New Holland FX25, FX28, FX38, FX45, FX48, FX58 Service Repair Manual 87051240 - PDF DOWNLOAD by www.heydownloads.com

FX25, FX45, FX28, FX38, FX48, FX58 REPAIR MANUAL COMPLETE CONTENTS SECTION 00 - GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SECTION 10 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SECTION 14 - LIVE P.T.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SECTION 21 - TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SECTION 23 - 4WD LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SECTION 25 - FRONT MECHANICAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SECTION 29 - HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 5 SECTION 33 - BRAKES AND CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SECTION 35 - HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SECTION 50 - CAB CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SECTION 55 - ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SECTION 60 - PRODUCT FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SECTION 64 - CUTTERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SECTION 70 - EJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

The following pages are the collation of the contents pages from each section and chapter of the FX25 -- FX58 Repair manual. Complete Repair part # 87051240. 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 FX25 -- FX58 Forage Harvesters.

87051246

7/04

SECTION 00 - GENERAL INFORMATION BOOK 1 - 87051241

Chapter 1 - General CONTENTS Section

Description

Page

00.000

General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Explanation of machine and attachment serial numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Units of measure -- conversion chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Drivelines and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Lubricant application guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SECTION 10 - ENGINE BOOK 1 - 87051241

Chapter 1 - Iveco Aifo Engine CONTENTS Section

Description

Page

10.101

Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10.106

Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10.218

Fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

10.242

Removal and installation of fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

10.400

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 14 -- LIVE P.T.O. BOOK 1 - 87051241

Chapter 1 - Main Drive Gearbox CONTENTS Section

Description

Page

14.100

Removal of the main drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal of shields and doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal of p.t.o. shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal of the battery box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal of the fuel reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removal of the main drive belt assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Removal of the hydraulic and the hydrostatic pump assembly . . . . . . . . . . . . . . . . . . . . . . 9 Removal of the main drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Replacing the rubber damper on the engine output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Splitting the main drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Disassembly and assembly of the components in the rear half of the gearbox . . . . . . . . . 14 Disassembly and assembly of the front half of the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . 19 Removal and disassembly of hydraulic clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Removal and installation of the pressure hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Replacing clutch plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Replacing the seals in the clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Removal and installation of the clutch driven shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Installation of the clutch into the gearbox half . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Connecting the two gearbox halves together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Installation of the main drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Installing the main drive gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Installation of the hydraulic and the hydrostatic pump assemblies . . . . . . . . . . . . . . . . 31 Installation of the main drive belt assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Installation of the fuel reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Installing the battery box and the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Installing the PTO shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Starting up the forage harvester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

SECTION 21 -- TRANSMISSION BOOK 1 - 87051241

Chapter 1 - Traction Gearbox CONTENTS Section

Description

Page

21.145

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Gearbox shafts and shifting diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassembly of traction gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Assembly of traction gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 23 -- 4WD LINES BOOK 1 - 87051241

Chapter 1 - 4WD Angle Gearbox CONTENTS Section

Description

Page

23.000

Removal from the base unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Disassembly of 4WD angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Assembly of 4WD angle gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation on base unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 25 -- FRONT MECHANICAL DRIVE BOOK 1 - 87051241

Chapter 1 - Final Drives CONTENTS Section

Description

Page

25.310

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Disassembly and assembly of final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 29 -- HYDROSTATIC TRANSMISSION BOOK 2 - 87051242

Chapter 1 -- Hydrostatic Transmission CONTENTS Section

Description

Page

29.212

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydrostatic circuit and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Filling and bleeding the hydrostatic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

29.216

Hydrostatic pump -- Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Operation of the multifunction valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hydrostatic motor -- Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SECTION 33 -- BRAKES AND CONTROL BOOK 2 - 87051242

Chapter 1 -- Brakes and Control CONTENTS Section

Description

Page

33.110

Parking brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

33.202

Replacement of the brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Brake cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bleeding the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassembly and assembly of brake shoes and discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION 35 -- HYDRAULIC SYSTEM BOOK 2 - 87051242

Chapter 1 -- General CONTENTS Section

Description

Page

35.000

Torque tables for hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

35.304

Disassembly and assembly of pump group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 35 -- HYDRAULIC SYSTEM BOOK 2 - 87051242

Chapter 2 -- Work Hydraulics -- Attachment Height Control CONTENTS Section

Description

Page

35.000

Circuit diagrams -- Attachment height control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

35.300

Hydraulic reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Low pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 High pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Non return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

35.304

Work hydraulics pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 High pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

35.410

Attachment height control valve (EMR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Attachment compensation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Hydropneumatic accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Attachment lift cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

SECTION 35 -- HYDRAULIC SYSTEM BOOK 2 - 87051242

Chapter 3 -- Work Hydraulics -- Base Unit CONTENTS Section

Description

Page

35.000

Circuit diagrams -- Base unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

35.310

Stack valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Load sensing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cutterhead reverse drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Spout rotation pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Quick release couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Spout lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SECTION 35 -- HYDRAULIC SYSTEM BOOK 2 - 87051242

Chapter 4 -- Steering Hydraulics CONTENTS Section

Description

Page

35.000

Circuit diagrams -- Steering hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

35.310

Steering hydraulics pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Steering cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 35 -- HYDRAULIC SYSTEM BOOK 2 - 87051242

Chapter 5 -- Low Pressure Hydraulics CONTENTS Section

Description

Page

35.000

Circuit diagrams -- Low pressure hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

35.300

Low pressure hydraulic reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Oil change and fill procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

35.310

Low pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Low pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Main drive belts tensioning cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Spout deflector cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

SECTION 35 -- HYDRAULIC SYSTEM BOOK 2 - 87051242

Chapter 6 -- Hi--Flow Hydraulics CONTENTS Section

Description

Page

35.000

Circuit diagrams -- Hi--flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 50 -- CAB CLIMATE CONTROL BOOK 2 - 87051242

Chapter 1 -- Cab Cimate Control CONTENTS Section

Description

Page

50.000

Correct use of the air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Storage maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

50.200

Air conditioning circuit and component specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Compressor clutch replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

50.206

Ventilation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 55 -- ELECTRICAL SYSTEM BOOK 3 - 87051243

Chapter 1 -- Electrical Circuits CONTENTS Section

Description

Page

55.000

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

55.100

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION 55 -- ELECTRICAL SYSTEM BOOK 3 - 87051243

Chapter 3 -- Wiring Diagrams FX NA CONTENTS Section

Description

Page

55.000

Wiring diagrams FX NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 55 -- ELECTRICAL SYSTEM BOOK 4 - 87051244

Chapter 4 -- Can Network Basics CONTENTS Section

Description

Page

55.000

General layout electronic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Can spy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Error codes messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Fault finding routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SECTION 55 -- ELECTRICAL SYSTEM BOOK 4 - 87051244

Chapter 5 -- Calibration CONTENTS Section

Description

Page

55.000

Machine calibration with Laptop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Machine calibration with PDT tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 55 -- ELECTRICAL SYSTEM BOOK 4 - 87051244

Chapter 6 -- Software Update CONTENTS Section

Description

Page

55.000

Software update with Laptop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Software update with PDT tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 55 -- ELECTRICAL SYSTEM BOOK 4 - 87051244

Chapter 7 -- Troubleshooting CONTENTS Section

Description

Page

55.000

Error messages overview -- Machine error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- Attachment height control error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 -- Caterpillar error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 List of Can identifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Detailed analysis per function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

SECTION 60 -- PRODUCT FEED BOOK 5 - 87051245

Chapter 1 -- Feed Rolls CONTENTS Section

Description

Page

60.103

Removal and installation of lower feed rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

60.107

Inspection between upper feed rolls and cutterhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Flip down upper feed rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Detaching -- attaching of attachment with upper feed rolls . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Removal -- installation of upper feed rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Disassembly and assembly of upper feed roll drive chain box . . . . . . . . . . . . . . . . . . . . . . . 22

SECTION 60 -- PRODUCT FEED BOOK 5 - 87051245

Chapter 2 -- Length-Of-Cut and Feed Roll Drive Gearbox CONTENTS Section

Description

Page

60.122

Gearbox shafts and shifting diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal of length-of-cut gearbox from the chopperbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Length-of-cut gearbox assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Length-of-cut gearbox disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Installation of length-of-cut gearbox on the chopperbody . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SECTION 60 -- PRODUCT FEED BOOK 5 - 87051245

Chapter 3 -- Electromagnetic Reversing Gearbox CONTENTS Section

Description

Page

60.165

Operation of electromagnetic reversing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removing the reversing gearbox from the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Disassembly and assembly of the electromagnetic clutch (type Warner) . . . . . . . . . . . . . . . 8 Burnishing procedure of the electromagnetic clutch (type Warner). . . . . . . . . . . . . . . . . . . . 11 Disassembly and assembly of the electromagnetic clutch (type Stromag) . . . . . . . . . . . . 13 Removal and installation of feed roll and attachment drive safety clutch . . . . . . . . . . . . . . 18 Disassembly and assembly of the reversing gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SECTION 64 -- CUTTERHEAD BOOK 5 - 87051245

Chapter 1 -- Chopping CONTENTS Section

Description

Page

64.000

Splitting of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Attaching and detaching the attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal -- installation of chopper body with A-frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removal -- installation of chopper body with hydraulic jack . . . . . . . . . . . . . . . . . . . . . . . . . 12

64.106

Removal -- installation of rotor and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

64.130

Removal -- installation of cutterhead gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Disassembly and assembly of cutterhead gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

64.150

Removal -- installation of shearbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Removal and installation of shearbar support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

SECTION 70 -- EJECTION BOOK 5 - 87051245

Chapter 1 -- Blower CONTENTS Section

Description

Page

70.000

Inspection between cutterhead and blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

70.120

Removal and installation of blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

70.100

Removal and installation of blower gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassembly and assembly of blower gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

SECTION 00 -- GENERAL INFORMATION Chapter 1 -- General CONTENT Section

Description

Page

00.000

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

GENERAL INSTRUCTIONS

IMPORTANT NOTICE All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND service technicians, in strict accordance with the instructions given and using any specific tools necessary. Anyone performing the operations described herein without strictly following the instructions is personally responsible for any eventual injury or damage to property.

to prevent damaging the seal lip on the shaft, position a protective guard during installation operations

O--RING SEALS Lubricate the O--RING seals before inserting them in the seats, this will prevent them from overturning and twisting, which would jeopardise sealing efficiency.

SEALING COMPOUNDS SHIMMING For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add up the recorder values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value indicated for each on shim.

ROTATING SHAFT SEALS

Apply one of the following sealing compounds on the mating surfaces marked with an X: RTV SILMATE, RHODORSIL CAF 1 or LOCTITE PLASTIC GASKET. Before applying the sealing compound, prepare the surfaces as follows: --

remove any incrustations using a metal brush;

thoroughly de--grease the surfaces using one of the following cleaning agents: trichlorethylene, petrol or a water and soda solution.

For correct rotating shaft seal installation, proceed as follows: --

before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes

BEARINGS When installing bearings it is advised to:

thoroughly clean the shaft and check that the working surface on the shaft is not damaged position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that they will deviate the fluid towards the inner side of the seal coat the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing lip and the dust lip on double lip seals with grease

insert the seal in its seat and press down using a flat punch, do not tap the seal with a hammer or mallet

whilst inserting the seal, check that the it is perpendicular to the seat; once settled, make sure that it makes contact with the thrust element, if required

heat the bearings to 80 to 90 0C before fitting on the shafts;

allow the bearings to cool before installing them from the outside.

SPRING PINS When fitting split socket spring pins, ensure that the pin notch is positioned in the direction of the force required to stress the pin. Spiral spring pins do not require special positioning.

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

SPARE PARTS Only use original NEW HOLLAND spare parts bearing the logo shown below.

Only original spare parts guarantee the same quality, duration and safety as they are the same parts that are assembled during production. Only original NEW HOLLAND parts can offer this guarantee. When ordering spare parts, always provide the following information: Before applying the sealing compound, prepare the surfaces as follows:

essential for reliable repair operations

accurately built and rigorously tested so as to offer efficient and long--lasting operation

By using these tools, Repair Personnel will benefit from: --

operating in optimal technical conditions

Forage Harvester model (commercial name) and serial number

obtaining the best results

engine type and number

saving time and effort

part number of the ordered part, which can be found in the ”Microfiches” or the ”Spare Parts Catalogue”, used for order processing

working in safe conditions

NOTE TOOLS The tools that NEW HOLLAND propose and illustrate in this manual are: --

specifically researched and designed for use with NEW HOLLAND Forage Harvesters

Wear limit values indicated for certain parts should be considered to be recommended, but not binding. The terms ”front”, ”rear”, ”right--hand” and ”left-hand” (when referred to different parts) are intended as seen from the driving position with the Forage Harvester in the normal direction of movement.

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

MOVING THE FORAGE HARVESTER WITH THE BATTERY REMOVED External power supply cables should only be connected to the respective positive and negative cable terminals, using efficient clamps that guarantee adequate and secure contact. Disconnect all services (lights, windshield wipers, etc.) before starting the Forage harvester. If the Forage harvester electrical system requires checking, carry out operations with the power supply connected. Once checking is completed, disconnect all services and switch off the power supply before disconnecting the cables.

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

SAFETY REGULATIONS WARNING AND DANGER SYMBOL This warning symbol points out important personal safety messages. Carefully read the following safety regulations and observe advised precautions in order to avoid potential hazards and safeguard your health and safety. In this manual the symbol is accompanied by the following key--words: WARNING -- Warnings concerning unsuitable repair operations that may jeopardise the safety of Repair personnel. DANGER -- Specific warnings concerning potential hazards for operator safety or for other persons directly or indirectly involved.

ACCIDENT PREVENTION

•

Most accidents or injuries that occur in workshops are the result of non--observance of simple and fundamental safety regulations. For this reason, IN MOST CASES THESE ACCIDENTS CAN BE AVOIDED by foreseeing possible causes and consequently acting with the necessary caution and care.

Do not carry out repair operations with someone sitting in the driver’s seat, unless the person is a trained technician who is assisting with the operation in question.

•

Do not operate the machine or use any of the implements from different positions, other than the driver’s seat.

•

Do not carry out operations on the machine with the engine running, unless specifically indicated.

•

Stop the engine and check that the hydraulic circuits are pressure--free before removing caps, covers, valves, etc.

•

All repair and maintenance operations must be carried out using extreme care and attention.

•

Service steps and platforms used in the workshop or elsewhere should be built according to standard accident prevention regulations.

•

Disconnect the batteries and label all controls to indicate that the Forage Harvester is being serviced. Any parts that are to be raises must be locked in position.

•

Do not check or fill fuel tanks, accumulator batteries, nor use starting liquid when smoking or near naked flames, as these fluids are inflammable.

•

Brakes are inoperative when manually released for repair or maintenance purposes. Use blocks or similar devices to control the machine in these conditions.

Accidents may occur with all types of machine, regardless of how well the machine in question was designed and built. A careful and judicious service technician is the best guarantee against accidents. Precise observance of the most basic safety rule is normally sufficient to avoid many serious accident

DANGER Never carry out any cleaning, lubrication or maintenance operations when the engine is running.

SAFETY URLE General guidelines •

Carefully follow specified repair and maintenance procedures.

•

Do not wear rings, wristwatches, jewellery, unbuttoned or loose articles of clothing such as: ties, torn clothing, scarves, open jackets or shirts with open zips that may remain entangled in moving parts. It is advised to wear approved safety clothing, e.g.: non--slip footwear, gloves, safety goggles, helmets, etc.

6 •

•

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 The fuel nozzle should always be in contact with the filling aperture. Maintain this position until filling operations are completed in order to avoid possible sparks caused by the accumulation of static electricity. Only use specified towing points for towing the Forage Harvester. Connect parts carefully. Make sure that all pins and/or locks are secured in position before applying traction. Never remain near the towing bars, cables or chains that are operating under load.

•

Do not smoke, use naked flames, or cause sparks in the area when fuel filling or handling highly inflammable liquids.

•

Never use naked flames for lighting when working on the machine or checking for leaks.

•

All movements must be carried out carefully when working under, on or near the Forage Harvester. Wear protective equipment: helmets, goggles and special footwear.

•

When carrying out checks with the engine running, request the assistance of an operator in the driver’s seat. The operator must maintain visual contact with the service technician at all times.

•

If operating outside the workshop, position the Forage Harvester on a flat surface and lock in position. If working on a slope, lock the Forage Harvester in position. Move to a flat area as soon as is safely possible.

•

Transport Forage Harvesters that cannot be driven using a trailer or a low--loading platform trolley, if available.

•

When loading or unloading the Forage Harvester from the trailer (or other means of transport), select a flat area capable of sustaining the trailer or truck wheels. Firmly secure the Forage Harvester to the truck or trailer and lock the wheels in the position used by the carrier.

•

Electric heaters, battery--chargers and similar equipment must only be powered by auxiliary power supplies with efficient ground insulation to avoid electrical shock hazards.

•

Damaged or bent chains or cables are unreliable. Do not use them for lifting or towing. Always use suitable protective gloves when handling chains or cables.

•

Always use suitable hoisting or lifting devices when raising or moving heavy parts.

•

Take extra care if bystanders are present.

Chains should always be safely secured. Make sure that the hitch--up point is capable of sustaining the load in question. Keep the area near the hitch--up point, chains or cables free of all bystanders.

•

Never pour gasoline or diesel oil into open, wide or low containers.

•

Maintenance and repair operations must be carried out in a CLEAN and DRY area. Eliminate any water or oil spillage immediately.

•

Never use gasoline, diesel oil or other inflammable liquids as cleaning agents. Use non--inflammable, non toxic commercially available solvents.

•

Do not create piles of oil or grease--soaked rags as they represent a serious fire hazard. Always store rags in a closed metal container. Before starting the Forage harvester or implements, make sure that the driver’s seat is locked in position. Also check that there are no persons within the Forage harvester or implement range of action.

•

Empty pockets of all objects that may fall unobserved into the Forage harvester parts.

•

In the presence of protruding metal parts, use protective goggles or goggles with side guards, helmets, special footwear and gloves.

•

Wear safety goggles with side guards when cleaning parts with compressed air.

•

Limit the air pressure to a maximum of 2.1 bar, according to local regulations.

•

Do not run the engine in confined spaces without suitable ventilation.

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 •

When welding, use protective safety devices: tinted safety goggles, helmets, special overalls, gloves and footwear. All persons present in the area where welding is taking place must wear tinted goggles. NEVER LOOK DIRECTLY AT THE WELDING ARC WITHOUT SUITABLE EYE PROTECTION.

•

Metal cables tend to fray with repeated use. Always use suitable protective devices (gloves, goggles, etc.) when handling cables.

•

Handle all parts carefully. Do not put your hands or fingers between moving parts. Wear suitable safety clothing -- safety goggles, gloves and shoes.

ELECTRICAL SYSTEMS •

If it is necessary to use auxiliary batteries, remember that both ends of the cables must be connected as follows: (+) with (+) and (--) with (--). Avoid short--circuiting the terminals. GAS RELEASED FROM BATTERIES IS HIGHLY INFLAMMABLE. During charging, leave the battery compartment uncovered to improve ventilation. Never check the battery charge using ”jumpers” (metal objects placed on the terminals). Avoid sparks or flames near the battery zone. Do not smoke to prevent explosion hazards.

•

Before servicing operations, check for fuel or current leaks.Eliminate any eventual leaks before proceeding with work.

•

Never charge batteries in confined spaces.Make sure that there is adequate ventilation in order to prevent accidental explosion hazards as a result of the accumulation of gases released during charging operations.

•

Always disconnect the batteries before performing any kind of servicing on the electrical system.

START UP •

Never run the engine in confined spaces that are not equipped with adequate ventilation for exhaust gas extraction.

•

Never place the head, body, limbs, feet, hands or fingers near fans or rotating belts.

HYDRAULIC SYSTEMS •

A liquid leaking from a tiny hole may be almost invisible but, at the same time, be powerful enough to penetrate the skin. Therefore,NEVER USE HANDS TO CHECK FOR LEAKS but use a piece of cardboard or wood for this purpose. If any liquid penetrates skin tissue, call for medical aid immediately. Failure to treat this condition with correct medical procedure may result in serious infection or dermatosis.

•

In order to check the pressure in the system use suitable instruments.

ENGINE •

Always loosen the radiator cap slowly before removing it to allow any remaining pressure in the system to be discharged. Filling up with coolant should only be carried out with the engine stopped or idling (if hot)..

•

Never fill up with fuel when the engine is running, especially if hot, in order to prevent the outbreak of fire as a result of fuel spillage.

•

Never check or adjust fan belt tension when the engine is running. Never adjust the fuel injection pump when the Forage Harvester is moving.

•

Never lubricate the Forage Harvester when the engine is running.

WHEELS AND TYRES •

Make sure that the tyres are correctly inflated at the pressure specified by the manufacturer. Periodically check the rims and tyres for damage.

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

•

Stand away from (at the side of) the tyre when checking inflation pressure.

REMOVAL AND RE--FITTING

•

Do not use parts of recovered wheels as incorrect welding brazing or heating may weaken and eventually cause damage to the wheel.

•

Never cut or weld a rim mounted with an inflated tyre.

Lift and handle all heavy parts using suitable hoisting equipment. Make sure that parts are sustained by appropriate hooks and slings. Use the hoisting eyebolts for lifting operations. Extra care should be taken if persons are present near the load to be lifted.

To remove the wheels, lock both the front and rear wheels. After having raised the Forage Harvester, position supports underneath, according to regulations in force.

•

Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing -- safety goggles, gloves and shoes.

•

Avoid twisting chains or metal cables. Always wear safety gloves when handling cables or chains.

•

Deflate the tyre before removing any objects that may be jammed in the tyre tread.

•

Never inflate tyres using inflammable gases, as this may result in explosions and injury to bystanders.

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 EXPLANATION OF MACHINE AND ATTACHMENT SERIAL NUMBERS

MACHINE SERIAL NUMBER

FX300-375-450/ FX9630-9640-9645

Series 01 to 14

FX25-45

Series 01 to 06

Example : n° 2901001

2901001: The first two digits identify the model: FX300 = 27 FX375 = 29 FX450 = 30 FX25 = 39 FX45 = 47

9630 = 19 9640 = 21 9645 = 22

FX300 = 27 FX375 = 29 FX450 = 30 FX28 = 13 FX38 = 14 FX48 = 15 FX58 = 16

FX25 = 39 FX45 = 47 FX28NA = 23 FX38NA = 24 FX58NA = 26

305033001 : The third digit indicates the product line. There are 5 product lines in Zedelgem: TX/TF combine harvesters: TC/L combine harvesters: Combine headers: Balers: Forage Harvesters:

1 2 3 4 5

305033001 : These 3 digits indicate the batch in which the machine was made. 305033001 : Product line number (5) and batch (033) together form the series number (5033).

2901001: The third and the fourth digit indicates the serie in which the machine was made. 2901001: The last 3 digits are a sequential number for each model within a serie.

305033001 : The last 3 digits are a sequential number for each model within a batch. Summarizing we can say that this machine is the first FX 450 of serie 5033.

So this machine is the first FX375 of serie 01.

ATTACHMENT SERIAL NUMBER PRODUCT IDENTIFICATION Example : n° 5320502 FX300-375-450/ FX25-45

Series 5033 to 5080

FX28-58 FX28NA-58NA

Series 8083 to ...

Example : n° 305033001

305033001: The first two digits identify the model within a product line:

5320502 : Code for header type 5320502 : Serie in which the machine was made. 5320502 : Attachment number and colour

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

AVAILABLE HEADERS 300N6 (Fiatagri): 300N6 (New Holland):

5320501 5320001

340WX, 350Wx, 360N These headers have a nonsequential serial numbering. For details ask your national service organization.

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 CONVERSION CHART Linear 1 mm

0.03937 in

1 in

25.4 mm

1 Km

0.6214 miles

1 mile

1.6093 km

3.281 ft

1 ft

0.3048 m

2.471 acre

1 acre

0.4047 ha

1 litre

0.0063 barrel

1 barrel

158.987 litre

1 litre

0.028 US bushel

1 US bushel

35.2391 litre

1 litre

0.2642 US gal

1 US gal

3.7853 litre

1 litre

1.057 US quart

1 US quart

0.9464 litre

1 mm3

0.061 in3

1 in3

16387 mm3

2.204 pound

1 pound

0.4536 kg

0.7376 lbf.ft

1 lbf ft

1.3558 Nm

1.358 hp

1 hp

0.746 kW

14.505 lbf/in2(psi)

1 lbf/in2(psi)

0.06894 bar

lbf/in2(psi)

6.894 kPa

Area 1 ha Volume

Weight 1 kg Torque 1 Nm Power 1 kW Pressure 1 bar

lbf/in2(psi)

1 kPa

0.145

1 pa

10 --5 bar

1 bar

100 kPa

((1.8 x ° C) + 32) ° F

1 °F

(0.56 x (° F -- 32))°C

Temparature 1 °C

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON-METRES -- Nm (FOOT POUNDS -- LBF. FT) FOR NORMAL ASSEMBLY APPLICATIONS

METRIC HARDWARE AND LOCKNUTS NOMINAL SIZE

PLATED W/ZnCr

UNPLATED

PLATED W/ZnCr

UNPLATED

PLATED W/ZnCr

LOCKNUT CL.8 W/CL8.8 BOLT

CLASS 5.8 UNPLATED

CLASS 8.8

CLASS 10.9

1.7 (15*)

2.2 (19*)

2.6 (23*)

3.4 (30*)

3.7 (33*)

4.8 (42*)

1.8 (16*)

5.8 (51*)

7.6 (67*)

8.9 (79*)

12 (102*)

13 (115*)

17 (150*)

6.3 (56*)

14 (124*)

18 (159*)

22 (195*)

28 (248*)

31 (274*)

40 (354*)

15 (133*)

M10

28 (21)

36 (27)

43 (32)

56 (41)

61 (45)

79 (58)

30 (22)

M12

49 (36)

63 (46)

75 (55)

97 (72)

107 (79)

138 (102)

53 (39)

M16

121 (89)

158 (117)

186 (137)

240 (177)

266 (196)

344 (254)

131 (97)

M20

237 (175)

307 (226)

375 (277)

485 (358)

519 (383)

671 (495)

265 (195)

M24

411 (303)

531 (392)

648 (478)

839 (619)

897 (662)

1160 (855)

458 (338)

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

PROPERTY CLASS

CLOCK MARKING

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON-METRES -- Nm (FOOT POUNDS -- LBF. FT) FOR NORMAL ASSEMBLY APPLICATIONS

INCH 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

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

SAE GRADE 8 UNPLATED or PLATED SILVER

PLATED W/ZnCr GOLD

14 (121*) 18 (157*) 28 (250*) 37 (324* ) 50 (37) 65 (48) 80 (59) 104 (77) 123 (91) 159 (117) 176 (130) 229 (169) 244 (180 ) 316 (233) 432 (319) 560 (413) 698 (515) 904 (667) 1048 (773) 1356 (1000)

LOCKNUTS GR.B w/GR5 BOLT

GR.C w/GR8 BOLT

NOMINAL SIZE

6.9 (61*) 14 (125* ) 26 (19) 41 (30) 61 (45) 88 (65) 122 (90) 217 (160) 350 (258) 523 (386)

9.8 (86*) 20 (176*) 35 (26) 57 (42) 88 (64) 125 (92) 172 (127) 306 (226) 494 (364) 739 (545)

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

GRADE IDENTIFICATION

GRADE A NO NOTCHES GRADE B ONE CIRCUMFERENTIAL NOTCH GRADE C TWO CIRCUMFERENTIAL NOTCHES

GRADE IDENTIFICATION GRADE A NO MARKS GRADE B THREE MARKS GRADE C SIX MARKS MARKS NEED NOT BE LOCATED AT CORNERS

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

DRIVELINES AND COMPONENTS Listed below and in the figure on the opposite page are all the forage harvester functional components and their drives. FX300-375-450 / FX9630-9640-9645 / FX25-45

Series 01 to 14 Series 5033 to 5080

The speeds and torques mentioned apply to the nominal engine speed of 1950 rpm. At this speed the engine will deliver its maximum power. Speed (rpm)/ Torque (Nm) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.

Lower front feed roll (or metal detector roll) Smooth roll Upper front feed roll Upper front feed roll drive chain

54-91-132-221 120-202-291-487 55-93-134-225

Upper rear feed roll Cutterhead Cutterhead gearbox Cutterhead drive shaft Blower Reversing gearbox drive shaft Main drive belt Cutterhead reverse drive hydraulic motor Engine Main drive transfer gearbox Hydrostatic pump Work hydraulics pump Steering hydraulics pump Low pressure hydraulics pump Electromagnetic clutch (forward drive) Electromagnetic clutch (reverse drive) Reversing gearbox Stop pawl wheel Cut-out clutch Blower gearbox Lower crop processor roll Upper crop processor roll Crop processor drive belt Feed rolls drive shaft Upper feed rolls slip clutch Length-of-cut gearbox Attachment drive p.t.o. shaft

98-164-237-396 1141 2568 686 (760) 1950 750 - 800 1950 2791 2791 2791 2791 1500 Nm 1500 Nm 497 (172 reverse) 1900 Nm 3780 3360 497 (172 reverse) 1000 Nm 383 (133 reverse)

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

52661

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

FX28-38-48 / FX28NA-38NA FX58 / FX58NA

Series 8083 to .... Series 8083 to ....

The speeds and torques mentioned apply to the nominal engine speed of 1950 rpm for FX28--38--48 or to the nominal engine speed of 2100 rpm for FX58. At this speed the engine will deliver its maximum power.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.

FX28-38-48 Speed (rpm)/ Torque (Nm)

FX58 Speed (rpm)/ Torque (Nm)

Lower front feed roll (or metal detector roll) Smooth roll Upper front feed roll Upper front feed roll drive chain

54-91-132-221 120-202-291-487 55-93-134-225

58-98-142-238 129-218-313-524 59-100-144-242

Upper rear feed roll Cutterhead Cutterhead gearbox Cutterhead drive shaft Blower Reversing gearbox drive shaft Main drive belt Cutterhead reverse drive hydraulic motor Engine Main drive transfer gearbox Hydrostatic pump Work hydraulics pump Steering hydraulics pump Low pressure hydraulics pump Electromagnetic clutch (forward drive) Electromagnetic clutch (reverse drive) Reversing gearbox Stop pawl wheel Cut-out clutch Blower gearbox Lower crop processor roll Upper crop processor roll Cop processor drive belt Feed rolls drive shaft Upper feed rolls slip clutch Length-of-cut gearbox Attachment drive p.t.o. shaft

98-164-237-396 1141

106-177-255-426 1229

2568 686 (760) 1950

2765 663 (735) 2100

750 - 800 1950

808 - 862 2100

2791 2791 2791 2791 1500 Nm (1100 lbf.ft) 1500 Nm (1100 lbf.ft)

3006 3006 3006 3006 1500 Nm (1100 lbf.ft) 1500 Nm (1100 lbf.ft)

497 (172 reverse) 1900 Nm (1400 lbf.ft)

535 (185 reverse) 1900 Nm (1400 lbf.ft)

3780 3360

4070 3620

497 (172 reverse) 1200 Nm (800 lbf.ft)

535 (185 reverse) 1200 Nm (800 lbf.ft)

383 (133 reverse)

412 (143 reverse)

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

52870

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

LUBRICANT APPLICATION GUIDE Item

Servicing interval Amount /unit [litres] ----

AMBRA GR9 or AMBRA GR75 MD

Change: -- after first 100 h -- every 300 h or annually

6.3

AMBRA HYPOIDE 90

Change: -- after first 100 h -- every 300 h or annually

4.3

Change: -- after first 100 h -- every 300 h or annually

1.4

Four-wheel drive gearbox

Change: -- after first 100 h -- every 300 h or annually

1.4

Traction gearbox

Change: -- after first 100 h -- every 600 h or annually

Steering axle Change: mechanical -- after first 100 h four-wheel -- every 600 h or drive annually [option]

Grease fittings Feed roll gearbox

Cutterhead gearbox

Reversing gearbox

Blower gearbox

Final drive gearbox

Item

Rear-wheel planetary drives [option]

10 h 50 h 100 h

NEW HOLLAND Brand name

Servicing interval

Change: -- after first 100 h -- every 600 h or annually

NEW HOL- Lubric- International LAND ant specification Specifica- grade tion NH710A NLGI2 or NH720A NLGI2 NH520A

SAE 80W-90

API GL5 MIL-L-2105D

AMBRA HYPOIDE 90

NH520A

SAE 80W-90

API GL5 MIL-L-2105D

AMBRA HYPOIDE 90

NH520A

SAE 80W-90

API GL5 MIL-L-2105D

AMBRA HYPOIDE 90

NH520A

SAE 80W-90

API GL5 MIL-L-2105D

AMBRA HYPOIDE 90

NH520A

SAE 80W-90

API GL5 MIL-L-2105D

AMBRA HYPOIDE 90

NH520A

SAE 80W-90

API GL5 MIL-L-2105D

AMBRA HYPOIDE 90

NH520A

SAE 80W-90

API GL5 MIL-L-2105D

AMBRA HYPOIDE 90

NH520A

SAE 80W-90

API GL5 MIL-L-2105D

Amount /unit [litres]

NEW HOLLAND Brand name

NEW HOLLAND Specification

Lubricant grade

International specification

AMBRA HYPOIDE 90

NH520A

SAE 80W-90

API GL5 MIL-L-2105D

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1 Item

Servicing interval

Amount /unit [litres]

Upper feed roll drive chain box

Change: -- after first 100 h -- every 600 h or annually

Chains Threaded rods Pivot points

-- weekly

Engine (oil + filters)

Check daily Change: -- after first 100 h FX28-38-48: -- every 300 h FX58: -- every 250 h

FX28-38 -48: 23

Change every two years

Reservoir: 0.5

Brake system

0.5

NEW HOLLAND NEW HOLBrand name LAND Specification AMBRA HYPOIDE 90

NH520A

Lubricant grade

International specification

SAE 80W-90

API GL5 MIL-L-2105D

Sparingly

AMBRA HYPOIDE 90

NH520A

SAE 80W-90

-- every 200 h -- every 200 h

API GL5 MIL-L-2105D

AMBRA SUPERGOLD MULTIGRADE

NH330G

SAE 15W-40

API CF4/SG

AMBRA SYNTFLUID 4 MULTIGRADE

NH800A

NHTSA 116 DOT4, ISO 4925

AMBRA HYDROSYSTEM 46HV

NH646H

ISO VG 46

DIN 51524 part 2

AMBRA HYDROSYSTEM 46HV

NH646H

ISO VG 46

DIN 51524 part 2

AMBRA HYDROSYSTEM 46HV

NH646H

ISO VG 46

DIN 51524 part 2

MIL-L-2104E

FX58: 34

System: 2 Hydraulic and hydrostatic system (oil + filters)

Check daily Change: -- after first 100 h -- every 600 h or annually

Main hydraulic clutch

Check daily Change: -- after first 100 h -- every 600 h or annually

High capacity rear hydraulics (oil + filter) [accessory]

Check daily Change: -- after first 100 h -- every 600 h or annually

Reservoir: 38 System: 93 Reservoir: 7 System: 10 Reservoir: 70 System: 77

SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1

SECTION 10 -- ENGINE -- CHAPTER 1

SECTION 10 -- ENGINE Chapter 1 -- Iveco Aifo Engine CONTENT Section

Description

Page

10.101

Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10.106

Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10.218

Fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

10.242

10.400

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 10 -- ENGINE -- CHAPTER 1

2 CYLINDER HEAD BOLTS

Cylinder head seal has a “TOP” mark. Oil cylinder head screws with UTOM oil and tighten to 150 Nm following sequence given in Figure 12. Repeat tightening at same torque. Now tighten the bolts in the same sequence over 2 x 120° in 2 steps.

52023

VALVE CLEARANCE Adjust the clearance between the rockers and the valves using wrench 1 and feeler gauge 2. Running clearance is intake 0.30 mm and exhaust 0.40 mm. Bring the cylinder to be adjusted at expansion stroke. The cylinder valves will be closed while the rockers of the symmetrical cylinders are balancing. Symmetrical cylinders are 1--6, 2--5 and 3--4. NOTE: When reassembling the engine, to adjust the clearance between the rockers and the valves faster, proceed as follows: 1. Rotate the crankshaft.

30365

2. Balance cylinder N° 1 valves and adjust the valves marked with an asterisk, following the sequence indicated in the scheme.

Cylinder N° 1

Intake

Exhaust

3. Balance valves of cylinder N° 6 and adjust the valves marked with an asterisk, following the sequence indicated in the scheme.

Cylinder N° 1

Intake

Exhaust

SECTION 10 -- ENGINE -- CHAPTER 1

FUEL INJECTORS Fuel injector components 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Exhaust union Washers Casing Washers Union Adjust washer Spring Cap Spacer Nozzle Retaining nut

51864

Injectors consists of a nozzle holder and a nozzle. The injector function is to admit atomised fuel under pressure into the combustion chamber. NOTE: The injectors are the same as used on the TX68 and TF78 combines but the calibration pressure is different!

Bench test and calibration To calibrate an injector means to give its spring such a load that the pressure preset for injection is necessary to lift up the nozzle needle. Correct calibration pressure is obtained by changing the adjusting washer 6 (Fig. 3) thickness, so as to suitably changes spring load 7. Injector 1 test and calibration are carried out using tool 2 (Ref. IVECO 99301116). The calibration value should be 250 +-- 08 bar. After calibration, verify the nozzle seal acting on the pump until the gauge indicates a pressure of 120 bar. Check that a pressure drop from 120 to 70 bar takes place in 4â&#x20AC;? to 20â&#x20AC;?. Injector mounting bolts torque: 21 Nm.

51865

SECTION 10 -- ENGINE -- CHAPTER 1

4 FUEL INJECTION PUMP Removal (Fig. 5 to 7)

1. Clean the pump area carefully. 2. Disconnect all components and assemblies which may interfere with the disassembly procedure in the injection pump area. 3. Disconnect the throttle control actuator. 4. Remove delivery pump 1.

55152

5. Unscrew the fittings of high--pressure lines 2 from both the pump and the injectors. 6. Remove the brackets used to secure lines 2 to the engine and move them inwards. 7. Remove fuel and oil supply lines 3 and return lines 4. 8. Disconnect all remaining lines. 9. Disconnect the engine stop solenoid cable 5. 10. Remove mounting bolts 6 and nuts 7. 11. Remove the pump carefully.

55153

12. Plug up all openings of the lines and pump carefully to avoid dust ingress.

WARNING Handle all components with great care. Do not insert your hands or fingers in between components. Wear appropriate safety clothing, including goggles, gloves and safety boots.

55159

SECTION 10 -- ENGINE -- CHAPTER 1

Installation 1. Make sure the O--ring seals are correctly fitted on the pump lubrication duct and distribution crankcase. 2. Slide the pump on the drive shaft ensuring the larger tooth and slot are properly matched. 3. Position the pump is such a way as to ensure that the slotted holes in the pump housing are properly aligned with the pump mounting studs. 4. Tighten nuts 7 and bolts 6. 5. Turn the flywheel until the injection timing 10 (Fig. 8) is accurately aligned with indicator 11. The advance for the different engine types is: the correct injection timing is stamped in the flywheel. 6. Reassemble fuel and oil lines and engine controls.

55155

SECTION 10 -- ENGINE -- CHAPTER 1

6 TIMING

If you have doubts about the exact timing you can verify the relationship between the start of the injection and the plunger position. 1. Remove the inspection cap 19 (Fig. 9) corresponding to plunger N° 1 from the pump. 2. Ensure plunger N° 1 is in the initial delivery position (IDP), i.e. lower position. 3. Use special tool 12 (Ref. IVECO 99365183), including gauge 13. Place the tool’s stem on top of the pump tappet.

55154

4. Pre--charge the gauge by 2 to 3 mm. 5. Turn the flywheel to find the lowest position of plunger N° 1. 6. Reset the gauge to zero. 7. Turn the flywheel by approximately half a turn in the opposite direction to normal rotation. 8. Now turn the flywheel the other way and check when the injection advance mark on the flywheel coincides with the window indicator, the plunger stroke should be:

55157

Engine hp

Timing degree

Piston travel mm

300 hp

19°

3.35 -- 3.55

375 hp

8°

5.00 -- 5.10

450 hp

8°

5.00 -- 5.10

9. If you obtain a different measurement: ---

---

Loosen bolts 15 (Fig. 10). Change the position of cam 16 (Fig. 10) in order to obtain the correct pre--stroke (375 and 450 hp only). On the 300 hp engine rotate plate 17 (Fig. 11). Check the stroke again and tighten nuts 15 to 100 Nm.

If a gauge is not available, the pump can be correctly timed by means of the overflow DROP SYSTEM.

55156

SECTION 10 -- ENGINE -- CHAPTER 1

Proceed as follows (Fig. 12): 1. Remove the electric stop and put the accelerator at maximum speed. 2. Close plunger outlets 2, 3, 4, 5, 6. 3. Position the throttle control lever on minimum (1/4 of its travel). 4. Connect hand pump 17 (Ref. IVECO 99365034) to the injection pump inlet port and close the pump outlet port. 5. Bleed the system.

55158

6. Position the flywheel so as to align the 8° or 19° mark (item 10 -- Fig. 8) with indicator 11. 7. Remove cap 19 (Fig. 9) and check that plunger N° 1 is in the initial delivery position, i.e. lower position. 8. Alternatively, check whether the valves of the N° 1 cylinder are closed. N° 6 cylinder valves will be balanced. If they are not, turn the engine crankshaft one full turn. 9. Turn the engine crankshaft clockwise about half a turn while looking at the flywheel. 10. Operate hand pump 17 while at the same time turning the engine crankshaft counterclockwise. NOTE: This procedure must be carried out slowly but steadily, with no interruptions. 11. Stop the crankshaft rotation as soon as fuel stops flowing from the N° 1 plunger connector. 12. Check that the 8° or 19° mark (item 10 -- Fig. 8) is aligned with indicator 11. If necessary, change position of cam 16 (Fig. 10 -- 375 and 450 hp) or plate 17 (Fig. 11 -- 300 hp). 13. Complete the procedure as described above under item 9 on previous page.

30361

SECTION 10 -- ENGINE -- CHAPTER 1

8 COOLING SYSTEM

The engine cooling system consists of a centrifugal pump driven by a crankshaft. Two thermostats on cylinder head outlet end 9 control the engine running temperature.

55160

Longitudinal section of water pump 1. 2. 3. 4. 5. 6. 7. 8.

Seal Pump body Seal Control gear Bearing Seal gasket Seal ring Wheel

51867

Coolant thermostat --

Beginning of opening: 79° C + 2° C

End of opening: 95° C

51866

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

SECTION 14 -- LIVE P.T.O. Chapter 1 -- Main Drive Gearbox CONTENT Section

Description

Page

14.100

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

REMOVAL OF THE MAIN DRIVE GEARBOX 1. Park the machine on a place where it is possible to reach with a forklift from the rear and the right-hand sides. There must also be about 1,5 m of free space above the rear end of the spout. 2. Stop the engine and remove the ignition key. 3. Apply the hand brake. 4. Switch off the battery switch.

DANGER Wait until all rotating parts have come to a complete stop before opening the safety guards.

Removal of shields and doors 5. Open door 1. Disconnect the wires to the rotary screen motor and the brush actuator. Lift away the door from the machine. 6. Remove shield 2 from the machine.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

7. Open door 1. Disconnect the wires to the rotary screen drive motor and the brush actuator and lift away the door. 8. Open doors 2 and 3 and remove them from the machine.

2 9. Pull out cover plates 1 and 2.

3 10. Remove PTO guards 1 and 2. 11. Disconnect cutterhead speed sensor 3 with its bracket. 12. Remove grease guard plate 1 Fig. 5.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

Removal of p.t.o. shafts 13. Remove the cutterhead drive shaft bolts at 4 Fig. 4. Remove the main drive shaft bolts at 4 and the conical bolt at 2. Remove shaft 3 from the machine.

NOTE: The cutterhead drive shaft is difficult to remove when the chopper body is installed on the forage harvester. However, it is possible to remove the rear half of the drive shaft and to lift it over the cutterhead gearbox to the front. Before disconnecting both drive shaft halves from each other, check whether the position marks are still visible. If not, make new marks.

14. Remove the 4WD shaft (if installed).

Removal of the battery box 15. Switch off main battery switch 2. 16. Remove cover 1 of the battery box.

6 17. Mark battery cables 1 and 2 and disconnect them. 18. Remove the batteries from the battery box. 19. Mark and disconnect all the other wires that come into the battery box at 3.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

20. Loosen the ten screws 1 that secure the battery box to the machine frame and the right--hand side platform.

DANGER Be careful when loosening these screws. Even without batteries in it, the battery box is quite heavy. Two persons are needed to do this job. 21. Pull the battery box carefully away from the forage harvester and do not damage the free wires. 22. Tie up the wires away from the working area so they do not get damaged.

Removal of the fuel reservoir 23. Remove fuel cap 1 together with the filler filter. 24. Drain the fuel reservoir through the filler opening by means of a pump, or by creating a siphon. The remaining fuel can be drained via the plastic screw on the deposit bassin (lowest part of the fuel reservoir).

NOTE: Take care not to spill fuel nor to pollute the drained fuel or the fuel reservoir. The plastic screw (with gasket) has to be reinstalled with a torque of 15 Nm (11 lbf. ft). When a forklift with long forks and a sufficient capacity is available, it is not necessary to drain all the fuel from the fuel reservoir.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

NOTE: Mark the items before removal so you can easily reconnect them later. 25. Disconnect the two electric connectors 2 from the fuel level sender Fig. 10 and 11.

26. Disconnect the two fuel pipes 1 from the fuel level sender Fig. 10 and 11.

27. Remove round plate 3 together with the fuel level sender Fig. 10 and 11. 10 28. Remove nut 5 and washer 4 Fig. 10 and 11 if installed. NOTE: IVECO engines: Fig. 10.

NOTE: CATERPILLAR engines: Fig. 11.

11 29. Remove the two screws 1 securing the water separator to the protection plate of the fuel reservoir.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

30. Remove clamp 1 (securing one of the hydraulic hoses coming from the steering cylinder to the protection plate of the fuel reservoir). 31. Support the fuel reservoir and the protection plate from underneath, for example with a forklift equipped with long lifter arms. Drive in the forklift arms preferably from the rear.

13 32. Remove the six screws 1 (four at the front, two at the rear) attaching the protection plate of the fuel reservoir to the frame of the machine.

14 33. Simultaneously loosen the nuts on the three rods 1 (two on the left--hand side and one on the right-hand side) to lower the fuel reservoir.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

34. If a forklift or a platform with a capacity of at least 5000 kg is available: lift the forage harvester rear end using the lift eyes on the rear bumper.

DANGER Make sure that the forage harvester can not move while lifting.

DANGER Make sure that the connections between the forklift or the platform and the lifting eyes are strong enough and that they are installed in a safe way. 35. Pull the fuel reservoir and its protection plate out to the rear.

36. If no forklift or platform is available, use a jack 1. 37. Install jack 1 under rear axle 2 on the right--hand side and remove the rear wheel. 38. Jack up the forage harvester until the fuel reservoir filler neck can pass under the forage harvester frame and pull out the fuel reservoir and its protection plate to the right--hand side of the machine.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

Removal of the main drive belt assembly 39. Remove plastic straps 1 from the wiring loom to the cutterhead speed sensor. 40. Remove upper protection plate 2 of the fuel reservoir. 41. Remove the main drive belt assembly as is described earlier in this section.

Removal of the hydraulic and the hydrostatic pump assembly 42. Drain the hydraulic and hydrostatic oil reservoir(s) through hoses 1.

NOTE: Note the correct routing of hoses and pipes. NOTE: Collect all oil that is dripping from the hydraulic components. IMPORTANT: Protect all hose endings, pipe endings and all pump ports from dirt. Any dirt in the system can cause severe damage to the system or even total destruction of pumps, valves, etc.

43. Disconnect hose 7 Fig. 20 and 3 Fig. 21 from the low pressure pump. 44. Disconnect hose 6 Fig. 20 and 4 Fig. 21 from the hydraulic pump for steering. 45. Disconnect hose 5 Fig. 20 and 5. Fig. 21 from the work hydraulic pump.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

46. Disconnect hoses 2, 3 and 4 from the left hand side of the hydrostatic pump Fig. 20. 47. Disconnect hose 6 underneath the hydrostatic pump (Fig. 21). 48. Disconnect the hydraulic pipe or (hose) 7 on the right hand side of the hydrostatic pump in both ends (Fig. 21). 49. Loosen or remove the hydraulic pipe 1 Fig. 20 and 21.

21 50. Disconnect the electric connector 1 from the right--hand side of the hydrostatic pump.

51. Disconnect hydraulic pipe 1 from the top of the main drive clutch housing. 52. Remove hydraulic pipe 2 from the machine. 53. Disconnect return oil hose 3 from the clutch housing. NOTE: Collect the oil coming from the low pressure circuit. NOTE: Drain the remaining oil (about 4 litres) through the plug at the bottom of the main drive gearbox housing. 54. Check that all connections to the pumps have been disconnected and nothing hinders the removal of the pumps. The pump group is heavy. Make sure it is well supported before removal.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

55. Remove the three bolts 1 and pull the pump group away from the gearbox.

24 Removal of the main drive gearbox 56. Remove screws, washers and nuts 1 and also the screws, washers and nuts on the sides. Remove the shielding plates 3, 2 and 4 between the engine and the main drive gearbox.

25 57. Remove all but the two upper screws 1 which secure the main drive transfer gearbox to the engine. 58. Check that no obstacle hinders the removal of the main drive transfer gearbox.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

59. Drive a fork lift or a cart with special tool 1 Fig. 27 and 28 or a jack underneath the main drive transfer gearbox and create a solid support between the main drive transfer gearbox and the supporting device. NOTE: The gearbox is heavy, about 125 kg. 60. Remove the two remaining screws 1 Fig. 26.

28 61. Pull the gearbox until the drive shaft is free from the coupler to the engine and remove the assembly from the machine as shown in Figure 27. 62. When placing the main drive gearbox on the floor or on a work table, protect input shaft splines 1 from damage with wooden blocks.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

REPLACING THE RUBBER DAMPER ON THE ENGINE OUTPUT SHAFT 63. Check the condition of the rubber vibration damper 3 whenever the main drive transfer gearbox or the engine are removed from the machine. If any signs of damage are visible then replace the damper. 64. Remove screws and washers 1 and lift away flange 2. 65. Note the position of the parts and dismount damper 3 from flange 2 and splined hub 4.

30 NOTE: The rubber dampers must be installed in a predetermined way. The wide end of the triangular mark 1 must be turned towards the nut.

31 66. Install the rubber damper 3 onto the splined hub 4. The sharp end of the triangular mark on the rubber damper must point towards the screw head 5. 67. Install the hub and rubber damper assembly 3, 4 onto the flange 2 and tighten up the damper fastening screws to a torque of 400 Nm (295 lbf. ft). 68. Install the pre--assembled flange 2 onto the flywheel of the engine and tighten screws 1.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

SPLITTING THE MAIN DRIVE GEARBOX 69. Install special tool 3, or a similar one. A chain can also be used. The important thing is that the upper gearbox half 1 is well balanced and stays parallel to the lower gearbox half 2. 70. Drive down, or remove guide pins 4 at both ends of the gearbox. 71. Remove all Allen screws 5.

33 72. Separate the two gearbox halves 1 and 2. NOTE: The gearbox halves are sealed with a liquid sealant and may be glued together.

DISASSEMBLY AND ASSEMBLY OF THE COMPONENTS IN THE REAR HALF OF THE GEARBOX 73. Pull out the shaft and gear assembly 3 from gearbox housing 2. 74. Pull out gear assembly 4 from gearbox half 2.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

75. Remove circlip 5 from the shaft and gear assembly 3. 76. Mark gear 6 so it can be reinstalled in the same way onto shaft 3 as when it was removed.

36 77. Press shaft 3 out from gear 6. 78. Pull away the bearing inner race from shaft 3.

37 79. Remove the bearing outer races 7 from gear 6. NOTE: There is a circlip between the bearings inside the gear. NOTE: The bearing inner races 8 must be installed with the wide edge to the outside.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

80. Install circlip 9 into the gear 6. 81. Drive bearing inner race 8 onto shaft 3. Note the wide side of the inner race should be seated against the shaft head. 82. Install bearing outer races 7 into gear 6. 83. Install gear 6 with bearing components 7 and 8 onto shaft 3. 84. Install circlip 5. 85. Install O--rings 10 and 11 onto shaft 3. 39 86. Remove bearings 12 and 13 from gear 4. 87. Install new bearings 12 and 13 onto gear 4. NOTE: The open bearing (no seals) 12 is installed on the shorter shaft side of gear 4. Bearing 13 with a seal on one side is installed on the longer shaft side of the gear 4 with the seal towards the end of the shaft.

40 88. Turn gearbox half 2 to the position shown in Figure 41 and support it well. 89. Remove Allen screws 1 and remove cover 3 over shaft 4.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

90. Remove seal 5 from cover 3. 91. Open up stake washer 6 and remove special nut 7 from shaft 4, with the special tool as shown in Figure 43.

42 92. Special tool 8.

43 93. Drive shaft 4 out of gearbox half 2. 94. Remove the two asymmetric bearings from gearbox half 2.

44 95. Remove Allen screws 2. 96. Remove gear 3 from shaft 4. 97. Remove outer clutch body 1 from shaft 4.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

98. Install outer clutch body 1 onto shaft 4. 99. Install gear 3 onto shaft 4. 100. Install Allen screws 2 and secure them in place. 101. Use a thread retainer when installing screws 2 Fig. 45 and 46. 102. Tighten screws 2 to a torque of 17 Nm (12.5 lbf. ft) Fig. 45.

46 103. Install the asymmetric bearings 1 into gearbox half 2. NOTE: The wide surfaces of the outer races of the bearings should touch each other, the narrow surfaces should be seated against the shoulder in gearbox half 2 and against locking nut 7. 104. Lift gearbox half 2 on top of the shaft assembly and drive the bearings onto shaft 4 using a suitable pipe.

47 105. Install washer 6 and special nut 7 and lock the bearings in place. Use special tool 8 Fig. 43.

48 106. Install new O-ring to cover 1. 107. Install cover 1 with the pre--installed seal. Install Allen screws 2 with some thread locking compound. 108. Tighten Allen screws 2 to a torque of 17 Nm (12.5 lbf. ft).

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

109. Turn the gearbox half 2 as shown in Figure 50 and support it well. 110. Pre--install gear assemblies 3 and 4 into gearbox half 2.

50 111. Install a new pilot bearing 1 into shaft 2.

DISASSEMBLY AND ASSEMBLY OF THE FRONT HALF OF THE GEARBOX Removal and disassembly of hydraulic clutch 112. Turn gearbox half 1 as shown in Figure 52 and support it well. 113. Remove bearing 4 from shaft 6. NOTE: Replace this bearing 4 every time the gearbox is opened up. Check shaft 6 for wear and replace if damaged. 114. Disconnect hydraulic hose 5 from gearbox housing 1. 52

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

115. Check circlips 2 and 3 Fig. 52. Replace if damaged. 116. Remove the circlip 1 from shaft 6.

53 117. Remove positioning screw 1 for the clutch pressure sleeve Fig. 54 and 55. NOTE: Replace this screw if damaged or bent.

54 118. Grip pressure sleeve 3 (a sleeve connected to hydraulic hose 2) and clutch assembly 4 Fig. 55 and 56 with both hands and lift the clutch assembly over the shaft and out from the gearbox housing half.

55 119. Sometimes clutch assembly 4 is so tight that a puller is needed. NOTE: Sleeve 3 is a matched part of clutch 4. If the sleeve is, or gets damaged a new clutch assembly needs to be installed Fig. 55.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

Removal and installation of the pressure hose NOTE: The sealing elements inside sleeve 3 Fig. 55 are made of a soft metal and are very sensitive to damage. Be careful not to damage them and oil the surfaces before assembly. NOTE: Mark sleeve 3 and clutch cylinder 4 before removing sleeve 3. The sleeve must be installed with the hole for the positioning screw 1 in a correct position. 120. Remove and discard the old hydraulic hose assembly 5. 121. Install the new hose assembly 5 onto the sleeve as shown in Figures 57 and 58 but do not tighten completely.

122. Loosen hose 5 at the connection to banjo 7 Fig. 57 and turn hose 5 as shown in Figure 58 (50 to 55_ from the horizontal plane) and then tighten into this position (25--30 Nm) (19 -- 22 lbf. ft).

58 123. Let sleeve 3 rest on clutch cylinder 4. 124. Adjust banjo connector 7 and hose 5 to the position shown in Figure 59. 125. Hose 5 should pass clutch cylinder 4 at a distance of 0,5 mm from the clutch as shown in Figure 59. 126. Tighten banjo connector 7 (52--58 Nm) (39 -- 42 lbf. ft) and hose 5 into this position.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

Replacing clutch plates 127. Remove Allen screws 1 from pressure plate 2. NOTE: The Allen screws 1 are installed with a thread retainer. 128. Install two M10 x 50 screws 3 and press up pressure plate 2.

60 129. Remove the old disc pack 4 and check inner body 6 for any damage. 130. Remove springs 5 and check them for any damage. 131. Clean holes 7 for the Allen screws from oil and dirt. 132. Install new disc pack 4. Install alternately ”inner” and ”outer” discs. The first and the last disc should be an inner disc.

61 133. Install springs 5 Fig. 61. 134. Install pressure plate 2 Fig. 62. 135. Use two M6 x 50 screws and two M6 nuts and washers as guiding and installation tools for the pressure plate. Press the pressure plate onto the inner body with the M6 nuts until Allen screws 1 can be installed. 136. Install Allen screws 1 with a thread locking compound and tighten to a torque of 17 Nm (12.5 lbf. ft). 62

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

Replacing the seals in the clutch 137. Mark sleeve 3 and clutch cylinder 4. 138. Remove sleeve 3 with a rotating movement from clutch cylinder 4. Do not use tools. NOTE: The sleeve is a matched part with the clutch cylinder. If the ring is worn, or damaged then replace the clutch cylinder.

63 139. Remove Allen screws 8 from clutch cylinder 4. NOTE: The Allen screws are installed with a thread locking compound.

64 140. Mark clutch cylinder 4 and clutch piston 9 in order to make a correct installation possible. 141. Install two screws M6 x 70 and press up the piston/cylinder assembly from the inner clutch body.

65 142. Check the condition of roll pins 1 and replace as necessary. 143. Mark the position of oil hole 2 close to one of the roll pins 1 and replace the O--ring if necessary.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

144. Carefully split piston 9 from cylinder 4. 145. Remove seal 5 and the two O--rings behind it .

67 146. Install O--rings 1 into groove 2 of the piston and make sure they are next to each other and not crossed. 147. Install seal 3 on top of the previously installed O--rings 1. NOTE: It is possible to install the seal without special tools.

68 148. Remove inner seal 1 and the O--ring behind it from the inner surface of the piston.

69 149. Install O--ring 1 into inner groove 2. 150. Install seal 3 into the groove on top of O--ring 1. NOTE: It is possible to install the seal without special tools.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

151. Check the condition of O--ring 1 and replace as necessary. 152. Mark the position of the oil hole and check that roll pins 2 are intact. NOTE: Pay attention: it is possible to install the â&#x20AC;?piston and cylinder assemblyâ&#x20AC;? 180_ wrong. It would be impossible to engage the clutch then. It is also possible to replace the clutch plates now.

71 153. Oil the parts and install piston 1 into cylinder 2.

72 154. Install piston/cylinder assembly 1 on to the clutch body. NOTE: Make sure that the oil channels are in the correct position. 155. Clean the holes for the Allen screws and install Allen screws 2 with a thread locking compound and tighten to a torque of 17 Nm (12.5 lbf. ft).

73 156. Lubricate and install sleeve/hose assembly 1 carefully with a rotating movement onto the clutch cylinder as shown in Figure 74. NOTE: Do not use tools for this installation.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

Removal and installation of the clutch driven shaft 157. Remove spacer bushings 1 and spacer washers 2 from shaft 3.

75 158. Press out shaft 2 from gearbox half 1. 159. Check the shaft for any wear or damage and replace as necessary.

76 160. Remove seal 2 from gearbox half 1. NOTE: The seal will be damaged at removal and must be replaced.

77 161. Remove circlip 2 from gearbox housing half 1. 162. Replace bearing 3 in gearbox housing. 163. Reinstall circlip 2. 164. Install a new seal 2 (Fig. 77).

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

165. Install and press shaft 2 into gearbox half 1.

79 Installation of the clutch into the gearbox half 166. Install two spacer washers 1 and two spacer bushings 3 onto shaft 2. 167. Screw in guide bolt 4 so it just enters inside the gearbox half.

80 168. Grip pressure sleeve 3, hydraulic hose 2 and clutch assembly 1 Fig. 81 and 82) with both hands and lift the clutch assembly over shaft 4. 169. Screw guide bolt 5 into the hole in sleeve 3. Make sure sleeve 3 is free on bolt 5 and clutch 1. Tighten guide bolt 5 to 37--43 Nm (28 -- 31 lbf. ft). NOTE: Use some thread locking compound when securing bolt 5 in place.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

170. Install circlip 1 onto shaft 2. NOTE: There should be a maximum axial play of 1 mm between clutch and circlip. 171. If the play is more than 1 mm, remove the clutch and insert an extra spacer washer 1 (Fig. 80).

82 172. Install special tool 2 as shown in Figure 83, to align the clutch into its operating position. 173. Connect hydraulic hose 3 to gearbox half 1 (25--30 Nm) (19 -- 22 lbf. ft). NOTE: Make sure the hose connector and the connector in the gearbox housing line up. If not reinstall the hose as shown in Fig. 58 and 59. 174. Check that hose 3 does not touch the walls of gearbox housing 1. 175. Check that the pressure sleeve is free and square on the clutch. If not then re--adjust the hydraulic hose installation.

176. Remove special tool 2 from gearbox half 1.

CONNECTING THE TWO GEARBOX HALVES TOGETHER 177. Align clutch plates 1.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

178. Install special tool 1 on top of clutch plates 3. NOTE: Use an old or new outer body of the clutch as special tool.

85 179. Connect a hydraulic hand pump 1 to the gearbox at connecting union 2 (Figures 85 and 86). 180. Apply and keep applying sufficient hydraulic pressure to lock the clutch pack. 181. Remove special tool 1 (Fig. 85).

86 182. Keep the clutch plates locked and move gearbox half 1 on top of gearbox half 2 as shown in Figure 87. 183. Apply a liquid sealant on the contact surface of gearbox half 2. 184. Lower gearbox half 1 on top of gearbox half 2. Make sure you do not damage the clutch plates.

87 185. Drive in or install guide pins 4 at both ends of the gearbox. 186. Install all Allen screws 5. 187. Remove special tool 3, or any other arrangement from gearbox half 1.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

INSTALLATION OF THE MAIN DRIVE GEARBOX Installing the main drive gearbox 188. Install gearbox 1 onto special support 2, or any other sturdy support.

89 189. Attach the support with gearbox 1 to a forklift equipped with long forks. NOTE: The gearbox is heavy, about 125 kg (see fig. 27). 190. Clean gearbox contact surface 3 and the corresponding surface on the engine. 191. Apply pressure resistant grease (NLGI class 2) to the splines of shaft 2. 192. Move the gearbox inside the machine and push it in place. 90

193. Install the two screws 1. 194. Remove the gearbox support from the machine. 195. Install the rest of the screws 1 and secure in place.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

196. Install shielding plates 3, 2 and 4 (Fig. 92) between the engine and the main drive gearbox, with screws, washers and nuts 1 and also the screws,--washers and nuts on the sides.

92 Installation of the hydraulic and the hydrostatic pump assemblies 197. Install the hydraulic and the hydrostatic pump assemblies onto the main drive gearbox. 198. Install screws 1 using a thread locking compound (type 2).

93 199. Connect return oil hose 3 to the gearbox housing. 200. Install hydraulic pipe 2 between the gearbox and the low pressure valve. 201. Connect hydraulic pipe 1 to the gearbox housing. NOTE: The hydraulic tubes should be installed without interference and tension.

94 202. Connect electric connector 1 to the right--hand side of the hydrostatic pump. IMPORTANT: Make sure all hydraulic and hydrostatic connecting unions are clean before assembly. Torque tables for ferrules, connections and ball type unions are shown in Section 35 - Hydraulic system of the Repair Manual.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

203. Connect or install hydraulic pipe 1 Fig. 96 and 97 (2 x 125 Nm) (2 x 92 lbf. ft). 204. Connect hydraulic pipe (or hose) 7 to the right-hand side of the hydrostatic pump 205. Connect hose 6 underneath the hydrostatic pump and tighten the nut to a torque of 210 Nm (155 lbf. ft). 206. Connect hoses 2, 3 and 4 to the left--hand side of the hydrostatic pump Fig. 97. Tighten screws 2 and 4 to 105 Nm (77 lbf. ft) and union nut 3 to 34 Nm (25 lbf. ft). 96 207. Connect hose 5 Fig. 97 and pipe 5 Fig. 96 to the work hydraulic pump. 208. Connect hose 6 Fig. 97 and pipe 4 Fig. 96 to the hydraulic pump for steering. 209. Connect hose 7 Fig. 97 and hose 3 Fig. 96 to the low pressure pump. Tighten the screws for hose 7 to a torque of 115 Nm (85 lbf. ft). NOTE: Do not fill up the hydraulic and hydrostatic circuits at this point in time.

Installation of the main drive belt assembly 210. Install the main drive belt assembly as described earlier in this section. 211. Install upper protection plate 2 of the fuel reservoir. 212. Install plastic straps 1 to hold the wiring loom to the cutterhead speed sensor.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

Installation of the fuel reservoir 213. If a jack 1 is used. 214. Jack up the forage harvester until the fuel reservoir filler neck can pass under the forage harvester frame and push in the fuel reservoir together with its protection plate from the right hand side of the machine, until the assembly is in a correct position to be lifted up (use a forklift with long forks). 215. Install the rear wheel and remove jack 1. The rear wheel bolts torque is 220 Nm (162 lbf. ft) for 2WD and 450 Nm (332 lbf. ft) for 4WD.

216. If a fork lift or a platform with a capacity of at least 5000 kg is available: lift the forage harvester rear end using the lift eyes on the rear bumper.

DANGER Make sure that the forage harvester can not move while lifting.

DANGER Make sure that the connections between the fork lift or the platform and the lifting eyes are strong enough and that they are installed in a safe way. 217. Push the fuel reservoir and its protection plate in from the rear.

100

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

218. Carefully lift up the fuel reservoir with its protection plate until the three rods (two on the left-hand side and one on the right--hand side) and the left--hand side support plate can be secured in place with washers and nuts 1.

101 219. Install six screws 1. (four at the front, two at the rear) to attach the protection plate of the fuel reservoir to the frame of the machine. 220. Remove the tool you used to lift up the fuel reservoir.

102 221. Install clamp 1 that secures one of the hydraulic hoses coming from the steering cylinder to the protection plate of the fuel reservoir.

103 222. Install the two screws 1 and the water separator to the protection plate of the fuel reservoir.

104

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

223. Install nut 5 and washer 4 Fig. 105 and 106. 224. Install round plate 3 together with the fuel level sender Fig. 105 and 106. 225. Connect the two fuel pipes 1 to the fuel level sender Fig. 105 and 106. 226. Connect the two electric connectors 2. to the fuel level sender Fig. 105 and 106. NOTE: IVECO engines: Fig. 105.

105

NOTE: CATERPILLAR engines: Fig. 106.

106 227. Install fuel cap 1 together with the filler filter. 228. Check that the plastic screw (with gasket) has been installed on the deposit bassin. The screw should be installed with a torque of 15 Nm (11 lbf. ft).

107

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

Installing the battery box and the batteries

DANGER The battery box is quite heavy. Two persons are needed to do this job. 229. Prepare the removed wires so they can be routed to the inside of the battery box. 230. Install the battery box and secure in place with screws and washers 1. 108 231. Install the wires at 3. 232. Lift the batteries into the battery box and secure them in place with the clamp. 233. Install battery cables 1 and 2.

109 234. Install cover 1 of the battery box.

110 Installing the PTO shafts 235. Install the 4WD shaft (on a 4WD machine). 236. Install grease guard plate 1. 237. Install main drive shaft 3 and secure in place with screws and washers 4 and the conical bolt at 2 (60 Nm) (44 lbf. ft). 238. Bring the cutterhead drive shaft into the machine from the front.

111

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

239. Install the cutterhead drive shaft with screws and washers 4. 240. Connect the cutterhead speed sensor 3 with its bracket. 241. Install PTO guards 1 and 2.

112 Starting up the forage harvester 242. Fill up the fuel reservoir and bleed the fuel system as described in chapter 5.16.1 Fuel system, paragraph Bleeding the fuel system in the Operatorâ&#x20AC;&#x2122;s Manual. NOTE: Do not start the engine at this point. 243. Fill up and bleed the low pressure hydraulic system as described in Section 35 Hydraulic system, chapter 5, paragraph Filling the system after (re) installing the main drive gearbox in the Repair Manual. NOTE: Do not start the engine at this point. 244. Fill up and bleed the hydrostatic system as described in Section 1, chapter 29, paragraph Filling and bleeding the hydrostatic system in the Repair Manual. NOTE: Switch on the main electric switch 2 fig. 110 at the battery box. Start the engine and follow the procedures as described above.

SECTION 14 -- LIVE P.T.O. -- CHAPTER 1

245. Install doors 3 and 2 onto the forage harvester 246. Lift door 1 in place and connect the wires to the rotary screen drive motor and brush actuator

113 247. Install cover plates 2 and 1.

114 248. Install shield 2 onto the machine. 249. Lift door 1 in place and connect the wires to the rotary screen drive motor and brush actuator.

115 Test all functions of the machine and repair if necessary.

SECTION 21 -- TRANSMISSION -- CHAPTER 1

SECTION 21 -- TRANSMISSION Chapter 1 -- Traction Gearbox CONTENT Section

Description

Page

21.145

SECTION 21 -- TRANSMISSION -- CHAPTER 1

2 LUBRICATION Oil change •

After the first 100 operating hours

•

Thereafter, every 600 operating hours or annually

Gearbox capacity 15 litres

Oil specification Use AMBRA HYPOIDE 90 oil (ref. NH520A) or an oil meeting the following specification: --

API GL5 or MIL--L--2105 D

Viscosity grade: SAE 80W -- 90

SECTION 21 -- TRANSMISSION -- CHAPTER 1

GEARBOX SHAFT Shaft A: half--shafts from differential Shaft B: transmission main shaft Shaft C: countershaft Shaft D: drive shaft

51140

SHIFTING DIAGRAM First gear: 1 -- 2 -- 3 -- 4 differential Second gear: 1 -- 2 -- 5 -- 6 differential Third gear: 1 -- 2 -- 7 -- 8 differential Fourth gear: 1 -- 2 -- 9 differential

SECTION 21 -- TRANSMISSION -- CHAPTER 1

DISASSEMBLY OF TRACTION GEARBOX General 1. Remove the chopper body from the base unit. 2. Remove the blower from the base unit. 3. Remove the hydrostatic motor with the housing from the gearbox. 4. Loosen or remove the items fastened to the upper part of the gearbox: -----

Shifter shaft Differential cable Handbrake cable Electric wires

5. Note the position of the differential lock lever and shaft. 6. Remove the cover by removing bolts A..

Removal of selector forks and shifter shafts 1. Drive out roll pins B. 2. Move shifter shafts C to the right--hand side and remove selector forks D. Ensure balls and springs do not fall into the gearbox.

4 Removal of drive shaft 1. Remove the selector fork and shifter shafts. 2. Remove cover E. 3. Remove circlip F and slide it halfway the shaft G. 4. Drive shaft G to the left--hand side.

SECTION 21 -- TRANSMISSION -- CHAPTER 1

5. Remove ball bearing H and slide circlip F and gear I from shaft G. 6. Remove shaft G from the left--hand side.

6 Removal of the countershaft NOTE: This shaft can be removed without removing shifter shafts C (Fig. 4) or input shaft G (Fig. 5). 1. Remove the four--wheel drive (refer to paragraph headed “Four--wheel drive angle gearbox”) (right--hand side). 2. Remove the handbrake shoe and disc (refer to paragraph headed “Disassembly of brake shoe and discs”). 3. Remove the five nuts J (Fig. 7) and drive out bearing housing K (Fig. 8) from the inside using a plastic hammer.

4. Install special tool L (part n° 80434443) and install bearing housing K the other way around (Fig. 9). 5. Drive the shaft out to the right until the left--hand part of the shaft is detached from the left--hand bearing. 6. Remove bearing housing K and special tool L (Fig. 9).

7. Remove the shaft together with gears M and N. Finally remove gear O (Fig. 9).

SECTION 21 -- TRANSMISSION -- CHAPTER 1

Removal of transmission main shaft NOTE: This shaft can be removed without removing the input shaft or the countershaft. 1. Remove the four--wheel drive on the right--hand side (refer to paragraph headed “Four--wheel drive angle gearbox”). 2. Remove the brake shoes and discs on both sides (refer to paragraph headed “Disassembly of brake shoes and discs”). 3. Remove the selector forks and shifter shafts (refer to paragraph headed “Removal of selector forks and shifter shafts”).

4. Remove bearing housing P by removing the six nuts Q and by screwing two bolts into the bearing housing P.

5. Pull bearing R from the shaft using special puller S (part n° 84014512) on the right--hand side.

6. Drive the shaft to the left--hand side and remove slotted nut 1, lock washer 2 and bearing R1.

SECTION 21 -- TRANSMISSION -- CHAPTER 1

7. Remove ring 3, gear 5, needle bearing 6 and circlip 7 through the aperture in the left--hand side of the gearbox (Fig. 13). 8. Remove the shaft with the remaining gears from the gearbox.

51141

Removal of the half--shaft from the differential 1. Remove the four--wheel drive on the right--hand side (refer to paragraph headed “Four--wheel drive angle gearbox”). 2. Remove the brake shoes and discs on both sides (refer to paragraph headed “Disassembly of brake shoes and discs”). 3. Carefully remove oil seal ring T, O--ring X and circlip U on both sides. 14

SECTION 21 -- TRANSMISSION -- CHAPTER 1

4. Pull out both shafts V together with bearings W.

15 Removal of the differential NOTE: For a possible disassembly of the differential control lever, refer to Fig. 16. 1. Remove both half--shafts (Fig. 15). 2. Remove six nuts 8 (Fig. 17). 3. Remove bearing housing 9 by screwing in two bolts 10 (M8x60) instead of two M8x16 bolts (Fig. 17). 4. Proceed in the same way on the other side and remove differential 11 (Fig. 17).

51144

NOTE: Remove the differential lock jaws and spring together with the left--hand bearing housing 9 (Fig. 17).

51143

SECTION 21 -- TRANSMISSION -- CHAPTER 1

ASSEMBLY OF TRACTION GEARBOX Assembly of the differential 1. Install the bearing housing 12 with six nuts 8 on the right--hand side (Fig. 17). 2. Position the differential between bearing housing 12 and bearing housing 9, and drive bearing housing 9 to the right--hand side (Fig. 17). NOTE: Before driving bearing housing 9 to the right-hand side, install the differential lock jaws and spring between the differential and bearing housing 9 (Fig. 17). 3. Install the six nuts 8 on the left--hand side securing bearing housing 9 (Fig. 17).

Assembly of the half--shafts of the differential 1. Install bearing W on shaft V (Fig. 18). 2. Install shaft V, circlip U, O--ring X and oil seal ring T. Ensure that oil seal ring T is installed as deep as possible (Fig. 19). 3. Proceed in the same way on both sides. NOTE: An alternative way to disassemble the left-hand half--shaft V with the differential lock is: 18 --

Before installation of housing 9 on the gearbox, pre--assemble housing 9 together with shaft V, bearing W, O--ring X, oil seal T and circlip U as one unit.

Slide the differential lock jaws and spring onto half--shaft V.

Slide the whole unit into the gearbox and secure with nuts 8 19

SECTION 21 -- TRANSMISSION -- CHAPTER 1

Assembly of transmission main shaft 1. Position shaft 36 in its aperture in the gearbox and install from the left--hand side in following sequence: ---

Sleeve 34, needle bearing 32, gear 33, shifting gear 30, shifter ring 31 (Fig. 20). Needle bearing 28, gear 29, sleeve 27, ring 26, ring 25, needle bearing 23, gear 24, shifting gear 21, shifter ring 22 and circlip 20 (Fig. 20). Ring 19, needle bearing 17, gear 18 and ring 16 (Fig. 20).

2. Install special tool Z (part nÂ° 80434446) (Fig. 21). 3. Install bearing R1 on the left--hand side of the shaft and drive it further with the shaft in the gearbox (Fig. 21). 4. Install special tool Y (part nÂ° 80434450) (Fig. 21). 5. Install bearing R on the right--hand side (Fig. 21) and bearing housing P (Fig. 22). Drive bearing housing P to the left--hand side and tighten it with nuts Q (Fig. 22). 6. Remove special tools Z and Y. 21 7. Drive the shaft and bearing R1 to the right--hand side. 8. Install lock washer 2 and slotted nut 1 (Fig. 12). Tighten nut 1 with a torque of 130 Nm.

SECTION 21 -- TRANSMISSION -- CHAPTER 1

Assembly of the countershaft Install following parts on the shaft outside the gearbox. 1. Bearing 44 on the right--hand side (the small gear on the right--hand side is part of the shaft). 2. Narrow ring 42. 3. Gear 41, with the wider part of the hub to the lefthand side. 4. Wide ring 40.

5. Gear 39, with the wider part of the hub to the lefthand side (Fig. 23). Introduce the reassembled shaft in the gearbox and install: 6. Gear 38, with the wider part of the hub to the right--hand side (Fig. 23). 7. Gasket together with bearing housing K using special tool Z (part n° 80434446) (Fig. 24). Tighten bearing housing K with nuts J (Fig. 7). 8. Left--hand bearing 37, maintaining a minimum axial clearance between the gears (Fig. 23).

Assembly of the drive shaft 1. Install input shaft G with the pre--assembled lefthand bearing in the gearbox and slide gear I with circlip F on the shaft. 2. Install the right--hand bearing and cover E. 3. Slide gear I and circlip F to the left--hand side in the right place. 4. Install the left--hand bearing against gear I keeping a minimum clearance and ensuring that the filler opening in the bearing outer ring is located at ±25° before the vertical axial line.

SECTION 21 -- TRANSMISSION -- CHAPTER 1

Assembly of selector shafts and forks 1. Install ball and spring in selector forks A using special tool B (part nÂ° 80434416) (Fig. 26).

26 2. Slide selector shafts C in forks D (the notch pointing upwards) and secure the latter with pins B which are themselves secured with a piece of wire (Fig. 27).

27 Calculation of shims to be installed on the shafts ON INPUT, DRIVE OR CLUTCH SHAFT AND THE COUNTERSHAFT The permissible axial clearance of these shafts is 0.2 to 0.6 mm. 1. Depth of bearing in gearbox.

2 mm

2. Raised part on the clutch housing:

1.2 mm

Difference: 3. Thickness of gasket: Total:

0.8 mm 0.15 mm 0.95 mm

Shims to be installed: 0.75 to 0.35 mm. ON TRANSMISSION MAIN SHAFT The permissible axial clearance of this shaft is 0.5 to 0.8 mm. To calculate the shims, proceed in the same way as explained above.

51142

SECTION 21 -- TRANSMISSION -- CHAPTER 1

Assembly of the cover Install the cover and adjust pawl 45 (Fig. 28) as follows: 1. Position the shifter shaft in third or fourth gear. 2. Turn in adjusting bolt 46 until it is tight and unscrew one turn. Tighten the lock nut. 3. Position the shifter shaft in first or second gear. Turn in adjusting bolt 47 until it is tight and unscrew one turn. Tighten the lock nut.

51144

NOTE: Make sure the differential lock control is correctly assembled, and that the fork goes into its slot (Fig. 29). Fill the gearbox with 15 litres SAE 80W--90 (API-GL5) oil. NOTE: To remove bearing R (Fig. 11), special puller S has to be used. The previous version (part nÂ° 80434463) cannot be used any longer, but it can be modified. Refer to Fig. 31, and to Fig. 30 for the bore diameter. To have good results, make the finger out of 42CrMoS4V+S material.

51146

51145

SECTION 21 -- TRANSMISSION -- CHAPTER 1

SECTION 23 -- 4WD LINES -- CHAPTER 1

SECTION 23 -- 4WD LINES Chapter 1 -- 4WD Angle Gearbox CONTENT Section

Description

Page

23.000

SECTION 23 -- 4WD LINES -- CHAPTER 1

REMOVAL FROM BASE UNIT 1. Drain the oil from the gearbox. 2. Remove the drive shaft to the rear axle by removing bolts A. 3. Disconnect and plug the hydraulic pipe coming to the clutch at B.

30642

1 4. Remove bolts A and B, remove rubber coupling C (Fig. 2). 5. Remove gearbox fastening bolts at D. Note the location and number of shims, if installed. Remove the gearbox from the machine (Fig. 2).

DISASSEMBLY OF 4 WHEEL DRIVE ANGLE GEARBOX -- Figure 2 1. Remove bolts G and cover H. Cover H was sealed with a liquid sealant. 2. Remove bolts E and remove the input gear assembly from the gearbox. Do not damage O--ring J and shims K. 3. If necessary, separate shaft M from gear L. Do not damage O--ring N. 4. Remove seal P (will be damaged), lock nut R and lock washer Q. 5. Press gear L out of housing F, and remove bearings S from housing F. 6. Remove bolts T and pull out shaft V together with the clutch assembly. 7. Remove lock nut W and lock washer AA, and press shaft V out of the clutch assembly. 8. Remove seal BB, bearing race EE, circlip CC and bearing DD. 9. Remove lock nut GG, lock washer HH, ring JJ, and press shaft KK out of the gearbox housing.

SECTION 23 -- 4WD LINES -- CHAPTER 1

30642

SECTION 23 -- 4WD LINES -- CHAPTER 1

ASSEMBLY OF 4 WHEEL DRIVE ANGLE GEARBOX -- Figure 3 1. Install bearing outer races LL in the gearbox housing. 2. Press bearing LL onto shaft KK. Press in shaft KK with installed gear until the bearing seats against the gear. 3. Install the second bearing LL onto the shaft end. Install ring JJ, lock washer HH and lock nut GG. 4. Tighten the lock nut GG until the bearing pretension is 1.0 to 2.5 Nm. Lock the nut in place with washer HH. 5. Install bearings EE, circlip CC, and seal BB into the clutch housing. 6. Install lock washer AA and lock nut W until the bearing pretension is 1.0 to 2.5 Nm. Lock the nut in place with washer AA. 7. Install the drive housing with bolts FF. Install the shaft and clutch assembly V and secure with bolts T. 8. Install bearings S into housing F, and gear L. Press gear L into place. Secure with lock washer Q and lock nut R. 9. Tighten lock nut R until the bearing pretension is 1.0 to 2.5 Nm and lock the nut in place with washer Q. 10. Install seal P. 11. Install O--ring N. Press shaft M into gear L, and secure in place. 12. Install the input shaft assembly into the gearbox. Do not forget the O--ring J, and adjust the backlash to 0.2 -- 0.3 mm with shims K. 13. Apply liquid sealant on the contact surfaces and install cover H with bolts G.

SECTION 23 -- 4WD LINES -- CHAPTER 1

30642

SECTION 23 -- 4WD LINES -- CHAPTER 1

INSTALLATION ON BASE UNIT 1. Install drive flange MM on the handbrake shaft (Fig. 3). 2. Install the centering flange shown in Figure 4 (special tool) on flange MM (Fig. 3). 3. Install bearing shaft M with the gearbox on the flange (Fig. 3). 4. Install bolts D with sufficient shims between the gearbox and the base unit frame, and fasten the gearbox with bolts D (Fig. 3).

30643

5. Remove the special tool and install rubber coupler C (Fig. 3).

6. Install drive shaft F with bolts A. 7. Connect the hydraulic pipe to the clutch housing at B. 8. Fill the gearbox housing with 1.4 litre hydraulic oil. Use AMBRA HYPOIDE 90 oil (ref. NH520A) or an oil meeting the following specification: -- API GL5 or MIL--L--2105 D -- Viscosity grade: SAE 80W--90 30642

9. Bleed the system: a) Put the gearbox in neutral. b) Apply the handbrake and make sure the machine cannot move. c) Start the forage harvester engine. d) Engage the four--wheel drive. e) Open bleed screw A (Fig. 6) until the oil escaping is free from air bubbles, then close the bleed screw. 30644

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1

SECTION 25 -- FRONT MECHANICAL DRIVE Chapter 1 -- Final Drives CONTENT Section

Description

Page

25.310

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1

LUBRICATION

DISASSEMBLY OF FINAL DRIVES

General data

Output shaft

The filler and oil level plugs are positioned at a different height as the final drives are installed inclined.

1. After draining the oil, remove cover P, three bolts G, washer F, shims H and the cover on top of the housing.

Depending on whether the final drive is installed on the left or the right--hand side, one plug is for checking the oil level and one for filling. The lower plug will always be the oil level plug.

