2054, 2056, 2058 2064 and 2066 Combines 48 John Deere Werke Zweibriicken TM4505 (0S5DECO0)Group 05 General Information ELECTRICAL CIRCUIT MALFUNCTIONS L117540 1-Fuse ‘The four possible circuit malfunctions are: 1. High resistance circuit 2. Open circuit 3. Grounded circuit 4, Shorted circuit ‘There are only three “areas” in a simple electrical circuit where circuit malfunction can occur (see simple circuit above) 1, Before the controlling switch (A) 2. After the controlling switch but before the load (8) 3, After the load (C) 2Load Component malfunctions can easily be confused with circuit malfunctions, Caution must thereforé be exercised when isolating the cause of the problem. Example: A component may not operate before an ‘electrical connection is disconnected, but it operates when the connector is reconnected. Reason: High resistance in the circuit created a voltage drop at the connector terminals, preventing the proper amount of current from flowing to the ‘component. ‘TM4505 (0SDECOO) 240-05-1 Z Series Combines NESEGeneral Information/Open Circuit OPEN CIRCUIT L117541 ‘A-WVoltage Source B—Controting Switch (c—Component Terminal High Resistance Circuit A high resistance circuit can result in slow, dim or no ‘component operation (i.8. loose, corroded, dirty or olly terminals, gauge of wire too small or broken. strands in cable). ‘An open circuit results in no component operation, as the circuit is incomplete (E) (i.e. broken wire, terminals disconnected, open protection device or switch). cHLoad H—Ground Open Circuit FComponent Terminal ‘Test for a high resistance circult (D) or an oper circuit (E) 2s follows: 1. With controling switch (B) closed and load (6) connected, check for proper voltage at an easily accessible location between (C) and (F). 2. If voltage is low, move toward voltage source (A) to locate point of voltage drop. b. If voltage Is correct, move toward load (G) and ground terminal (H) to locate point of voltage drop. 2. Repair circuit as required. 8, Repeat operational check after completing the repair ‘TMAa505 (050EC00) 240-05-2 Z Series Combines PN=a87General Information/Grounded Circuit GROUNDED CIRCUIT L117542 A a A-Component Terminal ‘c—Controting Switch E-Grounded Circuit G—Loss Component Terminal Component Terminal Component Terminat H—Component Terminal ‘A grounded circuit results in no component operation _—_2. Disconnect load (G) at (F). and the fuse will blow (Le. power wire to ground). 3. With controlling switch (C) open, check for Test for a grounded circuit (E) as follows: continulty to ground between (D) and (H). 41. Controlling switch (C) open, fuse not blown. It there is continuity, there is a grounded circuit between (D) and (H). a. If there is continuity, there is @ grounded circuit between (B) and (C). 4, Repair circuit as required. . No continuity, go to 2. 5. Repeat operational check after completing the repair. ‘TM4505 (05DECOO) 240-05-3 Z Series Combines PN=a88General Information/Shorted Circuit SHORTED CIRCUIT 117543 ‘A~Component Terminal ‘B—Gircuit Connector (C—Circuit Connector ‘D_Componont Terminal E-Loadtype Component A shorted circuit usually results in two components. ‘operating when one of the switches is closed (.e. improper wire-to-wire contact) Test for a shorted (I) or improperly wired circuit as, follows: 4. Tum on switch (G) for correct component (F) to operate. 2. Start at controlling switch (H) of component (E) which should not be operating and disconnect wire at terminal (A). 3. Follow circuit and disconnect wire at connectors (8, C or D) until component ceases to operate. 4, The shorted circuit or improper connection will be between the last two locations at which the wire was disconnected. In the example above, between (B) and (©), M4505 (050EC00) 240-05-4 F--Load-type Component G—Switen H-Controting Switch shorted Cireut 6. Repair circuit: a, Wires not in a loom: Wrap individual wires with electrical tape and band as required. b. Wires in a loom: If hot spots exist in the shorted area of harness, replace harness. If hot spots are not noticeable, install a new wire of proper gauge between last two connections. Tape wire to outside of hares. 6. Repeat operational check after completing the repair. Z Series Combines PN=388General Information/Reading a Functional Schematic HOW TO READ A FUNCTIONAL SCHEMATIC : A -4. 1 — Main distribution wiring harness W 2—Cab wiring harness 3.— Switch console wiring hamess 4 — Comer post wiring harriess 5 — Armrest wiring hamess 6 — Air conditioning and fan wiring hares 7 — Basic wiring hamess, front Se eee 8 — Steering column wiring hamess W 9 — Basic wiring hamess, rear W 10 — Feeder house wiring hamess W 12 — Wiring harness, Saran engine W 13 — Wiring harness, Waterloo engine W 14 — Optional equipment wiring harness W 15 — Grain tank wiring hamess W 17 — Battery ground cable W 18 — Positive battery cable W 20 — Straiv hood wiring hamess W 21 — Power supply cable W 22 — Header wiring harness W 23 — Combine data center wiring harness W 25 — Chopper wiring harness W 26 — Chaff spreader wiring hares W 27 — Wiring harness, straw warning device W 28 — Ground cable, straw warning device W 29 — Leveling system wiring harness W 82 — Header lighting wiring hamess W 39 — Wiring harness, electrical mirror adjustment TM4505 (0SDECOO) 240-10-2 Z Series Combines. PNstot> Functional Schematics & Harness Diagrams, up to Ser.No. 062721/Component Survey COMPONENT SURVEY Section Wiring Harness 1 — Reel speed control. o cee 19 2 — DIAL-AMATIC™ relay board : 3 — Electronic speed monitoring system. 