3, if replacing compressor.

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17 8. Remove four bolts, 1 and 2 and remove brace pieces, 3 and 4. 9. Remove the air compressor with gasket, 5, from the engine gear case by removing two flanged cap screws, 6, and hard washers, 7.

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6 18

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SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3 Installation IMPORTANT: To install adjustable O-ring fittings, follow this procedure: 1. Inspect components to ensure that male and female threads and sealing surfaces are free of burrs, nicks and scratches, or any foreign material. 2. Lubricate O-ring with light coat of system fluid or a compatible lubricant to help the O-ring slide smoothly into the port and avoid damage. 3. Back off lock nut as far as possible. Make sure back--up washer is not loose and is pushed up as far as possible to beginning of threads for lock nut. 4. Screw fitting into port until the back-up washer contacts the face of the port. Over tightening may damage washer. 5. To align the tube end of the fitting to accept incoming tube or hose assembly, unscrew the fitting by the required amount, but not more than one full turn. Using two wrenches, hold fitting in desired position and tighten locknut. IMPORTANT: Compressor must be timed to engine. 6. Set engine crankshaft position to TDC (top dead center) at cylinder #1. To verify this position, remove threaded plastic plug, 1, in front of timing gear cover and turn engine so timing mark on injection pump drive gear aligns with the TDC mark, 2.

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19 7. To rotate engine to TDC timing, remove plug, 1, in front side of flywheel housing.

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SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3 8. Use engine rotating tool 380000732 to rotate engine flywheel.

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21 9. Stand the air compressor on a bench and view it from the gear end. Rotate the gear so the “I” timing mark, 1, is at the three o’clock position, or aligned with a divot, 2, in the housing. Once the compressor is timed correctly, it may be installed on engine.

1 2

NOTE: There are two similar marks on the gear that look like “[I]” and “I”. The timing mark that is to be used is “I”.

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22 10. Mount the air compressor with gasket, 1, to the engine gear case and secure with two M12 x 35 flanged cap screws, 2, and hard washers, 3. Tighten to 77 N⋅m (57 ft-lb).

11. Replace plugs in timing gear cover and flywheel housing. 12. Loosely attach brace, 4, to compressor flange with two M10 x 30 flanged cap screws, 6, and loosely attach spacer, 5, to brace, 4, with two more of same screws. Loosely attach spacer, 5, to engine block with two M10 x 50 flanged cap screws. Tighten all screws to 43 N⋅m (32 ft-lb) while ensuring that all parts move to close up any gaps and support the compressor in a stress-free position. 13. Install straight fittings, 8 and 9, into compressor using Loctite® 542t on threads.

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6 23

SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3 14. Install O-ring elbow, 1, in compressor, making sure to lubricate O-ring to avoid damage.

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24 15. Install rubber elbow, 1, to beaded stem fitting, 2, on compressor head with clamp, 3, and connect rest of air supply line.

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25 16. Install two O-ring elbows, 1, into compressor head.

17. Install coolant line, 2, from left front fitting on compressor to lower fitting on head. 18. Install coolant line, 3.

19. Install 3/16 I.D. hose, 4, on elbow fitting installed in previous step, in compressor.

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4 26

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SECTION 90 -- PLATFORM, CAB, BODYWORK, DECALS -- CHAPTER 3 20. Connect hose, 1, to elbow fitting in block, 2. Make sure hose is not kinked, twisted or rubbing any other tube, hose, or the compressor. 21. Install two clamps, 3, to tie the two coolant tubes together.

3 5

22. Install hose, 4, to fitting, 5, in air discharge port.

1 2 4

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27 23. Tighten all line fittings after all lines are connected and secured in place with clamps. 24. Add engine coolant to cooling system per operator’s manual. 25. Start engine to charge system with air. Allow the air system to build pressure to governor cutout. Stop engine and use a soap and water solution at connection points to check for air leaks. Make any necessary repairs.

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PERFORMANCE TESTING Test the air system as follows: 1. Connect the air blow-off hose to one of the outlet fittings, 1. 2. Bleed the system pressure down substantially. 3. Start engine and with engine running at full governed speed, the compressor should reach governor cutout pressure, then unload. 4. If the compressor does not reach governor cutout pressure, check for air leaks in the system. If engine RPM is per operator’s manual specifications, system plumbing leakage must be checked and, if necessary, repaired. For more complete troubleshooting info, refer to troubleshooting chart in this chapter. 5. If compressor fails to unload, verify proper governor operation.

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