2. Press output shaft B out of the housing, keeping bearing C and seal D installed on the shaft.

Type

4. Remove sealing D from the output shaft.

3. Remove the rings of bearings C and E out of the housing.

Gear ratio 10/75 Maintenance Change the oil -- after first 100 working hours -- every 600 working hours, or annually Gearbox capacity 5 litres (each gearbox) Oil specification Use AMBRA HYPOIDE 90 oil (ref. NH520A) or an oil meeting the following specification: -- API GL5 or MIL--L--2105 D -- Viscosity grade: SAE 80W--90

Input shaft 1. Remove bearing covers and S and shims I. 2. Push the shaft out of the housing. 3. Remove the bearing rings out of the housing and remove the bearings from the shaft.

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1

50361

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1

ASSEMBLY OF FINAL DRIVES

Output shaft

Input shaft

1. Install the rings of bearings C and E in the housing.

1. Install both bearings on the shaft and oil the bearings. 2. Introduce the preassembled shaft in the housing.

2. Grease seal D (with multipurpose grease NLGI2) and install the seal and bearing C on shaft B. 3. Introduce the gear in the housing.

3. Install the bearing rings of bearings L and M.

4. Push shaft B in the housing until the seal is completely inside.

4. Install bearing cover R using sealing paste.

5. Lay the housing flat on the wheel flange.

5. Install a new seal in bearing cover S and install the cover.

6. Install circlips N, bearing E and washer F. 7. Press the bearing on the shaft by tightening bolts G to 90 Nm (66 lbf.ft) torque.

End play adjustment 1. Tighten the bolts of cover S to 34 Nm (25 lbf.ft) torque.

Preload adjustment

2. Loosen the bolts.

1. Loosen the three bolts G until a small end play is obtained on the output shaft.

3. Tighten the bolts again and at the same time check with a dial gauge on the top of shaft K whether the end play is still 0.1 mm (0,004’’).

2. Install a dial gauge on washer F and tighten the three bolts G uniformly until an end play = O is obtained.

4. Measure the end play between the housing and bearing cover S and install shims I for the same value. Tighten the bolts again to 34 Nm (25 lbf.ft) torque. Check the end play again which should now be 0.05 to 0.1 mm (0,002’’ -- 0,004’’). If not so, shims should be removed or added.

3. Remove the three bolts G and washer F.

5. Apply sealing paste between bearing cover S and the housing, and between the separate shims. 6. Tighten the bolts of bearing cover S to 34 Nm (25 lbf.ft) torque.

4. Measure distance X between the shaft end and the bearing edge. 5. Install shims to the same value as the measured value X -- 0.3 mm (X -- 0,012’’). 6. Install washer F and bolts G and tighten the bolts to 235 Nm (173 lbf.ft) torque. 7. Apply sealing paste to cover P and install the cover. Install the housing cover with a new gasket. 8. Fill the final drive housings with 5 litres oil each. Use AMBRA HYPOIDE 90 oil (ref. NH520A) or an oil meeting the following specification: -- API GL5 or MIL--L--2105 D -- Viscosity grade: SAE 80W--90

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1

50361

SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1

SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1

SECTION 29 -- HYDROSTATIC TRANSMISSION Chapter 1 -- Hydrostatic Transmission CONTENT Section

Description

Page

29.212

29.216

SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1

LUBRICATION IMPORTANT: Pay attention to CLEANLINESS: Dirt or other contamination are in most cases the reason for the breakdown of a hydraulic circuit. Oil level Ensure that all hydraulic cylinders are retracted before checking the oil level. Check the oil level daily on the oil dipstick fitted to cap 1 (Fig. 1). If necessary, add oil through the filler opening. Keep the oil level between the minimum and maximum marks on the oil dipstick.

58205

Recommended oil and filter change intervals â&#x20AC;˘ â&#x20AC;˘

After the first 100 operating hours Thereafter, every 600 operating hours, or once every year.

To change oil and filter, proceed as follows: 1. Thoroughly clean the surrounding area of the reservoir and filler cap 1 (Fig. 1). 2. Remove the filler cap/oil dipstick B (Fig. 1). 30484

3. Drain the oil from the reservoir through drain hose F (Fig. 3). 4. Remove hydrostatic oil filter D (Fig. 2). 5. Fill the hydrostatic filter bowl with oil. 6. Apply a film of oil to the gasket and screw on the new filter by hand. Tighten firmly but DO NOT USE TOOLS. 7. Fill the reservoir up to the maximum mark on the oil level dipstick B (Fig. 1). 30479

SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1

8. Start the engine. The low hydrostatic charge pressure warning light must extinguish as soon as the engine starts. If not, contact your dealer for assistance (Fig. 4). 9. Run the engine at idle speed for five minutes and move the ground speed control lever slowly forward and backward with the gearshift lever in neutral and the rear--wheel drive [if installed] disengaged. Oil capacity Reservoir: 38 litres. Entire system capacity: 93 litres. Oil specification Use AMBRA HYDROSYSTEM 46HV (ref. NH646H) or an oil meeting the following specification: -- DIN 51524 part 2 or ISO VG46 -- Viscosity grade: 46

30535

SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1

HYDROSTATIC NENTS

CIRCUIT

AND

COMPO-

Circuit A

Engine

Pump with variable displacement

Main drive transfer gearbox

Charge pump (gerotor--type pump)

Hydrostatic pump housing

Pump charge pressure relief valve (24 bar)

Work hydraulic pump housing

Displacement control valve (electrical)

Steering hydraulic pump

Servo pressure relief valves

Low pressure pump

Multifunction valves

To low pressure relief valve (see Hydraulics, Section 7)

Set at 420 bar

Hydrostatic motor

Set at 450 bar

Hydrostatic oil reservoir

By--pass

Hydraulic oil reservoir

Charge check valves

Low pressure circuit hydraulic oil reservoir

Motor charge pressure relief valve (24 bar)

Shuttle valve (spring--centred to a closed position) The shuttle valve establishes a circuit between the main line that is at the low pressure side and the charge pressure relief valve 7.

Motor with fixed displacement

Filter

Reservoir

Cooler

Thermovalve

Servocylinder

Orifice check valves

Filler cap breather

SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1

SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1 Pump operation (Fig. 5 and 6) NEUTRAL The hydropump swash plate is perpendicular to the axis of rotation. There is no axial movement of the pistons so there is no displacement in the high pressure lines. The charge pump turns and serves oil to the check valves which are open and to the charge pump relief valve. If the pressure exceeds 24 bar, the charge pump relief valve 3 will open and oil will flow through this valve to the pump case. RIGHT--HAND ROTATION The operator moves the control handle of control valve 4, thereby actuating the servocylinders. The swash plate is now positioned at a certain angle. The hydropump pushes oil under pressure to the hydromotor. The charge check valve on the high pressure side is closed. The hydromotor runs. The shuttle valve is actuated. Oil flows from the low pressure side through the charge pressure relief valve (24 bar) to the motor case. This oil serves as a coolant for the hydromotor and will be added to the lubrication oil. Via a case drain line the oil will flow to the pump case, through the pump case and over the heat exchanger back to the reservoir. LEFT--HAND ROTATION With the handle in the rearward position, the servocylinders are actuated in the opposite direction and the swash plate is moved to the opposite angle. The hydropump pushes the oil under high pressure to the other side of the hydromotor causing the output shaft to turn in the opposite direction.

SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1

FILLING AND BLEEDING THE HYDROSTATIC SYSTEM After repair or replacement of a hydrostatic element a complete refill is required. NOTE: Before mounting a new motor or a new pump, shipment oil should be drained from the new pump or motor case. 1. Place the machine on level ground. 2. Place wooden blocks or similar in front of and behind the traction wheels to keep the machine stationary.

43156

3. Place the ground speed control lever and the gearshift lever in the cab in neutral position. 4. Fill the hydrostatic oil reservoir up to the maximum mark on the oil dipstick B (Fig. 1) with an approved hydrostatic oil. 5. Loosen the charge pump line at the inlet of the charge pump (port S) and bleed the system until oil comes through the charge pump port S (Fig. 7). 6. Loosen the overflow plug C of the hydrostatic motor (Fig. 8).

51133

7. Loosen the pipe connection between the hydrostatic pump and the thermostatic valve at the pump R (Fig. 7). Fill oil through the hydrostatic pump until oil comes out through overflow opening C (Fig. 8) of the hydrostatic motor. 8. Retighten overflow plug C. Continue to fill oil until the pump casing is full. Reconnect the pipe connections to the motor and pump and tighten to 34 Nm torque (Fig. 7 and 8). 9. Disconnect the connector A of the stop solenoid in the engine compartment (Fig. 9). 10. Connect a manometer, preferably a damped one, with a 500 bar range in gauge connection Q (high pressure forward) (Fig. 7). 11. Crank the engine with the starter motor for 30 seconds, wait for one minute to cool the starter motor, crank again for 30 seconds or until a minimum pressure of 2 bar has been reached. 12. Reinstall electric connector A to the stop solenoid in the engine compartment (Fig. 9).

30675

SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1 13. Start the engine, let it run on low idle until the recorded pressure is at least 20 bar. 14. Let the engine run at low idle, shift to fourth gear and apply the foot brake pedals firmly. Gently push the hydrostatic control lever forward a short stroke, so a minimum pressure of 30 and a maximum pressure of 300 bar is recorded. Keep the pressure on for one minute. 15. Repeat the procedure described in the previous paragraph, but reverse. 16. Check the oil level in the reservoir. If necessary, add oil to the maximum level on the oil dipstick and check the system for leaks. 17. With the engine running on low idle shift the gearbox to neutral, position the hydrostatic control lever at half stroke for one minute, both forward and in reverse. 18. Increase the engine speed to high idle, position the hydrostatic control lever at maximum forward and maximum rearward for two minutes each. 19. Measure and write down the gauge pressure at full stroke in reverse position. This pressure should be 25 +/--4 bar (flush pressure). 20. With the hydrostatic control lever in neutral position and the engine at high idle, measure and write down the pressure reading. This pressure (charge pressure) should be 4 +/--2 bar higher than the value measured in step 19. 21. With the engine at high idle, shift to fourth gear, press down both brake pedals firmly and apply the handbrake. Move the hydrostatic control lever fully forward for a maximum of 10 seconds. The measured pressure should be between 420 and 450 bar (high pressure forward). 22. Stop the engine, remove the manometer, check the oil level and possible leaks and correct, if necessary.

SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1

HYDROSTATIC PUMP

50820

A. B. C. D.

Input shaft Charge pump Cylinder block assembly Swash plate

SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1 The hydrostatic pump characteristics can be found on the identification plate which is installed on the pump.

90 R 100 EA 1A8 S 3 C7 E0S GBA 424228

Series 90, closed circuit

Right--hand rotation pump

100

100 cm3/rev max. displacement

Electrical displacement control (linear)

Pressure limiter in port A and B

SAE A with sealed cover 9T -- 16/32

Twin ports

Possible to connect a suction filter

No limiters

Splined shaft 23T -- 16/32 pitch

20 cm3/rev charge pump displacement

Control orifice dia 0.81 mm

GBA

Downhill kit

420 bar high pressure port B

420 bar high pressure port A

28 bar charge pressure setting

SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1

OPERATION OF THE MULTIFUNCTION VALVE (4 FUNCTIONS)

50823

11 A. High pressure B. Charge pressure L. To servo control cylinder

The multifunction valves 6 (Fig. 11) or G (Fig. 12) are incorporated in the pump.

42567

SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1 1. CHARGE CHECK VALVES (ITEM 6d, Fig. 6) When the pressure on carrier C is greater than the pressure of spring D, carrier C moves to the left taking piston E with it. Oil flows from B to A to fill up the system.

2. PRESSURE LIMITER (P.O.R.) -- 420 BAR (item 6a, Fig. 6) (Pressure override) When the high pressure exceeds 420 bar, the pressure on poppet F pushes it to the left and allows oil to flow to the servo control cylinder through port L.

3. HIGH PRESSURE RELIEF VALVE -- 450 BAR (item 6b, Fig. 6) The flow for the pressure limiter stage must pass through the orifice G in piston E, generating a pressure differential across the orifice. When the pressure in piston E exceeds the closing force of the internal valve pressure (due to the pressure drop across the orifice) acting on the left side plus the force of spring D, piston E moves to the left and allows oil to flow to the charge circuit.

4. BY--PASS (item 6c, Fig. 6) When the external hex part H is turned 3.5 revolutions counter--clockwise, the force exerted on poppet F is reduced. This sets the pressure limiter at a very low setting. When the pump shaft is not turning but pressure is generated in the high pressure lines due to external influences (motor working as a pump), poppet F moves to the left and oil flows through part L. At this stage, piston E can easily move to the left and the oil from A (high pressure) flows to port B. NOTE: When the machine has to be towed, shift the gearbox to neutral.

SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1

HYDROSTATIC MOTOR

50821

E. F. G. H.

Cylinder block assembly Output shaft Motor swash plate Shuttle valve

SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1 The hydrostatic motor characteristics can be found on the identification plate which is installed on the motor.

90 M 100 NC 0 N 8 N 0 C7 W 00 NNN 000024

Series 90, closed circuit

Bi--directional motor

100

100 cm3/rev max. displacement

Standard execution

Twin ports

Standard execution

Shaft 23 teeth -- 16/32 pitch

Loop flushing valve

Not applicable

NNN

Not applicable

24 bar charge pressure

SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1

SECTION 33 -- BRAKES AND CONTROL -- CHAPTER 1

SECTION 33 -- BRAKES AND CONTROL Chapter 1 -- Brakes and Control CONTENT Section

Description

Page

33.110

Parking brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

33.202

SECTION 33 -- BRAKES AND CONTROL -- CHAPTER 1

PARKING BRAKE ADJUSTMENT 1. Disengage the handbrake in the cab. 2. Check if the dimension is 219 mm as shown in Fig. 1. NOTE: When measuring the above dimension, ensure that cable A is tensioned by pulling lever B. 3. Loosen lock nuts C and thereafter bolts D. 52001

4. If necessary (see step 2), adjust the dimension to 219 mm with nuts E. Make sure that cable A is straight. Tighten nuts E. 5. Tighten bolts D simultaneously by hand until they touch the brake blocks (Fig. 1). 6. Engage and disengage the handbrake in the cab a few times. 7. Check the tightness of bolts D. If possible, tighten them simultaneously by hand. Turn them an extra quarter of a turn with a spanner (Fig. 1). 8. Engage and disengage the handbrake in the cab a few times. 9. Loosen bolts D and tighten them simultaneously by hand, if possible (Fig. 1). 10. The adjustment is correct when, while engaging the handbrake in the cab, the tension begins at the 6th or 7th tooth of the locking ratchet. If not, repeat steps 8 and 9 until the adjustment is correct. 11. Tighten lock nuts C (ensure that bolts D are not turning with nuts C (Fig. 1). 12. Check again that the dimension still is 219 mm. If not, repeat the adjustment from step 2 onwards.

30225

SECTION 33 -- BRAKES AND CONTROL -- CHAPTER 1

REPLACEMENT OF THE BRAKE LININGS Removal 1. Bring the brake fluid level to a minimum. 2. Remove cover B. 3. Disconnect the electric wires on connectors C.

30254

4. Remove pins D out of the bracket housings. 5. Take out the brake linings.

CAUTION If the seals (VITON type), protecting the cylinders, have been exposed to temperatures in excess of 315Â°C, the material will not burn, but will decompose and one of the products formed is hydrofluoric acid. This is an extremely corrosive acid which is almost impossible to remove once it has contaminated the skin.

30253

Installation 1. Press the cylinders in the brake lining housings to the outside. 2. Install the new brake linings. 3. Secure the brake linings with pins D (Fig. 4). 4. Connect the electric wires. 5. Check the brakes.

SECTION 33 -- BRAKES AND CONTROL -- CHAPTER 1

BRAKE CYLINDERS Functioning of the brake main cylinder The two main cylinders are mutually connected with connectors B and C, further with pipe K to the fluid reservoir and with pipes D to the brake cylinders. Fluid from the fluid reservoir enters the brake main cylinder through port E (pedal not engaged). When both brake pedals are engaged, port E is shut off by seal I, and fluid is pressed through port F to the brake cylinder. Ball H is lifted up in both main cylinders A by plunger J.

50587

When only one brake pedal is engaged, port E is also shut off by seal I and fluid is pressed through port F to the brake cylinder. In the other main cylinder, ball H is pressed down by the fluid pressure coming from the first cylinder through connector B and seat G. The fluid flow is stopped by seal P.

50588

SECTION 33 -- BRAKES AND CONTROL -- CHAPTER 1

BLEEDING BRAKES Bleeding the left--hand side circuit 1. Slide one end of a transparent hose over bleed screw F1 and insert the other end of the hose in a can partially filled with brake fluid. 2. Open the brake cylinder bleed screw F1. 3. Depress the left--hand side brake pedal several times until fluid flows into the can. 4. Close bleed screw F1. 5. Depress the left--hand side brake pedal several times to build up a pressure. 6. Keep the pedal depressed. 7. Open the bleed screw F1 slightly to allow air and fluid to escape through the transparent hose. 8. Close bleed screw F1. 9. Release the brake pedal. 10. Remove the transparent hose from bleed screw F1 and repeat steps 1 to 10 for bleed screws F2 and F3.

Bleeding the connection pipe between the two main cylinders 1. Slide the transparent hose over the right--hand side bleed screw F1. 2. Open the right--hand side bleed screw F1. 3. Depress and hold the right--hand side brake pedal depressed. 4. Depress the left--hand side brake pedal once and keep it depressed. 5. Release the right--hand side pedal and then the left--hand side pedal 6. Repeat steps 3, 4 and 5.

50587

SECTION 33 -- BRAKES AND CONTROL -- CHAPTER 1

Bleeding the right--hand side circuit 1. With the transparent hose slide over the right-hand side bleed screw F1 depress the right-hand side brake pedal several times until brake fluid flows into the can. 2. Close the right--hand side bleed screw F1. 3. Depress the right--hand side brake pedal several times to build up a pressure. 4. Keep the pedal depressed. 5. Open slightly the right--hand side bleed screw F1 to allow air to escape through the transparent hose. 6. Close bleed screw F1. 7. Release the brake pedal. 8. Repeat steps 3 to 7 until fluid free of air bubbles flows through the transparent hose. 9. Remove the transparent hose from bleed screw F1 and repeat steps 1 to 9 for bleed screws F2 and F3.

SECTION 33 -- BRAKES AND CONTROL -- CHAPTER 1

DISASSEMBLY AND ASSEMBLY OF BRAKE SHOES AND DISCS Disassembly of brake shoes 1. Remove the four--wheel drive on the right--hand side (refer to paragraph headed â&#x20AC;&#x153;Four--wheel drive angle gearboxâ&#x20AC;?). 2. Remove handbrake shoe A by loosening two bolts. 3. Remove brake line B by loosening bolts C on both sides.

30298

4. Loosen brake line D from the bleed nipple holder E on both sides. 5. Remove brake shoes F by loosening bolts G through the holes of the disc on both sides.

30296

Disassembly of brake discs 1. Remove circlip H and hand brake disc J on the right--hand side. 2. Remove slotted nut K, lock washer L and brake disc M on both sides.

Assembly of brake discs 1. Install brake disc M, lock washer L and slotted nut K. Tighten nut K with a torque of 180 Nm on both sides. 2. Install circlip N on the transmission main shaft. 3. Install handbrake disc J and circlip H.

30299

SECTION 33 -- BRAKES AND CONTROL -- CHAPTER 1

Assembly of brake shoes 1. Install bleed nipple P in bleed nipple holder E on both sides. 2. Install brake line D on the lower brake shoes F and ensure that there is a washer between the nipple and the brake shoe. 3. Install brake shoe F and fasten with bolts G on both sides. Tighten bolts G with a torque of 266 Nm. 30296

4. Install brake line B with nipples R on both sides and ensure there is a washer between the nipple and the brake shoe and between the nipple and the bolt. 5. Install brake shoe A and fasten it with two bolts. 6. Install the four--wheel drive on the right--hand side (refer to paragraph headed â&#x20AC;&#x153;Four--wheel drive angle gearboxâ&#x20AC;?).

30298

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

SECTION 35 -- HYDRAULIC SYSTEM Chapter 1 -- General CONTENT Section

Description

Page

35.000

Torque tables for hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

35.304

Disassembly and assembly of pump group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

TORQUE TABLES FOR HYDRAULIC COMPONENTS UNION NUTS AND FERRULES Union nuts

55009

1 Ferrules The ferrule must be pre-assembled on the tube. Tighten the union nut as specified in the table below. The ferrule and screw thread are greased. Torque Nm (lbf.ft)

Tube outer diameter mm (in)

Min.

Max.

8 (0.32)

15 (11)

20 (15)

10 (0.4)

25 (18)

30 (22)

12 (0.47)

35 (26)

40 (29)

16 (0.63)

50 (37)

55 (40)

18 (0.71)

60 (44)

70 (51)

22 (0.87)

100 (74)

110 (81)

28 (1.10)

110 (81)

120 (88)

55010

METRIC FITTINGS Unions Are suitable for use with union nuts and ferrules and ball-type nipples.

55011

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

Connections Are screwed in ISO metric thread - tolerance class 6H - with a tightening torque as specified in the table below. Torque Nm (lbf.ft)

Tube outer diameter mm (in)

Min.

Max.

8 (0,32)

40 (29)

45 (33)

10 (0,40)

65 (48)

70 (51)

12 (0,47)

80 (59)

85 (63)

16 (0,63)

100 (74)

120 (88)

18 (0,71)

120 (88)

140 (103)

22 (0,87)

200 (147)

220 (164)

28 (1,10)

350 (257)

380 (280)

55012

Swivel nut with ball-type nipple Are suitable for use with female unions D1

Torque Nm (lbf.ft.)

Min.

Max.

M14 x 1.5

M16 x 1.5

15 (11)

20 (15)

M18 x 1.5

20 (15)

25 (18)

M24 x 1.5

30 (22)

35 (26)

M26 x 1.5

M30 x 2

M36 x 2

55013

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

PUMP GROUP -- DISASSEMBLY AND ASSEMBLY The pump group consists of four pumps driven by the engine A via the main drive transfer gearbox B. C: Hydrostatic pump: see Section 29. -- Traction -- Four-wheel drive clutch (option) D: Work hydraulics pump: -- Attachment height control -- Reverse drive of the cutterhead -- Spout rotation and vertical movement -- Auxiliary rear hydraulics (option) -- Auxiliary front hydraulics E: Steering hydraulics pump: -- Steering -- Auto-Pilot [accessory] F: Low pressure pump: -- Main drive clutch -- Main drive belts stretching cylinder

Disassembly of the pum group

WARNING Before starting a service job, always: Shut off the engine. Remove the ignition key. Switch off the battery switch. Wait until all parts have completely stopped rotating.

In this paragraph, the following will be explained: -- Removal of the three hydraulic pumps from the hydrostatic pump. -- Separation of the three hydraulic pumps.

55014

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

Removal of the triple pump from the hydrostatic pump 1. Drain the hydraulic oil reservoir. NOTE: FX / 96: Series 13 FX 25 / 45: Series 05 From these Series onwards, the hydrostatic and hydraulic oil reservoirs are no longer separate, except for the lower part (Refer to paragraph headed ‘‘Hydraulic reservoir R2’’ further in this Section). In order to drain the reservoir completely (e.g. when the oil in the reservoir has to be changed), oil should be drained through both drain hoses.

30479

2. Remove the left-hand side shielding.

43138

8 3. Remove hoses a and b from the low pressure pump F (Fig. 9 and 11). 4. Remove hose c and pipe d from the steering hydraulic pump E. 5. Remove hose e and pipe f from the work hydraulic pump D. 6. Unscrew cap screws g. 7. Remove the triple pump from the hydrostatic pump. 52624

55015

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

Splitting of the triple pump The triple pump consists of four main components (Fig. 11 to 14): D: Work hydraulics pump E: Steering hydraulics pump U: Connecting piece (Fig. 14) F: Low pressure pump The low pressure pump F is connected to the connecting piece U with two cap screws h. The connecting piece is connected to the steering hydraulic pump with four cap screws j.

52592

55119

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

55120

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

55122

1. 2. 3. 4. 5. 6. 7. 8. 9.

Four cap screws h (M8) Two cap screws j (M10) Four nuts (M8) Four washers (M8) Two washers (M10) O-ring seal (towards the steering hydraulics pump) O-ring seal (towards the low pressure pump) Intermediate piece Fitting sleeve (connection between drive shafts)

The steering hydraulics pump E is connected to the work hydraulics pump D with 4 long stud bolts k (M10 x 185.5 mm) (Fig. 13). These bolts are screwed into the part that connects the triple pump to the hydrostatic pump. The steering and the work hydraulics pumps are tightened to each other with special M10 nuts l on these stud bolts (Fig. 13). The drive shafts of the latter pumps are connected to each other with coupling m (Fig. 13 and 15).

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

Assembly of the pump group Assemble in the reverse order of the disassembly sequence. IMPORTANT: Below is a list of recommended torques. Ignoring these torques may lead to severe damage to the pumps. Verify the seals for wear or damage. Replace when necessary. Also verify that the seals are properly seated before attaching the pumps to each other.

Cap screw h: 44 - 54 Nm (32--40 lbf.ft) Cap screw j: 26 - 31 Nm (19--23 lbf.ft) Stud bolt k in the connecting piece (to the hydrostatic pump): 5 - 10 Nm (4--7 lbf.ft) Nut l (on stud bolt k): 44 - 54 Nm (32--40 lbf.ft) Hose a: 110 - 120 Nm (81--88 lbf.ft) Torque tables for ferrules, connections and ball-type nipples can be found in paragraph headed ‘‘Torque tables for hydraulic components” at the beginning of this section. Installation of the pump group to the hydrostatic pump Cap screws g: 27 - 37 Nm (20--27 lbf.ft)

40537

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

SECTION 35 -- HYDRAULIC SYSTEM Chapter 2 -- Work Hydraulics -- Attachment Height Control CONTENT Section

Description

Page

35.000

Circuit diagrams -- Attachment height control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

35.300

35.304

35.410

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

WORK HYDRAULICS HEIGHT CONTROL 1A

ATTACHMENT

FX/96

Series 01 to 10

FX25/45

Series 01 and 02

Circuit diagram -- Figure 1 A

Engine

Main drive transfer gearbox

Hydrostatic pump

Work hydraulics pump

Steering hydraulics pump

Low pressure pump

High pressure relief valve

Attachment height control valve (E.M.R.)

Pressure sensor

Compensation valve

Accumulators

Non-return valve

Low pressure filter

Filler opening with filter

Drain hose

Oil reservoir R1

Hydrostatic oil reservoir

Hydraulic oil reservoir

Low pressure hydraulic oil reservoir

Breather with filter and non-return valve

To/from steering valve (without Auto-Pilot)

Stack valve

To steering valve (with Auto-Pilot)

From steering valve (with Auto-Pilot)

From cutterhead reverse drive motor

Attachment lift cylinders

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2 1A

FX/96

Series 01 to 10

FX25/45

Series 01 and 02

52593

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

4 1B

FX300-375 / 9630-9640 / 28--38

Series 13 > ............

FX450 / 9645 / 48--58

>> 1C

FX25/45

Series 05 > ............

Circuit diagram -- Figure 2 A

Engine

Main drive transfer gearbox

Hydrostatic pump

Work hydraulics pump

Steering hydraulics pump

Low pressure pump

High pressure relief valve

Attachment height control valve (E.M.R.)

Pressure sensor

Compensation valve

Accumulators

Non-return valve

Low pressure filter

High pressure filter

Oil cooler

Filler opening with filter

Drain hose

Oil reservoir R1 = R2

Hydraulic oil reservoir

Low pressure hydraulic oil reservoir

Breather with filter and non-return valve

Suction filter

To/from steering valve (without Auto-Pilot)

Thermovalve

Stack valve

To steering valve (with Auto-Pilot)

From steering valve (with Auto-Pilot)

From cutterhead reverse drive motor

Attachment lift cylinders

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2 1B

FX300-375 / 9630-9640 / 28--38

Series 13 > ............

FX450 / 9645 / 48--58

>> 1C

FX25/45

Series 05 > ............

52594

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

6 1C

FX300-375 / 9630-9640 / 28--38

<< 1B

FX450 / 9645 / 48--58

Series 13 > ............

FX25/45

<< 1B

Circuit diagram -- Figure 3 A

Engine

Main drive transfer gearbox

Hydrostatic pump

Work hydraulics pump

Steering hydraulics pump

Low pressure pump

High pressure relief valve

Attachment height control valve (E.M.R.)

Pressure sensor

Compensation valve

Accumulators

Non-return valve

Low pressure filter

High pressure filter

Oil cooler

Filler opening with filter

Drain hose

Oil reservoir R1 = R2

Hydraulic oil reservoir

Low pressure hydraulic oil reservoir

Breather with filter and non-return valve

Suction filter

To/from steering valve (without Auto-Pilot)

Thermovalve

Stack valve

To steering valve (with Auto-Pilot)

From steering valve (with Auto-Pilot)

From cutterhead reverse drive motor

Attachment lift cylinders

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2 1C

FX300-375 / 9630-9640 / 28--38

<< 1B

FX450 / 9645 / 48--58

Series 13 > ............

FX25/45

<< 1B

52595

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

HYDRAULIC RESERVOIR -- Figures 4 and 5 (Item R2 -- Fig. 1, 2 or 3) Oil specification Use AMBRA HYDROSYSTEM 46HV oil (ref. NH646H) or an oil meeting the following specification: --

DIN 51524 Part 2 or ISO VG46

Viscosity grade: 46

Oil change --

After the first 100 operating hours

Thereafter, every season or every 600 operating hours.

Refer to the Operatorâ&#x20AC;&#x2122;s Manual, chapter 3.5.

Capacity Figure 4: FX/96

Series 01 to 10

FX25/45

Series 01 and 02

Reservoir: 20 litres (21 qts.) Entire system: 35 litres (37 qts.) The reservoir consists of two completely separate reservoirs: the hydraulic reservoir (R2) and the hydrostatic reservoir (R1). The hydraulic reservoir is used for the work hydraulics system and the steering hydraulics system.

55144

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

Figure 5: FX/96

Series 13 > ............

FX25/45

Series 05 > ............

Reservoir: 38 litres (40 qts.) Entire system: 93 litres (98 qts.) (i.e. hydraulic + hydrostatic system) Both the hydraulic system (work hydraulics and steering hydraulics) and the hydrostatic system use oil from one reservoir. The separation plate inside the reservoir is perforated, except for the lower part (¦ 1/4 of the complete volume). That is to ensure a minimum oil level (¦ 3 litres) (3,2 qts.) for the steering system in case the hydraulic or the hydrostatic system is leaking oil.

52587

LOW PRESSURE FILTER -- Figures 4 and 5 (Item N -- Fig. 1, 2 or 3) The low pressure filter is installed on top of the hydraulic reservoir and has a by-pass (non-return) valve set to 1.15 bar (17 psi). Filter change At every (hydraulic) oil change.

HIGH PRESSURE FILTER -- Figure 6 (Item NN - Fig. 2 or 3) FX/96

Series 13 > ............

FX25/45

Series 05 > ............

The high pressure filter NN is installed between the electronic box and the spout base and has a by-pass (non-return) valve set to 3.5 bar (51 psi). Filter change At every oil change the filter element has to be changed. Refer to the Operator’s Manual, chapter 3.5.

52588

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

NON--RETURN VALVE (Item M -- Fig. 1, 2 or 3) Function This valve is set to 2 bar (29 psi). The valve is meant to ensure an oil pressure in the return line from the stalk valves V. This is to prevent the cutterhead reverse drive motor from running dry while the cutterhead is running in forward direction (refer to Chapter 3 -- Figures 1 and 2).

Figure 4: FX/96

Series 01 to 10

FX25/45

Series 01 and 02

This non-return valve is installed in front of the low pressure filter (Fig. 1). In case the valve had to be replaced, tighten the valve with a torque of 120 to 140 Nm (88 to 103 lbf.ft.). The elbow must be installed on the valve with a torque of 40 to 50 Nm (29 to 37 lbf.ft.). FX/96

Series 13 > ............

FX25/45

Series 05 > ............

The non-return valve is situated between the stalk valves V (Fig. 2 or 3) and the high pressure filter NN. NOTE: Ensure to install non-return valve M according to the symbol mark. (Oil flow is from stack valves V towards oil reservoir R2).

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2 BREATHER (Item S -- Fig. 1, 2 or 3) The breather allows the air in the reservoir to escape whenever a considerable oil flow arrives at the reservoir (e.g. when lowering the attachment).

WORK HYDRAULICS PUMP -- Figure 7 Specifications Gear pump Output per revolution: 19.2 cc (1,17 cu.in.) Direction of rotation: clockwise Pression on suction side: 0.3 - 1 bar (absolute) (4,3--14,5 psi) Maximum pressure: 210 bar (3045 psi) Maximum peak pressure: 230 bar (3335 psi) Maximum speed: 3000 rpm Minimum speed with maximum pressure: 1000 rpm

Legend to Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

Set of two bushings Pump housing Cover plate (to the hydrostatic pump) Cover plate (to the steering hydraulics pump) Driving gear Driven gear Anti-extrusion seal (2 off) Seal (2 off) Plug Plug M5 cap screw (torque 2.5 - 3.4 Nm) (1.8 - 2.5 lbf.ft) (2 off) Circlip Dowel pin (4 off) O-ring (2 off) Lip seal (2 off) O-ring

55124

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

HIGH PRESSURE RELIEF VALVE -- Figures 8 and 9 (Item G -- Fig. 1, 2 or 3) The high pressure relief valve G is situated on the right-hand side of the hydraulic reservoir. This valve is set at 160 bar (2320 psi) and protects the hydraulic circuit. NOTE: On machines equipped with an 8-row maize attachment (600 N8) or a Kemper Champion 6000 attachment, this valve must be replaced with a similar valve set at 180 bar (2610 psi). Exception: Models FX450 / 9645 / 48--58 from Series 13 onwards, which have larger diameter attachment lift cylinders, can keep the 160 bar (2320 psi) relief valve.

55146

51726

ATTACHMENT HEIGHT CONTROL VALVE (EMR) -- Figures 10 and 11 (Item H -- Fig. 1, 2 or 3) This valve is situated on the right-hand side of the forage harvester, under the stack valve. Figure 11 shows both a schematic drawing and a section of the attachment height control valve.

55145

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

Legend to Figure 10 and 11

Load sensing valve

Attachment height control spool

Oil flow from work hydraulics pump

Pilot line

Oil flow from or to the compensation valve

Pilot line

Oil flow from or to attachment lift cylinders

Restriction

Oil flow to stack valve

Flow limiter valve

Oil flow from or to the cutterhead reverse drive engaging valve

Non-return valve

Oil flow from or to the cutterhead reverse drive motor

Pressure relief valve (200 bar)

Adjustable restriction

Oil flow to hydraulic reservoir

Restriction

Port to K, 10

Restriction

Port to D

Spring

Port to V

Restricting pilot line

Port to R2

Chamber

Restriction grooves

Pressure line

Restriction

Chamber

Restriction grooves

Chamber

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

52596

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

16 Neutral position

The attachment height control spool b is not activated and thus remains in neutral position. The work hydraulics pump D pumps oil to port P:

â&#x20AC;˘

Maximum pressure (due to pressure relief valve G): a. Standard: 160 bar (2320 psi) b. Machines equipped with an 8-row maize attachment (600N8) or a Kemper Champion 6000 attachment: -- 180 bar (2610 psi): all models, except for FX450 / 9645 / 48--58 from Series 13 onwards -- 160 bar (2320 psi): model FX450 / 9645 / 48--58 up to Series 13

52 l/min (55 qts/min) (engine speed: 1900 rpm).

The load sensing valve a divides this oil flow first in two flows: 1. A small oil flow (Âą 4 litres/min) (4,2 qts/min) goes through restriction e to stack valve V. 2. The second flow (about the same amount) goes through restriction k. Control spool b does not permit any oil flow via line q. On the contrary, some oil can flow through pilot line d, via restrictions j, s and i to reservoir R2. The inlet pressure (port P) is also seated at the bottom of the load sensing valve a through pilot line c. When the inlet pressure is high enough to overcome the force of spring l and the pressure on this side of the load sensing valve a, valve a will move against spring l. This movement will open restriction e and close restriction k. Closing restriction k causes the pressure in the pilot line c to drop. This will move valve a over a certain distance back again, which closes restriction e and opens restriction k.

According to the level of the inlet pressure, the load sensing valve a will find an equilibrium position. Most of the oil flow will now go through the more opened restriction e to stack valve V.

Attachment lifting position The attachment height control spool b is moved to the left (according to the cross-section in Figure 11). The distance of movement of spool b depends on the average voltage that is put on the pushing solenoid. This average voltage depends on the input signal which the electronic attachment height control module receives. This input signal can come from either the attachment height control switch on the multifunction lever or from the pressure sensor on compensation valve K (see further). The signal from the attachment height control switch is always the same, which results in a definite position of the attachment height control spool b and, as a result, in a definite lifting (or lowering) speed of the attachment. The signal from the pressure sensor on the compensation valve depends on the difference between the calibrated and the measured pressure. As a result, in this case the position of the attachment height control spool b varies with the measured difference in pressure. In lifting position, oil can flow via restriction k through line q, to chamber n. Another oil flow reaches chamber n through pilot lines d and m. Both oil flows result in a drop of pressure in the neighbourhood of valve a. This means that load sensing valve a will now find an equilibrium that closes restriction e and that opens restriction k.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2 NOTE: The oil flow to the stack valve V, via restriction e, is at least 3.8 l/min. Depending on the distance spool b was moved, restriction p will be more or less open. The grooves on spool b provide a more sensitive control of the small oil flows through p. The grooves also result in a smoother transition when spool b starts moving. Pressure now builds up in chamber t, which forces valve f to move to the right (according to the crosssection on Figure 11). The pressure on the other side of valve f is on or below return oil pressure. Namely, restriction j is closed and restriction i brakes any pressure from the return circuit side. Valve f moving to the right, unlocks the opening to non-return valve g. Now oil can flow through chamber v via port A to Attachment lift cylinders 10 (and compensation valve K) .

Attachment lowering position The attachment height control spool b is moved to the right (according to the cross-section in Figure 11) over a certain distance, depending on the average voltage put on the left-hand side solenoid. Restriction p is closed. So, there is no oil flow through line q. Restriction w is more or less opened to the return circuit and allows the oil pressure in chambers v and t to drop to oil return pressure. The high oil pressure in chamber z, due to the weight of the attachment, and the low pressure in chamber v cause the non-return valve g to close. Similar to the neutral position, load sensing valve a moves to the right (according to the cross-section in Figure 11). The inlet oil flow is now divided into two flows. The major flow goes via restriction e to stack valve V. The minor flow goes via restriction k and pilot line d towards the rear side of valve f. The pressure on this

side is in between inlet pressure and return pressure due to restriction i. This means that this pressure is higher than the pressure in chamber t. This difference in pressure moves valve f to open the non-return valve g, which results in a lowering of the attachment. The oil flow from port A to control spool b results in a rise of pressure in chamber t. This moves valve f back again and tries to close the non-return valve g. The heavier the attachment, the more valve g will be closed to reduce the lowering speed. The lowering speed of the attachment is adjustable with the adjustable restriction i. Permitting more oil flow from pilot line d through restruction i to the return circuit, decreases the pressure on the rear side of valve f. This will reduce the lowering speed. Less oil flow through restriction i will increase the lowering speed.

Pressure relief valve h This valve is set to 200 bar (2900 psi). It protects the non-return valve g against overpressure in chamber z. Overpressure can originate when driving over bumpy surfaces.

Emergency hand buttons With these buttons, situated on both sides of the attachment height control valve H (Fig. 2 and 3) and 18), the attachment height control spool b can be activated manually. This is meant to be used in emergency cases. It may also be a useful instrument to check whether an error is situated in the electric wiring to the solenoids or in the attachment height control valve H itself. Push the rear button (closest to the door) to lower the attachment. Use the front button (closest tot the cab) to lift the attachment.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

18 Specifications Solenoid: 0-12 V

ATTENTION Never put 12V continuously to a solenoid as this will cause the solenoid to burn. It is allowed to put 12V on a solenoid as a pulse or maximum 7V continuously! Maximum permitted pressures: --

port P:

250 bar (3625 psi)

port R

5 bar (72,5 psi)

port N

200 bar (2900 psi)

Maximum oil flow: --

lifting attachment:

45 l/min (12 gpm)

lowering attachment:

63 l/min (17 gpm)

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

ATTACHMENT COMPENSATION VALVE -Figures 12 and 13 (Item K -- Fig. 1, 2 or 3) The compensation valve K is situated between the blower and the reversing gearbox above the traction axle. The attachment height control can be achieved in three modes. These modes can be chosen with the attachment height control selector switch on the arm rest module (refer to chapter 2.6 in the Operatorâ&#x20AC;&#x2122;s Manual). The electric circuit pilots the attachment height control valve H in these three modes: --

Transport mode: Manual operation of the attachment.

Stubble height mode: Atachment operates at a preset height.

Compensation mode: Attachment remains on the ground with a preset pressure.

In position 0, when the solenoid a is not activated, the attachment cylinders 10e and 10f are not directly connected with the accumulator(s). The oil flows between ports s and z via pilot line g, through valve h and orifice j. This is to increase the reaction time when lifting or lowering the attachment. In position 1, the solenoid is activated and pushes valve h against the spring. In this position oil can flow freely between ports S and Z via the outside of valve h. The attachment cylinders are directly connected with the accumulators, which absorb pressure shocks.

55147

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

55140

The compensation valve K functions as follows: Transport mode Always open (Solenoid a activated) Compensation mode a. When pressing the automatic attachment height control button: The compensation valve is closed until the attachment touches the ground. At that moment the compensation valve is opened. b. While working in compensation mode: always open. c. While lifting or lowering the attachment with the attachment height control switch (leaving compensation mode): Compensation valve is closed. Compensation valve opens 2 seconds after the switch was released.

Stubble height mode a. When pressing the automatic attachment height control button: Compensation valve is closed. Compensation valve opens 3.5 seconds after the button was released. b. While working in stubble height mode: always open. c. While lifting or lowering the attachment with the attachment height control switch (leaving stubble height mode): Compensation valve is closed. Compensation valve opens 2 seconds after the switch was released. Pressure sensor J measures the pressure in the attachment cylinders to give input for the attachment compensation system.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2 Specifications Solenoid: 0-12 V

ATTENTION Never put 12V continuously to a solenoid as this will cause the solenoid to burn. It is allowed to put 12V on a solenoid as a pulse or maximum 7V continuously! Switching only happens when the oil flow is about 0 l/min. Nominal oil flow: 100 l/min (26 gpm). Max. permitted pressure: 200 bar (2900 psi).

PRESSURE SENSOR (Item J -- Fig. 1, 2 or 3) This sensor measures the pressure in the attachment lift cylinders. The electronic attachment height control module compares this measured pressure with the pressure chosen with the ground pressure potentiometer on the arm rest module (refer to chapters 2.6 and 4.16 in the Operatorâ&#x20AC;&#x2122;s Manual). The electronic attachment height control module translates this difference in pressure in a voltage signal to one of the solenoids on the attachment height control valve H (Fig. 2 and 3). For instance, when the attachment (in compensation mode) is lifted by a stone, the pressure in the attachment cylinders drops below the chosen pressure. The electronic attachment height control module activates the front (lifting) solenoid of the attachment height control valve to compensate for the drop of pressure with an oil flow towards the attachment lift cylinders. The magnitude of the oil flow (i.e. the distance the attachment height control spool b moves) depends on the average voltage put on the solenoid of the attachment height control valve, which depends on the measured difference in pressure. Specifications Pressure: 0-160 bar (0--2320 psi) Supply: 8-12V Signal: Supply voltage + [0.25 to 0.75V]

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

HYDROPNEUMATIC ACCUMULATORS (Item L -- Fig. 2 and 3) When the attachment has to be changed from maize attachment to pick-up attachment, or vice versa, the pressure in the lift cylinders changes because of the difference in weight. This difference affects the required ground pressure level and, consequently, the accumulators required. FX/96 Series 01 to 10

FX300-375 / 9630-9640 FX 28--38 Series 13 > ..........

FX25/45 Series 01 and 02 (Figures 1 and 2)

FX25/45 Series 05 and 06 (Figure 2)

340W 350W 345W 355W 365W 360N4 300N6

Two accumulators: -- accumulator b: 70 bar -- accumulator c: 35 bar Between the two accumulators, a tap d is installed. Always leave tap d in open position.

Two accumulators: -- 70 bar -- 35 bar Tap deleted.

Kemper Champion 4500

Add a 100 bar accumulator Add a 100 bar accumula(instead of tap d). tor.

600N8 Kemper Champion 6000

Add a 100 bar accumulator (instead of tap d) and replace the 160 bar high pressure relief valve G by a 180 bar valve.

Attachment

ATTENTION To improve the stability of the forage harvester when equipped with heavy attachment, counterweight must be installed. Refer to paragraph 9.1 in the Operator’s Manual to know the recommended amount and combination of counter weights used. Furthermore, changing the attachment implies a recalibration of the ground level, the stubble height level and the ground pressure. The calibration procedure is explained in chapter 4.16 in the Operator’s Manual. Apart from this, the InfoView monitor must also be recalibrated for a new attachment width and attachment height. Refer to paragraph 4.17.4 in the Operator’s Manual.

FX450 / 9645 / FX 48--58 Series 13 > .......... (Figure 3)

Three accumulators: -- 85 bar -- 55 bar -- 30 bar No tap.

Add a 100 bar accumulator and replace the 160 bar high pressure relief valve G by a 180 bar valve.

It may even be necessary to check the potentiometer adjustment (measuring the height of the attachment). Refer to chapter 5.21 in the Operator’s Manual. One side of a hydropneumatic accumulator is filled with nitrogen. The other side is connected to the hydraulic lines to the attachment lift cylinders.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

Filling Required tools: ---

Bottled nitrogen Special tool (valve + pressure gauge) (Bosch ref. No. 0538103012)

Procedure 1. First loosen the umbracco screw on the accumulator. 2. Connect the special tool to the accumulator and to the bottle of nitrogen. 3. Open valve m and read the pressure registered on the pressure gauge. If necessary, add nitrogen by opening valve l. When the correct pressure is obtained, close valves m and l, bleed excess pressure through valve n and disconnect the special tool. 4. Tighten the umbracco screw.

40573

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

ATTACHMENT LIFT CYLINDERS (Item 10 -- Fig. 2 and 3) a

Piston rod

Seal ring

Cylinder

Seal ring

Locking wire

Scraper ring

Piston guide ring (2x)

(Dis)assembly groove

Locking groove

55141

55142

55143

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

To disassemble piston rod a (and the seal rings thereafter), move piston rod a until locking wire c is visible through the hydraulic line connection on cylinder b. Through this opening, locking wire c can be pushed (Fig. 16a) into groove h. In this position, locking wire c allows piston rod a to be pulled out. To reassemble, replace seals e and f installing them with their grooves (Fig. 14) facing inward using the special tool, as shown in Figure 17. Then install scraper ring g. After assembly of piston rod a, reinstall locking wire c in its original groove j (Fig. 16b).

30238

30239

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

SECTION 35 -- HYDRAULIC SYSTEM Chapter 3 -- Work Hydraulics -- Base Unit CONTENT Section

Description

Page

35.000

Circuit diagrams -- Base unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

35.310

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

CIRCUIT DIAGRAMS -- BASE UNIT 2A

FX/96

Series 01 to 10

FX25/45

Series 01 and 02

Circuit diagram -- Figure 1

Cutterhead reverse drive motor

Engine

Pressure relief valve

Main drive transfer gearbox

Spout rotation motor

Hydrostatic pump

Front hydraulics quick-release couplings

Work hydraulics pump

External front hydraulics

Steering hydraulics pump

Low pressure pump

Rear hydraulics quick-release couplings[accessory]

High pressure relief valve

External rear hydraulics

Attachment height control valve (E.M.R.)

Orifice

Compensation valve

Spout lift cylinder

Accumulators

Non-return valve

Low pressure filter

Filler opening with filter

Drain hose

Oil reservoir R1

Hydrostatic oil reservoir

Hydraulic oil reservoir

Low pressure hydraulic oil reservoir

Breather with filter and non-return valve

To/from steering valve (without Auto-Pilot)

Stack valve VA

Load sensing valve

Cutterhead reverse drive engaging valve

Spout rotation control

Auxiliary front hydraulics control valve

Auxiliary rear hydraulics control valve[accessory]

Spout height control valve

Top plate

To steering valve (with Auto-Pilot)

From steering valve (with Auto-Pilot)

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3 2A

FX/96

Series 01 to 10

FX25/45

Series 01 and 02

52597

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

4 2B

FX/96

Series 13 > 5080

FX25/45

Series 05 > 5080

Circuit diagram -- Figure 2 A

Engine

Main drive transfer gearbox

Hydrostatic pump

Check valve

Work hydraulics pump

Steering hydraulics pump

Low pressure pump

Thermovalve

Stack valve VA

Load sensing valve

Cutterhead reverse drive engaging valve

Spout rotation control

Auxiliary front hydraulics control valve

Auxiliary rear hydraulics control valve[accessory]

High pressure relief valve

Spout height control valve

Attachment height control valve (E.M.R.)

Top plate

Compensation valve

To steering valve (with Auto-Pilot)

Non-return valve

From steering valve (with Auto-Pilot)

Low pressure filter

High pressure filter

Oil cooler

Filler opening with filter

Cutterhead reverse drive motor

Drain hose

Pressure relief valve

Oil reservoir

Spout rotation motor

Front hydraulics quick-release couplings

R1 = R2

Hydraulic oil reservoir

External front hydraulics

Low pressure hydraulic oil reservoir

Rear hydraulics quick-release couplings[accessory]

Breather with filter and non-return valve

External rear hydraulics

Suction filter

Orifice

To/from steering valve (without Auto-Pilot)

Spout lift cylinder

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3 2B

FX/96

Series 13 > 5080

FX25/45

Series 05 > 5080

52598

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

6 2C

FX28--58

Series 5083 > .........

Circuit diagram -- Figure 3 A

Engine

Main drive transfer gearbox

Hydrostatic pump

Check valve

Work hydraulics pump

Steering hydraulics pump

Low pressure pump

Thermovalve

Stack valve VA

Load sensing valve

Cutterhead reverse drive engaging valve

Spout rotation control

Auxiliary front hydraulics control valve

Auxiliary rear hydraulics control valve[accessory]

High pressure relief valve

Spout height control valve

Attachment height control valve (E.M.R.)

Top plate

Compensation valve

To steering valve (with Auto-Pilot)

Non-return valve

From steering valve (with Auto-Pilot)

Low pressure filter

High pressure filter

Oil cooler

Filler opening with filter

Cutterhead reverse drive motor

Drain hose

Pressure relief valve

Oil reservoir

Spout rotation motor

Front hydraulics quick-release couplings

R1 = R2

Hydraulic oil reservoir

External front hydraulics

Low pressure hydraulic oil reservoir

Rear hydraulics quick-release couplings[accessory]

Breather with filter and non-return valve

External rear hydraulics

Suction filter

Orifice

To/from steering valve (without Auto-Pilot)

Spout lift cylinder

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3 2C

FX28--58

Series 5083 > .........

31345

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

HYDRAULIC RESERVOIR R2 LOW PRESSURE FILTER N HIGH PRESSURE FILTER NN NON-RETURN VALVE M BREATHER S WORK HYDRAULICS PUMP D HIGH PRESSURE RELIEF VALVE G ATTACHMENT HEIGHT CONTROL VALVE H (EMR) Refer to paragraph ‘‘Work hydraulics - Attachment height control’’.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

STACK VALVE -- Figure 4 (Item V -- Fig. 1 , 2 or 3) The stack valve is a modular system. This means that control valves can be added or removed quickly. When (re)assembling the stack valve, pay attention to the sequence (1 - 2 - 3) and the tightening torques of the bolts. Also adhere to the original sequence of installation of the valves and orifices.

43165

51139

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

Repair of control valves If a control valve does not respond to a switch command, either an electrical or a hydraulic problem may be the cause. â&#x20AC;˘

Electrical cause: No power supply to the solenoid spool or failure of solenoid spool. Result: The solenoid does not operate the valve spool. In this case, the valve spool can be manually activated by pushing on the rubber cap of the solenoid and moving the valve spool into an operating position.

DANGER Before activating a solenoid manually, ensure that everybody stands clear of the machine. Activate it just long enough to notice that the valve works.

Front button (closest to the cab)

Rear button (closest to the door)

Spout height control valve

DOWN

Auxiliary rear hydraulics control valve

Pressure RIGHT

Pressure LEFT

Auxiliary front hydraulics control valve

Pressure RIGHT

Pressure LEFT

Spout rotation control valve

RIGHT

LEFT

Cutterhead reverse drive

As a provisional solution, if there is no power available on a solenoid, the electrical wires of another valve (which is not needed at that moment) may be connected to the failed solenoid.

ATTENTION Never put 12V continuously to a solenoid as this will cause the solenoid to burn. It is allowed to put 12V on a solenoid as a pulse or maximum 7V continuously! â&#x20AC;˘

Hydraulic cause: Repair of an individual valve is not possible. Only replacement of the seal rings is possible.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

LOAD SENSING VALVE -- Figure 6 (Item VA -- Fig. 1, 2 or 3) System in neutral The work hydraulics pump D pumps oil via the attachment height control valve H (EMR) to the load sensing valve VA (Fig. 1 or 2 or 3). As no control valve (VB ... VF) is activated yet, pressure builds up between ports P and a. At the spring side c of the load sensing spool d, the pressure is approximately identical to the return oil pressure. When the pressure between ports P becomes high enough to surpass spring c (6 bar) and the return oil pressure, the load sensing spool d moves to the left (position 1). This connects inlet port P directly to return port R. The oil flows straight to hydraulic reservoir R2.

48103

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

CUTTERHEAD REVERSE DRIVE MOTOR (Item 1 -- Fig. 1, 2 or 3) The cutterhead reverse drive motor is situated on the right-hand side of the forage harvester at the front side of the engine (Fig. 7). Specifications -- Gear motor -- Output per revolution: 26.5 cc (1,62 cu.in) -- Max. pressure: 210 bar (3045 psi) -- Max. peak pressure: 230 bar (3335 psi) -- Max. speed: 3,000 rpm -- Min. speed at max. pressure: 800 rpm

55006

When the motor (i.e. valve solenoid VB) is not activated and the cutterhead is engaged (in forward drive), the motor works as an idling pump (Fig. 1, 2 or 3) The hydraulic line to the return circuit adds oil to the pump (motor) circuit or returns oil from that circuit. Another hydraulic line (dotted line in Figure 1, 2 or 3) returns the motor leak oil straight to the reservoir R2.

FX/96

Series 13 > 5080

FX25/45

Series 05 > 5080

Figures 2 and 8 Machines of the Series mentioned are equipped with a check valve CV. This non-return valve is situated between the pressure side (VB) and the return side (R2). The purpose of this valve is to avoid underpressure at the pressure side (VB) when the engine speed drops while driving the cutterhead in reverse. NOTE: If the check valve is installed in the wrong direction, the cutterhead reverse drive motor will not be able to drive the cutterhead (no pressure). NOTE: The non-return valve inside valve VB (Fig. 1) is removed from the above-mentioned Series onwards (Fig. 2 or 3).

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3 FX28--58

Series 5083 > .........

Figures 3 and 9 Machines of the Series mentioned are equipped with a reverse drive motor with built--in non--return valve. NOTE: Itâ&#x20AC;&#x2122;s possible to install this reverse drive motor on older units.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

14 FX/96

Series 01 > 5080

FX25/45

Series 01 > 5080

43158

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Dowel pin (4 off) Plastic plugs (2 off) Bolt (M10) (16 off) Washer (M10) (16 off) Circlip O-ring (4 off) O-ring (2 off) O-ring (2 off) Seal Bushing (2 off) Pump house

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Cover plate Cover plate Pump gear Pump gear Anti-extrusion seal (2 off) --Joint (2 off) -Gear pump chamber plate (2 off) Draining plug

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3 SPOUT VALVE

ROTATION

PRESSURE

RELIEF

(Item 2 -- Fig. 1, 2 or 3) This valve is mounted on top of the spout rotation motor. It protects motor 3 and its support from excessive tension when the spout reaches its mechanical stops. As shown in the circuit diagram (Fig. 1, 2 or 3), this valve protects both directions of rotation. FX 300--450/9635--9645 FX 25/45 The valves 4 and 5 open when the difference in pressure is 65 bar (950 psi) (at 60 l/min) (13,2 gpm). The valves are factory-set and sealed.

FX 28/58 The valve 1 opens when the difference in pressure is 65 bar (950 psi) at 50 l/min (13,2 gpm). The valve 1 is factory--set and sealed.

SPOUT ROTATION MOTOR (Item 3 -- Fig. 1, 2 or 3) This is an Orbit-type motor.7 Specifications --

Geometric displacement: 200 cc/rev (12,2 cu.in./ rev)

Max. speed continuous/intermitting: 300/375 rpm

Max. oil flow cont./int.: 60/75 l/min (16/20 gpm)

Max. differential pressure cont./int: 100/140 bar (1450/2030 psi)

Max. inlet or outlet pressure: 140/175 bar (2030/2540 psi)

Max. torque cont./int.: 24.3/33.5 Nm (18/24,5 lbf.ft)

Max. performance: 6.4/8.4 kW

When installing the motor or the worm wheel, special attention has to be paid to the adjustment of motor and worm wheel in relation to each other and to their supports (Fig. 13). Adjust the worm wheel as close as possible to the crown gear and eliminate possible axial play of the worm.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

To adjust, proceed as follows: FX/96

Series 01 to 10

FX25/45

Series 01 and 02

1. Check worm gear a for axial play. Maximum allowed axial play: 0.25 mm (0,01â&#x20AC;?). 2. To remove possible play, loosen bolts b and install shims between worm bracket g and bearing block d at e. Retighten bolts b. 3. Loosen the four worm gear bracket bolts f + j and adjust bracket g with bolts h so that there is no rotational play on the spout. 4. Rotate the spout a full cycle both left and right to ensure it moves freely. Readjust, if necessary. 5. Retighten all hardware and install all grease lines and covers. 6. Tighten bolts f + j to 95 Nm (70 lbf.ft) torque and retighten them after the first 50 operating hours. NOTE: Covers and grease lines are removed for clarity

FX/96

Series 13 > ............

FX25/45

Series 05 > ............

1. Check worm gear a for axial play. Maximum allowed axial play: 0.25 mm (0,01â&#x20AC;?). 2. To remove possible play, loosen bolts b and install shims between worm bracket g and bearing block d at e. Retighten bolts b. 3. The worm gear assembly pivots around the bolt and bushing connection j. 4. Loosen the three worm gear bracket bolts f and adjust bracket g with bolts h so that there is no rotational play on the spout. 5. Rotate the spout a full cycle both left and right to ensure it moves freely. Readjust, if necessary. 6. Retighten all hardware and install all grease lines and covers. Tighten bolts f to 95 Nm (70 lbf.ft) torque and retighten them after the first 50 operating hours.

30584

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3 QUICK--RELEASE COUPLINGS (Items 4 and 6 -- Fig. 1, 2 or 3) Specifications Maximum oil flow:

15 l/min (4 gpm)

Maximum pressure:

160 (180) bar (2320/2610 psi) (pressure relief valve G)

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

SPOUT LIFT CYLINDER (Item 9 -- Fig. 1, 2 or 3)

Cylinder disassembly and assembly

43168

14 a

Piston

Hole

Cylinder

Seal ring

Piston guide

O-ring

Piston guide

Seal ring

Bolt

O-ring

Washer

Scraper ring

Guide ring

Rod

Seal ring

5. Remove all seals (be careful not to scratch the grooves). 6. Replace the seals, taking into account the direction of the seal grooves. 7. When reassembling the cylinder, tighten bolt e with a torque of 142 Nm (105 lbf.ft).

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

Reinstallation of spout lift cylinder Pay attention to following remarks: --

Clean the ball joints r before reinstalling them.

Adjust the ball joints in such a way that, when the cylinder is fully retracted, the rubber cushion underneath the spout lies on the spout support.

The depth to which the ball joints are screwed in, must at least be equal to the diameter width of their threaded rod (M20 or M30).

Tighten the ball joints r to a torque of 170 to 180 Nm (125--132 lbf.ft).

Tighten nuts s to a torque of 190 Nm (140 lbf.ft)

Do not forget to reinstall orifice t.

43169

15 FX/96

Series 01 to 05

Orifice t is installed in the connection to the cylinder.

FX/96

Series 06 > ............

FX25/45

Series 01 > ............

Orifice t is installed in the connection of the same hydraulic line to the stalk valve VF.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

SECTION 35 -- HYDRAULIC SYSTEM Chapter 4 -- Steering Hydraulics CONTENT Section

Description

Page

35.000

Circuit diagrams -- Steering hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

35.310

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

STEERING HYDRAULICS -- 4WD WITHOUT AUTO--PILOT 3A

FX/96

Series 01 > ..........

FX25/45

Series 01 > ..........

Circuit diagram -- Figure 1 A

Engine

Main drive transfer gearbox

Hydrostatic pump

Work hydraulics pump

Steering hydraulics pump

Low pressure pump

From/ to header height control valve (EMR)

Non-return valve

Low pressure filter

Orifice

Filler opening with filter

Drain hose

Oil reservoir R1

Hydrostatic oil reservoir

Hydraulic oil reservoir

Low pressure hydraulic oil reservoir

Breather with filter and non-return valve

Steering valve (without Auto-Pilot)

From stack valve

From cutterhead reverse drive motor

Steering cylinders

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4 3A

FX/96

Series 01 > ..........

FX25/45

Series 01 > ..........

52599

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

STEERING HYDRAULICS -- 2WD WITHOUT AUTO--PILOT 3B

FX/96

Series 01 > ..........

FX25/45

Series 01 > ..........

Circuit diagram -- Figure 2 A

Engine

Main drive transfer gearbox

Hydrostatic pump

Work hydraulics pump

Steering hydraulics pump

Low pressure pump

From/ to header height control valve (EMR)

Non-return valve

Low pressure filter

Orifice

Filler opening with filter

Drain hose

Oil reservoir R1

Hydrostatic oil reservoir

Hydraulic oil reservoir

Low pressure hydraulic oil reservoir

Breather with filter and non-return valve

Steering valve (without Auto-Pilot)

From stack valve

From cutterhead reverse drive motor

Steering cylinders

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4 3B

FX/96

Series 01 > ..........

FX25/45

Series 01 > ..........

52800

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

HYDRAULIC RESERVOIR R2 LOW PRESSURE FILTER N NON-RETURN VALVE M BREATHER S Refer to paragraph ‘‘Work hydraulics - Attachment height control’’.

ORIFICE 0r FX/96

Series 13 > ..........

FX25/45

Series 05 > ..........

From these Series onward, an orifice has been installed at pressure port P of steering valve T.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

STEERING HYDRAULICS PUMP

55123

3 Bushing Pump housing Cover plate Cover plate Driving pump gear Driven pump gear Anti-extrusion seal (2 off) Seal

9. 10. 11. 12. 13. 14. 15.

Shaft coupling Plug (2 off) -M5 bolt (torque: 2.45 to 3.43 Nm!) (1,8 -- 2,5 lbf.ft) Dowel pin (4 off) O-ring O-ring (2 off)

Specifications

Maximum pressure: 250 bar (3625 psi)

Gear pump

Maximum peak pressure: 280 bar (4060 psi)

Output per revolution: 6 cc (0,37 cu.in.)

Maximum speed: 4,000 rpm

Direction of rotation: clockwise

Pressure on suction side: 0.3 -- 1 bar (absolute) (4,35 -- 14,5 psi)

Minimum speed at maximum pressure: 1,400 rpm

1. 2. 3. 4. 5. 6. 7. 8.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

8 STEERING VALVE

The steering valve is situated at the front under the cab. The Danfoss steering valve OSPC 100 ON consists of a selector valve and an orbit pump. The purpose of having an orbit pump built in the valve is to have a perfect ratio between the steering wheel and the steering cylinder, and to guarantee a manual operation in case of breakdown. The steering wheel controls the selector valve and the orbit pump. The valve sleeve is held in neutral by leaf springs. These leaf springs only allow a minor shifting between the valve sleeve and the spool when turning the steering wheel. Four ports discharge into the valve body. P:

Pressure inlet

Return to reservoir

L and R:

Left and right cylinder connection to steering.

A ball is fitted between the ports P and T. During normal operation the ball is pushed on its seat, closing the connection between P and T. When no oil under pressure (e.g. failure of hydraulic pump) flows from the pump into port P, steering will still be possible as the return oil pushes the ball from its seat and flows into suction line P. The pressure relief valve, situated between inlet P and return T, is set to 140 bar (2030 psi). The double-acting shock-valve situated between ports L and R is set to 200 bar (2900 psi).

50482

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4 STEERING CYLINDERS Disassembly and assembly -- Figure 5

WARNING This cylinder has an important safety function. Do not attempt to repair it unless you are totally familiar with it. Only use new genuine NEW HOLLAND parts.

1. Unscrew piston guide c using a hook spanner (hole j). 2. Pull out the ‘‘rod q - piston a - piston guide d’’ assembly. 3. Unscrew bolt e attaching piston a to piston guide d. 4. Remove piston a from piston guide d. 5. Remove all seals (be careful not to scratch the grooves). 6. Replace the seals, taking into account the direction of the seal grooves. 7. When reassembling the cylinder, tighten bolt e with a torque of: -- 108 Nm (79 lbf.ft) for 2WD steering cylinders -- 164 Nm (120 lbf.ft) for 4WD steering cylinder

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

43157

5 a

Piston

Hole

Cylinder

Seal ring

Piston guide

O-ring

Piston guide

Seal ring

Bolt

O-ring

Washer

Scraper ring

Guide ring

Rod

Seal ring

Toe--in adjustment, steering ball joints, steering wheel stops Refer to the Operatorâ&#x20AC;&#x2122;s Manual, chapter 5.13.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4 STEERING HYDRAULICS -- 4WD WITH AUTO-PILOT 3C

FX/96

Series 01 > ..........

FX25/45

Series 01 > ..........

Circuit diagram -- Figure 6 A

Engine

Main drive transfer gearbox

Hydrostatic pump

Work hydraulics pump

Steering hydraulics pump

Low pressure pump

From/ to attachment height control valve (EMR)

Non-return valve

Low pressure filter

Orifice

Filler opening with filter

Drain hose

Oil reservoir R1

Hydrostatic oil reservoir

Hydraulic oil reservoir

Low pressure hydraulic oil reservoir

Breather with filter and non-return valve

From stack valve

Pressure relief valve

Steering valve (with Auto-Pilot)

Selector valve

Auto-Pilot valve

From cutterhead reverse drive motor

Steering cylinders

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

12 3C

FX/96

Series 01 > ..........

FX25/45

Series 01 > ..........

52601

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4 STEERING HYDRAULICS -- 2WD WITH AUTO-PILOT 3D

FX/96

Series 01 > ..........

FX25/45

Series 01 > ..........

Circuit diagram -- Figure 7 A

Engine

Main drive transfer gearbox

Hydrostatic pump

Work hydraulics pump

Steering hydraulics pump

Low pressure pump

From/ to attachment height control valve (EMR)

Non-return valve

Low pressure filter

Orifice

Filler opening with filter

Drain hose

Oil reservoir R1

Hydrostatic oil reservoir

Hydraulic oil reservoir

Low pressure hydraulic oil reservoir

Breather with filter and non-return valve

From stack valve

Pressure relief valve

Steering valve (with Auto-Pilot)

Selector valve

Auto-Pilot valve

From cutterhead reverse drive motor

Steering cylinders

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

14 3D

FX/96

Series 01 > ..........

FX25/45

Series 01 > ..........

52602

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4 Contrary to the steering valve T used without AutoPilot (type OSPC 100 ON), this steering valve X (type OSPB 100 ON) does not contain a selector valve nor a pressure relief valve. This steering valve only consists of an orbit pump. The selector valve Y is integrated in the Auto-Pilot valve Z. The pressure relief valve W is a separate component on the forage harvester. At port P of the steering valve X an orifice Or (dia. 2.5 mm) (0,1â&#x20AC;?) is installed. The widest part of it has to face port P.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 4

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

SECTION 35 -- HYDRAULIC SYSTEM Chapter 5 -- Low Pressure Hydraulics CONTENT Section

Description

Page

35.000

Circuit diagrams -- Low pressure hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

35.300

35.310

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

LOW PRESSURE HYDRAULICS -- 4WD 4A

FX/96

Series 01 > 13

FX25/45

Series 01 > 05

Circuit diagram -- Figure 1 A

Engine

Main drive transfer gearbox

Hydrostatic pump

Work hydraulics pump

Steering hydraulics pump

Low pressure pump

Low pressure valve

Main hydraulic clutch (is part of B).

Filter

Pressure contacts

Drain hose

Oil reservoir R1

Hydrostatic oil reservoir

Hydraulic oil reservoir

Low pressure hydraulic oil reservoir

Main drive belts tensioning cylinder

Four-wheel drive clutch

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5 4A

FX/96

Series 01 > 13

FX25/45

Series 01 > 05

52603

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

LOW PRESSURE HYDRAULICS -- 4WD 4B

Series 14 > ..........

FX25/45

Series 06 > ..........

Circuit diagram -- Figure 2 A

Engine

Main drive transfer gearbox

Hydrostatic pump

Work hydraulics pump

Steering hydraulics pump

Low pressure pump

Low pressure valve

Main hydraulic clutch (is part of B).

Filter

Pressure contacts

Drain hose

Oil reservoir R1

Hydrostatic oil reservoir

Hydraulic oil reservoir

Low pressure hydraulic oil reservoir

Main drive belts tensioning cylinder

Hydraulic spout deflector cylinder

Four--wheel drive clutch

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5 4B

Series 14 > ..........

FX25/45

Series 06 > ..........

31340

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

LOW PRESSURE HYDRAULICS -- 4WD + HYDRAULIC DEFLECTOR (FIELD INSTALLED KIT) 4C

FX/96

Series 01 > 13

FX25/45

Series 01 > 05

Circuit diagram -- Figure 3 A

Engine

Main drive transfer gearbox

Hydrostatic pump

Work hydraulics pump

Steering hydraulics pump

Low pressure pump

Low pressure valve

Main hydraulic clutch (is part of B).

Filter

Pressure contacts

Drain hose

Oil reservoir R1

Hydrostatic oil reservoir

Hydraulic oil reservoir

Low pressure hydraulic oil reservoir

Main drive belts tensioning cylinder

Four--wheel drive clutch

Hydraulic spout deflector cylinder

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5 4C

FX/96

Series 01 > 13

FX25/45

Series 01 > 05

34341

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

LOW PRESSURE HYDRAULICS -- 2WD 4D

FX/96

Series 01 to 09

FX25/45

Series 01

Circuit diagram -- Figure 4 A

Engine

Main drive transfer gearbox

Hydrostatic pump

Work hydraulics pump

Steering hydraulics pump

Low pressure pump

Low pressure valve

Main hydraulic clutch (is part of B).

Filter

Pressure contacts

Drain hose

Oil reservoir

Hydrostatic oil reservoir

Hydraulic oil reservoir

Low pressure hydraulic oil reservoir

Main drive belts tensioning cylinder

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5 4D

FX/96

Series 01 to 09

FX25/45

Series 01

52604

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

LOW PRESSURE HYDRAULICS -- 2WD 4E

FX/96

Series 10 > 13

FX25/45

Series 02 > 05

Circuit diagram -- Figure 5 A

Engine

Main drive transfer gearbox

Hydrostatic pump

Work hydraulics pump

Steering hydraulics pump

Low pressure pump

Low pressure valve

Main hydraulic clutch (is part of B).

Filter

Pressure contacts

Drain hose

Oil reservoir

Hydrostatic oil reservoir

Hydraulic oil reservoir

Low pressure hydraulic oil reservoir

Main drive belts tensioning cylinder

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5 4E

FX/96

Series 10 > 13

FX25/45

Series 02 > 05

52605

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

LOW PRESSURE HYDRAULICS -- 2WD 4F

Series 14 > ..........

FX25/45

Series 06 > ..........

Circuit diagram -- Figure 6 A

Engine

Main drive transfer gearbox

Hydrostatic pump

Work hydraulics pump

Steering hydraulics pump

Low pressure pump

Low pressure valve

Main hydraulic clutch (is part of B).

Filter

Pressure contacts

Drain hose

Oil reservoir R1

Hydrostatic oil reservoir

Hydraulic oil reservoir

Low pressure hydraulic oil reservoir

Main drive belts tensioning cylinder

Hydraulic spout deflector cylinder

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5 4F

Series 14 > ..........

FX25/45

Series 06 > ..........

31342

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

LOW PRESSURE HYDRAULICS -- 2WD + HYDRAULIC DEFLECTOR (FIELD INSTALLED KIT) 4G

FX/96

Series 01 > 13

FX25/45

Series 01 > 05

Circuit diagram -- Figure 7 A

Engine

Main drive transfer gearbox

Hydrostatic pump

Work hydraulics pump

Steering hydraulics pump

Low pressure pump

Low pressure valve

Main hydraulic clutch (is part of B).

Filter

Pressure contacts

Drain hose

Oil reservoir R1

Hydrostatic oil reservoir

Hydraulic oil reservoir

Low pressure hydraulic oil reservoir

Main drive belts tensioning cylinder

Hydraulic spout deflector cylinder

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5 4G

FX/96

Series 01 > 13

FX25/45

Series 01 > 05

31343

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

LOW PRESSURE HYDRAULIC RESERVOIR R3 Oil level The oil level should be checked daily on the dipstick of filler cap 1.

Capacity Reservoir: 7 litres (7.4 qts) Entire system: 10 litres (10,6 qts) 58209

Oil specification Use AMBRA HYDROSYSTEM 46HV oil (ref. NH646H) or an oil meeting the following specification: DIN 51524 Part 2 or ISO VG46 Viscosity grade: 46

Oil change After the first 100 operating hours Thereafter: -- when the flow indicator 2 becomes red (Fig. 8) or, -- every 600 operating hours or, -- every year

OIL FILTER This self-indicating filter must be changed at every oil change. NOTE: Check the flow indicator with the engine running.

58210

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5 OIL CHANGE AND FILL PROCEDURES

3. Unscrew the suction line from the low pressure pump.

Oil change 4. Fill the suction line with oil. 1. Drain the oil reservoir. 5. Screw the section line back to the pump. 2. Thoroughly clean the surrounding area of filter 3. 3. Remove the filter bowl.

6. Carry out the oil pressure check procedure below.

4. Fill the reservoir to the dipstick mark. 5. Fill the new filter bowl with new hydraulic oil. 6. Apply a film of oil to the gasket of the new filter bowl. 7. Screw on the new filter by hand. Tighten firmly but DO NOT USE TOOLS. 8. Carry out the oil pressure check procedure below.

Filling the system when (re)installing the low pressure pump

Oil pressure check procedure 1. First check the oil level in the reservoir. 2. Start the engine and let it run at low idle. 3. Switch ON the Harvest switch. Check if the main drive belts are tensioned by the cylinder. If not, shutt off the engine and check whether the suction line to the low pressure pump is filled with oil. 4. If the belts are tensioned, reverse the feed rolls to lift the pawl and switch ON the cutterhead drive switch.

1. Fill the suction line before connecting it to the pump.

5. Increase the engine speed to at least 1700 rpm.

2. Carry out the oil pressure check procedure below.

6. Watch the ‘‘Main drive clutch oil pressure’’ warning light on the instrument panel.

Flling the system after (re)installing the main drive transfer gearbox 1. First fill the main drive transfer gearbox from the top until the oil level in the reservoir rises (i.e. 4 to 5 litres of oil). 2. Fill the oil reservoir through the filler cap to the dipstick mark.

7. This warning light should not be illuminated or at least disappear within 15 seconds. If the warning light remains illuminated, stop the engine and search for the cause. With the engine running at 1900 rpm and the cutterhead engaged, the pressure measured at pressure check point W should be: • •

31-33 bar (450--480 psi) at an oil temperature of 30-40_C (86--104_F) 30 bar (435 psi) at an oil temperature of 75-85_C (170--190_F)

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

LOW PRESSURE PUMP

55121 55121

10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Bushing Bushing Pump house Cover plate Cover Driven pump gear Driven pump gear Anti-extrusion seal Inner seal Outer seal (2 off) Bolt (4 off)

Specifications ----

Gear pump Output per revolution: 6 cc (0,37 cu.in.) (0,1 cu.in.) Direction of rotation: clockwise

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

Plastic plug Plastic plug --Circlip Circlip Dowel pin O-ring -Oil baffle

Pressure on suction side: 0.3 to 1 bar (absolute) (4,5 to 14,5 psi) Maximum pressure: 210 bar (3045 psi) Maximum peak pressure: 230 bar (3335 psi) Maximum speed: 5,000 rpm Minimum speed at max. pressure: 1,200 rpm

-----

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

LOW PRESSURE VALVE The low pressure valve is situated above the hydrostatic pump.

FX/96

Series 01 > 13

FX25/45

Series 01 > 05

To main hydraulic clutch

To/from hydraulic cylinder (main drive belts)

Not used

To 4-WD clutch (option)

Not used

Pressure contact 24 bar (350 psi) (main drive clutch)

MP1

Pressure contact 5 bar (70 psi) (hydrostatic charge pump)

From low pressure pump

From hydrostatic charge pump

To return circuit (hydraulic reservoir) To the main drive transfer gear-box gears

To return circuit (low pressure hydraulic reservoir)

Pressure check point

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

20 FX/96

Series 14 > ...........

FX25/45

Series 06 > ...........

To main hydraulic clutch

To/from hydraulic cylinder (main drive belts)

To/from hydraulic spoat deflector cylinder

To 4-WD clutch (option)

Not used

Pressure contact 24 bar (350 psi) (main drive clutch)

MP1

Pressure contact 5 bar (70 psi) (hydrostatic charge pump)

From low pressure pump

From hydrostatic charge pump

To return circuit (hydraulic reservoir) To the main drive transfer gear-box gears

To return circuit (low pressure hydraulic reservoir)

Pressure check point

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

Valve a -- main drive clutch and main drive belts cylinder

52085

This oil flow is meant to cool and lubricate the rotating parts inside the main drive transfer gearbox and flows via the overflow line r to the oil reservoir R3. The pressure at port B (the hydraulic cylinder) is not high enough to stretch the main drive belts.

When starting the forage harvester, the solenoid of valve a is automatically activated into position 1. The low pressure pump F pumps oil via port P. This oil flow is divided in an oil flow straight to the oil reservoir R3 (hydraulic line n) and an oil flow to the main drive transfer gearbox (hydraulic line q). --

NOTE: The main drive clutch H is part of the main drive transfer gearbox.

When switching ON the Harvest switch, none of the solenoids of valve a is activated. The valve moves back to neutral position. The pressure is now completely on the hydraulic cylinder, which stretches the main drive belts.

22 --

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5 When switching ON the cutterhead drive switch, valve a is activated into position 2.

Valve b -- 4WD clutch This valve is activated when:

NOTE: To achieve this step, the Harvest switch must be switched ON and the pawl of the metal detection stop system must be lifted from the pawl wheel.

---

The low pressure pump will pump oil via port A to the main hydraulic clutch H (hydraulic line s).

The pressure contact at port MP 1 switches off when the pressure, delivered by the charge pump of the hydrostatic pump C, drops below 5 bar (73 psi). In that case, the feed rolls will stop immediately.

The flow resistance of the clutch is such that the pressure on port B is still high enough to keep the main drive belts tensioned. The oil flow through the main hydraulic clutch H arrives at reservoir R3 via hydraulic line r. The pressure in this system is maximum 30 bar (435 psi), due to the pressure relief valve k. The pressure contact at port MP warns the operator through the ‘‘main drive clutch oil pressure’’ warning light that the pressure has dropped below 24 bar (348 psi). This is to protect the main clutch from slipping.

ATTENTION Never put 12V continuously to a solenoid as this will cause the solenoid to burn. It is allowed to put 12V on a solenoid as a pulse or maximum 7V continuously! The warning will only be activated in following conditions: ---

When the cutterhead is engaged When the engine speed is at least 1700 rpm

The Harvest switch is switched ON The 4-wheel drive switch is switched ON

After 5 seconds the main clutch will be disengaged giving the cutterhead, blower and spout time to clear. The engine slows down to low idle. Another 5 seconds later the engine will stop. Check the hydrostatic system.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

Valve D

Valve c

Valve d is not used. FX/96

Series 01 > 13

FX25/45

Series 01 > 05

Valve c is not used (Fig. 14). NOTE: Valves c and d are used in case the forage harvester is rebuilt with a field installed hydraulic spout deflector cylinder. FX/96

Series 14 > ..........

FX25/45

Series 06 > ..........

Valve C controls the hydraulic spout deflector cylinder (Fig. 15). The valve is activated when: ---

The harvest switch is switched on. Spout deflector rocker switch is activated (up or down).

31344

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

MAIN DRIVE BELTS TENSIONING CYLINDER

43160

16 a

Piston

Cylinder

Locking wire

Piston guide ring (2x)

Seal ring

Guide ring

Seal ring

The disassembly and assembly instructions are similar to those for the attachment lift cylinders.

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

SPOUT DEFLECTOR CYLINDER

17 1. 2. 3. 4. 5. 6. 7.

Bolt Washer Piston guide Guide ring Seal ring Seal ring Cylinder

1. Unscrew piston guide 9 using a hook spanner (cavity 13). 2. Pull out the “piston 8 -- piston guide 3” assembly. 3. Unscrew bolt 1 attaching piston 8 to piston guide 3. 4. Remove piston 8 from piston guide 3. 5. Remove all seals (be careful not to scratch the grooves). 6. Replace the seals taking into account the direction of the seal grooves. 7. When reassembling the cylinder, tighten bolt 1 with a torque of 34 Nm (25 lbf.ft).

8. 9. 10. 11. 12. 13. 14.

Piston Piston guide O--ring Seal ring O--ring Cavity Scraper ring

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 5

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 6

SECTION 35 -- HYDRAULIC SYSTEM Chapter 6 -- Hi--Flow Hydraulics CONTENT

Section

Description

Page

35.000

Circuit diagrams -- Hi--flow hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 6

HI--FLOW HYDRAULICS -- EUROPE 5A

FX/96

Series 01 > 5080

FX28--48

Series 5083 > ......

Circuit diagram -- Figure 1 A

Engine

Supporting bearing

Pump

Control valve

Quick--release couplings

Pressure relief valve

Low pressure valve

Drain plug

Oil reservoir

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 6 5A

FX/96

Series 01 > 5080

FX28--48

Series 5083 > ......

52606

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 6

HI--FLOW HYDRAULICS -- EUROPE 5B

FX58

Series 5083 > ......

Circuit diagram -- Figure 2 A

Engine

Supporting bearing

Pump

Control valve

Quick--release couplings

Pressure relief valve

Low pressure valve

Drain plug

Oil reservoir

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 6 5B

FX58

Series 5083 > ......

31347

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 6

HI--FLOW HYDRAULICS -- NORTH AMERICA 5C

FX25/45

Series 01 > 06

FX58

Series 5083 > ......

Circuit diagram -- Figure 3 A

Engine

Supporting bearing

Pump

Control valve

Quick--release couplings

Pressure relief valve with extra, controlled oil return flow

Low pressure valve

Drain plug

Oil reservoir

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 6 5C

FX25/45

Series 01 > 06

FX58

Series 5083 > ......

52607

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 6

HI--FLOW HYDRAULICS -- NORTH AMERICA 5D

FX25/45

Series 5033 > 5080

FX28--48

Series 5083 > ......

Circuit diagram -- Figure 4 A

Engine

Supporting bearing

Pump

Control valve

Quick--release couplings

Pressure relief valve with extra, controlled oil return flow

Low pressure valve

Drain plug

Oil reservoir

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 6 5D

FX25/45

Series 5033 > 5080

FX28--48

Series 5083 > ......

31346

SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 6

SECTION 50 -- CAB CLIMATE CONTROL -- CHAPTER 1

SECTION 50 -- CAB CLIMATE CONTROL Chapter 1 -- Cab Cimate Control CONTENT Section

Description

Page

50.000

50.200

50.206

Ventilation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 50 -- CAB CLIMATE CONTROL -- CHAPTER 1

CORRECT USE OF THE AIRCONDITIONING SYSTEM --

Keep door and window closed.

Use the airconditioning as much as possible.

Use the airconditioning only with the ventilator in position I or II.

Control the desired temperature with the airconditioning knob (thermostat).

Regularly pay attention to the following: --

The status of the sight glass and the moisture indicator (Fig. 2).

The cleanliness of the condenser and evaporator.

The cleanliness of the air intake filters.

The cleanliness of the air recycling filter 4 (Fig. 3).

The water dropping at the drain tubes.