4 — Harvest performance monitor 5 — Combine data center 6 — Header controt 8 9 0 1 2 — Leveling control box, Hilimaster — Control board, combine data center — Float control — Relay board, combine — Radio... 5 13 — Citizen band A14 — Relay and diode board AMS —Fuse board 2.2... 0c cess eeeeeeeteeueees A168 —Waming module |... 2.2... peer oa) A147 — Waring module 1! 18 — Infotrak monitor center. - DPE S> SSD yy = SS55S55S555S555eEEE 1 — Sending unit, brake fuid level 2 — Sending unit, engine oil pressure - 3 —Light sensor... 4 — Sending unit, coolant temperature | 5 — Sending unit, reel speed 6 — Sending unit, ground speed. 7 — Sending unit, hydraulic ofl fter 8 — Sending unit, hydraulic oil temperature 9 — Thermostat retain epsinstfezing) 0 — Sending unit, air leaner. 4 2 3 4 5 6 7 8 — Sending unit, fuel tank : Hom... fone — Temperature switch, air conditioning — Low pressure switch, air conditioning — High pressure switch, air conditioning . — Speed sending unit, straw chopper — Speed sending unit, tailings elevator — Speed sending unit, cross shaker. B 19 — Speed sending unit, clean grain elevator 8 20 — Speed sending unit, chaff spreader B21 — Straw walker sensor, right-hand B 22 — Straw walker sensor, left-hand sensor (S-walker machine) B 24 — Sieve sensor (G-walker machine) B 25 — Sending unit, grain tank indicator 1/2 . B 26 — Sending unit, grain tank indicator 3/4 B 27 — Sending unit, grain tank indicator 4/4 ‘TMA505 (05DECO0) 240-10-3 Z Series Combines eneteeFunctional Schematics & Harness Diagrams, up to Ser.No. 062721/Component Survey Section Wing Harness 8 28 — Sending unit, engine speed ... 2 w 12; w13 B 29 — Sending unit, threshing cylinder speed eee 22 w7 B 30. — Sending unit, fan speed ; Lilla w7 8.31 — Pressure switch, main clutch 2 we B34 — Sending unit, hydr. oil fil level 12.1222 erest0 wo 8.95 — Sending unit, hyd. oi fil evel 2 : Sooo 08 we B39 — Loudspeaker, lefthand : 08 we B 40 — Loudspeaker, right-hand | 108 we E 1 —Headlight, let-hand . .. 212 w7 E 2 —Headlight, righthand - 212 w7 E 3 —Rear work light... 220.222 ee eenT Ww 20 E 4 — Cab roof work light, outer th 2221) rest w2 E 5 — Cab roof work light, inner rh. 7 w2 E 6 — Cab roof work light, outer Ih 7 w2 E 7 — Cab roof work light, inner Lh, M7 we E 8 — Unloading auger work light 7 wis E 9 — Cigarette tighter . ; 1 w3 E 10 — Grain tank lighting 207 was E 11 — Lighting (according to local reciremonts) 12 w7 E 12 — Cab interior lighting . : w2 E 13 — Taillight, lot-hand w 20 E 14 — Tail light, right-hand Ww 20 E15 — Clearance light, lef-hand |. w7 E16 — Clearance light, right-hand w7 E17 —Straw hood lighting... . w20 E 18 — Platform work light, righthand w7 E 19 — Platform work light, left-hand w7 E 22 — Registration plate lighting... gop Ww 20 E23 — Clearance light, header, lefthand |... eee iZ wa2 E 24 — Clearance light, header, right-hand... 2. wll t2 Ww 32 E 25 — Work light, mirror bracket... . Sadousebeeontl? w2 E 26 — Work light, mirror bracket - 7 w2 F 1 —Fuse, 7.5 amps., spare. 5 - ats F 2 —Fuse, 75 amps., spare. 5 - AMS F 3 —Fuse, 7.5 amps., spare - AMS F 4 — Fuse, 7.5 amps., spare - AMS F 5 —Fuse, 15 amps., spare 5 A1S F 6 —Fuse, 15 amps., spare .. - A1s F 7 — Fuse, 30 amps., spare |. - AtS F 8 —Fuse, 7.5 amps. fan and threshing cylinder speed adjustment . 225 Ans ‘TMA505 (05DECO0) 240-10-4 Z Series Combines, PNsagaFunctional Schematics & Hamess Diagrams, up to Ser.No. 062721/Component Survey Section Wiring Harness F 9 — Fuse 7.5 amps., parking light, .h 12 A15 F 10 — Fuse 7.5 amps., parking light, 11 : 2 A15 F 11 — Fuse 30 amps., fan adjustment Bosoe6 25 At5 F 12 — Fuse 15 amps., stop lights, reel speed adjustment eo wee 19 A1S F 13 — Fuse 30 amps., cab roof work lights 7 ANS F 14 —Fuse 7.5 amps., straw wamning device, electronic infotrak monitor. ‘i . +18 AS F 16 — Fuse 7.5 amps., engine shutoff solenoid. | +. 03NB A 15 F 17 —Fuso 7.5 amps., instrument lighting 2 ANS F 18 — Fuse 7.5 amps., radio, citizen band, clock 08 A1S F 19 — Fuse 30 amps., platform work lights and rear work light ats F 20 — Fuse 7.5 amps., flasher functions. . A158 F 21 — Fuse 15 amps., radiator cleaner motor A1s F 22 — Fuse 7.5 amps., radio, citizen band, clock At F 23 — Fuse 1 amps., separator and header fi clutch : 2 At5 F 24 — Fuse 7.5 amps., indicator lights, temperature gauge . . 5 05 AMS F 25 — Fuse 7.5 amps, low-beam headight, Ih... 2 AS F 26 — Fuse 7.5 amps., header controls ef 26 A15 F 27 — Fuse 15 amps., hom ... eee rece 100) AG F 28 — Fuse 7.5 amps, combine data center : 25 AS F 29 — Fuse 15 amps., leveling system eee a) A1S F 30 — Fuse 7.5 amps., four-wheel drive... 