STORAGE MAINTENANCE Operate the airconditioning unit with the engine on idle speed and the ventilator on position II for at least five minutes once a month during the storage period (i.e. to oil all compressor seals and to avoid leakages). NOTE: The airconditioning system must only be operated if the cab temperature is 21Â°C or more. The airconditioning system must only be operated if the ambient temperature is higher than 10Â°C. ATTENTION: It is fully recommended to have the airconditioning system checked yearly by a specialist (before the start of the harvest season). ATTENTION: After recharging of the system by a specialist, ensure the engine speed is set at low idle, then engage and run the airconditioning system for two (2) minutes to allow the system gas and lubrication to normalise. After this initial run--up the system can be used normally.

SECTION 50 -- CAB CLIMATE CONTROL -- CHAPTER 1

AIR CONDITIONING CIRCUIT Components 1. 2. 3. 4. 5. 6. 7. 8. 9.

Compressor High pressure switch High pressure charge port Condenser Filter--drier Expansion valve Evaporator Low pressure charge port Low pressure switch

51125

SECTION 50 -- CAB CLIMATE CONTROL -- CHAPTER 1

SPECIFICATIONS

NOTE: The use of R134a in an automotive airconditioning compressor requires special attention to lubrication. A specific PAG--type oil, Sanden SP--20, has been developed to suit the SD7H15. Care must be taken to avoid incorrect oils being used as SP--20 is the only lubricant approved for use with the SD7H15.

Refrigerant Specification: R134 a Amount: 2100 gr

Compressor clutch Rated voltage: DC 12V

Compressor

Break--away torque: 34 Nm (3.5 kgf.m)

Type: SANDEN SD7H15KG7862

Minimum engagement voltage: 7.5 V

Displacement per revolution: 154.9 cc Oil capacity: 360 cc (Sanden SP--20) (135 cc in compressor + 225 cc in circuit)

Power consumption: 49 W Belt type: A type

Circuit parameters

Airconditioning

Ambient temperature °C

Low pressure bar High pressure bar

Not in operation

4.5

Not in operation

6.5

In operation

0.5 to 1

In operation

Low pressure switch Switch normally open: non adjustable Cut--in set point: 2.5 bar ± 0.3 bar Cut--out set point: 0.3 bar ± 0.15 bar Switch body colour: bronze

High pressure switch Switch normally closed: non adjustable Cut--out set point: 28 bar ± 1.5 bar Cut--in set point: 19 bar ± 1.5 bar Switch body colour: green

SECTION 50 -- CAB CLIMATE CONTROL -- CHAPTER 1

Filter--drier A sight glass and a ring--shaped moisture indicator serve for determining the condition of the R134 a. IF: -- The glass shows a milky refrigerant without air bubbles, then the refrigerant is OK. --

The glass shows air bubbles: lack of refrigerant.

The moisture indicator is blue: filter and refrigerant are OK.

The moisture indicator is red: too much moisture: filter--drier has to be replaced.

The moisture indicator is brown or black: too much contamination: filter--drier has to be replaced.

NOTE: The filter--drier must be replaced when the airconditioning circuit has been opened. 1. 2. 3.

Outlet Sight glass and moisture indicator Inlet

51126

SECTION 50 -- CAB CLIMATE CONTROL -- CHAPTER 1

COMPRESSOR CLUTCH REPLACEMENT Clutch removal 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.

30288

3 Remove the clutch plate using a puller. Align the puller centre bolt to the compressor shaft. Thumb tighten the 3 puller bolts into the threaded holes. Turn the centre bolt clockwise until the front plate is loosened.

30287

4 Remove the shaft key by lightly tapping it loose with a slot screw driver and hammer.

30291

5 Remove the internal bearing snap ring.

30290

SECTION 50 -- CAB CLIMATE CONTROL -- CHAPTER 1

Remove the front housing external snap ring.

30292

7 Remove the rotor pulley assembly: -- Insert the lips of the jaws into the internal bearing snap ring groove. -- Place the rotor puller shaft protector over the exposed shaft.

30295

30289

9 Align the thumb head bolts to the puller jaws and finger--tighten.

30286

SECTION 50 -- CAB CLIMATE CONTROL -- CHAPTER 1

Turn the puller centre bolt clockwise until the rotor pulley is free.

30280

11 Remove the field coil Loosen the coil lead wire from the clip on top of the compressor front housing.

30281

12 Remove the snap ring and the field coil.

30294

13 Clutch 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.

30293

SECTION 50 -- CAB CLIMATE CONTROL -- CHAPTER 1

Support the compressor on the 4 mounting ears at the compressor rear side. If using a vise, clamp only the mounting ears, never the compressor body itself. Align the rotor assy squarely on the front housing hub. Using a hammer and a special tool, tap until the rotor bottoms to the compressor front housing hub.

30283

15 Reinstall the internal bearing snap ring. Reinstall the front housing external snap ring.

30284

16 Replace the front plate assy. Check that the original clutch shims are in place on the compressor shaft. Replace the compressor shaft key. Align the front plate keyway to the compressor shaft key. Using a shaft protector, tap the front plate to the shaft until it has bottomed to the clutch shims.

30282

17 Replace the shaft hex nut and torque to 35 to 40 Nm (3.5 to 4 kgf.m). Check the air gap with a feeler gauge (0.4 to 0.8 mm). 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.

30285

SECTION 50 -- CAB CLIMATE CONTROL -- CHAPTER 1

VENTILATION UNIT The ventilation unit is situated underneath the seat. 1. 2. 3. 4. 5.

Ventilator Thermostat Evaporator Air recycling filter Drink storage place

IMPORTANT: -- If the drink storage door is open, the ventilator and airconditioning system are switched off. -- Flipping up the operator’s seat to get access to the ventilation unit does NOT switch off the ventilator and airconditioning system! • Take care not to injure your fingers. • The ventilator will now have very low resistance, which can cause the fuse (F3) to be blown.

51124

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

SECTION 55 -- ELECTRICAL SYSTEM Chapter 1 -- Electrical Circuits CONTENT Section

Description

Page

55.000

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

55.100

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 1 GENERAL INFORMATION Wires The wiring diagram is drawn following the DIN 40719 standards. Each page contains a part of the complete wiring diagram, not necessarily a complete group. Color code Ten colours of wires are used on the combine, each color having its specific signification. --

Red (rd):+ 12 V without passing the ignition switch

Black (zw): directly earthed to the frame

White (wt): connected with the pin of a switch which engages a system that increases something (e.g. increase of drum rpm)

Grey (gr): connected with the pin of a switch which disengages a system that decreases something

Brown (br): signal wire from the rpm monitor to a sensor

Blue (bl): earth of sensors through the monitor

Green (gn): wire to non rpm sensors (e.g. engine oil pressure, temperature, etc)

Orange (or): lighting

Yellow (ge): lighting

Purple (pu): to rear direction indicator lights.

On the upper part of the page, the + 12 V lines are drawn.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

The line at the top (first line) always is at + 12 V (when the main battery switch is engaged). Lines 2 and 3 have + 12 V when relays K6 and K9 are energized. This happens when the ignition switch is engaged.

820

E.g.

100

110

120

130

52865 1

Wire identification The wiring diagram is marked as follows: --

X16p01: Connector X16, position 01

893: Wire number

6: Wire section is 6 mm2

wt: Wire color (white)

X108p02: Connector X108, position 02

52866 2

This information is printed at regular distances on the wire itself, e.g. X16/01 < - 893 - > X108/02 Thick drawn lines in the wiring diagrams do not exist as a wire but are lines in the printed circuit.

51844 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 1

4 Fuses

A fuse can protect one or more electrical circuits. When more circuits are protected, the first time the fuse is mentioned, the drawing is as follows (really connected):

51845 4

The other circuits that are protected by the same fuse are drawn as follows: (*): The line reference indicates the line on which all connections (lines) with that particular fuse are mentioned.

51846 5

SYMBOLS All symbols used in the wiring diagram are drawn according to the DIN 40719 standard and are marked with a letter and a number. Each letter components.

represents

group

similar

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 The letters used can be found in following list: Letter

Component

Example

Monitors, prints

Radio, CB, displays

Commutator from non-electrical into electrical signals, and vice versa

Sensor, horn, sender elements of water, air, oil temperature and pressure, buzzer

Condensers

Accumulator equipment

Accumulators

Lighting

All lamps, except warning lights, dashboard lights

Safety components

All fuses

Generators

Battery, alternator

Control components

All control lamps

Relays

All relays, flasher unit, 12/24 V transformer

Inductive components

Coils in relays Motors

Motors

Varistor motors, ventilator, actuators

Amplifier, controller

Voltage controller

Measuring instrument

Clock, fuel and water temperature gauge

Resistances

Potentiometer, preheating

Switch

All switches

Transformer

Ignition coils

Commutator from electrical signals into other electrical signals

Frequence commutator, converter

Semi-conductors

Diodes, transistors, thyristors

Wiring looms, antennas

CB and radio antenna, coax wires

Connectors

All connectors, plugs

Mechanical components electrically energized

Hydraulic valve, electromagnetic clutches, electrical valve on injection pump.

Electrical filter

Suppressor

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 1

The letters used can be found in following list: Symbol

Description Electrical motor, actuator

Lamp

Double-acting lamp

Diode

Led (light emitting diode)

Fuse

Socket (female)

Plug in (male)

Automatic fuse

Buzzer

Inductive sensor

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 Symbol

Description Horn

Ignition switch

Solenoid for control valves

Flashing unit

Battery

Gauge

Electromagnetic clutch

Adjustable resistance

Bipolar switch

Loudspeaker

Alternator

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 1

8 Symbol

Description Wiper motor

Electric starter motor

Normally closed switch, manually controlled

Normally open switch, mechanical control by pedal

Normally open switch, mechanically controlled

Normally closed switch, mechanically controlled

Normally open switch, controlled by a pressure sender

Normally open switch, controlled by under-pressure

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 Symbol

Description Normally closed switch, controlled by over-pressure

Normally open switch, controlled by a temperature sender

Normally closed switch, controlled by a level indicator

Normally open switch, controlled by the grain level indicator

Relay

Airconditioning ventilation motor

Mirror motor

The switches are drawn in the position as they are removed from the forage harvester.

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 1

Relays A fuse can protect one or more electrical circuits. NOTE: Never use relays with a diode parallel with the coil or without a suppressor. Relays with terminal references 1 - 2 - 3 - 4 - 5 (see diagrams) have no suppressor and are soldered to the printed circuit. The relays can be recognized by the drawing on the relay housing (Figures 6 to 8). Use relays with drawing as shown in Figure 6.

52867 6

Do not use relays with drawings as shown in Figures 7 and 8.

52868 7

52869 8

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

CONNECTORS X168 X199 X328 X500 X625 X630 X653

1 2

ZDA0428A

9 X106

10 X194 X195 X196

ZDA0429A

11 X193 X198

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 1

X92 X604 X625

13 X401 X402 X403 X404 X405 X406 X407 X408 X409 X410 X411 X412 X413 X414 X416 X417 X421 X422 X423 X424 X431 X433 X480

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15

ZDA0436A

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

X303 X415 X432 X434 1 14 2 15 3 16 4 17 5 18 6 19 7 20 8 21 9 22 10 23 11 24 12 25 13

ZDA0437A

X57

35 34 33 17 16 15 14

ZDA0438A

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 1

X91 X121 X131 X132 X169 X170 X257 X608 X620 X638 X644 X645

2 3 1

ZDA0425A

17 X105 X134 X171 X191 X331 X600 X601 X606 X607 X612 X615 X616 X635 X636 X637 X639 X641

2 3 1

ZDA0427A

X329

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

X21 X184 X323 X609 X614 X621 X649

ZDA0447A

20 X318 X319 X613

21 X192 X617 X618 X619 X640 X648

2 3

6 7

ZDA0446A

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 1

X26 X302 X306 X503 X505 X512 X513

1 3

2 6

14 15

ZDA0444A

X332 X511

ZDA0439A

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

X06 X500 X502 X507

16 24

ZDA0441A

X509

ZDA0440A

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 1

X501

5 10

15 22

23 29

33 37

ZDA0442A

X10 X305 X504 X506 X508

15 21

20 22

ZDA0443A

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

X260

29 X155

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 1

X627

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 3 -- Wiring Diagrams FX NA

CONTENT Section

Description

Page

55.000

Wiring diagrams FX NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 ELECTRICAL DIAGRAMS

Ref. 1a 1b 1c 1d

Line 10 10 10 10

Group / Series STARTER CIRCUIT 24V FX25 39.01 > 5080

FX45 47.01 > 5080

STARTER CIRCUIT 24V FX28NA 5083 > 5168

FX38NA

5083 > 5168

STARTER CIRCUIT 24V FX28NA 5186 > 5206

FX38NA

5186 > 5206

STARTER CIRCUIT 24V IVECO FX28NA 5218 > .... FX38NA

STARTER CIRCUIT 24V CATERPILLAR FX58NA 5083 > 5168

STARTER CIRCUIT 24V CATERPILLAR FX58NA 5186 > 5206

STARTER CIRCUIT 24V CATERPILLAR FX58NA 5218 > ....

520

ENGINE THROTTLE CONTROL FX25 39.01 > 5080 FX45

2b 2c

520 520

5218 > ....

47.01 > 5080

ENGINE THROTTLE CONTROL FX28NA 5083 > 5168 FX38NA

5083 > 5168

ENGINE THROTTLE CONTROL FX28NA 5186 > 5206 FX38NA

5186 > 5206

520

ENGINE THROTTLE CONTROL IVECO FX28NA 5218 > .... FX38NA 5218 > ....

520

ENGINE THROTTLE CONTROL CATERPILLAR FX58NA 5083 > 5168

520

ENGINE THROTTLE CONTROL CATERPILLAR FX58NA 5186 > 5206

520

ENGINE THROTTLE CONTROL CATERPILLAR FX58NA 5218 > ....

690

HYDROSTATIC CONTROL FX25 39.01 > 5080

FX45 47.01 > 5080

HYDROSTATIC CONTROL FX28NA 5083 > 5206

FX38NA

3b 3c 3d

690 690 690

HYDROSTATIC CONTROL IVECO FX28NA 5218 > .... FX38NA

5083 > 5206 5218 > ....

HYDROSTATIC CONTROL CATERPILLAR FX58NA 5083 > 5206

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 Ref.

Line

Group / Series

690

HYDROSTATIC CONTROL CATERPILLAR FX58NA 5218 > ....

860

FOUR--WHEEL DRIVE FX25 39.01 > 39.05

FX45

47.01 > 47.05

FOUR--WHEEL DRIVE FX25 39.06 > 5080

FX45

47.06 > 5080

FOUR--WHEEL DRIVE FX28NA 5083 > ....

FX38NA

4b 4c

860 860

5083 > ....

FX58NA

5083 > ....

1030

ELECTRONIC SYSTEM: MULTIFUNCTIONAL LEVER AND INSTRUMENT PANEL 1 FX25 39.01 > 39.04 FX45 47.01 > 47.04

1030

ELECTRONIC SYSTEM: MULTIFUNCTIONAL LEVER AND INSTRUMENT PANEL 1 FX25 39.05 > 5080 FX45 47.05 > 5080

1030

ELECTRONIC SYSTEM: MULTIFUNCTIONAL LEVER AND INSTRUMENT PANEL 1 FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....

1540

ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1 FX25 39.01 > 5080 FX45 47.01 > 5080

1540

ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1 FX28NA 5083 > 5206 FX38NA 5083 > 5206 FX58NA 5083 > 5206

1540

ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1 FX28NA 5218 > .... FX38NA 5218 > .... FX58NA 5218 > ....

2050

ELECTRONIC SYSTEM: ELECTRONIC BOX 2 FX25 39.01 > 39.04 FX45 47.01 > 47.04

2050

ELECTRONIC SYSTEM: ELECTRONIC BOX 2 FX25 39.05 > 5080 FX45 47.05 > 5080

2050

ELECTRONIC SYSTEM: ELECTRONIC BOX 2 FX28NA 5083 > 5206 FX38NA 5083 > 5206

FX58NA

5083 > 5206

ELECTRONIC SYSTEM: ELECTRONIC BOX 2 FX28NA 5218 > .... FX38NA 5218 > ....

FX58NA

5218 > ....

7d 8a 8b 8c 8d 8e

2050 2390 2390 2390 2390 2390

CPU INPUTS AND DISPLAY FX25 39.01 > 39.05 FX45

47.01 > 47.05

CPU INPUTS AND DISPLAY FX25 39.06 > 5080 FX45

47.06 > 5080

CPU INPUTS AND DISPLAY FX28NA 5083 > 5168 FX38NA

5083 > 5168

CPU INPUTS AND DISPLAY FX28NA 5174 > 5206 FX38NA

5174 > 5206

CPU INPUTS AND DISPLAY FX58NA 5083 > 5168

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

4 Ref.

Line

Group / Series

2390

CPU INPUTS AND DISPLAY FX58NA 5174 > 5206

2390

CPU INPUTS AND DISPLAY FX28NA 5218 > .... FX38NA

9a 9b 9c 9d

2900 2900 2900 2900

5218 > ....

ENGINE PROTECTION FX25 39.01 > 39.05

FX45 47.01 > 47.05

ENGINE PROTECTION FX25 39.06 > 5080

FX45

ENGINE PROTECTION FX28NA 5083 > 5206

FX38NA

FX58NA

5218 > ....

47.06 > 5080

ENGINE PROTECTION IVECO FX28NA 5218 > .... FX38NA

5083 > 5206 5218 > ....

2900

ENGINE PROTECTION CATERPILLAR FX58NA 5218 > ....

10a

3410

SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HYDRAULICS FX25 39.01 > 39.01 FX45 47.01 > 47.01

10b

3410

SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HYDRAULICS FX25 39.02 > 39.04 FX45 47.02 > 47.04

10c

3410

SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HYDRAULICS FX25 39.05 > 39.05 FX45 47.05 > 47.05

10d

3410

SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HYDRAULICS FX25 39.06 > 5074 FX45 47.06 > 5074

10e

3410

SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HYDRAULICS FX25 5080 > 5080 FX45 5080 > 5080

10f

3410

SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HYDRAULICS FX28NA 5083 > 5168 FX38NA 5083 > 5168 FX58NA 5083 > 5168

10g

3410

SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HYDRAULICS FX28NA 5186 > .... FX38NA 5186 > .... FX58NA 5186 > ....

11a

3920

METAL DETECTOR FX25 39.01 > 39.01

FX45 47.01 > 47.01

METAL DETECTOR FX25 39.02 > 5080

FX45 47.02 > 5080

METAL DETECTOR FX28NA 5083 > 5168

FX38NA

11b 11c

3920 3920

5083 > 5168

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 Ref. 11d 11e

Line 3920 3920

Group / Series METAL DETECTOR IVECO FX28NA 5186 > 5206 FX38NA

5186 > 5206

METAL DETECTOR IVECO FX28NA 5218 > .... FX38NA

5218 > ....

11f

3920

METAL DETECTOR CATERPILLAR FX58NA 5083 > 5168

11g

3920

METAL DETECTOR CATERPILLAR FX58NA 5186 > 5206

11h

3920

METAL DETECTOR CATERPILLAR FX58NA 5218 > ....

12a

4260

CROP PROCESSOR FX25 39.01 > 5080

FX45

CROP PROCESSOR FX28NA 5083 > ....

FX38NA

SPOUT CONTROL FX25 39.01 > 39.05

FX45

47.01 > 47.05

SPOUT CONTROL FX25 39.06 > 5080

FX45

47.06 > 5080

SPOUT CONTROL FX28NA 5083 > ....

FX38NA

12b 13a 13b 13c

4260 4430 4430 4430

47.01 > 5080 5083 > ....

5083 > ....

FX58NA

5083 > ....

FX58NA

5083 > ....

14a

4770

ROTARY DUST SCREENS AND CENTRAL GREASING SYSTEM FX25 39.01 > 39.01 FX45 47.01 > 47.01

14b

4770

ROTARY DUST SCREENS AND CENTRAL GREASING SYSTEM FX25 39.02 > 5080 FX45 47.02 > 5080

14c

4770

ROTARY DUST SCREENS FX28NA 5083 > ....

FX38NA

5083 > ....

15a

4940

REVERSE DRIVE CUTTERHEAD AND SHARPENING FX25 39.01 > 5080 FX45 47.01 > 5080

15b

4940

REVERSE DRIVE CUTTERHEAD AND SHARPENING FX28NA 5083 > .... FX38NA 5083 > ....

16a 16b 17a 17b

5450 5450 5790 5790

AUTOMATIC GREASING SYSTEM FX25 39.02 > 5080 FX45

5083 > ....

FX58NA

5083 > ....

FX58NA

5083 > ....

FX58NA

5083 > 5168

47.02 > 5080

AUTOMATIC GREASING SYSTEM FX28NA 5083 > .... FX38NA SHEARBAR ADJUSTMENT FX25 39.01 > 5080 FX45

FX58NA

5083 > ....

47.01 > 5080

SHEARBAR ADJUSTMENT FX28NA 5083 > 5168 FX38NA

5083 > 5168

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

6 Ref. 17c 18a 18b 18c 19a 19b

Line 5790 6300 6300 6300 6470 6470

Group / Series SHEARBAR ADJUSTMENT FX28NA 5186 > .... FX38NA

5186 > ....

SILAGE ADDITIVE APPLICATION FX25 39.01 > 39.01 FX45

47.01 > 47.01

SILAGE ADDITIVE APPLICATION FX25 39.02 > 5080 FX45

47.02 > 5080

SILAGE ADDITIVE APPLICATION FX28NA 5083 > .... FX38NA AUTO--PILOT FX25 39.01 > 5080

FX45

AUTO--PILOT FX28NA 5083 > ....

FX38NA

5083 > ....

FX58NA

5186 > ....

FX58NA

5083 > ....

FX58NA

5083 > ....

FX58NA

5083 > ....

47.01 > 5080 5083 > ....

20a

6810

HEADER HEIGHT CONTROL (HHC) FX25 39.01 > 5080 FX45 47.01 > 5080

20b

6810

HEADER HEIGHT CONTROL (HHC) FX28NA 5083 > .... FX38NA

5083 > ....

21a

7320

COOLANT TEMPERATURE AND FUEL GAUGE FX25 39.01 > 39.05 FX45 47.01 > 47.05

21b

7320

COOLANT TEMPERATURE AND FUEL GAUGE FX25 39.06 > 5080 FX45 47.06 > 5080

21c

7320

COOLANT TEMPERATURE AND FUEL GAUGE FX28NA 5083 > 5206 FX38NA 5083 > 5206

21d

7320

COOLANT TEMPERATURE AND FUEL GAUGE IVECO FX28NA 5218 > .... FX38NA 5218 > ....

21e

7320

COOLANT TEMPERATURE AND FUEL GAUGE IVECO FX58NA 5083 > 5206

21f

7320

COOLANT TEMPERATURE AND FUEL GAUGE CATERPILLAR FX58NA 5218 > ....

22a

7830

PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN FX25 39.01 > 5080 FX45 47.01 > 5080

22b

7830

PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN FX28NA 5083 > .... FX38NA 5083 > .... FX58NA

23a

8340

DIRECTION INDICATOR AND HAZARD WARNING LIGHTS FX25 39.01 > 5080 FX45 47.01 > 5080

23b

8340

DIRECTION INDICATOR AND HAZARD WARNING LIGHTS FX28NA 5083 > .... FX38NA 5083 > .... FX58NA

24a

8680

OPERATING LIGHTS AND BEACONS FX25 39.01 > 5080 FX45 47.01 > 5080

5083 > ....

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 Ref.

Line

Group / Series

24b

8680

OPERATING LIGHTS AND BEACONS FX28NA 5083 > 5206 FX38NA 5083 > 5206

24c

8680

OPERATING LIGHTS AND BEACONS IVECO FX28NA 5218 > .... FX38NA 5218 > ....

24d

8680

OPERATING LIGHTS AND BEACONS FX58NA 5083 > 5206

24e

8680

OPERATING LIGHTS AND BEACONS FX58NA 5218 > ....

25a

9190

AIR CONDITIONING FX25 39.01 > 39.01

FX45

47.01 > 47.01

AIR CONDITIONING FX25 39.02 > 39.05

FX45

47.02 > 47.05

AIR CONDITIONING FX25 39.06 > 5080

FX45

47.06 > 5080

AIR CONDITIONING FX28NA 5083 > ....

FX38NA

CAB FX25

39.01 > 39.01

FX45

47.01 > 47.01

CAB FX25

39.02 > 39.04

FX45

47.02 > 47.04

CAB FX25

39.05 > 5080

FX45

47.05 > 5080

25b 25c 25d 26a 26b 26c 26d

9190 9190 9190 9700 9700 9700 9700

CAB FX28NA

5083 > ....

FX38NA

5083 > ....

27a

10210

MIRROR CONTROL AND WINDSHIELD HEATING FX25 39.01 > 39.04 FX45 47.01 > 47.04

27b

10210

MIRROR CONTROL AND WINDSHIELD HEATING FX25 39.05 > 5080 FX45 47.05 > 5080

27c

10210

MIRROR CONTROL AND WINDSHIELD HEATING FX28NA 5083 > .... FX38NA 5083 > ....

28a 28b 29a 29b

10720 10720 10890 10890

FLIP--UP MAIZE HEADER FX25 39.01 > 5080

FX45

FLIP--UP MAIZE HEADER FX28NA 5083 > ....

FX38NA

FX58NA

5083 > ....

FX58NA

5083 > ....

FX58NA

5083 > ....

FX58NA

5083 > ....

47.01 > 5080 5083 > ....

HIGH FLOW REAR HYDRAULICS FX25 39.01 > 39.04 FX45

47.01 > 47.04

HIGH FLOW REAR HYDRAULICS FX25 39.05 > 5080 FX45

47.05 > 5080

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

8 Ref. 29c

Line 10890

Group / Series HIGH FLOW REAR HYDRAULICS FX28NA 5083 > .... FX38NA

5083 > ....

30a

11560

ELECTRONIC ENGINE CONTROL CATERPILLAR FX58NA 5083 > 5206

30b

11560

ELECTRONIC ENGINE CONTROL CATERPILLAR FX58NA 5218 > ....

31a

11900

ELECTRONIC ENGINE CONTROL IVECO FX28NA 5218 > .... FX38NA 5218 > ....

FX58NA

5083 > ....

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 LIST OF SYMBOLS AND WHERE TO FIND THEM A.

Prints and Monitors

Code

Description

Location

Line

A1.

Radio

Cab roof

9900

A2.

Cab roof

9910

A8.

InfoView monitor display (print)

InfoView monitor

2780

A9.

Header height indicator

Instrument panel

2840

A10.

CPU print

Central electronic box

1810

A11.

Engine surveillance

CPU print

2970

A12.

RH–side door sensor interface

CPU print

3620

A13.

Crop processor roll clearance measuring

CPU print

4360

A14.

Bosch interface

CPU print

7280

A15.

Sensor interface

CPU–print

2610

A16.

Meter input

CPU print

7410

A17.

AC–compressor surveillance

CPU print

9400

A18.

Engine rpm control

CPU print

620

A20.

Adjust–o–Matic print

Central electronic box

A21.

Ground speed control

Adjust–o–Matic print

710

A22.

Switch–on control

Adjust–o–Matic print

3570

A23.

Sharpening control

Adjust–o–matic print

5300

A24.

Shearbar adjustment control

Adjust–o–Matic print

6100

A25.

Metal detector control

Adjust–o–Matic print

3990

A30.

Lights print

Central electronic box

1960

A31.

Reverse buzzer control

Lights print

820

A32.

12 V Auto–Pilot

Lights print

6480

A34.

Silage additive control

Lights print

6390

A35.

Brake lights control

Lights print

8310

A36.

Operating lights and beacons control

Lights print

8870

A37.

AC–compressor control

Lights print

9350

A40.

Actuator print

Central electronic box

2110

1690

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

Code

Description

Location

Line

A41.

Throttle control

Actuator print

550

A42.

Engine protection

Actuator print

3040

A43.

Spout deflector control (electrically)

Actuator print

4630

A44.

Crop processor roll clearance control

Actuator print

4270

A45.

Bosch interface

Actuator print

7220

A46.

Auto–Pilot amplifier

Actuator print

6680

A47.

Rotary screen control

Actuator print

4780

A48.

Flip–up control

Actuator print

10740

A49.

Feed rolls reverse control

Actuator print

3470

Engine rpm

CPU

A50.

Valve print

Central electronic box

A51.

4WD control

Valve print

900

A52.

Switch–on control

Valve print

3440

A53.

Auxiliary hydraulics control

Valve print

3880

A54.

Spout rotation control (hydraulically)

Valve print

4570

A55.

Cutterhead reverse drive control

Valve print

4970

A56.

High flow rear hydraulics control

Valve print

10910

A57.

Feed rolls reverse control

Actuator print

3470

A60.

Bosch HHC module

Central electronic box

7220

A70.

Auto–Pilot module

Central electronic box

6650

A80.

Direction indicator print

Central electronoc box

8530

A81.

Electronic control box

Engine

11870

A82.

Electronic injection box

Engine

11800

A83.

CAN gateway

A84.

Engine electronic control box

Engine

11960

A116.

High flow rear hydraulics switch–on

Dashboard print

11020

A150.

Dashboard LED’s

Dashboard print

1370

A151.

Alarm LED print

Instrument panel

2980

A152.

LED control

Instrument panel

3530

A153.

Metal detector LED control

Dashboard print

4150

A154.

LED control

Dashboard print

5060

620 2250

4100

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

Code

Description

Location

Line

A155.

LED control

Dashboard print

2540

A156.

Compressor LED’s control

Dashboard print

9470

A160.

3 switch print

Instrument panel

1630

A161.

3 switch print

Instrument panel

900

A162.

3 switch print

Instrument panel

560

A163.

Switch–on input

3 switch print in dashboard

3630

A171.

Sharpening control print

Adjust–o–Matic panel

5170

A172.

Shearbar adjustment output

Adjust–o–Matic panel

5890

A180.

Multifunctional lever print

Underneath multifunctional lever

1100

A181.

Ground speed control

Multifunctional lever print

750

A182.

Switch–on control

Multifunctional lever print

3750

A183.

Spout control

Multifunctional lever print

4610

A184.

Header height operation

Multifunctional lever print

6950

A185.

Auto–Pilot control

Multifunctional lever print

6720

A190.

Arm rest module print

Arm rest module

6900

A300.

Dashboard print

Instrument panel

1240

A301.

Engagement switch print

Instrument panel

3470

A302.

Adjust–o–Matic control

Dashboard print

5000

A303.

Switch on operating lights and beacons

Dashboard print

8740

A304.

Silage additive application operation

Dashboard print

6330

A305.

Auto–Pilot operation

Dashboard print

6760

A306.

Crop processor roll clearance operation Dashboard print

4350

A307.

Metal detector switch–on

Dashboard print

4080

A320.

CAN–Dashboard print

Instrument panel

1240

A321.

Start input

Instrument panel

300

A322.

Auxiliary hydraulics control

Dashboard print

3810

Spout height control

Cab floor

4480

A323.

Brake contact input

Dashboard print

8270

A324.

Air conditioning operation

Dashboard print

9200

A325.

Meter control

Dashboard print

7330

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

12 Code

Description

Location

Line

A326.

Brake alarm input

Instrument panel

2660

A327.

Operator’s seat control

print in dashboard

3800

Location

Line

Sensors, limit switches, buzzers, speakers

Code

Description

B1.

Engine oil pressure contact

2910

B2.

Engine coolant temperature contact

2930

B3.

Engine oil temperature contact

Engine

2950 11680

B4.

Hydrostatic oil pressure contact

2970

B5.

Hydrostatic oil temperature contact

2410

B7.

Air filter underpressure contact

Air filter

2440

B11.

Engine temperature sender

Engine

7400

B12.

Fuel level sender

In fuel tank

7420

B13.

Header pressure sensor

Behind blower

7130

B16.

Ground speed sensor

Traction gearbox

2570

B23.

Engine speed sensor

Engine tailshaft pulley

2540

B29.

Horn

Underneath steering platform

7840

B31.

Loudspeaker 1

Cab roof

9850

B32.

Loudspeaker 2

Cab roof

9940

B40.

Reverse buzzer

Left–hand side of the machine at the rear

B41.

Wheel sensor

On steering axle, left–hand side

B42.

Air temperature sensor

Engine

11570

B43.

Engine rpm sensor 1

Engine

11610

810 6630

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

Code

Description

Location

Line

B44.

Engine rpm sensor 2

Engine

11650

B45.

Turbo pressure sensor

Engine

11720

B46.

Air pressure sensor

Engine

11760

B47.

Oil pressure sensor

Engine

11800

B48.

Fuel temperature sensor

Engine

11830

B50.

Knock sensor left

Shearbar left

6260

B51.

Oil temperature sender

Engine

7380

B61.

Thermostat switch

Dashboard print

9230

B100.

Main clutch oil pressure contact

Low pressure valve

2460

B101.

Cutterhead speed sensor

Rear right–hand cutterhead drive pulley

2600

B102.

Right–hand side door sensor

Right–hand side door

3640

B103.

Spout end of travel sensor

Spout base

4640

B104.

Crop processor roll speed sensor

B105.

Coolant temperature contact

Cutterhead gearbox

2470

B106.

Knock sensor

Shearbar right–hand adjuster arm

6240

Knock sensor right

Shearbar right

6240

B107.

Sharpening stone cover sensor

On top of the chopper body

5220

B108.

Adjust sharpening stone sensor

Left–hand side of chopper body

5370

B109.

Sharpening stone home position

Left–hand side of chopper body

5340

B110.

Metal detector

Lower front feed roll

3990

B111.

Maize header sensor – right–hand side

At front of maize header

6560

B112.

Maize header sensor – left–hand side

At front of maize header

6510

4360

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

14 E.

Lighting

Code

Description

Location

Line

E1.

Beacon 1

Behind cab

8960

E2.

Beacon 2

Behind cab

8980

E3.

Brake light, left

Rear of machine

8300

Direction indicator, left rear

Dashboard

8630

Parking light, left

Rear of machine

8010

Brake light, right

Rear of machine

8320

Direction indicator, right rear

Dashboard

8570

Parking light, right

Rear of machine

8150

Direction indicator, left front

Dashboard

8610

Parking light, front left

Front of machine

7970

Additional parking light, front left

Front of machine

7990

Direction indicator, left front additional

Dashboard

8630

Direction indicator, right front

Dashboard

8590

Parking light, front right

Front of machine

8110

Additional parking light, front right

Front of machine

8130

Direction indicator, right front additional

Dashboard

8560

E15.

Head lights, left

Front of machine

8200

E16.

Head lights, right

Front of machine

8240

E17.

Additional brake light (Germany)

Rear of machine

8290

E5.

E7.

E8.

E11.

E12.

Additional parking light (Germany) E27.

Operating light, left 1

8170 Railing platform

Operating light, left 2 E28.

Operating light, right 1

8760 8780

Railing platform

Operating light, right 2

8790 8810

E29.

Spot light, left

Cab roof

8850

E30.

Spot light, right

Cab roof

8870

E34.

Stubble light, left

Cab roof

8820

E35.

Stubble light, right

Cab roof

8840

E37.

Cab spot light

Cab roof

9970

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

Code

Description

Location

Line

E38.

Cab interior light

Cab roof

E41.

Licence plate lights

Rear of machine

8030

E45.

Reverse drive operating light

Rear of engine hood

9000

E100.

Spout operating light

Spout

8930

10010

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

16 F.

Fuses

Code

Description

Location

Line

F2.

15A

Horn lights

Fuse print

7840

F3.

25A

Operator’s seat fan + gauges

Fuse print

7330

Air conditioning fan F4.

15 A

Printed circuits fuse after contact

9230 Fuse print

1650

CPU print

2060

Metal detector

3930

HHC contact

6990

F5.

10A

Direction indicators

Fuse print

8350

F6.

25A

Windshield wiper + mirrors

Fuse print

9760 10190

F7.

10A

Automatic greasing after contact

Fuse print

4900 5460

F8.

25A

Silage application

Bottom of central electronic box

6440

40A

Silage application fuse behind relay

Bottom of central electronic box

6440

F9.

15A

Parking lights, right--hand side

Fuse print

8090

F10.

15A

Parking lights, left--hand side

Fuse print

7950

F11.

15A

Contact

Fuse print

260

25A

Contact

Fuse print

260

F12.

10A

Dashboard 12 V sockets

Fuse print

9710

F13.

10A

Automatic greasing

Fuse print

4880

Clock, radio, CB, cab lights

9870

F14.

25A

Road lights

Fuse print

7850

F15.

10A

CPU print

Fuse print

1760

F16.

15A

Hazard warning lights

Fuse print

8360

F17.

25A

Valve print

Fuse print

2200

HHC print

6980

F18.

30A

Adjust–o–Matic print

Fuse print

1640

F19.

25A

Actuator print

Fuse print

2050

F20.

30A

Operating lights print

Fuse print

1890

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 Code

Description

Location

Line

F21.

25A

Operating lights print

Fuse print

1900

F22.

25A

Operating lights print

Fuse print

1910

F23.

15A

Main beam head lights

Fuse print

8190

F24.

15A

Dipped head lights

Fuse print

8230

F42.

Rear windshield heating

Cab roof

F43.

Fan

Central electronic box

10530 9330

Generators, batteries

Code

Description

Location

Line

G1.

Battery

In battery box

G2.

Battery

In battery box

G3.

Alternator

Leftâ&#x20AC;&#x201C;hand side of engine

200

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

18 H.

Control lights (mostly LED’s)

Code

Description

Location

Line

H1.

Engine oil pressure LED

Instrument panel

2910

H2.

Engine oil and coolant temp. LED

Instrument panel

2930

H3.

Battery charge/voltage LED

Instrument panel

2400

H4.

Hydrostatic oil temperature LED

Instrument panel

2410

H5.

Hydrostatic oil pressure LED

Instrument panel

2970

H6.

Air filter obstruction LED

Instrument panel

2440

H7.

Brake linings/brake fluid level LED

Instrument panel

2490

H8.

Parking brake LED

Instrument panel

2500

H13.

Compressor overpressure LED

Instrument panel

9460

H14.

Compressor underpressure LED

Instrument panel

9470

H15.

Main beam head lights indicator light

Steering column

7880

H16.

Direction indicators control light

Steering column

8440

H17.

Trailer direction indicators control light

Steering column

8370

H18.

HHC red control LED

Arm rest module

6820

H19.

HHC green control LED

Arm rest module

6840

H20.

Auto–Pilot ON control light

Steering column

6640

H21.

Field mode LED

Instrument panel

3530

H22.

Metal detector LED

Instrument panel

4140

H24.

Main drive clutch oil pressure LED

Instrument panel

2460

H25.

Sharpening stone cover LED

Instrument panel

5050

H26.

Cutterhead gearbox oil temp. LED

Instrument panel

2470

H120.

Shearbar adjustment routine LED

LED # 2 in Adjust–o–Matic panel

5860

H121.

1 minute sharpening LED

LED # 3 in Adjust–o–Matic panel

5100

H122.

2 minutes sharpening LED

LED # 4 in Adjust–o–Matic panel

5120

H123.

3 minutes sharpening LED

LED # 5 in Adjust–o–Matic panel

5140

H124.

Interrupt sharpening routine LED

LED # 6 in Adjust–o–Matic panel

5160

H125.

Shearbar adjustment rpm fault LED

LED # 7 in Adjust–o–Matic panel

5780

H126.

Shearbar adjustment motor fault LED

LED # 8 in Adjust–o–Matic panel

5800

H127.

Shearbar adjustment sensor fault LED

LED # 9 in Adjust–o–Matic panel

5820

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

Code

Description

Location

Line

H128.

Adjust cutterhead knives LED

LED # 10 in Adjust–o–Matic panel

5840

H129.

Adjust–o–Matic ready to use LED

LED # 1 in Adjust–o–Matic panel

5860

Code

Description

Location

Line

K1.

12 V after contact relay

Fuse print in central electronic box

310

K2.

Silage additive relay

Fuse print in central electronic box

6430

K3.

Parking lights relay

Fuse print in central electronic box

7930

K51.

12/24 V start relay

In battery box

140

K52.

Start relay

In battery box

180

Relays

210 K53.

Mirror control relay, right–hand side

Cab roof

10310

K54.

Mirror control relay, left–hand side

Cab roof

10350

K55.

Rear windshield heating relay

Cab roof

10460

K56.

Fan relay

Console module in cab

9280

K57.

Fan ground relay

Console module in cab

9310

K58.

Grease pressure switches relay

K68.

Pre--heating

K69.

Electronic motor control

5540 12040 180

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

20 M.

Motors

Code

Description

Location

Line

M1.

Starter motor

Engine

130

M2.

Throttle actuator

Left–hand side of engine

540

M11.

Fan motor

Underneath operator’s seat

9310

M12.

Front windshield wiper motor

Cab roof

9810

M13.

Right–hand side mirror

Right–hand side of cab

10410

M14.

Left–hand side mirror

Left–hand side of cab

10360

M15.

Additional mirror, right–hand side (Germany only)

Right–hand side of cab

10490

M19.

Additional fan

M20.

Spout deflector motor

Near spout deflector

4590

M21.

Crop processor roll clearance motor

On top of chopper body

4280

M22.

Sharpening stone cover motor

Right–hand side of chopper body

5290

M23.

Sharpening stone motor

Left–hand side of chopper body

5410

M24.

Shearbar left–hand adjuster motor

Left–hand side of chopper body

6140

M25.

Shearbar right–hand adjuster motor

Right–hand side of chopper body

6170

M26.

Left–hand rotary screen drive motor

Left–hand door

4780

M27.

Right–hand rotary screen drive motor

Right–hand door

4800

M28.

Rotary screen brush actuator

Left

4820

M29.

Rotary screen brush actuator

Right

4850

M31.

Rear windshield wiper motor

Rear windshield

M32.

Front windshield washer pump

Cab roof

M33.

Side windows washer pump

Side windows

10150

M34.

Rear windshield washer pump

Rear windshield

10150

M35.

Right–hand side window wiper motor

Right–hand side window

10140

M36.

Left–hand side window wiper motor

Left–hand side window

10140

9290

10140 9830

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 P.

Measuring equipment

Code

Description

Location

Line

P1.

Engine temperature meter

Console module in cab

7330

P2.

Fuel gauge

Console module in cab

7350

P4.

Clock

Cab roof

9850

Line

Resistances

Code

Description

Location

R1.

Engine heating

Engine

R4.

Header height sensor

Chopper body, left–hand side

R5.

Multifunctional lever position potentiometer

Underneath multifunctional lever

R6.

Stubble height control potentiometer

Arm rest module

6820

R7.

Ground pressure control potentiometer

Arm rest module

6850

R14.

Auto–Pilot centering potentiometer

Steering column

6610

R15.

Rear windshield heating

Rear windshield

10480

R30.

Crop processor roll clearance potentiometer

Left–hand side of chopper body

R31.

CAN resistance

Engine

12040 7160 750

4300 11740

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

22 S.

Switches

Code

Description

Location

S17.

Contact switch

Instrument panel

S20.

Header down switch

Multifunctional lever

6920

S22.

Header up switch

Multifunctional lever

6940

S28.

Emergency stop switch

Button # 4 in multifunctional lever

3710

S29.

Reverse feed rolls switch

Switch # 1 in multifunctional lever

3720

S30.

Automatic header height control switch

Switch # 6 in multifunctional lever

3740

(former override switch)

Line 250

6930

S31.

Multifunctional lever neutral position switch

Underneath multifunctional lever

S35.

HHC selector switch

Arm rest module

6870

S36.

Handbrake contact

Handbrake

2650

S37.

Fan + air conditioning switch

Console module in cab

9250

S38.

Front windshield wiper switch

Cab roof

9760

S39.

Mirror control switch

Cab roof

10260

S40.

Mirror selection + heating switch

Cab roof

10510

S41.

Auxiliary hydraulics up

Cab floor

3800

Spout up foot switch S42.

Auxiliary hydraulics down

710

4440 Cab floor

Spout down foot switch

3820 4460

S45.

Brake fluid level contact

Brake fluid

2670

S58.

Brake contact

Underneath steering platform

8240

S59.

Combined light switch

Steering column

7850 8450

S60.

Air conditioning safety switch

Console module in cab

9230

S62.

Compressor overpressure contact

Compressor

9380

S63.

Compressor underpressure contact

Compressor

9420

S64.

Main battery switch

At the front of the battery box

S65.

Hazard warning lights switch

Steering column

8400

S66.

Brake linings sensor

Disc brakes

2500

S67.

Brake linings sensor

Disc brakes

2500

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 Code

Description

S67.

Greasing pump

S70.

Brake linings sensor

Disc brakes

2500

S71.

Brake linings sensor

Disc brakes

2500

S74.

Cold start switch

Console module in cab

S77.

Auto–Pilot engagement switch

S78.

Shearbar left–hand end of travel micro

Left–hand adjuster motor

switch (cutterhead)

(cutterhead)

Shearbar left–hand end of travel micro

Left–hand adjuster motor

6020

Right–hand adjuster motor

5990

Right–hand adjuster motor

6050

S79.

Location

23 Line 5490

250 6580 5960

switch (scraper) S80.

Shearbar right–hand end of travel microswitch(cutterhead)

S81.

Shearbar right–hand end of travel microswitch(scraper)

S82.

Sharpening stone cover closed microswitch

Inside sharpening stone cover motor

5260

S83.

Seat switch

Operator’s seat

3740

S84.

Cab door switch

Cab door

9980

S85.

Switch for spout rotation to the right– slow

Switch # 2 in multifunctional lever

4670

S86.

Switch for spout rotation to the left – fast

Switch # 2 in multifunctional lever

4650

S87.

Switch for spout rotation to the left – slow

Switch # 2 in multifunctional lever

4630

S88.

Spout deflector down switch

Switch # 2 in multifunctional lever

4730

S89.

Spout deflector up switch

Switch # 2 in multifunctional lever

4710

S90.

Feed rolls forward switch

Switch # 1 in multifunctional lever

3680

S91.

Auto–Pilot button

Multifunctional lever

6720

S91.

Auto–Pilot switch

Switch # 5 in multifunctional lever

3760

S92.

Stop feed rolls switch

Switch # 1 in multifunctional lever

3700

S93.

Switch for spout rotation to the right – fast

Switch # 2 in multifunctional lever

4690

S101.

Cutterhead switch

Switch # 14 in instrument panel

3630

S102.

4WD tumbler switch

Switch no. 15 in instrument panel

890

S103.

Engine throttle control switch

Switch in instrument panel

550

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

Code

Description

Location

Line

S105.

Safe harvest switch

Switch # 2 in instrument panel

3440

S106.

Metal detector switch

Switch # 3 in instrument panel

4070

S108.

Auto–Pilot main switch

Switch # 5 in instrument panel

6750

S109.

Silage additive application switch

Switch # 6 in instrument panel

6320

S110.

Operating lights switch

Switch # 7 in dashboard

8710

S111.

Beacons switch

Switch # 8 in dashboard

8790

S112.

Power reverse switch

Switch # 9 in instrument panel

3520

S113.

Adjust–o–Matic switch

Switch # 10 in instrument panel

5050

S114.

Cutterhead reverse drive switch

Switch # 11 in instrument panel

4970

S115.

Crop processor roll clearance switch

Switch # 12 in instrument panel

4340

S120.

Shearbar adjustment switch

Switch # 2 in Adjust–o–Matic panel

5820

S121.

1 minute sharpening switch

Switch # 3 in Adjust–o–Matic panel

5100

S122.

2 minutes sharpening switch

Switch # 4 in Adjust–o–Matic panel

5120

S123.

3 minutes sharpening switch

Switch # 5 in Adjust–o–Matic panel

5140

S124.

Interrupt sharpening routine switch

Switch # 6 in Adjust–o–Matic panel

5160

S125.

Additional mirror switch, right–hand side (Germany only)

Cab roof

10480

S126.

Front windshield washer switch

Cab roof

9810

S127.

Side windows wiper/washer switch

Cab roof

10080

S128.

Rear windshield wiper/washer switch

Cab roof

10070

S129.

Flip–up selector switch

Console module

10760

S130.

Engine electronic control box diagnostics switch

S137.

High flow rear hydraulics switch

S138.

Grease pressure switch 8R or 6R

5560

S139

Grease pressure switch cutterhead

5570

S140

Automatic greasing switch

5530

12000 Dashboard

11010

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 V.

Semi--conductors (diodes)

Code

Description

Location

V21.

Direction indicators diode, left

Lights print in central electronic box

10970

V22.

Direction indicators diode, right

Lights print in central electronic box

10950

V24.

Pawl system diode

Adjust–o–Matic print in central electronic box

3960

Line

Connectors

Code

Description

Location

Line

X130.

Direction indicator socket, rear right

Rear of machine

8550

X130.

Trailer 12 V socket

Rear of machine

8050

X147.

12 V socket, right–hand side

Right–hand side, underneath head light

7950

X148.

12 V socket, left–hand side

Left–hand side, underneath head light

8090

X150.

12 V socket

Console module

9710

X151.

12 V socket

Console module

9730

X456.

CAN/RS232 connector

Instrument panel

2800

X510.

Silage additive application socket

Bottom of central electronic box

6440

X511.

Automatic greasing system socket

Bottom of central electronic box

4880

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

26 Y.

Valves

Code

Description

Location

Line

Y19.

Header down valve

Stack valve

7020

Y20.

Header up valve

Stack valve

7040

Y21.

Cols start aid

Y22.

Electro–mechanical valve

Low pressure hydraulic valves

Y23.

Engine stop solenoid

Near injection pump on LH side of engine

Y25.

Compensation valve

Y27.

Compressor

Left–hand side of engine

Y28.

Hydrostatic pump

Mounted on LH side of main drive gearbox

Y31.

Cutterhead reverse drive valve

Stack valve

4950

Y32.

Spout rotation left

Stack valve

4540

Y33.

Spout rotation right

Stack valve

4570

Y34.

Front auxiliary hydraulics up valve

Stack valve

3830

Y35.

Front auxiliary hydraulics down

Stack valve

3860

Y36.

Rear auxiliary hydraulics up valve

Stack valve

3870

Y37.

Rear auxiliary hydraulics down valve

Stack valve

3900

Y38.

Spout height up

Stack valve

4500

Y39.

Spout height down

Stack valve

4530

Y40.

Main drive clutch neutral position valve

Low pressure valve

3450

Y41.

Electro–magnetic feed roll clutch forward

Behind reversing gearbox

3480

Y42.

Stop pawl solenoid

Above pawl wheel

4020

Y43.

Electro–magnetic feed roll clutch reverse

Behind reversing gearbox

3510

Y44.

Valve for main drive clutch +

Low pressure valve

3420

250 870 3030 7060 9340 700

main drive belt idler Y45.

Spout deflector up

Stack valve

4580

Y46

Spout deflector down

Stack valve

4610

Y48.

Ticker solenoid (test signal generator)

Shearbar right–hand adjuster arm

6200

Y49.

Tip trailer up valve

Right–hand side of engine

10890

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

Code

Description

Location

Line

Y50.

Tip trailer down valve

Right–hand side of engine

Y51.

Valve for Auto–Pilot left

Underneath steering platform

6550

Y52.

Valve for Auto–Pilot right

Underneath steering platform

6580

Y57.

Pressure relief valve

10940

Y61.

Valve A, fold up -- fold down side row units

10820

Y62.

Valve B, fold up -- fold down side row units

10830

Y63.

Valve A, slide--in -- slide out side row units

10800

Y64.

Valve B, slide in -- slide out side row units

10810

Y65.

Valve A, swing in -- swing out crop guide tubes

10780

Y66.

Valve B, swing in -- swing out crop guide tubes

10790

10920

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

28 1a

STARTER CIRCUIT 24V FX25 39.01 > 5080

FX45 47.01 > 5080

Code

Description

Location

A321.

Start input

Instrument panel

300

F11.

15A Contact

Fuse print

260

G1.

Battery

In battery box at right–hand side of machine

G2.

Battery

In battery box at right–hand side of machine

G3.

Alternator

Left–hand side of engine

200

K1.

12 V after contact relay

Fuse print

310

K51.

12/24 V start relay

In battery box

140

K52.

Start relay

In battery box

210

M1.

Starter motor

Engine

130

S17.

Contact switch

Instrument panel

250

S64.

Main battery switch

At the front of the battery box

S74.

Cold start switch

Console module in cab

Y21.

Cols start aid

Line:

10 -- 340

Line

30 250 250

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

30 1b

STARTER CIRCUIT 24V FX28NA 5083 > 5168

FX38NA

5083 > 5168

Code

Description

Location

A321.

Start input

Instrument panel

300

F11.

15Acontact

Fuse print

260

G1.

Battery

In battery box at right–hand side of machine

G2.

Battery

In battery box at right–hand side of machine

G3.

Alternator

Left–hand side of engine

200

K1.

12 V after contact relay

Fuse print

310

K51.

12/24 V start relay

In battery box

140

K52.

Start relay

In battery box

210

M1.

Starter motor

Engine

130

S17.

Contact switch

Instrument panel

250

S64.

Main battery switch

At the front of the battery box

S74.

Cold start switch

Console module in cab

Y21.

Cols start aid

Line:

10 -- 340

Line

30 250 250

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

32 1c

STARTER CIRCUIT 24V IVECO FX28NA 5186 > 5206 FX38NA

5186 > 5206

Code

Description

Location

A321.

Start input

Instrument panel

300

F11.

15A contact

Fuse print

260

G1.

Battery

In battery box at right–hand side of machine

G2.

Battery

In battery box at right–hand side of machine

G3.

Alternator

Left–hand side of engine

200

K1.

12 V after contact relay

Fuse print

310

K51.

12/24 V start relay

In battery box

140

K52.

Start relay

In battery box

210

M1.

Starter motor

Engine

130

S17.

Contact switch

Instrument panel

250

S64.

Main battery switch

At the front of the battery box

S74.

Cold start switch

Console module in cab

Y21.

Cols start aid

Line:

10 -- 340

Line

30 250 250

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

34 1d

STARTER CIRCUIT 24V IVECO FX28NA 5218 > .... FX38NA

5218 > ....

Code

Description

Location

A321.

Start input

Instrument panel

300

F11.

15A contact

Fuse print

260

G1.

Battery

In battery box at right–hand side of machine

G2.

Battery

In battery box at right–hand side of machine

G3.

Alternator

Left–hand side of engine

200

K1.

12 V after contact relay

Fuse print

310

K51.

12/24 V start relay

In battery box

140

K52.

Start relay

In battery box

180

K69.

Electronic motor control

M1.

Starter motor

Engine

130

S17.

Contact switch

Instrument panel

250

S64.

Main battery switch

At the front of the battery box

S74.

Cold start switch

Console module in cab

Y21.

Cols start aid

Line:

10 -- 340

Line

180

30 250 250

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

36 1e

STARTER CIRCUIT 24V CATERPILLAR FX58NA 5083 > 5168

Code

Description

Location

A321.

Start input

Instrument panel

300

F11.

15A contact

Fuse print

260

G1.

Battery

In battery box at right–hand side of machine

G2.

Battery

In battery box at right–hand side of machine

G3.

Alternator

Left–hand side of engine

200

K1.

12 V after contact relay

Fuse print

310

K51.

12/24 V start relay

In battery box

140

K52.

Start relay

In battery box

210

M1.

Starter motor

Engine

130

S17.

Contact switch

Instrument panel

250

S64.

Main battery switch

At the front of the battery box

S74.

Cold start switch

Console module in cab

Y21.

Cols start aid

Line:

10 -- 340

Line

30 250 250

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

38 1f

STARTER CIRCUIT 24V CATERPILLAR FX58NA 5186 > 5206

Code

Description

Location

A321.

Start input

Instrument panel

300

F11.

15A contact

Fuse print

260

G1.

Battery

In battery box at right–hand side of machine

G2.

Battery

In battery box at right–hand side of machine

G3.

Alternator

Left–hand side of engine

200

K1.

12 V after contact relay

Fuse print

310

K51.

12/24 V start relay

In battery box

140

K52.

Start relay

In battery box

210

M1.

Starter motor

Engine

130

S17.

Contact switch

Instrument panel

250

S64.

Main battery switch

At the front of the battery box

S74.

Cold start switch

Console module in cab

Y21.

Cols start aid

Line:

10 -- 340

Line

30 250 250

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

40 1g

STARTER CIRCUIT 24V CATERPILLAR FX58NA 5218 > ....

Code

Description

Location

A321.

Start input

Instrument panel

300

F11.

15A contact

Fuse print

260

G1.

Battery

In battery box at right–hand side of machine

G2.

Battery

In battery box at right–hand side of machine

G3.

Alternator

Left–hand side of engine

200

K1.

12 V after contact relay

Fuse print

310

K51.

12/24 V start relay

In battery box

140

K52.

Start relay

In battery box

210

M1.

Starter motor

Engine

130

S17.

Contact switch

Instrument panel

250

S64.

Main battery switch

At the front of the battery box

S74.

Cold start switch

Console module in cab

Y21.

Cols start aid

Line:

10 -- 340

Line

30 250 250

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

42 2a

ENGINE THROTTLE CONTROL FX25 39.01 > 5080 FX45

47.01 > 5080

Code

Description

Location

A41.

Throttle control

Actuator print

550

A162.

3 switch print

Instrument panel

560

M2.

Throttle actuator

Leftâ&#x20AC;&#x201C;hand side of engine

540

S103.

Engine throttle control switch

Switch in instrument panel

550

Line:

520 -- 680

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

44 2b

ENGINE THROTTLE CONTROL FX28NA 5083 > 5168 FX38NA

5083 > 5168

Code

Description

Location

A41.

Throttle control

Actuator print

550

A162.

3 switch print

Instrument panel

560

M2.

Throttle actuator

Leftâ&#x20AC;&#x201C;hand side of engine

540

S103.

Engine throttle control switch

Switch in instrument panel

550

Line:

520 -- 680

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

46 2c

ENGINE THROTTLE CONTROL FX28NA 5186 > 5206 FX38NA

5186 > 5206

Code

Description

Location

A41.

Throttle control

Actuator print

550

A162.

3 switch print

Instrument panel

560

M2.

Throttle actuator

Leftâ&#x20AC;&#x201C;hand side of engine

540

S103.

Engine throttle control switch

Switch in instrument panel

550

Line:

520 -- 680

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

48 2d

ENGINE THROTTLE CONTROL IVECO FX28NA 5218 > .... FX38NA 5218 > ....

Code

Description

Location

A162.

3 switch print

Instrument panel

560

S103.

Engine throttle control switch

Switch in instrument panel

550

Line:

520 -- 680

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

50 2e

ENGINE THROTTLE CONTROL CATERPILLAR FX58NA 5083 > 5168

Code

Description

Location

A41.

Throttle control

Actuator print

550

A49.

Engine rpm

CPU

620

A162.

3 switch print

Instrument panel

560

S103.

Engine throttle control switch

Switch in instrument panel

550

Line:

520 -- 680

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

52 2f

ENGINE THROTTLE CONTROL CATERPILLAR FX58NA 5186 > 5206

Code

Description

Location

A18.

Engine rpm

CPU

620

A41.

Throttle control

Actuator print

550

A162.

3 switch print

Instrument panel

560

S103.

Engine throttle control switch

Switch in instrument panel

550

Line:

520 -- 680

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

54 2g

ENGINE THROTTLE CONTROL CATERPILLAR FX58NA 5218 > ....

Code

Description

Location

A18.

Engine rpm

CPU

620

A162.

3 switch print

Instrument panel

560

S103.

Engine throttle control switch

Switch in instrument panel

550

Line:

520 -- 680

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

56 3a

HYDROSTATIC CONTROL FX25 39.01 > 5080

FX45 47.01 > 5080

Code

Description

Location

A21.

Ground speed control

Adjust–o–Matic print

710

A31.

Reverse buzzer control

Lights print

820

A181.

Ground speed control

Multifunctional lever print

750

B40.

Reverse buzzer

Left–hand side of the machine at the rear

810

R5.

Multifunctional lever position potentiometer

Underneath multifunctional lever

750

S31.

Multifunctional lever neutral position switch

Underneath multifunctional lever

710

Y28.

Hydrostatic pump

Mounted on left–hand side of main drive gearbox

700

Line:

690 -- 850

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

58 3b

HYDROSTATIC CONTROL FX28NA 5083 > 5206

FX38NA

5083 > 5206

Code

Description

Location

A21.

Ground speed control

Adjust–o–Matic print

710

A31.

Reverse buzzer control

Lights print

820

A181.

Ground speed control

Multifunctional lever print

750

B40.

Reverse buzzer

Left–hand side of the machine at the rear

810

R5.

Multifunctional lever position potentiometer

Underneath multifunctional lever

750

S31.

Multifunctional lever neutral position switch

Underneath multifunctional lever

710

Y28.

Hydrostatic pump

Mounted on left–hand side of main drive gearbox

700

Line:

690 -- 850

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

60 3c

HYDROSTATIC CONTROL IVECO FX28NA 5218 > .... FX38NA

5218 > ....

Code

Description

Location

A21.

Ground speed control

Adjust–o–Matic print

710

A31.

Reverse buzzer control

Lights print

820

A181.

Ground speed control

Multifunctional lever print

750

B40.

Reverse buzzer

Left–hand side of the machine at the rear

810

R5.

Multifunctional lever position potentiometer

Underneath multifunctional lever

750

S31.

Multifunctional lever neutral position switch

Underneath multifunctional lever

710

Y28.

Hydrostatic pump

Mounted on left–hand side of main drive gearbox

700

Line:

690 -- 850

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

62 3d

HYDROSTATIC CONTROL CATERPILLAR FX58NA 5083 > 5206

Code

Description

Location

A21.

Ground speed control

Adjust–o–Matic print

710

A31.

Reverse buzzer control

Lights print

820

A181.

Ground speed control

Multifunctional lever print

750

B40.

Reverse buzzer

Left–hand side of the machine at the rear

810

R5.

Multifunctional lever position potentiometer

Underneath multifunctional lever

750

S31.

Multifunctional lever neutral position switch

Underneath multifunctional lever

710

Y28.

Hydrostatic pump

Mounted on left–hand side of main drive gearbox

700

Line:

690 -- 850

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

64 3e

HYDROSTATIC CONTROL CATERPILLAR FX58NA 5218 > ....

Code

Description

Location

A21.

Ground speed control

Adjust–o–Matic print

710

A31.

Reverse buzzer control

Lights print

820

A181.

Ground speed control

Multifunctional lever print

750

B40.

Reverse buzzer

Left–hand side of the machine at the rear

810

R5.

Multifunctional lever position potentiometer

Underneath multifunctional lever

750

S31.

Multifunctional lever neutral position switch

Underneath multifunctional lever

710

Y28.

Hydrostatic pump

Mounted on left–hand side of main drive gearbox

700

Line:

690 -- 850

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

66 4a

FOUR--WHEEL DRIVE FX25 39.01 > 39.05

FX45

47.01 > 47.05

Code

Description

Location

Line

A51.

4WD control

Valve print

900

A161.

3 switch print

Instrument panel

900

S102.

4WD tumbler switch

Switch no. 15 in instrument panel

890

Y22.

Electroâ&#x20AC;&#x201C;mechanical valve

Low pressure hydraulic valves

870

Line:

860 -- 1020

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

68 4b

FOUR--WHEEL DRIVE FX25 39.06 > 5080

FX45

47.06 > 5080

Code

Description

Location

Line

A51.

4WD control

Valve print

900

A161.

3 switch print

Instrument panel

900

S102.

4WD tumbler switch

Switch no. 15 in instrument panel

890

Y22.

Electroâ&#x20AC;&#x201C;mechanical valve

Low pressure hydraulic valves

870

Line:

860 -- 1020

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

70 4c

FOUR--WHEEL DRIVE FX28NA 5083 > ....

FX38NA

5083 > ....

FX58NA

5083 > ....

Code

Description

Location

Line

A51.

4WD control

Valve print

900

A161.

3 switch print

Instrument panel

900

S102.

4WD tumbler switch

Switch no. 15 in instrument panel

890

Y22.

Electroâ&#x20AC;&#x201C;mechanical valve

Low pressure hydraulic valves

870

Line:

860 -- 1020

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

72 5a

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 ELECTRONIC SYSTEM: MULTIFUNCTIONAL LEVER AND INSTRUMENT PANEL 1 FX25 39.01 > 39.04 FX45 47.01 > 47.04

Code

Description

Location

Line

A150.

Dashboard LED’s

Dashboard print

1370

A180.

Multifunctional lever print

Underneath multifunctional lever

1100

A300.

Dashboard print

Instrument panel

1240

A320.

CAN–Dashboard print

Instrument panel

1240

Line:

1030 -- 1530

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

74 5b

ELECTRONIC SYSTEM: MULTIFUNCTIONAL LEVER AND INSTRUMENT PANEL 1 FX25 39.05 > 5080 FX45 47.05 > 5080

Code

Description

Location

Line

A150.

Dashboard LED’s

Dashboard print

1370

A180.

Multifunctional lever print

Underneath multifunctional lever

1100

A300.

Dashboard print

Instrument panel

1240

A320.

CAN–Dashboard print

Instrument panel

1240

Line:

1030 -- 1530

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

76 5c

ELECTRONIC SYSTEM: MULTIFUNCTIONAL LEVER AND INSTRUMENT PANEL 1 FX28NA 5083 > .... FX38NA 5083 > .... FX58NA 5083 > ....

Code

Description

Location

Line

A150.

Dashboard LED’s

Dashboard print

1370

A180.

Multifunctional lever print

Underneath multifunctional lever

1100

A300.

Dashboard print

Instrument panel

1240

A320.

CAN–Dashboard print

Instrument panel

1240

Line:

1030 -- 1530

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

78 6a

ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1 FX25 39.01 > 5080 FX45 47.01 > 5080

Code

Description

Location

Line

A10.

CPU print

Central electronic box

1810

A20.

Adjust–o–Matic print

Central electronic box

1690

A30.

Lights print

Central electronic box

1960

A160.

3 switch print

Instrument panel

1630

F4.

15A -- Printed circuits

Fuse print

1650

F15.

10A -- CPU print

Fuse print

1760

F18.

30A -- Adjust–o–Matic print

Fuse print

1640

F20.

30A -- Operating lights

Fuse print

1890

F21.

25A -- Operating lights

Fuse print

1900

F22.

25A -- Operating lights

Fuse print

1910

Line:

1540 -- 2040

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

80 6b

ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1 FX28NA 5083 > 5206 FX38NA 5083 > 5206 FX58NA 5083 > 5206

Code

Description

Location

Line

A10.

CPU print

Central electronic box

1810

A20.

Adjust–o–Matic print

Central electronic box

1690

A30.

Lights print

Central electronic box

1960

A160.

3 switch print

Instrument panel

1630

F4.

15A -- Printed circuits

Fuse print

1650

F15.

10A -- CPU print

Fuse print

1760

F18.

30A -- Adjust–o–Matic print

Fuse print

1640

F20.

30A -- Operating lights

Fuse print

1890

F21.

25A -- Operating lights

Fuse print

1900

F22.

25A -- Operating lights

Fuse print

1910

Line:

1540 -- 2040

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

ELECTRONIC SYSTEM: INSTRUMENT PANEL 2 AND ELECTRONIC BOX 1 FX28NA 5218 > .... FX38NA 5218 > .... FX58NA 5218 > ....

Code

Description

Location

Line

A10.

CPU print

Central electronic box

1810

A20.

Adjust–o–Matic print

Central electronic box

1690

A30.

Lights print

Central electronic box

1960

A160.

3 switch print

Instrument panel

1630

F4.

15A -- Printed circuits

Fuse print

1650

F15.

10A -- CPU print

Fuse print

1760

F18.

30A -- Adjust–o–Matic print

Fuse print

1640

F20.

30A -- Operating lights

Fuse print

1890

F21.

25A -- Operating lights

Fuse print

1900

F22.

25A -- Operating lights

Fuse print

1910

Line:

1540 -- 2040

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

84 7a

ELECTRONIC SYSTEM: ELECTRONIC BOX 2 FX25 39.01 > 39.04 FX45 47.01 > 47.04

Code

Description

Location

Line

A40.

Actuator print

Central electronic box

2110

A50.

Valve print

Central electronic box

2250

F4.

15A -- CPU print

Fuse print

2060

F17.

25A -- Valve print

Fuse print

2200

F19.

25A -- Actuator print

Fuse print

2050

Line:

2050 -- 2380

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

86 7b

ELECTRONIC SYSTEM: ELECTRONIC BOX 2 FX25 39.05 > 5080 FX45 47.05 > 5080

Code

Description

Location

Line

A40.

Actuator print

Central electronic box

2110

A50.

Valve print

Central electronic box

2250

F4.

15A -- CPU print

Fuse print

2060

F17.

25A -- Valve print

Fuse print

2200

F19.

25A -- Actuator print

Fuse print

2050

Line:

2050 -- 2380

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

88 7c

ELECTRONIC SYSTEM: ELECTRONIC BOX 2 FX28NA 5083 > 5206 FX38NA 5083 > 5206

FX58NA

5083 > 5206

Code

Description

Location

Line

A40.

Actuator print

Central electronic box

2110

A50.

Valve print

Central electronic box

2250

F4.

15A -- CPU print

Fuse print

2060

F17.

25A -- Valve print

Fuse print

2200

F19.

25A -- Actuator print

Fuse print

2050

Line:

2050 -- 2380

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

90 7d

ELECTRONIC SYSTEM: ELECTRONIC BOX 2 FX28NA 5218 > .... FX38NA 5218 > ....

FX58NA

5218 > ....

Code

Description

Location

Line

A40.

Actuator print

Central electronic box

2110

A50.

Valve print

Central electronic box

2250

F4.

15A -- CPU print

Fuse print

2060

F17.

25A -- Valve print

Fuse print

2200

F19.

25A -- Actuator print

Fuse print

2050

Line:

2050 -- 2380

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

92 8a

CPU INPUTS AND DISPLAY FX25 39.01 > 39.05 FX45

47.01 > 47.05

Code

Description

Location

Line

A8.

InfoView monitor display (print)

InfoView monitor

2780

A9.

Header height indicator

Instrument panel

2840

A15.

Sensor interface

CPUâ&#x20AC;&#x201C;print

2610

A155.

LED control

Dashboard print

2540

A326.

Brake alarm input

Instrument panel

2660

B5.

Hydrostatic oil temperature contact

B7.

Air filter underpressure contact

Air filter

2440

B16.

Ground speed sensor

Traction gearbox

2570

B23.

Engine speed sensor

Engine tailshaft pulley

2540

B100.

Main clutch oil pressure contact

Low pressure valve

2460

B101.

Cutterhead speed sensor

Cutterhead drive pulley

2600

B105.

Coolant temperature contact

Cutterhead gearbox

2470

H3.

Battery charge/voltage LED

Instrument panel

2400

H4.

Hydrostatic oil temperature LED

Instrument panel

2410

H6.

Air filter obstruction LED

Instrument panel

2440

H7.

Brake linings/brake fluid level LED

Instrument panel

2490

H8.

Parking brake LED

Instrument panel

2500

H24.

Main drive clutch oil pressure LED

Instrument panel

2460

H26.

Cutterhead gearbox oil temp. LED

Instrument panel

2470

S36

Handbrake contact

Handbrake

2650

S45.

Brake fluid level contact

Brake fluid

2670

S66.

Brake linings sensor

Disc brakes

2500

S67.

Brake linings sensor

Disc brakes

2500

S70.

Brake linings sensor

Disc brakes

2500

S71.

Brake linings sensor

Disc brakes

2500

X456.

CAN/RS232 connector

Instrument panel

2800

Line:

2390 -- 2890

2410

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

94 8b

CPU INPUTS AND DISPLAY FX25 39.06 > 5080 FX45

47.06 > 5080

Code

Description

Location

Line

A8.

InfoView monitor display (print)

InfoView monitor

2780

A9.

Header height indicator

Instrument panel

2840

A15.

Sensor interface

CPUâ&#x20AC;&#x201C;print

2610

A155.

LED control

Dashboard print

2540

A326.

Brake alarm input

Instrument panel

2660

B5.

Hydrostatic oil temperature contact

B7.

Air filter underpressure contact

Air filter

2440

B16.

Ground speed sensor

Traction gearbox

2570

B23.

Engine speed sensor

Engine tailshaft pulley

2540

B100.

Main clutch oil pressure contact

Low pressure valve

2460

B101.

Cutterhead speed sensor

Cutterhead drive pulley

2600

B105.

Coolant temperature contact

Cutterhead gearbox

2470

H3.

Battery charge/voltage LED

Instrument panel

2400

H4.

Hydrostatic oil temperature LED

Instrument panel

2410

H6.

Air filter obstruction LED

Instrument panel

2440

H7.

Brake linings/brake fluid level LED

Instrument panel

2490

H8.

Parking brake LED

Instrument panel

2500

H24.

Main drive clutch oil pressure LED

Instrument panel

2460

H26.

Cutterhead gearbox oil temp. LED

Instrument panel

2470

S36

Handbrake contact

Handbrake

2650

S45.

Brake fluid level contact

Brake fluid

2670

S66.

Brake linings sensor

Disc brakes

2500

S67.

Brake linings sensor

Disc brakes

2500

S70.

Brake linings sensor

Disc brakes

2500

S71.

Brake linings sensor

Disc brakes

2500

X456.

CAN/RS232 connector

Instrument panel

2800

Line:

2390 -- 2890

2410

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

96 8c

CPU INPUTS AND DISPLAY FX28NA 5083 > 5168 FX38NA

5083 > 5168

Code

Description

Location

Line

A8.

InfoView monitor display (print)

InfoView monitor

2780

A9.

Header height indicator

Instrument panel

2840

A15.

Sensor interface

CPUâ&#x20AC;&#x201C;print

2610

A155.

LED control

Dashboard print

2540

A326.

Brake alarm input

Instrument panel

2660

B5.

Hydrostatic oil temperature contact

B7.

Air filter underpressure contact

Air filter

2440

B16.

Ground speed sensor

Traction gearbox

2570

B23.

Engine speed sensor

Engine tailshaft pulley

2540

B100.

Main clutch oil pressure contact

Low pressure valve

2460

B101.

Cutterhead speed sensor

Cutterhead drive pulley

2600

B105.

Coolant temperature contact

Cutterhead gearbox

2470

H3.

Battery charge/voltage LED

Instrument panel

2400

H4.

Hydrostatic oil temperature LED

Instrument panel

2410

H6.

Air filter obstruction LED

Instrument panel

2440

H7.

Brake linings/brake fluid level LED

Instrument panel

2490

H8.

Parking brake LED

Instrument panel

2500

H24.

Main drive clutch oil pressure LED

Instrument panel

2460

H26.

Cutterhead gearbox oil temp. LED

Instrument panel

2470

S36

Handbrake contact

Handbrake

2650

S45.

Brake fluid level contact

Brake fluid

2670

S66.

Brake linings sensor

Disc brakes

2500

S67.

Brake linings sensor

Disc brakes

2500

S70.

Brake linings sensor

Disc brakes

2500

S71.

Brake linings sensor

Disc brakes

2500

X456.

CAN/RS232 connector

Instrument panel

2800

Line:

2390 -- 2890

2410

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

98 8d

CPU INPUTS AND DISPLAY FX28NA 5174 > 5206 FX38NA

5174 > 5206

Code

Description

Location

Line

A8.

InfoView monitor display (print)

InfoView monitor

2780

A9.

Header height indicator

Instrument panel

2840

A15.

Sensor interface

CPUâ&#x20AC;&#x201C;print

2610

A155.

LED control

Dashboard print

2540

A326.

Brake alarm input

Instrument panel

2660

B5.

Hydrostatic oil temperature contact

B7.

Air filter underpressure contact

Air filter

2440

B16.

Ground speed sensor

Traction gearbox

2570

B23.

Engine speed sensor

Engine tailshaft pulley

2540

B100.

Main clutch oil pressure contact

Low pressure valve

2460

B101.

Cutterhead speed sensor

Cutterhead drive pulley

2600

B105.

Coolant temperature contact

Cutterhead gearbox

2470

H3.

Battery charge/voltage LED

Instrument panel

2400

H4.

Hydrostatic oil temperature LED

Instrument panel

2410

H6.

Air filter obstruction LED

Instrument panel

2440

H7.

Brake linings/brake fluid level LED

Instrument panel

2490

H8.

Parking brake LED

Instrument panel

2500

H24.

Main drive clutch oil pressure LED

Instrument panel

2460

H26.

Cutterhead gearbox oil temp. LED

Instrument panel

2470

S36

Handbrake contact

Handbrake

2650

S45.

Brake fluid level contact

Brake fluid

2670

S66.

Brake linings sensor

Disc brakes

2500

S67.

Brake linings sensor

Disc brakes

2500

S70.

Brake linings sensor

Disc brakes

2500

S71.

Brake linings sensor

Disc brakes

2500

X456.

CAN/RS232 connector

Instrument panel

2800

Line:

2390 -- 2890

2410

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

100 8e

CPU INPUTS AND DISPLAY FX58NA 5083 > 5168

Code

Description

Location

Line

A15.

Sensor interface

CPUâ&#x20AC;&#x201C;print

2610

A155.

LED control

Dashboard print

2540

A326.

Brake alarm input

Instrument panel

2660

B5.

Hydrostatic oil temperature contact

B7.

Air filter underpressure contact

Air filter

2440

B16.

Ground speed sensor

Traction gearbox

2570

B100.

Main clutch oil pressure contact

Low pressure valve

2460

B101.

Cutterhead speed sensor

Cutterhead drive pulley

2600

B105.

Coolant temperature contact

Cutterhead gearbox

2470

H3.

Battery charge/voltage LED

Instrument panel

2400

H4.

Hydrostatic oil temperature LED

Instrument panel

2410

H6.

Air filter obstruction LED

Instrument panel

2440

H7.

Brake linings/brake fluid level LED

Instrument panel

2490

H8.

Parking brake LED

Instrument panel

2500

H24.

Main drive clutch oil pressure LED

Instrument panel

2460

H26.

Cutterhead gearbox oil temp. LED

Instrument panel

2470

S36

Handbrake contact

Handbrake

2650

S45.

Brake fluid level contact

Brake fluid

2670

S66.

Brake linings sensor

Disc brakes

2500

S67.

Brake linings sensor

Disc brakes

2500

S70.

Brake linings sensor

Disc brakes

2500

S71.

Brake linings sensor

Disc brakes

2500

Line:

2390 -- 2720

2410

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

101

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

102 8f

CPU INPUTS AND DISPLAY FX58NA 5174 > 5206

Code

Description

Location

Line

A15.

Sensor interface

CPUâ&#x20AC;&#x201C;print

2610

A155.

LED control

Dashboard print

2540

A326.

Brake alarm input

Instrument panel

2660

B5.

Hydrostatic oil temperature contact

B7.

Air filter underpressure contact

Air filter

2440

B16.

Ground speed sensor

Traction gearbox

2570

B100.

Main clutch oil pressure contact

Low pressure valve

2460

B101.

Cutterhead speed sensor

Cutterhead drive pulley

2600

B105.

Coolant temperature contact

Cutterhead gearbox

2470

H3.

Battery charge/voltage LED

Instrument panel

2400

H4.

Hydrostatic oil temperature LED

Instrument panel

2410

H6.

Air filter obstruction LED

Instrument panel

2440

H7.

Brake linings/brake fluid level LED

Instrument panel

2490

H8.

Parking brake LED

Instrument panel

2500

H24.

Main drive clutch oil pressure LED

Instrument panel

2460

H26.

Cutterhead gearbox oil temp. LED

Instrument panel

2470

S36

Handbrake contact

Handbrake

2650

S45.

Brake fluid level contact

Brake fluid

2670

S66.

Brake linings sensor

Disc brakes

2500

S67.

Brake linings sensor

Disc brakes

2500

S70.

Brake linings sensor

Disc brakes

2500

S71.

Brake linings sensor

Disc brakes

2500

Line:

2390 -- 2720

2410

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

103

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

104 8g

CPU INPUTS AND DISPLAY FX28NA 5218 > .... FX38NA

5218 > ....

FX58NA

5218 > ....

Code

Description

Location

Line

A8.

InfoView monitor display (print)

InfoView monitor

2780

A9.

Header height indicator

Instrument panel

2840

A15.

Sensor interface

CPUâ&#x20AC;&#x201C;print

2610

A155.

LED control

Dashboard print

2540

A326.

Brake alarm input

Instrument panel

2660

B5.

Hydrostatic oil temperature contact

B7.

Air filter underpressure contact

Air filter

2440

B16.

Ground speed sensor

Traction gearbox

2570

B100.

Main clutch oil pressure contact

Low pressure valve

2460

B101.

Cutterhead speed sensor

Cutterhead drive pulley

2600

B105.

Coolant temperature contact

Cutterhead gearbox

2470

H3.

Battery charge/voltage LED

Instrument panel

2400

H4.

Hydrostatic oil temperature LED

Instrument panel

2410

H6.

Air filter obstruction LED

Instrument panel

2440

H7.

Brake linings/brake fluid level LED

Instrument panel

2490

H8.

Parking brake LED

Instrument panel

2500

H24.

Main drive clutch oil pressure LED

Instrument panel

2460

H26.

Cutterhead gearbox oil temp. LED

Instrument panel

2470

S36

Handbrake contact

Handbrake

2650

S45.

Brake fluid level contact

Brake fluid

2670

S66.

Brake linings sensor

Disc brakes

2500

S67.

Brake linings sensor

Disc brakes

2500

S70.

Brake linings sensor

Disc brakes

2500

S71.

Brake linings sensor

Disc brakes

2500

X456.

CAN/RS232 connector

Instrument panel

2800

Line:

2390 -- 2890

2410

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

105

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

106 9a

ENGINE PROTECTION FX25 39.01 > 39.05

FX45 47.01 > 47.05

Code

Description

Location

Line

A11.

Engine surveillance

CPU print

2970

A42.

Engine protection

Actuator print

3040

A151.

Alarm LED print

Instrument panel

2980

B1.

Engine oil pressure contact

2910

B2.

Engine coolant temperature contact

2930

B3.

Engine oil temperature contact

2950

B4.

Hydrostatic oil pressure contact

2970

H1.

Engine oil pressure LED

Instrument panel

2910

H2.

Engine oil and coolant temp. LED

Instrument panel

2930

H5.

Hydrostatic oil pressure LED

Instrument panel

2970

Y23.

Engine stop solenoid

Near fuel injection pump on leftâ&#x20AC;&#x201C; hand side of engine

3030

Line:

2900 -- 3060

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

107

108 9b

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 ENGINE PROTECTION FX25 39.06 > 5080

FX45

47.06 > 5080

Code

Description

Location

Line

A11.

Engine surveillance

CPU print

2970

A42.

Engine protection

Actuator print

3040

A151.

Alarm LED print

Instrument panel

2980

B1.

Engine oil pressure contact

2910

B2.

Engine coolant temperature contact

2930

B3.

Engine oil temperature contact

2950

B4.

Hydrostatic oil pressure contact

2970

H1.

Engine oil pressure LED

Instrument panel

2910

H2.

Engine oil and coolant temp. LED

Instrument panel

2930

H5.

Hydrostatic oil pressure LED

Instrument panel

2970

Y23.

Engine stop solenoid

Near fuel injection pump on leftâ&#x20AC;&#x201C; hand side of engine

3030

Line:

2900 -- 3060

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

109

110 9c

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 ENGINE PROTECTION FX28NA 5083 > 5206

FX38NA

5083 > 5206

Code

Description

Location

Line

A11.

Engine surveillance

CPU print

2970

A42.

Engine protection

Actuator print

3040

A151.

Alarm LED print

Instrument panel

2980

B1.

Engine oil pressure contact

2910

B2.

Engine coolant temperature contact

2930

B3.

Engine oil temperature contact

2950

B4.

Hydrostatic oil pressure contact

2970

H1.

Engine oil pressure LED

Instrument panel

2910

H2.

Engine oil and coolant temp. LED

Instrument panel

2930

H5.

Hydrostatic oil pressure LED

Instrument panel

2970

Y23.

Engine stop solenoid

Near fuel injection pump on leftâ&#x20AC;&#x201C; hand side of engine

3030

Line:

2900 -- 3060

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

111

112 9d

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 ENGINE PROTECTION IVECO FX28NA 5218 > .... FX38NA

5218 > ....

Code

Description

Location

Line

A11.

Engine surveillance

CPU print

2970

A42.

Engine protection

Actuator print

3040

A151.

Alarm LED print

Instrument panel

2980

B1.

Engine oil pressure contact

2910

B4.

Hydrostatic oil pressure contact

2970

H1.

Engine oil pressure LED

Instrument panel

2910

H2.

Engine oil and coolant temp. LED

Instrument panel

2930

H5.

Hydrostatic oil pressure LED

Instrument panel

2970

Line:

2900 -- 3060

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

113

114 9e

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 ENGINE PROTECTION CATERPILLAR FX58NA 5218 > ....

Code

Description

Location

Line

A11.

Engine surveillance

CPU print

2970

A42.

Engine protection

Actuator print

3040

A151.

Alarm LED print

Instrument panel

2980

B4.

Hydrostatic oil pressure contact

H1.

Engine oil pressure LED

Instrument panel

2910

H2.

Engine oil and coolant temp. LED

Instrument panel

2930

H5.

Hydrostatic oil pressure LED

Instrument panel

2970

Line:

2900 -- 3060

2970

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

115

116 10a

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HYDRAULICS FX25 39.01 > 39.01 FX45 47.01 > 47.01

Code

Description

Location

Line

A12.

RH–side door sensor interface

CPU print

3620

A22.

Switch–on control

Adjust–o–Matic print

3570

A52.

Switch–on control

Valve print

3440

A53.

Auxiliary hydraulics control

Valve print

3880

A152.

LED control

Instrument panel

3530

A163.

Switch–on input

3 switch print in dashboard

3630

A182.

Switch–on control

Multifunctional lever print

3750

A301.

Switches

Instrument panel

3470

A322.

Auxiliary hydraulics control

Dashboard print

3810

A327.

Seat switch input

Dashboard print

3800

B102.

Right–hand side door sensor

Right–hand side door

3640

H21.

Field mode LED

Instrument panel

3530

S28.

Emergency stop switch

Button # 4 in multifunctional lever

3710

S29.

Reverse feed rolls switch

Switch # 1 in multifunctional lever

3720

S30.

Automatic header height control switch (former override switch)

Switch # 6 in multifunctional lever

3740

S41.

Auxiliary hydraulics up

Cab floor

3800

S42.

Auxiliary hydraulics down

Cab floor

3820

S83.

Seat switch

Operator’s seat

3740

S90.

Feed rolls forward switch

Switch # 1 in multifunctional lever

3680

S91.

Auto–Pilot switch

Switch # 5 in multifunctional lever

3760

S92.

Stop feed rolls switch

Switch # 1 in multifunctional lever

3710

S101.

Cutterhead switch

Switch # 14 in instrument panel

3630

S105.

Safe harvest switch

Switch # 2 in instrument panel

3440

S112.

Power reverse switch

Switch # 9 in instrument panel

3520

Y34.

Front auxiliary hydraulics up valve

Stack valve

3830

Y35.

Front auxiliary hydraulics down valve

Stack valve

3860

Y36.

Rear auxiliary hydraulics up valve

Stack valve

3870

Y37.

Rear auxiliary hydraulics down valve

Stack valve

3900

Y40.

Main drive clutch neutral position valve

Low pressure valve

3450

Y41.

Electro–magnetic feed roll clutch forward

Behind reversing gearbox

3480

Y43.

Electro–magnetic feed roll clutch reverse

Behind reversing gearbox

3510

Y44.

Valve for main drive clutch + main drive belt idler

Low pressure valve

3420

Line:

3410 -- 3910

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

117

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

118 10b

SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HYDRAULICS FX25 39.02 > 39.04 FX45 47.02 > 47.04

Code

Description

Location

Line

A12.

RH–side door sensor interface

CPU print

3620

A22.

Switch–on control

Adjust–o–Matic print

3570

A52.

Switch–on control

Valve print

3440

A53.

Auxiliary hydraulics control

Valve print

3880

A152.

LED control

Instrument panel

3530

A163.

Switch–on input

3 switch print in dashboard

3630

A182.

Switch–on control

Multifunctional lever print

3750

A301.

Engagement switch print

Instrument panel

3470

A322.

Auxiliary hydraulics control

Dashboard print

3810

A327.

Operator’s seat control

print in dashboard

3800

B102.

Right–hand side door sensor

Right–hand side door

3640

H21.

Field mode LED

Instrument panel

3530

S28.

Emergency stop switch

Button # 4 in multifunctional lever

3710

S29.

Reverse feed rolls switch

Switch # 1 in multifunctional lever

3720

S30.

Automatic header height control switch

Switch # 6 in multifunctional lever

3740

S41.

Auxiliary hydraulics up

Cab floor

3800

S42.

Auxiliary hydraulics down

Cab floor

3820

S83.

Seat switch

Operator’s seat

3740

S90.

Feed rolls forward switch

Switch # 1 in multifunctional lever

3680

S91.

Auto–Pilot switch

Switch # 5 in multifunctional lever

3760

S92.

Stop feed rolls switch

Switch # 1 in multifunctional lever

3710

S101.

Cutterhead switch

Switch # 14 in instrument panel

3630

S105.

Safe harvest switch

Switch # 2 in instrument panel

3440

S112.

Power reverse switch

Switch # 9 in instrument panel

3520

Y34.

Front auxiliary hydraulics up valve

Stack valve

3830

Y35.

Front auxiliary hydraulics down valve

Stack valve

3860

Y36.

Rear auxiliary hydraulics up valve

Stack valve

3870

Y37.

Rear auxiliary hydraulics down valve

Stack valve

3900

Y40.

Main drive clutch neutral position valve

Low pressure valve

3450

Y41.

Electro–magnetic feed roll clutch forward

Behind reversing gearbox

3480

Y43.

Electro–magnetic feed roll clutch reverse

Behind reversing gearbox

3510

Y44.

Valve for main drive clutch + main drive belt idler

Low pressure valve

3420

Line:

3410 -- 3910

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

119

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

120 10c

SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HYDRAULICS FX25 39.05 > 39.05 FX45 47.05 > 47.05

Code

Description

Location

Line

A12.

RH–side door sensor interface

CPU print

3620

A22.

Switch–on control

Adjust–o–Matic print

3570

A52.

Switch–on control

Valve print

3440

A53.

Auxiliary hydraulics control

Valve print

3880

A152.

LED control

Instrument panel

3530

A163.

Switch–on input

3 switch print in dashboard

3630

A182.

Switch–on control

Multifunctional lever print

3750

A301.

Engagement switch print

Instrument panel

3470

A322.

Auxiliary hydraulics control

Dashboard print

3810

A327.

Operator’s seat control

print in dashboard

3800

B102.

Right–hand side door sensor

Right–hand side door

3640

H21.

Field mode LED

Instrument panel

3530

S28.

Emergency stop switch

Button # 4 in multifunctional lever

3710

S29.

Reverse feed rolls switch

Switch # 1 in multifunctional lever

3720

S30.

Automatic header height control switch

Switch # 6 in multifunctional lever

3740

S41.

Auxiliary hydraulics up

Cab floor

3800

S42.

Auxiliary hydraulics down

Cab floor

3820

S83.

Seat switch

Operator’s seat

3740

S90.

Feed rolls forward switch

Switch # 1 in multifunctional lever

3680

S91.

Auto–Pilot switch

Switch # 5 in multifunctional lever

3760

S92.

Stop feed rolls switch

Switch # 1 in multifunctional lever

3710

S101.

Cutterhead switch

Switch # 14 in instrument panel

3630

S105.

Safe harvest switch

Switch # 2 in instrument panel

3440

S112.

Power reverse switch

Switch # 9 in instrument panel

3520

Y34.

Front auxiliary hydraulics up valve

Stack valve

3830

Y35.

Front auxiliary hydraulics down valve

Stack valve

3860

Y36.

Rear auxiliary hydraulics up valve

Stack valve

3870

Y37.

Rear auxiliary hydraulics down valve

Stack valve

3900

Y40.

Main drive clutch neutral position valve

Low pressure valve

3450

Y41.

Electro–magnetic feed roll clutch forward

Behind reversing gearbox

3480

Y43.

Electro–magnetic feed roll clutch reverse

Behind reversing gearbox

3510

Y44.

Valve for main drive clutch + main drive belt idler

Low pressure valve

3420

Line:

3410 -- 3910

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

121

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

122 10d

SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HYDRAULICS FX25 39.06 > 5074 FX45 47.06 > 5074

Code

Description

Location

Line

A12.

RH–side door sensor interface

CPU print

3620

A22.

Switch–on control

Adjust–o–Matic print

3570

A52.

Switch–on control

Valve print

3440

A53.

Auxiliary hydraulics control

Valve print

3880

A152.

LED control

Instrument panel

3530

A163.

Switch–on input

3 switch print in dashboard

3630

A182.

Switch–on control

Multifunctional lever print

3750

A301.

Engagement switch print

Instrument panel

3470

A322.

Auxiliary hydraulics control

Dashboard print

3810

A327.

Operator’s seat control

print in dashboard

3800

B102.

Right–hand side door sensor

Right–hand side door

3640

H21.

Field mode LED

Instrument panel

3530

S28.

Emergency stop switch

Button # 4 in multifunctional lever

3710

S29.

Reverse feed rolls switch

Switch # 1 in multifunctional lever

3720

S30.

Automatic header height control switch

Switch # 6 in multifunctional lever

3740

S41.

Auxiliary hydraulics up

Cab floor

3800

S42.

Auxiliary hydraulics down

Cab floor

3820

S83.

Seat switch

Operator’s seat

3740

S90.

Feed rolls forward switch

Switch # 1 in multifunctional lever

3680

S91.

Auto–Pilot switch

Switch # 5 in multifunctional lever

3760

S92.

Stop feed rolls switch

Switch # 1 in multifunctional lever

3710

S101.

Cutterhead switch

Switch # 14 in instrument panel

3630

S105.

Safe harvest switch

Switch # 2 in instrument panel

3440

S112.

Power reverse switch

Switch # 9 in instrument panel

3520

Y34.

Front auxiliary hydraulics up valve

Stack valve

3830

Y35.

Front auxiliary hydraulics down valve

Stack valve

3860

Y36.

Rear auxiliary hydraulics up valve

Stack valve

3870

Y37.

Rear auxiliary hydraulics down valve

Stack valve

3900

Y40.

Main drive clutch neutral position valve

Low pressure valve

3450

Y41.

Electro–magnetic feed roll clutch forward

Behind reversing gearbox

3480

Y43.

Electro–magnetic feed roll clutch reverse

Behind reversing gearbox

3510

Y44.

Valve for main drive clutch + main drive belt idler

Low pressure valve

3420

Line:

3410 -- 3910

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

123

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

124 10e

SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HYDRAULICS FX25 5080 > 5080 FX45 5080 > 5080

Code

Description

Location

Line

A12.

RH–side door sensor interface

CPU print

3620

A22.

Switch–on control

Adjust–o–Matic print

3570

A52.

Switch–on control

Valve print

3440

A53.

Auxiliary hydraulics control

Valve print

3880

A152.

LED control

Instrument panel

3530

A163.

Switch–on input

3 switch print in dashboard

3630

A182.

Switch–on control

Multifunctional lever print

3750

A301.

Engagement switch print

Instrument panel

3470

A322.

Auxiliary hydraulics control

Dashboard print

3810

A327.

Operator’s seat control

print in dashboard

3800

B102.

Right–hand side door sensor

Right–hand side door

3640

H21.

Field mode LED

Instrument panel

3530

S28.

Emergency stop switch

Button # 4 in multifunctional lever

3710

S29.

Reverse feed rolls switch

Switch # 1 in multifunctional lever

3720

S30.

Automatic header height control switch

Switch # 6 in multifunctional lever

3740

S41.

Auxiliary hydraulics up

Cab floor

3800

S42.

Auxiliary hydraulics down

Cab floor

3820

S83.

Seat switch

Operator’s seat

3740

S90.

Feed rolls forward switch

Switch # 1 in multifunctional lever

3680

S91.

Auto–Pilot switch

Switch # 5 in multifunctional lever

3760

S92.

Stop feed rolls switch

Switch # 1 in multifunctional lever

3710

S101.

Cutterhead switch

Switch # 14 in instrument panel

3630

S105.

Safe harvest switch

Switch # 2 in instrument panel

3440

S112.

Power reverse switch

Switch # 9 in instrument panel

3520

Y34.

Front auxiliary hydraulics up valve

Stack valve

3830

Y35.

Front auxiliary hydraulics down valve

Stack valve

3860

Y36.

Rear auxiliary hydraulics up valve

Stack valve

3870

Y37.

Rear auxiliary hydraulics down valve

Stack valve

3900

Y40.

Main drive clutch neutral position valve

Low pressure valve

3450

Y41.

Electro–magnetic feed roll clutch forward

Behind reversing gearbox

3480

Y43.

Electro–magnetic feed roll clutch reverse

Behind reversing gearbox

3510

Y44.

Valve for main drive clutch + main drive belt idler

Low pressure valve

3420

Line:

3410 -- 3910

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

125

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

126 10f

SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HYDRAULICS FX28NA 5083 > 5168 FX38NA 5083 > 5168 FX58NA 5083 > 5168

Code

Description

Location

Line

A12.

RH–side door sensor interface

CPU print

3620

A22.

Switch–on control

Adjust–o–Matic print

3570

A52.

Switch–on control

Valve print

3440

A53.

Auxiliary hydraulics control

Valve print

3880

A57.

Feed rolls reverse control

Actuator print

3470

A152.

LED control

Instrument panel

3530

A163.

Switch–on input

3 switch print in dashboard

3630

A182.

Switch–on control

Multifunctional lever print

3750

A301.

Engagement switch print

Instrument panel

3470

A322.

Auxiliary hydraulics control

Dashboard print

3810

A327.

Operator’s seat control

print in dashboard

3800

B102.

Right–hand side door sensor

Right–hand side door

3640

H21.

Field mode LED

Instrument panel

3530

S28.

Emergency stop switch

Button # 4 in multifunctional lever

3710

S29.

Reverse feed rolls switch

Switch # 1 in multifunctional lever

3720

S30.

Automatic header height control switch

Switch # 6 in multifunctional lever

3740

S41.

Auxiliary hydraulics up

Cab floor

3800

S42.

Auxiliary hydraulics down

Cab floor

3820

S83.

Seat switch

Operator’s seat

3740

S90.

Feed rolls forward switch

Switch # 1 in multifunctional lever

3680

S91.

Auto–Pilot switch

Switch # 5 in multifunctional lever

3760

S92.

Stop feed rolls switch

Switch # 1 in multifunctional lever

3710

S101.

Cutterhead switch

Switch # 14 in instrument panel

3630

S105.

Safe harvest switch

Switch # 2 in instrument panel

3440

S112.

Power reverse switch

Switch # 9 in instrument panel

3520

Y34.

Front auxiliary hydraulics up valve

Stack valve

3830

Y35.

Front auxiliary hydraulics down valve

Stack valve

3860

Y36.

Rear auxiliary hydraulics up valve

Stack valve

3870

Y37.

Rear auxiliary hydraulics down valve

Stack valve

3900

Y40.

Main drive clutch neutral position valve

Low pressure valve

3450

Y41.

Electro–magnetic feed roll clutch forward

Behind reversing gearbox

3480

Y43.

Electro–magnetic feed roll clutch reverse

Behind reversing gearbox

3510

Y44.

Valve for main drive clutch + main drive belt idler

Low pressure valve

3420

Line:

3410 -- 3910

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

127

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

128 10g

SWITCHES INSTRUMENT PANEL, MULTIFUNCTIONAL LEVER AND AUXILIARY HYDRAULICS FX28NA 5186 > .... FX38NA 5186 > .... FX58NA 5186 > ....

Code

Description

Location

Line

A12.

RH–side door sensor interface

CPU print

3620

A22.

Switch–on control

Adjust–o–Matic print

3570

A49.

Feed rolls reverse control

Actuator print

3470

A52.

Switch–on control

Valve print

3440

A53.

Auxiliary hydraulics control

Valve print

3880

A152.

LED control

Instrument panel

3530

A163.

Switch–on input

3 switch print in dashboard

3630

A182.

Switch–on control

Multifunctional lever print

3750

A301.

Engagement switch print

Instrument panel

3470

A322.

Auxiliary hydraulics control

Dashboard print

3810

A327.

Operator’s seat control

print in dashboard

3800

B102.

Right–hand side door sensor

Right–hand side door

3640

H21.

Field mode LED

Instrument panel

3530

S28.

Emergency stop switch

Button # 4 in multifunctional lever

3710

S29.

Reverse feed rolls switch

Switch # 1 in multifunctional lever

3720

S30.

Automatic header height control switch

Switch # 6 in multifunctional lever

3740

S41.

Auxiliary hydraulics up

Cab floor

3800

S42.

Auxiliary hydraulics down

Cab floor

3820

S83.

Seat switch

Operator’s seat

3740

S90.

Feed rolls forward switch

Switch # 1 in multifunctional lever

3680

S91.

Auto–Pilot switch

Switch # 5 in multifunctional lever

3760

S92.

Stop feed rolls switch

Switch # 1 in multifunctional lever

3710

S101.

Cutterhead switch

Switch # 14 in instrument panel

3630

S105.

Safe harvest switch

Switch # 2 in instrument panel

3440

S112.

Power reverse switch

Switch # 9 in instrument panel

3520

Y34.

Front auxiliary hydraulics up valve

Stack valve

3830

Y35.

Front auxiliary hydraulics down valve

Stack valve

3860

Y36.

Rear auxiliary hydraulics up valve

Stack valve

3870

Y37.

Rear auxiliary hydraulics down valve

Stack valve

3900

Y40.

Main drive clutch neutral position valve

Low pressure valve

3450

Y41.

Electro–magnetic feed roll clutch forward

Behind reversing gearbox

3480

Y43.

Electro–magnetic feed roll clutch reverse

Behind reversing gearbox

3510

Y44.

Valve for main drive clutch + main drive belt idler

Low pressure valve

3420

Line:

3410 -- 3910

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

129

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

130 11a

METAL DETECTOR FX25 39.01 > 39.01

FX45 47.01 > 47.01

Code

Description

Location

Line

A25.

Metal detector control

Adjust–o–Matic print

3990

A153.

Metal detector LED control

Dashboard print

4150

A307.

Metal detector switch–on

Dashboard print

4080

B110.

Metal detector

Lower front feed roll

3990

F4.

15A -- Metal detector

Fuse print

3930

H22.

Metal detector LED

Instrument panel

4140

S106.

Metal detector switch

Switch # 3 in instrument panel

4070

Y42.

Stop pawl solenoid

Above pawl wheel

4020

Line:

3920 -- 4250

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

131

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

132 11b

METAL DETECTOR FX25 39.02 > 5080

FX45 47.02 > 5080

Code

Description

Location

Line

A25.

Metal detector control

Adjust–o–Matic print

3990

A153.

Metal detector LED control

Dashboard print

4150

A307.

Metal detector switch–on

Dashboard print

4080

B110.

Metal detector

Lower front feed roll

3990

F4.

15A -- Metal detector

Fuse print

3930

H22.

Metal detector LED

Instrument panel

4140

S106.

Metal detector switch

Switch # 3 in instrument panel

4070

V24.

Pawl system diode

Adjust–o–Matic print in central electronic box

3960

Y42.

Stop pawl solenoid

Above pawl wheel

4020

Line:

3920 -- 4250

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

133

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

134 11c

METAL DETECTOR FX28NA 5083 > 5168

FX38NA

5083 > 5168

Code

Description

Location

Line

A25.

Metal detector control

Adjust–o–Matic print

3990

A153.

Metal detector LED control

Dashboard print

4150

A307.

Metal detector switch–on

Dashboard print

4080

B110.

Metal detector

Lower front feed roll

3990

F4.

15A -- Metal detector

Fuse print

3930

H22.

Metal detector LED

Instrument panel

4140

S106.

Metal detector switch

Switch # 3 in instrument panel

4070

V24.

Pawl system diode

Adjust–o–Matic print in central electronic box

3960

Y42.

Stop pawl solenoid

Above pawl wheel

4020

Line:

3920 -- 4250

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

135

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

136 11d

METAL DETECTOR IVECO FX28NA 5186 > 5206 FX38NA

5186 > 5206

Code

Description

Location

Line

A25.

Metal detector control

Adjust–o–Matic print

3990

A153.

Metal detector LED control

Dashboard print

4150

A307.

Metal detector switch–on

Dashboard print

4080

B110.

Metal detector

Lower front feed roll

3990

F4.

15A -- Metal detector

Fuse print

3930

H22.

Metal detector LED

Instrument panel

4140

S106.

Metal detector switch

Switch # 3 in instrument panel

4070

V24.

Pawl system diode

Adjust–o–Matic print in central electronic box

3960

Y42.

Stop pawl solenoid

Above pawl wheel

4020

Line:

3920 -- 4250

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

137

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

138 11e

METAL DETECTOR IVECO FX28NA 5218 > .... FX38NA

5218 > ....

Code

Description

Location

Line

A25.

Metal detector control

Adjust–o–Matic print

3990

A153.

Metal detector LED control

Dashboard print

4150

A307.

Metal detector switch–on

Dashboard print

4080

B110.

Metal detector

Lower front feed roll

3990

F4.

15A -- Metal detector

Fuse print

3930

H22.

Metal detector LED

Instrument panel

4140

S106.

Metal detector switch

Switch # 3 in instrument panel

4070

V24.

Pawl system diode

Adjust–o–Matic print in central electronic box

3960

Y42.

Stop pawl solenoid

Above pawl wheel

4020

Line:

3920 -- 4250

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

139

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

140 11f

METAL DETECTOR CATERPILLAR FX58NA 5083 > 5168

Code

Description

Location

Line

A25.

Metal detector control

Adjust–o–Matic print

3990

A153.

Metal detector LED control

Dashboard print

4150

A307.

Metal detector switch–on

Dashboard print

4080

B110.

Metal detector

Lower front feed roll

3990

F4.

15A -- Metal detector

Fuse print

3930

H22.

Metal detector LED

Instrument panel

4140

S106.

Metal detector switch

Switch # 3 in instrument panel

4070

V24.

Pawl system diode

Adjust–o–Matic print in central electronic box

3960

Y42.

Stop pawl solenoid

Above pawl wheel

4020

Line:

3920 -- 4250

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

141

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

142 11g

METAL DETECTOR CATERPILLAR FX58NA 5186 > 5206

Code

Description

Location

Line

A25.

Metal detector control

Adjust–o–Matic print

3990

A153.

Metal detector LED control

Dashboard print

4150

A307.

Metal detector switch–on

Dashboard print

4080

B110.

Metal detector

Lower front feed roll

3990

F4.

15A -- Metal detector

Fuse print

3930

H22.

Metal detector LED

Instrument panel

4140

S106.

Metal detector switch

Switch # 3 in instrument panel

4070

V24.

Pawl system diode

Adjust–o–Matic print in central electronic box

3960

Y42.

Stop pawl solenoid

Above pawl wheel

4020

Line:

3920 -- 4250

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

143

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

144 11h

METAL DETECTOR CATERPILLAR FX58NA 5218 > ....

Code

Description

Location

Line

A25.

Metal detector control

Adjust–o–Matic print

3990

A83.

CAN gateway

A153.

Metal detector LED control

Dashboard print

4150

A307.

Metal detector switch–on

Dashboard print

4080

B110.

Metal detector

Lower front feed roll

3990

F4.

15A -- Metal detector

Fuse print

3930

H22.

Metal detector LED

Instrument panel

4140

S106.

Metal detector switch

Switch # 3 in instrument panel

4070

V24.

Pawl system diode

Adjust–o–Matic print in central electronic box

3960

Y42.

Stop pawl solenoid

Above pawl wheel

4020

Line:

3920 -- 4250

4100

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

145

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

146 12a

CROP PROCESSOR FX25 39.01 > 5080

FX45

47.01 > 5080

Code

Description

Location

Line

A13.

Crop processor roll clearance measuring

CPU print

4360

A44.

Crop processor roll clearance control

Actuator print

4270

A306.

Crop processor roll clearance operation Dashboard print

4350

B104.

Crop processor roll speed sensor

4360

M21.

Crop processor roll clearance motor

On top of chopper body

4280

R30.

Crop processor roll clearance potentiometer

Leftâ&#x20AC;&#x201C;hand side of chopper body

4300

S115.

Crop processor roll clearance switch

Switch # 12 in instrument panel

4340

Line:

4260 -- 4420

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

147

148 12b

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 CROP PROCESSOR FX28NA 5083 > ....

FX38NA

5083 > ....

FX58NA

5083 > ....

Code

Description

Location

Line

A13.

Crop processor roll clearance measuring

CPU print

4360

A44.

Crop processor roll clearance control

Actuator print

4270

A306.

Crop processor roll clearance operation Dashboard print

4350

B104.

Crop processor roll speed sensor

4360

M21.

Crop processor roll clearance motor

On top of chopper body

4280

R30.

Crop processor roll clearance potentiometer

Leftâ&#x20AC;&#x201C;hand side of chopper body

4300

S115.

Crop processor roll clearance switch

Switch # 12 in instrument panel

4340

Line:

4260 -- 4420

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

149

150 13a

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 SPOUT CONTROL FX25 39.01 > 39.05

FX45

47.01 > 47.05

Code

Description

Location

Line

A43.

Spout deflector control (electrically)

Actuator print

4630

A54.

Spout rotation control (hydraulically)

Valve print

4570

A183.

Spout control

Multifunctional lever print

4610

A322.

Spout height control

Cab floor

4480

B103.

Spout end of travel sensor

Spout base

4640

M20.

Spout deflector motor

Near spout deflector

4590

S41.

Spout up foot switch

Switch in cab floor

4440

S42.

Spout down foot switch

Switch in cab floor

4460

S85.

Switch for spout rotation to the right– slow

Switch # 2 in multifunctional lever

4670

S86.

Switch for spout rotation to the left – fast

Switch # 2 in multifunctional lever

4650

S87.

Switch for spout rotation to the left – slow

Switch # 2 in multifunctional lever

4630

S88.

Spout deflector down switch

Switch # 2 in multifunctional lever

4730

S89.

Spout deflector up switch

Switch # 2 in multifunctional lever

4710

S93.

Switch for spout rotation to the right – fast

Switch # 2 in multifunctional lever

4690

Y32.

Spout rotation left

Stack valve

4540

Y33.

Spout rotation right

Stack valve

4570

Y38.

Spout height up

Stack valve

4500

Y39.

Spout height down

Stack valve

4530

Line:

4430 -- 4760

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

151

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

152 13b

SPOUT CONTROL FX25 39.06 > 5080

FX45

47.06 > 5080

Code

Description

Location

Line

A43.

Spout deflector control (electrically)

Actuator print

4630

A54.

Spout rotation control (hydraulically)

Valve print

4570

A183.

Spout control

Multifunctional lever print

4610

A322.

Spout height control

Cab floor

4480

B103.

Spout end of travel sensor

Spout base

4640

S41.

Spout up foot switch

Switch in cab floor

4440

S42.

Spout down foot switch

Switch in cab floor

4460

S85.

Switch for spout rotation to the right– slow

Switch # 2 in multifunctional lever

4670

S86.

Switch for spout rotation to the left – fast

Switch # 2 in multifunctional lever

4650

S87.

Switch for spout rotation to the left – slow

Switch # 2 in multifunctional lever

4630

S88.

Spout deflector down switch

Switch # 2 in multifunctional lever

4730

S89.

Spout deflector up switch

Switch # 2 in multifunctional lever

4710

S93.

Switch for spout rotation to the right – fast

Switch # 2 in multifunctional lever

4690

Y32.

Spout rotation left

Stack valve

4540

Y33.

Spout rotation right

Stack valve

4570

Y38.

Spout height up

Stack valve

4500

Y39.

Spout height down

Stack valve

4530

Y45.

Spout deflector up

Stack valve

4580

Y46

Spout deflector down

Stack valve

4610

Line:

4430 -- 4760

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

153

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

154 13c

SPOUT CONTROL FX28NA 5083 > ....

FX38NA

5083 > ....

FX58NA

5083 > ....

Code

Description

Location

Line

A43.

Spout deflector control (electrically)

Actuator print

4630

A54.

Spout rotation control (hydraulically)

Valve print

4570

A183.

Spout control

Multifunctional lever print

4610

A322.

Spout height control

Cab floor

4480

B103.

Spout end of travel sensor

Spout base

4640

S41.

Spout up foot switch

Switch in cab floor

4440

S42.

Spout down foot switch

Switch in cab floor

4460

S85.

Switch for spout rotation to the right– slow

Switch # 2 in multifunctional lever

4670

S86.

Switch for spout rotation to the left – fast

Switch # 2 in multifunctional lever

4650

S87.

Switch for spout rotation to the left – slow

Switch # 2 in multifunctional lever

4630

S88.

Spout deflector down switch

Switch # 2 in multifunctional lever

4730

S89.

Spout deflector up switch

Switch # 2 in multifunctional lever

4710

S93.

Switch for spout rotation to the right – fast

Switch # 2 in multifunctional lever

4690

Y32.

Spout rotation left

Stack valve

4540

Y33.

Spout rotation right

Stack valve

4570

Y38.

Spout height up

Stack valve

4500

Y39.

Spout height down

Stack valve

4530

Y45.

Spout deflector up

Stack valve

4580

Y46

Spout deflector down

Stack valve

4610

Line:

4430 -- 4760

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

155

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

156 14a

ROTARY DUST SCREENS AND CENTRAL GREASING SYSTEM FX25 39.01 > 39.01 FX45 47.01 > 47.01

Code

Description

Location

Line

A47.

Rotary dust screen control

Lights print

4790

F7.

10A -- Automatic greasing after contact

Fuse print

4860

F13.

10A -- Automatic greasing before contact

Fuse print

4880

M26.

Left–hand rotary screen drive motor

Left–hand door

4780

M27.

Right–hand rotary screen drive motor

Right–hand door

4800

X511.

Automatic greasing system socket

Bottom of central electronic box

4880

Line:

4770 -- 4930

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

157

158 14b

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 ROTARY DUST SCREENS FX25 39.02 > 5080

FX45

47.02 > 5080

Code

Description

A47.

Rotary screen control

M26.

Left–hand rotary screen drive motor

Left–hand door

4780

M27.

Right–hand rotary screen drive motor

Right–hand door

4800

M28.

Rotary screen brush actuator

Left

4820

M29.

Rotary screen brush actuator

Right

4850

Line:

4770 -- 4930

Location

Line 4780

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

159

160 14c

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 ROTARY DUST SCREENS FX28NA 5083 > ....

FX38NA

5083 > ....

FX58NA

Code

Description

A47.

Rotary screen control

M26.

Left–hand rotary screen drive motor

Left–hand door

4780

M27.

Right–hand rotary screen drive motor

Right–hand door

4800

M28.

Rotary screen brush actuator

Left

4820

M29.

Rotary screen brush actuator

Right

4850

Line:

4770 -- 4930

Location

5083 > ....

Line 4780

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

161

162 15a

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 REVERSE DRIVE CUTTERHEAD AND SHARPENING FX25 39.01 > 5080 FX45 47.01 > 5080

Code

Description

Location

Line

A23.

Sharpening control

Adjust–o–matic print

5300

A55.

Cutterhead reverse drive control

Valve print

4970

A154.

LED control

Dashboard print

5060

A171.

Sharpening control print

Adjust–o–Matic panel

5170

A302.

Adjust–o–Matic control

Dashboard print

5000

B107.

Sharpening stone cover sensor

On top of the chopper body

5220

B108.

Adjust sharpening stone sensor

Left–hand side of chopper body

5370

B109.

Sharpening stone home position sensor

Left–hand side of chopper body

5340

H25.

Sharpening stone cover LED

Instrument panel

5050

H121.

1 minute sharpening LED

LED # 3 in Adjust–o–Matic panel

5100

H122.

2 minutes sharpening LED

LED # 4 in Adjust–o–Matic panel

5120

H123.

3 minutes sharpening LED

LED # 5 in Adjust–o–Matic panel

5140

H124.

Interrupt sharpening routine LED

LED # 6 in Adjust–o–Matic panel

5160

M22.

Sharpening stone cover motor

Right–hand side of chopper body

5290

M23.

Sharpening stone motor

Left–hand side of chopper body

5410

S82.

Sharpening stone cover closed microswitch

Inside sharpening stone cover motor

5260

S113.

Adjust–o–Matic switch

Switch # 10 in instrument panel

5050

S114.

Cutterhead reverse drive switch

Switch # 11 in instrument panel

4970

S121.

1 minute sharpening switch

Switch # 3 in Adjust–o–Matic panel

5100

S122.

2 minutes sharpening switch

Switch # 4 in Adjust–o–Matic panel

5120

S123.

3 minutes sharpening switch

Switch # 5 in Adjust–o–Matic panel

5140

S124.

Interrupt sharpening routine switch

Switch # 6 in Adjust–o–Matic panel

5160

Y31.

Cutterhead reverse drive valve

Stack valve

4950

Line:

4940 -- 5440

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

163

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

164 15b

REVERSE DRIVE CUTTERHEAD AND SHARPENING FX28NA 5083 > .... FX38NA 5083 > ....

FX58NA

5083 > ....

Code

Description

Location

Line

A23.

Sharpening control

Adjust–o–matic print

5300

A55.

Cutterhead reverse drive control

Valve print

4970

A154.

LED control

Dashboard print

5060

A171.

Sharpening control print

Adjust–o–Matic panel

5170

A302.

Adjust–o–Matic control

Dashboard print

5000

B107.

Sharpening stone cover sensor

On top of the chopper body

5220

B108.

Adjust sharpening stone sensor

Left–hand side of chopper body

5370

B109.

Sharpening stone home position sensor

Left–hand side of chopper body

5340

H25.

Sharpening stone cover LED

Instrument panel

5050

H121.

1 minute sharpening LED

LED # 3 in Adjust–o–Matic panel

5100

H122.

2 minutes sharpening LED

LED # 4 in Adjust–o–Matic panel

5120

H123.

3 minutes sharpening LED

LED # 5 in Adjust–o–Matic panel

5140

H124.

Interrupt sharpening routine LED

LED # 6 in Adjust–o–Matic panel

5160

M22.

Sharpening stone cover motor

Right–hand side of chopper body

5290

M23.

Sharpening stone motor

Left–hand side of chopper body

5410

S82.

Sharpening stone cover closed microswitch

Inside sharpening stone cover motor

5260

S113.

Adjust–o–Matic switch

Switch # 10 in instrument panel

5050

S114.

Cutterhead reverse drive switch

Switch # 11 in instrument panel

4970

S121.

1 minute sharpening switch

Switch # 3 in Adjust–o–Matic panel

5100

S122.

2 minutes sharpening switch

Switch # 4 in Adjust–o–Matic panel

5120

S123.

3 minutes sharpening switch

Switch # 5 in Adjust–o–Matic panel

5140

S124.

Interrupt sharpening routine switch

Switch # 6 in Adjust–o–Matic panel

5160

Y31.

Cutterhead reverse drive valve

Stack valve

4950

Line:

4940 -- 5440

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

165

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

166 16a

AUTOMATIC GREASING SYSTEM FX25 39.02 > 5080 FX45

47.02 > 5080

Code

Description

Location

Line

F7.

10A -- Automatic greasing after contact

Fuse print

5460

K58.

Grease pressure switches relay

5540

S67.

Greasing pump

5490

S138.

Grease pressure switch 8R or 6R

5560

S139.

Grease pressure switch cutterhead

5570

S140.

Automatic greasing switch

5530

Line:

5450 -- 5610

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

167

168 16b

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 AUTOMATIC GREASING SYSTEM FX28NA 5083 > .... FX38NA

5083 > ....

FX58NA

5083 > ....

Code

Description

Location

Line

F7.

10A -- Automatic greasing after contact

Fuse print

5460

K58.

Grease pressure switches relay

5540

S67.

Greasing pump

5490

S138.

Grease pressure switch 8R or 6R

5560

S139.

Grease pressure switch cutterhead

5570

S140.

Automatic greasing switch

5530

Line:

5450 -- 5610

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

169

170 17a

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 SHEARBAR ADJUSTMENT FX25 39.01 > 5080 FX45

47.01 > 5080

Code

Description

Location

Line

A24.

Shearbar adjustment control

Adjust–o–Matic print

6100

A172.

Shearbar adjustment output

Adjust–o–Matic panel

5890

B106.

Knock sensor

Shearbar right–hand adjuster arm

6240

H120.

Shearbar adjustment routine LED

LED # 2 in Adjust–o–Matic panel

5860

H125.

Shearbar adjustment rpm fault LED

LED # 7 in Adjust–o–Matic panel

5780

H126.

Shearbar adjustment motor fault LED

LED # 8 in Adjust–o–Matic panel

5800

H127.

Shearbar adjustment sensor fault LED

LED # 9 in Adjust–o–Matic panel

5820

H128.

Adjust cutterhead knives LED

LED # 10 in Adjust–o–Matic panel

5840

H129.

Adjust–o–Matic ready to use LED

LED # 1 in Adjust–o–Matic panel

5860

M24.

Shearbar left–hand adjuster motor

Left–hand side of chopper body

6140

M25.

Shearbar right–hand adjuster motor

Right–hand side of chopper body

6170

S78.

Shearbar left–hand end of travel microswitch (cutterhead)

Left–hand adjuster motor (cutterhead)

5960

S79.

Shearbar left–hand end of travel microswitch (scraper)

Left–hand adjuster motor

6020

S80.

Shearbar right–hand end of travel microswitch (cutterhead)

Right–hand adjuster motor

5990

S81.

Shearbar right–hand end of travel microswitch (scraper)

Right–hand adjuster motor

6050

S120.

Shearbar adjustment switch

Switch # 2 in Adjust–o–Matic panel

5820

Y48.

Ticker solenoid (test signal generator)

Shearbar right–hand adjuster arm

6200

Line:

5790 -- 6290

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

171

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

172 17b

SHEARBAR ADJUSTMENT FX28NA 5083 > 5168 FX38NA

5083 > 5168

FX58NA

5083 > 5168

Code

Description

Location

Line

A24.

Shearbar adjustment control

Adjust–o–Matic print

6100

A172.

Shearbar adjustment output

Adjust–o–Matic panel

5890

B50.

Knock sensor left

Shearbar left

6260

B106.

Knock sensor

Shearbar right–hand adjuster arm

6230

H120.

Shearbar adjustment routine LED

LED # 2 in Adjust–o–Matic panel

5860

H125.

Shearbar adjustment rpm fault LED

LED # 7 in Adjust–o–Matic panel

5780

H126.

Shearbar adjustment motor fault LED

LED # 8 in Adjust–o–Matic panel

5800

H127.

Shearbar adjustment sensor fault LED

LED # 9 in Adjust–o–Matic panel

5820

H128.

Adjust cutterhead knives LED

LED # 10 in Adjust–o–Matic panel

5840

H129.

Adjust–o–Matic ready to use LED

LED # 1 in Adjust–o–Matic panel

5860

M24.

Shearbar left–hand adjuster motor

Left–hand side of chopper body

6130

M25.

Shearbar right–hand adjuster motor

Right–hand side of chopper body

6160

S78.

Shearbar left–hand end of travel microswitch (cutterhead)

Left–hand adjuster motor (cutterhead)

5960

S79.

Shearbar left–hand end of travel microswitch (scraper)

Left–hand adjuster motor

6020

S80.

Shearbar right–hand end of travel microswitch (cutterhead)

Right–hand adjuster motor

5990

S81.

Shearbar right–hand end of travel microswitch (scraper)

Right–hand adjuster motor

6050

S120.

Shearbar adjustment switch

Switch # 2 in Adjust–o–Matic panel

5820

Y48.

Ticker solenoid (test signal generator)

Shearbar right–hand adjuster arm

6190

Line:

5790 -- 6290

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

173

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

174 17c

SHEARBAR ADJUSTMENT FX28NA 5186 > .... FX38NA

5186 > ....

FX58NA

5186 > ....

Code

Description

Location

Line

A24.

Shearbar adjustment control

Adjust–o–Matic print

6100

A172.

Shearbar adjustment output

Adjust–o–Matic panel

5890

B50.

Knock sensor left

Shearbar left

6260

B106.

Knock sensor

Shearbar right–hand adjuster arm

6230

H120.

Shearbar adjustment routine LED

LED # 2 in Adjust–o–Matic panel

5860

H125.

Shearbar adjustment rpm fault LED

LED # 7 in Adjust–o–Matic panel

5780

H126.

Shearbar adjustment motor fault LED

LED # 8 in Adjust–o–Matic panel

5800

H127.

Shearbar adjustment sensor fault LED

LED # 9 in Adjust–o–Matic panel

5820

H128.

Adjust cutterhead knives LED

LED # 10 in Adjust–o–Matic panel

5840

H129.

Adjust–o–Matic ready to use LED

LED # 1 in Adjust–o–Matic panel

5860

M24.

Shearbar left–hand adjuster motor

Left–hand side of chopper body

6130

M25.

Shearbar right–hand adjuster motor

Right–hand side of chopper body

6160

S78.

Shearbar left–hand end of travel microswitch (cutterhead)

Left–hand adjuster motor (cutterhead)

5960

S79.

Shearbar left–hand end of travel microswitch (scraper)

Left–hand adjuster motor

6020

S80.

Shearbar right–hand end of travel microswitch (cutterhead)

Right–hand adjuster motor

5990

S81.

Shearbar right–hand end of travel microswitch (scraper)

Right–hand adjuster motor

6050

S120.

Shearbar adjustment switch

Switch # 2 in Adjust–o–Matic panel

5820

Line:

5790 -- 6290

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

175

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

176 18a

SILAGE ADDITIVE APPLICATION FX25 39.01 > 39.01 FX45

47.01 > 47.01

Code

Description

Location

Line

A34.

Silage additive control

Lights print

6390

A304.

Silage additive application operation

Dashboard print

6330

F8.

25A -- Silage application

Bottom of central electronic box

6440

K2.

Silage additive relay

Fuse print

6430

S109.

Silage additive application switch

Switch # 6 in instrument panel

6320

X510.

Silage additive application socket

Bottom of central electronic box

6440

Line:

6300 -- 6460

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

177

178 18b

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 SILAGE ADDITIVE APPLICATION FX25 39.02 > 5080 FX45

47.02 > 5080

Code

Description

Location

Line

A34.

Silage additive control

Lights print

6390

A304.

Silage additive application operation

Dashboard print

6330

F8.

25A -- Silage application

Bottom of central electronic box

6440

K2.

Silage additive relay

Fuse print

6430

S109.

Silage additive application switch

Switch # 6 in instrument panel

6320

X510.

Silage additive application socket

Bottom of central electronic box

6440

Line:

6300 -- 6460

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

179

180 18c

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 SILAGE ADDITIVE APPLICATION FX28NA 5083 > .... FX38NA

5083 > ....

FX58NA

5083 > ....

Code

Description

Location

Line

A34.

Silage additive control

Lights print

6390

A304.

Silage additive application operation

Dashboard print

6330

F8.

40A -- Silage application

Bottom of central electronic box

6440

K2.

Silage additive relay

Fuse print

6430

S109.

Silage additive application switch

Switch # 6 in instrument panel

6320

X510.

Silage additive application socket

Bottom of central electronic box

6440

Line:

6300 -- 6460

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

181

182 19a

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 AUTO--PILOT FX25 39.01 > 5080

FX45

47.01 > 5080

Code

Description

Location

Line

A32.

12 V Auto–Pilot

Lights print

6480

A46.

Auto–Pilot amplifier

Actuator print

6680

A70.

Auto–Pilot module

Central electronic box

6650

A185.

Auto–Pilot control

Multifunctional lever print

6720

A305.

Auto–Pilot operation

Dashboard print

6760

B41.

Wheel sensor

On steering axle, left–hand side

6630

B111.

Maize header sensor – right–hand side

At front of maize header

6560

B112.

Maize header sensor – left–hand side

At front of maize header

6510

H20.

Auto–Pilot ON control light

Steering column

6640

R14.

Auto–Pilot centering potentiometer

Steering column

6610

S77.

Auto–Pilot engagement switch

S91.

Auto–Pilot button

Multifunctional lever

6720

S108.

Auto–Pilot main switch

Switch # 5 in instrument panel

6750

Y51.

Valve for Auto–Pilot left

Underneath steering platform

6550

Y52.

Valve for Auto–Pilot right

Underneath steering platform

6580

Line:

6470 -- 6800

6590

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

183

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

184 19b

AUTO--PILOT FX28NA 5083 > ....

FX38NA

5083 > ....

FX58NA

5083 > ....

Code

Description

Location

Line

A32.

12 V Auto–Pilot

Lights print

6480

A46.

Auto–Pilot amplifier

Actuator print

6680

A70.

Auto–Pilot module

Central electronic box

6650

A185.

Auto–Pilot control

Multifunctional lever print

6720

A305.

Auto–Pilot operation

Dashboard print

6760

B41.

Wheel sensor

On steering axle, left–hand side

6630

B111.

Maize header sensor – right–hand side

At front of maize header

6560

B112.

Maize header sensor – left–hand side

At front of maize header

6510

H20.

Auto–Pilot ON control light

Steering column

6640

R14.

Auto–Pilot centering potentiometer

Steering column

6610

S77.

Auto–Pilot engagement switch

S91.

Auto–Pilot button

Multifunctional lever

6720

S108.

Auto–Pilot main switch

Switch # 5 in instrument panel

6750

Y51.

Valve for Auto–Pilot left

Underneath steering platform

6550

Y52.

Valve for Auto–Pilot right

Underneath steering platform

6580

Line:

6470 -- 6800

6590

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

185

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

186 20a

HEADER HEIGHT CONTROL (HHC) FX25 39.01 > 5080 FX45 47.01 > 5080

Code

Description

Location

Line

A14.

Bosch interface

CPU print

7280

A45.

Bosch interface

Actuator print

7220

A60.

Bosch HHC module

Central electronic box

7220

A184.

Header height operation

Multifunctional lever print

6950

A190.

Arm rest module print

Arm rest module

6900

B13.

Header pressure sensor

Behind blower

7130

F4.

15A -- HHC contact

Fuse print

6990

F17.

25A -- HHC print

Fuse print

6980

H18.

HHC red control LED

Arm rest module

6820

H19.

HHC green control LED

Arm rest module

6840

R4.

Header height sensor

Chopper body, leftâ&#x20AC;&#x201C;hand side

7160

R6.

Stubble height control potentiometer

Arm rest module

6820

R7.

Ground pressure control potentiometer

Arm rest module

6850

S20.

Header down switch

Multifunctional lever

6920

S22.

Header up switch

Multifunctional lever

6940

S30.

Automatic HHC button

Multifunctional lever

6930

S35.

HHC selector switch

Arm rest module

6870

Y19.

Header down valve

Stack valve

7020

Y20.

Header up valve

Stack valve

7040

Y25.

Compensation valve

Line:

6810 -- 7310

7060

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

187

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

188 20b

HEADER HEIGHT CONTROL (HHC) FX28NA 5083 > .... FX38NA

5083 > ....

FX58NA

5083 > ....

Code

Description

Location

Line

A14.

Bosch interface

CPU print

7280

A45.

Bosch interface

Actuator print

7220

A60.

Bosch HHC module

Central electronic box

7220

A184.

Header height operation

Multifunctional lever print

6950

A190.

Arm rest module print

Arm rest module

6900

B13.

Header pressure sensor

Behind blower

7130

F4.

15A -- HHC contact

Fuse print

6990

F17.

25A -- HHC print

Fuse print

6980

H18.

HHC red control LED

Arm rest module

6820

H19.

HHC green control LED

Arm rest module

6840

R4.

Header height sensor

Chopper body, leftâ&#x20AC;&#x201C;hand side

7160

R6.

Stubble height control potentiometer

Arm rest module

6820

R7.

Ground pressure control potentiometer

Arm rest module

6850

S20.

Header down switch

Multifunctional lever

6920

S22.

Header up switch

Multifunctional lever

6940

S30.

Automatic HHC button

Multifunctional lever

6930

S35.

HHC selector switch

Arm rest module

6870

Y19.

Header down valve

Stack valve

7020

Y20.

Header up valve

Stack valve

7040

Y25.

Compensation valve

Line:

6810 -- 7310

7060

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

189

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

190 21a

COOLANT TEMPERATURE AND FUEL GAUGE FX25 39.01 > 39.05 FX45 47.01 > 47.05

Code

Description

Location

Line

A16.

Meter input

CPU print

7410

A325.

Meter control

Dashboard print

7330

B11.

Engine temperature sender

Engine

7400

B12.

Fuel level sender

In fuel tank

7420

F3.

25A -- Operatorâ&#x20AC;&#x2122;s seat fan + gauges

Fuse print

7330

P1.

Engine temperature meter

Console module in cab

7330

P2.

Fuel gauge

Console module in cab

7350

Line:

7320 -- 7480

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

191

192 21b

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 COOLANT TEMPERATURE AND FUEL GAUGE FX25 39.06 > 5080 FX45 47.06 > 5080

Code

Description

Location

Line

A16.

Meter input

CPU print

7410

A325.

Meter control

Dashboard print

7330

B11.

Engine temperature sender

Engine

7400

B12.

Fuel level sender

In fuel tank

7420

F3.

25A -- Operatorâ&#x20AC;&#x2122;s seat fan + gauges

Fuse print

7330

P1.

Engine temperature meter

Console module in cab

7330

P2.

Fuel gauge

Console module in cab

7350

Line:

7320 -- 7480

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

193

194 21c

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 COOLANT TEMPERATURE AND FUEL GAUGE FX28NA 5083 > 5206 FX38NA 5083 > 5206

Code

Description

Location

Line

A16.

Meter input

CPU print

7410

A325.

Meter control

Dashboard print

7330

B11.

Engine temperature sender

Engine

7400

B12.

Fuel level sender

In fuel tank

7420

F3.

25A -- Operatorâ&#x20AC;&#x2122;s seat fan + gauges

Fuse print

7330

P1.

Engine temperature meter

Console module in cab

7330

P2.

Fuel gauge

Console module in cab

7350

Line:

7320 -- 7480

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

195

196 21d

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 COOLANT TEMPERATURE AND FUEL GAUGE IVECO FX28NA 5218 > .... FX38NA 5218 > ....

Code

Description

Location

Line

A16.

Meter input

CPU print

7410

A325.

Meter control

Dashboard print

7330

B12.

Fuel level sender

In fuel tank

7420

B51.

Oil temperature sender

Engine

7380

F3.

25A -- Operatorâ&#x20AC;&#x2122;s seat fan + gauges

Fuse print

7330

P1.

Engine temperature meter

Console module in cab

7330

P2.

Fuel gauge

Console module in cab

7350

Line:

7320 -- 7480

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

197

198 21e

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 COOLANT TEMPERATURE AND FUEL GAUGE CATERPILLAR FX58NA 5083 > 5206

Code

Description

Location

Line

A16.

Meter input

CPU print

7410

A325.

Meter control

Dashboard print

7330

B12.

Fuel level sender

In fuel tank

7420

B51.

Oil temperature sender

Engine

7380

F3.

25A -- Operatorâ&#x20AC;&#x2122;s seat fan + gauges

Fuse print

7330

P1.

Engine temperature meter

Console module in cab

7330

P2.

Fuel gauge

Console module in cab

7350

Line:

7320 -- 7480

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

199

200 21f

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 COOLANT TEMPERATURE AND FUEL GAUGE CATERPILLAR FX58NA 5218 > ....

Code

Description

Location

Line

A16.

Meter input

CPU print

7410

A325.

Meter control

Dashboard print

7330

B12.

Fuel level sender

In fuel tank

7420

B51.

Oil temperature sender

Engine

7380

F3.

25A -- Operatorâ&#x20AC;&#x2122;s seat fan + gauges

Fuse print

7330

P1.

Engine temperature meter

Console module in cab

7330

P2.

Fuel gauge

Console module in cab

7350

Line:

7320 -- 7480

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

201

202 22a

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN FX25 39.01 > 5080 FX45 47.01 > 5080

Code

Description

Location

Line

A35.

Brake lights control

Lights print

8310

A323.

Brake contact input

Dashboard print

8270

B29.

Horn

Underneath steering platform

7840

E3.

Brake light, left

Rear of machine

8300

E3.

Parking light, left

Rear of machine

8010

E5.

Brake light, right

Rear of machine

8320

E5.

Parking light, right

Rear of machine

8150

E7.

Parking light, front left

Front of machine

7970

E8.

Additional parking light, front left

Front of machine

7990

E11.

Parking light, front right

Front of machine

8110

E12.

Additional parking light, front right

Front of machine

8130

E15.

Head lights, left

Front of machine

8200

E16.

Head lights, right

Front of machine

8240

E17.

Additional parking light (Germany)

Rear of machine

8170

E17.

Additional brake light (Germany)

Rear of machine

8290

E41.

Licence plate lights

Rear of machine

8030

F2.

15A -- Horn lights

Fuse print

7840

F9.

15A -- Parking light, right

Fuse print

8090

F10.

15A -- Parking light, left

Fuse print

7950

F14.

25A -- Road lights

Fuse print

7850

F23.

15A -- Main beam head lights

Fuse print

8190

F24.

15A -- Fuse dipped head lights

Fuse print

8230

H15.

Main beam head lights indicator light

Steering column

7880

K3.

Parking lights relay

Fuse print

7930

S58.

Brake contact

Underneath steering platform

8280

S59.

Combined light switch

Steering column

7850

X130.

Trailer 12 V socket

Rear of machine

8050 8170 8300

X147.

12 V socket, right–hand side

Right–hand side of machine, underneath head light

7950

X148.

12 V socket, left–hand side

Left–hand side of machine, underneath head light

8090

Line:

7830 -- 8330

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

203

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

204 22b

PARKING LIGHTS, HEAD LIGHTS, BRAKE LIGHTS AND HORN FX28NA 5083 > .... FX38NA 5083 > .... FX58NA

5083 > ....

Code

Description

Location

Line

A35.

Brake lights control

Lights print

8310

A323.

Brake contact input

Dashboard print

8270

B29.

Horn

Underneath steering platform

7840

E3.

Brake light, left

Rear of machine

8300

E3.

Parking light, left

Rear of machine

8010

E5.

Brake light, right

Rear of machine

8320

E5.

Parking light, right

Rear of machine

8150

E7.

Parking light, front left

Front of machine

7970

E8.

Additional parking light, front left

Front of machine

7990

E11.

Parking light, front right

Front of machine

8110

E12.

Additional parking light, front right

Front of machine

8130

E15.

Head lights, left

Front of machine

8200

E16.

Head lights, right

Front of machine

8240

E17.

Additional brake light (Germany)

Rear of machine

8290

E17.

Additional parking light (Germany)

Rear of machine

8170

E41.

Licence plate lights

Rear of machine

8030

F2.

15A -- Horn lights

Fuse print

7840

F9.

15A -- Parking light, right

Fuse print

8090

F10.

15A -- Parking light, left

Fuse print

7950

F14.

25A -- Road lights

Fuse print

7850

F23.

15A -- Main beam head lights

Fuse print

8190

F24.

15A -- Fuse dipped head lights

Fuse print

8230

H15.

Main beam head lights indicator light

Steering column

7880

K3.

Parking lights relay

Fuse print

7930

S58.

Brake contact

Underneath steering platform

8280

S59.

Combined light switch

Steering column

7850

X130.

Trailer 12 V socket

Rear of machine

8050 8170 8300

X147.

12 V socket, right–hand side

Right–hand side of machine, underneath head light

7950

X148.

12 V socket, left–hand side

Left–hand side of machine, underneath head light

8090

Line:

7830 -- 8330

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

205

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

206 23a

DIRECTION INDICATOR AND HAZARD WARNING LIGHTS FX25 39.01 > 5080 FX45 47.01 > 5080

Code

Description

A80.

NA Direction indicator print

E3.

Direction indicator, left rear

Dashboard

8630

E5.

Direction indicator, right rear

Dashboard

8570

E7.

Direction indicator, left front

Dashboard

8610

E8.

Direction indicator, left front additional

Dashboard

8630

E11.

Direction indicator, right front

Dashboard

8590

E12.

Direction indicator, right front additional

Dashboard

8560

F5.

10A -- Direction indicator

Fuse print

8350

F16.

15A -- Hazard warning lights

Fuse print

8360

H16.

Direction indicators control light

Steering column

8440

H17.

Trailer direction indicators control light

Steering column

8370

S59.

Combined switch

Steering column

8450

S65.

Hazard warning lights switch

Steering column

8420

X130.

Connector tow hook

Rear of machine

8550 8640

Line:

8340 -- 8670

Location

Line 8530

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

207

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

208 23b

DIRECTION INDICATOR AND HAZARD WARNING LIGHTS FX28NA 5083 > .... FX38NA 5083 > .... FX58NA

Code

Description

A80.

NA Direction indicator print

E3.

Direction indicator, left rear

Dashboard

8630

E5.

Direction indicator, right rear

Dashboard

8570

E7.

Direction indicator, left front

Dashboard

8610

E8.

Direction indicator, left front additional

Dashboard

8630

E11.

Direction indicator, right front

Dashboard

8590

E12.

Direction indicator, right front additional

Dashboard

8560

F5.

10A -- Direction indicator

Fuse print

8350

F16.

15A -- Hazard warning lights

Fuse print

8360

H16.

Direction indicators control light

Steering column

8440

H17.

Trailer direction indicators control light

Steering column

8370

S59.

Combined switch

Steering column

8450

S65.

Hazard warning lights switch

Steering column

8420

X130.

Connector tow hook

Rear of machine

8550 8640

Line:

8340 -- 8670

Location

5083 > ....

Line 8530

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

209

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

210 24a

OPERATING LIGHTS AND BEACONS FX25 39.01 > 5080 FX45 47.01 > 5080

Code

Description

Location

Line

A36.

Operating lights and beacons control

Lights print

8870

A303.

Switch on operating lights and beacons

Dashboard print

8740

E1.

Beacon 1

Behind cab

8960

E2.

Beacon 2

Behind cab

8980

E27.

Operating light, left 1

Railing platform

8760

E27.

Operating light, left 2

Railing platform

8780

E28.

Operating light, right 1

Railing platform

8790

E28.

Operating light, right 2

Railing platform

8810

E29.

Spot light, left

Cab roof

8850

E30.

Spot light, right

Cab roof

8870

E34.

Stubble light, left

Cab roof

8820

E35.

Stubble light, right

Cab roof

8840

E45.

Reverse drive operating light

Rear of engine hood

9000

E100.

Spout operating light

Spout

8930

S110.

Operating lights switch

Switch # 7 in dashboard

8710

S111.

Beacons switch

Switch # 8 in dashboard

8790

Line:

8680 -- 9010

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

211

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

212 24b

OPERATING LIGHTS AND BEACONS FX28NA 5083 > 5206 FX38NA 5083 > 5206

Code

Description

Location

Line

A36.

Operating lights and beacons control

Lights print

8870

A303.

Switch on operating lights and beacons

Dashboard print

8740

E1.

Beacon 1

Behind cab

8960

E2.

Beacon 2

Behind cab

8980

E27.

Operating light, left 1

Railing platform

8760

E27.

Operating light, left 2

Railing platform

8780

E28.

Operating light, right 1

Railing platform

8790

E28.

Operating light, right 2

Railing platform

8810

E29.

Spot light, left

Cab roof

8850

E30.

Spot light, right

Cab roof

8870

E34.

Stubble light, left

Cab roof

8820

E35.

Stubble light, right

Cab roof

8840

E45.

Reverse drive operating light

Rear of engine hood

9000

E100.

Spout operating light

Spout

8930

S110.

Operating lights switch

Switch # 7 in dashboard

8710

S111.

Beacons switch

Switch # 8 in dashboard

8790

Line:

8680 -- 9010

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

213

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

214 24c

OPERATING LIGHTS AND BEACONS IVECO FX28NA 5218 > .... FX38NA 5218 > ....

Code

Description

Location

Line

A36.

Operating lights and beacons control

Lights print

8870

A303.

Switch on operating lights and beacons

Dashboard print

8740

E1.

Beacon 1

Behind cab

8960

E2.

Beacon 2

Behind cab

8980

E27.

Operating light, left 1

Railing platform

8760

E27.

Operating light, left 2

Railing platform

8780

E28.

Operating light, right 1

Railing platform

8790

E28.

Operating light, right 2

Railing platform

8810

E29.

Spot light, left

Cab roof

8850

E30.

Spot light, right

Cab roof

8870

E34.

Stubble light, left

Cab roof

8820

E35.

Stubble light, right

Cab roof

8840

E45.

Reverse drive operating light

Rear of engine hood

9000

E100.

Spout operating light

Spout

8930

S110.

Operating lights switch

Switch # 7 in dashboard

8710

S111.

Beacons switch

Switch # 8 in dashboard

8790

Line:

8680 -- 9010

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

215

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

216 24d

OPERATING LIGHTS AND BEACONS FX58NA 5083 > 5206

Code

Description

Location

Line

A36.

Operating lights and beacons control

Lights print

8870

A303.

Switch on operating lights and beacons

Dashboard print

8740

E1.

Beacon 1

Behind cab

8960

E2.

Beacon 2

Behind cab

8980

E27.

Operating light, left 1

Railing platform

8760

E27.

Operating light, left 2

Railing platform

8780

E28.

Operating light, right 1

Railing platform

8790

E28.

Operating light, right 2

Railing platform

8810

E29.

Spot light, left

Cab roof

8850

E30.

Spot light, right

Cab roof

8870

E34.

Stubble light, left

Cab roof

8820

E35.

Stubble light, right

Cab roof

8840

E45.

Reverse drive operating light

Rear of engine hood

9000

E100.

Spout operating light

Spout

8930

S110.

Operating lights switch

Switch # 7 in dashboard

8710

S111.

Beacons switch

Switch # 8 in dashboard

8790

Line:

8680 -- 9010

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

217

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

218 24e

OPERATING LIGHTS AND BEACONS FX58NA 5218 > ....

Code

Description

Location

Line

A36.

Operating lights and beacons control

Lights print

8870

A303.

Switch on operating lights and beacons

Dashboard print

8740

E1.

Beacon 1

Behind cab

8960

E2.

Beacon 2

Behind cab

8980

E27.

Operating light, left 1

Railing platform

8760

E27.

Operating light, left 2

Railing platform

8780

E28.

Operating light, right 1

Railing platform

8790

E28.

Operating light, right 2

Railing platform

8810

E29.

Spot light, left

Cab roof

8850

E30.

Spot light, right

Cab roof

8870

E34.

Stubble light, left

Cab roof

8820

E35.

Stubble light, right

Cab roof

8840

E45.

Reverse drive operating light

Rear of engine hood

9000

E100.

Spout operating light

Spout

8930

S110.

Operating lights switch

Switch # 7 in dashboard

8710

S111.

Beacons switch

Switch # 8 in dashboard

8790

Line:

8680 -- 9010

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

219

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

220 25a

AIR CONDITIONING FX25 39.01 > 39.01

FX45

47.01 > 47.01

Code

Description

Location

Line

A17.

AC–compressor surveillance

CPU print

9400

A37.

AC–compressor control

Lights print

9350

A156.

Compressor LED’s control

Dashboard print

9470

A324.

Air conditioning operation

Dashboard print

9200

B61.

Thermostat switch

Dashboard print

9230

F3.

25A -- Air conditioning fan

Fuse print

9230

H13.

Compressor overpressure LED

Instrument panel

9460

H14.

Compressor underpressure LED

Instrument panel

9470

M11.

Fan motor

Underneath operator’s seat

9310

S37.

Fan + air conditioning switch

Console module in cab

9250

S60.

Air conditioning safety switch

Console module in cab

9230

S62.

Compressor overpressure contact

Compressor

9380

S63.

Compressor underpressure contact

Compressor

9420

Y27.

Compressor

Left–hand side of engine

9340

Line:

9190 -- 9520

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

221

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

222 25b

AIR CONDITIONING FX25 39.02 > 39.05

FX45

47.02 > 47.05

Code

Description

Location

Line

A17.

AC–compressor surveillance

CPU print

9400

A37.

AC–compressor control

Lights print

9350

A156.

Compressor LED’s control

Dashboard print

9470

A324.

Air conditioning operation

Dashboard print

9200

B61.

Thermostat switch

Dashboard print

9230

F3.

25A -- Air conditioning fan

Fuse print

9230

F43.

Fan

Central electronic box

9330

H13.

Compressor overpressure LED

Instrument panel

9460

H14.

Compressor underpressure LED

Instrument panel

9470

K56.

Fan relay

Console module in cab

9280

K57.

Fan ground relay

Console module in cab

9310

M11.

Fan motor

Underneath operator’s seat

9310

S37.

Fan + air conditioning switch

Console module in cab

9250

S60.

Air conditioning safety switch

Console module in cab

9230

S62.

Compressor overpressure contact

Compressor

9380

S63.

Compressor underpressure contact

Compressor

9420

Y27.

Compressor

Left–hand side of engine

9340

Line:

9190 -- 9520

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

223

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

224 25c

AIR CONDITIONING FX25 39.06 > 5080

FX45

47.06 > 5080

Code

Description

Location

Line

A17.

AC–compressor surveillance

CPU print

9400

A37.

AC–compressor control

Lights print

9350

A156.

Compressor LED’s control

Dashboard print

9470

A324.

Air conditioning operation

Dashboard print

9200

B61.

Thermostat switch

Dashboard print

9230

F3.

25A -- Air conditioning fan

Fuse print

9230

F43.

Fan

Central electronic box

9330

H13.

Compressor overpressure LED

Instrument panel

9460

H14.

Compressor underpressure LED

Instrument panel

9470

K56.

Fan relay

Console module in cab

9280

K57.

Fan ground relay

Console module in cab

9310

M11.

Fan motor

Underneath operator’s seat

9310

M19.

Additional fan

S37.

Fan + air conditioning switch

Console module in cab

9250

S60.

Air conditioning safety switch

Console module in cab

9230

S62.

Compressor overpressure contact

Compressor

9380

S63.

Compressor underpressure contact

Compressor

9420

Y27.

Compressor

Left–hand side of engine

9340

Line:

9190 -- 9520

9290

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

225

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

226 25d

AIR CONDITIONING FX28NA 5083 > ....

FX38NA

5083 > ....

FX58NA

5083 > ....

Code

Description

Location

Line

A17.

AC–compressor surveillance

CPU print

9400

A37.

AC–compressor control

Lights print

9350

A156.

Compressor LED’s control

Dashboard print

9470

A324.

Air conditioning operation

Dashboard print

9200

B61.

Thermostat switch

Dashboard print

9230

F3.

25A -- Air conditioning fan

Fuse print

9230

F43.

Fan

Central electronic box

9330

H13.

Compressor overpressure LED

Instrument panel

9460

H14.

Compressor underpressure LED

Instrument panel

9470

K56.

Fan relay

Console module in cab

9280

K57.

Fan ground relay

Console module in cab

9310

M11.

Fan motor

Underneath operator’s seat

9310

M19.

Additional fan

S37.

Fan + air conditioning switch

Console module in cab

9250

S60.

Air conditioning safety switch

Console module in cab

9230

S62.

Compressor overpressure contact

Compressor

9380

S63.

Compressor underpressure contact

Compressor

9420

Y27.

Compressor

Left–hand side of engine

9340

Line:

9190 -- 9520

9290

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

227

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

228 26a

CAB FX25

39.01 > 39.01

FX45

47.01 > 47.01

Code

Description

Location

Line

A1.

Radio

Cab roof

9900

A2.

Cab roof

9910

B31.

Loudspeaker 1

Cab roof

9850

B32.

Loudspeaker 2

Cab roof

9940

E37.

Cab spot light

Cab roof

9970

E38.

Cab interior light

Cab roof

10010

F6.

25A -- Windshield wiper + mirrors

Fuse print

9760

F12.

10A -- Dashboard 12 V sockets

Fuse print

9710

F13.

10A -- Clock, radio, CB, cab lights

Fuse print

9870

M12.

Windshield wiper motor

Cab roof

9820

P4.

Clock

Cab roof

9850

S38.

Windshield wiper switch

Cab roof

9760

S84.

Cab door switch

Cab door

9980

X150.

12 V socket

Console module

9710

X151.

12 V socket

Console module

9730

Line:

9700 -- 10030

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

229

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

230 26b

CAB FX25

39.02 > 39.04

FX45

47.02 > 47.04

Code

Description

Location

Line

A1.

Radio

Cab roof

9900

A2.

Cab roof

9910

B31.

Loudspeaker 1

Cab roof

9850

B32.

Loudspeaker 2

Cab roof

9940

E37.

Cab spot light

Cab roof

9970

E38.

Cab interior light

Cab roof

10010

F6.

25A -- Windshield wiper + mirrors

Fuse print

9760

F12.

10A -- Dashboard 12 V sockets

Fuse print

9710

F13.

10A -- Clock, radio, CB, cab lights

Fuse print

9870

M12.

Windshield wiper motor

Cab roof

9820

P4.

Clock

Cab roof

9850

S38.

Windshield wiper switch

Cab roof

9760

S84.

Cab door switch

Cab door

9980

X150.

12 V socket

Console module

9710

X151.

12 V socket

Console module

9730

Line:

9700 -- 10030

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

231

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

232 26c

CAB FX25

39.05 > 5080

FX45

47.05 > 5080

Code

Description

Location

Line

A1.

Radio

Cab roof

9900

A2.

Cab roof

9910

B31.

Loudspeaker 1

Cab roof

9850

B32.

Loudspeaker 2

Cab roof

9940

E37.

Cab spot light

Cab roof

9970

E38.

Cab interior light

Cab roof

10010

F6.

25A -- Windshield wiper + mirrors

Fuse print

9760 10190

F12.

10A -- Dashboard 12 V sockets

Fuse print

9710

F13.

10A -- Clock, radio, CB, cab lights

Fuse print

9870

M12.

Windshield wiper motor

Cab roof

9820

M31.

Rear windshield wiper motor

Rear windshield

M32.

Front windshield washer pump

Cab roof

M33.

Side windows washer pump

Side windows

10150

M34.

Rear windshield washer pump

Rear windshield

10150

M35.

Right–hand side window wiper motor

Right–hand side window

10140

M36.

Left–hand side window wiper motor

Left–hand side window

10140

P4.

Clock

Cab roof

9850

S38.

Windshield wiper switch

Cab roof

9760

S84.

Cab door switch

Cab door

9980

S126.

Front windshield washer switch

Cab roof

9810

S127.

Side windows wiper/washer switch

Cab roof

10080

S128.

Rear windshield wiper/washer switch

Cab roof

10070

X150.

12 V socket

Console module

9710

X151.

12 V socket

Console module

9730

Line:

9700 -- 10200

10140 9830

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

233

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

234 26d

CAB FX28NA

5083 > ....

FX38NA

5083 > ....

FX58NA

5083 > ....

Code

Description

Location

Line

A1.

Radio

Cab roof

9900

A2.

Cab roof

9910

B31.

Loudspeaker 1

Cab roof

9850

B32.

Loudspeaker 2

Cab roof

9940

E37.

Cab spot light

Cab roof

9970

E38.

Cab interior light

Cab roof

10010

F6.

25A -- Windshield wiper + mirrors

Fuse print

9760 10190

F12.

10A -- Dashboard 12 V sockets

Fuse print

9710

F13.

10A -- Clock, radio, CB, cab lights

Fuse print

9870

M12.

Windshield wiper motor

Cab roof

9820

M31.

Rear windshield wiper motor

Rear windshield

M32.

Front windshield washer pump

Cab roof

M33.

Side windows washer pump

Side windows

10150

M34.

Rear windshield washer pump

Rear windshield

10150

M35.

Right–hand side window wiper motor

Right–hand side window

10140

M36.

Left–hand side window wiper motor

Left–hand side window

10140

P4.

Clock

Cab roof

9850

S38.

Windshield wiper switch

Cab roof

9760

S84.

Cab door switch

Cab door

9980

S126.

Front windshield washer switch

Cab roof

9810

S127.

Side windows wiper/washer switch

Cab roof

10080

S128.

Rear windshield wiper/washer switch

Cab roof

10070

X150.

12 V socket

Console module

9710

X151.

12 V socket

Console module

9730

Line:

9700 -- 10200

10140 9830

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

235

236 27a

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 MIRROR CONTROL AND WINDSHIELD HEATING FX25 39.01 > 39.04 FX45 47.01 > 47.04

Code

Description

Location

F42.

Rear windshield heating circuit breaker

Cab roof

10530

K53.

Mirror control relay, right–hand side

Cab roof

10310

K54.

Mirror control relay, left–hand side

Cab roof

10350

K55.

Rear windshield heating relay

Cab roof

10460

M13.

Right–hand side mirror

Right–hand side of cab

10410

M14.

Left–hand side mirror

Left–hand side of cab

10360

M15.

Additional mirror, right–hand side (Germany only)

Right–hand side of cab

10490

R15.

Rear windshield heating

Rear windshield

10480

S39.

Mirror control switch

Cab roof

10260

S40.

Mirror selection + heating switch

Cab roof

10510

Line:

10210 -- 10540

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

237

238 27b

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 MIRROR CONTROL AND WINDSHIELD HEATING FX25 39.05 > 5080 FX45 47.05 > 5080

Code

Description

Location

F42.

Rear windshield heating circuit breaker

Cab roof

10530

K53.

Mirror control relay, right–hand side

Cab roof

10310

K54.

Mirror control relay, left–hand side

Cab roof

10350

K55.

Rear windshield heating relay

Cab roof

10460

M13.

Right–hand side mirror

Right–hand side of cab

10410

M14.

Left–hand side mirror

Left–hand side of cab

10360

M15.

Additional mirror, right–hand side (Germany only)

Right–hand side of cab

10490

R15.

Rear windshield heating

Rear windshield

10480

S39.

Mirror control switch

Cab roof

10260

S40.

Mirror selection + heating switch

Cab roof

10510

S125.

Additional mirror switch, right–hand side (Germany only)

Cab roof

10480

Line:

10210 -- 10540

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

239

240 27c

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 MIRROR CONTROL AND WINDSHIELD HEATING FX28NA 5083 > .... FX38NA 5083 > ....

FX58NA

5083 > ....

Code

Description

Location

F42.

Rear windshield heating circuit breaker

Cab roof

10530

K53.

Mirror control relay, right–hand side

Cab roof

10310

K54.

Mirror control relay, left–hand side

Cab roof

10350

K55.

Rear windshield heating relay

Cab roof

10460

M13.

Right–hand side mirror

Right–hand side of cab

10410

M14.

Left–hand side mirror

Left–hand side of cab

10360

M15.

Additional mirror, right–hand side (Germany only)

Right–hand side of cab

10490

R15.

Rear windshield heating

Rear windshield

10480

S39.

Mirror control switch

Cab roof

10260

S40.

Mirror selection + heating switch

Cab roof

10510

S125.

Additional mirror switch, right–hand side (Germany only)

Cab roof

10480

Line:

10210 -- 10540

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

241

242 28a

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 FLIP--UP MAIZE HEADER FX25 39.01 > 5080

FX45

47.01 > 5080

Code

Description

Location

A48.

Flip–up control

Actuator print

10740

S129.

Flip–up selector switch

Console module

10760

Y61.

Valve A, fold up -- fold down side row units

10820

Y62.

Valve B, fold up -- fold down side row units

10830

Y63.

Valve A, slide--in -- slide out side row units

10800

Y64.

Valve B, slide in -- slide out side row units

10810

Y65.

Valve A, swing in -- swing out crop guide tubes

10780

Y66.

Valve B, swing in -- swing out braces crop guide tubes

10790

Line:

10720 -- 10880

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

243

244 28b

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 FLIP--UP MAIZE HEADER FX28NA 5083 > ....

FX38NA

5083 > ....

FX58NA

5083 > ....

Code

Description

Location

A48.

Flip–up control

Actuator print

10740

S129.

Flip–up selector switch

Console module

10760

Y61.

Valve A, fold up -- fold down side row units

10820

Y62.

Valve B, fold up -- fold down side row units

10830

Y63.

Valve A, slide--in -- slide out side row units

10800

Y64.

Valve B, slide in -- slide out side row units

10810

Y65.

Valve A, swing in -- swing out crop guide tubes

10780

Y66.

Valve B, swing in -- swing out braces crop guide tubes

10790

Line:

10720 -- 10880

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

245

246 29a

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 HIGH FLOW REAR HYDRAULICS FX25 39.01 > 39.04 FX45

47.01 > 47.04

Code

Description

V21.

Diode high pressure valve

10970

V22.

Diode high pressure valve

10950

Y49.

Tip trailer up valve

Right–hand side of engine

10890

Y50.

Tip trailer down valve

Right–hand side of engine

10920

Y57.

High pressure valve trailer

Line:

10890 -- 11050

Location

Line

10940

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

247

248 29b

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 HIGH FLOW REAR HYDRAULICS FX25 39.05 > 5080 FX45

47.05 > 5080

Code

Description

Location

A56.

High flow rear hydraulics control

Valve print

10910

A116.

High flow rear hydraulics switch–on

Dashboard print

11020

S137.

High flow rear hydraulics switch

Dashboard

11010

V21.

Diode high pressure valve

10970

V22.

Diode high pressure valve

10950

Y49.

Tip trailer up valve

Right–hand side of engine

10890

Y50.

Tip trailer down valve

Right–hand side of engine

10920

Y57.

High pressure valve trailer

Line:

10890 -- 11050

Line

10940

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

249

250 29c

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 HIGH FLOW REAR HYDRAULICS FX28NA 5083 > .... FX38NA

5083 > ....

FX58NA

5083 > ....

Code

Description

Location

A56.

High flow rear hydraulics control

Valve print

10910

A116.

High flow rear hydraulics switch–on

Dashboard print

11020

S137.

High flow rear hydraulics switch

Dashboard

11010

V21.

Diode high pressure valve

10970

V22.

Diode high pressure valve

10950

Y49.

Tip trailer up valve

Right–hand side of engine

10890

Y50.

Tip trailer down valve

Right–hand side of engine

10920

Y57.

High pressure valve trailer

Line:

10890 -- 11050

Line

10940

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

251

252 30a

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 ADDITIONAL LIGHTS FOR FLIP--UP ATTACHMENTS FX58NA 5083 > 5206

Code

Description

Location

A81.

Electronic cintrol box

Engine

11870

A82.

Electronic injection box

Engine

11800

B3.

Oil temperature sensor

Engine

11680

B42.

Air temperature sensor

Engine

11570

B43.

Engine rpm sensor 1

Engine

11610

B44.

Engine rpm sensor 2

Engine

11650

B45.

Turbo pressure sensor

Engine

11720

B46.

Air pressure sensor

Engine

11760

B47.

Oil pressure sensor

Engine

11800

B48.

Fuel temperature sensor

Engine

11830

R31.

CAN resistance

Engine

11740

Line:

11560 -- 11890

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

253

254 30b

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 ELECTRONIC ENGINE CONTROL CATERPILLAR FX58NA 5218 > ....

Code

Description

Location

A81.

Electronic cintrol box

Engine

11870

A82.

Electronic injection box

Engine

11800

B3.

Oil temperature sensor

Engine

11680

B42.

Air temperature sensor

Engine

11570

B43.

Engine rpm sensor 1

Engine

11610

B44.

Engine rpm sensor 2

Engine

11650

B45.

Turbo pressure sensor

Engine

11720

B46.

Air pressure sensor

Engine

11760

B47.

Oil pressure sensor

Engine

11800

B48.

Fuel temperature sensor

Engine

11830

R31.

CAN resistance

Engine

11740

Line:

11560 -- 11890

Line

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

255

256 31a

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3 ELECTRONIC ENGINE CONTROL IVECO FX28NA 5218 > .... FX38NA 5218 > ....

Code

Description

Location

A84.

Engine electronic control box

Engine

K68.

Pre--heating

R1.

Engine heating

S130.

Engine electronic control box diagnostics switch

12000

X189.

Engine electronic control box connector

12020

Line:

11900 -- 12060

Line 11960 12040

Engine

12040

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

257

258

SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

SECTION 55 -- ELECTRICAL SYSTEM Chapter 4 -- Can Network Basics CONTENT Section

Description

Page

55.000

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

CAN NETWORK BASICS The main reason for building an integrated electrical / electronic system is the increasing demand for more functions and ease of operation! The CAN (Controller Area Network) is a communication system that links several microprocessors, using two leads to send information between them. These two leads are known as the bus. Instead of leading wiring harnesses all over the machine, functions are grouped and collected into Input and Output stations (on electronic printed circuits). These I/O stations are linked by only a small number of wires with a serial data transmission network. The network connects all stations. As such it is merely a way of transporting information/messages from one place to another in the machine.

GENERAL LAYOUT ELECTRONIC SYSTEM Electronic components a

Cab area

Cab sections connected to the network: • InfoView Monitor: contains nodes A and S Remark: Node A: InfoView/dashboard operation Node S: Symbols and languages • • •

Instrument Panel Multifunction lever and armrest module Floor console module

Electronic Box

Printed circuits located in the electronic box and connected to the network: • CPU printed circuit: contains node B • AOM printed circuit: contains node D • Lights printed circuit • Electric motor and actuator printed circuit • Valve printed circuit • Bosch module • Auto–Pilot module [accessory]

Metal Detector

Contains node M. d

Caterpillar Engine (Only for FX58)

A communication link is established between the controller of the Caterpillar engine and the Electronic Box to exchange information between both systems. The electronic control unit can only be updated and configured by an official Caterpillar representative. Conclusion The electronics on the Forage Harvester contain four memories, located on several electronic printed circuits, which are responsible for the functional operation of the machine. They are all flash memories that can be updated by means of PC laptop or PDT tool. This means that when a new software revision is released, no hardware changes have to be carried out and no EPROM’s have to be changed. Only a new installation disk (for PC laptop) or a new cartridge (for PDT tool) is necessary to install the new software revision. This happens via a DIN connector underneath the dashboard. REMARK: Module: used to indicate the hardware and printed circuit boards all over the machine. Node: used to indicate the software that translates all input messages to output messages.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

ZDA0481A

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

ELECTRONIC SYSTEM LAYOUT

3 Input Switches Sensors: Pressure / Temperature sensors Header height sensors RPM sensors Proximity sensors Potentiometers

Analog signals (from input or to output) Examples: •

0 or 12V constant voltage (from switches; most end users)

•

0 or 12V variable voltage (potentiometer)

•

PWM signal

variable voltage (to proportional electro valves)

PWM: pulse width modulation.

Digital Information (see also picture 2) Output To end users: Electromagnetic valves Electromagnetic clutches Actuators Solenoids Electric motors Lights

All information that passes through the CAN Network. The medium can be: Fibre optics Flat cable Standard cable

Interfaces (located on the printed circuit boards) Translates an analog signal to a digital signal, or Translates a digital signal to an analog signal.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 Software A sequential decision making process, where the presence of particular input signals result in a desired task (output) being achieved. If all the necessary input signals are not present, or are introduced in the wrong sequence, then the desired task or action will not be achieved. The software program determines the function of the machine, where all inputs and requisites for a particular task or action are specified. Changing the software program can effect the machine function as a result of the input requirement specifications for a particular output being changed. Calibrations Calibration effect machine function and error code reporting. Calibrations are achieved through the InfoView monitor and by using the PDT tool (or P.C.). The calibration procedure dictated a choice to the software program. This change in the software decision making process enables us to adapt the mode of operation of the machine to respect any additional equipment that is installed, or refine the operation of a particular function to suit the working environment. Additional info: 1. Each Node contains a particular software program that is unique to that location. Therefore the Software cannot be transferred from one Node to another. 2. The calibrations preferences are held on Three Nodes, when the engine is started these preferred choice or setting on each Node are compared. If the choices or settings on one Node are different from the others the Nodes in the majority will influence and change choices or settings of the Node that is in the minority. 3. With an integrated system, the functionality of the system can NOT be deduced from the wiring diagram (in comparison with a classical wired system).

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

6 CAN SPY

Decimal and hexadecimal counting To enable us to count up to Sixteen and only use One digit position (to enable the large volume of information to be displayed) the Hexadecimal counting system has been introduced.

Decimal Numbe r

NOTE: Zero is a number in the decimal counting system and can be considered as the first option in the sequence of Ten numbers.

Thousands

Hundreds

Tens

Units

If only One digit position is available on the display, then 0 -- 9 (Ten options) can be expressed. If Two digit positions are available on the display, then 0 -- 99 (One Hundred options) can be expressed. In simple terms: 28 is formed of Eight Units and Two groups of Ten (= 2 x 10 + 8). 6789 is formed of Nine Units, Eight groups of Ten, Seven groups of One Hundred and Six groups of One Thousand (= 6 x 1000 + 7 x 100 + 8 x 10 + 9).

Hexadecimal Decimal number

Hexadecimal number

NOTE: Zero is a number in the hexadecimal counting system and can be considered as the first option in the sequence of Sixteen numbers. To enable us to express the Eleventh option and beyond, letters of the Alphabet are used (A, B, C, D, E, F). The same counting principals apply in hexadecimal counting as in decimal counting.

Units are expressed in one digit from 0 -- F. Then groups of Sixteen are expressed in the first digit position and the Units shown in the Second giving 00 -FF. Some calculators have an automatic hexadecimal -decimal conversion option.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 Sixteen X Sixteen X Sixteen

Sixteen X Sixteen

Sixteens

Units

Example: Hexadecimal

Decimal

(2 x 16) + 0 = 32

2FA3

(2 x 163)+(F x 162)+(A x 161)+3

2FA3

(2 x 4096)+(15 x 256)+(10 x 16)+3

2FA3

8192+3840+160+3 = 12195

A clear example of hexadecimal counting can be observed when recalling identifier 1327 of the CAN-SPY mode. This is the CAN identifier for date and time. The counting of the seconds gives a fair idea of what hexadecimal counting is.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

How to use the CAN Identifiers

4 The CAN--system provides the ability to obtain ”inside information” for component or continuity fault diagnosis. This system is called the ”CAN--SPY troubleshooting”. The CAN--SPY system enables us to check the presence and status of input and output signals within the electronic system for each component or function. This information can be recalled on the InfoView monitor and used in conjunction with the Can Spy notes. Once the CAN--SPY mode and the right identifier are selected, you are able to compare the expected values given in the CAN--SPY notes with the values provided by the electronic system. Any difference between these two values, for any given situation can be of help to isolate the location of a fault in the electronic system. A logical process of elimination should be used, where each expected value from the inputs, prerequisites or outputs for a particular function are checked in sequence. When checking Output and Status values it is often necessary to follow normal operating procedures during testing. Some individual Output or Status values will not be available unless all preceding inputs or functions are present.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

How to Enter CAN--SPY Simultaneously press MEM and ESC on the InfoView panel. The Can Spy screen will appear and shows the following information: •

•

The identifier number or ”Page number” (e.g. 1280). This can be changed with the scroll buttons. Four words in the bottom text line (shown as xxxx xxxx xxxx xxxx). Each word contains four digits.