0... eee eee eer) AMS F 31 — Fuse 7.5 amps., speed monitoring system pee ee ANS F 32 — Fuse 7.5 amps., low-beam headight, hn 212 ats F 33 — Fuse 15 amps., raise/lower header 226 AMS F 34 — Fuse 15 amps., hazard waming lights... <<. ets ats F 35 — Fuse 15 amps., revolving warning lights... wit AMS F 36 — Fuso 15 amps., windshield wiper, grain tank lighting . or ats F 37 — Fuse 7.5 amps., miror adjustment - +16 ats F 38 — Fuse 7.5 amps., performance monitor a 123 AS £ $9 — Fuse 18 amps. grain tank unloading sytem ar A45 F 40 — Fuse 30 amps. starter switch . see lo4 A1S F 41 — Fuse 15 amps., concave adjustment BendoobneJ ats F 42 — Fuse 30 amps., air conditioning system 45 AMS F 43 — Fuse 7.6 amps., DIALAMATIC™ ... 20 ats | F 44 — Fuse 7.5 ampe., ful-beam headight, In. 2 ats F 45 — Fuse 15 amps., reel control. .... SII 28 ats F 46 — Fuse 15 amps., starting aid 2NB ANS F 47 — Fuse 15 amps., spare . .. ~ A168 F 48 — Fuse 7.5 amps., altemator D+ 201 A15 F 49 — Fuse 15 amps., cigarette lighter, seat compressor. . See yt ANS F 50 — Fuse 7.5 amps., fullbeam headlight, rh. 2 ANB zemacooorreseoua2 ‘TM4505 (0SDECO0) 240-10-5 Z Series Combines PN=dodFunctional Schematics & Hamess Diagrams, up to Ser.No. 062721/Component Survey 1 — Battery 12 V, 68 AH 2 — Alternator — Brake fluid indicator light... = Engine oil pressure indicator ight — Parking brake indicator light — Coolant temperature indicator light = inal Igt,unloang auger swing — Fuel level indicator ight ....... — Hydraulic oll iter indicator light — Hydraulic oil temperature indicator ight — Four-wheel drive indicator light — Air cleaner indicator light . . — Alternator indicator light — Alarm light (‘STOP") 3. — Tum signal light, rear left-hand - 4 — Tur signal light, rear right-hand 5 — Tum signal light, front left-hand }& — Tum signal light, front right-hand H47 — Additional turn signal light, left-hand H 18. — Additional turn signal light, right-hand H 19. — Indicator ight, straw warning device H20 —Buzer .... : H 21 — Revolving hazard warning light H 22 — High pressure i H 23. — Indicator ight, straw chopper speed H 24 — Indicator light, talings elevator speed « H 25 — Indicator light, cross shaker speed . . H 26 — Indicator light, grain elevator speed H 27 — Grain tank fil indicator light 1/2 . | H 28 — Grain tank fil indicator light 3/4 H 29 — Grain tank fil indicator light 4/4 H 31 — Indicator light, fan speed. H 32 — Indicator light, cylinder speed H 33. — Full-beam indicator light H 34 — Tum signal indicator light 1, combine . H 35 — Tum signal indicator light 2, taller . 1136 — Revolving hazard waming light . . - H 37 — Hillmaster combine, automatic operation H 38 —Hillmaster combine, manual operation H 39 — Hillmaster combine, end siop H 40 — Hydraulic oll level indicator light EXTTILTLTTLTIIIITT OO H 42 — Turn signal light, header, right-hand H 43 — Stop light, left-hand , H 44 — Stop light, righthand K 1 — Starting motor relay K 2 —Basic relay .... K 3 —Basic relay icator light (AC system) H 41 — Tum signal light, header, left-hand . . . - Section ot ot Wiring w 12; w 13; w 32 Ww 20 w 20 w 12; A168 A18 Harness wi3 wi13 wigs TM4505 (05DECO0) 240-10-6 Z Series Combines PN=AOS,Functional Schematics & Hamess Diagrams, up to Ser.No. 062721/Component Survey 4 — Buzzer timer relay 5 — Flasher : 6 — Relay, straw warning device » 7 — Relay, work lights 8 9 0 — Hillmaster leveling relay, iefthand — Hillmaster leveling relay, right-hand — Relay, fan speed alarm : K 11 — Relay, cylinder speed alarm K 12 — Relay, field operation — road travel . K 13 — Relay, lower header quickly K 14 — Relay, lower header slowly . K 15 — Relay, raise header quickly K 16 — Relay, raise header slowly K 17 — Relay, lower reel K 18 — Relay, raise real... . K 19 — Relay, move reel to the rear K 20 — Relay, move reel to the front K 21 — Relay, separator clutch K 22 —Relay, straw warning device . K 23 — Safety relay, header drive K 24 — Safely relay, unloading auger drive” K 28 — Relay, adjust feeder house speed K 29 — Relay, adjust feeder house speed K 32 — Relay, adjust ree! speed ef K 33 — Relay, adjust ree! speed — Timer relay, header drive K 36 — Relay, adjust fan speed . x K 25 — Timer relay, unloading auger swing . K 37 — Relay, adjust fan speed . .. M 1 —Starting motor . M. 2 —Reol speed adjusting motor M_ 3 — Windshield wiper motor M 4 —Cab fan M_ 5 — Seat compressor i M 8 —Concave adjusting motor... M_9 —Fan speed adjusting motor . . M11 — Windshield washer pump M12 — Radiator cleaner motor .. M43. — Distributor adjusting motor ...... . P 1 — Coolant temperature gauge . P 2 —Fuel gauge . : P. 3. —Header height gauge P 5 — Grain loss indicator P 7 —Clock .. : P 8 — Distributor gauge. Section Wiring Harness Ata At Ata A15 A A A’ wt4 A1S Als Ats At4 | Ata AM Ata Aw Ata ANS At Att Ais Als Att Atd Ald Ata T4605 (05DECO0) 240-10-7 Z Series Combines PN=HOS2 Functional Schematics & Hamess Diagrams, up to Ser.No. 062721/Component Survey Section Wiring Harness R 1 —Fanresisor...... we R 2 —Potentiometer, concave adjustment” w7 R 3 —Potentiometer, header height . wis R_ 4 — Sending unit, header height . Ww? R_5 — Potentiometer, reel height wie R’ 6 — Sending unit, reel height... we22 RT — Potentiometer, reel horizontal position wi4 R_8 — Sending unit, reel horizontal position . w22 R_9 — Resistor, LED fuse tester . AMS R 13 —Potentiometer, header float. w14 R 14 —Potentiometer, distributor adjustment W25 S 1 —Starter switch... 