The four words in the bottom text line contain the information of the CAN system in hexadecimal numbers.

ZDA482A

CAN--SPY in practice: The CAN identifier values are shown in four columns known as ’Words’. In each word there are four digit positions. There are four basic rules that must be used to calculate the appropriate value from the notes: 1. Only add values together. Never subtract. 2. Identify the function status statements that match the current machine situation (’true statements’) and add the relevant values together. 3. Only add values in the same word and the same digit position. 4. Calculate the ’expected value’ on paper and then check that it corresponds to the value given on the Info View screen. NOTE: Values in the same Word that are not relevant to the function description are shown in the notes as =.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

CAN ID Data description

word1 word2 word3 word4

1282

Header down switch

Pressed

8===

1282

Header down switch

Not Pressed

4===

1282

Feed rolls reverse switch

Pressed

2===

1282

Feed rolls reverse switch

Not Pressed

1===

Function Description Can Identifier (Page) Number

Word One, Digit Position One Function Status Statement

The function descriptions are found in group of four (A group is defined by the digit position within a particular word), where each individual status is given by

a value of 8, 4, 2 or 1. No matter how these values or combination (using each value only once) of values are added together a unique value will result.

Example 1

CAN ID Data description

word1 word2 word3 word4

1282

Header down switch

Pressed

8===

1282

Header down switch

Not Pressed

4===

1282

Feed rolls reverse switch

Pressed

2===

1282

Feed rolls reverse switch

Not Pressed

1===

1. Enter the CAN--SPY on page 1282, It is likely that no switches on the multifunction lever are pressed. Therefore the ’true statements’ are: • Header down switch, not pressed. Which has a value of 4. • Feed rolls reverse switch not pressed. Which has a value of 1.

2. Press and hold the header down switch. The machine status has now changed, so we must add the corresponding values shown in the notes that are relevant to the new situation. These are: • Header down switch, is pressed. Which has a value of 8. • Feed rolls reverse switch not pressed. Which has a value of 1.

If these two values are added together the ’expected value’ on the InfoView monitor in word one, digit position one is 5. Look at the InfoView monitor in identifier (’page’) number 1282 and confirm that a value of 5 is shown in word one, digit position one. If there is a value of 5 is shown continue in a logical sequence.

If these two values are added together the ’expected value’ on the InfoView monitor in word one, digit position one is 9. Look at the InfoView monitor in identifier (’page’) number 1282 and confirm that a value of 9 is shown in word one, digit position one. If there is a value of 9 is shown continue in a logical sequence.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 3. Press and hold both the header down switch and the feed roll reverse switch simultaneously. The machine status has now changed again, so we must add the corresponding values shown in the notes that are relevant to this new situation. These are: • Header down switch, is pressed. Which has a value of 8. • Feed rolls reverse switch not pressed. Which has a value of 2. If these two values are added together the ’expected value’ on the InfoView monitor in word one, digit position one is 10 (expressed in decimal terms). The InfoView monitor must express this value using only one digit position and uses the hexadecimal expression for a decimal 10 which is A. Look at the InfoView monitor at identifier number 1282 and confirm that a value of A is shown in word one, digit position one. If

there is a value of A the following conclusions can be made. Conclusion: By pressing and holding the switches (to change the machine status) and checking that the values shown on the InfoView monitor against the relevant value in the notes. We not only confirm the correct function of the switch but also the connections through classical wiring, PCB tracks and in some case the Optical Fibre communications. Having checked the function of these two switches and found a satisfactory result the CAN--SPY system can be used to check each individual input or status that the Software requires to implement an output signal or change in status. These other functions may be found on other pages. Knowledge of the function of the machine is a benefit when diagnosing complex failures.

Example 2

CAN ID Data description

word1 word2 word3 word4

1282

Multifunction Lever

Out of Neutral

1282

Header down switch In Neutral

=1==

1282

Ground Speed Potentiometer

==XX

In the CAN--SPY notes the value XX is shown in word 3, digit position 3 & 4. XX refers to a variable input received from a sensor, in this case the ground speed control potentiometer located below the multifunction lever. The values in word 3, digit position 2 refer to the status of the neutral switch, which is also located below the multifunction lever. In neutral the switch has an added value of 1, out of neutral it has an added value of 2, in word 3, digit position 2. The comment column gives the parameters within which the XX value must be set and the overall range

Comments

=2==

In Neutral XX=5C±20 or 48 <XX<71. Limit 00 <XX<D0±10

of the potentiometer. If the multifunction lever is moved from the position where the neutral switch value changes from 2 to 1(either from FWD to neutral, or from REV to neutral), the XX value should be in a range of 5C (Hexadecimal) plus or minus a decimal value of twenty, or a range (in hexadecimal terms) of 48 -- 71. The acceptable range over the total travel of the potentiometer is from 00 to D0 ± 10 (decimal).

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

12 Example 3

CAN ID Data description

word1 word2 word3 word4

1283

Adjust O--Matic Main switch

Switched ON

8===

1283

Cutterhead Reversing switch

Switched OFF

4===

1283

Power Reverse switch

Switched ON

2===

1283

Crop Processor roll clearance close switch

Pressed

1===

1. When the ignition switched on, enter CAN--SPY on page 1283. Ensure that none of the relevant switches are switched on or pressed, the only true statement is: • Cutterhead reversing switch, switched off. Which has a value of 4. In this situation the value shown in word two, digit position one should be 4. NOTE: the other functions relevant to this word and digit position are either not pressed or are off. Therefore these statements can be considered as not true and the relevant values do not need to be considered. In addition the comment column tells that when the switch is open then the value is 0. 2. Switch on the power reverse switch. The machine status has now changed, so we must add the corresponding values shown in the notes that are relevant to the new situation. These are: • Cutterhead reversing switch, switched off. Which has a value of 4. • Power reverse switch, switched on. Which has a value of 2. If these two values are added together the ’expected value’ on the InfoView monitor in word two, digit position one is 6. Look at the InfoView monitor at identifier (’page’) number 1283 and confirm that a value of 6 is shown in word two, digit position one. If a value of 6 is shown, continue in a logical sequence.

NOTE: The other functions relevant to this word and digit position are either not pressed or are off. Therefore these statements can be considered as not true and the relevant values do not need to be considered. In addition the comment column tells that when the switch is open then the value is 0. 3. Switch on the Adjust--o--Matic main switch. Leaving the cutterhead reverse switch off and the power reverse switch off. The machine status has now changed again, so we must add the corresponding values shown in the notes that are relevant to the new situation. These are: • Cutterhead reversing switch, switched off. Which has a value of 4. • Power reverse switch on. Which has a value of 2. • Adjust--o--Matic Main switch on. Which has a value of 8. If these three values are added together the ’expected value’ on the InfoView monitor in word two, digit position one is 14 (decimal). The InfoView monitor must express this value using only one digit position and uses the hexadecimal expression for a decimal 14 which is E. Look at the InfoView monitor at identifier (’page’) number 1283 and confirm that a value of E is shown in word two, digit position one. If there is a value of E, continue in a logical sequence. NOTE: The other functions relevant to this word and digit position are either not pressed or are off. Therefore these statements can be considered as not true and the relevant values do not need to be considered. In addition the comment column tells that when the switch is open then the value is 0.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 4. Press and hold the crop processor clearance close switch. Leaving the Adjust--o--Matic main switch on, the cutterhead reverse switch off and the power reverse switch on. The machine status has now changed again, so we must add the corresponding values shown in the notes that are relevant to the new situation. These are: • • • •

Crop processor clearance close switch, pressed. Which has a value of 1. Cutterhead reversing switch, switched off. Which has a value of 4. Power reverse switch, switched on. Which has a value of 2. Adjust--o--Matic main switch, switched on. Which has a value of 8.

If these four values are added together the ’expected value’ on the InfoView monitor in word two, digit position one is 15 (decimal). The InfoView monitor must express this value using only one digit position and uses the hexadecimal expression for a decimal 15 which is F. Look at the InfoView monitor at identifier (’page’) number 1283 and confirm that a value of F is shown in word two, digit position one. If there is a value of F, continue in a logical sequence.

5. Switch the cutterhead reversing switch, and hold the crop processor clearance close switch. Leaving the Adjust--o--Matic main switch on, and the power reverse switch on. The machine status has now changed again, so we must add the corresponding values shown in the notes that are relevant to the new situation. These are: • • •

Crop processor clearance close switch, pressed. Which has a value of 1. Power reverse switch on. Which has a value of 2. Adjust--o--Matic Main switch on. Which has a value of 8.

If these three values are added together the ’expected value’ on the InfoView monitor in word two, digit position one is 11 (decimal). The InfoView monitor must express this value using only one digit position and uses the hexadecimal expression for a decimal 11 which is B. Look at the InfoView monitor at identifier (’page’) number 1283 and confirm that a value of B is shown in word two, digit position one. If there is a value of B, the following conclusions can be made.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

ERROR CODES MESSAGES

6 All interfaces are built in such a way that they can deduce an interruption in the signal. This interruption can be a short circuit or an open circuit from the sensor / switch or to an end user (motor, valve). The interface will send a message on the CAN system, which will be translated into an error message on the InfoView monitor. Also refer to chapter 9/4b ’’Error messages overview’’. Once an interruption in the signal for an end user is detected, the electronic system will automatically stop to power the output line. Possible causes: -- Open or short circuit in wiring loom or connectors. -- Sensor or end user shorted or damaged. -- Interface defect. Action: 1. Check wiring and connections. 2. Check switch/sensor or end user (motor, valve). 3. Check interface visually (located on printed circuit boards).

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

Wiring checking procedure: 1. Is there an open circuit in the wiring? Check each cable separately for infinity resistance. And

2. Is there a shorted circuit in the wiring loom? Check each pair of cables for 0 resistance. And

EL--003

3. Is there a shorted circuit with the ground? Check each cable separately with ground for 0 resistance. REMARK: If a problem only occurs now and then, the problem will most likely be related to bad contacts in connectors or bad connections in switches. In this case, it is recommended to test with a new (self--made) wiring loom directly connected between the output on the electronic printed circuit and the end user. Make sure you never contact the original wiring loom and disconnect all original cables at the beginning and at the end. 9

16 •

• •

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 ATTENTION Never put 12 V (battery voltage) to an end user (electric motor, actuator or electro valve) when the wiring loom is still connected to the printed circuit, as this will burn the electronic components on the printed circuit. Always disconnect the end user from the central electronic box before testing it. When doing this test, be sure the end user can stand 12 V power supply. Some valves have a supply voltage of 7V. 10

FAULT FINDING ROUTINE 1. After listening to the customer, try to check the faulty function to make sure the malfunction is not due to a user mistake or to the calibration. Try related functions to reduce scope of diagnosis. Consult the Operator’s Manual or the Repair Manual. 2. Make sure it is not a mechanical, hydraulic or fuse failure. 3. Check the InfoView memory in the Service Mode for errors related to this problem. If so, delete all the errors, switch on the engine and perform the failed function. Then check if the error has reappeared in the memory. 4. If the error has reappeared, the problem is probably electrical. Consult the error code list and the electrical diagrams to locate the problem. 5. If there is a network error code, solve this first before checking anything else. A printed circuit or connections between printed circuits can cause a network error. 6. If the error code concerns an output, a quick way to check is to power the element directly from the central box. Disconnect the connection at the printed circuit and power the pins related to the problem from the fuse, which powers the printed circuit. In this way a simultaneous check of the wiring and of the final element is performed. If the wiring or the final element is not OK, use the electrical diagrams.

7. If there is no error code related to the problem, check the output of the Bus CAN with the CAN identifiers and the functional classification. If the output of the Bus CAN is OK, check the connections on the printed circuit, the wiring and the final element (as described in point 5). 8. If the wiring and the final element are OK, the failure is probably due to the output interface. Check the electrical diagrams to locate the corresponding printed circuit and replace it. 9. In case the outputs of the Bus CAN are incorrect, check the inputs one by one with the identifier list and the detailed analysis per function (refer to section 55 chapter 7). 10. If an input identifier is incorrect, check the element relating to this identifier. 11. If the input (switch or sensor) is correct, the failure is probably related to the printed circuit.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

Listen to the customer. Check faulty function yourself.

Try related operations to reduce scope of diagnosis

Malfunction due to user mistake or calibration

Yes

Explain how to use the function correctly

No Hydraulic or Mechanical Fault

Yes

Perform repair of mechanic or hydraulic circuit. Use Repair Manual

Fuse burned?

Yes

Replace fuse.

No Error Codes in InfoView Error list, related to the problem

Yes

Is the problem related to the end user? Yes

Error Code concerns an output

CAN--ID for end user is correct? No

Perform output and wiring test by powering the end user. Disconnect at printed circuit

Consult Error Code list and Electrical Diagrams

Check CAN--ID for inputs one by one A

Yes

Test successfull?

No Interface can be defective. Replace printed circuit

Repair electrics or replace end user

CAN--ID for Input is correct

Yes Check next Input

No Check input switch/sensor

Input switch/ sensor defect

Interface can be defective. Replace printed circuit.

Yes

Solve this first before checking anything else. Consult Error Code List and Electrical Diagrams

Yes

Network Error Code stored?

Yes

Repair electrics or replace input switch/ sensor

Yes

Perform output and wiring test by powering the end user, disconnected at the printed circuit. Consult Error Code List and Electrical Diagrams.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

SECTION 55 -- ELECTRICAL SYSTEM Chapter 5 -- Calibration CONTENT Section

Description

Page

55.000

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

MACHINE CALIBRATION WITH LAPTOP Apart from the calibrations and settings carried out on the InfoView monitor like e.g. the Attachment Height Control calibration (see section 4.17.4 of the Operatorâ&#x20AC;&#x2122;s Manual), an initial machine (re) calibration can be carried out with a Laptop--PC, e.g. after a rework or after installing different tyres. The latter is normally carried out in the plant before shipment, but there may be circumstances in which the calibration has to be repeated. The following calibrations can be found in the Laptop--program and on the PDT cartridge:

PC#

Calibration

Serial number

Maximum handle position

Minimum forward current to hydrostatic pump

Minimum backward current to hydrostatic pump

Acceleration hydrostatic pump

Caterpillar / New Holland Engine

Rear auxiliary hydraulics

High flow hydraulics

Four wheel drive

Rotary screens

Rotary screen brushes

Air conditioning

Latched header height

Low pressure valves

Stromag feed rolls engagement clutch

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 How to use the system To enter the machine calibration program, proceed as follows: 1. Put your laptop PC on the steering wheel. 2. Switch ON the computer. When working in Windows 3.1 or 3.11, EXIT Windows first. When working in Windows 95 or later, go to “Start -- Shut Down” menu and “Restart the computer in MS--DOS Mode”. 3. When arriving in DOS, ‘C:\’ must be visible on the screen. If necessary type ‘CD\’ and press the ENTER key to return to the root directory C:\>. 4. Make sure the proper REV--level machine software is installed on your computer.

5. Connect the update cable to your computer and to the instrument panel. 6. Type ‘CANMENU’ and press the ENTER key. The menu is shown on the display and the directory has changed into ‘C:\CANHARV>’. 7. Type ‘FX’ and press the ENTER key to enter the correct directory (C:\CANHARV\FX>). 8. Type ‘CALIBR’ and press the ENTER key to start the update procedure. 9. The following menu will appear on the screen. NOTE: The PC--calibration file CAL_PDT for the European service people is included on the installation disk and will therefore automatically be stored on the hard disk of the computer when the software is installed.

European service people (cal_pdt)

Calibration of: a: b: c: d: e: f: g: h: i: j: k: l: m: n: o:

Serial number Maximum handle position Minimum forward current to hydrostatic pump Minimum backward current to hydrostatic pump Acceleration hydrostatic pump Caterpillar / New Holland Engine Rear auxiliary hydraulics High flow hydraulics Four wheel drive Rotary screens Rotary screen brushes Air conditioning Latched header height Low pressure valves Stromag feedrolls engagement clutch

eXit

Make your choice:

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Calibration instruction Pick one of the calibrations from the menu and follow the instructions on the screen. Text NOT printed in bold is informative and merely meant to elucidate the calibration.

a : Serial number Do you want to input serial number ? [y,n] Type y in case you want to do so. Give serial number : Insert the machine serial number and press Enter to confirm.

b : Maximum handle position Do you want to calibrate maximum handle position ? [y,n] Type y if you want to do so. Move the handle to its maximum forward position and press the enter key.

c : Minimum forward current to hydrostatic pump Do you want to calibrate minimum forward current to hydrostatic pump ? [y,n] Type y if you want to do so. Set ground speed to minimum forward speed and press the enter key. Choose second or third gear with the engine at low idle. Now move the handle slowly forwards until the machine starts to crawl. Now move slowly backwards until the machine stops and press the enter key.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 d : Minimum backward current to hydrostatic pump Do you want to calibrate minimum backward current to hydrostatic pump ? [y,n] Type y in case you want to do so. Set ground speed to minimum backward speed and press the enter key. Choose second or third gear with the engine at low idle. Now move the handle slowly backwards until the machine starts to crawl. Now move slowly forwards until the machine stops and press the enter key.

e : Acceleration hydrostatic pump Low acceleration hydrostatic pump ? [y,n] For low acceleration of the hydrostatic pump below 20 Km/h, press y This calibration is compulsory for Germany, Austria, Switzerland and Italy. So, for these countries always press y. For other countries, normal acceleration of the hydrostatic pump may be used, press n.

f : Caterpillar / New Holland Engine Caterpillar engine installed ? [y,n] Only for FX58 Caterpillar machines, press y. For all other FX Forage Harvesters with Iveco--Aifo engines, press n.

g : Rear auxiliary hydraulics Rear hydraulics installed ? [y,n] When rear auxiliary hydraulics are installed on your machine, press y ; otherwise press n

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 h : High flow hydraulics High flow hydraulics installed ? [y,n] When high flow hydraulics are installed on your machine, press y. Otherwise press n.

i : Four wheel drive Four wheel drive installed ? [y,n] When four wheel drive is installed on your machine, press y. Otherwise press n.

j : Rotary screens Rotary screens installed ? [y,n] When rotary screens are installed on your machine, press y. Otherwise press n.

k : Rotary screen brushes Rotary screen brushes installed ? [y,n] When rotary screen brushes are installed on your machine, press y. Otherwise press n.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 l : Air conditioning Air conditioning installed ? [y,n] When there is Air Conditioning installed on your machine, press y. Otherwise press n.

m : Latched header height Do you want to change latched header height ? [y,n] This calibration is compulsory for Italy only. So, for Italy always choose y. Set header to latched height and press the enter key. Set machine at HARVEST mode and choose the latched header height. Now press the enter key. When switching to ROAD mode, the header will latch at the calibrated height.

n : Low pressure valves Low pressure valves installed ? [y,n] Only for European pre series machines (series 01), press n. For all other machines (European and USA), press y.

o : Stromag feedrolls engagement clutch Reverse feedrolls engagement output for Stromag clutch on actuator print ? [y,n] On machines from serial nr 5083 (season 1999) onwards, the reverse feedrolls engagement output is moved to the actuator printed circuit. For these machines press y. For all other machines, before serial nr 5083, press n.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

8 x : eXit

Choose x to leave the calibration program and return to the c:\canharv\fx directory.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 MACHINE CALIBRATION WITH PDT--TOOL The Portable Diagnostic Tool (PDT) is a hand--held tool used to download software and perform calibration of the FX Forage Harvesters. The download software and calibration programme is stored on a cartridge, which is plugged into the base of the PDT unit. When replacing the cartridge, the PDT tool can also be used to download software and perform diagnostic routines on other New Holland products.

52526

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Installing and operating the pdt tool NOTE: Text that is typed bold is text that appears on the display of the PDT. Plug the cartridge into the adapter slot located at the bottom of the PDT tool. Be careful: It is possible to plug in the cartridge upside down. If so, the PDT tool cannot function. Connect the different connectors of the adapter cable to the top of the diagnostic tool, to the power plug in the operatorâ&#x20AC;&#x2122;s cab and to the DIN plug at the bottom of the instrument panel.

After a few seconds, the following text appears on the screen: This is the main menu. With the UP/DOWN arrow keys the arrow > can be moved. Use the UP/DOWN arrow keys on the PDT tool to select the required function and press Enter, or press 1 to choose Download Software, or 2 to Calibrate the FX forage harvester. If a mistake is made when selecting the required function, press the MODE key on the PDT tool and it will recall the previous page on the display.

Select Operation 1 > 2 -

Download Calibrate

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 Machine calibration Starting from the main menu, use the UP/DOWN arrow keys on the PDT tool to select Calibrate and press the Enter key, or press the corresponding number. The following â&#x20AC;&#x2DC;calibration menuâ&#x20AC;&#x2122; appears on the screen: Use the UP/DOWN arrow keys on the PDT tool to select the item you want to calibrate and press Enter, or choose one of the numbers 1 to 9.

The following pages explain how to calibrate your machine. NOTE: Before calibrating, switch on the ignition key! If not, no calibration is possible and no error messages will appear on the screen.

Select Device : 1 > 2 3 4 5 6 7 8 9 101112131415-

Serial Number Max Handle Pos Pump Fwd Current Pump Back Current Acceleration CAT / NH Engine Rear Aux. Hydr. High Flow Hydr. Four wheel drive Rotary Screens Rot. Screen Brush Air Conditioning Latched Header Low Press. Valve Stromag Clutch

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

1. Calibration of Serial Number Select ‘1--Serial Number’ in the calibration menu. Press ‘1--Yes’ to continue the calibration. Press ‘2--No’ to stop the calibration and return to the calibration menu.

When ‘1--Yes’ is pressed, the following message will appear. Insert the machine serial number and press Enter to confirm.

Do you want to input a Serial Number ? 1-Yes

2-No

Enter Serial Number XXXXXXXXX Press Enter to confirm

The serial number is now entered into the memory of your machine.

CALIBRATING ...

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 2. Calibration of maximum handle position Select ‘2--Max Handle Pos’ in the calibration menu.

Do you want to Calibrate Maximum Handle Position ?

Press ‘1--Yes’ to continue the calibration. Press ‘2--No’ to stop the calibration and return to the calibration menu.

1-Yes

When ‘1--Yes’ is pressed, the following message will appear. Move the ground speed handle to its maximum forward position and press the Enter key.

Set handle into maximum forward position

2-No

Press Enter

Your selection is now transferred into the memory of your machine.

CALIBRATING ...

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

3. Calibration of minimum forward current to hydrostatic pump. Select ‘3--Pump Forw Current’ in the calibration menu.

Do you want to calibrate Min Forward Current to pump ? 1-Yes

2-No

Press ‘1--Yes’ to continue the calibration. Press ‘2--No’ to stop the calibration and return to the calibration menu.

When ‘1--Yes’ is pressed, the following message will appear and 8 red warning lights under the display will start flashing.

When the Enter key is pressed, the following message will appear. Choose second or third gear with the engine at low idle. Move the handle slowly forwards until the machine starts to crawl. Now move the handle slowly backwards until the machine stops. Press the Enter key.

Your selection is now transferred into the memory of your machine.

WARNING : This may cause sudden movement. Press Enter

Move handle forward until machine crawls. Back off, until stop Press Enter

CALIBRATING ...

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 4. Calibration of minimum backward current to hydrostatic pump. Select ‘3--Pump Back Current’ in the calibration menu.

Do you want to calibrate Min Backward Current to pump ? 1-Yes

2-No

Press ‘1--Yes’ to continue the calibration. Press ‘2--No’ to stop the calibration and return to the calibration menu.

When ‘1--Yes’ is pressed, the following message will appear and 8 red warning lights under the display will start flashing.

When the Enter key is pressed, the following message will appear. Choose second or third gear with the engine at low idle. Move the handle slowly backwards until the machine starts to crawl. Now move the handle slowly forwards until the machine stops. Press the Enter key.

Your selection is now transferred into the memory of your machine.

WARNING : This may cause sudden movement. Press Enter

Move handle forward until machine crawls. Back off, until stop Press Enter

CALIBRATING ...

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

5. Calibration of hydrostatic pump acceleration Select ‘5--Acceleration’ in the calibration menu. For low acceleration of the hydrostatic pump below 20 km/h, select ‘1--Installed’. This calibration is compulsory for Germany, Austria, Switzerland and Italy. So, for these countries always choose 1. For other countries, normal acceleration of the hydrostatic pump may be used, select ‘2--Not Installed’.

After your selection, the following message will appear. Press ‘1--Yes’ to continue the calibration. Press ‘2--No’ to stop the calibration and return to the calibration menu.

After ‘1--Yes’ is pressed, your selection is transferred into the memory of your machine.

Low Acceleration of Hydrostatic Pump 1 > Installed 2 - Not Installed

Do you want to clear the old calibration figures ? 1-Yes

2-No

CALIBRATING ...

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 6. Calibration of Caterpillar / New Holland Engine. Select ‘6--CAT / NH Engine’ in the calibration menu. Only for FX58 Caterpillar machines, select ‘1--Installed’. For all other FX Forage Harvesters with Iveco--Aifo engines, select ‘2--Not Installed’.

After your selection, the following message will appear. Press ‘1--Yes’ to continue the calibration. Press ‘2--No’ to stop the calibration and return to the calibration menu.

After ‘1--Yes’ is pressed, your selection is transferred into the memory of your machine.

CATERPILLAR Engine (only for FX58) ? 1 > Installed 2 - Not Installed

Do you want to clear the old calibration figures ? 1-Yes

2-No

CALIBRATING ...

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

7. Calibration of Rear auxiliary hydraulics. Select ‘7--Rear Aux. Hydr’ in the calibration menu. Select ‘1--Installed’ if rear auxiliary hydraulics is installed on your machine. Select ‘2--Not Installed’ if rear auxiliary hydraulics is not installed. Rear hydraulics is an option.

After your selection, the following message will appear. Press ‘1--Yes’ to continue the calibration. Press ‘2--No’ to stop the calibration and return to the calibration menu.

After ‘1--Yes’ is pressed, your selection is transferred into the memory of your machine.

Rear Hydraulics 1 > Installed 2 - Not Installed

Do you want to clear the old calibration figures ? 1-Yes

2-No

CALIBRATING ...

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 8. Calibration of high flow hydraulics. Select ‘8--High flow Hydr’ in the calibration menu. Select ‘1--Installed’ if high flow hydraulics is installed on your machine. Select ‘2--Not Installed’ if high flow hydraulics is not installed. High flow hydraulics is an option.

After your selection, the following message will appear. Press ‘1--Yes’ to continue the calibration. Press ‘2--No’ to stop the calibration and return to the calibration menu.

After ‘1--Yes’ is pressed, your selection is transferred into the memory of your machine.

High Flow Hydraulics 1 > Installed 2 - Not Installed

Do you want to clear the old calibration figures ? 1-Yes

2-No

CALIBRATING ...

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

9. Calibration of four wheel drive. Select ‘9--Four Wheel Drive’ in the calibration menu. Select ‘1--Installed’ if four wheel drive is installed on your machine. Select ‘2--Not Installed’ if four wheel drive is not installed. Four wheel drive is an option.

After your selection, the following message will appear. Press ‘1--Yes’ to continue the calibration. Press ‘2--No’ to stop the calibration and return to the calibration menu.

After ‘1--Yes’ is pressed, your selection is transferred into the memory of your machine.

Four Wheel Drive 1 > Installed 2 - Not Installed

Do you want to clear the old calibration figures ? 1-Yes

2-No

CALIBRATING ...

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 10. Calibration of rotary screens. Select ‘10--Rotary Screens.’ in the calibration menu.

Rotary Screens 1 > Installed 2 - Not Installed

Select ‘1--Installed’ if rotary screens are installed on your machine. Select ‘2--Not Installed’ if rotary screens are not installed. Rotary screens are an option on the FX300.

After your selection, the following message will appear. Press ‘1--Yes’ to continue the calibration. Press ‘2--No’ to stop the calibration and return to the calibration menu.

After ‘1--Yes’ is pressed, your selection is transferred into the memory of your machine.

Do you want to clear the old calibration figures ? 1-Yes

2-No

CALIBRATING ...

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

11. Calibration of rotary screen brushes. Select ‘11--Rot. Screen Brush’ in the calibration menu. Select ‘1--Installed’ if rotary screen brushes are installed on your machine. Select ‘2--Not Installed’ if rotary screen brushes are not installed. Rotary screen brushes are an option.

After your selection, the following message will appear. Press ‘1--Yes’ to continue the calibration. Press ‘2--No’ to stop the calibration and return to the calibration menu.

After ‘1--Yes’ is pressed, your selection is transferred into the memory of your machine.

Rotary Screen Brushes 1 > Installed 2 - Not Installed

Do you want to clear the old calibration figures ? 1-Yes

2-No

CALIBRATING ...

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 12. Calibration of Air Conditioning. Select ‘12--Air Conditioning’ in the calibration menu.

Air Conditioning 1 > Installed 2 - Not Installed

Select ‘1--Installed’ if Air Conditioning is installed on your machine. Select ‘2--Not Installed’ if Air Conditioning is not installed. Air Conditioning is an option.

After your selection, the following message will appear. Press ‘1--Yes’ to continue the calibration. Press ‘2--No’ to stop the calibration and return to the calibration menu.

After ‘1--Yes’ is pressed, your selection is transferred into the memory of your machine.

Do you want to clear the old calibration figures ? 1-Yes

2-No

CALIBRATING ...

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

13. Calibration of latched header height. Select ‘13--Latched Header’ in the calibration menu. Press ‘1--Yes’ to continue the calibration. Press ‘2--No’ to stop the calibration and return to the calibration menu.

After ‘1--Yes’ is pressed, the following message will appear. This calibration is compulsory for Italy only. So, for Italy always choose ‘1--Yes’.

Do you want to clear the old calibration figures ? 1-Yes

2-No

Do you want to Set a latch Header Height 1-Yes

2-No

For other countries, choose ‘2--No’ .

After ‘1--Yes’ is pressed, the following message will appear. Set machine at HARVEST mode and choose the latched attachment height. Now press the Enter key. When switching to ROAD mode, the header will latch at the calibrated height.

When the enter key is pressed, your selection is transferred into the memory of your machine.

Select Harvest mode and choose the latched height. If done, press Enter

CALIBRATING ...

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 14. Calibration of low pressure valves. Select ‘14--Low Press. Valve’ in the calibration menu.

Low Press. Valve 1 > Installed 2 - Not Installed

Check the serial number of the machine involved. Only for European pre series machines (series 01), select ‘2--Not Installed’ . For all other machines (European and USA), select ‘1-- Installed’ .

After your selection, the following message will appear. Press ‘1--Yes’ to continue the calibration. Press ‘2--No’ to stop the calibration and return to the calibration menu.

After ‘1--Yes’ is pressed, your selection is transferred into the memory of your machine.

Do you want to clear the old calibration figures ? 1-Yes

2-No

CALIBRATING ...

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

15. Calibration of Stromag feedrolls engagement clutch. Select ‘15--Stromag Clutch’ in the calibration menu.

Stromag Feedrolls Engagement Clutch on Actuator Print 1-Yes

2-No

Check the serial number of the machine involved. On machines from serial nr 5083 (season 1999) onwards, the reverse feed rolls engagement output is moved to the actuator printed circuit. For these machines, select ‘1--Yes’. For all other machines, before serial nr 5083, select ‘2--No’.

After your selection, the following message will appear. Press ‘1--Yes’ to continue the calibration. Press ‘2--No’ to stop the calibration and return to the calibration menu.

After ‘1--Yes’ is pressed, your selection is transferred into the memory of your machine.

Do you want to clear the old calibration figures ? 1-Yes

2-No

CALIBRATING ...

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

SECTION 55 -- ELECTRICAL SYSTEM Chapter 6 -- Software Update

CONTENT Section

Description

Page

55.000

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

SOFTWARE UPDATE WITH LAPTOP 10 step software installation guide NOTE: Although most commands in this instruction are typed in CAPS, it is not necessary to use caps.

Action 1

Switch on the computer

When working in Windows 3.1 or 3.11, EXIT Windows first. When working in Windows 95 or later, go to “Start -- Shut Down” menu and “Restart the computer in MS--DOS Mode”.

Comments

To Exit Windows, •

•

close all applications by double clicking in the top left corner. or key simultaneously Alt and F4.

When arriving in DOS, C:\> must be visible on To return to the root directory : the screen. • Type CD\ and press ENTER. (also called the “root directory”) • Type CD.. + ENTER a few times until you see C:\>. On computers with AZERTY--keyboards, press AltGr and the key with the \ on it.

Insert the floppy disk with the correct Machine Software Revision in the Floppy Disk Drive.

Type A: and press the ENTER key.

Type INSTALL and press the ENTER key.

Follow the instructions on the screen.

When the files have been copied to the hard disk, remove the floppy disk.

When the installation is finished, return to the root directory of your computer.

To see how to return to the root directory (C:\>) see point 3 above.

Type CANMENU and press the ENTER key to proceed to the update or calibration procedures.

The program offers several help--possibilities. Choose either one of the help comments that are displayed.

For complete installation, always answer Y to the questions that appear on the screen.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

10 step machine software update guide NOTE: Although most commands in this instruction are typed in CAPS, it is not necessary to use caps.

Action 1

Put your laptop PC on the steering wheel

Switch ON the computer. When working in Windows 3.1 or 3.11, EXIT Windows first. When working in Windows 95 or later, go to “Start -- Shut Down” menu and “Restart the computer in MS--DOS Mode”.

Comments

To Exit Windows, •

•

close all applications by double clicking in the top left corner. or key simultaneously Alt and F4.

Connect the update cable to your computer and to the instrument panel.

Type CANMENU and press the ENTER key. The menu is shown on the display and the directory is changed to C:\CANHARV\. Type FX or TF and press the ENTER key depending on the machine to update. (C:\CANHARV\FX or C:\CANHARV\TF)

Type UPDATE and press the ENTER key to start the update procedure.

Choose the node you want to update.

The program offers several help--possibilities. Choose either one of the help comments that are displayed.

Possibilities : • •

A+S, B, D, or M A+S, B, C

for FX machines. for TF Combines.

Choose the communication mode. Always type 0.

With your computer configuration only the RS232 (0) option is valid.

As soon as the message “... waiting for communication with node” appears on the screen, switch on ignition. When the update procedure was successful and the computer returns to the C:\CANHARV\XX directory, switch off ignition.

XX = FX or TF depending your selection in step 5.

Repeat steps 6 to 10 until all nodes have been updated successfully.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

SOFTWARE UPDATE WITH PDT--TOOL. The Portable Diagnostic Tool (PDT) is a hand--held tool used to download software and perform calibration of the FX Forage Harvesters. The download software and calibration programme is stored on a cartridge, which is plugged into the base of the PDT unit. When replacing the cartridge, the PDT tool can also be used to download software and perform diagnostic routines on other New Holland products.

52526

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 INSTALLING AND OPERATING THE PDT TOOL NOTE: Text that is typed bold is text that appears on the display of the PDT. Plug the cartridge into the adapter slot located at the bottom of the PDT tool. Be careful: It is possible to plug in the cartridge upside down. If so, the PDT tool cannot function. Connect the different connectors of the adapter cable to the top of the diagnostic tool, to the power plug in the operatorâ&#x20AC;&#x2122;s cab and to the DIN plug at the bottom of the instrument panel. After a few seconds, the following text appears on the screen: This is the main menu. With the UP/DOWN arrow keys the arrow > can be moved. Use the UP/DOWN arrow keys on the PDT tool to select the required function and press Enter, or press 1 to choose Download Software, or 2 to Calibrate the FX forage harvester. If a mistake is made when selecting the required function, press the MODE key on the PDT tool and it will recall the previous page on the display.

Select Operation 1 > 2 -

Download Calibrate

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

SOFTWARE DOWNLOAD Select FX Node : Starting from the main menu, use the UP/DOWN arrow keys on the PDT tool to select Download and press the Enter key, or press the corresponding number. The following ‘Download menu’ appears on the screen: Use the UP/DOWN arrow keys on the PDT tool to select the node(s) you want to download and press Enter, or choose one of the numbers 1 to 4. When downloading, the operator can see the progress of the download (expressed in percentages) on the display. After downloading software, the PDT will automatically verify if the download was successful.

1 2 3 4

> -

Display (A&S) Central box Adjustomatic Metal Detector

NOTE: The download of nodes A and S is performed consecutively and may take about 30 minutes. After completion of the download process, use Up/ Down arrow keys to select the next node, or choose the corresponding number of the node to be downloaded. Example of downloading ‘Central Box’ Node: When selection 2 has been entered, the following message will appear. Display view 1

When the Enter key is pressed, next message appears. Switch on ignition without starting the engine. At the same time a running light (warning LED’s) on the machine dashboard will start functioning. Display view 2

DOWNLOAD NODE B RAM : bootb.chx ROM : haksb.chx Press Enter

TURN IGNITION KEY OFF AND THEN ON AGAIN

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Display view 3 DOWNLOADING BOOT FILE TO RAM PROGRESS = XX %

Display view 4 ******************** ERASING PROGRAM MEMORY ********************

Display view 5 DOWNLOAD IN PROGRESS NODE : ”B” Progress = XX %

After finishing the download, the PDT continues verifying the programme memory. Display view 6

VERIFYING PROGRAM MEMORY Progress = XX %

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Display view 7 ***************** WRITING VERIFICATION BYTES TO MEMORY

Software download process has been finished. Press Enter to return to the Download menu. Display view 8

NOTE: If a problem occurs during downloading, the following message will appear: Press Enter to return to the Download menu and try again to download the software node.

***************** PROGRAM MEMORY Download is correct Press Enter

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

SECTION 55 -- ELECTRICAL SYSTEM Chapter 7 -- Troubleshooting CONTENT Section

Description

55.000

Error messages overview

Page

-- Machine error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- Attachment height control error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 -- Caterpillar error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 List of Can identifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Detailed analysis per function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

MACHINE ERROR MESSAGES

Error Code

Description

Importance

001

LCD NETWORK ERROR

High

General CAN network failure. Information sent out by the different nodes, through the optical fibres and the flat cable, is not arriving. If the outgoing communication from the InfoView monitor to dashboard can node, from the dashboard can node to the AOM node and from the AOM node to the CPU node is interrupted. All the nodes react as if there is no network, as if they are not connected to the network. This failure can be caused by any node on the network or by a network path that generates so many errors that all the nodes can not communicate any more.

Explanation :

Action : Check software revision on service page. Is x.x displayed? Yes Check software rev. of each node on CANSPY. Press “Mem“ and “ESC“ button before switching on ignition

Is only CAN. Id of Node B incorrect? Value “00“ displayed? No Is CAN--ID of Node B, Node D 2 Node M incorrect? Value “00” displayed for these Nodes? Yes Replace the flat cable between dashboard and InfoView monitor

Check flat cable connection between dashboard CAN Node and InfoView monitor. Connection and flat cable correct Yes Try new Dashboard CAN printed circuit of known performance Problem Solved? No

Try new AOM printed circuit of known performance

Disconnect fiber optic cable arriving from dashboard at AOM black connector? Red light is visible at end of fiber optic? No Try new Dashboard CAN printed circuit of known performance

Yes

Communication from AOM white connector to CPU black connector is incorrect. Possible to download Software Node B?

Yes

Restart the machine. If problem persists, restart check routine from beginning?

No Disconnect fiber optic cable at CPU black connector. Red light is visible at end of fiber optic?

No Install new small fiber optic cable and try new AOM printed circuit of known performance

Yes

Try new CPU printed circuit of known performance.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

002

OTHER NETWORK ERROR

High

Explanation :

General CAN network failure. Information sent out by the different nodes, through the optical fibres and the flat cable, is not arriving. This error is caused by a lot of erroneous message transmissions and indicates a low quality communication combined with a lot of network traffic.

Action :

See ERROR 1.

Error Code

Description

Importance

003

NETWORK OVERLOAD

High

Explanation :

Too much or unclear data information on the CAN Bus. This error report will be always accompanied by error 001 and/or 002. Too busy traffic on the local network. Software revision necessary.

Action :

Load the latest software revision.

Error Code

Description

Importance

004

SOFTWARE ERROR

High

Explanation :

Software fault or failure has been detected.

Action :

Load the latest software revision.

Error Code

Description

Importance

010

AOM DASHBOARD NETW.

High

Explanation :

The dashboard CAN node, closest to the LCD, is not transmitting CAN messages on a regular basis (at least 1 message / 2 seconds). It is possible that all communication between the LCD and the other nodes is correct although this dashboard CAN node is not transmitting messages to the InfoView monitor node on a regular basis. On machines sold before 1996, this node is located just behind the AOM user panel. On the machines sold from 1996 on, this node is the main dashboard node mounted in the centre of the dashboard.

Action :

Check the flat cable connection between the dashboard CAN node and LCD node. If not correct, replace the flat cable between dashboard and InfoView monitor. If correct, replace the dashboard CAN node for latest type of dashboards or replace old type of dashboard by new type. If the problem persists, try a new InfoView monitor of known performance (Do not forget to download software when changing InfoView monitor).

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

011

DASHBOARD NETW. ERROR

High

Explanation :

The dashboard CAN node is not transmitting messages on a regular basis (at least 1 message / 2 seconds). This error is only valid for machines with an old dashboard where two microprocessors are located. This error code is related to the dashboard printed circuit, mounted in the centre of the dashboard. This dashboard node serves the dashboard switches and the warning lights above the switches. On new type of dashboards, this error message should not appear as the function of both microprocessors is grouped in one microprocessor.

Action :

Replace the old type of dashboard by new type.

Error Code

Description

Importance

012

HANDLE NETWORK ERROR

High

Explanation :

The multifunction handle node is not transmitting CAN messages on a regular basis (at least 1 message / 2 seconds). It is possible that all communication between the LCD and the other nodes is correct although this handle node is not transmitting messages to the InfoView monitor node on a regular basis.

Action :

Refer to wiring diagram: line 1050. Check the connection between the instrument panel and the multifunction lever. Check for open and shorted circuits at power wire 1001--wt, at ground wires 1002--br and 1074--bl and at CAN communication wires 1003--gn and 1004--ge. If wiring is not correct, locate and repair open or shorted circuit. If wiring is correct, replace the vertical handle printed circuit. If the problem persists, try a new dashboard with known performance.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

013

CENTRAL NETW. ERROR

High

Explanation :

The CPU node in the central box is not transmitting CAN messages on a regular basis (at least 1 message / 2 seconds). It is possible that all communication between the LCD and the other nodes is correct although this CPU node is not transmitting CAN messages to the AOM node on a regular basis.

Action :

Communication from CPU white connecter to AOM black connector is incorrect? Possible to download Software Node B

Yes

Restart the machine and check software revision.

No Disconnect fiber optic cable at the AOM black connector arriving from the CPU printed circuit. Red light is visible at end of fiber optic? No Install new small fiber optic cable and try new CPU printed circuit of known performance.

Yes

Try New AOM printed circuit of known performance

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

015

AOM NETWORK ERROR

High

Explanation :

The AOM node in the central box is not transmitting CAN messages on a regular basis (at least 1 message / 2 seconds). It is possible that all communication between the LCD and the other nodes is correct although this AOM node is not transmitting CAN messages to the dashboard node on a regular basis. Mostly error messages 15 and 13 appear together.

Action :

Communication from AOM white connector to Dashboard black connector is incorrect? Possible to download software node D

Yes

Restart the machine and check software revision

No Disconnect fiber optic cable at the dashboard black connector arriving from the AOM printed circuit Red light is visible at end of fiber optic No Clean fiber optic cables between dashboard and AOM printed circuit. Problem persists? Yes

Try new AOM printed circuit of known performance

Yes

Try new Dashboard CAN printed circuit of known performance

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

100

TOTAL ENGINE HOURS =

Medium

Explanation :

There is more than 10 hours difference between the total amount of engine hours stored in the CPU Memory and the total engine hours in the InfoView monitor memory. Remark: Switching off the battery key before turning off the ignition may result in memorising an incorrect engine hour value in the InfoView Monitor or in the CPU. Different total hours are detected in the nodes on the network. REMARK: This error is displayed in a special error page format. REMARK: The error counter is automatically cleared when the selection of the right total engine hours is made. So the error will not be displayed any more showing the right total engine hours or showing engine hours differences of < 10h while looking up the errors through the error overview.

Action :

The total amount of engine hours, stored in the CPU and InfoView monitor, can only be equalised when the error report automatically appeared after starting the engine. On the special error 100 layout, the two different engine hours are indicated. One of the values has an arrow in front of it. Move the arrow in front of the selected hour value with the help of the ”ARROW” keys. Confirm your choice by pressing the “Enter” key. The selected engine hours are now stored in both memories, together with the related threshing hours and hectares (or acres). Press the “ESC” button to return to work screen. This error will not be stored in the error overview list.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

113

CROP. PROC. SENSOR O

Medium

Explanation :

The crop processor RPM sensor is disconnected from the CPU printed circuit.

Action :

If no crop processor is installed, check in the InfoView calibration for “CROP PROCESSOR : NO”. If the crop processor is installed, refer to the wiring diagram: sensor B104, line 4350. Open the connector at the crop processor rpm sensor. Turn on ignition and check for 8 Volts at the end of wire 2047--BR. If not correct, locate and repair the open circuit in the brown wire. If correct, check for ground at the end of wire 2048--BL. If not correct, locate and repair the open circuit in the blue wire. If correct, replace the sensor.

Crop Processor installed?

Check info view calibration for “Crop Processor: No”

Yes Open connector at the Crop Processor RPM Sensor. Check for 8V at the end of the brown wire

Locate and repair the open circuit in the brown wire.

Yes

Check for ground at end of wire 2048 -- bl

Yes

Replace CP RPM Sensor (B104).

Locate and repair the open circuit in the blue wire.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

114

CROP. PROC. SENSOR --

Medium

Explanation :

The power wire (brown) of the crop processor RPM sensor is shorted to ground (blue wire or frame ground).

Action :

If no crop processor is installed, check in the InfoView calibration for “CROP PROCESSOR : NO”. If the crop processor is installed, refer to the wiring diagram: sensor B104, line 4350. Locate and repair shorted circuit to ground in the wire 2097--BR. After repair, check if 8 Volts arrives on the brown wire at the RPM sensor.

Error Code

Description

Importance

115

CROP. PROC. SENSOR +

Medium

Explanation :

The power wire (brown) of the crop processor RPM sensor is shorted to an external 12 Volts power supply.

Action :

If no crop processor is installed, check in the InfoView calibration for ”CROP PROCESSOR : NO”. If the crop processor is installed, refer to the wiring diagram: sensor B104, line 4350. Locate and repair shorted circuit to 12 Volts in the wire 2097--BR. After repair, check if 8 Volts arrives on the brown wire at the RPM sensor.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

117

EMD NETWORK ERROR

Medium

Explanation :

This Error Code is related to the function of the network connections between the metal detector itself and the AOM--print (A20). Physically these connections consist of the wires 2097 and 2098 and their connections to the printed circuit boards. When there is no CAN--info available on the network for more than 60 seconds, while the EMD--output signal is 12V, this Error Code will appear. Error Code 117 overrides all Error Codes that are generated by the metal detector (270--277).

Action :

Refer to wiring diagram: line 3980 and 3990. Check network connections. Locate and repair open circuit, shorted circuit, shorted circuit to frame ground or to an external 12 V power supply in wires 2097 and 2098. Disconnect wire 2097 and 2098 in central box and at metal detector (see wiring diagram: line 3980 and 3990) Check for: Open and short circuit, Frame short circuit, Short circuit to 12V.

Open or short circuit?

Yes

Repair open or short circuit.

Reconnect wires 2097 and 2098 correctly. Download the correct software.

Problem solved?

No Try with new electronic board (A20) or a new metal detector. Electronic Module

Reconnect wires 2097 and 2098 correctly.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

118

CATERP NETWORK ERROR

Medium

Explanation :

This Error Code is related to the function of the network connections between the Caterpillar itself and the AOM--print (A20). Physically these connections consist of the wires 2097 and 2098 and their connections to the printed circuit boards. When there is no CAN--info available on the network for more than 20 seconds, this Error Code will appear. Only valid for FX58. Error Code 118 overrides all Error Codes that are generated by the Caterpillar engine.

Action :

Check network connections (wire 2097 and 2098) for open circuit, shorted circuit, shorted circuit to frame ground or to an external 12 V power supply.

Error Code

Description

Importance

120

GROUND SPEED SENS. O

Medium

Explanation :

The ground speed RPM sensor is disconnected.

Action :

Refer to wiring diagram: sensor B16, line 2570. Open the connector at the ground speed rpm sensor. Turn on ignition and check for 8 Volts at the end of wire 263--BR. If not correct, locate and repair the open circuit in the brown wire. If correct, check for ground at the end of wire 264--BL. If not correct, locate and repair the open circuit in the blue wire. If correct, replace the sensor.

Error Code

Description

Importance

121

GROUND SPEED SENS. --

Medium

Explanation :

The power wire (brown) of the ground speed RPM sensor is shorted to ground (blue wire or frame ground).

Action :

Refer to the wiring diagram: sensor B16, line 2570. Locate and repair shorted circuit to ground in the wire 263--BR. After repair, check if 8 Volts arrives on the brown wire at the RPM sensor.

Error Code

Description

Importance

122

GROUND SPEED SENS. +

Medium

Explanation :

The power wire (brown) of the ground speed RPM sensor is shorted to an external 12 Volts power supply.

Action :

Refer to the wiring diagram: sensor B16, line 2570. Locate and repair shorted circuit to 12 Volts in the wire 263--BR. After repair, check if 8 Volts arrives on the brown wire at the RPM sensor.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

125

ENGINE RPM SENSOR O

Medium

Explanation :

The engine RPM sensor is disconnected. Suppressed for Caterpillar engine!

Action :

Refer to wiring diagram: sensor B23, line 2540. Open the connector at the ground speed rpm sensor. Turn on ignition and check for 8 Volts at the end of wire 274--BR. If not correct, locate and repair the open circuit in the brown wire. If correct, check for ground at the end of wire 273--BL. If not correct, locate and repair the open circuit in the blue wire. If correct, replace the sensor.

Error Code

Description

Importance

126

ENGINE RPM SENSOR --

Medium

Explanation :

The power wire (brown) of the engine RPM sensor is shorted to ground (blue wire or frame ground). Suppressed for Caterpillar engine!

Action :

Refer to the wiring diagram: sensor B23, line 2540. Locate and repair shorted circuit to ground in the wire 274--BR. After repair, check if 8 Volts arrives on the brown wire at the RPM sensor.

Error Code

Description

Importance

127

ENGINE RPM SENSOR +

Medium

Explanation :

The power wire (brown) of the engine RPM sensor is shorted to an external 12 Volts power supply. Suppressed for Caterpillar engine!

Action :

Refer to the wiring diagram: sensor B23, line 2540. Locate and repair shorted circuit to 12 Volts in the wire 274--BR. After repair, check if 8 Volts arrives on the brown wire at the RPM sensor.

Error Code

Description

Importance

130

CUTTERHEAD SENSOR O

Medium

Explanation :

The cutterhead RPM sensor is disconnected.

Action :

Refer to the wiring diagram: sensor B101, line 2600. Open the connector at the ground speed rpm sensor. Turn on ignition and check for 8 Volts at the end of wire 2027--BR. If not correct, locate and repair the open circuit in the brown wire. If correct, check for ground at the end of wire 2028--BL. If not correct, locate and repair the open circuit in the blue wire. If correct, replace the sensor.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

131

CUTTERHEAD SENSOR --

Medium

Explanation :

The power wire (brown) of the cutterhead RPM sensor is shorted to ground (blue wire or frame ground).

Action :

Refer to the wiring diagram: sensor B101, line 2600. Locate and repair shorted circuit to ground in the wire 2027--BR. After repair, check if 8 Volts arrives on the brown wire at the RPM sensor.

Error Code

Description

Importance

132

CUTTERHEAD SENSOR +

Medium

Explanation :

The power wire (brown) of the cutterhead RPM sensor is shorted to an external 12 Volts power supply.

Action :

Refer to the wiring diagram: sensor B101, line 2600. Locate and repair shorted circuit to 12 Volts in the wire 2027--BR. After repair, check if 8 Volts arrives on the brown wire at the RPM sensor.

Error Code

Description

Importance

145

ATTACHM HEIGHT S. O/--

Medium

Explanation :

The attachment height sensor is disconnected or shorted to ground.

Action :

Refer to wiring diagram: sensor R4, line 7150. Locate and repair open circuit or shorted circuit to ground in the wire 229--GN, starting form X415 p12 at the CPU printed circuit. If the InfoView error message is accompanied by a header self--diagnostic message, refer to the attachment control trouble--shooting section to check the attachment height sensor circuit.

Error Code

Description

Importance

146

ATTACHM HEIGHT S. +

Medium

Explanation :

The attachment height sensor is shorted to an external 12V--power supply.

Action :

Refer to wiring diagram: sensor R4, line 7150. Locate and repair shorted circuit to 12 Volts in the wire 229--GN, starting form X415 p12 at the CPU printed circuit. If the InfoView error message is accompanied by a header self--diagnostic message, refer to the attachment control trouble--shooting section to check the attachment height sensor circuit.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

147

ATTACHM HEIGHT RANGE

Medium

Explanation :

The attachment height bargraph is not calibrated correctly. The same attachment height is calibrated for ground and raised position.

Action :

Restart the header height calibration routine and calibrate different attachment heights. if error code returns, the sensor voltage does not change. Check pivot arm and sensor.

Error Code

Description

Importance

148

CP DISTANCE SENS. O/--

Medium

Explanation :

The crop processor distance sensor is disconnected or shorted to ground.

Action :

If no crop processor is installed, check in the InfoView calibration for “CROP PROCESSOR : NO”. If the crop processor is installed, refer to wiring diagram: sensor R30, line 4300. Locate and repair open circuit or shorted circuit to ground in the wires 2049, 2050 and 2051.

Error Code

Description

Importance

149

CP DISTANCE SENS. +

Medium

Explanation :

The crop processor distance sensor is shorted to an external 12V--power supply.

Action :

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

150

CROP PROCESSOR SENS.

Medium

Explanation :

There is no voltage change of the crop processor distance sensor while the CP electric motor is powered.

Action :

If no crop processor is installed, check in the InfoView calibration for â&#x20AC;&#x153;CROP PROCESSOR : NOâ&#x20AC;?. If the crop processor is installed, check crop processor sensor linkage. If correct, check potentiometer voltage with different sensor angle. If same voltage, change potentiometer. If different voltages, try other CPU printed circuit.

Check for correct CP sensor linkage

Repair Crop Processor Sensor Linkage

Check CP Mechanical Components Turn Manually

Yes

Is the electric Motor rotating while he is powered?

Repair, grease or clear CP mechanical Components

Try new electric motor of known performance.

Yes

Test CP Electric Motor Function Correct?

Yes

Measure sensor voltage with different angle positions.

Same voltage readings with different angles?

Yes

Replace Sensor

Try other CPU printed circuit.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

170

DISPLAYTEMP TOO HIGH

Medium

Explanation :

The InfoView monitor temperature is too high. If the monitor temperature is above 70 Â°C, the display will become blank and the contrast light intensity will decrease. If the temperature decreases below 70 Â°C., then the display will be reactivated again. At this time, the error report 170 will appear on the screen.

Action :

Decrease the monitor ambient temperature by switching on the cab air conditioning system or by driving the machine in the shadow.

Error Code

Description

Importance

171

SUPPLY VOLT = XX.X V

Medium

Explanation :

The battery voltage is lower than 10 Volts. The actual voltage is shown at the bottom of the screen and will always be available through the service page error overview.

Action :

Recharge the battery or check the alternator for proper functioning.

Error Code

Description

Importance

180

CPU PRINT ERROR

Medium

Explanation :

Poor communication arriving at CPU printed circuit through the flat cable, that connects CPU, light, actuator and valve printed circuits.

Action :

Disconnect the flat cable at the rear of the CPU. Clear all error reports in the service overview. If the error 180 appears again, replace the CPU printed circuit. If this is not the case, replace the flat cable.

Error Code

Description

Importance

181

LIGHTS PRINT DISCONN

Medium

Explanation :

Poor communication from light printed circuit through the flat cable, that connects CPU, light, actuator and valve printed circuits.

Action :

Check the flat cable male--female connections. If no visible damage, replace first the flat cable. If the problem still persists, replace the light printed circuit.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

182

ACTUATOR PRINT DISC

Medium

Explanation :

Poor communication from actuator printed circuit through the flat cable, that connects CPU, light, actuator and valve printed circuits.

Action :

Check the flat cable male--female connections. If no visible damage, replace first the flat cable. If the problem still persists, replace the actuator printed circuit.

Error Code

Description

Importance

183

HYDRO PRINT DISCONN

Medium

Explanation :

Poor communication from valve printed circuit through the flat cable, that connects CPU, light, actuator and valve printed circuits.

Action :

Check the flat cable male--female connections. If no visible damage, replace first the flat cable. If the problem still persists, replace the valve printed circuit.

Error Code

Description

Importance

220

ENGINE DOOR SENSOR O

Medium

Explanation :

The right hand side door sensor is disconnected.

Action :

Refer to wiring diagram: sensor B102, line 3650. Open the connector at the right hand side door sensor. Turn on ignition and check for 8 Volts at the end of wire 2033--BR. If not correct, locate and repair the open circuit in the brown wire. If correct, check for ground at the end of wire 2034--BL. If not correct, locate and repair the open circuit in the blue wire. If correct, replace the sensor.

Error Code

Description

Importance

221

ENGINE DOOR SENSOR --

Medium

Explanation :

The power wire (brown) of the right hand side door sensor is shorted to ground (blue wire or frame ground).

Action :

Refer to the wiring diagram: sensor B102, line 3650. Locate and repair shorted circuit to ground in the wire 2033--BR. After repair, check if 8 Volts arrives on the brown wire at the sensor.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

222

ENGINE DOOR SENSOR +

Medium

Explanation :

The power wire (brown) of the right hand side door sensor is shorted to an external 12 Volts power supply.

Action :

Refer to the wiring diagram: sensor B102, line 3650. Locate and repair shorted circuit to 12 Volts in the wire 2033--BR. After repair, check if 8 Volts arrives on the brown wire at the sensor.

Error Code

Description

Importance

223

STONE HOME SENSOR O

Medium

Explanation :

The sharpening stone home position sensor is disconnected.

Action :

Refer to wiring diagram: sensor B109, line 5350. Open the connector at the sharpening stone home position sensor. Turn on ignition and check for 8 Volts at the end of wire 2068--BR. If not correct, locate and repair the open circuit in the brown wire. If correct, check for ground at the end of wire 2069--BL. If not correct, locate and repair the open circuit in the blue wire. If correct, replace the sensor.

Error Code

Description

Importance

224

STONE HOME SENSOR --

Medium

Explanation :

The power wire (brown) of the sharpening stone home position sensor is shorted to ground (blue wire or frame ground).

Action :

Refer to the wiring diagram: sensor B109, line 5350. Locate and repair shorted circuit to ground in the wire 2068--BR. After repair, check if 8 Volts arrives on the brown wire at the sensor.

Error Code

Description

Importance

225

STONE HOME SENSOR +

Medium

Explanation :

The power wire (brown) of the sharpening stone home position sensor is shorted to an external 12 Volts power supply.

Action :

Refer to the wiring diagram: sensor B109, line 5350. Locate and repair shorted circuit to 12 Volts in the wire 2068--BR. After repair, check if 8 Volts arrives on the brown wire at the sensor.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

226

COVER CUTTERH. SENS. O

Medium

Explanation :

The sharpening stone cover sensor is disconnected.

Action :

Refer to wiring diagram: sensor B107, line 5230.

Open the connector at the sharpening stone cover sensor. Turn on ignition and check for 8 Volts at the end of wire 2060--BR. If not correct, locate and repair the open circuit in the brown wire. If correct, check for ground at the end of wire 2061--BL. If not correct, locate and repair the open circuit in the blue wire. If correct, replace the sensor.

Error Code

Description

Importance

227

COVER CUTTERH. SENS. --

Medium

Explanation :

The power wire (brown) of the sharpening stone cover sensor is shorted to ground (blue wire or frame ground).

Action :

Refer to the wiring diagram: sensor B107, line 5230. Locate and repair shorted circuit to ground in the wire 2060--BR. After repair, check if 8 Volts arrives on the brown wire at the sensor.

Error Code

Description

Importance

228

COVER CUTTERH. SENS. +

Medium

Explanation :

The power wire (brown) of the sharpening stone cover sensor is shorted to an external 12 Volts power supply.

Action :

Refer to the wiring diagram: sensor B107, line 5230. Locate and repair shorted circuit to 12 Volts in the wire 2060--BR. After repair, check if 8 Volts arrives on the brown wire at the sensor.

Error Code

Description

Importance

229

OUT OF STONE SENS. O

Medium

Explanation :

The adjust sharpening stone sensor is disconnected.

Action :

Refer to wiring diagram: sensor B108, line 5380. Open the connector at the adjust sharpening stone sensor. Turn on ignition and check for 8 Volts at the end of wire 2066--BR. If not correct, locate and repair the open circuit in the brown wire. If correct, check for ground at the end of wire 2067--BL. If not correct, locate and repair the open circuit in the blue wire. If correct, replace the sensor.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

230

OUT OF STONE SENS. --

Medium

Explanation :

The power wire (brown) of the adjust sharpening stone sensor is shorted to ground (blue wire or frame ground).

Action :

Refer to the wiring diagram: sensor B108, line 5380. Locate and repair shorted circuit to ground in the wire 2066--BR. After repair, check if 8 Volts arrives on the brown wire at the sensor.

Error Code

Description

Importance

231

OUT OF STONE SENS. +

Medium

Explanation :

The power wire (brown) of the sharpening stone home position sensor is shorted to an external 12 Volts power supply.

Action :

Refer to the wiring diagram: sensor B108, line 5380. Locate and repair shorted circuit to 12 Volts in the wire 2066--BR. After repair, check if 8 Volts arrives on the brown wire at the sensor.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

232

SPOUT LIMIT SWITCH

Medium

Explanation :

The spout rotation valve is activated for more than 5 seconds while the spout end of travel sensor is still detecting metal.

Action :

Refer to wiring diagram: sensor B103, line 4630.

Is spout rotating when pressing the spout left/right FAST buttons Yes

Readjust spout end of travel sensor

Check spout end of travel sensor adjustment. Adjustment correct? Yes

Locate and repair open or shorted circuit

Check for 8 Volt at end of wire 2041 -- br check for ground at end of wire 2042 -- bl Yes

Replace spout end of travel sensor.

Problem solved?

No Try new actuator printed circuit of known performance.

Try Manual override on hydraulic valve spout rotating? Yes

Consult spout rotation fault finding routine

Check and repair draulic circuit

hy-

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

270

EMD NOISE LEVEL LOW

Medium

Explanation :

When there is a low signal from one ore both channels during working operation (cutterhead and feed rolls engaged), this error code is generated. This message can only appear 12 seconds after the feed rolls are engaged. It indicates a bad contact between the sensor and the electronics of the metal detector or inside the electronics.

Action :

Remove the metal detector and check the connections between the sensor and the electronics. Try temporary with higher feed roll speed.

Problem solved?

Yes

Too low magnetic noise from feed rolls.

Check on which channel (left or right) the peak noise reading is lower than 03, whatever the feed roll speed is. See CAN Identifier page 1276, word 3 and 4.

If possible, continue working in a higher feed roll speed. But do not charge any electronic component.

Remove metal detector and disconnect wiring loom from sensor to electronic Module. Check coil resistance of both channels

Open or short circuit?

No Replace EMD electronic module:

Yes

Open or short circuit in wiring loom to coils?

Yes

No Replace upper part (coils and magnets).

If possible, repair open or short circuit in wiring loom.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

271

EMD OUTPUT LINE --

Medium

Explanation :

This Error Code is related to the (classical) output line (wire 2096). When there is no detection, this output signal is 12 Volt; if a metal detection takes place, the voltage will drop to 0 Volt for 1 second. In case the metal detector determines an output voltage that is < 7.5V, while it expects the signal to be high (=12V), this error code is generated. It is likely that the wire is short--circuited to earth. This message can only appear after the feed rolls have been activated for the first time. Thereafter this test is executed until the ignition is switched off.

Action :

Refer to wiring diagram: line 3960. Check continuity of wire 2096. Locate and repair the frame short circuit in wire 2096. If no frame short circuit can be found in the wire 2096, replace the EMD electronic module.

Error Code

Description

Importance

272

EMD OUTPUT LINE +

Medium

Explanation :

This Error Code is related to the (classical) output line (wire 2096). In case the metal detector determines an output voltage that is > 1.0V, while it expects the signal to be low (=0V) during a metal detection, this error code is generated. It is likely the wire is shorted to 12V. This message can only appear after the feed rolls have been activated for the first time. Thereafter this test is executed until the ignition is switched off.

Action :

Refer to wiring diagram: line 3960. Check continuity of wire 2096. Locate and repair the short circuit to 12 V in the wire 2096. If no short circuit to 12 V can be found in the wire 2096, replace the EMD electronic module.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

273

EMD CHANNEL FAULT

Medium

Explanation :

In case the coil and amplifier test fails during the run time test, this error code will be displayed. The expected signal is a peak noise reading of 16 (hex). The allowed tolerance on the signal ranges from OD to 1F (hex).

Action :

Remove the detector and check the connections between the sensor and the electronic module.

Check on which channel (left or right) the peak noise reading is not between OD and 1F during the run time test. See CAN Identifier page 1276, word 3 and 4.

Remove metal detector and disconnect wiring loom from sensor to electronic module. Check coil resistance of both channels

Open or short circuit?

No Replace EMD electronic module:

Yes

Open or short circuit in wiring loom?

Yes

No Replace upper part (coils and magnets).

If possible, repair open or short circuit in wiring loom.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

274

EMD NOISE LEVEL HIGH

Medium

Explanation :

This Error Code is related to the setting of the adaptive threshold. This error message can be generated when during working operation the system becomes so noisy that one of the adaptive thresholds is beyond the adaptive limits. Consequently, there is a risk that small ferrous objects will not be detected.

Action :

Work temporary in fixed mode. Replace the metal detector feed roll and execute a quick adapt routine. If the problem persists check if other feed rolls are creating excessive magnetic noise. At last, try new metal detector of known performance.

Error Code

Description

Importance

275

EMD NETWORK ERROR

Medium

Explanation :

Suppressed in software Rev99 or later. Remark: the metal detector can only report this error code after the CAN communication problem has been repaired. By that time the problem has already been reported by the Adjust--O--Matic printed circuit by means of error code 117.

Action :

Error Code

Description

Importance

276

EMD PROCESSOR FAULT

Medium

Explanation :

There are 2 situations during which this Error Code will appear: 1. Flash Code â&#x20AC;&#x153;checksumâ&#x20AC;? does not correspond with stored value. This error code can only appear shortly after the ignition is switched ON. 2. There is a problem with the reading or writing of values to EEprom, e.g. the storing of threshold settings.

Action :

Load new software. If this does not solve the problem, replace metal detector electronics.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

277

EMD FRAME GROUND

Medium

Explanation :

In case the frame earth test fails during the run time test, this error code will be displayed.

Action :

Check the following earth connections : 1. Flat earth strap connections between EMD electronic module and metal detector shaft. 2. Flat earth strap connections between metal detector shaft and chopper body frame. 3. Earth connection between chopper body frame and base unit frame. Check also for corrosion.

Error Code

Description

Importance

278

EMD OUTPUT FAILURE

Medium

Explanation :

This error code is generated when the (classical) output signal is low (0V) for more than 60 seconds, while the CAN--messages appear normal.

Action :

Refer to wiring diagram: line 3960. Check continuity in wire 2096. Locate and repair the open circuit in the wire 2096. If no open circuit can be found in the wire 2096, check for voltage drop to 0 volt when a metal detection is simulated while the wire 2096 is disconnected. If correct, try with new AOM printed circuit of known performance. If not correct, try new EMD electronic module of known performance.

Error Code

Description

Importance

279

EMD POWER FAILURE

Medium

Explanation :

This error code is generated when the (classical) output signal is low (0V) for more than 60 seconds, while at the same time there are no CAN--messages for more than 60 seconds either. Possibly there is no power to the metal detector at all, or the power was interrupted.

Action :

Check fuse F4. Check continuity in wire 2094 (power supply). Check continuity in wire 2096 (classic output line) and the continuity in wires 2097 and 2098 (CAN network lines). (See flow chart)

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Fuse F4 burned?

Yes

Replace fuse F4.

Disconnect wire 2094 and 2095 in central box and at metal detector.

Check for: Open and short circuit, Frame short circuit, Short circuit to 12 V.

Open or short circuit?

Yes

No Reconnect wires 2094 and 2095 correctly.

Disconnect wires 2096, 2097 and 2098 in central box and at metal detector.

Repair open or short circuit.

Reconnect wires 2094 and 2095 correctly.

Check for: Open and short circuit, Frame short circuit.

Open or short circuit?

Yes

No Reconnect wires 2096, 2097 and 2098 correctly.

Download the correct software.

Problem solved?

No Try with new electronic board (A20) or a new metal detector electronic Module.

Repair open or short circuit.

Reconnect wires 2096, 2097 and 2098 correctly.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

301

DASHBOARD SWITCH 1

Medium

Explanation :

Malfunction of the high capacity hydraulics rocker switch (1st dashboard switch).

Action :

Replace switch. If problem persists, replace complete dashboard. In case of several dashboard switch error reports, check all flat cables inside dashboard.

Error Code

Description

Importance

302

DASHBOARD SWITCH 2

Medium

Explanation :

Malfunction of the harvest function tumbler switch (2nd dashboard switch).

Action :

Replace switch. If problem persists, replace complete dashboard. In case of several dashboard switch error reports, check all flat cables inside dashboard.

Error Code

Description

Importance

303

DASHBOARD SWITCH 3

Medium

Explanation :

Malfunction of the metal detector rocker switch (3rd dashboard switch).

Action :

Replace switch. If problem persists, replace complete dashboard. In case of several dashboard switch error reports, check all flat cables inside dashboard.

Error Code

Description

Importance

304

DASHBOARD SWITCH 4

Medium

Explanation : Action :

Not used

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

305

DASHBOARD SWITCH 5

Medium

Explanation :

Malfunction of the auto--pilot main switch (5th dashboard switch).

Action :

Replace switch. If problem persists, replace complete dashboard.

In case of several dashboard switch error reports, check all flat cables inside dashboard.

Error Code

Description

Importance

306

DASHBOARD SWITCH 6

Medium

Explanation :

Malfunction of the silage additive applicator tumbler switch (6th dashboard switch).

Action :

Replace switch. If problem persists, replace complete dashboard. In case of several dashboard switch error reports, check all flat cables inside dashboard.

Error Code

Description

Importance

307

DASHBOARD SWITCH 7

Medium

Explanation :

Malfunction of the operating lights tumbler switch (7th dashboard switch).

Action :

Replace switch. If problem persists, replace complete dashboard. In case of several dashboard switch error reports, check all flat cables inside dashboard.

Error Code

Description

Importance

308

DASHBOARD SWITCH 8

Medium

Explanation :

Malfunction of the beacon tumbler switch (8th dashboard switch).

Action :

Replace switch. If problem persists, replace complete dashboard. In case of several dashboard switch error reports, check all flat cables inside dashboard.

Error Code

Description

Importance

309

DASHBOARD SWITCH 9

Medium

Explanation :

Malfunction of the power reverse tumbler switch (9th dashboard switch).

Action :

Replace switch. If problem persists, replace complete dashboard. In case of several dashboard switch error reports, check all flat cables inside dashboard.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

310

DASHBOARD SWITCH 10

Medium

Explanation :

Malfunction of the main Adjust--O--Matic tumbler switch (10th dashboard switch).

Action :

Replace switch. If problem persists, replace complete dashboard. In case of several dashboard switch error reports, check all flat cables inside dashboard.

Error Code

Description

Importance

311

DASHBOARD SWITCH 11

Medium

Explanation :

Malfunction of the cutterhead reverse drive switch (11th dashboard switch).

Action :

Replace switch. If problem persists, replace complete dashboard. In case of several dashboard switch error reports, check all flat cables inside dashboard.

Error Code

Description

Importance

312

DASHBOARD SWITCH 12

Medium

Explanation :

Malfunction of the crop processor roll clearance switch (12th dashboard switch).

Action :

Replace switch. If problem persists, replace complete dashboard. In case of several dashboard switch error reports, check all flat cables inside dashboard.

Error Code

Description

Importance

313

DASHBOARD SWITCH 13

Medium

Error Code

Description

Importance

314

DASHBOARD SWITCH 14

Medium

Explanation :

Not used

Action :

Explanation :

Malfunction of the cutterhead drive tumbler switch (14th dashboard switch).

Action :

Replace switch. If problem persists, replace complete dashboard. In case of several dashboard switch error reports, check all flat cables inside dashboard.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

315

DASHBOARD SWITCH 15

Medium

Explanation :

Malfunction of the 4--wheel drive tumbler switch (15th dashboard switch).

Action :

Replace switch. If problem persists, replace complete dashboard.

In case of several dashboard switch error reports, check all flat cables inside dashboard.

Error Code

Description

Importance

316

DASHBOARD SWITCH 16

Medium

Explanation :

Malfunction of the throttle control rocker switch (16th dashboard switch).

Action :

Replace switch. If problem persists, replace complete dashboard. In case of several dashboard switch error reports, check all flat cables inside dashboard.

Error Code

Description

Importance

330

HANDLE SWITCH 1 ^

Medium

Explanation :

Malfunction of the feed rolls forward engagement switch (1st handle switch, up).

Action :

Check connections on the vertical handle print. If correct, try another handle with known performance. If correct, replace handle.

Error Code

Description

Importance

331

HANDLE SWITCH 1 v

Medium

Explanation :

Malfunction of the feed rolls stop switch (1st handle switch, down).

Action :

Check connections on the vertical handle print. If correct, try another handle with known performance. If correct, replace handle.

Error Code

Description

Importance

332

HANDLE SWITCH 2 <

Medium

Explanation :

Malfunction of the spout left switch, slow speed.

Action :

Check connections on vertical handle print. If correct, try another handle with known performance. If correct, replace handle.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

333

HANDLE SWITCH 2 >

Medium

Explanation :

Malfunction of the spout right switch, slow speed.

Action :

Check connections on vertical handle print. If correct, try another handle with known performance. If correct, replace handle.

Error Code

Description

Importance

334

HANDLE SWITCH 2^

Medium

Explanation :

Malfunction of the spout deflector up switch.

Action :

Check connections on vertical handle print. If correct, try another handle with known performance. If correct, replace handle.

Error Code

Description

Importance

335

HANDLE SWITCH 2v

Medium

Explanation :

Malfunction of the spout deflector down switch.

Action :

Check connections on vertical handle print. If correct, try another handle with known performance. If correct, replace handle.

Error Code

Description

Importance

336

HANDLE SWITCH 2<<

Medium

Explanation :

Malfunction of the spout left switch, fast speed.

Action :

Check connections on vertical handle print. If correct, try another handle with known performance. If correct, replace handle.

Error Code

Description

Importance

337

HANDLE SWITCH 2>>

Medium

Explanation :

Malfunction of the spout right switch, fast speed.

Action :

Check connections on vertical handle print. If correct, try another handle with known performance. If correct, replace handle.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

338

HANDLE SWITCH 3^

Medium

Explanation :

Malfunction of the attachment up switch (3rd handle switch, up).

Action :

Check connections on vertical handle print. If correct, try another handle with known performance. If correct, replace handle.

Error Code

Description

Importance

339

HANDLE SWITCH 3v

Medium

Explanation :

Malfunction of the attachment down switch (3rd handle switch, down).

Action :

Check connections on vertical handle print. If correct, try another handle with known performance. If correct, replace handle.

Error Code

Description

Importance

340

HANDLE SWITCH 4

Medium

Explanation :

Malfunction of the quick--stop handle switch (4th handle switch).

Action :

Check connections on vertical handle print. If correct, try another handle with known performance. If correct, replace handle.

Error Code

Description

Importance

341

HANDLE SWITCH 5

Medium

Explanation :

Malfunction of the auto--pilot handle switch (5th handle switch).

Action :

Check connections on vertical handle print. If correct, try another handle with known performance. If correct, replace handle.

Error Code

Description

Importance

342

HANDLE SWITCH 6

Medium

Explanation :

Malfunction of the automatic attachment height control switch (6th handle switch).

Action :

Check connections on vertical handle print. If correct, try another handle with known performance. If correct, replace handle.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

343

HANDLE SWITCH 1vv

Medium

Explanation :

Malfunction of the feed rolls reverse switch (1st handle switch, down -- down).

Action :

Check connections on vertical handle print. If correct, try another handle with known performance. If correct, replace handle.

Error Code

Description

Importance

350

GROUND SPEED POT--M.

Medium

Explanation : Action :

Malfunction of the ground speed potentiometer of the multi--function lever.

Check connectors at potentiometer and vertical handle printed circuit. Connections correct?

Repair connections.

Fixate potentiometer with gear.

Readjust Neutral potentiometer value

Check potentiometer manually does resistance change correct?

Yes Check potentiometer fixation with small gear Fixation correct? Yes Check potentiometer value on CANSPY page 1282 word 3 digit 3 & 4. Is value between range of 48--71 (5C Âą 20) at the moment the neutral position switch leaves the neutral position (from 1 to 2) Yes Check potentiometer value on CANSPY for full forward and reverse position. Is value between 00 -DO Âą 10?

Yes

Replace vertical handle prinked circuit

Try with new potentiometer

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

351

STOP GROUND SPEED SW

Medium

Explanation : Action :

Malfunction of the neutral position switch of the multi--function lever.

Check connections at neutral position switch and Handle printed circuit Connections correct?

Repair connections.

Improve adjustment of the neutral position switch

Replace neutral position switch.

Yes Check neutral position switch adjustment Adjustment correct? Yes Check neutral position on CANSPY page 1282, word 3 digit 2. When moving the handle Does the value “0“ appears? Yes Test out the switch manually. (Test normal open 2 Normal closed positions switch correct? Yes

Replace vertical handle printed circuit.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

360

NO ENGINE OIL PRESS.

Medium

Explanation :

The engine oil pressure contact stays closed for more than 5 seconds after the engine is started, as if the engine oil pressure stays low.

Action :

Refer to the wiring diagram: sensor B1, line 2910. Check for shorted circuit to ground in wire 56--GN. If shorted circuit is found, repair first. If no shorted circuit can be found, replace the engine oil pressure switch.

Error Code

Description

Importance

361

OIL PRESS SENS FAULT

Medium

Explanation :

The engine oil pressure contact is open, as if high engine oil pressure is detected, before the engine is started.

Action :

Refer to the wiring diagram: sensor B1, line 2910. Check for open circuit in wire 56--GN. If open circuit is found, repair first. If no open circuit can be found, the replace the engine oil pressure switch.

Error Code

Description

Importance

362

NO HYDROST. PRESSURE

Medium

Explanation :

The hydrostatic oil pressure contact stays closed for more than 5 seconds, after the engine is started, as if the hydrostatic oil pressure stays low.

Action :

Refer to the wiring diagram: sensor B4, line 2970. Check for shorted circuit to ground in wire 58--GN. If shorted circuit is found, repair first. If no shorted circuit can be found, replace the hydrostatic oil pressure switch.

Error Code

Description

Importance

363

HYDROST. SENSOR FAULT

Medium

Explanation :

The hydrostatic oil pressure contact is open, as if high hydrostatic oil pressure is detected, before the engine is started.

Action :

Refer to the wiring diagram: sensor B4, line 2970. Check for open circuit in wire 58--GN or wire 041--ZW. If open circuit is found, repair first. If no open circuit can be found, replace the hydrostatic oil pressure switch.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

364

CAT OIL TEMP. SENSOR

Medium

Explanation :

The CAT engine oil temperature sensor is open for app. 5 minutes after the engine is started, as if high engine oil temperature is detected. Only valid for FX58.

Action :

Refer to the wiring diagram: sensor R51, line 7380. Check for open circuit in wire 2183--GN. If open circuit is found, repair first. If no open circuit can be found, replace the CAT engine oil temperature sensor.

Error Code

Description

Importance

370

COVER CUTTERHEAD EOT

Medium

Explanation :

Power was supplied to the sharpening cover electric motor but the sharpening cover did not arrive to its home (closed) position.

Action :

Refer to wiring diagram: sharpening cover closed limit switch S82 Readjust sharpening cover limit switch. Make sure the limit switch S82 (wires 2092--gn and 2093--bl) in the sharpening cover electric motor is open when the sharpening cover is closed. If error messages 370 and 483 appears together, repair first error message 483.

Error Code

Description

Importance

371

AOM POWER FAILURE

Medium

Explanation :

Fuse (F18) to power AOM printed circuit is blown.

Action :

Replace Fuse F18 in central box. If problem persists, check connections of fuse holder with the fuse printed circuit. If problem persists, try with other AOM printed circuit of known performance.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

400

CROP PROC.DIST. ACT.

Medium

Explanation :

Crop processor distance electric motor is open or shorted.

Action :

If no crop processor is installed, check in the InfoView calibration for â&#x20AC;&#x153;CROP PROCESSOR : NOâ&#x20AC;?. If the crop processor is installed, refer to the wiring diagram: Motor M21, line 4270.

Check CP mechanical components CAN CP been turned manually by key?

Repair, grease or clean CP mechanical components.

Yes Open connector at the CP electric motor check for battery voltage at the connector arriving from central box when the CP switch is pressed. (Select Harvest Mode first) 12V measured

Locate and repair open or shorted circuit

Yes Power electric motor from separate battery (Insert fuse in power cables.) Motor functioning? Yes Reconnect everything and try again.

Check for open or shorted circuit in wires 2052--gn and 2053--wt open or shorted circuit?

Replace CP electric motor

Try new actuator printed circuit with known performance (A40)

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

401

SPOUT DEFLECTOR ACT.

Medium

Explanation :

Spout deflector actuator or solenoid is open or shorted.

Action :

Refer to the wiring diagram: Motor M20, line 4600 for machines with electric deflector. Hydraulic valve Y45 and Y46 for machines with hydraulic deflector. Machines where spout deflector is moved by electric actuator (M20). Machines where spout deflector is moved by hydraulic cylinder. Open connector at spout deflector actuator. Check for battery voltage at the connector when the spout deflector switches are pressed. 12V measured?

Try new actuator printed circuit with known performance

Yes Locate and repair open or shorted circuit

Yes

Power electric actuator from separate battery (insert fuse in power cables). Motor functioning?

Check for open or shorted circuit in wires 2039--wt and 2040--gr. Open or shorted circuit?

Replace spout deflector actuator

Yes

Try again

Open both connectors at electro valves on low pressure valve. Check for battery voltage at both connectors when the correct spout deflector switch is pressed. 12V measured on both connectors? Yes

Check Hydraulic circuit

Check for open or shorted circuit in wiring loom where there was no battery voltage measured. 1. 2039--wt and 2030--zw 2. 2040--gr and 2030--zw Open or shorted circuit found? Yes

Locate and repair open or shorted circuit

Try new actuator printed circuit with known performance

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

420

HYDROSTATIC PUMP O

Medium

Explanation :

The hydrostatic pump is not functioning due to open circuit.

Action :

Refer to wiring diagram: electro valve Y28, line 700. Disconnect electro valve on hydrostatic pump and check for coil resistance of 24 Ohm. If not correct, replace electro valve on hydrostatic pump. If correct, check for open circuit in wires 394--wt and 395--gr. If open circuit is found, repair open circuit, otherwise try with new Adjust--O--Matic printed circuit of known performance.

Error Code

Description

Importance

421

HYDROSTATIC PUMP --

Medium

Explanation :

The hydrostatic pump is not functioning due to shorted circuit.

Action :

Refer to wiring diagram: electro valve Y28, line 700. Disconnect electro valve on hydrostatic pump and check for coil resistance of 24 Ohm. If not correct, replace electro valve on hydrostatic pump. If correct, check for shorted circuit or shorted circuit to ground in wires 394--wt and 395--gr. If shorted circuit is found, repair shorted circuit, otherwise try with new Adjust--O--Matic printed circuit of known performance.

Error Code

Description

Importance

422

HYDROSTATIC PUMP +

Medium

Explanation :

The hydrostatic pump is not functioning due to shorted circuit to external 12 V power supply.

Action :

Refer to wiring diagram: electro valve Y28, line 700. Disconnect electro valve on hydrostatic pump and check for coil resistance of 24 Ohm. If not correct, replace electro valve on hydrostatic pump. If correct, check for shorted circuit to 12 V in wires 394--wt and 395--gr. If shorted circuit is found, repair shorted circuit, otherwise try with new Adjust--O--Matic printed circuit of known performance.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

440

AIRCONDITION. CLUTCH

Medium

Explanation :

The air conditioning electric clutch is open or shorted.

Action :

Refer to wiring diagram: electric clutch Y27, line 9340.

If no air conditioning is installed on the machine, recalibrate the air conditioning option by means of the PDT or PC calibration program. If air conditioning is installed, disconnect the air conditioning clutch Y27. Check for battery voltage at Y27 while the air conditioning is activated. If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 401--wt. If no open or shorted circuit can be found, try new lights printed circuit of known performance. If battery voltage is measured at the end connector, power the electric clutch with separate battery (insert fuse in power cable). If the clutch is not functioning, try new electric clutch Y27 of known performance. If the clutch can be activated with separate battery, connect everything and try again.

Error Code

Description

Importance

446

ROTARY SCREEN MOTOR

Medium

Explanation :

The rotary screen electric motors are open or shorted.

Action :

Refer to wiring diagram: electric motors M26 and M27, line 4780. If no rotary screens are installed on the machine, recalibrate the rotary screen option by means of the PDT or PC calibration program. If rotary screens are installed, disconnect both connectors at rotary screen motors. Check for battery voltage at M26 and M27 the engine is running. If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2147--wt and/or 2149--wt. If no open or shorted circuit can be found, try new actuator printed circuit of known performance. If battery voltage is measured at the end connectors, power the electric motors with separate battery (insert fuse in power cable). If one or more rotary screen motor is not functioning, try new electric motor of known performance. If both electric motors can be activated with separate battery, connect everything and try again.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

453

SPOUT RIGHT HYDR.SOL

Medium

Explanation :

The solenoid of the spout right rotation hydraulic valve is open or shorted.

Action :

Refer to wiring diagram : hydraulic valve Y33, line 4570. Disconnect the solenoid Y33 on the stack valve. Check for battery voltage at Y33 while the spout right fast rotation switch is pressed. If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2005--wt and/or wire 2006--zw. If no open or shorted circuit can be found, try new hydraulic printed circuit of known performance. If battery voltage is measured at the end connector, check coil resistance of the solenoid (a resistance of app. 4 ohm should be measured) or eventually power the solenoid with separate battery (insert fuse in power cable). If the valve is not functioning, try new hydraulic valve Y33 of known performance. If the coil resistance is correct and the hydraulic valve is functioning, connect everything and try again.

Error Code

Description

Importance

454

SPOUT LEFT HYDR.SOL

Medium

Explanation :

The solenoid of the spout left rotation hydraulic valve is open or shorted.

Action :

Refer to wiring diagram : hydraulic valve Y32, line 4550. Disconnect the solenoid Y32 on the stack valve. Check for battery voltage at Y32 while the spout left fast rotation switch is pressed. If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2003--wt and/or wire 2004--zw. If no open or shorted circuit can be found, try new hydraulic printed circuit of known performance. If battery voltage is measured at the end connector, check coil resistance of the solenoid (a resistance of app. 4 ohm should be measured) or eventually power the solenoid with separate battery (insert fuse in power cable). If the valve is not functioning, try new hydraulic valve Y32 of known performance. If the coil resistance is correct and the hydraulic valve is functioning, connect everything and try again.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

455

REAR HYDR. DOWN SOL.

Medium

Explanation :

The solenoid of the rear hydraulics down valve is open or shorted.

Action :

Refer to wiring diagram : solenoid Y37, line 3900.

If no rear auxiliary hydraulics is installed on the machine, recalibrate the rear auxiliary hydraulics option by means of the PDT or PC calibration program. If rear auxiliary hydraulics is installed, disconnect the solenoid Y37 on the stack valve. Check for battery voltage at Y37 while the rear hydraulics down valve is activated. If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2013--wt and/or wire 2014--zw. If no open or shorted circuit can be found, try new hydraulic printed circuit of known performance. If battery voltage is measured at the end connector, check coil resistance of the solenoid (a resistance of app. 4 ohm should be measured) or eventually power the solenoid with separate battery (insert fuse in power cable). If the valve is not functioning, try new hydraulic valve Y37 of known performance. If the coil resistance is correct and the hydraulic valve is functioning, connect everything and try again.

Error Code

Description

Importance

456

REAR HYDR. UP SOL.

Medium

Explanation :

The solenoid of the rear hydraulics up valve is open or shorted.

Action :

Refer to wiring diagram : solenoid Y36, line 3880. If no rear auxiliary hydraulics is installed on the machine, recalibrate the rear auxiliary hydraulics option by means of the PDT or PC calibration program. If rear auxiliary hydraulics is installed, disconnect the solenoid Y36 on the stack valve. Check for battery voltage at Y36 while the rear hydraulics up valve is activated. If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2011--wt and/or wire 2012--zw. If no open or shorted circuit can be found, try new hydraulic printed circuit of known performance. If battery voltage is measured at the end connector, check coil resistance of the solenoid (a resistance of app. 4 ohm should be measured) or eventually power the solenoid with separate battery (insert fuse in power cable). If the valve is not functioning, try new hydraulic valve Y36 of known performance. If the coil resistance is correct and the hydraulic valve is functioning, connect everything and try again.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

457

MAIN DRIVE HYDR.SOL.

Medium

Explanation :

The solenoid of the main drive hydraulic valve is open or shorted.

Action :

Refer to wiring diagram : solenoid (Y44) and Y40, line 3430. Disconnect the solenoid Y40 on the low pressure valve. Check for battery voltage at Y40 while the engine is running and the cutterhead is engaged. If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2019--wt and/or wire 292--zw. If no open or shorted circuit can be found, try new hydraulic printed circuit of known performance. If battery voltage is measured at the end connector, check coil resistance of the solenoid (a resistance of app. 3--10 ohm should be measured) or eventually power the solenoid with separate battery (insert fuse in power cable). If the valve is not functioning, try new hydraulic valve Y40 of known performance. If the coil resistance is correct and the hydraulic valve is functioning, connect everything and try again.

Error Code

Description

Importance

458

4 WHEEL DRIVE SOLEN.

Medium

Explanation :

The 4 wheel drive solenoid is open or shorted.

Action :

Refer to wiring diagram : solenoid Y22, line 880. If no 4 wheel drive is installed on the machine, recalibrate the 4 wheel drive option by means of the PDT or PC calibration program. If 4 wheel drive is installed, disconnect the solenoid Y22 on the low pressure valve. Check for battery voltage at Y22 while the 4 wheel drive is activated. If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 40--wt and/or wire 41--zw. If no open or shorted circuit can be found, try new hydraulic printed circuit of known performance. If battery voltage is measured at the end connector, check coil resistance of the solenoid (a resistance of app. 3--10 ohm should be measured) or eventually power the solenoid with separate battery (insert fuse in power cable). If the valve is not functioning, try new hydraulic valve Y22 of known performance. If the coil resistance is correct and the hydraulic valve is functioning, connect everything and try again.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

459

SPOUT DOWN HYDR.SOL.

Medium

Explanation :

The solenoid of the spout down hydraulic valve is open or shorted.

Action :

Refer to wiring diagram : solenoid Y39, line 4530.

Disconnect the solenoid Y39 on the stack valve. Check for battery voltage at Y39 while the spout down switch is pressed. If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2017--gr and/or wire 2018--zw. If no open or shorted circuit can be found, try new hydraulic printed circuit of known performance. If battery voltage is measured at the end connector, check coil resistance of the solenoid (a resistance of app. 4 ohm should be measured) or eventually power the solenoid with separate battery (insert fuse in power cable). If the valve is not functioning, try new hydraulic valve Y39 of known performance. If the coil resistance is correct and the hydraulic valve is functioning, connect everything and try again.

Error Code

Description

Importance

460

SPOUT UP HYDR.SOL.

Medium

Explanation :

The solenoid of the spout up hydraulic valve is open or shorted.

Action :

Refer to wiring diagram : solenoid Y38, line 4510. Disconnect the solenoid Y38 on the stack valve. Check for battery voltage at Y38 while the spout up switch is pressed. If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2015--gr and/or wire 2016--zw. If no open or shorted circuit can be found, try new hydraulic printed circuit of known performance. If battery voltage is measured at the end connector, check coil resistance of the solenoid (a resistance of app. 4 ohm should be measured) or eventually power the solenoid with separate battery (insert fuse in power cable). If the valve is not functioning, try new hydraulic valve Y38 of known performance. If the coil resistance is correct and the hydraulic valve is functioning, connect everything and try again.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

461

REVERSER CUTTERHEAD

Medium

Explanation :

The solenoid of the reverse cutterhead hydraulic valve is open or shorted.

Action :

Refer to wiring diagram : solenoid Y31, line 4960. Disconnect the solenoid Y31 on the stack valve. Check for battery voltage at Y31 while the cutterhead reverse switch is switched on (harvest function activated). If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2001--wt and/or wire 2002--zw. If no open or shorted circuit can be found, try new hydraulic printed circuit of known performance. If battery voltage is measured at the end connector, check coil resistance of the solenoid (a resistance of app. 4 ohm should be measured) or eventually power the solenoid with separate battery (insert fuse in power cable). If the valve is not functioning, try new hydraulic valve Y31 of known performance. If the coil resistance is correct and the hydraulic valve is functioning, connect everything and try again.

Error Code

Description

Importance

463

REVERSE FEEDINGROLLS

Medium

Explanation :

The feed rolls reverse electro magnetic clutch is open or shorted.

Action :

Refer to wiring diagram : electric clutch Y43, line 3510. On machines build before season ’99 (up to serial number 5080), the feed rolls reverse output is located on the hydraulic printed circuit. On machines build from season ’99 onwards (serial number 5083 onwards), the feed rolls reverse output is located on the actuator printed circuit. If the machine is installed with software revision REV99 or later, recalibrate first the new ’stromag feed rolls engagement clutch’ option by means of PDT or PC calibration program. If problem persists after recalibration, disconnect the electric clutch Y43. Check for battery voltage at Y43 while the feed rolls reverse output is activated (harvest function activated). If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2029--wt and/or wire 2030--zw. If no open or shorted circuit can be found, try new hydraulic printed circuit on machines before season ’99 or try new actuator printed circuit on machines from season ’99 onwards. If battery voltage is measured at the end connector, check coil resistance of the electric clutch (a resistance of app. 1--2 ohm should be measured for the Stromag clutch) or eventually power the electric clutch with separate battery (insert fuse in power cable). If the clutch is not functioning, try new electro magnetic clutch Y43 of known performance. If the coil resistance is correct and the electro magnetic clutch is functioning, connect everything and try again.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

464

FRONT HYDR. UP SOL.

Medium

Explanation :

The solenoid of the front hydraulics up valve is open or shorted.

Action :

Refer to wiring diagram : solenoid Y34, line 3840.

Disconnect the solenoid Y34 on the stack valve. Check for battery voltage at Y34 while the front hydraulics up valve is activated. If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2007--wt and/or wire 2008--zw. If no open or shorted circuit can be found, try new hydraulic printed circuit of known performance. If battery voltage is measured at the end connector, check coil resistance of the solenoid (a resistance of app. 4 ohm should be measured) or eventually power the solenoid with separate battery (insert fuse in power cable). If the valve is not functioning, try new hydraulic valve Y34 of known performance. If the coil resistance is correct and the hydraulic valve is functioning, connect everything and try again.

Error Code

Description

Importance

465

FRONT HYDR. DOWN SOL

Medium

Explanation :

The solenoid of the front hydraulics down valve is open or shorted.

Action :

Refer to wiring diagram : solenoid Y35, line 3860. Disconnect the solenoid Y35 on the stack valve. Check for battery voltage at Y35 while the front hydraulics down valve is activated. If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2009--wt and/or wire 2010--zw. If no open or shorted circuit can be found, try new hydraulic printed circuit of known performance. If battery voltage is measured at the end connector, check coil resistance of the solenoid (a resistance of app. 4 ohm should be measured) or eventually power the solenoid with separate battery (insert fuse in power cable). If the valve is not functioning, try new hydraulic valve Y35 of known performance. If the coil resistance is correct and the hydraulic valve is functioning, connect everything and try again.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

467

HIGH CAP.HYDR.UP SOL

Medium

Explanation :

The solenoid of the high capacity up hydraulic valve is open or shorted.

Action :

Refer to wiring diagram : solenoid Y49, line 10900. If no high capacity hydraulics is installed on the machine, recalibrate the high capacity hydraulics option by means of the PDT or PC calibration program. If high capacity hydraulics is installed, disconnect the solenoid Y49 on the hydraulic. valve. Check for battery voltage at Y49 while the high capacity up hydraulic valve is activated. If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2167--wt and/or wire 017--zw. If no open or shorted circuit can be found, try new hydraulic printed circuit of known performance. If battery voltage is measured at the end connector, check coil resistance of the solenoid (for open or shorted circuit) or eventually power the solenoid with separate battery (insert fuse in power cable). If the valve is not functioning, try new hydraulic valve Y49 of known performance. If the hydraulic valve is functioning, connect everything and try again.

Error Code

Description

Importance

468

HIGH CAP.HYDR.DO SOL

Medium

Explanation :

The solenoid of the high capacity down hydraulic valve is open or shorted.

Action :

Refer to wiring diagram : solenoid Y50, line 10920. If no high capacity hydraulics is installed on the machine, recalibrate the high capacity hydraulics option by means of the PDT or PC calibration program. If high capacity hydraulics is installed, disconnect the solenoid Y50 on the hydraulic valve. Check for battery voltage at Y50 while the high capacity down hydraulic valve is activated. If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2168--wt and/or wire 017--zw. If no open or shorted circuit can be found, try new hydraulic printed circuit of known performance. If battery voltage is measured at the end connector, check coil resistance of the solenoid (for open or shorted circuit) or eventually power the solenoid with separate battery (insert fuse in power cable). If the valve is not functioning, try new hydraulic valve Y50 of known performance. If the hydraulic valve is functioning, connect everything and try again.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

482

FEEDROLL FORW. CLUTCH

Medium

Explanation :

The feed rolls forward electro magnetic clutch is open or shorted.

Action :

Refer to wiring diagram : electric clutch Y41, line 3490.

Disconnect the electric clutch Y41. Check for battery voltage at Y41 while the feed rolls forward output is activated (machine started, cutterhead engaged). If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2023--wt and/or wire 2030--zw. If no open or shorted circuit can be found, try new Adjust-O--Matic printed circuit with known performance. If battery voltage is measured at the end connector, check coil resistance of the electric clutch (a resistance of app. 1--2 ohm should be measured for the Stromag clutch) or eventually power the electric clutch with separate battery (insert fuse in power cable). If the clutch is not functioning, try new electro magnetic clutch Y41 of known performance. If the coil resistance is correct and the electro magnetic is functioning, connect everything and try again.

Error Code

Description

Importance

483

COVER CUTTERH. MOTOR

Medium

Explanation :

Sharpening stone cover electric motor is open or shorted.

Action :

Refer to wiring diagram : electric motor M22, line 5300. Disconnect the electric motor M22. Check for battery voltage at M22 while the cover motor is activated (e.g. open cover for inspection). If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2062--wt and/or wire 2063--gr. If no open or shorted circuit can be found, try new Adjust-O--Matic printed circuit with known performance. If battery voltage is measured at the end connector, check coil resistance of the electric motor (a resistance of app. 0.4--1 ohm should be measured) or eventually power the electric clutch with separate battery (insert fuse in power cable). If the motor is not functioning, try new electric motor M22 of known performance. If the coil resistance is correct and the electric motor is functioning, connect everything and try again.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

484

ACTIVE PAWL SOLENOID

Medium

Explanation :

The active pawl solenoid is open or shorted.

Action :

Refer to wiring diagram : solenoid Y42, line 4020. Disconnect the solenoid Y42. Check for battery voltage at Y42 while the quick stop switch is pressed. If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2025--wt and/or wire 2026--zw. If no open or shorted circuit can be found, try new Adjust-O--Matic printed circuit with known performance. Check also diode V24. If battery voltage is measured at the end connector, power the solenoid clutch with separate battery (insert fuse in power cable). If the solenoid is not functioning, try new solenoid Y42 of known performance. If the solenoid is functioning, connect everything and try again.

Error Code

Description

Importance

485

AOM MOTOR L FAILURE

Medium

Explanation :

The shearbar left--hand adjuster electric motor is open or shorted.

Action :

Refer to wiring diagram : electric motor M24, line 6140. Disconnect the electric motor M24. Check for battery voltage at M24 while the left AOM electric motor is activated (e.g. during full pull). If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2080--wt and/or wire 2081--gr. If no open or shorted circuit can be found, try new Adjust-O--Matic printed circuit with known performance. If battery voltage is measured at the end connector, check coil resistance of the electric motor (a resistance of app. 0.4--1 ohm should be measured) or eventually power the electric clutch with separate battery (insert fuse in power cable). If the motor is not functioning, try new electric motor M24 of known performance. If the coil resistance is correct and the electric motor is functioning, connect everything and try again.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

486

AOM MOTOR R FAILURE

Medium

Explanation :

The shearbar right--hand adjuster electric motor is open or shorted.

Action :

Refer to wiring diagram : electric motor M25, line 6170.

Disconnect the electric motor M25. Check for battery voltage at M25 while the right AOM electric motor is activated (e.g. during full pull). If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2082--wt and/or wire 2083--gr. If no open or shorted circuit can be found, try new Adjust-O--Matic printed circuit with known performance. If battery voltage is measured at the end connector, check coil resistance of the electric motor (a resistance of app. 0.4--1 ohm should be measured) or eventually power the electric clutch with separate battery (insert fuse in power cable). If the motor is not functioning, try new electric motor M25 of known performance. If the coil resistance is correct and the electric motor is functioning, connect everything and try again.

Error Code

Description

Importance

487

SHARP MOTOR FAILURE

Medium

Explanation :

Sharpening stone electric motor is open or shorted.

Action :

Refer to wiring diagram : electric motor M23, line 5410. Disconnect the electric motor M23. Check for battery voltage at M23 while the sharpening stone motor is activated. If no battery voltage can be measured, locate and repair the open or shorted circuit in wire 2064--wt and/or wire 2065--gr. If no open or shorted circuit can be found, try new Adjust-O--Matic printed circuit with known performance. If battery voltage is measured at the end connector, check coil resistance of the electric motor (a resistance of app. 0.4--1 ohm should be measured) or eventually power the electric clutch with separate battery (insert fuse in power cable). If the motor is not functioning, try new electric motor M23 of known performance. If the coil resistance is correct and the electric motor is functioning, connect everything and try again.

Error Code

Description

Importance

488

OUT OF STONE

Medium

Explanation :

The electronic system detected a worn sharpening stone.

Action :

Readjust sharpening stone in holder, if necessary replace sharpening stone and/or readjust magnetic sensor B108.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error Code

Description

Importance

489

CUT.KNIVES WORN DOWN

Medium

Explanation :

The electronic system detected one or more worn knives.

Action :

1. The shearbar has travelled to its rearmost position and needs readjusting. Clean space between shearbar and scraper, and adjust shearbar forward by means of the full pull procedure. Subsequently adjust the cutterhead knives. Or 2. The space between the shearbar and the cutterhead frame is filled with dirt and crop. Move the shearbar away from the cutterhead (full pull) and remove the dirt/crop between shearbar and cutterhead frame.

Error Code

Description

Importance

490

AOM NOISE TOO HIGH

Medium

Explanation :

The electronic system detected a too high AOM noise at the beginning or during the shearbar procedure.

Action :

Reduce or increase the engine speed. If this does not help, search machine for loose parts generating a hammering noise. If problem remains unsolved, check and replace if necessary cutterhead bearings. Refer to wiring diagram : AOM sensors B106 and B50, line 6230. Check for open or shorted circuit in wiring loom to AOM sensors, wires 2058--gn and/or 2059--bl. On machines from season â&#x20AC;&#x2122;99, two AOM sensors are installed in parallel. If problem remains unsolved, try first with new AOM sensor(s) and later with new Adjust-O--Matic printed circuit of known performance.

Error Code

Description

Importance

545

FUEL LEVEL SENS --

Low

Explanation :

Fuel level potentiometer is shorted to ground.

Action :

Refer to wiring diagram : sensor B12, line 7420. Disconnect fuel level sensor and check resistance range of sensor between 3 and 350 Ohm. If not correct, try with new sensor of known performance. If correct, locate and repair shorted circuit to ground in the wire 291--gn. If problem remains unsolved, try with new CPU printed circuit of known performance.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Code

Description

Importance

546

FUEL LEVEL SENS O/+

Low

Explanation :

Fuel level potentiometer disconnected or shorted to external power supply.

Action :

Refer to wiring diagram : sensor B12, line 7420.

Disconnect fuel level sensor and check resistance range of sensor between 3 and 350 Ohm. If not correct, try with new sensor of known performance. If correct, locate and repair open circuit or shorted circuit to 12 Volt in wires 291--gn and/or 292--zw. If problem remains unsolved, try with new CPU printed circuit of known performance.

Error Code

Description

Importance

550

ENGINE TEMP SENS --

Low

Explanation :

Engine coolant temperature sensor shorted to ground

Action :

Refer to wiring diagram : sensor B11, line 7400. Locate and repair shorted circuit to ground in the wire 290--gn. If problem remains unsolved, try first with new engine coolant temperature sensor and later with new CPU printed circuit of known performance.

Error Code

Description

Importance

551

ENGINE TEMP SENS O/+

Low

Explanation :

Engine coolant temperature sensor disconnected or shorted to external power supply.

Action :

Refer to wiring diagram : sensor B11, line 7400. Locate and repair open circuit to shorted circuit to 12 Volt in the wire 290--gn. If problem remains unsolved, try first with new engine coolant temperature sensor and later with new CPU printed circuit of known performance.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

ATTACHMENT HEIGHT CONTROL ERROR MESSAGES The blinking sequence of the red self--diagnostic control light identifies an error report. The blinking sequence always consists of 2 periods separated by a short interval. Then, after a longer interval, the blinking sequence will repeat again. The first period indicates the first digit of the error report, the second period indicates the second digit. Example Error report 23

52002

General Information: After repair, most of the attachment height control error reports must be cleared by switching off the ignition.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Error reports

Code 11

Connector X57 Pin 37 -- (35)

Explanation Open circuit of the power line to the attachment height control module A60 (fuse F17). Or output failure of the attachment height control module A60. Remarks: If the open circuit occurs before the attachment lift solenoid was activated, then error 14 appears. Action Refer to the wiring diagram: line 6980. Check for 12 Volts at X57/29 of the attachment height control module A60. If not correct, locate and repair open circuit at fuse F17 or wiring 1030 rd. If the previous step was correct, replace the attachment height control module A60.

Code 12

Connector X57 Pin 19 -- (35)

Explanation Open circuit of the power line to the attachment height control module A60 (fuse F17). Or output failure of the attachment height control module A60. Remarks: If the open circuit occurs after the attachment lowering solenoid was activated, then error 14 appears. Action Refer to the wiring diagram: line 6980. Check for 12 Volts at X57/29 of the header height control module A60. If not correct, locate and repair open circuit in fuse F17 or wire 1030 rd. If the previous step was correct, replace the header height control module A60.

Code 13

... Pin 35 -- (37) -- (19)

Explanation Shorted circuit of the wires from the attachment height control module A60 to the attachment lift and/ or lowering solenoid. This shorted circuit may blow fuse F17. Remarks: A shorted circuit to the common ground wire will create error 13 and cuts off the power automatically. A shorted circuit to the frame creates no error and will blow up the fuse F17. Action Refer to the wiring diagram: line 7030. Locate and repair the shorted circuit in the wires 226 gr and/or 227 Wt, or at the lowering (Y19) and/ or lift solenoid (Y20).

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

56 Code 14

... Pin 35 -- (37) -- (19) -- (29)

Explanation No current coming back from the attachment lift or lowering solenoids at the attachment height control connector X57/35. This can be due to: -- Open circuit at the solenoid wires -- Solenoid failure. -- No input power at the attachment height control module connector X57/29 (fuse F17). -- Attachment height control module A60 failure. Action Refer to the wiring diagram: line 7030. Locate and repair open circuit in the wires 225 zw, 226 gn, 227 Wt or at the lowering (Y19) and lift solenoid. (Y20). Check for 12 Volts at X57/29 of the attachment height control module A60. If not correct, locate and repair open circuit in fuse F19 or wire 235 Rd. If all previous steps were correct, replace the attachment height control module A60.

Code 15

... Pin 9

Explanation The common power wire to the attachment height control switches is shorted to the ground or to an external 12 Volts power supply. Remark: The Attachment height control switches are simulated by the actuator printed circuit on wires 209 wt, 210 wt, 211 wt and 212 wt. Common power wire: 209 -- wt fast speed wire: 212 -- wt Header down wire: 210 -- wt Header up wire: 211 -- wt Action Refer to the wiring diagram: line 7050. Locate and repair shorted circuit in the wire 209 Wt of the attachment height control switches.

Code 16

... Pin 2 -- 20

Explanation Open or shorted to ground wires of the attachment control selector switch (S35). Remark: The attachment control selector switch S35 is simulated by the actuator printed circuit on wires 214--bl, 221--br, 222--gn. common power wire: 214--bl selector switch wires: 221--br and 222--gn Action Refer to the wiring diagram: line 7160. Locate and repair open circuit or shorted circuit in the wires 214 Bl, 221 Br and/or 222 Gn (together with error 18). Remark: Shorted circuit in wire 221 Br will lock the attachment height control without error messages.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Code 17

... Pin 29

Explanation Battery voltage higher than 18 Volts. Action Check and repair the alternator regulator.

Code 18

... Pin 21

Explanation Incorrect signal from the attachment control selector switch S35 due to open wire or shorted to an unacceptable external power supply. Action Refer to the wiring diagram: line 7160. If error 18 is accompanied of error 16, locate and repair open circuit in wire 222 Gn. If not, locate and repair shorted circuit to 12 Volt at wire 222 -- Gn. Refer to the header lift trouble shooting section for correct voltages at the header control module connector X57/21.

Code 21

... Pin 6

Explanation Incorrect signal from the attachment height sensor R4. Action Refer to the wiring diagram: line 7160. Check attachment height sensor R4 adjustment and recalibrate the attachment height control (Info View Calibration). Locate and repair open circuit in wires 228 Bl or 238 Br. Remark: open circuit in sensor information wire 229 Gn will not create an error report. Or locate and repair shorted circuit to ground in the sensor information wire 229 Gn. Remark: shorted circuit to ground of the wire 238 Br will lock to attachment height control without creating a error report; Each time the sorted circuit is interrupted, both control lights (green and red) will blink to start up the attachment height control. Or replace the header height sensor R4.

Code 22

... Pin 22

Explanation Incorrect signal from the stubble height potentiometer R6. Remark: The stubble height potentiometer R6 Voltage is simulated by the actuator printed circuit on wire 216 gn. Action Refer to the wiring diagram: line 7140. Locate and repair open circuit in wire 216 Gn. Remark: shorted circuit to ground of the wire 216 Gn will not create an error report but will unable the stubble height control.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

58 Code 23

... Pin 8

Explanation Incorrect signal from the attachment lift cylinder oil pressure sensor B13. Action Refer to the wiring diagram: line 7120. Locate and repair open circuit in wires 236 Bl or 238 Br. Remark: open circuit in sensor information wire 229 Gn will not create an error report. Or locate and repair shorted circuit to ground in the sensor information wire 237 Gn. Remark: shorted circuit to ground of the wire 238 Br will lock to attachment height control without creating a error report. Each time the sorted circuit is interrupted, both control lights (greeen and red) will blink to start up the attachment height control. Or replace the oil pressure sensor B13.

Code 24

... Pin 5

Explanation Incorrect signal from the compensation potentiometer R7. Remark: the compensation potentiometer R7 Voltage is simulated by the actuator printed circuit on wire 2176 zw (X57/05). Action Refer to the wiring diagram: line 7130. Locate and repair open circuit in wire 217 Gn. Remark: shorted circuit to ground of the wire 217 Gn will not create an error report but will unable the compensation control.

Code 25

... Pin 3 -- 36

Explanation The attachment fast moving switch was activated before the lift or lowering switch was activated. Remark: The attachment height control switches are simulated by the actuator printed circuit on wires 209 -- wt, 210 --wt, 211 -- wt and 212 -- wt. This means Voltage on wire 212 -- wt arrives before voltage on wire 210 -- wt or 211-- wt at attachment height control module A60. Action Refer to the wiring diagram: line 7090. Locate and repair open circuit in wire 210 Wt or 211 Wt. Or replace the header lift/lowering switches.

Code 33

... Pin 27

Explanation Shorted to ground circuit at the automatic switch S30. Action Refer to the wiring diagram: line 7010. If the error 33 appears after ignition and activating the automatic switch S30, locate and repair shorted circuit to ground in wire 208 Wt (from the header height module A3 connector X57/13).

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Code 35

... Pin 29

Explanation Battery voltage lower than 10 Volts. Action Recharge battery or check alternator and repair if necessary.

Code 36 Explanation Failure of the hydraulic header lift control valve. Electrical components are correct. Action Clean the hydraulic spools or replace the hydraulic control valve.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

CATERPILLAR ERROR MESSAGES

Error Description

CID--FMI Nr

Flash Code

CAN--ID Page 1353

Cylinder 1 Fault

1--11

Word 2 : 8===

Cylinder 2 Fault

2--11

Word 2 : 4===

Cylinder 3 Fault

3--11

Word 2 : 2===

Cylinder 4 Fault

4--11

Word 2 : 1===

Cylinder 5 Fault

5--11

Word 2 : =8==

Cylinder 6 Fault

6--11

Word 2 : =4==

Check Timing Sensor Calibration

22--13

Word 2 : =2==

8 Volt Supply Above Normal

41--03

Word 2 : =1==

8 Volt Supply Below Normal

41--04

Word 2 : ==8=

Invalid Throttle Signal

91--08

Word 2 : ==4=

Throttle Sensor Calibration

91--13

Word 2 : ==2=

Low Fuel Pressure Warning

94--01

Word 2 : ==1=

Fuel Pressure Sensor Open Circuit

94--03

Word 2 : ===8

Fuel Pressure Sensor Short Circuit

94--04

Word 2 : ===4

Low Oil Pressure Warning

100--01

Word 2 : ===2

Oil Pressure Sensor Open Circuit

100--03

Word 2 : ===1

Oil Pressure Sensor Short Circuit

1100--04

Word 3 : 8===

Very Low Oil Pressure

100--11

Word 3 : 4===

Boost Pressure Reading Stuck High

102--00

Word 3 : 2===

Boost Pressure Sensor Open Circuit

102--03

Word 3 : 1===

Boost Pressure Sensor Short Circuit

102--04

Word 3 : =8==

High Inlet Manifold Temperature Warning

105--00

Word 3 : =4==

Inlet Manifold Temp Sensor Open Circuit

105--03

Word 3 : =2==

Inlet Manifold Temp Sensor Short Circuit

105--04

Word 3 : =1==

Very High Inlet Manifold Temperature

105--11

Word 3 : ==8=

Atmospheric Pressure Sensor Open Circ

108--03

Word 3 : ==4=

Atmospheric Pressure Sensor Short Circ

108--04

Word 3 : ==2=

High Coolant Temperature Warning

110--00

Word 3 : ==1=

Coolant Temperature Sensor Open

110--03

Word 3 : ===8

Coolant Temperature Sensor Short

110--04

Word 3 : ===4

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error Description

CID--FMI Nr

Flash Code

CAN--ID Page 1353

Very High Coolant Temperature

110--11

Word 3 : ===2

Low Coolant Level Warning

111--01

Word 3 : ===1

Intermittent Battery

168--02

Word 4 : 8===

High Fuel Temperature Warning

174--00

Word 4 : 4===

Fuel Temperature Sensor Open Circuit

174--03

Word 4 : 2===

Fuel Temperature Sensor Short Circuit

174--04

Word 4 : 1===

Engine Overspeed Warning

190--00

Word 4 : =8==

Loss of Engine RPM Signal

190--02

Word 4 : =4==

5 Volt Supply Above Normal

232--03

Word 4 : =2==

5 Volt Supply Below Normal

232--04

Word 4 : =1==

Incorrect Engine Software

252--11

Word 4 : ==8=

Personality Module Fault

252--12

Word 4 : ==4=

Check Customer or System Parameters

253--02

Word 4 : ==2=

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

LIST OF CAN IDENTIFIERS

Identifier Function Page Number

Comments

1275

Data from metal detector to central box

Magn noise, thresholds, detection

1276

Data from metal detector to central box

Hardw & softw level, peak values,

1277

Data from central box to metal detector

Not used

1278

Data from central box to metal detector

Switch status, fixed thresholds

1279

Not used

1280

Not available for user

Used during PC -- calibrations

1281

Not available for user

Used for supplier testing

1282

Multifunction lever inputs

1283

Dashboard switches inputs

1284

Not used

1285

Not used

1286

AOM panel on dashboard inputs

1287

Armrest module inputs

1288

Ground speed

1289

Engine rpm

1290

Crop processor rpm

1291

Not used

1292

Not used

1293

Cutterhead rpm

1294

Not used

1295

Not used

1296

Not used

1297

Not used

1298

Not used

1299

Not used

1300

Not used

1301

Missed metal detection date

1302

Not available for user

1303

CPU print inputs and outputs

1304

Adjust--o--Matic inputs and outputs

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Identifier Function Page Number

Comments

1305

Total cutterhead and engine hours

1306

Total hectares

1307

Not used

1308

Not used

1309

Not used

1310

Not used

1311

Not used

1312

Not used

1313

Header height, ground press, CP rolls

1314

Dashboard leds

1315

Adjust--o--Matic leds on dashboard

1316

Not used

1317

Header height control leds

1318

Fuel level and engine temperature

1319

Limb home and Adjust--o--Matic

1320

Not available for user

Used for internal communication

1321

Not available for user

Used for internal communication

1322

Not available for user

Used for internal communication

1323

Not available for user

Used for internal communication

1324

Not available for user

Used for internal communication

1325

Not used

1326

Software revisions (node A and S)

1327

Date and time

1328

Not available for user

Used for softw download to EMD

1329

Not available for user

Used for softw download to EMD

1330

Not used

1331

Memorised calibration data in node A

Speed calibrations, serial nr

1332

Memorised calibration data in node B

Speed calibrations, serial nr

1333

Not used

1334

Memorised calibration data in node D

Speed calibrations, serial nr

1335

Not available for user

Used for plant testing

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Identifier Function Page Number

Comments

1336

Not available for user

Used for plant testing

1337

Not available for user

Used for plant testing

1338

Not available for user

Used for plant testing

1339

Memorised calibration data in node A

PC calibrations (auto--voting)

1340

Memorised calibration data in node B

PC calibrations (auto--voting)

1341

Not used

1342

Memorised calibration data in node D

PC calibrations (auto--voting)

1343

Memorised calibration data in node A

PC calibrations (auto--voting)

1344

Memorised calibration data in node B

PC calibrations (auto--voting)

1345

Memorised calibration data in node D

PC calibrations (auto--voting)

1346

Not used

1347

CPU print outputs

1348

CPU print outputs

1349

Adjust--o--Matic outputs

1350

Not used

1351

Not used

1352

Caterpillar engine

1353

Caterpillar engine

Metal detector

Software

Metal detector

1276

Group

1276

CAN ID

Set

In operation

Peak noise level right channel, -- values

Peak noise level right channel, + values

Peak noise level left channel, -- values

Peak noise level left channel, + values

Error code 270

Error code 271

Error code 272

Error code 273

Error code 274

Error code 275

Error code 276

Error code 277

EMD software version : node M

EMD hardware version

Run time test procedure

Not used

Data from Metal detector to Central Box

Data Description

==XX

=1==

=2==

=4==

=8==

===1

===2

===4

===8

==1=

==2=

==4=

==8=

XX==

==XX

XX==

==XX

XX==

word1 word2 word3 word4

Comments

Limits : 00 < XX < 7F

===0 : not set

==0= : not set

See software revisions

=0== : not in operation

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Metal detector

1278

Group

1278

CAN ID

Quick Adapt routine activated

Status

===1

===2

Forage harvester driving forwards Status

===4

Forage harvester driving back- Status wards

=X==

1===

2===

4===

6===

8===

===6

Status

word1 word2 word3 word4

Status

Forage harvester stopped

EMD threshold setting in fixed mode

Adaptive mode selected

Feed rolls forward

Feed rolls reverse

Feed rolls stopped

Cutterhead disengaged

Identifier to Metal detector

Data Description

Comments

===1 : Quick adapt routine started

= 0 when adaptive mode is selected = 0 < X < 8 when fixed mode is selected

0=== : Fixed mode selected

0=== : cutterhead engaged

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 66

Spout

Header

1282

Not used Header height override switch

Header

Feed rolls

Spout

1282

Spout slow left switch

Feed rolls stop switch

Header height override switch

Not used

1282

Header up switch

Spout fast right switch

Spout

1282

Feed rolls reverse switch

Not used

Feed rolls

1282

Feed rolls reverse switch

1282

Feed rolls

1282

Header down switch

Not used

Header

1282

Header down switch

Not pressed

Pressed

Not pressed

Pressed

Not pressed

Pressed

Not pressed

Pressed

Not pressed

Pressed

Not pressed

Pressed

Not pressed

Pressed

Input identifiers from Multifunction Lever

Data Description

1282

Header

1282

Group

1282

CAN ID

===1

===2

===4

===8

==1=

==2=

==4=

==8=

=1==

=2==

=4==

=8==

1===

2===

4===

8===

4===

8===

word1 word2 word3 word4

Comments

When the fast switch is pressed,

Attention : (also for spout right switch)

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Group

Spout

Auto--Pilot

Spout

Quick stop

Feed rolls

Ground speed

CAN ID

1282

Ground speed Potentiometer

Multifunction lever

Feed rolls forward switch

Quick stop switch

Spout slow right switch

Auto--Pilot switch

Spout deflector down switch

Spout deflector up switch

Spout fast left switch

In neutral

Out of neutral

Not pressed

Pressed

Not pressed

Pressed

Not pressed

Pressed

Not pressed

Pressed

Not pressed

Pressed

Not pressed

Pressed

Not pressed

Pressed

Data Description

===1

===2

===4

===8

==1=

==2=

==4=

==8=

=1==

=2==

=4==

=8==

1===

2===

==XX

=1==

=2==

word1 word2 word3 word4

Comments

In neutral XX = 5C +/-- 20 or 48<XX<71 limits : 00 < XX < D0 +/-- 10

(internal structure of the multifunction lever)

also the slow switch is pressed.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 68

AOM

Cutterhead

Power reverse

1283

Switched ON Pressed

Crop processor roll clearance close switch

Switched OFF

Switched ON

Power reverse switch

Cutterhead reversing switch

Adjust--O--Matic main switch

===1

1283

Engaged

Brakes

1283

Parking brake switch

===2

Pressed

Crop processor roll clearance open switch

===8

==1=

1283

Closed

===4

Airco switch in cab

1283

==2=

Not used

1283

==4=

1283

Not used

1283

==8=

Not used

1283

=1==

=2==

=4==

=8==

1===

2===

4===

8===

1===

2===

4===

8===

word1 word2 word3 word4

1283

Not used

1283

Airco

Not used

Insufficient fluid

Brakes fluid level switch (for brake lights)

Brakes

1283

Sufficient press

Brakes pressure switch

Person on seat

Brakes

Seat switch

Pressed

1283

Seat

1283

Spout down switch

Pressed

Not used

Spout

1283

Spout up switch

Input Identifiers from Dashboard Switches

Data Description

1283

Spout

1283

Group

1283

CAN ID

Comments

0=== : switch not pressed ; 1=== : pressed

0=== : switched off

0=== : switched on

0=== : switched off

===0 : switch open ; ===1 : switch closed

===0 : switch not pressed ; ===2 : pressed

==0= : switch open ; ==1= : switch closed

See troubleshooting -- air conditioning

Airco switch is a combination of several switches

=0== : switch open ; =4== : switch closed

=0== : switch open ; =8== : switch closed

0=== : switch open ; 2=== : switch closed

0=== : switch not pressed ; 4=== : pressed

0=== : switch not pressed ; 8=== : pressed

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Auto--Pilot

Lights

Acid plug

Lights

Auto--Pilot

Lights

Harvest functs

Metal detector

High flow

1283

Switched ON

Operating lights switch (spot lights)

1283

Not used

Pressed

High flow

1283

High flow hydraulics close switch

Metal detector

1283

Switched OFF Pressed

Harvest switch

Harvest functs

1283 Metal detector off switch

Not used

Pressed

High flow hydraulics open switch

1283

Pressed

Metal detector on switch

Switched ON

Operating lights switch (spot lights) Harvest switch

Switched OFF

Auto--Pilot main switch

Beacon lights switch

Silage additive applicator main Switched OFF switch

Switched OFF

Auto--Pilot main switch

===1

===2

===4

===8

==1=

==2=

==4=

1283

Switched OFF

Lights

1283

Operating lights switch

==8=

=2==

Silage additive applicator main Switched ON switch

Switched OFF

=4==

Acid plug

Power reverse switch

Switched ON

=8==

1283

Power reverse

1283

Cutterhead reversing switch

Switched OFF

=1==

Cutterhead

1283

Adjust--O--Matic main switch

=1==

=2==

=4==

=8==

1===

2===

4===

8===

word1 word2 word3 word4

Not used

AOM

1283

Data Description

1283

Group

CAN ID

Comments

=0== : not pressed

= road mode ; =0== : switched on

0=== : not pressed

= harvest mode ; 0=== : switched off

===0 : switched ON to operating lights

===0 : switched on

==0= : switched ON to operating lights

==0= : switched on

==0= : switched ON to operating lights

==0= : switched off

=0== : switched on

=0== : switched off

=0== : switched on

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 70

Cutterhead engaging switch

Cutterhead

4WD

Engine

4WD

Cutterhead

Engine

1286

Throttle down switch

Cutterhead engaging switch

Four--wheel drive switch

Throttle up switch

Four--wheel drive switch

Not used

1286

Pressed

Switched ON

Pressed

Switched OFF

Pressed

A--o--m shearbar adjustment switch

AOM

1286

Not used

Pressed

A--o--m sharpening routine (1 min) switch

AOM

1286

Pressed

A--o--m sharpening routine (2 min) switch

AOM

1286

Not used

Pressed

A--o--m sharpening routine (3 min) switch

AOM

1286

2===

Pressed

A--o--m stop sharpening/adjustment switch

AOM

1286

===1

===2

===4

===8

==1=

==2=

==4=

==8=

=1==

=2==

=4==

=8==

1===

4===

Not used

8===

word1 word2 word3 word4

1286

Input Identifiers from AOM on Dashboard

Data Description

Not used

1286

Group

1286

CAN ID

Comments

===0 : not pressed

===0 : switched off

===0 : not pressed

==0= : switched on

=0== : not pressed

0=== : not pressed

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Bosch

1287

1290

Engine

1289

1290

Engine

1289

Ground speed

Bosch

1287

1288

Bosch

1287

Ground speed

Bosch

1287

1288

Bosch

1287

1288

Bosch

1287

Group

1287

CAN ID

Crop processor rpm

Crop Processor RPM Identifier

Calibrated maximum engine speed

Engine rpm

Engine RPM Identifier

Ground speed displayed

Ground speed based on PC calibration

Ground Speed Identifier

Transport mode selected

Compensation mode selected

Stubble height / Ultrasonic mode selected

Stubble height /Ultrasonic not mode selected

Stubble height potentiometer

Ground pressure potentiometer

Identifiers From Armrest Module

Data Description

XXXX

XX==

==XX

XXXX

00==

10==

04==

08==

XXXX

word1 word2 word3 word4

Comments

Rotation per minute -- hexadecimal code

Ground speed in mm/s based on display calibration

Ground speed in mm/s based on PC calibration

Limits : 00 < XX < E5 +/-- 10

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Cutterhead

Airco

1303

Cutterhead

Ground speed

Engine

1303

Engine oil pressure switch

Engine

1303

Insufficient press

Excessive press

Insufficient press

Worn out

Insufficient press

Harvest functs Harvest mode activated

Status

Engine air filter under pressure switch Insufficient press

Hydrostatic / hydraulic oil temp switch Temp too high

Hydrostatic oil pressure switch

Main drive oil pressure switch

Cutterhead gearbox oil temperature Temp switch too high

Not used

1303

Airco high pressure switch

Airco low pressure switch

Brakes worn out

Brakes

1303

Identifiers From CPU Print

Missed metal detection date

Missed Metal Detection Date

Cutterhead rpm

Cutterhead RPM Identifier

Data Description

Not used

1303

Metal detector

1301

1293

Group

1303

1301

1293

CAN ID

==1=

==2=

==4=

==8=

=1==

=2==

=4==

=8==

1===

2===

4===

8===

XXXX

word1 word2 word3 word4

Comments

==0= : switch open ; ==2= : switch closed

==0= : switch open ; ==4= : switch closed

==0= : switch open ; ==8= : switch closed

=0== : switch open ; =1== : switch closed

=0== : switch open ; =2== : switch closed

=0== : switch open ; =4== : switch closed

0=== : switch open ; 1=== : switch closed

0=== : switch open ; 2=== : switch closed

0=== : switch open ; 4=== : switch closed

Hours : Minutes Day Month Year (decimal code)

Rotation per minute -- hexadecimal code

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Engine

Cutterhead

Engine

Spout

1303

Input status

Output status

Status

Output status

Status

Spout rotation end--of--travel sensor Activated

Alternator charging

Cutterhead reverse engaged

Engine quick stop activated

Four--wheel drive engaged

Engine quick stop disabled

Status

Temp too high

Park lights on

Lights

Software

1303

Software version : Node B

Not used

1303

Output status

Engine coolant temperature switch Temp too high Not used

Engine

1303

Engine oil temperature switch

1303

Engine

1303

Harvest functs Right--hand screen door sensor Door closed

4WD

1303

Engine

1303

Latched height Header height latched

Automatic header height control selected Status

1303

Not used

1303

Bosch

Not used

Output status

1303

Main drive clutch engaged

1303

Cutterhead

Not used

1303

Feed rolls reverse engaged

Data Description

Not used

Feed rolls

Group

1303

CAN ID

===1

===2

===4

===8

===1

===2

===4

===8

==1=

==2=

==4=

==8=

=1==

=2==

=4==

=8==

1===

2===

4===

8===

word1 word2 word3 word4

Comments

See software revisions

===0 : lights off ; ===1 : lights on

===0 : Switch open ; ===8 : Switch closed

==0= : switch open ; ==1= : switch closed

==0= : screen door open

==0= : spout not end of course

==0= : alternator not charging

=0== : cutterhead reverse not engaged

=0== : engine emergency stop not activated

=0== : four wheel drive not engaged

Engine started after quick stop

Header latched at calibrated height (Italy)

Bosch automatic resume given

===0 : main drive not engaged

===0 : feed rolls reverse not engaged

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 74

Feed rolls

1304

Adjust--O--Matic mode

AOM

Ground speed

Metal detector

AOM

1304

Input status

Status

Output status

Input status

Status

Measured background noise and measured threshold limit during adjust operation

Metal detector status

Ground speed > 90 % Vmax calibrated by PC

Sharpener stone at home posi- Input status tion

Sharpener stone worn out

Activate Reverse Buzzer

Check AOM sensors request

Continue AOM adjustment request

Not used

1304

Feed rolls forward engaged

Metal detected

Sharpener door closed

Metal detector

AOM

1304

Sharpener door open

1304

AOM

1304

Driving forwards

Not used

Ground speed

1304

Driving backwards

Identifiers From Adjust--O--Matic Print

Data Description

1304

Ground speed

1304

Group

1304

CAN ID

===1

===2

===4

===8

==1=

==2=

==4=

==8=

=1==

=2==

=4==

=8==

1===

2===

4===

8===

XX==

word1 word2 word3 word4

Comments

Normal value : +/-- 60 ; max value for still good operation : AA

===0 : enabled ; ===1 : disabled

===0 : ground speed < 90 % Vmax

===0 : sharpener stone not at home position

===0 : sharpener stone not worn out

==1= : set ; ==0= : not set

==2= : set ; ==0= : not set

==4= : set ; ==0= : not set

==8= : set ; ==0= : not set

=0== : feed rolls forward not engaged

=0== : no metal detected

0=== : sharpener door between open and closed

0=== : not driving

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

AOM

Software

Ground speed

1304

Header

1313

Totals

1313

1306

Totals

1305

1306

Totals

1305

Group

CAN ID

Crop processor distance

Ground pressure

Header height

Identifier Header Height / Pressure / CP Distance

Total ha

Identifier Total HA

Total engine hours

Total cutterhead hours

Identifier Total Hours

Current to hydrostatic pump

Software version : Node D

Last measured knives hit peak value during adjust operation

Data Description

==XX

XXXX

==XX

XXXX

==XX

XXXX

word1 word2 word3 word4

Comments

Limits : 3B < XX < 79

Not used

Limits : 40 < XX < A0 +/-- 10

Total ha in 0,01 -- hexadecimal code. Only visible after 10 sec when engine is started.

Engine hrs in seconds -- hexadecimal code. Only visible after 10 sec when engine is started.

Cutterhead hrs in seconds -- hexadecimal code. Only visible after 10 sec when engine is started.

Limits: 0000 < XXXX < +/--1199 (= +/-- 105 mA)

See software revisions

Always some digits higher than the measured background noise.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Brakes

Ground speed

Engine

1314

Brakes

1314

Harvest functs

1314

Not used

Parking brake led

Harvest/Road mode led

Metal detector led

Metal detector

Main drive clutch oil pressure led

1314

Not used

1314

Not used

1314

Not used

Engine oil pressure led

Engine temperature led

Battery alternator led

Hydrostatic / hydraulic oil temperature led

Brakes led

1314

Cutterhead

Engine

1314

Lights up

Engine air filter under pressure Lights up led

Hydrostatic oil pressure led

Ground speed

1314

Identifiers Dashboard Leds

Data Description

Not used

1314

Group

1314

CAN ID

===1

===2

===4

===8

==1=

==2=

==4=

==8=

=1==

=2==

=4==

=8==

1===

2===

4===

8===

word1 word2 word3 word4

Comments

===0 : extinguished

===0 : extinguished = harvest mode

===0 : extinguished

==0= : extinguished

=0== : extinguished

0=== : extinguished

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Airco

Cutterhead

AOM

Header

1314

AOM

1315

Group

CAN ID

Lights up

A--o--m motor fault led

A--o--m sensor fault led

A--o--m service led

A--o--m OK led

A--o--m shearbar adjustment led

A--o--m sharpening routine 1 min led

A--o--m sharpening routine 2 min led

Lights up

Identifiers Adjust O Matic Leds

Header height indication led bar

Sharpener door led

Cutterhead gearbox oil temperature led

Airco Low pressure led

Airco High pressure led

Data Description

=2==

=4==

=8==

1===

2===

4===

8===

==X=

=8==

1===

2===

4===

XX==

word1 word2 word3 word4

Comments

=0== : extinguished

0=== : extinguished

Red led : 0 09 ; lowest yellow led : 0 05 ; all yellow leds : F F7

=0== : extinguished

0=== : extinguished

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 78

Engine

1318

Header

A--o--m sharpening routine 3 min led

AOM

1315

1317

A--o--m stop sharpening/adjustLights up ment led

AOM

1315

Header

Not used

1315

1317

===1

Not used

1315

1317

===2

Not used

1315

Lights up

Engine coolant temperature sensor

Fuel level sensor

Reference value

Identifiers Analog Sensors (Fuel, Temp)

Green auto--diagnostic indicator led

Red self--diagnostic control led Lights up

Identifiers Header Height Control Leds

Lights up

===4

Not used

1315

XXXX

4===

2===

===8

==1=

==2=

==4=

==8=

=1==

Not used

Lights up

1315

A--o--m rpm fault led

XXXX

word1 word2 word3 word4

Not used

AOM

1315

Data Description

1315

Group

CAN ID

Comments

Limits :

Limits : 0176 < XXXX < 09A6

===0 : extinguished

=0== : extinguished

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Limb Home

AOM

1319

Software

1327

Software

1326

1327

Software

1326

Limb Home

1319

Group

1319

CAN ID

Minutes

Hours

Year of construction

Year

Month

Identifiers Date & Time

Software version : node S ( symbols )

Software version : node A ( functions )

Day

Status

Identifiers From InfoView Monitor

Continue AOM adjustm. during forward drive

Stop AOM adjustment during forward drive

Answer on limb home request

Activate limb home request

Identifiers Limb Home and AOM

Data Description

==XX

XX==

XXXX

==XX

XX==

XXXX

===1

===2

XXXX

word1 word2 word3 word4

Comments

Hexadecimal code

See software revisions

===1 : set ; ===0 : not set

===2 : set ; ===0 : not set

0000 : not answered yet ; 55CC : ’yes’ is answered ; 1111 : ’no’ is answered

53CA : to raise the request ; else 0000

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 80

Calibrations

1331

Calibrations

1332

Calibrations

1334

Calibrations

1332

Calibrations

1331

Group

1331

CAN ID

Serial number

Calibrated maximum current to hydr. pump

Calibrated maximum speed

Calibration Identifiers stored in NODE D

Serial number

Calibrated maximum current to hydr. pump

Calibrated maximum speed

Calibration Identifiers stored in NODE B

Serial number

Calibrated maximum current to hydr. pump

Calibrated maximum speed

Calibration Identifiers stored in NODE A

Data Description

XXXX

word1 word2 word3 word4

Comments

Hexadecimal code

Maximal value : 1199 (= +/-- 105 mA)

mm/s (hexadecimal code)

Hexadecimal code

Maximal value : 1199 (= +/-- 105 mA)

mm/s (hexadecimal code)

Hexadecimal code

Maximal value : 1199 (= +/-- 105 mA)

mm/s (hexadecimal code)

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Calibrations

1342

Calibration Identifiers (2) stored in NODE D

1342

Calibrated latched header height

Calibrated maximum handle position

Calibrated min backward hydrostatic current

Calibrated min forward hydrostatic current

Calibrated values initialised

Calibrated low pressure valve

Calibrated rear hydraulics

Calibrated ground speed constant

Calibration Identifiers (2) stored in NODE B

1340

Calibrations

Calibration Identifiers (2) stored in NODE A

Data Description

1339

Group

1342

CAN ID

2===

4===

8===

=XXX

XXXX XXXX

==XX

XX==

word1 word2 word3 word4

Comments

Hexadecimal code

always 2===

0=== : not calibrated (no) ; 4=== : calibrated (yes)

0=== : not calibrated (no) ; 8=== : calibrated (yes)

Hexadecimal code

Same as page 1342

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Calibrations

1345

Calibrated shearbar gap

Calibrated full engine speed in road mode

Only NA

Calibrated fixed deflector posi- Only NA tion

Calibrated active pal stop system

Calibrated rotary screens

Calibrated high flow hydraulics

Calibrated air conditioning

Calibrated sharpen on the move

Calibrated four--wheel drive

Calibrated low acceleration hydrostatic pump

Calibrated Caterpillar engine

Calibrated stromag clutch on actuator print

Only NA

Calibration Identifiers (3) stored in NODE D

1345 Calibrated rotary screen brushes

Calibration Identifiers (3) stored in NODE B

1344

Calibrations

Calibration Identifiers (3) stored in NODE A

Data Description

1343

Group

1345

CAN ID

===8

===4

===2

===1

==8=

==4=

==2=

==1=

=8==

=4==

=2==

=1==

===X

word1 word2 word3 word4

Comments

Possible values : 2 to 8

===0: not calibrated (no); ===8: calibrated (yes)

===0: not calibrated (no); ===4: calibrated (yes)

===0: not calibrated (no); ===2: calibrated (yes)

===0: not calibrated (no); ===1: calibrated (yes)

==0=: not calibrated (no); ==8=:calibrated (yes)

==0=: not calibrated (no); ==4=:calibrated (yes)

==0=: calibrated (yes); ==2=: not calibrated (no)

==0=: calibrated (yes); ==1=: not calibrated (no)

=0==: not calibrated (no); =8==:calibrated (yes)

=0==: not calibrated (no); =4==:calibrated (yes)

=0==: not calibrated (no); =2==:calibrated (yes)

=0==: not calibrated (no); =1==:calibrated (yes)

Same as page 1345

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Spout

Engine

Rotary Screens

Header

Auto--Pilot

Engine

Header

1347

Group

1347

CAN ID

Output status

Bosch ground pressure pot simulation

Bosch stubble height pot simulation

Output status

Bosch transport mode off switch Output status simulation

Bosch header up switch simulation

Bosch stubble height mode switch simulation

Bosch ground press mode switch simulation

Bosch automatic resume switch simulation

Engine stop solenoid -- hold

Auto--Pilot resume switch simulation

Bosch header up/down fast switch simulation

Bosch header down switch simulation

Rotary screens

Open crop processor

Close crop processor

Engine speed up

Engine speed down

Spout deflector down

Spout deflector up

Output Identifiers from CPU print

Data Description

===1

===2

==1=

==2=

=2==

=8==

===1

===2

==1=

==2=

==4=

=1==

=2==

=8==

2===

4===

==XX

XX==

word1 word2 word3 word4

Comments

Limits : OA < XX < E5 +/-- 10

===1 : activated ; ===0 : not activated

===2 : activated ; ===0 : not activated

==1= : activated ; ==0= : not activated

==2= : activated ; ==0= : not activated

==4= : activated ; ==0= : not activated

=1== : activated ; =0== : not activated

=2== : activated ; =0== : not activated

=8== : activated ; =0== : not activated

2=== : activated ; 0=== : not activated

4=== : activated ; 0=== : not activated

===1 : activated ; ===0 : not activated

===2 : activated ; ===0 : not activated

==1= : activated ; ==0= : not activated

==2= : activated ; ==0= : not activated

=2== : activated ; =0== : not activated

=8== : activated ; =0== : not activated

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 84

Operating lights

Lights

1348

Rear drive buzzer

Lights

Auto--Pilot

Airco

Acid plug

1348

1348 Not used Not used

1348

Power to silage additive applicator

Airco compressor clutch

Power to Auto--Pilot

Beacon lights

Brake lights

Not used

1348

Spout light

Spots lights

Not used

Work lights (rear)

1348

Lights

1348

Output status

Work lights (operating and spot Output status lights)

Not used

Lights

1348

Work lights (operating lights)

Output Identifiers from CPU print

Data Description

1348

Lights

1348

Group

1348

CAN ID

===1

===2

===4

===8

==1=

==2=

==4=

==8=

=1==

=2==

=4==

=8==

1===

2===

4===

8===

word1 word2 word3 word4

Comments

===2 : activated ; ===0 : not activated

===4 : activated ; ===0 : not activated

===8 : activated ; ===0 : not activated

==1= : activated ; ==0= : not activated

==2= : activated ; ==0= : not activated

==4= : activated ; ==0= : not activated

=1== : activated ; =0== : not activated

=2== : activated ; =0== : not activated

=4== : activated ; =0== : not activated

2=== : activated ; 0=== : not activated

4=== : activated ; 0=== : not activated

8=== : activated ; 0=== : not activated

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Spout

1348

Feed rolls reverse engaged

Feed rolls

Cutterhead

Spout

4WD

1348

Front hydraulics up

Front Hydr

Spout

1348

Spout rotation L & R pwm

Not used

Front hydraulics down

1348

Not used

Four--wheel drive engaged

Spout down

Spout up

Cutterhead reverse engaged

1348

Front Hydr

Not used

1348

Main drive belt not tensioned

Not used

1348

Spout rotation Right

Spout rotation Left

Spout

1348

Rear hydraulics down

Not used

Rear Hydr

1348

Rear hydraulics up

1348

Rear Hydr

1348

Main drive clutch engaged

Not used

Cutterhead

1348

Output status

Data Description

1348

Group

CAN ID

===1

===2

===4

===8

==1=

==2=

==4=

==8=

=1==

=2==

=4==

=8==

1===

2===

4===

==XX

=1==

=2==

=4==

=8==

word1 word2 word3 word4

Comments

Hexadecimal code

=1== : activated ; =0== : not activated

=4== : activated ; =0== : not activated

===1 : engaged ; ===0 : not engaged

===2 : activated ; ===0 : not activated

===4 : activated ; ===0 : not activated

===8 : engaged ; ===0 : not engaged

==1= : not tensioned ; ==0= : tensioned

==2= : engaged ; ==0= : not engaged

=1== : activated ; =0== : not activated

=2== : activated ; =0== : not activated

1=== : activated ; 0=== : not activated

2=== : activated ; 0=== : not activated

4=== : engaged ; 0=== : not engaged

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 86

CAT Engine

1352

AOM

1349

CAT Engine

AOM

1349

1352

AOM

1349

CAT Engine

AOM

1349

1352

AOM

1349

CAT Engine

AOM

1349

1352

AOM

1349

CAT Engine

AOM

1349

1352

AOM

1349

1352

AOM

1349

Group

1349

CAN ID

Output status

Status

Calibrated maximum engine rpm

Engine oil pressure

Inlet manifold pressure

Status

Load percentage at current en- Status gine speed

Inlet air temperature

Fuel temperature

Coolant temperature

CATERPILLAR Engine Information

Sharpen routine engaged

Active stop pawl system

Right AOM electric motor to knives

Right AOM electric motor forward

Left AOM electric motor to knives

Left AOM electric motor forward

Sharpener door close

Sharpener door open

Ticker solenoid activated

Chopper body not fitted

Output Identifiers from AOM print

Data Description

==XX

XX==

===1

===2

===4

===8

==1=

==2=

==4=

==8=

=1==

=2==

==XX

XX==

==XX

XX==

XXXX

word1 word2 word3 word4

Comments

Range : 0 to 8031.875 rpm (0.125 rpm/bit)

Range : 0kPa to +1000kPa (4kPa/bit)

Range : 0kPa to +500 kPa (2kPa/bit)

Range : 0% to 125% (1%/bit)

Range : --40°C to +210°C (1C/bit)

===1 : activated ; ===0 : not activated

===2 : activated ; ===0 : not activated

===4 : activated ; ===0 : not activated

===8 : activated ; ===0 : not activated

==1= : activated ; ==0= : not activated

==2= : activated ; ==0= : not activated

==4= : activated ; ==0= : not activated

==8= : activated ; ==0= : not activated

not longer used

=2== : not fitted ; =0== : fitted

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

CAT Engine

1353

Group

1353

CAN ID

Error codes report

Engine rpm Status

Status

CATERPILLAR Engine Information

Data Description

XXXX XXXX

XXXX

word1 word2 word3 word4

Comments

See detailed list

Range : 0 to 8031.875 rpm (0.125 rpm/bit)

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 DETAILED ANALYSIS PER FUNCTION

Function

Operators manual section

1. Electric conditions, engine running or not running

4.1//6.7

2. Engine quick stop system

2.4

3. Harvest mode

2.3

4. Engine acceleration

2.3

5. Cutterhead engagement

2.3/4.2

6. Feed rolls forward engagement

2.3/4.2

7. Feed rolls reverse engagement

2.3/4.2

8. Power reverse

4.3.2

9. Four--wheel drive

4.12.2

10. Spout rotation

4.11

11. Raise/lower spout

4.11

12. Spout deflector

4.11

13. Reverse cutterhead

5.5

14. Auxiliary front hydraulics

4.15

15. Auxiliary rear hydraulics

4.15

16. Air conditioning

4.13

17. Silage additives application

4.10

18. Knife sharpening

2.5//4.7.1//5.5.3//6.2

19. Adjust --O-- Matic routine

2.5//4.7.2//5.5.4//6.3

20. Crop processor

5.6.1

21. Metal detector operation and trouble shooting

4.5//5.3//6.6

22. Attachment Height Control

4.3//5.23.1

23. Ground speed

6.5

24. High flow Hydraulics

2.3//4.15

25. Rotary Screens

5.19

26. Rotary Screen Brushes

5.19

27. Caterpillar engine 28. CAN netwerk

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

1. ELECTRIC CONDITIONS, ENGINE RUNNING OR NOT RUNNING

Conditions for “engine is not running” 1. Insufficient charge of the alternator and

Reason The system must know if the engine is running or not. A lot of functions can only be activated when the engine is physically running.

Indication

Insufficient engine oil pressure and No information from engine rpm sensor or 2. Insufficient charge of the alternator and

An indication for the engine running or not running are the rotary screens. As soon as one of the three conditions for “engine is running” is valid, also the rotary screens will rotate. Or, if the rotary screens rotate (engine running or not), this means that for the electronics the engine is started.

Conditions for “engine is running” 1. Indication that the alternator is charging or 2. Sufficient engine oil pressure and sufficient hydrostatic oil pressure or 3. Information from engine rpm sensor

Insufficient hydrostatic oil pressure and No information from engine rpm sensor

REMARK: If the engine is running, but there is no rotary screen rotation, possible consequences are: • No engagement of the cutterhead and feed rolls. • No pawl stop system. • Engine rpm not displayed on the screen. • Engine oil pressure led, battery alternator led and hydrostatic oil pressure led remain illuminated.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Can Spy CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

1303 Alternator charging

Input status

1303 Engine oil pressure switch

Insufficient press

=4==

=0==: Switch open; =4==: Switch closed

1303 Hydrostatic oil pressure switch

Insufficient press

==8=

==0=: Switch open; ==8=: Switch closed

XXXX

Rotation per minute -Hexadecimal code

1289 Engine rpm

Error messages

Error Code

Key words

125

Engine rpm sensor O

126

Engine rpm sensor --

127

Engine rpm sensor +

360

No engine oil press.

361

Oil press sens fault

362

No hydrost. pressure

363

Hydrost. sensor fault

Electrical diagrams Group 1: Alternator loading Group 9: Engine protection Group 8: Engine speed sensor

==8=

COMMENTS ==0=: Alternator not charging

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

2. ENGINE QUICK--STOP SYSTEM Engine oil pressure switch

Engine oil temperature switch

Engine oil pressure Led

Engine oil temperature Led

When: or or or

Engine coolant temperature switch

Hydrostatic oil pressure Led

Hydrostatic oil pressure switch

Engine quick-stop procedure activated

Engine stop solenoid Y23

Engine oil pressure < 1.3 bar Engine oil temperature > 126°C Engine coolant temperature > 110°C Hydrostatic oil pressure < 5 bar

the “engine quick--stop status” becomes high, the corresponding led starts to blink and the buzzer will sound. When the feed rolls are engaged, they will be disengaged immediately. 5 seconds later, the main drive clutch will be disengaged and the engine speed will drop, giving the cutterhead and the blower time to clear. After 10 seconds, the engine will stop automatically.

problems occurs

Led starts to blink, alarm sounds and feed rolls disengage

5 sec

10 secs

Main drive disengaged Engine speed to low idle

Engine stops automatically

To restart, start the engine twice without switching off the ignition.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 REMARK: 1. When a problem occurs and it only lasts for 5 seconds, work can be continued. However, the system will keep these 5 seconds in memory. When later on the problem starts again, the system will stop the engine after 5 seconds. 2. When a pressure sensor has an open circuit, an indication of the problem is shown on the dashboard when switching on the ignition (the corre-

sponding led will start to flash). Once the engine is started, everything will function normally. 3. When a temperature sensor has a shorted circuit, an indication of the problem is shown on the dashboard when switching on the ignition. Once the engine is started, the quick--stop system is activated and the engine will stop after 15 seconds.

Can Spy CAN ID

DATA DESCRIPTION

1303 Engine oil pressure switch

Insufficient press

word1 word2 word3 word4 =4==

COMMENTS =0==: Switch open; =4==: Switch closed

1303 Engine oil temperature Temp. too high switch

==1=

==0=: Switch open; ==1=: Switch closed

1303 Engine coolant temperature switch

Temp. too high

===8

===0: Switch open; ===8: Switch closed

1303 Hydrostatic oil pressure switch

Insufficient press

==8=

==0=: Switch open; ==8=: Switch closed

1314 Engine oil pressure led Lights up

=1==

=0==: Extinguished

1314 Engine temperature led

Lights up

=2==

=0==: Extinguished

1314 Hydrostatic / hydraulic oil temperature led

Lights up

=8==

=0==: Extinguished

1303 Engine quick--stop activated

Status

=2==

=0==: Engine quick--stop not activated

1303 Engine quick--stop dis- Status abled

=8==

Engine started after engine quick--stop

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

94 Error messages

Error Code

Key words

360

No engine oil press.

361

Oil press sens fault

362

No hydrost. pressure

363

Hydrost. sensor fault

Electrical diagrams Group 9 : Engine quick--stop system

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

3. HARVEST MODE

Harvest switch

Quick--stop switch

Right--hand screen door sensor

Harvest Mode activate (Status)

Harvest/ Road Mode Led

Ground speed sensor

When switching on the contact, the machine is always in Road Mode.

For switching to Harvest mode, four conditions must be met: 1.

The quick--stop switch may not be pressed

and

The right--hand screen door must be closed

and

The ground speed must be slower than 90% of the calibrated maximum ground speed

and

The Harvest switch must be switched into Harvest Mode after previous conditions are done.

When all these conditions are met, the Harvest/Road Mode led on the dashboard is not longer illuminated.

The machine switches immediately into ROAD Mode (with ignition on) when: 1.

The Harvest switch is switched into ROAD mode

The quick--stop switch is pressed

The ground speed has reached 90% of the calibrated maximum ground speed

The right--hand screen door has been opened.

The Harvest/Road mode led illuminates again.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

The Harvest tumbler switch must be switched to its HARVEST position in order to be able to harvest. When switched to ROAD position, the following functions will not be operational: •

Spout rotation

•

Spout height control

•

Auto--Pilot (accessory)

•

Adjust--O--MaticTM shearbar adjustment and knife sharpening

•

Cutterhead engagement and, therefore, feed roll and attachment engagement

•

4--wheel drive (optional)

•

Metal detector

•

Auxiliary hydraulics

•

Silage applicator

Can Spy CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

COMMENTS

1283 Harvest switch

Switched ON

8===

= Harvest Mode, 0===: Switched off

1283 Harvest switch

Switched OFF

=8==

= Road Mode, =0==: Switched on

1282 Quick--stop switch

Pressed

===8

1282 Quick--stop switch

Not pressed

===4

1303 Right--hand screen door sensor

Door closed

==2=

==0=: Screen door open

1288 Ground speed based on PC calibration

XXXX

Ground speed in mm/s based on PC calibration

1304 Ground speed > 90% Status Vmax calibrated by PC

===2

===0: Ground speed < 90% V max

1303 Harvest mode activated

Status

==1=

==0=: Road Mode

1314 Harvest/Road mode led

Lights up

===2

==0=: Extinguished = Harvest Mode

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

98 Error messages

Error Code

Key words

302

Dashboard switch 2 (Harvest switch)

340

Handle switch 4 (quick--stop switch)

220

Engine door sensor O

221

Engine door sensor --

222

Engine door sensor +

120

Ground speed sens. O

121

Ground speed sens. --

122

Ground speed sens. +

Electrical diagrams Group 8: Ground speed sensor (B16) Group10: Engine door sensor (B102)

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

100

4. ENGINE ACCELERATION Harvest Mode

Throttle control up switch

See group 3

Engine RPM sensor

Throttle control down switch

Full engine speed in Road Mode (NA) (PC Calibration)

Engine Throttle Control Manual or Automatic (PC Calibration)

Throttle actuator

A selection between Manual and Automatic Engine throttle control is available by means of a PC/PDT calibration. When Manual Throttle control is selected, the engine speed will rise or lower as long as the engine throttle switch is pressed. Once the engine speed reaches 1850 rpm in Harvest mode, the engine speed will automatically rise to full engine speed. When Automatic Throttle Control is selected, the engine speed rises automatically to 1750 rpm (1650 rpm for Caterpillar engines) in ROAD Mode and 270 rpm in Harvest Mode with one single pulse on the engine speed up bottom. Pushing once on the engine speed down button, the engine speed will automatically drop to low idle. As intermediate engine speed can be selected by giving a counter pulse on the engine speed button.

Scheme European machines

Switch Harvest switch into Road Mode

Switch Harvest switch into Harvest Mode

900 rpm IVECO 850 rpm CAT "

Throttle up engine speed Throttle down engine speed

Low Idle

Throttle up engine speed Throttle down engine speed

B 1750 rpm IVECO 1650 rpm CAT

B Full engine speed (2100 rpm IVECO, CAT)

Switch Harvest switch into Road Mode " Switch Harvest switch into Harvest Mode and throttle up engine speed

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

101

North American machines Answer Y (yes) to the question: “Do you want full engine speed in Road mode? (y, n)” during PC calibration (for NA only)

Full engine speed (2100 rpm) Y Throttle up engine speed

Throttle down engine speed B Low idle

REMARK: In case engine speed is higher than low idle speed, the engine speed automatically drops to low idle in the following cases: 1. Driver leaves seat (seat switch) 2. The cutterhead is engaged 3. The cutterhead is reversed 4. The A.O.M. shearbar adjustment is started The engine speed can only be increased 5 seconds after starting the engine.

Can Spy CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

COMMENTS

1303 Harvest mode activated

Status

==1=

==0=: Road Mode

1286 Throttle up switch

Pressed

===8

===0: Not pressed

1286 Throttle down switch

Pressed

===1

===0: Not pressed

XXXX

Rotation per minute -Hexadecimal code

1289 Engine rpm 1347 Engine speed down

Output status

==2=

==2=: Activated; ==0=: Not activated

1347 Engine speed up

Output status

==1=

==1=: Activated; ==0=: Not activated

1345 Calibrated full engine speed in road mode

NA only

===8

===0: not calibrated (no) ==8=: calibrated (yes)

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

102 Error messages

Error Code

Key words

316

Dashboard switch 16 (Throttle switch)

340

Handle switch 4 (quick--stop switch)

125

Engine rpm sensor O

126

Engine rpm sensor --

127

Engine rpm sensor +

Electrical diagrams Group 2: Throttle actuator Group 10: Engine rpm sensor and seat switch

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

103

104

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

5. CUTTERHEAD ENGAGEMENT

Harvest Mode See group 3

Cutterhead engaging switch

Engine RPM sensor

Cutterhead RPM sensor

Chopper body not present

Attachment height override switch

Low pressure Main drive valve installed clutch oil (PC--Calibration) pressure switch Main drive belt tensioned

Main drive clutch engaged

Main drive clutch oil pressure led

Road mode

Harvest mode

Cutterhead engaged

Y40 (Main drive clutch neutral position valve)

12V

Y44 (Main drive belt + Main drive clutch)

12V

Main drive belt

Not tensioned

See electrical diagrams

To engage the cutterhead: 1. Switch ON the ignition and start the engine. 2. Switch ON the Harvest switch. 3. Switch ON the cutterhead switch. 4. REVERSE the feed rolls.

Tensioned

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 REMARK: 1. All European machines (from Series 02 onwards) and North American machines have a low pressure valve installed. Only European preseries machines (Series 01) do not have a low pressure valve installed. Wrong calibration causes no cutterhead engagement. 2. To engage the cutterhead, the system must know whether the engine is running. (See Group 1 -- Electronic conditions: Engine Running/Not Running). 3. The cutterhead can be engaged only 5 sec after starting the engine. 4. After cutterhead engagement, the engine rpm will drop automatically to low idle. The engine speed must be throttled up again. 5. When the direction of rotation of the cutterhead is changed while the cutterhead is running (from forward to reverse, or vice versa), the drive will be disengaged first and the machine will wait until the cutterhead speed has dropped to less than 10 rpm. If you try to engage in the other direction of rotation, the user message “CUTTERHEAD RPM IS STILL > 10” will appear on the InfoView monitor display. As soon as the cutterhead has stopped, the next user message “REENGAGE CUTTERHEAD” is displayed. Only then the cutterhead can be reengaged in the other direction of rotation. Switch the respect-

105

ive cutterhead engagement switch OFF and ON again. 6. In case the cutterhead speed sensor has failed, and you want to engage the cutterhead in the opposite direction, the system is not able to check whether the cutterhead speed has actually dropped or not. In order to prevent damage to mechanical or hydraulic components, a 100 seconds count--down is started as soon as the cutterhead is disengaged. The following message appears on the screen: “WAIT UNTIL ENGAGE TIMER = 100”. When 0 has been reached, the cutterhead drive can be switched ON. The message “Reengage cutterhead” will appear. 7. Once the oil pressure switch on the low pressure valve has detected a pressure lower than 24 bar, the led on the instrument panel will flash. This is only when the engine is running at full speed to avoid slipping of the main drive belt. 8. When the chopper body is not present, it is no longer possible to engage the cutterhead in forward or reverse in the normal way. For test reasons, the output shaft can be engaged (forward direction) by simultaneously pressing the attachment height override switch and the cutterhead engagement switch.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

106 Can Spy CAN ID

DATA DESCRIPTION

1303 Harvest mode activated

Status

1342 Calibrated low pressure valve

word1 word2 word3 word4

COMMENTS

==1=

==0=: Road Mode

4===

0===: Not calibrated (no) 4===: Calibrated (yes)

1286 Cutterhead engaging switch

Switched ON

===2

===0: Switched off

1286 Cutterhead engaging switch

Switched OFF

==2=

==0=: Switched on

1289 Engine rpm

XXXX

Rotation per minute -Hexadecimal code

1293 Cutterhead rpm

XXXX

Rotation per minute -Hexadecimal code

===1

===0: Main drive not engaged

1303 Main drive clutch engaged

Output status

1348 Main drive belt tensioned

Output status

==1=

==1=: Not tensioned; ==0=: Tensioned

1348 Main drive clutch engaged

Output status

4===

4===: Engaged; 0===: Not engaged

1303 Main drive oil pressure Insufficient press switch

=1==

=0==: Switch open; =1==: Switch closed

1314 Main drive clutch oil pressure led

Lights up

==1=

==0=: Extinguished

1349 Chopper body not present

Statuts

=2==

=2==: Not present; =0==: Present

1282 Attachment height override switch

Pressed

===8

1282 Attachment height override switch

Not pressed

===4

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 Error messages

Error Code

Key words

314

Dashboard switch 14 (Cutterhead engagement switch)

342

Handle switch 6 (Attachment height override switch)

125

Engine rpm sensor O

126

Engine rpm sensor --

127

Engine rpm sensor +

130

Cutterhead sensor O

131

Cutterhead sensor --

132

Cutterhead sensor +

457

Main drive hydr. sol.

462

Main clutch idler

Electrical diagrams Group 8 Engine and cutterhead rpm (BE3 & B101) Main drive clutch oil pressure switch (B100) Group 10 Main drive clutch and belt solenoid (Y40 & Y44)

107

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

108

6. FEED ROLLS FORWARD ENGAGEMENT Harvest Mode See group 3

Cutterhead engaged See group 5

Feed rolls forward switch

Feed rolls stop switch

Feed rolls forward engaged

Seat switch

Pawl stop system

To engage the feed rolls forward drive: 1. Switch ON ignition and start the engine. 2. Switch ON the Harvest switch. 3. Engage the cutterhead. 4. Engage the feed rolls forward drive by pressing twice the upper side of the feedroll drive button. The feed rolls will stop automatically in the following cases: 1. The feed rolls stop button is pressed (lower side of feedroll drive button). 2. The seat switch is opened for at least 5 seconds. 3. The cutterhead is disengaged (see Cutterhead Engagement). 4. The Harvest mode is no longer active (see Harvest Mode). 5. When a metal detection takes place.

REMARK: 1. When pressing the quick--stop button, the electromagnetic clutch is no longer activated. The pawl stop system will be powered so that crop feeding is stopped immediately. 2. When the classical output line of the metal detector is open, it is not longer possible to engage the feedrolls forward (see group 21).

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

109

Can Spy CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

COMMENTS

1303 Harvest mode activated

Status

==1=

==0=: Road Mode

1303 Main drive clutch engaged

Output status

===1

===0: Main drive not engaged

1282 Feed rolls forward switch

Pressed

===2

1282 Feed rolls forward switch

Not pressed

===1

1282 Feed rolls stop switch

Pressed

===2

1282 Feed rolls stop switch

Not pressed

===1

1383 Seat switch

Person on seat

2===

0===: Switch opne; 2===: Switch closed

1304 Feed rolls forward engaged

Output status

=2==

=0==: Feed rolls forward not engaged

Error messages

Error Code

Key words

330

Handle switch 1 ^ (Feed rolls forward switch)

331

Handle switch 1 v (Feed rolls stop switch)

482

Feedroll forw. clutch

Electrical diagrams Group 10 Electromagnetic clutch for feed rolls forward drive (Y41) Seat switch (S83)

110

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

7. FEED ROLLS REVERSE ENGAGEMENT Feed rolls reverse switch

Harvest Mode See group 3

Stromag feed rolls engagement clutch (or calibration)

Feed rolls reverse engaged

To reverse the feed rolls: 1. Switch ON ignition and start the engine. 2. Switch ON the Harvest switch. 3. Reverse the feed rolls drive: Press and hold the feed rolls reverse key. The feed rolls will stop in the following cases: 1. When releasing the feed rolls reverse key. 2. When disengaging the cutterhead (see Cutterhead engagement). 3. When the Harvest mode is no longer active (see Harvest mode).

REMARK: 1. When the feed rolls rotate forward, first press the feed rolls stop switch. 2. It is not necessary to switch on the cutterhead in order to power the feedroll clutch. 3. With the introduction of a new actuator printed circuit, which from Sâ&#x20AC;&#x2122;99 onwards is responsible for the reverse engagement of the Stromag electro-magnetic clutch, a new calibration feature is introduced.

NOTE: Previously the reverse clutch activation was controlled by the valve printed circuit. With the new software both outputs on the actuator and the valve printed circuits are activated. The PC-calibration suppresses the error report from the valve printed circuit (series 5083 onwards) or suppresses the error report from the actuator printed circuit on machines before series 5083.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

111

Can Spy CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

1303 Harvest mode activated

Status

==1=

1282 Feed rolls reverse switch

Pressed

2===

1282 Feed rolls reverse switch

Not pressed

1===

1303 Feed rolls reverse engaged

Output status

===8

Error messages

Error Code

Key words

343

Handle switch 1 v v (Feed rolls reverse switch)

463

Feed roll reverse

Electrical diagrams Group 10: Electromagnetic clutch for feed rolls reverse drive (Y43)

COMMENTS ==0=: Road Mode

=0==: Feed rolls reverse not engaged

112

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

8. POWER REVERSE

Harvest Mode See group 3

Front Hydraulics UP

Feed rolls forward switch

Feed rolls reverse switch

Power Reverse switch

Front Hydraulics DOWN

When the Power Reverse is installed: â&#x20AC;˘ The pick--up windguard can be lifted hydraulically. â&#x20AC;˘ The eccentric position of the retractable pick--up fingers can be inversed hydraulically. The windguard flips up when the feed rolls are reversed. It will only flip down again when the feed rolls are reengaged. Operation 1. Switch ON ignition and start the engine. 2. Switch ON the Harvest switch. 3. Switch ON the Power Reverse switch. Front hydraulics Up is activated (12 V to electrovalve Y34) during 5 seconds when the feed rolls reverse switch is pressed. Front hydraulics Down is activated (12 V to electrovalve Y35) during 5 seconds when the feed rolls are reengaged.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

113

Can Spy CAN ID

DATA DESCRIPTION

word1 word2 word3 word4 ==1=

COMMENTS

1303 Harvest mode activated

Status

==0=: Road Mode

1283 Power Reverse switch

Switched ON

2===

0===: Switched off

1283 Power Reverse switch

Switched OFF

=2==

0===: Switched on

1282 Feed rolls forward switch

Pressed

===2

1282 Feed rolls forward switch

Not pressed

===1

1282 Feed rolls reverse switch

Pressed

2===

1282 Feed rolls reverse switch

Not pressed

1===

1348 Front hydraulics up

Output status

=1==

=1==: Activated; =0==: Not activated

1348 Front hydraulics down

Output status

=4==

=4==: Activated; =0==: Not activated

Error messages

Error Code

Key words

309

Dashboard switch 9 (Power Reverse switch)

330

Handle switch 1 ^ (Feed rolls forward switch)

343

Handle switch 1 v v (Feed rolls reverse switch)

464

Front hydr. up sol.

465

Front hydr. down sol.

Electrical diagrams Group 10: Auxiliary front hydraulics electrovalves Y34 & Y35.

114

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

9. FOUR--WHEEL DRIVE Harvest Mode See group 3

Four--wheel drive switch

Four--wheel drive calibrated (PC--Calibration)

Four--wheel drive engaged

To engage the four--wheel drive: 1. Switch ON ignition and start the engine. 2. Switch ON the Harvest switch. 3. Switch ON the four--wheel drive switch.

The four--wheel drive will be disengaged when: 1. The four--wheel drive switch is switched OFF. 2. The Harvest mode is no longer active (see Harvest mode)

REMARK: From Series 10 on (Series 02 North--America), 2WD machines are delivered without 4WD engaging solenoid on the low pressure valve. An additional calibration has to be carried out to avoid error messages. Refer to the PC calibration instructions.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

115

Can Spy CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

COMMENTS

1303 Harvest mode activated

Status

==1=

==0=: Road Mode

1286 Four--wheel drive switch

Switched OFF

==1=

==0=: Switched on

1286 Four--wheel drive switch

Switched ON

===4

===0: Switched off

==1=

==0=: Calibration (yes); ==1=: Not calibrated (no)

1345 Calibrated four--wheel drive 1303 Four--wheel drive engaged

Output status

Error messages

Error Code

Key words

315

Dashboard switch 15 (4WD switch)

458

4 wheel drive solen

Electrical diagrams Group 4: Four--wheel drive.

=4==

=0==: Four--wheel drive not engaged

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

116

10. SPOUT ROTATION Harvest Mode See group 3

Spout fast right switch

Spout rotation Right engaged

Spout slow right switch

Spout fast left switch

Spout slow left switch

Spout rotation end--of travel sensor

Spout rotation Left engaged

To rotate the spout: 1. Switch ON ignition and start the engine. 2. Switch ON the Harvest switch. 3. Rotate the spout using the spout operating switch.