01 we S 2 — Hydrostatic safety’ switch : o1 ws S 3 — Cold weather starting aid switch... owe WB S 4 — Indicator light test switch. w2 S_5 —Parking brake control switch w? S 6 —Header float switch ..... ws S 7 —Stop light switch w7 S 8 —Hom button .. a ws S 9 —Potentiometer, reel speed - wi4 S10 —Reel speed switch .... Ws S11 — Hazard warming light switch. we $12 — Tum signal switch we $13 — Light switch w2 8 14 — Grain tank lighting switch. Sacododon w2 S 15 — Switch,straw warning device (cross shaker) | 1.2... 112211 18 wo S16 — Switch, straw warning device (walkers) . 18 w20 S17 — Switch, straw warning device (chopper). 218 w20 S18 — Revolving hazard warning light switch 14 w2 $19 — Switch for cab roof work lights : w2 S 20 — Windshield wiper switch... . . we S21 — Windshield washer switch :07 w2 $22 —Fan switch ..... 215 we $23 — DIAL-A-MATIC™ switch 20 wi4 'S 24 — Speed monitoring switch, chopper 22 W25 S 25 — Air conditioning switch 25 we 8 27 — Switch, raise/lower header 26 Ws S28 — Automatic function switch . 6 ws S23 — Switch, reel h 26 Ws ‘TM4505 (05DECOO) 240-10-8 Z Series Combines PNeHO7Functional Schematics & Hames Diagrams, up to Ser.No. 062721/Component Survey Section Wiring Harness $30 — Switch, reel horizontal adjustment ee 26 ws S31 — Road safety switch 0.6... 605 2 we S32 — Switch, header control mo cose 28 wg S33 — Separator drive switch... : 24 w3 S34 — Header drive switch ‘i 21 wa 8 35 — Unloading auger drive switch a w3 '$ 36 — Switch, concave adjustment 25 ws $38 — Switch, combine data center 25 wis $39 — Switch, unloading auger swing. . 27 wa S40 — Switch, cylinder speed adjustment 25 ws & 41 — Suto, fan speed acute 25 ws $42 — Parking brake switch : +09 ws 8 44 — Four-wheel drive switch 28 wr 8 47 — Emergency cutoff switch 24 ws $48 — Work light switch... . 7 w2 S49 — Full-beam headlight switch 2 w2 S50 — Manual leveling control: switch 24 w3 S51 — Leveling control switch ‘automaticimanual w3 '$ 52 — Demoisturizer switch (air eonaticrng) wa $53 — Switch, header variable drive ........ 5. w3 S54 — Switch, distributor adjustment w14 $55 — Reverse travel switch .... ws '$ 59 — End switch, leveling to the left w29 $ 60 — End switch, leveling to the right 124 w29 § 62 — Switch header hozonal adjustment 29 ws S 63 — Battery switch . on W 12; W13 S 64 — Mirror adjusting switch 16 w 39 S65 — Mirror heater switch 216 w39 $66 — Switch, header lateral tt V 4 — Fuse tester 04 AMS V 13 — Diode ¥ 6 7 +26 AM V 14 — Diode ¥ 4 228 Att V15 —Diode ¥ 2... 26 At V 16 — Diodes Y 3 and Y 5 26 Aid V17 —Diode ¥ 18 Att V 18 — Diode ¥ 19 AM V19 —Diode ¥ 16 Ata (2) le<5\Ai/ onopopopenuponbedsosceanoaness Ata ‘TM4505 (05DECO0) 240-10-9 Z Series Combines PN=408,Functional Schematics & Hamess Diagrams, up to Ser.No. 062721/Component Survey Section Wiring Hames V21 —Diodes ¥ 22 and ¥ 23.2.2... 7 21 At5 V 24 — Diodes ¥ 26 and ¥ 27... : niz7, At’ V 25 — Diode ¥ 10 : 22 Aw V 26 — Diode ¥ 11 eee een Att V 27 — Diode ¥ 34 - 21 Aid V 28 — Diode ¥ 31 26 Ats V 29 — Diode Y 30 26 At v.30 —Diode ¥ 12... 224 AM V31 —Diode ¥ 13... 224 Aw V 82 — Diode K 13 Au V 33 — Diode K 14: At V 34 — Diode K 15 - Atd v.35 — Diode K 16 Ata V 36 — Diode K 17 Ata V 37 — Diode K 18 Ata V.38 —Diode K 19. . Ata V.39 — Diode K 20 ° Au V 40 — Diode K 28 ° Ay V 41 — Diode K 29 : AM V 42 — Diode, raise header | ‘i 26 At V43 — Diode, lower header. \V 44. — Diode, header horizontal adjustment | V 45. — Diode, header horizontal dustment V 48 — Diode, leveling to the left . V 47 — Diode, leveling to the right V 48. — Diode, header float contro! V51 —Diode'K 8 .. : V52 —Diode K 9. V 53 —Diode ¥ 14°. V 54 — Diode ¥ 15 — Ground connection, cab wiring harness — Ground connection, distribution harness lsoonnact pont, ro (USA) . — Fuse tester socket ......... — Connection, relay board . — Connection, relay board . .. — Connection, relay board... — Connection, relay board . .. — Connection, relay board . . — Connection, relay board . . — Connection, relay board - — Connection, relay board... — Connection, relay board . . XK KKK KK KK BSSISe0@evaanso _Derwaccnorar se nies ‘TM4505 (05DECO0) 240-10-10 Z Series Combines PNSsOSFunctional Schematics & Harness Diagrams, up to Ser.No. 062721/Component Survey Section Wiring Hames X15 — Traller socket... 0.6.65 tener wa X16 — Terminal, fuse board - ~ W 21; W 12 X17 — Connection, fuse board, Ih wi X 18 — Connection, fuse board, rh wi X 21 — Disconnect point, header wiring harness W 10; W 22 X 22 — Disconnect point, chopper wiring hamess . . . preeeenes W 9; W 25 X 23 — Disconnect point, cab... 2.2... e eee eee wr; w2 X 24 — Disconnect point, solenoid valve biock, basic hydraulics. . . - wo X 25 — Disconnect point, cab, - wisw2 X 28 — Disconnect point, cab - wtw2 X 27 — Disconnect point, cab _ wiw2 X 28 — Disconnect point, cab wiw2 X29 —Splice ..... - w2 X31. — Flasher control point (USA/Europe) cee peer(s) Wate X 32 — Disconnect point, header solenoid block on w 22 X 33. — Ground, rear basic wiring hamess ...... - wa X 34 — Ground, header ..... w 22 X 36 — Disconnect point, armrest wiring hamess - w2;W5 X 36 — Disconnect point, master control lever. ws X 37 — Disconnect point, switch console hamess - : w2ws X 38 — Disconnect point, optional eqpt. harness... .... oo W2; W146 X 39 — Disconnect point, relay board, data