REMARKS: 1. Depending on the selection in the InfoView monitor calibration (Type), it is possible to activate the spout deflector and the spout rotation at the same time. 2. The spout rotation speed depends on the value calibrated in the InfoView monitor (Type). Values are 80 minimum to 245 maximum. A good average slow speed is 150. When no slow speed can be obtained with an average calibrated value of 150 -- 160, check both diodes installed parallel to the spout rotation outputs. These two diodes are mounted on the new value printed circuit board (84068781). 3. Once the spout has reached its end--of--travel sensor (B103), the electrovalves Y32 or Y33 are no longer powered, and the rotation will stop. Release the rotation switch. It is possible to continue the rotation to the mechanical stop by pressing the released switch again.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

117

Can Spy CAN ID

DATA DESCRIPTION

1303 Harvest mode activated

Status

word1 word2 word3 word4 ==1=

1282 Spout slow right switch Pressed

COMMENTS ==0=: Road Mode

==2=

1282 Spout slow right switch Not pressed

==1=

1282 Spout fast right switch

Pressed

=2==

1282 Spout fast right switch

Not pressed

=1==

1282 Spout slow left switch

Pressed

8===

1282 Spout slow left switch

Not pressed

4===

1282 Spout fast left switch

Pressed

2===

1282 Spout fast left switch

Not pressed

1===

1303 Spout rotation end of travel sensor

Activated

==4=

==0=: Spout not end--of-travel

1348 Spout rotation left

Output status

=2==

=2==: Activated; =0==: Not activated

1348 Spout rotation right

Output status

=1==

=1==: Activated; =0==: Not activated

Error messages

Error Code

Key words

332

Handle switch 2 <

333

Handle switch 2 >

336

Handle switch 2 < <

337

Handle switch 2 > >

453

Spout right hydr. sol.

454

Spout left hydr. sol.

Electrical diagrams Group 13: Spout control.

Attention (also for spout left switch): When the fast switch is pressed, also the slow switch is pressed (internal structure of the MF Lever).

118

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

11. RAISE/LOWER SPOUT Harvest Mode See group 3

Spout Up switch

Spout Up engaged

To raise or lower the spout: 1. Switch ON ignition and start the engine. 2. Switch ON the Harvest switch. 3. To raise the spout, press the spout UP switch. 4. To lower the spout, press the spout DOWN switch.

Spout Down switch

Spout Down engaged

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

119

Can Spy CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

COMMENTS

1303 Harvest mode activated

Status

==1=

==0=: Road Mode

1283 Spout up switch

Pressed

8===

0===: Switch not pressed; 8===: Pressed

1283 Spout down switch

Pressed

4===

0===: Switch not pressed; 4===: Pressed

1348 Spout up

Output status

===4

===4: Activated; ===0: Not activated

1348 Spout down

Output status

===2

===2: Activated; ===0: Not activated

Error messages

Error Code

Key words

459

Spout down hydr. sol.

460

Spout up hydr. sol.

Electrical diagrams Group 13: Spout control.

120

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

12. SPOUT DEFLECTOR Spout deflector up switch

Spout deflector down switch

Spout deflector up engaged

Fixed deflector position (PC calibration)

Spout deflector down engaged

To raise or lower the spout deflector: 1. Switch ON ignition and start the engine. 2. To raise the spout deflector, press the spout deflector UP switch. 3. To lower the spout deflector, press the spout deflector DOWN switch.

REMARKS: 1. Depending on the selection in the InfoView monitor calibration (Type), it is possible to activate the spout deflector and the spout rotation at the same time. 2. Fixed deflector position (PC Calibration): NA machines only So: for Eur machines: answer No for NA machines: answer Yes On European machines, when switching on the Harvest switch, the spout deflector will automatically open up to halfway. When switching OFF the Harvest switch, the spout deflector will close automatically. On North American machines, switching between Harvest and Road Mode does not affect the deflector position.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

121

Can Spy CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

COMMENTS

1282 Spout deflector up switch

Pressed

=8==

1282 Spout deflector up switch

Not pressed

=4==

1282 Spout deflector down switch

Pressed

=2==

1282 Spout deflector down switch

Not pressed

=1==

1347 Spout deflector up

Output status

=8==

=8==: Activated; =0==: Not activated

1347 Spout deflector down

Output status

=2==

=2==: Activated; =0==: Not activated

1345 Calibration fixed deflector position

NA only

===4

===0: Not calibrated (no); ===4: Calibrated (yes)

Error messages

Error Code

Key words

334

Handle switch 2 ^

335

Handle switch 2 v

401

Spout deflector act.

Electrical diagrams Group 13: Spout control

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

122

13. REVERSE CUTTERHEAD

Harvest Mode See group 3

Main drive belt tensioned

Cutterhead reversing switch

Engine RPM sensor

Main drive clutch engaged

Cutterhead reverse engaged

Cutterhead RPM sensor

Chopper body not present

To reverse the cutterhead: 1. Switch ON ignition and start the engine. 2. Switch ON the Harvest switch. 3. Switch ON the cutterhead reversing switch.

Voltage

The output status is: Main clutch is not engaged

Y44

Main drive belt is not tensioned

Y40

12 V

Cutterhead reverse valve is engaged

Y31

12 V

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 REMARKS: (see cutterhead engagement: group 5) 1. To reverse the cutterhead, the system must know whether the engine is running. (See Group 1 -- Electronic conditions: Engine Running/Not Running). 2. The cutterhead can be reversed only 5 sec after starting the engine. 3. After cutterhead engagement, the engine rpm will automatically drop to low idle. Throttle up engine speed again. 4. When the direction of rotation of the cutterhead is changed while the cutterhead is running (from forward to reverse, or vice versa), the drive will be disengaged first and the machine will wait until the cutterhead speed has dropped to less than 10 rpm. If you try to engage in the other direction of rotation, the user message “CUTTERHEAD RPM IS STILL > 10” will appear on the InfoView monitor display. As soon as the cutterhead has

123

stopped, the next user message “REENGAGE CUTTERHEAD” is displayed. Only then the cutterhead can be reengaged in the other direction of rotation. Switch the respective cutterhead engagement switch OFF and ON again. 5. In case the cutterhead speed sensor has failed, and you want to engage the cutterhead in the opposite direction, the system is not able to check whether the cutterhead speed has actually dropped or not. In order to prevent damage to mechanical or hydraulic components, a 100 seconds count--down is started as soon as the cutterhead is disengaged. The following message appears on the screen: “WAIT UNTIL ENGAGE TIMER = 100”. When 0 has been reached, the cutterhead drive can be switched ON. The message “REENGAGE CUTTERHEAD” will appear.

Can Spy CAN ID

DATA DESCRIPTION

word1 word2 word3 word4 ==1=

COMMENTS

1303 Harvest mode activated

Status

==0=: Road Mode

1283 Cutterhead reversing switch

Switched OFF

4===

0===: Switched on

1283 Cutterhead reversing switch

Switched ON

=4==

=0==: Switched off

1289 Engine rpm

XXXX

Rotation per minute -Hexadecimal code

1293 Cutterhead rpm

XXXX

Rotation per minute -Hexadecimal code

1303 Cutterhead reverse engaged

Output status

1303 Main drive clutch engaged

Output status

1348 Main drive belt tensioned

Output status

1349 Chopper body not present

Statuts

=1== ===1

Must be ===0 ==1=

=2==

=0==: Cutterhead reverse not engaged

==1=: Not tensioned; ==0=: Tensioned =2==: Not present; =0==: Present

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

124 Error messages

Error Code

Key words

311

Dashboard switch 11 (Cutterhead reversing switch)

125

Engine rpm sensor O

126

Engine rpm sensor --

127

Engine rpm sensor +

130

Cutterhead rpm sensor O

131

Cutterhead rpm sensor --

132

Cutterhead rpm sensor +

457

Main drive hydr. sol.

461

Cutterhead reverse

462

Main clutch idler

Electrical diagrams Group 15: Cutterhead reverse

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

125

126

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

14. AUXILIARY FRONT HYDRAULICS Harvest Mode See group 3

Spout Up switch

Spout Down switch

Front Hydraulics UP

Front Hydraulics DOWN

Attachment height override switch

To use the auxiliary front hydraulics: 1. Switch ON ignition and start the engine. 2. Switch ON the Harvest switch. The front auxiliary hydraulic valves are powered (12 V on output) with the spout up/down switches in the cab floor, in combination with the attachment height override switch.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

127

Can Spy CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

COMMENTS

1303 Harvest mode activated

Status

==1=

==0=: Road Mode

1283 Spout up switch

Pressed

8===

0===: Switch not pressed; 8===: Pressed

1283 Spout down switch

Pressed

4===

0===: Switch not pressed; 4===: Pressed

1282 Attachment height override switch

Pressed

===8

1282 Attachment height override switch

Not pressed

===4

1348 Front hydraulics down

Output status

=4==

=4==: Activated; =0==: Not activated

1348 Front hydraulics up

Output status

=1==

=1==: Activated; =0==: Not activated

Error messages

Error Code

Key words

342

Handle switch 6 (Attachment height override switch)

464

Front hydr. up sol.

465

Front hydr. down sol.

Electrical diagrams Group 10: Auxiliary hydraulics

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

128

15. AUXILIARY REAR HYDRAULICS

Harvest Mode See group 3

Spout Up switch

Rear Hydraulics UP

Spout Down switch

Auto--Pilot switch

Rear Hydraulics installed (PC--Calibration

Rear Hydraulics DOWN

To use the auxiliary rear hydraulics: 1. Switch ON ignition and start the engine. 2. Switch ON the Harvest switch. The rear auxiliary hydraulic valves are powered (12 V on output) with the spout up/down switches in the cab floor, in combination with the Auto--Pilot switch.

REMARKS: Auxiliary rear hydraulics are an accessory. Machines without auxiliary rear hydraulics are delivered without electrovalve. An additional calibration has to be carried out to avoid error messages. Refer to the PC calibration instructions.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

129

Can Spy CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

COMMENTS

1303 Harvest mode activated

Status

==1=

==0=: Road Mode

1283 Spout up switch

Pressed

8===

0===: Switch not pressed; 8===: Pressed

1283 Spout down switch

Pressed

4===

0===: Switch not pressed; 4===: Pressed

1282 Auto--Pilot switch

Pressed

==8=

1282 Auto--Pilot switch

Not pressed

==4=

1348 Rear hydraulics up

Output status

2===

2===: Activated; =0==: Not activated

1348 Rear hydraulics down

Output status

1===

1===: Activated; 0===: Not activated

1342 Calibrated rear hydraulics

8===

Error messages

Error Code

Key words

341

Handle switch 5 (Auto--Pilot switch)

456

Rear hydr. down sol.

456

Rear hydr. up sol.

Electrical diagrams Group 10: Auxiliary hydraulics

0===: not calibrated (no); 8===: calibrated (yes)

130

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

16. AIR CONDITIONING

Airco thermo switch in cab

Airco compressor clutch

Airco high pressure switch

Airco low pressure switch

Airco high pressure led

Airco low pressure led

Switch on the air conditioning with the airco switch in the cab. This causes the electromagnetic clutch of the airco compressor to be powered (12V on output: see electrical diagrams). The airco switch in the cab is in fact a combination of three conditions: Airco Switch ON =

Fan speed switch (S37) in position 1, 2 or 3 and Airco thermo switch (B61) closed and Air conditioning safety switch (S60) closed

Airco Switch OFF =

Fan speed switch in position O or Airco thermo switch (B61) open or Air conditioning safety switch (S60) open

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 REMARKS: 1. When the compressor pressure is too low or too high, the power to the electromagnetic clutch will automatically drop to 0 volt to avoid damage of the compressor. (When the pressure is too low, there is no noise, only the led starts to blink). 2. The system should be informed if the air conditioning system is not installed to avoid continuous warning signals in the cab. See PC calibration.

131

3. The system must only be operated when the engine is warm and the interior temperature of the cab is 15Â°C minimum.

ATTENTION Ignoring this precaution may cause damage to the system.

Can Spy DATA DESCRIPTION

CAN ID

word1 word2 word3 word4

COMMENTS

1283 Airco switch in cab

Closed

==1=

==0=: Switch open; ==1=: Switch closed

1303 Airco low pressure switch

Press too low

2===

0===: Switch open; 2===: Switch closed

1303 Airco high pressure switch

Press too high

1===

0===: Switch open; 1===: Switch closed

1314 Airco high pressure led Lights up 1314 Airco low pressure led

Lights up

1348 Airco compressor clutch

Output status

Error messages

Error Code 440

Key words Airconditiong clutch

Electrical diagrams Group 24: Air conditioning

===4

4===

0===: Extinguished

2===

0===: Extinguished ===4: Activated; ===0: Not activated

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

132

17. SILAGE ADDITIVES APPLICATION Harvest Mode See group 3

Cutterhead Engaged See group 5

Feed rolls Engaged See group 6

Drive Forward See group 23x

Silage additive applicator main switch

Power to silage additive applicator

Conditions: 1. Switch ON ignition and start the engine. 2. Switch ON the Harvest switch. 3. Switch ON the silage additive applicator switch. 4. Engage cutterhead. 5. Engage feed rolls forward drive. 6. Drive forward.

REMARKS: The 12 V silage additives application socket output can be checked (silage additives applicator installed): 1. Switch the Harvest switch to Road position. 2. Switch ON the silage additive applicator switch.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

133

Can Spy CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

1303 Harvest mode activated

Status

1283 Silage additive applicator main switch

Switched ON

==8=

==0=: Switched off

1283 Silage additive applicator main switch

Switched OFF

===8

==0=: Switched on

1303 Main drive clutch engaged

Output status

===1

===0: Main drive not engaged

1304 Feed rolls forward engaged

Output status

=2==

=0==: Feed rolls forward not engaged

1304 Driving forward

Status

4===

0===: Not driving

1348 Power to silage additive applicator

Output status

===2

===2: Activated; ===0: Not activated

Error messages

Error Code 306

Key words Dashboard switch 6 (Silage additive applicator switch)

Electrical diagrams Group 17: Silage additive applicator

==1=

COMMENTS ==0=: Road Mode

134

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

18. KNIFE SHARPENING

Reverse Cutterhead See group 13

Throttle switch

AOM dashboard switch

Sharpening Door Open LED

motor sharpening door

motor sharpening stone

sharpening door open sensor

AOM panel “ok” LED

“cutterhead speed too low” LED

Home position sharpening stone sensor

1’ sharpening LED

grinding 1’,2’ or 3’ aom panel

reset button

sharpening on the move (NA) pc calibration

2’ sharpening LED

3’ sharpening LED

Reset button LED

“Failure of sharpening stone drive motor” LED

“Sharpening stone worn out” LED

Conditions 1. Start the engine and set speed at low idle 2. Disengage the feed rolls by pushing the feed roll drive switch (MF lever) 3. Disengage the cutterhead by switching off the cutterhead drive switch. Wait until the cutterhead has stopped rotating. 4. Ensure the harvest switch is switched to its harvest position 5. Switch on reverse drive cutterhead switch 6. Throttle up the engine speed until the cutterhead speed is at least 750 rpm. This will ensure a good sharpening quality. The higher the speed, the better the sharpening.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

135

Adjust--O--MaticTM

7. Switch ON the switch (instrument panel). The OK--light on the Adjust--O--MaticTM panel is illuminated. Press one of the automatic knife sharpening routine keys (1, 2 or 3 minutes). As a guide--line, the shortest time (one minute) is recommended, unless the knives are really worn. The light on the chosen key will illuminate during the sharpening operation. 8. The sharpener door warning light will start flashing, meaning the sharpener door is opening. 9. The Adjust--O--MaticTM system will now start sharpening the knives during 1, 2 or 3 minutes, depending on the selection that was made. During sharpening the sharpener door warning light will be illuminated. 10. The sharpener routine will stop after 1, 2 or 3 minutes, unless the routine is interrupted with the interrupt key. At the end of the sharpening cycle, the stone will travel across the cutterhead knives slowly for at least half a cycle. This is done to make sure the knives are properly sharpened and burrs are removed. 11. When sharpening is finished, the sharpener door closes automatically and the OK--light (Adjust--O--MaticTM panel) will illuminate.

REMARK: You can also sharpen the knifes with the cutterhead turning forward, however it is recommended to sharpen in reverse. The routine stays the same.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

136 Can Spy CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

COMMENTS

1283 AOM main switch

Switched ON

8===

0=== : switched off

1283 Cutterhead reversing switch

Switched OFF

4===

0=== : switched on

1283 AOM main switch

Switched OFF

=8==

=0== : switched on

1283 Cutterhead reversing switch

Switched ON

=4==

=0== : switched off

1286 AOM stop sharp./adj. switch

Pressed

2===

0=== : not pressed

1286 AOM sharp. rout. 3’

Pressed

1===

0=== : not pressed

1286 AOM sharp. rout. 2’

Pressed

=8==

=0== : not pressed

1286 AOM sharp. rout. 1’

Pressed

=4==

=0== : not pressed

XXXX

Rotation per minute -hexadecimal code

1293 Cutterhead rpm 1303 Cutterhead reverse engaged

Output status

=1==

1304 Sharpener door open

Input status

2===

0=== : sharpener door between open and closed

1304 Sharpener door closed Input status

1===

0=== : sharpener door between open and closed

1304 AOM Mode

Status

==8=

==8= : set ; ==0= : not set

1304 Sharpener stone worn out

Input status

===8

===0 : sharpener stone not worn out

1304 Sharpener stone at home position

Input status

===4

===0 : sharpener stone not at home position

1314 Sharpener door LED

Lights up

1315 AOM 2’ LED

Lights up

8===

0=== : extinguished

1315 AOM 1’ LED

Lights up

4===

0=== : extinguished

1315 AOM OK LED

Lights up

1===

0=== : extinguished

1315 AOM Service LED

Lights up

=8==

=0== : extinguished

1315 AOM Motor fault LED

Lights up

=2==

=0== : extinguished

1315 AOM rpm fault LED

Lights up

=1==

=0== : extinguished

1315 AOM stop sharp. LED

Lights up

===2

===0 : extinguished

1315 AOM sharp routine 3’ LED

Lights up

===1

===0 : extinguished

=8==

=0== : cutterhead reverse not engaged

=0== : extinguished

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

137 COMMENTS

1349 Sharpener door open

Output status

==8=

==8= : activated ; ==0= : not activated

1349 Sharpener door close

Output status

==4=

==4= : activated ; ==0= : not activated

1349 Sharpener routine engaged

Output status

===1

===1 : activated ; ===0 : not activated

Error messages

Error Code

Description

223

Stone home sensor O

224

Stone home sensor --

225

Stone home sensor +

226

Cover cutterh. sensor O

227

Cover cutterh. sensor --

228

Cover cutterh. sensor +

229

Out of stone sens. O

230

Out of stone sens. --

231

Out of stone sens. +

310

Dashboard switch 10

370

Cover cutterhead EOT

371

AOM Power failure

483

Cover cutterh. Motor

487

Sharp motor failure

488

Out of stone

489

Cut. knives worn down

Electrical scheme Group 15

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

138

19. ADJUST--O--MATIC ROUTINE There are two possibilities to start an automatic shearbar adjustment: With cutterhead turning forward and cutterhead turning backward.

Reverse cutterhead group 13 or engage cutterhead forward group 5

AOM Dashboard switch

AOM motor

Left

Right

Interrupt LED AOM Panel

Rear drive

Shearbar Adj. switch on AOM panel

shearbar adj. LED on AOM panel

Knocksensor(s)

AOM OK LED on AOM panel

interrupt button AOM routine on AOM panel

cutter head speed too low LED on AOM panel

Shearbar adj. motor failure LED AOM Panel

Buzzer

Primarily checks 1. Lock the stone pawl first to avoid the stone can lower during a sharpening cycle. Sharpen for at least three minutes to obtain a complete parallel cutterhead. 2. Check for play at the electric motors fixation points. 3. Verify the noise sensor installation. Max. 20 Nm Place sensor connector as high as possible. 4. Check all frame ground on sensor and Ticker Solenoid.

pc calibr shearbar gap

Knives worn Led AOM panel

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

139

5. Check knock sensor To start up the knock sensor check procedure, the engine has to be shut down, the contact must be ON; push the aom reset button while switching on the AOM dashboard switch. The ’sharpening stone’ warning led (Op. Manual symbol 10 page 2--19) on the aom display panel lights up to confirm you are in sensor test mode. To do the actual testing you have to hit the shearbar or somewhere close with a piece of iron (keys, screwdriver,...). If the sensor(s) is ok the reverse buzzer and LCD buzzer will sound, simultaneously the knock sensor led on the aom display lights up for a few seconds. After the buzzing stopped you can try again as long as you stay in the test mode. 6. Clean the area between shearbar and scraper. 7. Execute a full pull :

Switch on ignition and AOM Press ’Stop’ and ’Shearbar adjust’ button on AOM--Panel.

8. If necessary adjust all knives. (See procedure described in Operator’s Manual). 9. Clean the area between shearbar and cutterhead properly. 10. Check shearbar for scratches. If necessary turn or replace.

11. Verify messing plate under the shearbar.

140

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Conditions and description of Shearbar adjustment Procedure. Start the engine Switch on safe harvest button Switch on reverse cutterhead button Switch on aom dashboard button (ok LED aom display illuminates) When the shearbar adjustment button is pressed, the shearbar adjustment led illuminates during the whole adjustomatic procedure and 1°)

First the engine rpm drops to low idle.

2°)

Then the shearbar turns backwards (towards feed rolls). This includes : the LHS electric motor is powered first for 1 rotation & the RHS electric motor is powered also for 1 rotation. Check the output of the electric motors on CAN SPY Page : 1349 word 1 : ==2= (Left motor) 1349 word 2 : ===8 (Right motor)

3°)

error check during AOM procedure From time to time the knock sensors are being checked on optimum working condition. When at the beginning of an AOM procedure one or two sensors seem to work less, an error question message ”check sensors continue? Yes/no?” is displayed. As soon as this message appears you are in the sensor check procedure as described under primarily checks 5°. This way you can check the sensors even while the cutterhead is turning. * When ”yes” has been confirmed two situations may occur Or during testing now or later in the test procedure described under primarily checks 5°, whether the sensors needed repair or not, the sensor check was successful (equal to buzzer went off), the AOM procedure will continue its cycle. Or if there was no check, bad repair or no repair (equal to buzzer did not go off), the message ”adjust manually” will appear on the screen for a few seconds and the AOM procedure is terminated. * When ”No” has been confirmed, the AOM procedure stops. The measured machine background noise is displayed on: Page 1304, Word 2 : XX==.

4°)

The limit for background noise has been brought to 170 (= AAhex) Maximum and 60 (= 3Chex) average. If the first background noise measurement is too high, error 490 “AOM NOISE TOO HIGH” (= new) comes up the screen while sensor error led lights up on the aom panel. The background noise level is measured again. When the shearbar threshold is calculated, this value is displayed on Page 1304, Word 2 : XX== The last measured information from the sensor is displayed on : Page 1304, word 2, ==XX and is always a few digits higher than page 1304, Word 2 : CC==

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

141

5°)

Then the Shearbar adjustment is started and the shearbar turns forward (towards knives). First the LHS electric motor is powered for maximum 1 2/8 rotations. When the impact of the shearbar with the knives (measured noise) becomes higher than the Shearbar threshold, the forward rotation is stopped and the motor starts to back off the shearbar from the knives in parts of 1/18 rotation as long as the measured noise stays higher than the shearbar threshold. Then the LHS motor backs off for an extra 5/9 rotation. 1349 word 1 : ==2= (Left motor, back off) 1349 word 1 : ==1= (Left motor, towards knives) 1349 word 2 : ===8 (Right motor, back off) 1349 word 1 : ===4 (Right motor, towards knives)

6°)

The same procedure is repeated for the RHS electric motor.

7°)

Steps 6 and 7 are again repeated for the LHS and RHS electric motor. Only instead of 5/9 rotation extra back off, the system backs off the calibrated shearbar gap (default setting is 4/8). At the end of the aom procedure the LHS motor is turned 1/8th turn extra in order to establish a parallel shearbar.

REMARK I: When one adjustment step is finished (step 6--8) the system will wait one second before the next adjustment step (at the other side) will start, this to allow the Shearbar can stretch itself. REMARK II: AOM procedure, cutterhead turning forward. When executing the AOM procedure with the cutterhead turning forward, the AOM stops at each phase until the sensors heard a hit, from then on everything happens automatically. When nothing is heard, the operator has to acknowledge at each phase if he wants to continue or not. This way the operator has the time to react when the shearbar should hit the drum. There is no acknowledging procedure when turning the cutterhead backward. REMARK III: Once the shearbar has touched the knives, the system has to detect four knife approaches after each other (2 left and 2 right) without interruption. When during the shearbar adjustment the shearbar does not touch the knives, the counter for 4 knife approaches is reset. This happens when the shearbar goes direction knives but the shearbar does not touch the knives. This results in the powering of the electric motor at the other side. This symptom will create a constant shearbar adjustment. Possible causes : --) Round shape of the cutterhead. --) Play in the electric motor fixation points --) Shearbar pivoting around midpoint

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

142 Can Spy CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

COMMENTS

1283 AOM main switch

Switched ON

8===

0=== : switched off

1283 Cutterhead reversing switch

Switched ON

4===

0=== : switched on

1283 AOM main switch

Switched OFF

=8==

=0== : switched on

1283 Cutterhead reversing switch

Switched ON

=4==

=0== : switched off

1286 AOM sharpening/adjustment switch

Pressed

2===

0=== : not pressed

1286 AOM shearbar adj. switch

Pressed

=2==

=0== : not pressed

1286 Cutterhead engage switch

Switched OFF

==2=

==0= : switched on

1286 Cutterhead engage switch

Switched ON

===2

===0 : switched off

XXXX

Rotation per minute -hexadecimal code

1293 Cutterhead rpm 1304 AOM mode

Status

==8=

==8= : set ; ==0= : not set

1304 Continue AOM adjustment request

Status

==4=

==4= : set ; ==0= : not set

1304 Check AOM sensors request

Status

==2=

==2= : set ; ==0= : not set

1304 Activate Reverse Buzzer

Status

==1=

==1= : set ; ==0= : not set

1304 Measured background noise and measured threshold limit during adjust operation

XX==

Normal value : +/-- 60 ; max value for still good operation : AA

1304 Last measured knives hit peak value during adjust operation

==XX

Always some digits higher than the measured background noise.

1315 AOM OK LED

Lights up

1===

0=== : extinguished

1315 AOM Service LED

Lights up

=8==

=0== : extinguished

1315 AOM Sensor fault LED Lights up

=4==

=0== : extinguished

1315 AOM Motor fault LED

Lights up

=2==

=0== : extinguished

1315 AOM rpm fault LED

Lights up

=1==

=0== : extinguished

1315 AOM shearbar adjustment led

Lights up

===2

===0 : extinguished

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

1345 Calibrated shearbar gap

===X

143 COMMENTS

Possible values : 2 to 8

1348 Rear drive buzzer

Output status

==4=

==4= : activated ; ==0= : not activated

1349 Left AOM electric motor forward

Output status

==2=

==2= : activated ; ==0= : not activated

1349 Left AOM electric motor to knives

Output status

==1=

==1= : activated ; ==0= : not activated

1349 Right AOM electric motor forward

Output status

===8

===8 : activated ; ===0 : not activated

1349 Right AOM electric motor to knives

Output status

===4

===4 : activated ; ===0 : not activated

Error codes

Error Code

Description

310

Dashboard switch 10

371

Power failure AOM

485

AOM Motor left failure

486

AOM Motor right failure

489

Cut. knives worn down

490

AOM Noise too high

Electrical scheme See group 16

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

144

20. CROP PROCESSOR

Harvest Mode See group 3

CP Electric Motor

CP dashboard switch 12

CP Potentiometer

CP Rpm sensor

CP Calibration (InfoView Monitor)

LCD CP clearance Readout

Conditions: Put contact on. Go to safe harvest mode using the safe harvest button. Push the crop processor switch up to widen the crop processor gap ( up to 20 mm max) and down to make the gap smaller (up to 2 mm min).

REMARK: 1. To view the cp rpm on can spy, the engine has to be running and the cutterhead has to be engaged. 2. The users message â&#x20AC;&#x153;crop processor slippageâ&#x20AC;? comes up when the speed of the crop processor rolls drop below 2.5 times the cutterhead speed. With 0% slippage the cp roll speed is 3.2 times higher than cutterhead speed. When the cutterhead speed for instance is 1000 rpm, then the cp speed is 3200. When cp speed drops below 2500 (or 09C4Hex on can id page 1290) the user message comes up. 3. The electronic system should be informed if the crop processor is installed to avoid error reports. See InfoView Monitor calibration.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

145

Can Spy CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

1283 CP roll clearance open Pressed switch

===2

1283 CP roll clearance close Pressed switch 1290 CP Rpm

===0 : switch not pressed ; ===2 : pressed 1===

0=== : switch not pressed ; 1=== : pressed

XXXX

1313 CP distance

COMMENTS

Rotation per minute -hexadecimal code ==XX

Limits : 3B < XX < 79

1347 Close CP

Output status

===2

===2 : activated ; ===0 : not activated

1347 Open CP

Output status

===1

===1 : activated ; ===0 : not activated

Error codes

Error Code

Error code description

113

Crop. proc. sensor O

114

Crop. proc. sensor --

115

Crop. proc. sensor +

148

CP Distance sens. O/--

149

CP Distance sens. +

150

Crop Processor Sens.

312

Dashboard switch 12

400

Crop. proc. dist. act.

Electrical scheme See group 12

146

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

21. METAL DETECTOR OPERATION AND TROUBLESHOOTING Introduction The model FX/96 forage harvester is equipped with the Metalert III®/TM electronic metal detector (EMD). Metalert III®/TM has the following advantages over previous generations I and II: -- Modular construction: individual components can be replaced -- Adaptive threshold adjustment -- Manual threshold adjustment (fixed mode) -- On--board diagnostics (= Run time test) -- Display of important information on the InfoView monitor (noise readings, thresholds) -- Error codes -- CAN Identifiers The general function of the metal detector is explained in the Operator’s Manual, chapter 4.5 “Metal detector”.

METAL DETECTOR HARDWARE The metal detector consists of two parts: 1. The sensor (upper part) 2. The electronic module (lower part)

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

147

The sensor The heart of the metal detector is the sensor that contains the magnets and the coils.

Left Channel

Right Channel

It consists of 2 rows of permanent magnets. The magnets in one row are arranged offset to the other row. One row of magnets starts at the far left--hand side of the sensor. The other row starts at the far right--hand side. Between the two rows of magnets a permanent magnetic field exists. This magnetic field crosses the boundaries of the feed roll shell and â&#x20AC;&#x2DC;fillsâ&#x20AC;&#x2122; the space between the upper and lower front feed rolls. Since the magnetic field must not be disturbed by the feed roll, the feed roll is made of low magnetic stainless steel and demagnetised steel. Above the rows of magnets the coils are placed next to each other. Those coils are wired in two series. One row of coils starts at the far left--hand side of the sensor: this row is called the left channel. The other row starts at the far right--hand side and is called the right channel. NOTE: On the metal detector diagnostic page of the InfoView monitor, the left and right channel are referred to as channel A and channel B in order to avoid confusion as to where metal has entered the machine. When metal passes over the sensor, the magnetic field between the magnets is disturbed. A disturbance of the magnetic field will generate a current through the coils (channels). Depending on where the metal enters, the current may be generated in the coils of the left or right channel, or both.

148

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

The electronic module The current through the coils which is generated by a disturbance in the magnetic field is a relatively weak signal. If this signal would be sent directly to the electronic box on the base unit, it would be subjected to electromagnetic influences. Therefore, this signal is amplified first. Since the CAN system can only use digital information, the analog signal (magnetic noise) is converted to a digital signal by means of an A/D converter. Then the control unit compares the (digital) magnetic noise to the threshold level (available from adaptive or fixed mode). This depends on 2 parameters -- The extent to which the noise levels increase -- The setting of the thresholds (or trip levels).

So, the thresholds determine at which noise level a detection will take place. Since there are 2 channels, and positive and negative values for each channel, there are 4 thresholds in total. As soon as one of the thresholds is exceeded, the metal detector will trip. This will result in the following: -- The output voltage will drop from 12 Volt to 0 Volt for 1 second -- A CAN message will be transmitted informing that a metal detection has taken place. These signals will have the following consequences: -- The stop pawl solenoid will be activated, which will stop the feed rolls -- The feed rolls forward electromagnetic clutch will be disengaged -- The metal detector diagnostic page will appear on the InvoView monitor screen. The classic signal and the CAN message work completely independent from each other. This means that when the classic signal is not functioning for whatever reason, the CAN message will make sure the detection message is passed on, and vice versa.

X619 Amplifier

12 V 1Ground

ADC ADC

Control Unit

0 V : Detection 12 V : No Detection CAN Network

Amplifier

Coils

Output

Electronic Processor

Connector and wiring loom to central box

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

149

INFOVIEW MONITOR

52706

2 The metal detector page can be displayed on the InfoView monitor after key 10 is pressed. Since there are 2 channels, left and right, there are 2 bargraphs, CHAN A and CHAN B, as shown on the InfoView monitor display (Fig. 2). The black segments (A) on both bargraphs represent the peak magnetic noise readings in the two channels (measured during a period of 6 1/4 seconds). In case the machine would be perfectly quiet (which in reality is rare), the bargraphs would be empty. As soon as magnetic noise is detected, part of the histogram will be filled around the midpoint with black sections. The resolution of the noise readings is half a bargraph segment. NOTE: In case the background magnetic noise is high and the size or speed of the ferrous object is small, the magnetic disturbance caused by the object may not be able to exceed the magnetic noise. It will not be detected in that case, regardless, of the position of the threshold. The 4 lines B above the black sections represent the actual (fixed or adptative) threshold levels (or trip levels). When the magnetic noise readings exceed a threshold level, a metal detection will take place.

150

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

FIXED AND ADAPTIVE MODE There are 2 ways for setting the thresholds: -- Fixed: Manual setting of the thresholds -- Adaptive: Automatic setting in function of the average peak noise level. At the top of the InvoView screen the thresholds will either be marked “A” or “F” (see Figure 1). -- “A” stands for Adaptive Mode. -- “F” stands for Fixed Mode. To switch between adaptive and fixed mode, press the scroll down and scroll up buttons simultaneously when the metal detector page is displayed. The “A” will change to “F”, or vice versa. The range within which the thresholds can be set is the same, both for the adaptive and the fixed mode. It ranges from 1 1/2 to 5 1/2 blocks above or below the midpoint. Fixed mode The fixed thresholds are set manually between 1 1/2 to 5 1/2 blocks from the midpoint. It is generally recommended to set the fixed thresholds at 1 1/2 blocks removed from the noisiest reading (feed rolls engaged at full speed). These fixed thresholds are set symmetrically (same setting for all 4 thresholds). NOTE: The arrows to the left--hand side of the bargraph indicate the adaptive threshold levels. In the fixed mode, these are purely informative. These thresholds have to be adjusted manually by moving the lines B above and below the black sections. To do so, use the scroll up and down buttons and confirm the new settings by pressing the Enter key. After confirmation, the right--hand side arrows will jump to the same level as the lines B. Adaptive mode The adaptive thresholds are set automatically in function of the average peak noise readings, regardless of differences between the 4 noise levels. This means the thresholds are not necessarily set symmetrically, but can in fact differ significantly. To prevent the adaptive thresholds from changing too quickly, they represent a slow moving average of the peak noise readings of the last couple of minutes. During each 6.25 seconds, the 4 peak noise values are stored. These peak readings are averaged with the peak readings of the last 31 samples.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

151

When the background noise level of the feed rolls increases with time, the adaptive thresholds are automatically adjusted. When, however, the threshold limit of 5 1/2 blocks is crossed, the system will notify the operator by means of an error code. The figure below shows how Metalert II and III compare regarding the reaction of increased magnetic noise in function of time.

CEILING MAXIMUM LIMITATION II

III

FIXED DETECTION LEVEL AVERAGE DETECTION LEVEL

VOLTS

3 4 YEARS TIME

⇒

3 4 YEARS TIME

⇒ 3

Quick adjustment of the adaptive mode Although the adaptive thresholds are set relatively fast, there may be circumstances that letting them adjust automatically in the field is not fast enough, e.g. -- When the metal detector was replaced -- When the feed roll shell was replaced or demagnetized -- When a dent in the feed roll shell has increased the magnetic noise. In these cases the following can be done: -- Switch to fixed mode, or -- Carry out the quick--adjust routine of the adaptive mode. The quick--adjust routine will allow the adaptive thresholds to be set within a minute.

152

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Proceed as follows: 1. Start the engine. 2. Engage the cutterhead. 3. Engage the feed rolls. 4. Throttle up to full engine speed. 5. Recall the metal detector page of the InfoView monitor by pressing key 10 (refer to Figure 2). 6. Press key 6 on the InfoView monitor to start the quick adjustment procedure (refer to Figure 2).

Run time test (On--board diagnostics) The run time test is on--board diagnostic routine, initiated each 90 seconds when the cutter head is not engaged, However, the first run time test after disengaging the cutterhead starts after 120 seconds. This on--board diagnostic routine runs a test on the metal detector hardware to check if the left and right channel hardware components (coils, amplifiers, A/D converter and frame ground) are still working properly. The run time test consists of two parts: 1. The microprocessor checks the continuity of the coils in the EMD. (This is done by injecting a small current into the coils to simulate a disturbance in the magnetic field. This current is again measured by the microprocessor and verified if it corresponds with the injected current or within a small deviation). If this test fails, the run time test will be interrupted and an error code 273 will be communicated by the EMD microprocessor to the InfoView monitor. 2. The microprocessor checks the continuity of the metal detector frame ground. Flat earth cables can be found between the electronic module and the metal detector shaft, between the metal detector shaft and right--hand side of the chopper body unit. A good frame ground between chopper body unit and base unit is also necessary. If this test does not succeed, an error code 277 will be generated.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

153

TROUBLESHOOTING

52715

154

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Conditions When ignition is switched on, all information, such as threshold settings in InfoView Monitor, cutterhead and feed rolls status and machine driving status, is provided to the EMD microprocessor through the CAN network. (See CAN--Identifier 1278), who decides which actions need to be executed. When the cutterhead is engaged (even if feed rolls are not running yet), the EMD microprocessor monitors if metal is passing through the feed rolls. In other words, the EMD microprocessor continuously compares the measured magnetic noise with the calculated adaptive thresholds or the selected fixed thresholds. However, the adaptative thresholds calculation routine works only when the cutterhead and the feed rolls forward drive is engaged and the machine is driving forward. --

When the cutterhead is disengaged, every 90 seconds a “run time” test routine will be initiated to check all EMD components. However, the first “run time” test after disengaging the cutterhead starts after 120 seconds. When a metal detection takes place during working operation (cutterhead engaged), it will always be communicated by the metal detector to the Adjust--O--Matic printed circuit (the classic output line drops to 0 Volts and a CAN message is transmitted: see CAN Identifier 1304 first word: “Metal Detected”). The decision to stop the feedrolls is made by the Adjust--O--Matic based on the AOM “metal detector status” (see CAN Identifier 1304, first word: ===1).

The AOM “metal detector status” is enabled when the engine is started, harvest node is switched ON and the cutterhead is engaged (see CAN Identifier 1304, first word: ===1). The AOM “metal detector status” is disabled by means of the metal detector rocker switch on the instrument panel. The metal detector can be enabled by pressing the other side of the metal detector rocker should or by restarting the machine. When the AOM “Metal detector status” is enabled and a metal detection takes place, the following will happen: -- The stop pawl solenoid will be activated, which will stop the feed rolls -- The electromagnetic clutch will be disengaged -- The metal detector diagnostic page will appear on the InfoView monitor screen. However, when AOM “metal detector status” is disabled and a metal detection then takes places: -- The stop pawl solenoid will not be activated, which will not stop the feed rolls. -- The electromagnetic clutch will not be disengaged. -- The metal detector diagnostic page will not appear on the InfoView monitor screen. but: -- A user message “Metal Detector OFF” will appear on the InfoView monitor every 30 seconds together with one single beep. -- The date and hour of the metal detection will be stored in the “Missed Metal Detection Date” (See CAN Identifier page 1301).

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

155

When the classic output line (wire 2096) suddenly has an open circuit or is short--circuited to earth, the pawl stop system will be activated, although the signal is not generated by the metal detector. Also, it is not possible to reactivate the metal detector by pressing the feed rolls reverse switch as long as the problem is not solved. The following table explains whether the pawl stop system will be activated or not when a metal detection takes place.

Classic output

Wire 2096 not damaged

Wire 2096 shorted to 12 V

CAN Network EMO no network error

Feed rolls will stop

EMO network error (117)

Feed rolls will stop

Feed rolls will stop (NEW)

Feed rolls will not stop

ATTENTION: When diode V24 (located in the central box on X432) is defective or incorrectly installed, the Adjust--O--Matic printed circuit can be damaged and the metal detector stop system will no longer work. During working operation, several test routines are watching the EMD functionality. If one test is unsuccessful, it will be announced by means of an Error message.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

156 CAN Identifiers CAN ID

DATA DESCRIPTION

1276 RUN time test procedure

Running

1276 EMD hardware version

word1 word2 word3 word4 =1==

COMMENTS =0==: Not running

==XX

1276 EMD software version:

XX==

See software revisions

Node M 1276 Error code 277

Set

==8=

==0=: Not set

1276 Error code 276

Set

==4=

==0=: Not set

1276 Error code 275

Set

==2=

==0=: Not set

1276 Error code 274

Set

==1=

==0=: Not set

1276 Error code 273

Set

===8

==0=: Not set

1276 Error code 272

Set

===4

==0=: Not set

1276 Error code 271

Set

===2

==0=: Not set

1276 Error code 270

Set

===1

==0=: Not set

1276 Peak noise level left channel, + values

XX==

Limits: 00 < XX < 7F

1276 Peak noise level left channel, -- values

==XX

Limits: 00 < XX < 7F

1276 Peak noise level right channel, + values

XX==

Limits: 00 < XX < 7F

1276 Peak noise level right channel, -- values

==XX

Limits: 00 < XX < 7F

1278 Cutterhead disengaged

Status

8===

1278 Feed rolls stopped

Pressed

6===

1278 Feed rolls reverse

Pressed

4===

1278 Feed rolls forward

Pressed

2===

0===: Cutterhead engaged

1278 Adaptive node selected

1===

0===: Fixed mode selected

1278 EMD threshold setting in fixed node

=X==

= 0 when adaptive mode is selected. = 0 < X < 8 when fixed mode is selected

1278 Forage Harvester stopped

Status

===6

1278 Forage Harvester driving backwards

Status

===4

1278 Forage Harvester driving forwards

Status

===2

1278 Quick Adapt routine activated

Status

===1

1283 Metal detector ON switch

Pressed

4===

0===: Not pressed

1283 Metal detector OFF switch

Pressed

=4==

=0==: Not pressed

===1: Quick adapt routine started

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

1301 Missed metal detection date 1303 Harvest mode activated

XXXX

157 COMMENTS

Hours: Minutes Day Month Year (decimal code)

Status

==1=

==0=: Road mode

1303 Feed rolls reverse engaged Output status

===8

===0: Feed rolls reverse not engaged

1303 Main drive clutch engaged

Output status

===1

===0: Main drive not engaged

1304 Metal detected

Input status

=4==

=0==: No metal detected

1304 Feed rolls forward engaged Output status

=2==

=0==: Feed rolls forward not engaged

1304 Metal detector status

Status

===1

===0: Enabled ===1: Disabled

1314 Metal detector led

Lights up

===4

===0: Extinguished

1349 Active stop pawl stop system

Output status

===2

===2: Activated ===0: Not activated

Error Messages Error codes related to the electronic metal detector:

Error Code

Key Words

117

EMD Network error

270

EMD Noise level low

271

EMD Output line --

272

EMD Output line +

273

EMD Channel fault

274

EMD Noise level high

275

EMD Network error

276

EMD Processor fault

277

EMD Frame ground

278

EMD Output failure

279

EMD Power failure

REMARK: Error 275 is suppressed by software.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

158

22. ATTACHMENT HEIGHT CONTROL 1°)

Calibration

To avoid error messages during the attachment height calibration, first check the voltages for the minimum and maximum attachment height positions on the display, before starting the calibration procedure. The voltage when the attachment is raised must be higher than : 6,2 V. Preferably not higher than 6.7 V. The voltage when the attachment is lowered must be lower than : 5,0 V. To start the attachment height calibration : 1. Start the engine. 2. Press the “CAL” button on the InfoView Monitor. 3. Select and Enter “2--Attachment calibration”. 4. Go to “Semi Automatic HHC Calibration” and Enter “Yes”. Calibration procedure : 1. Calibration of the attachment height range: ground level. The attachment is lowered to ground level, which for the Bosch module corresponds with a pressure in the cyclinders of 0 bar.

start from a level above ground.

push “attachment down” for 2 seconds.

the attachment will automatically lower to ground level.

green LED: 5 blinks.

beep tone.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

159

2. Calibration of the attachment height range: upper position. Smax has to be higher than 6,2 V.

push “attachment up” for 2 seconds.

the attachment will automatically raise to its upper position.

beep tone

If Smax is lower than 6,2 V, the calibration procedure will interrupt and the following message will be displayed. Stop the machine and adjust first the attachment height sensor before restarting the attachment calibration procedure. CALIBRATION SEMI AUTOMATIC HHC CALIBRATION INTERRUPTED ATTACHM HEIGHT SENS. OUT OF RANGE READJUST SENSOR 06,0 V

160

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

3. Calibration of oil the pressure range: lower position. The attachment will lower to to S1 = Smin + 0,9 V. S1 has to be lower than 6,4 V.

push “attachment down” for 2 seconds.

the attachment will automatically lower to just above ground level

green LED: 8 blinks

beep tone

When the header is lowered for a second time, the system calculates the expected S1 = Smin + 0,9 V. has to be lower than 6,4 V. If this value is higher than 6,4 V, the system interrupts the calibration procedure with the following message: CALIBRATION SEMI AUTOMATIC HHC CALIBRATION INTERRUPTED ATTACHM HEIGHT SENS. OUT OF RANGE MIN > 5,5 V READJUST SENSOR 06,5 V

NOTE: If wait messages remains on screen at this point for more than 2 minutes, check performance at pressure sensor B13.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

161

4. Calibration of the oil pressure range: upper position. The attachment is raised completely, and then lowered to level S2 = Smax -- 0,1 V. And S2 has to be higher than S1 + 0,8 V.

-----

push ”attachment up” for 2 seconds. the attachment will automatically raise just under upper position green LED: 12 blinks beep tone

After reaching the last point S2, the system verifies the difference between S2 and S1. If the result is lower than 0,8 V, a build--in standard curve will be applied. This is indicated by the following message: CALIBRATION SEMI AUTOMATIC HHC CALIBRATION DEFAULT CALIBRATION APPLIED 06,5 V

When the difference between S2 and S1 is higher than 0,8 V, the calibration procedure will finish and the following message will be displayed. CALIBRATION

SEMI AUTOMATIC HHC CALIBRATION SUCCESSFUL

05,0 V

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

162 Conclusion:

Allowed voltage range for Smin, Smax, S1 and S2.

An example is worked out for a machine on which Smax = 6.8 V.

Conditions for Smin Calibration successful

Smax S2 S1 Smin

Default calibration

Calibration not possible

= 6,8 V = 6,7 V (Smax -- 0,1 V) < 5,9 V (S2 -- 0,8 V) < 5,0 V (S1 -- 0,9 V)

If the attachment lowest position was lower than 5,0 V, the calibration would have been successful. In case the lowest position would have been between 5,0 V and 5,5 V, which does not agree with condition S2 -- S1 > 0,8 V, the default calibration will be applied (a standard height--pressure line foreseen by Bosch). In case the lower position would be higher than 5,5 V, the calibration procedure cannot be carried out as the attachment is positioned to close to ground level in raised position.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

163

2°) Functional Operation a)

Compensation mode

True compensation or floatation ( compensation mode selected).

1. 2. 3. 4.

Attachment bumps: attachment raises -- pressure drops Compensation reaction: attachment raises -- pressure raises Attachment drops: attachment drops -- pressure raises Compensation reaction: attachment drops -- pressure drops

This mode is recommended when using a pick--up attachment. Start the engine and engage the cutterhead. Turn the attachment height control selector switch into ”pressure” position. Give a pulse on the automatic attachment height button. The attachment will automatically lower to the pre--selected pressure. Adjust the required ground pressure during harvesting by means of the ground pressure potentiometer. In this mode, the working pressure Pwork is adjusted with the potentiometer between 80% and 108% of the calibrated pressure P1 (= pressure calibrated in the low position, at sensor position S1). A line is drawn parallel to the line between P1 and P2 that runs through Pwork. The system will always try to maintain a position on this curve in function of sensor position S, for as long as the potentiometer remains in that position.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

164 2)

1. 2. 3.

Compensation in stubble height mode.

Attachment bumps: attachment raises -- pressure drops Compensation reaction: attachment raises -- pressure raises Obstruction passed: returns to preset stubble height

In the stubble height mode, the compensation will start working when the pressure drops below P1 -- 4 bar (P1 is the pressure at the calibration point just above ground level) at any stubble height. If for example P1 = 45 bar, then the compensation will always start working at 45 -- 4 bar = 41 bar, also if the pressure at the selected stubble height actually is 50 bar. So P1 determines the pressure at which the compensation will start working in stubble height control.

Stubble height mode

This mode is recommended when harvesting standing crops (e.g. maize) or when operating in stony conditions. Start the engine and engage the cutterhead. Turn the attachment height control selector switch into â&#x20AC;?Stubble heightâ&#x20AC;? position. Give a pulse on the automatic attachment height button. The attachment will automatically lower to the pre--selected height. Adjust the required attachment height during harvesting by means of the stubble height potentiometer. It is possible to adjust the attachment in the following stubble height range : Bottom level :

Ground level determined during calibration (Smin) --5% of the attachment height sensor operating range.

Top level :

Ground level determined during calibration (Smin) + 45% of the attachment height sensor operating range.

See following picture.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

165

5 3) Additional information : a) All signals from switches are communicated over the CAN network, but the attachment height control module (A60) does not communicate to the CAN network. For this reason all signals are again simulated by the actuator printed circuit.

Simulated functions: Attachment up and down switches : Common wire : 209--wt to X57/P09 ; 5 Volts. Switch up : 210--wt to X57/P36. Switch down : 211--wt to X57/17. Fast up or down (when harvest mode is selected) : 212--wt to X57/P03. Automatic Attachment height control button S30. Wire 206--wt to X57/P27 and wire 208--wt.

166

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Attachment height control selector switch S35; Wire 221--br to X57/P02, wire 214--bl to X57/P20 and wire 222--gn to X57/P21. Measured voltage at X57/P21 with selector switch S35 in following positions : Transport : between 63% and 80% of voltage at X57/P02. Compensation : between 21% and 42% of voltage at X57/P02. Stubble height : between 57% and 62% of voltage at X57/P02. Compensation potentiometer R7. Wire 2176--zw at X57/P05 ; between 0 and 10 Volts. Stubble height potentiometer R6. Wire 216--zw at X57/P22 ; between 0 and 10 Volts. Green led : Wire 215--gn at X57/P12. Red led : Wire 213--gn at X57/P31.

b) The attachment height sensor R4: Disconnect sensor : measured voltages with ground. X57/P39 : 9,5 Volts X57/P06 : 7,2 Volts Reconnect sensor. Sensor fully in : 7,2 Volts (app. 75% of voltage at X57/P39). Sensor fully out : 2,2 Volts (app. 25% of voltage at X57/P39).

c) Oil pressure sensor B13. Disconnect sensor : measured voltages with ground. X57/P39 : 9,5 Volts X57/P08 : 7,2 Volts Reconnect sensor. Oil pressure sensor on Max pressure (160 bar) : 7,2 Volts (app. 75% of voltage at X57/P39). Oil pressure sensor on Min pressure (0 bar) : 2,2 Volts (app. 25% of voltage at X57/P39).

4) Error messages : Refer to Attachment height control error messages list

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

167

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

168

23. GROUND SPEED

Hydrostatic oil pressure switch

Engine running See group 1

Hydrostatic oil temp. switch

MF handle forward = Drive forward

Speed indication on LCD

MF handle backward = Reverse drive

Servo valve hydrostatic pump

Reverse buzzer

Limb home procedure

Ground speed Rpm sensor

Mechanical conditions: * No handbrake * Machine in gear

Hydrostatic oil pressure led

PC Calibrations

Hydrostatic temperature led

Conditions 1. Engine is running. 2. Hydrostatic oil pressure is ok. 3. Hydrostatic oil temperature is ok. 4. Machine is not in limb home procedure. 5. Machine is in gear and handbrake is off. 6. To drive forward, the MF handle has to be moved to the front. To drive in reverse the MF handle has to be moved to the back. The reverse buzzer will sound as soon as the handle is out of neutral when moved to the back.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

169

What causes the machine to move? In short: A switch inside the handle monitors if the handle is in neutral. When moving the MF handle to the front or the rear the switch detects an out of neutral position. At the same time a potentiometer moves along with the movement of the handle. An electronic circuit inside the handle assembly makes sure that this movement is translated into a current which is transported to the hydrostatic servo valve in the hydrostatic pump. This valve again translates the current into a mechanical movement which controls the oil flow to the hydrostatic motor. This motor is responsible for the movement of the machine. Important things to know I: * In Road mode, the ground speed sensor is used to determine and regulate the maximum allowed speed. * In harvest mode, the ground speed sensor is NOT used to regulate the forward speed. A linear hydrostatic current curve is used to increase the forward speed. A maximum current of app. 105 mA (ID1304 word 4 = 1199) related to a maximum forward speed of app. 20 km/h in 3th gear. * When driving in harvest mode and exceeding a speed that is higher than 90% of the maximum calibrated forward speed, the machine will automatically go to ROAD mode, which means the engine rpm will drop back to 1650 rpm (Caterpillar engine) or 1750 rpm (Iveco engine). * If the ground speed sensor information is not available, the forward speed in ROAD mode will be set to a maximum of 90% of its maximum calibrated speed. * North America machines have the ability to select full engine speed in ROAD mode. II: It is not advisable but possible to move the machine with the handbrake on, however you will hear a warning signal from the LCD buzzer and the hand brake warning led on the dashboard will start blinking. III: Together with software introduction REV’99 a new function, the ’limb home’ procedure ( can id 1319) has been introduced: If a fault in the CAN communication between Multi--function Lever and dashboard occurs or if a Multi-function Lever errors code (error 12 or a combination of errors 350 & 351 together) occurs, resulting operator being unable to move the machine. The message ”urgent drive procedure continue yes/no” appears on the InfoView Monitor. 1. When choosing ”yes”, machine can be driven forward and rearwards at a speed of approximately 3 km /hour (depending of maximum speed calibration) using the crop processor gap adjustment switch on the dashboard (up = forward, down = rearward, spring loaded to centre = neutral). To escape from this mode switch off the contact. 2. When choosing ”no” the procedure is terminated. The fault must be repaired before the machine will move. IV: PC Calibration settings and LCD calibration settings are very important for ground speed troubleshooting. Before starting troubleshooting see that all calibrations are correctly done by following the instructions on laptop or pdt tool. They are for pc/pdt: * Maximum handle position * Minimum forward current to hydrostatic pump * Minimum backward current to hydrostatic pump * Ground speed constant * Maximum forward speed * Full engine speed in road mode (NA machines)

170

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7 All these calibrations can be checked through can id. And for LCD: * ground speed tuning in calibration mode on InfoView; its only purpose is displaying the correct speed on the info view, you cannot manipulate the real speed of the machine by changing the numbers. To make the meaning of the calibration values more clearly a potentiometervalue/speed diagram is given. As we can see here, when moving the handle forward, at first there is no movement of the machine until potentiometer value of 71Hex is reached. From then on we have a linear function until 90% of the maximum speed calibration has been reached. At this point the curve is no longer linear to prevent the machine from going above the calibrated speed. As for the reverse drive it is possible to drive up to about 15 kph, depending of the calibrated maximum speed, from there on the current to the pump stays the same. The hexadecimal numbers on the diagram are a reference, they don’t have to be exactly the same when checking a machine through can spy 1282, word 3. SPEED (V)

Vmax

Max. calibrated speed (¦ 30 km/h) 90% of max. calibrated speed (CANSPY page 1304)

FORWAR D DRIVE Vmin, FW

CANSPY Page 1283 -- word 3 = potentiometer value in HEX. Vmin, BW

Vmax, BW (¦ 15km/h)

REVERSE DRIVE

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

171

CAN SPY CAN ID

DESCRIPTION

word1 word2 word3 word4

1282 Multifunction lever

Out of neutral

=2==

1282 Multifunction lever

In neutral

=1==

1282 Ground speed potentiometer

==XX

1288 Ground speed based on PC calibration

COMMENTS

In neutral XX = 5C +/-- 20 or 48<XX<71 limits : 00 < XX < D0 +/-- 10

XXXX

Ground speed in mm/s based on PC calibration

1288 Ground speed displayed

XXXX

Ground speed in mm/s based on display calibration

1303 Hydrost. oil press. switch

Insufficient press

==8=

==0= : switch open ; ==8= : switch closed

1303 Hydrost. oil temp. switch

Temp too high

==4=

==0= : switch open ; ==4= : switch closed

1304 Drive backwards

Status

8===

0=== : not driving

1304 Drive forwards

Status

4===

0=== : not driving

1304 Ground speed > 90% V max. calibr. by pc

Status

===0 : ground speed < 90 % Vmax

1304 Current to hydrostatic pump

XXXX

Limits: 0000 < XXXX < +/--1199 (= +/-- 105 mA)

1314 Hydrostatic oil pressure LED

Lights up

4===

0=== : extinguished

1314 Hydrostatic oil temp. LED

Lights up

=8==

=0== : extinguished

1319 Activate Limb Home Request

Status

XXXX

53CA : to raise the request ; else 0000

1319 Answer Limb Home Request

Status

1331 Calibrated max speed

XXXX

1331 Calibrated max current to hydrost. pump 1342 Calibrated ground speed constant

0000 : not answered yet ; 55CC : ’yes’ is answered ; 1111 : ’no’ is answered mm/s (hexadecimal code)

XXXX

Maximal value : 1199 (= +/-105 mA)

=XXX

1342 Calibrated min forward current

Hexadecimal code XXXX

1342 Calibrated min backward current

Hexadecimal code XXXX

1342 Calibrated max handle pos.

Hexadecimal code XX==

Hexadecimal code

1345 Calibrated low acceleration hydr. pump

=8==

=0==: not calibrated (no); =8==:calibrated (yes)

1345 Calibrated full engine speed road mode

===8

===0: not calibrated (no); ===8: calibrated (yes)

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

172 Error codes

Error Codes

Description

120

Ground speed sensor O

121

Ground speed sensor --

122

Ground speed sensor +

350

Ground speed POT--M

351

Stop ground speed SW

362

No hydrost. pressure

363

Hydrost. sensor fault

420

Hydrostatic pump O

421

Hydrostatic pump --

422

Hydrostatic pump +

Electrical scheme See group 3

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

173

174

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

24. HIGH FLOW HYDRAULICS

Harvest Mode See group 3

High capacity hydraulics switch UP

High capacity hydraulics switch down

High capacity Hydraulics UP

PC Calibration High Flow Hydraulics

High capacity Hydraulics down

To use the high capacity hydraulics. 1. Switch ON ignition and start the engine. 2. Switch ON the Harvest switch. 3. Press the high capacity hydraulics UP switch to power the high capacity UP valve. Press the high capacity hydraulics DOWN switch to power the high capacity DOWN valve.

REMARKS: High capacity hydraulics are an accessory. To use the high capacity hydraulics, first the switch needs to be installed in the dashboard and the PC calibration “High Flow Hydraulics” needs to be set (check on CAN SPY page 1345). Afterwards the output lines can be powered.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

175

Can Spy CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

COMMENTS

1283 High Flow Hydraulics open switch

Pressed

2===

0=== : not pressed

1283 High Flow Hydraulics close switch

Pressed

=2==

=0== : not pressed

1345 Calibrated High Flow Hydraulics

==8=

Error Codes

Error Code

Key words

301

Dashboard switch 1

467

High cap. hydr. up sol.

468

High cap. hydr. down sol.

Electrical diagram Group 28: High capacity rear hydraulics.

==0=: not calibrated (no); ==8=:calibrated (yes)

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

176

25. ROTARY SCREENS Engine running See group 1

Rotary screen motor left

PC calibration rotary screen

Rotary screen motor right

Conditions: As soon as the engine starts running, the rotary screens start rotating.

REMARK: The electronic system should be informed if rotary screens are installed to avoid error reports. See PC Calibration. Can Spy CAN ID

DATA DESCRIPTION

1345 Calibrated rotary screens 1347 Rotary screens

===1 Output status

Error codes

Error Code 446

word1 word2 word3 word4

Description Rotary screen motor

COMMENTS ===0: not calibrated (no); ===1: calibrated (yes)

4===

4=== : activated ; 0=== : not activated

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

177

26. ROTARY SCREEN BRUSHES

Safe Harvest See group 3

PC calibration

LCD calibration

Dust screen brush actuator

Conditions: To enable the brushes to clean the rotary screens, the pc calibration ’rotary brushes’ has to be set first (check on can spy page 1345) . In the calibration/type menu of the LCD there are two options out of which you can choose to determine the frequency of the brush cleaning. There is a ’frequent’ option for heavy conditions (= every 8 minutes the brush engages 2 minutes) and there is a ’standard’ option (= brush engages 1 minute every 15 minutes). This feature is introduced with software version REV’99.

Can Spy CAN ID

DATA DESCRIPTION

1345 Calibrated rotary screen brushes

word1 word2 word3 word4 ==1=

Comments =0==: not calibrated (no); =1==:calibrated (yes)

Error codes

Error Code 445

Description Rotary screen brush

REMARK: Error 405 is suppressed by software. The actuator contains end of stroke switches which will create an error code every time the actuator is extracted or retracted. For this reason the error code is suppressed.

178

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

27. CATERPILLAR ENGINE

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

179

General Information 1°)

Power Supply

Power (12 V) is supplied from the actuator printed circuit X413 p07 to the Caterpillar electronic Control Module. Same output as the engine stop solenoid hold current on Aifo/Iveco engines. See electrical drawing group 9. Conclusion: -- 12 V after ignition, to be able to start the engine. -- Engine will stop immediately or can not be started when output line becomes low (0V). REMARK: Output current is approximately 3 Amp.

2°)

Engine Throttle control

New CPU printed circuit available for FX 58. Can also be used on other FX forage Harvesters. Special PWM output line only used for FX 58 on X415 p04. Frequency: 500 Hz Nominal (between 300 and 700 Hz) Pulse width minimum engine rpm (850 rpm): 20% Pulse width maximum engine rpm (2100 rpm): 80% The engine rpm in road mode for the Caterpillar engine is 1650 rpm, on Aifo machines it is 1750 rpm. See electrical diagram group 2.

3°)

CAN Network

The CAN communication wires to the Caterpillar engine are parallel on the CAN wires of the metal detector. See electrical diagram group 11. New AOM printed circuit involved, only for FX 58. Can not be used on other FX forage Harvesters. A CAN resistor R31 of app. 120 Ω is installed close to the Caterpillar electronic control Module to obtain a correct CAN communication.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

180

CAN IDENTIFIER LIST See complete CAN Identifier List CAN Identifier 1352 & 1353 CAN ID

DATA DESCRIPTION

word1 word2 word3 word4

1352 Coolant temperature

Status

XX==

1352 Fuel temperature

Status

==XX

1352 Inlet air temperature

COMMENTS Range : --40°C to +210°C (1C/bit)

==XX

Range : --40°C to +210°C (1C/bit)

Status

XX==

Range : --40°C to +210°C (1C/bit)

1352 Load percentage at current engine speed

Status

==XX

Range : 0% to 125% (1%/bit)

1352 Inlet manifold pressure

Status

XX==

Range : 0kPa to +500 kPa (2kPa/bit)

1352 Engine oil pressure

Status

==XX

Range : 0kPa to +1000kPa (4kPa/bit)

1352 Calibrated maximum engine Status rpm

XXXX

Range : 0 to 8031.875 rpm (0.125 rpm/bit)

1353 Engine rpm

Status

1353 Error codes report

Status

4°)

XXXX

Range : 0 to 8031.875 rpm (0.125 rpm/bit) XXXX

XXXX

See detailed list

Error codes reporting

Two wires from Caterpillar electronic control module towards the CPU printed circuit are used for error code reporting. When the Caterpillar electronic control module detects an error, the corresponding CAT error code number is shown on the InfoView Monitor below the engine rpm bargraph. Detailed list of Caterpillar error codes: see section 55--7B.

Error codes

Error Code

Description

118

Caterpillar Network Error

340

No Engine oil press.

361

Oil press. sens. fault

364

Cat. oil temp. sensor

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

181

5°) Engine protection -- From an engine coolant temperature of 103° C the Caterpillar software reduces the available engine power in steps of 25% per ° C. -- The engine is shut down by the NH electronic system (see point 1: power supply) when the engine coolant temperature reaches 105° C or when the engine oil pressure is less than 1 Bar. -- An additional engine oil temperature sensor located in the oil sump will stop the engine at a temperature of app. 118° C. This sensor is connected to the NH electronic system (see electrical wiring diagram: group 20) and is used as a back--up sensor to protect the Caterpillar engine when a CAN network fault occurs. This engine protection device is programmed to wait 10 minutes with engine below 1500 rpm or 3 minutes with the engine above 1500 rpm. This is to allow the oil temperature to rise above the minimum operating limit of the sensor. If the sensor or wiring to this sensor becomes defective, the engine shuts down. REMARK: Both protection devices work parallel to each other. The first who indicates an excessive temperature or pressure will activate the engine shut down procedure. So the engine will stop after 10 seconds. If the engine has been shut down, restart the engine by leaving the contact on and restart. Afterwards the message “AUTOMATIC ENGINE SHUT OFF DISABLED” will appear on the InfoView monitor.

6°) Caterpillar operation A FX machine with Caterpillar engine (FX 58) is operated a complete identical way as other FX for age Harvesters. Exceptions: -- The engine load bargraph at the right--hand side of the screen represents the engine power consumption. The top (narrow) segment represents the engine power range from 95% to 100%. The lower (wide) segment represents the engine power range from 100% to 110%. -- When the engine rpm drops below 1850 rpm and the power consumption is above 98%, a buzzer will warn the driver to slow down. Also the engine symbol will blink.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

182

28. CAN NETWORK

B InfoView Monitor

Adjust-O--Matic Node

Dashboard Node

CPU Node

B EMD

B Caterpillar Only FX 58

General procedure to diagnose CAN--NETWORK -- Verify Software Revision on Service page. • If Rev99 or later is displayed, correct software is installed and no network fault is present. • If Rev X.X is displayed, incorrect software revision is installed or a network fault is present. --

Check software revision CAN--Identifiers in CAN SPY

Node

Location

A&S

InfoView Monitor

1326 ==== ==== ==XX ==XX

CPU printed circuit

1303 ==== ==== ==XX ====

AOM printed circuit

1304 ==== ==== ==XX ====

Metal Detector

1276 ==== XX== ==== ====

CAN--Identifier

If one or more nodes contain a “00” --value or not the correct value, try to download the correct software revision in the corresponding nodes.

REMARK: If the AOM printed circuit is defective and a “OO” value is displayed on the CAN--Identifiers 1304, most probably a “00” will also be displayed for the B Node and M Node, as all communication goes over the AOM printed circuit.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

183

Conclusion: -- If B, D and M node indicate a “00” value, start to focus on the D--Node. • If the software download is finished correctly, check if the problem persists by starting the engine and clearing all error codes in the error overview. • If the software download procedure will not start, or is not finished correctly, a hardware problem is causing the problem. --

First check all power supplies to all printed circuits. • Check fuses F4 and F11. • Check for battery voltage when ignition is switched on: at X303 p07 in Dashboard at X417 p15 on CPU printed circuit at X4133 p14 on CPU printed circuit at X413 p08 on Actuate printed circuit at X619 p02 at Metal detector at X57 p24 at Bosh Module • Check for ground at X303 p10 in Dashboard at X417 p06 on CPU printed circuit at X433 p01/02 on AOM printed circuit at X619 p03 at Metal detector at X57 p28/07 at Bosh Module

If necessary, locate and repair open or shorted circuit in Electronic box. Replace fuses. Start engine again to verify if problem persists. --

Check fibber optics and flat cables and their connections. Refer also to error code list: errors 1 to 15.

To understand better the function of the network error codes imagine you are in the InfoView monitor. • Information sent out from the InfoView towards the CPU Node through the flat cable and optical fibbers is not arriving in one node. However the communication lines towards the InfoView Monitor are still correct. These nodes will lose synchronisation in communicating to each other and the InfoView monitor can not understand any longer the messages. For this reason, the InfoView monitor will display an Error 1 (and 2). • If information sent out from the CPU--Node towards the InfoView monitor is interrupted somewhere, the closest node can still communicate in a correct way and indicate he does not receive good information from the other node. In this way: an error 10 will be displayed in case of incorrect communication from dashboard to InfoView Monitor an error 13 will be displayed in case of incorrect communication from CPU--Node to AOM--node an error 15 will be displayed in case of incorrect communication from AOM--Node to dashboard. REMARK: An error 117 will be displayed in case of incorrect communication with the Metal detector. An error 118 will be displayed in case of incorrect communication with the Caterpillar electronic Module (only for FX 58).

184

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Additional Information Difficulties to download software: 1. Software download does not start. 2. Software download interrupts after a few seconds. We recommend to proceed as follows in case of a problem: 1. Make sure the batteries are fully charged. 2. When the software download does not start, try to switch the ignition key off and on again several times. 3. When the software download interrupts, it is possible to download an individual software node by connecting the fibre optics from the dashboard directly to the printed circuit you want to update. REMARK: Always write down the position of the optical wires before disconnecting so that you can reinstall them in the original position after software download.

For FX/96 Forage Harvesters proceed as follows: a) Download of node A and S (in InfoView monitor) Disconnect optical wires (from dashboard) in central box on the Adjust--O--Matic printed circuit. Only the InfoView can receive the CAN messages. After software download, (re)connect all optical wires to the original positions. b) Download of node B (in CPU printed circuit) Disconnect the small optical wires (from Adjust--O--Matic print) in the central box on the CPU printed circuit. Remove the optical wire (from the dashboard) located in the white sender of the AOM print and connect to the white sender of the CPU print. Proceed in the same way with the other optical wire in the black receiver. Only the InfoView and the CPU print can receive the CAN messages. After software download, (re)connect all optical wires to the original positions. c) Download of node D (in AOM printed circuit) Disconnect the small optical fibres in the central box on the CPU printed circuit. Disconnect the CAM communication line to the metal detector. Disconnect for example X431 on AOM printed circuit or X627 above RHS tractor wheel. Only the InfoView and the AOM print can receive the CAN messages. After software download, (re)connect all optical fibres to the original positions.

How to recognize a network error code: If a AOM network failure occurred, all AOM Leeds on the dashboard will illuminate, the led of the sharpening cover will start to flash and the work lights will illuminate. If a CPU network failure occurred, the engine oil pressure led, the engine coolant led, the battery led, the airco leds will illuminate or will start to flash, also the work lights will illuminate. REMARK: Since 1996, the errors 1 to 15 will only appear on the InfoView Monitor when the problem occurred while the engine was running. In all other cases, the errors will not appear, but the above described symptoms will indicate the presence of a Network failure.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

185

The Auto Voting PC--calibrations exchange The calibration preferences are stored on three nodes, e.g. InfoView Monitor, CPU and AOM printed circuits. When the engine is started these calibration settings are compared. If the choises or settings on one Node is different from the others, the Nodes in majority will influence and change the choises or settings of the node that is in the minority. For this reason never exchange two printed circuits at the same time.

Software download The Auto--Voting PC--calibrations exchange does not apply to the software itself, so always check new printed circuit boards if the correct software is installed (by means of the CAN--Identifiers), If not correct, always download the correct software first.

12 V battery voltage after ignition Engine hours cutterhead hours, hectare information and calibrations settings need to be stores after the engine has been stopped. Therefore permanent battery voltage need to arrive on InfoView Monitor, CPU and AOM printed circuit to store this information. REMARK: 12 V battery voltage can be found on flat cable, position 15 and 16 in InfoView Monitor. When no battery voltage arrives in InfoView Monitor you will not hear a relays click after 3 to 5 seconds after ignition has been switched off. This can result in an Error Code 100 after some time.

186

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

SECTION 60 -- PRODUCT FEED Chapter 1 -- Feed Rolls CONTENT Section

Description

Page

60.103

Removal and installation of lower feed rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

60.107

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

REMOVAL AND INSTALLATION OF LOWER FEED ROLLS LOWER FRONT FEED ROLL Removal and disassembly 1. Remove the upper feed roll module from the chopper body. 2. On the right-hand side, remove plates C and D by removing bolts A and B.

55126

3. Disconnect the metal detector cable at connector E and the ground cable at F. 4. Support the right-hand end of the lower feed roll and remove the locking bolt of the drive collar A. (Fig. 4). Push the collar towards the length-of-cut gearbox on the left-hand end of the feed roll (Fig. 4).

55127

5. Remove bolts G and H, loosen bolts J (Fig. 2) and lift away the side plate K. 6. Remove the lower front roll by lifting it out to the right.

55128

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

7. Remove mounting bolts B. 8. Pull flange and shaft assembly C out of the feed roll. 9. Pull the metal detector shaft D with flange and bearing assembly E out of the feed roll. NOTE: If the electronic box needs to be replaced, this can be done now.

30655

10. Remove ground cable A and the four electronic box fastening bolts B and tilt the box to the side.

55129

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

11. Remove the wire clamps C and disconnect the wires at connectors. 12. Install a new electronic box in reverse order of disassembly.

55130

13. Disassemble the flange assemblies E and F from the metal detector shaft D. 14. Disassemble bearings and seals and replace, if necessary.

30656

Assembly Install the lower front feed roll in the correct way. The arrow shows the feeding direction of the roll (Fig. 4). To assemble, proceed in reverse order of the disassembly sequence. Ensure to seal off possible openings in the feed roll with sealing paste.

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

SMOOTH ROLL Removal 1. Remove the upper feed roll assembly. 2. On the right-hand side, remove plates C and B by removing bolts A and B (Fig. 1). 3. Support the right-hand end of the lower feed roll. 4. Remove bolts G and H, loosen bolts J (Fig. 2) and lift away side plate K (Fig. 3). 5. Remove the smooth roll scraper.

55131

6. Remove bolt A from the smooth roll drive sleeve B.

7. Remove bolts C and remove the smooth roll to the right from the chopper body.

55132

8. Remove sleeve B from shaft G. 9. Remove circlip D, special bearing E and O-ring F from shaft G.

55133

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

10. Remove circlip H, locking collar J, bearing housing K with bearing, anti-wrap shield L and bushing M from shaft N.

55134

11 Assembly To assemble, proceed in reverse order of the removal sequence. NOTE: Before installing the smooth roll into the chopper body, push drive sleeve B onto shaft G (Fig. 10). Make sure the sleeve does not bind on the shaft. Install bushing M (Fig. 11) with the rounded surface towards the smooth roll. Bearing housing K has oblong holes C (Fig. 11). Adjust bearing housing K so that the smooth roll distance to the shearbar support P is the same on both ends of the smooth roll (Fig. 9). Adjust the smooth roll scraper so that there is a maximum clearance of 0.1 mm to the smooth roll.

SECTION 60 -- PRODUCT FEED -- CHAPTER 1 INSPECTION BETWEEN UPPER ROLLS AND CUTTERHEAD

FEED

NOTE: The attachment must remain attached to the forage harvester. Opening up the assembly 1. Lower the chopper body until the attachment rests on the ground. 2. Disconnect the two quickâ&#x20AC;&#x201C;release hydraulic couplings 2.

3. Maize attachment with Auto-Pilot only: Disconnect electric cable 3. 4. Remove the cover on the left-hand side.

5. If the chopper body is fitted with an automatic greasing system, disconnect the grease line(s) between the upper feed roll module and the chopper body. If there is a grease line to the attachment that is not coming from the upper feed rolls module, disconnect that one as well. 6. Disconnect attachment drive p.t.o. shaft 4.

58227

7. Remove cover 7 and bolt 6. Remove upper feed roll drive shaft 5 by pulling out shaft 8.

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

8. Unscrew clamping rods 9 between the upper feed roll module and the cutterhead. 9. Extend the hydraulic cylinders by giving the ‘‘attachment up’’ command from the multifunction lever.

58228

15 10. Install safety latches 10 by removing lynch pins 11 on both sides. A V–shaped gap will appear between the feed rolls and the cutterhead. This will enable you to inspect the cutterhead knives and the shearbar in a quick way (Fig. 17). If necessary, the cover above the cutterhead can be removed for an even better access.

16 Closing the assembly 1. Lift safety latches 10 from the cylinders and secure them with lynch pins 11 (Fig. 16). 2. Give the ‘‘attachment down’’ command from the multifunction lever to retract the hydraulic cylinders after ensuring nobody is near the machine.

30521

17 3. Reinstall clamping rods 9 between the upper feed roll module and the cutterhead, and tighten firmly.

58228

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

4. Reinstall attachment drive p.t.o. shaft 4.

58227

5. Reinstall upper feed roll drive shaft 5 with shaft 8 and bolt 6. Reinstall cover 7. NOTE: Make sure that the drive yokes on each end of the attachment drive shaft are in phase. Make sure that the attachment drive shaft is installed in such a way that the shaft end cannot touch the feed roll gearbox. 6. If the machine is fitted with an automatic greasing system, connect the grease line(s) to the upper feed roll module and the attachment. 7. Reinstall the cover on the leftâ&#x20AC;&#x201C;hand side.

8. Maize attachment with Auto-Pilot only: Connect electric cable 3. 9. Connect the two quickâ&#x20AC;&#x201C;release hydraulic couplings 2, if needed.

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

FLIP DOWN UPPER FEED ROLLS Opening up the assembly 1. Detach the attachment as described in paragraph headed ‘‘Attachment’’. 2. Remove the cover on the left-hand side. 3. If the attachment is fitted with an automatic greasing system, disconnect the grease line(s) to the upper feed roll module. 22

4. Remove cover 7 and bolt 6. Remove upper feed roll shaft 5 by pulling out shaft 8.

5. Unscrew clamping rods 9 between the upper feed rolls and the cutterhead.

58228

6. Place a wooden block (approximate height 25 cm) on the workshop floor where profile 10 is supposed to come. This is to protect your feet. 7. Flip down the upper feed roll module until it touches the wooden block.

WARNING Flipping down the upper feed rolls is a job to be carried out by at least three people. Utmost care should be taken. 58230

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

Closing the assembly 1. Lift up the upper feed roll module. 2. Reinstall clamping rods 9 between the upper feed roll module and the cutterhead, and tighten firmly.

58228

3. Reinstall upper feed roll drive shaft 5 with shaft 8 and bolt 6. NOTE: Make sure that the drive yokes on each end of the drive shaft are in phase. Make sure that the attachment drive shaft is installed in such a way that the shaft end cannot touch the feed roll gearbox. 4. If the attachment is fitted with an automatic greasing system, connect the grease line to the upper feed roll module. 5. Reinstall the cover on the left-hand side.

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

DETACHING -- ATTACHING OF ATTACHMENT WITH UPPER FEED ROLLS

Detaching 1. Install supports 1 on both sides of the pick-up attachment.

30884

27 In case of a maize attachment, lower supports 1 on both sides.

28 2. Remove the two pins 2 of the upper feed roll module underneath the chopper body (left and righthand side). 3. Lower the attachment to the ground until it rests on its supports and skids.

29 4. Disconnect quick-release hydraulic couplings 2. 5. Maize attachment with Auto-Pilot only: Disconnect electric cable 3. 6. Remove the cover on the left-hand side. 7. If the chopper body is fitted with an automatic greasing system, disconnect the grease line(s) between the upper feed roll module and the chopper body. If there is a grease line to the attachment that is not coming from the upper feed roll module, disconnect that one as well. 30

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

8. Disconnect attachment drive p.t.o. shaft 4.

58227

31 9. Remove cover 7 and bolt 6. Remove upper feed roll drive shaft 5 by pulling out shaft 8.

32 10. Unscrew clamping rods 9 between the upper feed roll module and the cutterhead. 11. Lower further until the lower feed rolls are loose. 12. Carefully reverse the harvester.

58228

33 13. Now all upper feed rolls are accessible.

30523

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

The cutterhead and the shearbar are accessible (Fig. 34 and 35).

52490

35 The accessibility to the cutterhead can be improved by removing cover 10 above the cutterhead.

58229

36 Attaching 1. Drive up to the attachment and lift the chopper body. 2. Reinstall the two pins 2 underneath the chopper body connecting the upper feed roll module to the chopper body. 3. Lower the attachment until the gap is closed (if necessary, use the attachment supports). 37 4. Reinstall clamp rods 9 between the upper feed roll module and the cutterhead, and tighten firmly.

58228

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

5. Reinstall attachment drive p.t.o. shaft 4.

58227

6. Reinstall upper feed roll drive shaft 5 with shaft 8 and bolt 6. NOTE: Make sure that the drive yokes on each end of the attachment drive shaft are in phase. Make sure that the attachment drive shaft is installed in such a way that the shaft end cannot touch the feed roll gearbox. 7. If the attachment is fitted with an automatic greasing system, connect the grease line(s) to the upper feed roll module and the attachment. 8. Reinstall the cover on the left-hand side.

9. Connect hydraulic quick-release couplings 2, if needed. 10. Maize attachment with Auto-Pilot only: Connect electric cable 3.

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

11. Relocate the supports at 1 of the pick-up attachment.

30884

42 In case of a maize attachment pull up the supports 1 on both sides.

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

REMOVAL -- INSTALLATION OF UPPER FEED ROLLS FX/96

Series 01 to 12

FX25-45

Series 01 to 04

Removal 1. Drain the oil from the upper feed roll chain box through plug 2. 2. Remove the upper feed roll module from the chopper body. 3. Release the feed roll spring tension and disconnect the springs from the upper feed roll assembly. 4. Remove support assembly A on both sides of the feed roll assembly. 58200

5. On both sides, remove bolt C and screw bolts D in to pull out pivot shafts B.

NOTE: Pivot shaft B in the chain box is installed with Oâ&#x20AC;&#x201C;rings C (Fig. 46). 6. Remove bolts D so the side plates are loose from the roll supporting bearing housings. 7. Remove bolts E and cover F. 8. Remove dowel pin G and pull out the drive shaft yoke. Do not lose shims W.

55125

45 9. Remove bolts H, J and L. 10. Remove four bolts K and lift out the cross bar. 11. Make an extractor plate and pull out chain box M from feed roll shafts P and Q. 12. Pull the leftâ&#x20AC;&#x201C;hand shaft suspension casting N from shafts P and Q. 13. Remove circlip S and pull out bearing R. 14. Remove circlip GG and pull out bearing T.

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

15. Remove ring AA, journal bearing BB and ring V from shaft Q. 16. Remove circlip FF, ring CC, journal bearing EE and ring DD from shaft Q. 17. To disassemble the chain box, refer to paragraph headed “Upper feed roll drive chain box”.

Assembly To assemble, proceed in reverse order of the disassembly sequence. NOTE: Install the pivot shafts using a liquid sealant.

30653

SECTION 60 -- PRODUCT FEED -- CHAPTER 1 FX/96

Series 13 > .........

FX25-45

Series 05 > .........

Removal 1. Detach the attachment as described in paragraph headed ‘‘Attachment’’. 2. Drain the oil from the upper feed roll chain box through plug 2. 3. Flip down the upper feed roll module as described in previous paragraph.

58200

4. Release the feed roll spring tension and disconnect the springs 1 from the upper feed roll assembly. Hold nut 6 in place with a flat wrench and loosen bolt 2.

58417

48 5. Loosen locknuts 2, remove cotterpins 3, remove nuts 4 and remove locknuts 2 on both sides.

49 6. Remove support A on both sides of the feed roll assembly. 7. On both sides, remove bolt C and screw in bolts D to pull out pivot shafts B. NOTE: Pivot shaft 28 in the chain box is installed with O–rings 29 (Fig. 52). Write down the quantity and position of shims at 15 and at 27. Retain them for the reassembly. 55125

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

8. Disconnect the shock absorbers at 1 and 2 on both sides.

51 9. Remove the upper feed roll assembly with a lifting tool out of the module. 10. Remove bolts 17, 24, 30 and covers 18, 25, 31 (Fig. 52). 11. Remove bolts 21 so the side plates are loose from the roll supporting bearing housings 12. Remove dowel pin 11 and pull out the drive shaft yoke 10. 13. Remove bolts 16, 26 and 32. 14. Remove eight bolts 34 and lift out the cross bar 33. 15. Pull out chain box 23 with an extractor plate from feed roll shafts 5 and 22. 16. Pull the suspension casting 14 from shafts 5 and 22. 17. Remove circlip 19 and pull out bearing 20. 18. Pull out bearing 13. 19. Remove shims 12, ring 9, journal bearing 8, shims 6 and washer 7 from shaft 5. 20. Remove ring 1, journal bearing 2, shims 4 and washer 3 from shaft 5. 21. To disassemble the chain box, refer to next paragraph. Assembly To assemble, proceed in reverse order of the disassembly sequence. NOTE: Install the pivot shafts using a liquid sealant.