center . veeeee eee wt X 40 — Disconnect point, cross shaker switch - we X 41. — Disconnect point, straw chopper... . Ww 20 X 42 — Disconnect point, data center control board wi X 43. — Disconnect point, straw hood hamess ~ W 20; W 9 X 44 — Disconnect point, basic hamess, rh... . rent w2w9 X 45 — Disconnect point, cab. « w2:wo X 46 — Disconnect point, platform wiring hamess W7.W2 X 47 — Disconnect point, hillmaster harness : - W 29; W 4 X 48. — Disconnect point, grain tank harness... - W415, Wo X 49. — Disconnect point, commer post harness... a - w2iw4 X 60 — Disconnect point, electronic box of ‘speed monitoring system... .. - wi X 51 — Disconnect point, header contro! cee wi X 52 — Disconnect point, DIAL-A-MATIC electronic box. . aaa wi X 53 — Disconnect point, spare . eceeereeneeee™ wi X 54 — Ground connection, engine wiring hamess coe - W 12; W143 X 55 — Disconnect point, combine data center W 2; W 23 X 56 — Disconnect point, reel speed control... ... wi ‘TM4505 (05DECO0) 240-10-11 Z Series Combines PNeai0Functional Schematics & Hamess Diagrams, up to Ser.No. 062721/Component Survey Section Wing Harness X 62 — Disconnect point, engine wiring hamess S W 12; W 13 X 64 — Ground connection, basic harness, |.h. ‘i eee wi X65. — Disconnect point, steering column hamess . eee W7;We X 66 — Disconnect point, air conditioning harness: S wwe X67 — Socket, rear axle... 09 wa X 68 — Socket, service platform 09, wa X69 — Splice... dou wa X 70 — Disconnect point, spare - wt X71 — Disconnect point, chaff spreat - W 25; W 26 X 72 — Disconnect point, data center relay board wi X 73. — Disconnect point, feeder house solenoid block |........... w 10 X 74 — Disconnect point, Hilimaster solenoid block Ww 29 X 78 — Connection, leveling control box . Ww 29 X 76 — Disconnect point, comer post hamess - w2;wa X77 — Disconnect point, feeder house hamess - W7; W140 X78 — Splice . cet eee we X79 — Spice wi X80 — Splice - - wi X81 — Splice... - wi X 82 — Disconnect point, front basic harness. - wrw4 X83 — Splice eee - wi X 86 — Splice - W 20 X87 — Splice .. - w 20 X 88 — Disconnect point, switch console harness’. - W2.W3 X89 — Splice ..... - w 20 X90 — Ground connection, straw hood . - w20 X91 — Disconnect point, walker sensor, left-hand - w20 X92. — Disconnect point, walker sensor, right-hand - w 20 X93 — Disconnect point, sieve sensor - wo X 4 — Dicoonect point, straw hood Hghing Sennen ener sera w 20 X95 — Disconnect point, spare... . - w 22 X96 — Disconnect point, ground. . - wa X 97 — Disconnect point, electric mirror adjustm. - W 2; W 39 X98 — Disconnect point, electric mirror adjustm, 7 X 100 — Ground connection, feeder house - w 10 X 101 — Disconnect point, header lighting . 5 peer W 22; W 32 X 102 — Disconnect point, undersiung cteprer ee ee X 104 — Disconnect point, spare . . . Goo gpose X 105 — Diagnostic socket . X 117 — Disconnect point, fuse board | X 118 — Disconnect point, fuse board... 2.2... Ee X 159 — Connection, Hillmaster end switch - w29 X 160 — Connection, Hillmaster end switch Bere TMA4505 (05DEC00) 1240-10-12 2 Series Combines pucett> Functional Schematics & Hamess Diagrams, up to Ser.No. 062721/Component Survey Section Wiring Hamess Y 1° — Pressure valve 1 2 wo Y 2 —Pressure valve 2 wo Y 3 — Solenoid, raise header wa Y 4 — Solenoid, lower header we Y § — Solenoid, raise header wo Y 6 — Solenoid, lower header wo Y 8 — Solenoid, ether starting aid w13 Y 9 — Solenoid, shut off engine .. . wi2 Y 10 — Solenoid, swing in unloading auger wo Y 11 — Solenoid, swing out unloading auger” wa Y 12 — Solenoid, leveling to the left... . w29 Y 13. — Solenoid, teveling to the right - w29 Y 14 — Solenoid, header horizontal position, left-hand . 29 W 10; W 41 Y 15 — Solenoid, header horizontal position, right-hand... . ef W-10; Ww 11 Y 46 — Solenoid, move reel to the front |. Ww 14, w 22 Y 17 — Solenoid, move reel to the rear W414; W232 Y 18 — Solenoid, lower reel W 11; W 22 Y 19 — Solenoid, raise reel . W 44; W 22 Y 20 — Solenoid, lower combine w29 Y 22 — Solenoid, engage separator we Y 23 — Solenoid, engage separator wo Y 26 — Solenoid, unloading grain wa Y 27 — Solenoid, unloading grain... we Y¥ 28 — Solenoid, reduce cylinder speed. wo Y¥ 29 — Solenoid, increase cylinder speed wo Y 30 — Solenoid, reduce feeder house speed 26 w10 Y 31. — Solenoid, increase feeder house speed : 26 w 10 Y 32 — Solenoid, four-wheel drive Sopobbeccsonanasor wa Y 33 — Compressor clutch eee eerie) W 13; W 12 Y 34 —Header clutch... 21 w7. Y 35 — Engine shutoff solenoid 03a wis _zcmucaconoreysous2 ‘TM4505 (05DECO0) 240-10-13 Z Series Combines puestaFunctional Schematics & Harness Diagrams, up to Ser.No. 062721/Component Survey ‘TM4505 (05DECOO) 240-10-14 Z Series Combines PusatFengemes vor cscsJ* Functional Schematics & Hamess Diagrams, up to Ser.No. 062721/Functional Schematic, Part 4 SE29 HEADER TILT Zx005240 ‘TM4505 (05DEC00) 2240-10-18 Z Series Combines pues?Functional Schematics & Hamess Diagrams, up to Ser.No. 062721/Functional Schematic, Part 4 ‘TM4505 (05DECO0) 240-10-19 Z Series Combines Pneaia[Functional Schematics & Hamess Diagrams, up to Ser.No. 062721/Miring and Hamess Diagrams, Harness Localién| LOCATION OF MAIN DISTRIBUTION WIRING HARNESS W1 WITH COMPONENTS a x118 A1S zx004159 [Twas05 (05DEC00) 240-10-21 7 Seis Combines noft \ eg EE al oY — | CE MLA SS|Funetional Schematics & Hamess Diagrams, up fo Ser.No. 062721/Wiring and Harness Diagrams, Harness Location| (PART 1), ARMREST WIRING HARNESS W5 AND AIR CONDITIONING WIRING HARNESS W6 WITH COMPONENTS LOCATION OF CAB WIRING HARNESS W2 Z Series Combines pnsaza 240-10-23 ‘TM4505 (05DECOO)[Functional Schematics & Harness Diagrams, up to Ser.No. 062721/Miring and Hamess Diagrams, Harness Location} LOCATION OF CAB WIRING HARNESS W2 (PART 2) WITH COMPONENTS 2X 003985 ‘TM4505 (0SDECOO) 240-10-25 Z Series Combines PNea2awe on fe eva) 2m SsanaHNH ONIN v9 RENE SSN Ca SN* [Functional Schematics & Hamess Diagrams, up to Ser.No. 062721/Wiring and Hamess Diagrams, Harness Location} LOCATION OF CAB WIRING HARNESS W2 (PART 3) AND REAR VIEW MIRROR WIRING HARNESS W39 WITH COMPONENTS * E26 ‘TM4505 (05DECO0) 240-10-27 Z Series Combines PNed26|Functional Schematics & Hamess Diagrams, up to Ser.No. 062721/Wiring and Hamess Diagrams, Harness Location| LOCATION OF SWITCH CONSOLE WIRING HARNESS W3 AND OPTIONAL EQUIPMENT WIRING HARNESS W14 WITH COMPONENTS S62 S53 S52 oggeercersrcerescen X37 X88 —rsmeccommise sess ‘TM4505 (0SDECO0) 240-10-29 Z Series Combines PN=d28\Functional Schematics & Hamess Diagrams, up to Ser.No. 062721/Wiring and Harness Diagrams, Harness Location} LOCATION OF CORNER POST WIRING HARNESS W4 WITH COMPONENTS zx003983 kaconnats so ‘TM4505 (05DECO0) 240-10-31 Z Series Combines PN=#a0eins ee 2 moore (ococ) stoma. 2M SS3NUVH ONT OISVE ANOLS JO NVYOVIG SSINUVH ANY ONRLIN|Functional Schematics & Hamess Diagrams, up to Ser.No. 062721/Wiring and Hamess Diagrams, Hamess Location) LOCATION OF FRONT BASIC WIRING HARNESS W7 WITH COMPONENTS .minaconons ‘TM4505 (0SDEC00) 240-10-33 Z Series Combines pNease‘Seuiguag sov0g 2 ve-or-ore. ___(o093050) sossun LOT SoH yOH SEH 6K ss 2M SS3NUVH ONT NINOS ONRETILS JO WVYOVIG SS3NUVH ANY ONIN, ‘aun uRR Sa Fue BUNTIRLERD CARS OO BURRS SUR B SIRNAS RUAN[Functional Schematics & Hamess Diagrams, up to Ser.No. 062721/Miing and Hamess Diagrams, Harness Location) LOCATION OF STEERING COLUMN WIRING HARNESS W8 WITH COMPONENTS 2x003987 TM4505 (05DECO0) 240-10-35 Z Series Com![Functional Schematics & Harness Diagrams, up to Ser.No. 062721/Miring and Hamess Diagrams, Hamess Location LOCATION OF REAR BASIC WIRING HARNESS W9, GRAIN TANK WIRING HARNESS W15, CHOPPER WIRING HARNESS W25 AND CHAFF SPREADER WIRING HARNESS: w26) 318 436 X68 S15 X62 x48 =8 / 7 X33 B31 ‘TM4505 (05DECO0) 240-10-37 Z Series Combines Naafsneoo7 Siam Suma Sou AOE BUN IZZERS CNRS & Gh SURANGA P RAIA ROMA]|Functional Schematics & Hamess Diagrams, up to Ser.No. 062721/Wiring and Harness Diagrams, Hamess Location| LOCATION OF FEEDER HOUSE WIRING HARNESS W10, HEADER WIRING HARNESS W22 AND HEADER LIGHTING WIRING HARNESS W32 WITH COMPONENTS umacoonzisesess0ctse ‘TM4505 (0SDECOO) 240-10-39 Z Series Combines PNeda3ELM ONY ZiM S3SSINUVH ONRIM SNIONS JO WYYOVIG SSENUVH ANY ONRLIN ee ue SURBEG SOUR BIE BAINTIZLERD CNRS 6 Bh SaaS SHRP EREURES ROOT[Functional Schematics & Hamess Diagrams, up to Ser.No. 062721/Miring and Hamess Diagrams, Harness Location) LOCATION OF ENGINE WIRING HARNESSES W12 AND W13 WITH COMPONENTS ‘TM4505 (05DECO0) 240-10-41 Z Series Combines puedaSeca ee 2 zrot-ove. (ooosace sean wo 4ees, 20 S19 CIM EM 236k LIS 91S 128 RK LOK SRK ania rit om 024A SSNUVH ONINIM COOH MVELS JO VHOVIO SS3NUVH ANY ONTAIM iss eancsnaSaaa Re TLS BLAH F ERONPS RUBIN[Functional Schematics & Hamess Diagrams, up to Ser.No. 062721/Wiring and Harness Diagrams, Hamess Location| LOCATION OF STRAW HOOD WIRING HARNESS W20 WITH COMPONENTS zxo03991 ‘TM4505 (05DECO0) 240-10-43 S16 sagooonatra eso Z Series Combines puedaae prov-ore on 62M SSINLIVH ONIM WLSAS ONMAAT JO WYYOVIG SSINAVH NY ONRLINNLOCATION OF LEVELING SYSTEM WIRING HARNESS W29 WITH COMPONENTS [Functional Schematics & Hamess Diagrams, up to Ser.No. 062721/WIring and Hamess Diagrams, Hamess Location) EOP c ig Lee "TM4505 (05DECOO) 240-10-45 Z Series Combines pNetas‘aetonl Schematics & hamess Diagrams, uo to Sera. 062721/Euse Board Ying and Hames Diem WIRING AND HARNESS DIAGRAM OF FUSE BOARD AIS suvein a 1 Sores Conbings 2400-46 600)Functional Schematics & Harness Diagrams, up to Ser.No. 062721/Fuse Board Components TM4505 (05DEC00) 240-10-48 Z Series Combines PNadd?Group 11 Functional Schematics & Harness Diagrams, from Ser.No. 062722 SECTION SURVEY SE 01 — Power supply / starting motor SE 02A — Cold weather starting aid, Waterloo engine ‘SE 028 — Cold weather starting aid, Saran engine SE 03A — Engine stop, Waterloo engine ‘SE 038 — Engine stop, Saran engine SE 04 — Fuse tester SE 05. — Instruments SE 08 — Chopper distributor adjustment SE 07 — Windshield washer system SE 08 — Radio, ctizen band, clock SE 09. — Indicator lights 1 SE 10 — Indicator lights II SE 11 — Cigarette lighter, sockets SE 12. — Light functions SE 13. — Flasher function SE 14 — Revolving hazard warning lights ‘SE 15. —Air conditioning system SE 16 — Electrical mirror adjustment SE 17 — Work tights SE 18 — Straw warning device SE 19 — Stop lights, eel speed adjustment SE 20 — DIALAMATIO™ SE 21 — Separator, header engagement SE 22 — Digital infotrak monitor, speed monitoring