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

DISASSEMBLY AND ASSEMBLY OF UPPER FEED ROLL DRIVE CHAIN BOX

which tensions the chain more is available from Service Parts.

Disassembly

3. Remove bolts E and pull apart the two chain box halves A and B (Fig. 54).

1. Remove the chain box from the chopper body as described in previous paragraph headed â&#x20AC;&#x153;Removal -- Installation of the upper feed rollsâ&#x20AC;&#x153;. 2. Remove oil dipstick A, bolts B and cover C (Fig. 53). NOTE: If only the chain is slack: Remove bolts K and replace chain tensioner D(Fig. 53). If the original version of the chain tensioner is not giving proper tension to the chain, a second version

NOTE: The chain box halves are sealed with a liquid sealant. 4. Remove sprockets G and H. Replace if necessary (Fig. 54). NOTE: Always replace both sprockets and the chain at the same time. 5. If necessary, replace bearings C, F, J and L, and seals D and K (Fig. 54).

30658

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

30659

SECTION 60 -- PRODUCT FEED -- CHAPTER 1

Assembly 1. Assemble the box in reverse order of disassembly. 2. Fill the gearbox with 0.5 litre of oil with the following specifications: -- API GL5 or MIL--L--2105 D -- Viscosity grade: SAE 80W -- 90

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

SECTION 60 -- PRODUCT FEED Chapter 2 -- Length-Of-Cut and Feed Roll Drive Gearbox CONTENT Section

Description

Page

60.122

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

GEARBOX SHAFTS AND SHIFTING DIAGRAM GEARBOX SHAFTS FROM THE LEFT Shaft A: Input shaft Shaft B: Counter shaft Shaft C: Upper feed roll drive intermediate shaft Shaft D: Upper feed roll drive gear Shaft E: Attachment drive shaft Shifter rod H: Long shifter rod for gear positions 1 and 2 Shifter rod J: Short shifter rod for gear positions LOW and HIGH

54831

GEARBOX SHAFTS FROM THE RIGHT Shaft A: Input shaft (not visible) Shaft B: Counter shaft Shaft C: Upper feed roll drive intermediate shaft Shaft D: Upper feed roll drive gear Shaft E: Attachment drive shaft Shaft F: Lower front feed roll (electronic metal detector roll) drive shaft Shaft G: Smooth roll drive shaft 54832

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

SHIFTING DIAGRAM

31058

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

REMOVAL OF THE LENGTH-OF-CUT GEARBOX FROM THE CHOPPER BODY 1. Drain the oil from the gearbox. 2. Remove guards A and B.

54833

4 3. Remove the p.t.o. shaft B from the gearbox. 4. Remove bolts D and cover E, and pull out upper feed roll drive shaft C. Remove shaft A. 5. Slide the smooth roll drive bushing towards the smooth roll. 6. Slide the lower front feed roll bushing towards the gearbox. 54834

5 7. Support the gearbox with a hoist or other lifting gear. 8. Remove the gearbox mounting bolts and bushings. If shims are installed, note the position and the quantity of shims installed. 9. Pull and lift the gearbox away with a hoist using the lifting eye provided. NOTE: The gearbox is heavy, take the necessary precautions to avoid accidents.

54835

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

LENGTH-OF-CUT GEARBOX DISASSEMBLY

4. Open stake lock washer Q and remove lock nut P and washer Q.

REMOVAL AND DIS ASSEMBLY OF THE INPUT SHAFT GROUP

5. Press shaft A out of bearing housing F and remove bearing T from shaft A.

1. Mark the position of bearing cap M and bearing housing F and remove grease fitting H.

6. Remove bearing cones D and J and seal S from bearing housing F.

2. Remove the four bolts and hardened washers G and pull out the input shaft assembly. Be careful not to damage shims at E or the O--ring C.

NOTE: Seals N and S will be damaged when they are removed.

3. Remove bolts and washers L and remove cover M from the bearing housing F. If damaged remove seal N. Take care not to damage O--ring K.

31059

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

REMOVAL OF UPPER FEED ROLL DRIVE SHAFT D AND INTERMEDIATE DRIVE SHAFT ASSEMBLY C 1. Remove bolts and washers H and cover Q.

3. Remove bushing K from shaft D. 4. Remove bearings E, G, M, and N from the shafts or bearing housings. Remove ring L. 5. Remove seals F and J.

NOTE: Cover Q was installed with liquid sealant. 2. Pull out shafts D and C and remove gear P from shaft C.

NOTE: Seals F and J will be damaged when they are removed.

31060

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

REMOVAL OF SMOOTH ROLL DRIVE SHAFT G

3. Remove circlip V and tap out shaft assembly G.

1. Remove bolts and washers C, bearing cap H and shims J. Take care not to damage O--ring D. Retain the shim pack J for later use.

4. Remove circlips S, W, and M.

NOTE: The removal of bearing cap H is necessary only if gear A or shaft B need to be removed from the gearbox or bearing F needs to be replaced.

2. Remove bolts Q and tap out housing R together with shaft assembly G and bearing cone E. Note the positions of the bolts.

5. Remove bearing components K and L, ring N and seal P. NOTE: Seal P will be damaged when it is removed. 6. Pull bearing F and gear A from shaft B. Note the way gear A is installed on the shaft.

31073

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

REMOVING COVER C FROM THE GEARBOX 1. Remove bolts and washers D and cover H. Take care not to damage O--ring J. 2. Remove circlip G from the shaft HH. 3. Remove circlip M from shaft F. 4. Remove bolts and washers Q and the bearing cap P. Take care not to damage seal L or O--ring K.

6. Remove bolts and hardened washers A and note the location of the bolts. Replace damaged washers. 7. Tap cover C loose from the gearbox and pull it away over the shafts. NOTE: Cover C was installed with liquid sealant. 8. If damaged, remove the bearings JJ, AA, T and R , circlips KK, FF, W, V and S from cover C and ring EE from shaft F.

5. Remove circlip N.

31072

SECTION 60 -- PRODUCT FEED -- CHAPTER 2 DISASSEMBLY OF SHAFT AND SPROCKET ASSEMBLIES B, E AND F 1. Remove bearing race H, circlip G, spacer ring J, gear D and the needle bearings C from shaft F (Fig. 11). 2. Pull gear C from shaft E and remove needle bearings B and D from gear C and shaft E (Fig. 12). 3. Remove nut K (installed with thread retainer) and washer G from shifter shaft H (Fig. 14).

6. Pull and lift out the shaft and gear assembly B (Fig. 13). Gear L and the bearing components A and C have to be removed at a later stage. 7. Remove nut M (installed with thread retainer), lock washer N, washer P and spring Q from shifter shaft J (Fig. 14). 8. Remove shifter fork R (Fig. 14) and and shifter gear A (Fig. 12) simultaneously. 9. Remove circlip J from the end of the shaft E and drive out the shaft (Fig. 12).

4. Remove shifter fork L (Fig. 14) and shifter gear A (Fig. 11) simultaneously.

10. Remove seal H, spacer K and O--ring L (Fig. 12).

5. Remove bolt E, special washer D and oil plate G from shaft B (Fig. 13).

NOTE: Seal H will be damaged when it is removed.

31063

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

11. Remove circlip S and pull out shifter fork T (Fig. 14) together with shaft and bearing assembly F (Fig. 11). Remove gear L (Fig. 13) from the gearbox.

15. Remove Allen screw FF, spring DD, ball CC, spring V and circlips W and AA. Pull the shifter shaft J out of the gearbox housing (Fig. 14).

12. Remove failed bearings, rings and seals from the housings of the gearbox main casting (Fig. 11, 12 and 13).

NOTE: O--ring BB will be damaged when shaft J is removed (Fig. 14).

13. Remove the bearing inner race C from gear L (Fig. 13). 14. Remove Allen screw C, spring D and ball B from the gearbox housing and circlip F from shaft H. (Fig. 14) Pull shaft H out of the gearbox housing.

16. Remove washers and bolts J and bearing cap K and shims H (Fig. 13). Retain the shims for later use. 17. Remove bearing cone A from the gearbox housing. (Fig. 13).

NOTE: O--ring E will be damaged when shaft H is removed (Fig. 14).

31064

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

54749

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

LENGTH-OF-CUT GEARBOX ASSEMBLY INSTALLATION OF THE (SHORT) SHIFTER SHAFT H INTO THE GEARBOX HOUSING 1. Remove any paint from shaft H and lubricate the shaft. 2. Move circlip A on the shaft as close as possible to the black knob. 3. Introduce the shaft into the gearbox. As soon as possible slide the O--ring E onto the lubricated shaft H so that it is seated in its groove at E. 4. Pull O--ring K into the housing far enough to install circlip A. Install circlip F. 5. Install ball B, spring D and Allen screw C. Lock screw C in place with thread retainer.

INSTALLATION OF THE (LONG) SHIFTER SHAFT J INTO THE GEARBOX HOUSING 1. Remove any paint from shaft J and lubricate the shaft. 2. Move circlip EE on the shaft as close as possible to the black knob. 3. Introduce shaft J into the gearbox. Slide the O-ring BB onto the lubricated shaft. Move shaft J so far that the O--ring can be installed in its groove at BB. Install circlips AA and W into their grooves. 4. Pull O--ring BB into the housing far enough to install circlip EE. 5. Install ball CC, spring DD and Allen screw FF. Secure screw FF in place with thread retainer.

31066

SECTION 60 -- PRODUCT FEED -- CHAPTER 2 INSTALLATION OF SHAFTS AND GEARS INTO THE GEARBOX HOUSING

4. Drive bearing inner race L onto shaft F and install circlip N. Keep the bearing outer race M together with this assembly.

Preassembly of lower feed roll drive shaft F 1. Install the two needle bearings J, gear H and spacer ring G and onto shaft F. 2. Install a set of three needle bearings E, gear carrier K and shifter gear D onto shaft F.

NOTE: Bearing component L may be heated up to 100Â°C maximum to facilitate the installation. NOTE: The disassembly is done in reverse order of the assembly sequence.

3. Install rings C and B and gear A onto shaft F.

31085

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

Preassembly of counter shaft B 1. Install bearing cups C and E into the gear assembly D. 2. Install bearing A on shaft B and drive it in until it is properly seated. 3. Install gear assembly D onto shaft B and install bearing F onto shaft B. NOTE: You can also heat up the bearing components A and F to 100Â° C maximum to facilitate the installation.

5. Tighten the lock nut H until there is no axial play in the assembly. A slight preload is needed, the shaft should not turn freely. 6. Secure nut H with washer J. 7. Install bearing inner race G. NOTE: Bearing component G may be heated up to 100Â° C maximum to facilitate the installation. NOTE: The disassembly is done in the reverse order of the assembly sequence.

4. Install locking washer J and stake nut H on shaft B.

31068

SECTION 60 -- PRODUCT FEED -- CHAPTER 2 SHAFTS, GEARS AND BEARINGS 1. Install dual roller bearing G in the gearbox housing and install the circlip M (Fig. 17). 2. Install the bearing cup A and cover K with bolts and washers J. Do not install shims at this time (Fig. 19). 3. Install bearing C onto gear L (Fig. 19) and lift the gear assembly into the gearbox housing.

5. Install spring V on shifter shaft J (Fig. 14) and simultaneously install shifter fork T and the pre assembled shaft F (Fig. 15) as shown in Figure 18. Install circlip S on the shifter shaft J (Fig. 14) 6. Install needle bearing N on shaft E (Fig. 17). 7. Install shaft E in place (Fig. 17) . Lubricate and install O--ring L, spacer ring K, circlip M and seal J. NOTE: Glue seal J in place with “Loctite 480”.

NOTE: The gear assembly must be in place before the shaft assembly F (Fig. 18) is installed.

8. Install the countershaft assembly B (Fig. 19) into the gearbox housing. At the same time gear L must be installed on shaft B (Fig. 19).

NOTE: Bearing component B may be heated up to 100° C maximum to facilitate the installation.

9. Install needle bearing C into gear D and bearing inner race B onto gear D. Retain the bearing, the ring and the circlip for later use (Fig. 17).

4. Install bearing M into the gearbox housing (Fig. 18).

NOTE: Secure bearing C in place with “Loctite 601”.

31069

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

10. Install gear assembly A--D on shaft E (Fig. 17) simultaneously with shifter fork R (Fig. 14). Install spring Q washer P lock washer N and nut M (Fig. 14).

12. Install the two needle bearings C into gear D (Fig. 18). 13. Install the gear and bearing assembly onto shaft F. (Fig. 18).

NOTE: Nut K should be installed with locking compound “Loctite 243” and tensioned to a torque of 70 Nm.

14. Install ring J circlip G and drive the bearing inner race H until it is seated on circlip F (Fig. 18).

11. Simultaneously install shifter ring A (Fig. 18) and shifter fork L, washer G and nut K (Fig. 14).

NOTE: Bearing component H may be heated up to 100°C to facilitate the installation.

NOTE: Nut K should be installed with locking compound “Loctite 243” and tensioned to a torque of 70 Nm.

31070

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

54749

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

INSTALLATION OF COVER C 1. Install bearing R and circlip S (Fig. 21) in the gearbox cover at shaft position G. 2. Install circlip W, bearing T and circlip V in the cover at shaft position B. 3. Install bearing AA and circlip FF in the cover at shaft position F. Retain the ring and circlips for later use. 4. Install circlip KK and bearing GG in the housing at shaft position E.

54836

5. Coat the gearbox contact surfaces with cover C with liquid sealant “Loctite 573”. 6. Lift the cover in place and secure it with hardened washers and bolts A. NOTE: Install bolts A with thread retainer “Loctite 243”. Torque the guide bolts to 22 Nm and the other bolts to 40 Nm. 7. Install the ring, circlip G on gear HH and O--ring J into cover H. Install the cover with bolts and washers D. 8. Install the ring, circlip N on shaft F and O--ring K into bearing cap P. Install cap P with washers and bolts Q. Install seal L. NOTE: Glue seal K in place with “Loctite 480”. 9. Install circlip M.

31072

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

INSTALLATION OF THE SMOOTH ROLL DRIVE SHAFT G

5. Install spacer N, seal P and circlip M.

1. Install gear A and bearing F onto shaft B.

NOTE: Glue seal P in place with “Loctite 480”.

NOTE: Bearing component F may be heated up to 100° C maximum to facilitate the installation.

6. Cover the contact surfaces of cover R with liquid sealant “Loctite 573”. Install the preassembled cover R onto the gearbox and fasten with washers and bolts Q.

NOTE: Gear A should be installed with the bearing puller grooves towards the shaft end. 2. Install circlip S, bearing K and circlip V in bearing housing R. 3. Install ring T and circlip W on shaft G. 4. Install bearing inner races L and AA on shaft G and slide the shaft assembly through bearing K.

NOTE: Install bolts Q with thread retainer “Loctite 243”. Torque the guide bolts to 22 Nm and the other bolts to 40 Nm. 7. Install bearing cup E in cover R. 8. Install O--ring D into cover H. Install cover H on the housing R with washers and bolts C. NOTE: Do not install shims at this time.

NOTE: Bearing components L and AA may be heated up to 100°C maximum to facilitate the installation.

31073

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

ASSEMBLY AND INSTALLATION OF INPUT SHAFT A •

Measuring the shimming value for bevel gear D and gearbox housing J.

1. Turn the gearbox so that the cover H (Fig. 22) faces down. 2. Tap shaft B down so it is perfectly seated at bearing F (Fig. 22). 3. Remove bearing cap K. Install a sufficient quantity of shims, reinstall bearing cap K and tighten it until there is no radial or axial play in shaft B. Turn shaft B a few turns so it centres perfectly.

54837

4. Measure distance A and write it down. Example Distance A = 33,30 mm

54838

•

Measuring the shimming value for the input shaft assembly.

1. Measure distance C on input shaft A. Measure this distance on different sides of the gear. Write down this measurement.

54839

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

2. Install oil seal S into bearing housing F. The open side of the seal should be towards the splined end of the shaft. NOTE: Glue seal S in place with “Loctite 480”. 3. Press bearing T onto shaft A until it is firmly seated against the gear. NOTE: Bearing T is thicker than bearing R. Ensure to install them in the correct order on shaft A.

31074

26 NOTE: Bearing component T may be heated up to 100° C to facilitate the installation. 4. Install bearing cup D into bearing housing F. 5. Install the gear and bearing assembly A into the bearing housing F (Fig. 26) and rotate the shaft 15 full turns so the bearing halves seat properly. 6. Measure distance D on different sides of the shaft. Write down the measurement. 7. Determine distance B from the following formula: B = D -- C

Example: C = 32.80 mm D = 61.30 mm B = 61.30 mm -- 32.80 mm = 28.50 mm Note down value B. 8. The number of 0,05 mm thick shims needed at E (Fig. 26 and 28) can be determined from the table here below.

Example A = 33.30 mm B = 28.50 mm The number of shims needed is 9.

54840

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

Number of 0.05 mm shims needed

A B = 28.3

B = 28.4

B = 28.5

B = 28.6

33.2

33.3

33.4

33.5

33.6

33.7

SECTION 60 -- PRODUCT FEED -- CHAPTER 2 PREASSEMBLY OF THE INPUT SHAFT AND BEARING HOUSING

7. Install O--ring K into bearing cap M and install the latter onto bearing housing F with bolts and washers L.

1. Remove shaft A from bearing housing F. 2. Install bearing cup J into bearing housing F. 3. Install bearing housing F onto the shaft A . 4. Install bearing R onto shaft A and press it in place but leave some axial play. 5. Install stake washer Q and stake nut P and tighten up the assembly until there is no axial play. Make sure there is no radial play on the shaft. Lock nut P in place with washer Q. NOTE: A slight preload is better than any axial or radial play. 6. Install grease fitting H into the bearing housing F.

NOTE: Install bolts L with thread retainer and torque to 8 Nm. 8. Install seal N with the open side towards the shaft end. NOTE: Glue seal S in place with â&#x20AC;&#x153;Loctite 480â&#x20AC;?. 9. Install O--ring C, install the predetermined quantity of shims at E. Install the preassembled input shaft into the gearbox and secure in place with washers and bolts G. NOTE: Install bolts G with thread retainer and torque to 40 Nm.

31075

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

BACKLASH ADJUSTMENT OF THE INPUT GEAR AND SHIMMING OF THE CONICAL BEARINGS ON COUNTER SHAFT B 1. Turn the gearbox as shown and tap down shaft B. 2. Lock shaft B with a large screwdriver. 3. Now measure the backlash = X on the input shaft A and write it down. 4. The thickness of the shim pack needed at J (Fig. 31) can be calculated with the following formula:

54841

(X -- 0,1) x 2 + 0,05 mm = shim pack in mm

Example: Measured value X = 0,25 mm (O,25 mm -- 0,1) x 2 + 0,05 mm = 0,35 mm. Note down the shim pack value,which for this example is 0.35 mm.

5. Loosen, but do not remove the bearing cap K (Fig. 29). 6. Turn the gearbox. Remove cover H and install the predetermined shim pack at J. Reinstall O-ring D. Install cover H with bolts and washers C. Give the bearing housing a light hit to free the bearing from any tension.

31076

54842

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

7. Turn the gearbox and remove bolts and washers J, cover K and previously installed shims (Fig. 29). Push bearing J as far down as possible (also refer to Fig. 33).

54749

8. Measure the distance Y from the upper side of the bearing to the surface of the casting and note down the value.

54843

9. Measure the distance Z on the bearing cap K (refer to Fig. 23). 10. The thickness of the shim pack needed at H (Fig. 32) can be calculated with the following formula: Y -- Z -- 0,05 = shim pack in mm 11. Install the pre determined shim pack at H (Fig. 32) and install bearing cap K with bolts and washers J. NOTE: Install bolts J with thread retainer â&#x20AC;&#x153;Loctite 243â&#x20AC;? and torque them to 20 Nm. 12. Check the backlash of the input shaft again which should be between 0,11 and 0,17 mm. If not, readjust. 13. Install plate G, washer D and bolt E (Fig. 32).

54844

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

INSTALLATION OF INTERMEDIATE GEAR, SHAFT ASSEMBLY C AND UPPER FEED ROLL DRIVE GEAR ASSEMBLY D

4. Install ring L into the bearing housing in cover Q.

1. Install gear P onto shaft C

6. Apply some good quality grease in both bearing housings of shaft C.

2. Install bearings E and N onto shaft C. Apply some good quality grease into the bearing housing in cover Q. Install the assembly into cover Q. 3. Pre install bearings G and M and bushing K onto shaft D.

5. Install preassembled shaft D in cover Q.

7. Apply liquid sealant on cover Q and install it on the gearbox with washers and bolts H. 8. Install seals F and J. NOTE: Glue seals F and J in place with “Loctite 480”.

NOTE: The chamfered end of bushing K should be turned away from bearing M.

31078

SECTION 60 -- PRODUCT FEED -- CHAPTER 2 INSTALLATION OF LENGTH-OF-CUT GEARBOX ON THE CHOPPERBODY 1. Install the gearbox in reverse order of the disassembly sequence. 2. Install shafts, clutches and bushings. 3. Fill the gearbox with oil. Gearbox capacity: 6,3 litres Oil specification: AMBRA HYPOIDE 90 oil (ref. NH520A) or an oil meeting the following specification: -- API GL5 or MIL--L--2105 D -- Viscosity grade: SAE 80W--90

SECTION 60 -- PRODUCT FEED -- CHAPTER 2

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

SECTION 60 -- PRODUCT FEED Chapter 3 -- Electromagnetic Reversing Gearbox CONTENT Section

Description

Page

60.165

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

OPERATION OF ELECTROMAGNETIC REVERSING GEARBOX

The reversing gearbox uses a planetary gear system controlled by an electromagnetic clutch and a three-position switch to turn the feed rolls in forward and reverse. â&#x20AC;˘

The planetary gear system:

1. 2. 3. 4.

Sun gear Planet gears Planet gear carrier Ring gear

â&#x20AC;˘

The electromagnetic (Fig. 2):

1. 2. 3.

Forward magnet (rotating) Armature Reverse magnet (stationary)

ZDA0412A

3 1

clutch: Type Warner

The forward magnet 1 is directly connected to the sun gear. As the sun gear is directly driven by the blower drive train, the forward magnet will always rotate when the main clutch is engaged. The armature 2 is connected to the planet gear carrier. The revers magnet 3 is rigidly installed on the reversing gearbox housing and will not rotate. Both magnets 1 and 3 have a 2,62 ohm resistance, are four pole and are able to transfer a 1.500 Nm torque when the voltage is 11V or more.

ZDA0413A

SECTION 60 -- PRODUCT FEED -- CHAPTER 3 â&#x20AC;˘

Type Stromag :

1. 2. 3. 4.

Forward magnet (stationary) Forward drive plate (rotating) Armature Reverse magnet

The forward magnet 1 is held stationary by a support plate which is installed onto the reversing gearbox. The forward drive plate 2 is directly connected to the sun gear. As the sun gear is directly driven by the blower drive train, the forward drive plate will always rotate when the main clutch is engaged. The armature 3 is connected to the planet gear carrier. The reverse magnet 4 is rigidly installed on the reversing gearbox housing and will not rotate. Both magnets have a xxxx ohm resistance, are x pole and are able to transfer a 1500 Nm torque when the voltage is 11 V or more.

3 â&#x20AC;˘

Switch

The switch 1 installed on the multifunction lever has three positions: 1. Push the upper part two times for feeding material. 2. Push the lower part once to stop the feed rolls. 3. Push the lower part a second time and the feed rolls will reverse as long as the switch is pressed down.

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

FORWARD (Feed rolls feed crop into the machine) •

TYPE WARNER

Press the upper part of the switch two times. The armature is attracted by the forward magnet rotate along with the forward magnet. As the planet gear carrier is connected to the armature, it will also rotate. This rotation causes the ring gear to rotate in the same direction and makes the feed rolls rotate forward. •

TYPE STROMAG

Press the upper part of the switch two times. The armature is attracted by the stationary forward magnet and is pulled against the forward drive plate and rotates along with the forward drive plate. As the planet gear carrier is connected to the armature, it will also rotate. This rotation causes the ring gear to rotate in the same direction and makes the feed rolls rotate forward. NEUTRAL (Feed rolls remain immobile) Press the lower part of the switch once and the gearbox goes into neutral. •

TYPE WARNER

The armature is separated from both magnets. •

TYPE STROMAG

The armature is separated from the reverse magnet and the forward drive plate. The sun gear causes the planet gears as well as the planet gear carrier to rotate. The ring gear remains immobile, the feed rolls do not rotate.

REVERSE (Feed rolls feed the crop out of the machine) Press the lower part of the switch a second time and hold it depressed. The armature is attracted by the reverse magnet and both remain immobile. The planet gear carrier also remains immobile. The sun gear makes the planet gears rotate, which in turn rotate the ring gear. This rotation makes the feed rolls turn in reverse.

SECTION 60 -- PRODUCT FEED -- CHAPTER 3 Item

Description

Input gear (from main clutch) 28

Intermediate gear (1)

Intermediate gear (2) to electromagnetic clutch

Sun gear

Planet gears

Ring gear

Intermediate gear

Output gear

Input shaft

2000 rpm

10.

Intermediate shaft

rpm

11.

Output shaft

rpm

Number of teeth

2 6 3

5 4

5 11 8

ZDA0411A

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

REMOVING THE REVERSING GEARBOX FROM THE MACHINE Removing the gearbox from the machine (both versions) 1. Drain the oil from the gearbox through hose A.

54845

9 2. Remove the three drive shafts A, B and C from the gearbox .

54846

10 3. Disconnect the electric cable to the stopping system at A.

54847

11 4. Disconnect the cable to the electromagnetic clutch at B.

54848

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

5. Remove the lock nut and washers D (Fig. 11 and 13). Remove the bolt, nut, washer and bushing at B (Fig. 11). Support the metal detector stopping system assembly. Remove the three bolts and washers C (Fig. 11) and lift out the stopping system. 6. Remove rod and washers E and bolt and washers F from the left hand end of the gearbox.

54849

13 7. Remove the bolts and washers G and lift the gearbox out from the forage harvester.

54850

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

DISASSEMBLY AND ASSEMBLY OF THE ELECTROMAGNETIC CLUTCH (TYPE WARNER) NOTE: The electromagnetic clutch can be disassembled without removing the reversing gearbox from the machine. Disassembly 1. Remove the grease shield H from the machine.

54850

15 2. Unplug the two wires from the stationery magnet at A and B. Note the position of the wires.

54851

16 3. Cut the plastic strap at CC, Unplug the two wires G at the brush holder F and unscrew the brush holder F from the shaft (Fig. 17 and 21).

54852

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

4. Bend up tab washer D and remove nut E. Remove the four nuts J and lock washers K (Fig. 18 and 21). 5. Pull away the magnet A. Note the position and the quantity of washers and shims L installed between magnet A and hub H (Fig. 19 and 21).

54853

6. Pull out hub H (Fig. 19 and 21). 7. If oil seal C is leaking, the seal can now be replaced (Fig. 21). NOTE: The seal should be glued in place with “Loctite 480”.

54854

8. Remove circlip B (Fig. 21). Remove shims N, note down the thickness of the shim pack and keep for later use. Remove clutch plate AA (Fig. 20 and 21). Remove shims Q and note down the thickness of the shim pack and retain it for later use. Remove the circlip V (Fig. 21). 9. If oil seal T is leaking, the seal can now be replaced (Fig. 21). NOTE: The seal should be glued in place with “Loctite 480”. 10. Remove the four nuts W, lock washers R and spacer rings S. Remove stationary magnet P from shaft BB (Fig. 21).

54855

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

31085

21 Assembly 1. Assemble the clutch in reverse order of disassembly. 2. Adjust the air gap between the clutch plate AA and the magnets P and A to 0,8 -- 2,0 mm by adding or reducing the number of shims at N and Q. It may also be necessary to add or reduce the number of washers at L. 3. Tighten nut E to a torque of 170 Nm (125 lbf.ft) and secure with the tab washer D.

SECTION 60 -- PRODUCT FEED -- CHAPTER 3 BURNISHING PROCEDURE OF THE ELECTROMAGNETIC CLUTCH (TYPE WARNER) When a new electro magnetic clutch, or new components of an electromagnetic clutch are installed, the new components need to be â&#x20AC;&#x153;burnishedâ&#x20AC;?. Proceed as follows:

7. Start the engine and run it at low idle.

WARNING Make sure the exhaust gasses are properly evacuated and nobody is standing in the vicinity of the machine. 8. Engage the cutterhead. the engine must remain on low idle.

1. Get hold of an electromagnetic clutch magnet. 2. Make three single threaded jumper wires of approximately 75 cm length. The cross section should be at least 2 mm. 3. Wires A and B need a ring terminal on one end and a pin terminal in the other end. Wire C needs a pin terminal in both ends. 4. Secure the ring terminals of wires A and B to the terminals of the loose clutch D. 5. Disconnect connector X432 from the Adjust-O--Matic printed circuit board inside the central electronic box.

WARNING Make sure the ignition is switched OFF or the battery switch is in the OFF position. 6. Install wires B and C to the pins 5 and 7 on the female side (loose end) of the connector X432.

9. Push wire C (the wire coming from pin 5 in connector X432) against connector X40 on the fuse printed circuit E inside the electronic box. The metal detector stop pawl will be activated. Activate the stop pawl for max 2 seconds at a time. 10. Push wire A (the wire coming from the loose clutch) against connector X41 on the fuse printed circuit E inside the electronic box. Activate the clutch for maximum one second. 11. After one second, remove wires A and C from the connectors X41 and X40. 12. Wait at least one minute to allow the clutch to cool down. 13. Repeat steps 9 to 12 ten times. NOTE: The feed roll cut--out clutch may create a rattling noise when slipping.

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

54856

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

DISASSEMBLY AND ASSEMBLY OF THE ELECTROMAGNETIC CLUTCH (TYPE STROMAG) NOTE: The electromagnetic clutch can be disassembled without removing the reversing gearbox from the machine. Disassembly 1. Remove the grease shield 1 from the machine. 2. Cut plastic strap at 2 and unplug the connectors at 1 and 3 from the magnets. Note the position of the connectors. 3. Remove clutch plate 5 by removing six bolts 6.

23 4. Remove rubber damper 1 by loosening nuts 2. If necessary remove plate 3.

24 5. Remove six bolts 5 and lock plate 10. 6. Pull away the magnet assembly 1. Note the position and the quantity of washers and shims at 4 (Fig. 26) installed between magnet assembly 1 and hub 6 (Fig. 26).

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

7. Remove nut 8 and washer 7. Pull out hub 6.

8. If oil seal 9 is leaking, the seal can now be replaced . NOTE: The seal should be glued in place with “Loctite 480”. 9. Remove circlip 12 and shim pack13, note down the thickness of the shim pack and keep for later use. 10. Remove clutch plate 14. 27

11. If oil seal 18 is leaking, the seal can now be replaced. 12. If oil seal 18 is leaking, the seal can now be replaced . NOTE: The seal should be glued in place with “Loctite 480”. 13. Remove four nuts 19 and lock washers. Remove stationary magnet 17. 28

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

Assembly 1. Check the condition of seal 18. If oil seal is leaking, the oil seal can be replaced. NOTE: The seal should be glued in place with â&#x20AC;&#x153;Loctite 480â&#x20AC;?. 2. Install stationary magnet 17 and tighten four bolts 19. 3. Install circlip16, shimpack 15 and armature14. Adjust air gap between armature 14 and stationary magnet 17 to 0.2 -- 0.4 mm at minimum opening and 0.2 -- 0.7 mm at maximum opening by adding or reducing the number of shims at 15.

15 16

ZDA0421A

17 30

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

4. Install shimpack 13 and circlip 12. It may also be necessary to add or reduce the number of shims at 13.

31 5. If oil seal 9 is leaking, the oil seal can be replaced. NOTE: The seal should be glued in place with â&#x20AC;&#x153;Loctite 480â&#x20AC;?.

32 6. Install bolts 11 with Loctite in hub 6 and tighten by hand . 7. Install hub 6, washer 7 and nut 8 on shaft (Fig. 32) . Tighten up nut to 170 Nm.

33 8. Install shim pack 4 and rotating magnet 1. Adjust air gap between armature 14 and rotating magnet 1 to 0.2 -- 0.4 mm at minimum opening and 0.2 -- 0.7 mm at maximum opening by adding or reducing the number of shims at 4 (Fig. 30). 9. Secure nut 8 with lock plate 10.

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

10. Install rubber damper 1 and fix with nuts 2 (Fig. 35). If removed, reinstall plate 3.

35 11. Reinstall clutch plate 5 with bolts 6. 12. Reinstall electric connectors 1 and 3 from the magnets. Install plastic strap at 2. 13. Reinstall grease shield 4.

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

REMOVAL AND INSTALLATION OF FEED ROLL AND ATTACHMENT DRIVE SAFETY CLUTCH NOTE: The feed roll and attachment drive safety clutch can be removed from the machine without removing the reversing gearbox from the machine.

Removal NOTE: The metal detector stopping system must be removed before the clutch assembly can be removed. 1. Remove the feed roll and attachment drive shaft A by removing the bolts B.

54857

37 2. Remove bolt C and bushing D and pull out the clutch and ratchet wheel assembly E.

54858

38 3. Remove special washer F and replace if damaged.

54859

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

Installation NOTE: The clutch must be installed on the reversing gearbox before the metal detector stopping system is installed. 1. Install the washer F onto the shaft with the “chamfered“ side facing towards the clutch.

54859

40 2. Install the clutch and ratchet wheel assembly E onto the shaft. 3. Install the bushing D and the bolt C. Apply “Loctite 242” on the threads of bolt C and tighten to a torque of 107 Nm (80 lbf.ft).

54858

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

DISASSEMBLY AND ASSEMBLY OF THE REVERSING GEARBOX Optional high blower speed 1. If installed, remove the high blower speed shaft F from the gearbox. 2. Remove bolts A and pull out cover B. Remove seal C. 3. Pull out shaft F with bearings D and E. 4. Assemble in reverse order when the rest of the gearbox has been assembled.

This section covers two versions of reversing gearboxes.

FX300-375-450/ FX9630-9640-9645

Series 01 to 12

FX25-45

Series 01 to 04

Gearboxes with a serial no: 746 or smaller.

FX300-375-450/ FX9630-9640-9645

Series 13 to 14 Series 5033 to ...

FX25-45

Series 05 to 06 Series 5033 to ...

FX28-38-48-58

Series 5083 to ...

Gearboxes with a serial no: 747 or higher. NOTE: Do check the serial number of the gearbox, because an older machine can be equipped with a recent gearbox.

30660

SECTION 60 -- PRODUCT FEED -- CHAPTER 3 FX300-375-450/ FX9630-9640-9645

Series 01 to 12

FX25-45

Series 01 to 04

4. Remove seal N and circlip P and drive out the planet carrier assembly H from the gearbox housing E.

Gearboxes with a serial no: 746 or smaller.

5. Disassembly planet carrier H proceeding in reverse order of the assembly procedure. See further under subheading â&#x20AC;&#x153;Reversing gearbox assemblyâ&#x20AC;?.

A. Reversing gearbox disassembly

6. Remove circlip J and bearing Q.

1. Remove bolts and washers A and T and pull apart the gearbox halves E and MM.

7. Remove circlip KK and spacer JJ and lift away ring gear R.

NOTE: The gearbox halves are sealed with a liquid sealant.

8. Remove shaft gear BB from the gearbox. Remove spacer ring AA and bearings S and V. Also remove seal W.

NOTE: Gear shafts C and G are symmetrical. They should be marked before removal. 2. Remove shaft C with bearings D and NN. Remove seals B and PP. Remove bearings D and NN from shaft C. NOTE: The seals will be damaged when removed. 3. Remove gear G with bearings F and LL. Remove bearings F and LL from shaft G.

9. Remove needle bearing CC and ring DD from shaft L. 10. Remove the three bolts HH and the three washers GG. Lift away the gear and shaft L from the gear box half MM 11. Remove circlip FF and bearing EE from shaft L

31086

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

B. Reversing gearbox assembly Disassembly of the planet carrier assembly is done in revers order of assembly. --

Preassembly of the planet carrier

1. Press bushing A into the gear E and clean away possible metal residue. 54860

44 2. Press bushings G into the planet carrier H. NOTE: The outer bushing should be pushed so far that there is 3 mm free space between the bushing and the seal. NOTE: The bushings G should be installed into H with â&#x20AC;&#x153;Loctite 641â&#x20AC;?. 3. Install spacers F, the preassembled gears E, spacers B and circlip C onto shafts D. 31087

45 --

Preassembly of shafts and bearings -- Figure 46

1. Install bearings D and NN onto shaft C. 2. Install bearings F and LL onto gear G. 3. Install bearing EE onto shaft L and secure with circlip FF. 4. Install bearings S and V, and spacer AA onto shaft BB. --

Installation of the preassembled parts into the gearbox housings MM and E -- Figure 46

1. Install the preassembled shaft L and bearing EE into the gearbox half MM and secure in place with washers GG and bolts HH. 2. Install the preassembled planet carrier in gearbox half E and install the circlip P.

SECTION 60 -- PRODUCT FEED -- CHAPTER 3 3. Install the preassembled shaft G into the gearbox half MM. 4. Install the preassembled shaft BB into the gear box half MM.

11. Replace studs K if they are damaged. Install the new studs with the shorter thread side into the gearbox using a thread locking compound.

5. Install the ring gear R, ring JJ and circlip KK on shaft L.

12. Install the electromagnetic and the header drive safety clutches onto the reversing gearbox as described at the beginning of this section.

6. Install the preassembled shaft C into the gearbox half MM

13. Install the optional high blower speed kit if it was removed.

7. Install bearing Q and circlip J into the gearbox housing half E.

14. Install the gearbox into the machine in reverse order of the removal sequence.

8. Install the preassembled planet carrier in gearbox half E and install the circlip P.

15. Fill the gearbox with oil:

9. Coat the lower gearbox half contact surface with liquid sealant (Loctite 573). Install the second gearbox half and secure it in place with washers and bolts A and T. 10. Install the seals B, N, M, W and PP. NOTE: Glue the seals in place with â&#x20AC;&#x153;Loctite 480â&#x20AC;?

Gearbox capacity: 4 litres Oil specification: Use AMBRA HYPOIDE 90 oil ( ref. NH520A) or an oil meeting the following specification: -- API GL5 or MIL--L--2105 D -- Viscosity grade: SAE 80W -- 90

31086

SECTION 60 -- PRODUCT FEED -- CHAPTER 3 3. Remove gear G with bearings F and NN. Remove bearings F and NN from shaft G.

FX300-375-450/ FX9630-9640-9645

Series 13 to 14 Series 5033 to ...

FX25-45

Series 05 to 06 Series 5033 to ...

4. Remove seal N and circlip P and drive out planet carrier assembly H from gearbox housing E.

FX28-38-48-58

Series 5083 to ...

5. Disassemble planet carrier H proceeding in reverse order of the assembly procedure. See further under subheading â&#x20AC;&#x2DC;Reversing gearbox assemblyâ&#x20AC;?.

Gearboxes with a serial no: 747 or higher.

A. Reversing gearbox disassembly

1. Remove bolts and washers A and T and pull apart the gearbox halves E and PP. NOTE: The gearbox halves are sealed with a liquid sealant. NOTE: Gear shafts C and G are symmetrical. They should be marked before removal. 2. Remove shaft C with bearings D and QQ. Remove seals B and RR. Remove bearings D and QQ from shaft C. NOTE: The seals will be damaged when they are removed.

6. Remove circlip J and bearing Q. 7. Remove circlip MM and spacer LL and lift away the ring gear R. 8. Remove shaft gear BB from the gearbox. Remove spacer ring AA and bearings S and V. Also remove seal W. 9. Remove needle bearing CC and ring DD from shaft L. 10. Remove three bolts KK and three washers JJ. Lift away the gear and shaft L from the gear box half PP. It may be necessary to remove cover FF from the gearbox half PP, Allen screw HH and special washer GG and to tap out the shaft and the bearing EE. NOTE: Cover FF will be damaged when removed.

31089

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

B. Reversing gearbox assembly Disassembly of the planet carrier assembly is done in revers order of assembly. --

Preassembly of the planet carrier

1. Press bushing A into gears E and clean away possible metal residue. 54860

48 2. Press bushings G into planet carrier R and install circlip J. NOTE: Bushings G should be installed with â&#x20AC;&#x153;Loctite 641â&#x20AC;?. 3. Install spacer rings F, the preassembled gears E, spacers B and circlip C onto shafts D.

31088

49 --

Preassembly of shafts and bearings -- Figure 50

1. Install bearings D and QQ onto shaft C. 2. Install bearings F and NN onto gear G. 3. Install bearing EE on shaft L and secure it with special washer GG and Allen screw HH. 4. Install bearings S and V, and spacer AA onto shaft BB. --

Installation of the preassembled parts into the gearbox housings PP and E -- Figure 50

1. Install the preassembled shaft L and bearing EE into the gearbox half PP and secure in place with washers JJ and bolts KK. 2. Install ring DD and needle bearing CC onto shaft L.

SECTION 60 -- PRODUCT FEED -- CHAPTER 3

3. Install the preassembled shaft G into the gearbox half PP. 4. Install preassembled shaft BB in gear box half PP. 5. Install ring gear R, ring LL and circlip MM on shaft L. 6. Install preassembled shaft C in gearbox half PP.

7. Install bearing Q and circlip J in gearbox housing half E. 8. Install preassembled planet carrier H into gearbox half E and install circlip P. 9. Coat the lower gearbox half contact surface with liquid sealant (Loctite 573). Install the second gearbox half and secure in place with washers and bolts A and T. 10. Install seals B, N, M, W and RR. Also install cover FF.

11. Replace studs K if they are damaged. Install new studs with the shorter thread side into the gearbox using a thread locking compound . 12. Install the electromagnetic and the header drive safety clutches onto the reversing gearbox as described at the beginning of this section. 13. Install the optional high blower speed kit if it was removed. 14. Install the gearbox in the machine in reverse order of the removal sequence. 15. Fill the gearbox with oil: Gearbox capacity: 4 litres Oil specification: Use AMBRA HYPOIDE 90 oil ( ref. NH520A) or an oil meeting the following specification: -- API GL5 or MIL--L--2105 D -- Viscosity grade: SAE 80W -- 90

NOTE: Glue the seals and the cover in place with â&#x20AC;&#x153;Loctite 480â&#x20AC;?.

31089

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

SECTION 64 -- CUTTERHEAD Chapter 1 -- Chopping CONTENT Section

Description

Page

64.000

64.106

Removal -- installation of rotor and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

64.130

64.150

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

SPLITTING OF COMPONENTS

WARNING Splitting of components must always be carried out with the utmost care and attention. Failure to do so may lead to severe injuries or even death.

The forage harvester offers several possibilities to detach functional elements of the machine in an easy way. These possibilities allow you to check, repair or replace almost every part of the chopper body and the blower in a quick way.

58225

1. 2. 3.

4. 5.

Attaching and detaching the attachment Inspection between the upper feed rolls and the cutterhead (refer to Section 60 -- chapter 1) Attaching and detaching the attachment with the upper feed rolls (refer to Section 60 -- chapter 1) Flip down the upper feed rolls (refer to Section 60 -- chapter 1) Inspection between the cutterhead (or the crop processor) and the blower(refer to Section 70 -chapter 1) Dismounting and mounting the chopper body

WARNING Follow the correct sequence of the proper procedure as detailed further in this paragraph.

SECTION 64 -- CUTTERHEAD -- CHAPTER 1 ATTACHING AND DETACHING THE ATTACHMENT

3 1

Detaching 1. Install supports 1 on both sides of the pick-up attachment (Fig. 3). In case of a maize attachment, lower supports 1 on both sides (Fig. 4). 2. Disconnect the two quick-release hydraulic couplings 2 (Fig. 6).

30884

3. Maize attachment with Auto-Pilot only: Disconnect electric cable 3 (Fig. 6). 4. If the attachment is fitted with an automatic greasing system, disconnect the grease line(s) to the attachment. 5. Disconnect attachment drive p.t.o. shaft 4 (Fig. 7). 6. Release quick-attach lever 5 on the right-hand side (Fig. 5). 58226

7. Lower the attachment until it rests both on the supports and on the skids. Lower further until the chopper body is completely released from the attachment. 8. Carefully reverse the machine and ensure the attachment is released from the chopper body.

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

Attaching 1. Drive up to the attachment and lower the chopper body until the hook mounted on the front of the chopper body can enter the attachment. 2. Lift the chopper body until it properly picks up the attachment. 3. Attach the quick attach lever 5 so that the hooks 6 are in full contact with pins 7. If not, adjust lever 5 with bolts 8 so that some resistance is felt when engaging latch 9 on pin 10 (Fig. 5). 5

4. Maize attachment with Auto-Pilot only: Connect electric cable 3 (Fig. 6). 5. If the attachment is fitted with an automatic greasing system, connect the grease line(s) to the attachment. 6. Connect the two quick-release hydraulic couplings 2, if needed (Fig. 6). 7. Install attachment drive main shaft 4 (Fig. 7). NOTE: Make sure that the drive yokes on each end of the attachment drive p.t.o. shaft are in phase. Make sure that the attachment drive shaft is installed in such a way that the shaft end cannot touch the feed roll gearbox.

8. Relocate the supports at 1 (Fig. 2) of the pick-up attachment. In case of a maize attachment, raise the supports (Fig. 4) on both sides.

58227

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

REMOVAL -- INSTALLATION OF CHOPPER BODY WITH A-FRAME

WARNING This operation should be carried out with utmost care and attention. Only an experienced tractor driver should be allowed to do this job. The cutterhead is removed from the machine with an A-frame that is mounted in a tractorâ&#x20AC;&#x2122;s 3-point hitch. This tractor must be at least 100 hp and sufficient front weight should be installed. The weight of the cutterhead/feed roll combination is almost 2000 kg. The tractor hydraulics should be in good condition to allow precise height control.

58233

Removal 1. Detach the attachment as described in the previous paragraph. 2. Lower the cutterhead to its lowest position.

58234

Keep them in a safe place so that they cannot be pinched between the cab and the chopper body 3. Disconnect all electric cables: -- 1 and 2 (Fig. 8) -- 4 and 5 (Fig. 9) Keep them in a safe place so that they cannot be pinched between the cab and the chopper body. 4. Remove the left-hand side cover of the chopper body. Remove the cutterhead drive shaft cover on the right-hand side of the chopper body. 58235

5. If the machine is fitted with an automatic greasing system, disconnect the grease line(s) to the chopper body.

6. Disconnect coolant tubes 3 (Fig. 8) to the cutterhead gearbox. 7. Unscrew clamping rods 6 (Fig. 10) and 7 (Fig. 11).

58236

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

8. Unlock pin 8 and push it towards the cutterhead. This pin will limit the chopper bodyâ&#x20AC;&#x2122;s rotation. Lock the pin in that position.

58236

12 IMPORTANT: Do not try to install both pin 8 (Fig. 12) and clamping rods 6 and 7 (Fig. 12) at the same time. Doing this and lifting the chopper body afterwards would cause irreparable damage to the chopper bodyâ&#x20AC;&#x2122;s triangular frame.

58235

13 58235

9. Remove feed roll drive shaft 9. The cutterhead drive shaft 10 (Fig. 13) does not necessarily have to be removed.

14 10. Remove hydraulic cylinder pins 11 underneath the chopper body on both sides. 11. Remove safety latches 12 by removing lynch pins 13 on both sides of the chopper body.

58237

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

12. Now install the A-frame 14 on the tractor and drive towards the chopper body (Fig. 17). The tractor must be perfectly in line with the chopper body.

CAUTION Do not use the A-frame for anything else than to carry the chopper body. Check the A-frame, and especially pin 15 on the upper part, for cracks before using it.

30531

16 13. Pick up the chopper body with pin 15 that is welded on top of the A-frame. 14. Adjust the third hitch point until the lower guides 16 come in the position as shown in the Figure. 15. Lift the tractor hitch until the lower part of the Aframe is pushing firmly against the chopper body. 16. Install the chain safety bolt on pin 15 of the Aframe. 58238

17 17. Remove the upper clamping rods 17 (Fig. 18) and 18 (Fig. 19). 18. Flip up clamps 19 (Fig. 18) and 20 (Fig. 19). 19. Lift the chopper body with the tractor hydraulics until the chopper bodyâ&#x20AC;&#x2122;s triangular frame is completely released from its brackets. NOTE: Do not lift the chopper body higher than necessary as this will damage the steering platform.

58235

18 20. Slowly drive forward ensuring that the chopper body does not interfere with the underside of the cab. Keep in mind that the chopper body now stands completely free of the base unit.

58236

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

21. Install the support legs under the chopper body. For the rear legs, use pins 11 (Fig. 15). Secure the pins! 22. Lower the 3-point hitch until the A-frame is released from the chopper body. 23. Drive the tractor away.

30532

20 24. Remove part 21 of the cutterhead drive shaft from the cutterhead gearbox.

58239

21 25. Reinstall this part on cutterhead drive shaft 22. NOTE: Make sure the drive yokes on each end of the cutterhead drive shaft are in phase.

58240

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

Mounting 1. Pick up the chopper body with the A-frame [mounted in the 3-point hitch of the tractor]. 2. Remove the support legs from the chopper body. NOTE: Make sure the feed roll and cutterhead drive shaft are lifted in such a way that they do not interfere with the chopper body.

58239

23 3. Carefully drive backward to the harvester making sure upper tube 23 of the chopper bodyâ&#x20AC;&#x2122;s triangular frame fits smoothly in its supports 24. 4. Lower the chopper body.

58240

24 5. Flip down clamps 19 (Fig. 25) and 20 (Fig. 26). 6. Reinstall clamping rods 17 (Fig. 25) and 18 (Fig. 26) around the upper tube and tighten firmly.

58235

25 7. Lower the tractor hitch until lower tube 25 (Fig. 23) rests on base unit 26 (Fig. 24).

58236

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

8. Reinstall safety latches 12 with lynch pins 13 on both sides.

58237

27 9. Reinstall hydraulic cylinders 27 (Fig. 28) with pins 11 (Fig. 27). 10. Lower the tractor hitch until it is released from the chopper body. 11. Drive the tractor away.

58240

28 12. Reinstall feed roll drive shaft 9.

29 13. Reinstall cutterhead drive shaft 10. It should be separated some 5 mm from the end of the cutterhead gearbox input shaft so that, when tightening the bolts on the splined end, the splines do not clamp on the broader spline-free end of the cutterhead gearbox input shaft. NOTE: Make sure the drive yokes on each end of the cutterhead drive shaft are in phase.

58235

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

14. Unlock pin 8, pull it out and lock it.

58236

31 15. Reinstall front clamping rods 6 (Fig. 32) and 7 (Fig. 31).

58235

32 16. Connect the cutterhead gearbox coolant tubes 3. 17. Connect electric cables: -- 1 and 2 (Fig. 33) -- 4 and 5 (Fig. 34) 18. If the machine is fitted with an automatic greasing system, connect the grease line(s) to the chopper body.

58233

33 19. Reinstall the cover on the left-hand side.

58234

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

REMOVAL -- INSTALLATION OF CHOPPER BODY WITH HYDRAULIC JACK Dismounting

WARNING This operation should be carried out with utmost care and attention on a level-paved surface. Only an experienced machine operator should be allowed to do this job. 1. Detach the attachment as described in the first paragraph of this section. 2. Raise the chopper body to its highest position by giving the “attachment up” command on the multifunction lever.

58237

3. Apply safety latches 12 (Fig. 35) by removing pins 13. 4. Install the hydraulic jack assembly 1 into the mounting bracket 2 and secure with pin 3 and hairpin cotter 4. NOTE: The hydraulic cylinder 5 must be facing forwards and the hydraulic hoses must be positioned facing the right-hand side of the machine. 5. Connect quick-coupler hose ends to the auxiliary front hydraulic ports 2.

58241

6. Completely retract the hydraulic jack cylinder 5 (Fig. 36) as described in chapter 2.6, heading ‘‘Front auxiliary hydraulics control’’. 7. Lift up safety latches 12 (Fig. 35) and secure them with lynch pins 13.

37 8. Lower the chopper body completely by giving the “attachment down” command on the multifunction lever in the cab. 9. Remove the chopper body hydraulic cylinder pins 11 (Fig. 37) on both sides of the chopper body. 10. Install the right and left-hand front jack mounts 6 (Fig. 38) and secure them in place with the hydraulic cylinder pins 11. 58405

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

11. Disconnect all electric cables: -- 1 and 2 (Fig. 39) -- 4 and 5 (Fig. 40) Keep them in a safe place so that they cannot be pinched between the cab and the chopper body. 12. Remove the left-hand side cover of the chopper body. Remove the cutterhead drive shaft cover on the right-hand side of the chopper body.

58233

39 13. If the machine is fitted with an automatic greasing system, disconnect the grease line(s) to the chopper body. 14. Disconnect coolant tubes 3 (Fig. 39) to the cutterhead gearbox.

58234

40 15. Lower the hydraulic jack 1 using the front auxiliary hydraulic system, as described in the Operatorâ&#x20AC;&#x2122;s Manual -- Section 2.6, until the jack foot contacts the ground surface.

58241

41 16. Install the front jacks 7 and adjust to contact the ground surface.

58405

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

17. Unscrew clamping rods 6 (Fig. 43) and 7 (Fig. 44). 18. Unlock pin 8 (Fig. 44) and push it towards the cutterhead. This pin will limit the chopper bodyâ&#x20AC;&#x2122;s rotation. Lock the pin in that position.

58235

43 IMPORTANT: Do not try to install both pin 8 and clamping rods 6 (Fig. 43) and 7 (Fig. 44) at the same time. Doing this and lifting the chopper body afterwards would cause irreparable damage to the chopper bodyâ&#x20AC;&#x2122;s triangular frame.

58236

44 19. Remove feed roll drive shaft 9. The cutterhead drive shaft 10 (Fig. 43) does not necessarily have to be removed.

45 20. Remove safety latches 12 by removing lynch pins 13.

58237

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

21. Remove the upper clamping rods 17 (Fig. 47) and 18 (Fig. 48). 22. Flip up clamps 19 (Fig. 47) and 20 (Fig. 48). 23. Make sure that the forage harvester’s steering wheels are in straight position allowing the forage harvester to move in a straight line.

58235

47 24. Now raise the rear of the chopper body with the hydraulic jack by activating the front auxiliary hydraulic system until the rear of the chopper body clears the top mount area on the machine’s main frame. 25. Do not touch the steering wheel!! Slowly reverse the machine away from the chopper body. Travel rearward approximately 1 m from the rear of the chopper body. 58236

48 26. Lock the hydraulic jack in place with pin 8. 27. Now the jack’s hydraulic hoses can be disconnected from the forage harvester.

58406

49 28. Remove part 21 of the cutterhead drive shaft from the cutterhead gearbox.

58239

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

29. Reinstall this part on the cutterhead drive shaft 22. NOTE: Make sure the drive yokes on each end of the cutterhead drive shaft are in phase.

58240

51 Mounting 1. Line up the forage harvester straight behind the chopper body and drive it to a distance of about 1 m behind it.

58241

52 2. Connect the hydraulic hoses of jack cylinder 5 (Fig. 52) to the auxiliary front hydraulic ports 2.

53 3. Check that guide chains 9 and 10 and springs 11 support cylinder 12 so that the cylinder pin mounts enter on the chopper body. NOTE: Make sure the feed roll and cutterhead drive shaft are lifted in such a way that they do not interfere with the chopper body.

58407

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

4. Slowly drive the forage harvester up to the chopper body and check that the chopper body is at the correct height to be attached to the forage harvester. Adjust for height and inclination with the jacks, if necessary.

58239

55 Drive forward until the upper tube 23 (Fig. 55) of the chopper bodyâ&#x20AC;&#x2122;s triangular frame fits smoothly in its supports 24.

58240

56 5. Lower the chopper bodyâ&#x20AC;&#x2122;s rear end and flip down clamps 19 and 20 around the upper tube.

58235

57 Tighten firmly.

58238

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

6. Lower the chopper bodyâ&#x20AC;&#x2122;s front end with jacks 7 until lower tube 25 (Fig. 60) rests on base unit 26 (Fig. 61).

58405

59 7. Reinstall safety latches 12 (Fig. 62) with lynch pins 13.

58239

60 8. Reinstall the hydraulic cylinders 27 with pins 11 (Fig. 62).

58240

61 9. Remove jacks 7 (Fig. 59).

58237

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

10. Reinstall feed roll drive shaft 9.

63 11. Reinstall cutterhead drive shaft 10. It should be separated some 5 mm from the end of the cutterhead gearbox input shaft so that, when tightening the bolts on the splined end, the splines do not clamp on the broader spline-free end of the cutterhead gearbox input shaft. NOTE: Make sure the drive yokes on each end of the cutterhead drive shaft are in phase.

58235

64 12. Unlock pin 8, pull it out and lock it. 13. Reinstall front clamping rods 6 (Fig. 64) and 7.

58236

65 14. Connect the cutterhead gearbox coolant tubes 3.

58233

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

15. Connect electric cables: -- 1 and 2 (Fig. 67) -- 4 and 5 (Fig. 68)

58233

67 16. If the machine is fitted with an automatic greasing system, connect the grease line(s) to the chopper body.

582340

68 17. Lift the chopper body to its highest position and lock it in place with the safety latches 12.

58237

69 18. Remove the hydraulic jack assembly 1 from underneath the chopper body. 19. Lift away the safety latches 12 (Fig. 69). 20. Reinstall the safety covers.

58241

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

REMOVAL -- INSTALLATION ROTOR AND BEARINGS Removal 1. Remove the chopper body from the machine 2. Swing down the upper feed roll assembly. 3. Remove the sharpener stone guard on the righthand side of the chopper body. 4. Remove the cutterhead gearbox as described in previous paragraph. 5. Remove bolt B and pull off the crop processor drive pulley A together with the overrun clutch. NOTE: If the crop processor is installed it should also be removed as described in the Operatorâ&#x20AC;&#x2122;s Manual.

71 6. On a chopper body without a crop processor, remove bolt B and spacer tube C

72 7. Drive shaft D out of the cutterhead NOTE: Shaft D has conical splines and may be very hard to remove.

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

8. Remove electrical wires and plastic straps from the triangular frame A and the top part B. Note the routing of the wires for reassembly.

74 9. Remove all bolts E holding the chopper body top assembly B and lift away the assembly. Also remove the sharpener stone cover F.

75 10. Remove the front cross bar.

76 11. Remove bolts C on both sides of the chopper body and lift away the triangular frame A (Fig. 74).

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

12. Remove bolts A on both sides, remove the bearing housings B and F. NOTE: Note the quantity and the location of shims installed at A for possible reuse.

78 13. Lift away the cutterhead assembly K

79 FX300-375-450/ FX9630-9640-9645

Series 01 to 10

FX25-45

Series 01 -- 02

An additional cutterhead bearing protection 1 can be installed on both sides of the cutterhead assembly K (Fig. 79). • Mark and drill six holes (6 x 60°) on ∅ 220 mm and tap them for M6 screws. • Install the grease shields 1 with lockwashers and nuts 2. 80

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

Assembly 1. Press bearing cups D and G in the cutterhead assembly. 2. Press bearing cones E and H in bearing housings B and F. 3. Install the cutterhead assembly K into the chopper body (Fig. 80). 81 4. Lubricate grooves J before installing bearing housings B and F (Fig. 81). 5. Install the bearing housings loosely in the chopper body. 6. Install the top of the chopper body B (Fig. 83) and the front cross bar C (Fig. 82).

82 7. Center the cutterhead K by installing shims at C and L. The maximum allowed distance between the outer end of a knife and the chopper body side plate is 3.2 mm (1/8â&#x20AC;&#x2122;â&#x20AC;&#x2122;) (Fig. 81).

83 8. Install shaft D as shown in the Figure.

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

9. Install the measuring gauge as shown in Figures 85 and 86. 10. The run-out should be measured on the outer edge of the bearing housing at M, on both sides of the chopper body. The allowed run- out is + 0.2 mm (0,008’’).

85 11. Adjust the bearing preload to between 4.5 and 6.75 Nm (3,3 -- 5 lbf.ft) by adding or removing the same quantity of shims at C and L (Fig. 84). The bearing housing bolts must be torqued to 240 Nm (175 lbf.ft). 12. Before installing the cutterhead gearbox, check the axial run-out at the inner end of the splines of shaft D (Fig. 84) . The run-out must not exceed 0.2 mm (0.001’’). To reduce the run-out,turn the shaft splines 40° at a time until the run-out is acceptable. 86 13. Install spacer tube C washer and bolt B. Tighten up bolt B to 500 Nm (370 lbf.ft). The thread must be dry and clean.

87 On a chopper body with a crop processor, install a spacer tube, a ring, the overrun clutch with pulley A, a second ring, two bearings, a washer and bolt B. Tighten up bolt B to 500 Nm (370 lbf.ft). The thread must be dry and clean.

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

14. Install cutterhead gearbox as described in previous paragraph. 15. If necessary, readjust the cutterhead knives as described in the Operator’s Manual paragraph “5.5.2 Regauging the knives”. 16. Swing up the upper feed roll assembly. 17. Install chopper body on the machine as described in previous paragraph. 18. Sharpen the knives as described in the Operator’s Manual, paragraph “4.7.1. Automatic sharpening”. 19. Adjust shearbar as described in the Operator’s Manual, paragraph “4.7.2. Automatic shearbar adjustment”. IMPORTANT: Ensure all guards and covers are reinstalled and all hardware is securely tightened.

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

REMOVAL -- INSTALLATION OF CUTTERHEAD GEARBOX Removal 1. Remove the chopper body from the machine. 2. Swing down the upper feed roll assembly. 3. Remove the sharpener stone guard on the righthand side of the chopper body. 4. Loosen or remove plastic straps and wires from the cutterhead gearbox. 5. Remove the temperature sensor from the gearbox and at the same time, drain the oil from the gearbox 6. Remove cover A, nut B and special washer C and the rubber clamping at D (Fig. 90). Mark the shaft to gearbox position before removing the gearbox. This is important to avoid vibrations when reinstalling the gearbox. NOTE: The gearbox is heavy, support it properly when removing it from the shaft.

89 7. Install two M12 x 100 bolts in holes E and press the gearbox from the conical splines of the shaft.

90 Installation Install cutterhead gearbox in reverse order of removal. Nut B (Fig. 89) must be torqued to 500 Nm. The thread must be dry and clean.

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

DISASSEMBLY AND ASSEMBLY OF CUTTERHEAD GEARBOX Disassembly

REMOVAL OF THE OIL COOLER The oil cooler can be pulled out of the gearbox housing. 1. Remove clamp A. 91

2. Carefully pull out the oil cooler. 3. Note that the two O-rings B and C are not identical.

REMOVAL OF SHAFTS AND BEARINGS

Input shaft 1. Remove bolts A, bearing cap B, shims C and shaft D. NOTE: Mark the position of bearing cap B in the gearbox housing before removing it. NOTE: A liquid sealant has been used at assembly of cap B and shims C. 2. Remove the bearings from shaft D, the bearing cup from bearing cap B, the bearing cup from the gearbox housing, shims Q and seal E

NOTE: A liquid sealant has been used at assembly of cap G and shims H. NOTE: It is not possible to remove seal J without damaging it. NOTE: Be extremely careful not to damage the oil cooler if it has been left inside the gearbox when removing the output shaft assembly. 2. Mark the position of the gearbox guide bracket K and cover M. 3. Remove bolts L, guide bracket K, cover M, bearing cup W, shims Y and seal Z 4. Press out shaft N together with gear P in the direction of the arrow. Take care not to damage the oil cooler. NOTE: Bearing T may interfere with the input shaft support inside the gearbox.

Output shaft

5. Remove bearings S and T from shaft N.

1. Remove bolts F, bearing cap G, shims H and seal J.

NOTE: Replace all bearings if other gearbox components are being replaced. NOTE: Input shaft D and gear P are only available as a matched set.

NOTE: Mark the position of bearing cap G in the gearbox housing before removing it.

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

30 GEARBOX ASSEMBLY

Before installing input shaft D, the amount of shims to be installed at Q must be determined. Proceed as follows: +

Input shaft code

Gearbox housing code

Bearing code

Shim value expressed in hundreds of a mm.

Code on input shaft D

Code on gearbox housing

A number is stamped in one of the ends of shaft D. The code is derived from the following table:

This code is stamped in the front of the gearbox, on the upper side close to the bearing cap G,

Measure

Code

Measure

Code

91.100 - 91.124

61.650 - 61.674

154

91.125 - 91.141

61.675 - 61.699

149

91.150 - 91.174

61.700 - 61.724

145

91.175 - 91.199

61.725 - 61.749

140

91.200 - 91.224

61.750 - 61.774

135

91.225 - 91.249

61.775 - 61.799

130

91.250 - 91.274

61.800 - 61.824

126

91.275 - 91.299

61.825 - 61.849

121

91.300 - 91.324

61.850 - 61.874

116

91.325 - 91.349

61.875 - 61.899

111

91.350 - 91.374

61.900 - 61.924

107

91.375 - 91.399

61.925 - 61.949

102

91.400 - 91.424

61.950 - 61.974

91.425 - 91.449

61.975 - 61.999

91.450 - 91.474

62.000 - 62.024

91.475 - 91.500

62.025 - 62.050

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

Bearing code This code is determined by dimension X. New bearings are packed together with a label indicating the code or the dimension expressed in hundreds of a mm. Dimension X

Code

28.000 - 28.025

28.026 - 28.050

28.051 - 28.075

28.076 - 28.100

28.101 - 28.125

28.126 - 28.150

28.151 - 28.175

28.176 - 28.200

Example: Input shaft Gearbox housing code Bearing code Total

91.310 = 08 116 = 116 28.090 = 04 = 128

Total shims value to be installed at Q (Fig. 92) = 1.28 mm. 0.025 - 0.3 - 0.4 mm shims are available.

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

Assembly of input shaft 1. Install shims at Q to the value previously calculated. 2. Install the bearing cup on top of the shims Q. 3. Install the preassembled input shaft D in the gearbox housing and install bearing cap B without seal E. 4. Install shims at C so that the bearing preload is between 0.56 and 1.13 Nm. Note down the required number of shims for possible later reference. Assembly of output shaf 1. If gear P was replaced, install the new gear on shaft N. Make sure the gear is properly seated and install bolts R. 2. Now check the run-out of gear P (measured on the rear side). Maximum tolerance is 0.2 mm. 3. Remove seals J and X if they are still installed. 4. Install bearing W into the bearing housing of cover M. 5. Install bearing S onto shaft N. 6. Install shaft assembly N into the gearbox housing. Do not damage the oil cooler, if installed.

10. Press the output shaft N further in by tightening bolts L until the backlash between gear P and the input shaft gear D is 0.2 mm to 0.28 mm. 11. Measure and install the required quantity of shims at Y. Reinstall cover M and tighten bolts L. 12. Adjust the end float of the shaft to between 0.02 and 0.12 mm by adding or removing shims at H. 13. Check the backlash. Readjust, if necessary, by adding an equal number of shims at H and Y. 14. Measure the torque for shafts N and D on shaft D. 15. Add to the measured value 0.56 - 1.13 Nm. Add shims at H and Y until the new preload value has been reached. 16. Recheck the backlash and reshim, if necessary. 17. Remove cover M and the bearing caps B and H. 18. Install seals at E, J and Z. 19. Cover the gearbox and shim surfaces with liquid sealant type 4 - ES 50.77. 20. Install bearing caps B and G, cover M and guide ring K. 21. Install the oil cooler. Apply liquid sealant in the Oring grooves before installing the O-rings and push in the cooler. 22. Install fastening bracket A (Fig. NO TAG).

7. Install cover M with bearing W. Do not install the shims at this time. Install bolts L but do not tighten them completely. 8. Install bearing T onto shaft N. 9. Install bearing cup V into the gearbox and install bearing cap G, but without shims. Tighten the bearing cap mounting bolts F and loosen the bolts again.

23. Reinstall the gearbox on the chopper body as described in previous paragraph. 24. Fill up the gearbox with 1.9 litres of API-GL-5, MIL-L-2105B, SAE 80W-90 oil. Check the oil level with the dipstick.

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

REMOVAL -- INSTALLATION OF SHEARBAR Removal 1. Detach the attachment with upper feed rolls or flip down the upper feed rolls as described in Section 60 -- chapter 1. 2. Thoroughly clean the space between the scraper and the shearbar 3 with a knife or a screwdriver until it is absolutely clean. Use compressed air, if available.

58423

3. Move the shearbar adjusting arms fully forward (away from the cutterhead) by using the automatic shearbar adjuster motors. Proceed as follows: 4. Turn the ignition key on, but do not start the engine. Switch on the harvest tumbler switch and then the Adjust-O-Maticâ&#x201E;˘ tumbler switch. Wait until the OK light on the Adjust-O-Maticâ&#x201E;˘ panel will illuminate.

ROAD

OFF

HARVEST

30550

5. While pressing the INTERRUPT button, simultaneously press the ADJUST SHEARBAR Button The shearbar will now automatically be moved on both sides to its foremost position.

30549

SECTION 64 -- CUTTERHEAD -- CHAPTER 1 6. While the shearbar is moving forward, the ADJUST SHEARBAR light is blinking and the buzzer beeps with short intervals. When the shearbar reaches its foremost position, the blinking light will extinguish and the buzzer stops beeping. The OK light will illuminate. The shearbar is pushed away from the knives by the adjuster motors, operating alternately on the left and the right-hand side, until the shearbar, or the adjuster arms, meet(s) a mechanical stop. Then each side is pulled towards the cutterhead three times. Check if the shearbar is really fully forward, but does not touch the scraper.

30549

98 7. Switch off the Adjust-O-Matic™ and the harvest tumbler switches. Turn off the ignition key. Check that the shearbar-to-chopper body frame clearance is the same on both sides of the chopper body. If not, adjust to the smaller clearance by turning the adjuster rod.

WARNING Adjusting the shearbar by turning the adjuster rods without turning of the ignition key will cause electric motor failure.

ROAD

OFF

HARVEST

30550

99 8. Remove clamping bolts 1 on both sides of the chopper body. Observe the assembly order of the washers and spacer, and retain them. 9. Remove mounting bolts 2 on both sides of the machine. Observe the order of the washers and retain them. 10. Remove the shearbar and the slide plate from the right-hand side of the machine. On some machines it may be necessary to loosen the crop guides to give more space for the shearbar. For loosening of the crop guides, refer to the operator’s manual, paragraph “5.4.2. Crop guides”. 11. Clean the shearbar and the shearbar support thoroughly (use an amery clotch to remove eventual rust).

100

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

Installation 1. Install the slide plate and the new shearbar or turn the old one. Spread a thin film of grease on the shearbar and the shearbar support before installing the shearbar. IMPORTANT: The shearbar has two cutting edges. It can be turned end for end, but never turned over. 2. Reinstall mounting bolts 2 on both sides of the machine and make sure the washers are installed in the correct order (the thin ones should be installed towards the arm). Tighten bolts 2 to a torque of 180 Nm (132 lbf.ft). Check that distance is equal on both sides of the machine. If not so, adjust manually to the smaller measurement. 3. Install clamping bolts 1 on both sides of the machine. Make sure to install the washers and the spacer in the correct order and tighten bolts 1 to a torque of 91 Nm (67 lbf.ft). IMPORTANT: Spread a thin film of grease between the clamping bolt washers and the shearbar. This is to prevent the washers from binding onto the shearbar. 4. If necessary, readjust the cutterhead knives as described in the Operator’s manual, paragraph ‘‘5.5.2 Regauging the knives’’. 5. Attach the attachment with upper feed rolls or flip up the upper feed rolls as described in Section 60 -- chapter 1. 6. Sharpen the knives as described in the Operator’s Manual, paragraph ‘‘4.7.1. Automatic sharpening’’. 7. Adjust the shearbar as described in the operator’s manual, paragraph ‘‘4.7.2. Automatic shearbar adjustment ’’. IMPORTANT: Ensure all guards and covers are reinstalled and all shearbar hardware is securely tightened.

101

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

REMOVAL -- INSTALLATION OF SHEARBAR SUPPORT Removal 1. Detach the attachment with as described in paragraph â&#x20AC;&#x153;Attaching and detaching the attachmentâ&#x20AC;?. 2. Flip down the upper feed rolls (refer to Section 60 -- chapter 1). 3. Remove the shearbar from the machine (refer to previous paragraph). 4. Remove the scraper from the machine. 5. Remove bolts A and B and spacer C from both sides of the chopper body.

102 6. Remove bolts D from underneath the machine.

103 7. Note the number and location of possible shims between the shearbar support and the chopper body frame at points E. 8. Remove the shearbar support to the right-hand side of the machine.

104

SECTION 64 -- CUTTERHEAD -- CHAPTER 1

Installation 1. Insert shearbar support from the right-hand side into the chopper body. 2. if necessary, install shims between the shearbar support and the chopper body frame at points E. 0.3 and 0.6 mm shims are available.

105 3. Install bolts D from underneath the machine.

106 4. Install spacer C, bolts B and A on both sides of the chopper body. 5. Reinstall the scraper and adjust as described in the Operator’s Manual, paragraph “5.4.1. Smooth roll scraper”.

107 6. Install the shearbar as described in previous paragraph. 7. Flip up the upper feed rolls. 8. Attach the attachment.

SECTION 70 -- EJECTION -- CHAPTER 1

SECTION 70 -- EJECTION Chapter 1 -- Blower CONTENT Section

Description

Page

70.000

Inspection between cutterhead and blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

70.120

Removal and installation of blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

70.100

SECTION 70 -- EJECTION -- CHAPTER 1

INSPECTION BETWEEN AND BLOWER

CUTTERHEAD

Opening up the assembly 1. Lower the chopper body/attachment to the ground. 2. Remove the cover on the left-hand side. 3. Unscrew front clamping rods 1 (Fig. 1) and 2 (Fig. 2). 4. Unlock pin 3 (Fig. 2) and push it toward the cutterhead. This pin will limit the chopper body’s rotation. Lock the pin in that position.

58231

IMPORTANT: Do not try to install both pin 3 (Fig. 2) and clamping rods 1 (Fig. 1) and 2 (Fig. 2) at the same time. Doing this and lifting the chopper body afterwards would cause irreparable damage to the chopper body’s triangular frame 5. Lift the chopper body. 6. Install safety latches 10 (Fig. 3) by removing lynch pins 11.

∧

A -shaped gap will appear between the cutterhead (or crop processor) and the blower. Inspection of the blower and the rear side of the cutterhead or the crop processor can now take place.

58232

Closing the assembly 1. Lift safety latches 10 (Fig. 3) and secure them with lynch pins 11. 2. Lower the chopper body. 3. Unlock pin 3 (Fig. 2), pull it out and lock it. 4. Reinstall the front clamping rods 1 (Fig. 1) and 2 (Fig. 2) and tighten them firmly. 5. Reinstall the cover on the left-hand side 3

SECTION 70 -- EJECTION -- CHAPTER 1

REMOVAL AND INSTALLATION OF BLOWER 1. Remove the chopper body from the base unit as explained in section 64 paragraph â&#x20AC;?Removal -installation of chopperbody 2. Remove bolt 1and pull drive shaft 2 away from blower gearbox.

3. Support the blower in hole 4.

4. Remove the three blower frame fastening bolts 3. 5. 1. First pull out the lower end and lower the blower away from the spout. 6. Reinstall the blower in reverse order of the removal sequence 7. Torque the blower fastening bolts 3 to 240 Nm (177 lbf.ft). Replace the bolts, if damaged

54534

SECTION 70 -- EJECTION -- CHAPTER 1

REMOVAL AND INSTALLATION OF BLOWER GEARBOX Removal 1. Remove the blower from the base unit as explained in previous paragraph â&#x20AC;?Removal and installation of blowerâ&#x20AC;?. 2. Remove the blower front plate 1 by removing all nuts, washers and bolts 2 from the front plate perimeter. 3. Remove the eight bolts and washers 3 and the coverplate.

4. Mark the position of the blower cone on the blower gearbox shaft. Install two bolts (M 12 x 70) in the holes 4 and press out the blower cone. NOTE: The blower cone is heavy; be careful when handling it. Mark the position of the gearbox on the blower frame.

5. Drain the oil from the blower gearbox through hose E.

55098

8 6. Remove shielding from behind of the blower 7. Remove hoses E and F from the gearbox 8. Remove rods G and H from the gearbox 9. Support the gearbox well and remove bolts J. 10. Lift the gearbox away from the blower frame

SECTION 70 -- EJECTION -- CHAPTER 1 Installation 11. To install the gearbox, proceed in reverse order of the disassembly sequence. 12. Adjust the blower cone in the blower housing as described in section 5 ”Adjustment and maintenance” of the Operator’s Manual 13. Fill the gearbox with oil: Gearbox capacity: 1.4 litres Oil specification: Use AMBRA HYPOIDE 90 oil ( ref. NH520A) or an oil meeting the following specification: -- API GL5 or MIL--L--2105 D -- Viscosity grade: SAE 80W -- 90

SECTION 70 -- EJECTION -- CHAPTER 1

GEARBOX DISASSEMBLY AND ASSEMBLY

FX300-375-450/ FX9630-9640-9645

Series 01 to 14 Series 5033 to 5077

FX25-45

Series 01 to 06 Series 5033 to 5077

BLOWER GEARBOX

Watteeuw

Disassembly 1. Remove bolts and washers FF and cover DD 2. Remove bolts and washers M and bearing cap G. NOTE: Do not damage the seal J. If the seal has to be removed, it will be damaged and must be replaced 3. Remove bolts and washers at E and input shaft K together with the bearing housing F and the bearing N NOTE: Do not damage the shims at D. Keep the shims for later use 4. If necessary, remove bearing inner race A from shaft K and the bearing B from the gearbox housing C. 5. Loosen stake lock washer H from stake nut L and remove the nut and the washer. 6. If necessary, press shaft K out of the bearing N and bearing housing F and then bearing N out of bearing housing F. 7. Remove bolts and washers AA, cover W and shims BB from the gearbox housing C. 8. Remove cotter pin S, castle nut T and spacer washer V. 9. Reinstall nut T and drive or press out shaft KK, or use two M12 x 70 bolts and pull out shaft KK 10. Carefully remove bearing CC, gear EE, spacer GG and bearing HH. If necessary, remove the bearing cups Q and LL from the housing C. If damaged replace seal JJ.

31079

SECTION 70 -- EJECTION -- CHAPTER 1

Assembly Output shaft 1. Check the condition of the seal JJ and replace if damaged. Lubricate the seal cavity 2. Install bearing cup LL. 3. Carefully introduce shaft KK into the gearbox housing C. 4. While installing shaft KK, install simultaneously bearing HH, spacer GG and gear EE. Drive or press them in place. NOTE: Install gear S on the splines 5. Install bearing CC onto shaft KK and drive it in, install spacer washer V and castle nut T onto shaft KK. 6. Tighten up the assembly and install cotter pin S. Make sure that all parts are well seated. 7. Install bearing cup Q into the housing and press it as far as it can go. 8. 1. Install bearing cap W in place and measure distance Y. The thickness of the shim pack is Y + 0,025 mm (0.001”). Install the determined amount of shims at BB. The axial play should be 0,01 -- 0,05 mm (0.0004” -- 0.002”) for shaft KK, if not readjust. NOTE: Install at least one 0,025 mm (0.001”) shim. 9. When the axial play is correct, coat the contact surfaces of the gearbox housing, shims BB and the bearing cap W with liquid sealant and reinstall bearing cap W. Install washers and bolts AA and torque to 52 Nm (38 lbf.ft) . 10. Recheck the axial play and readjust, if necessary.

31080

SECTION 70 -- EJECTION -- CHAPTER 1

Input shaft 1. Install bearing N into bearing housing F. 2. Lock bearing N in place by installing stake lockwasher H and stake nut L. Secure stake nut L in place with stake lockwasher H. 3. Drive the bearing N and the bearing housing F onto gear shaft K. 4. Install bearing inner race A and bearing B onto shaft K. 5. Install the shaft assembly into gearbox housing C. Do not tighten completely. 6. Adjust the backlash to 0,1 -- 0,15 mm (0.004â&#x20AC;? -0.006â&#x20AC;?) by adding a sufficient number of shims at D. NOTE: The backlash is measured on the splines of the input shaft K. There is no formula for the shim pack calculation. 7. Apply liquid sealant to the surfaces of the housing F, cap G and the shims D. Torque bolts E to 26 Nm (19 lbf.ft) and bolts M to 12Nm (9 lbf.ft). 8. Apply liquid sealant onto the cover DD and install it with washers and bolts FF. Torque bolts FF to 26 Nm (19 lbf.ft).

31080

SECTION 70 -- EJECTION -- CHAPTER 1 FX300-375-450/

Series 5078 to ...

FX25-45 FX28-38-48-58

Series 5078 to ... Series 5083 to ...

BLOWER GEARBOX

CORNER

Disassembly 1. Remove bolts GG and cover EE. 2. Remove bolts M and lift out shaft K and bearing housing L. 3. Remove shaft K from bearing housing L. 4. Remove seal J, circlip H, shims G and bearing cup F from the bearing housing L. NOTE: Measure the thicknes of shim pack G and note it down. 5. Remove bearing E from shaft K. 6. Remove bearing C from shaft K and shims D. NOTE: Do not damage the shims D. Keep the shims for later use. Measure and note down the thickness of shimpack D. 7. If necessary, remove bearing cup B from gearbox housing CC. 8. Remove bolts AA, cover T and shims Q from the gearbox housing CC. Keep the shims for later use. 9. Remove cotter pin V, castle nut W and spacer washer BB. 10. Reinstall castle nut W and drive out shaft LL, or use two M12 x 70 bolts and pull out shaft LL. 11. Carefully remove gear DD, shims FF, spacer HH and bearing A and S. If necessary, remove bearing cup JJ and S from the gearbox housing CC. Measure the thicknes of shimpack FF and note it down and keep the shims for later use. NOTE: Do not damage seal KK. If the seal has to be removed, it will be damaged and must be replaced.

31081

SECTION 70 -- EJECTION -- CHAPTER 1

Assembly Input shaft 1. Install bearing E onto shaft K. 2. Install the same quantity of shims at D as you removed during disassembly. If you need to restart shimming from scratch then install a 1.00 mm (0.04â&#x20AC;?) shim pack. NOTE: No shimming codes are provided. 3. Install bearing C onto shaft K. 4. Install bearing cup B into the gearbox housing CC. 5. Install the preassembled shaft K and bearingsC and E into the gearbox housing CC. 6. Install bearing housing L with bolts M. 7. Install bearing cup F into housing L and press it as far down as possible. 8. Install as many shims as possible between the bearing cup F and the circlip cavity H. Install circlip H. 9. The rotating torque on shaft K should be 5 to 30 Nm (3.6 -- 22 lbf.ft) without oil seal J. Output shaft 10. Check the condition of seal KK and replace, if damaged. Lubricate the seal cavity. 11. Install bearing cup JJ if it was removed. 12. Carefully introduce shaft LL into the gearbox housing CC. 13. While installing shaft LL, install simultaneously bearing A, spacer HH, shims FF,gear DD. Drive or press them in place. 14. Install the same quantity of shims at FF as you removed during disassembly. If you need to restart shimming from scratch then install a 1.50 mm (0.06â&#x20AC;?) shim pack. NOTE: No shimming codes are provided. Install gear DD on the splines.

31082

SECTION 70 -- EJECTION -- CHAPTER 1

15. Install bearing S onto shaft LL and drive it fully in, install spacer washer BB and castle nut W onto shaft LL. 16. Tighten up the assembly and install cotter pin V. 17. Install bearing cup R into the bearing housing and push it as far down as you can get it. 18. Measure the distance Y from the upper end of the bearing to the surface of the casting CC, and note down the value (Fig. 15). 19. Measure the distance Z on the cover T (Fig. 15). 20. The quantity of shims needed at Q can be calculated with the following formula: Y -- Z + 0,25 = shim pack in mm. Y -- Z + 0.01 = shim pack in Inch. 21. The quantity of shims needed at Q (Fig. 14) Install bearing cap T with with the calkulated shim pack at Q ensuring an axial play of 0,01 -- 0,05 mm (0.0004” -- 0.002”) for shaft LL. 22. Recheck the axial play and readjust, if necessary.

31082

Adjusting the shimming 23. Block gear DD and measure the backlash on the splines of shaft K. The backlash should be 0.1 to 0.2 mm (0.004” -- 0.008”). 24. If the backlash need to be adjusted it should be done by removing shims at FF (reduces the backlash) or by adding shims at FF (increases the backlash).

SECTION 70 -- EJECTION -- CHAPTER 1

25. When the backlash is within the permissible tolerance then check the tooth flank contact area. 26. The tooth contact area should be as shown. 27. If not then adjust by removing or adding shims at D. 28. When the shimming is correct then install oilseal J and cover EE. Tighten bolts GG to 26 Nm (19 lbf.ft), bolts AA to 52 Nm (38 lbf.ft) and bolts M to 26 Nm (19 lbf.ft).

31084