system ‘SE 23. — Harvest performance monitor SE 24 — Hillmaster leveling system SE 25A — Separator adjustment ~ SE 258 — Separator adjustment, ‘combine data center SE 26 — Header adjustments (cutting height, reel, float) SE 27 — Grain tank unloading system SE 28 — Four-wheel drive SE 29 — Header horizontal adjustment SE 30 — Float control SE 31 — Reverse drive alarm SE 32 — Timer relay ‘TM4505 (0SDECOO) 240-11-1 P Z Series CombinesFunctional Schematics & Hames Diagrams, from Ser.No. 062722/Wiring Hamess Survey WIRING HARNESS SURVEY W 1 — Main distribution wiring hamess W 2—Cab wiring hamess W 3 — Switch console wiring harness W 4 — Comer post wiring harness W 5 — Armrest wiring hamess W 6 — Air conditioning and fan wiring harness W 7 — Basic wiring hamess, front W. 8— Steering column wiring harness W 9 — Basie wiring harness, rear W 10 — Feeder house 1g hamess W 11 — Feeder house wiring hamess, USA W 12 — Wiring harness, Saran engine W 13 — Wiring harness, Waterioo engine W 14 — Optional equipment wiring hamess W 15 — Grain tank wiring hamess W 18 — Positive battery cable W 20 — Straw hood wiring hamess W 21 — Power supply cable W 22 — Header wiring hamess W 23— Combine data center wiring hamess W 24 — Wiring harness for sieve motors W 25 — Chopper witing hamess ‘TWA5DS (0SDECO0) 240-11-2 W 26 — Chaff spreader wiring harness W 27 — Wiring hamess, straw waming device W 28 — Ground cable, straw warning device W 29 — Leveling system wiring hamess W 30 — Citizens’ Band antenna W 31 — Radio antenna W 32 — Header lighting wiring harness W 33 — Wing hamess for ultrasonic sensors W 34— Whing hamess for Logie relay board W 35 — Frame wiring harness switch (220mm) W 36 — Wiring hamess switch, batt. neg, terminal W 37 — Foursineel drive wing harness W 38 — Whing harness, miror adjustment W 39 — Wiring harness, electrical miror adjustment W 40 — Header wiring hamess W 41 — Header wiring hamess, without hydraulics (Europe) W 42 — Unterslung chopper wiring harness W 45 — 25 ft. header wiring harness (USA) W 46 — Header wiring hamess with DIAL-A-MATIC™ W 47 — Adapter cable for header electr. clutch NOTE: See Group 10 for all wiring plans not shown here. Z Series Combines PussFunctional Schematics & Hamess Diagrams, from Ser.No. 062722/Component Survey COMPONENT SURVEY Section Wiring Harness A 1 — Reel speed control. . wi A 2 —DIAL-A-MATIC™ relay board wi ‘A 3 — Electronic speed monitoring system . . wi ‘A 4 — Harvest performance monitor. we A 5 — Combine data center 608 w 23 A 6 —Header control ........ : wi A 8 — Leveling control box (Hillmaster) w 29 A 9 — Control board, combine data center . wi A10 —Float control w3 A11 —Relay board, combine dat wi w2 w2 14 — Relay and diode board w2 A15 — Fuse board . wt A16 — Warning module I: wa A1T — Warning module It w4 A 18 — Infotrak monitor w2 B 1 — Sending unit, brake fluid level . . w7 B 2 — Sending unit, engine oil pressure Ww 12; w 13 B 3 —Light sensor... .. ee w2 B 4 — Sending unit, coolant temperature W 12; 13, B 5 — Sending unit, ree! speed w 22 B 6 — Sending unit, ground speed. w7 B 7 —Sending unit, hydraulic oll filter... | wa B 8 — Sending unit, hydraulic oil temperature . wo B_9 — Thermostat (protection against freezing) we B 10 — Sending unit, air cleaner . : wt B 11 — Sending unit, fuel tank wa Bela teeHomenpe eer teriier 5 w7 B13 —Temperature switch, air conditioning |. w2 B 14 — Low pressure switch, air conditioning . w2 B15 —High pressure switch, air conditioning . Ww 12, w 13 B16 — Speed sending unit, straw chopper . w 25 B 17 — Speed sending unit, tailings elevator wr | B18 — Speed sending unit, cross-shaker wo B 19 — Speed sending unit, clean grain elevator w7 B 20 — Speed sending unit, chaff spreader w 26 B21 — Straw walker sensor, right-hand w 20 B 22 — Straw walker sensor, left-hand w 20 B 23 — Sieve sensor (5-walker machine) wa B 24 — Sieve sensor (6-walker machine)... .. .. wo B 25 — Sending unit, grain tank indicator 1/2 ws B 26 — Sending unit, grain tank indicator 3/4 ws B 27 — Sending unit, grain tank indicator 4/4 wis Pe macootes 19168 ‘TM4505 (05DECO0) 240-11-3 Z Series Combines er* Functional Schematics & Hamess Diagrams, from Ser.No. 062722/Component Survey Section Witing Harness B 28 — Sending unit, engine speed 5 co BD w 12; W413 B 29 — Sending unt, threshing cylinder speed | ere w7 B 30 — Sending unit, fan speed... . me 2 w7 B 31 — Pressure switch, main clutch 2 we B 34 — Sending unit, hydr. oil fil level 1. 10 we B 35 — Sending unit, hye. oil fil level 2 09 we B 39 — Loudspeaker, left-hand 08 wa B 40 — Loudspeaker, right-rand -. |: 208 wa B43 — Reverse drive alarm, buzzer . 234 w20 E 4 —Headight, left-hand ee ee oer eri2 w7 E 2 —Headight, righthand ree a w7 E 3 — Rear work light... . nee 7 w20 E 4 —Cab roof work light, outer rh. | no8 ee w2 E 5 —Cab roof work light, inner rh, 7 w2 E 6 — Cab roof work light, outer Lh, 7 w2 E 7 —Cab roof work light, inner Lh. - 7 w2 E 8 — Unloading auger work light 17 wis E 9 —Cigaretio lighter. 5 1" wa E 10 — Grain tank lighting : 7 wis E11 — Lighting (according to local requremenis) 12 w7 E 12 — Cab interior lighting . o7 w2 E13 — Tail ight, lef-hand - | 12 w20 E14 —Tall ight, right-hand. 12 w20 E 18 — Clearance light, lefthand 12 w7 E 16 — Clearance light, right-hand 12 w7, E17 — Straw hood lighting . o7 Ww 20 E 18 — Platform work light, right-hand 17 w7 E 19 — Platform work light, left-hand 17 w7 E 22 — Registration plate lighting 12 w20 E 23 — Clearance light, header, lef-hand 12 w 32 E 24 — Clearance light, header, right-hand 12 we E 25 — Work light, mirror bracket . . 7 w2 E 26 — Work light, mirror bracket - 7 we F 4 —Fuse, 7.5 amps., spare... 0.5... ~ At F 2 —Fuse, 7.5 amps., spare .. - AMS F 3 —Fuse, 75 amps., spare AMS F 4 —Fuse, 7.5 amps, spare. A1S F 5 —Fuse, 15 amps., spare A15 F 6 —Fuse, 15 amps, spare oe At F 7 —Fuse, 30 amps., spares... : - AtS F 8 —Fuse, 7.5 amps, fan and threshing cylinder speed adjustment... 62... eee eee 5 As anus ssuses ‘TM4505 (05DECO0) 240-11-4 Z Series Combines PNeastFunctional Schematics & Hamess Diagrams, ftom Ser. 062722/Component Survey ‘Section Wiring Harness | F 9 —Fuse 7.5 amps, parking light, rh. a ans F 10 — Fuse 7.5 amps. parking light, Lh 2 Ais F 11, — Fuse 30 amps, fan adjustment 25 ANS F 42 — Fuse 15 amps., stop lights, reel speod adusiment - vo eeeeceteeereee es 18 ats F 13. — Fuse 30 amps, cab root work lights . a7 Ans F 14 —Fuse 7.5 amps, staw waring device, electronic infotak ronfor 18 Ans F 15 — Fuse 15 amps, csttbutor agjusiment on straw chopper 68 ANS F 16 —Fuse 7.5 amps., engine shui-ff solencid AB OAS F 17 — Fuse 7.5 amps. instrument lighting ve AMS F 18 — Fuse 7.5 amps., radio, citizen band, clock ....... eee 08 ANS F 19 — Fuse 30 amps. platform work fights and rear work ight. boos meri ats F 20 —Fuse 7.6 amps. flasher funcions | : Lite ANS F 21 — Fuse 15 amps. radiator cleaner motor a ats F 22 — Fuse 7.5 amps, radio, citzen band, clock _ 08 As F 23 — Fuse 16 amps. separator and header clutch . 224 ANS F 24 — Fuse 7.5 amps., indicator lights, temperature gauge. ats F 25 — Fuse 7.5 amps.,low-beam headight, Ih ats F 26 — Fuse 7.5 amps., header controls A15 F 27 —-Fuse 15 amps., horn . ANS F 28 — Fuse 7.5 amps, combine dala center . Ans F 29 — Fuse 15 amps. leveling system =. Ai5 F 30 — Fuse 7.5 amps. fourvheel drive Ais F 31 — Fuse 7.5 amps. speed monitoring SYSOM soveverrstcneenneee es Ans £2 — Fuse 7.5 amps, lowbeam headlight, rh Ais F 33 — Fuse 15 amps, raisefower header "= ats F 34 — Fuse 15 amps., hazerd warning ighs Ans F 35 — Fuse 15 amps.,revoWving warming ights 14 Ans F 36 — Fuse 15 amps., windshield wiper, grain tank lighting o7 A115 £97 — Fuse 7.5 amps., mirror adjustment Ute ats F 38 — Fuse 7.5 amps., performance monitor . . eee BB ANS F 39 — Fuse 15 amps., grain tank unloading ees oe ee OT ANS F 40 — Fuse 30 amps. starter switch . . . o1 ANS F 41 — Fuso 15 amps., concave adjusiment 25 ANS F 42 — Fuse 30 amps, air condoning system us ANS F 43 — Fuse 7.5 amps, DIALAMATIO™ 2 ATS F a4 — Fuse 7.5 amps. ful-boam headlight, Lh 2 ats F 45 — Fuse 15 amps.. reel contol 26 Ans F 43 — Fuse 15 amps, starting aid ‘2B AS F 47 — Fuse 18 amps., spare... - Aas F 48 — Fuse 7.5 amps, allemator D+ | a1 ats pineccomen mean “TWaS05 (05DECO0) 240-14-5 Z Series Combines PueasFunctional Schematics & Hamess Diagrams, from Ser.No. 062722/Component Survey Section Wiring Hamess | F 49 — Fuse 15 amps., cigarette lighter, seat Compressor... eee ee cee ats F 50 — Fuse 7.5 amps., fulbeam headlight, rh oe 12 A1S F 51 — Fuse 7.5 amps., electro-clutch for header drive... . -3t wiani3 F 52 — Fuse 7.5 amps,, reverse drive alarm... 23H wr2wi3 G 1 —Battery 12 Vv, 88 AH ot Ww 12; W 13, G 2 —Attemator .... 2 Ot W 12; W 13 H 1 — Brake fluid indicator tight 09 wa H_ 2. — Engine oll pressure indicator light 03 w4 H_ 3. — Parking brake indicator light 09 wa H 4 — Coolant temperature indicator light . 09 wa H_ 5 — Indicator light, unloading auger swing 10 w4 H 6 — Fuel level indicator light wa H 7 —Hydraulic olf fiter indicator light «ee ee eee ee wa H_ 8 — Hydraulic oll temperature indicator light eee £09 wa H_9 — Fourawheel drive indicator light... eee eee e eee eee 10 wa H 10 — Air cleaner indicator ight : wa H 11 — Altemator indicator light w4 H 12 — Alarm light (STOP)... 2. wa H 13. —Turn signal light, rear left-hand... : a w 20 H 14 — Turn signal light, rear right-hand ono 13 Ww 20 H 15 —Tum signal light, front left-hand . : 13 w7 H 16 — Turn signal light, front right-hand 8 w7 H 17 — Additional tur signal light, left-hand 3 wr H 18. — Additional turn signal light, right-hand B wo H 19 — Indicator light, straw warning device 03 wa H20 — Buzzer .... 08 w2 H21 — Revolving hazard waming fight <<... 4 we H 22 — High pressure indicator light (AC system) . 40 w4 H 23 — Indicator light, straw chopper speed 09 w4 H 24 — Indicator light, tailings elevator speed 09 wa H 25 — Indicator light, cross shaker speed weet eee ee eee 1 09 wa H 26 — Indicator light, grain elevator speed Pe 09 wa H 27 — Grain tank fil indicator light 1/2... . nee ee 0 wa H 28 — Grain tank fil indicator light 3/4 . eeeeeneeeeeened) wa H 23 — Grain tank fil indicator light 4/4... eee a0) wa H 31. — Indicator light, fan speed... 09 wa H 32. — Indicator light, cylinder speed 09 wa 133 — Full-beam indicator tight . . 12 we H 34 — Tum signal indicator light 1, combine 13 we H 35. — Tum signal indicator light 2, trailer renner eorta we H 38 — Revolving hazard warning light 4 wa H 37 —Hillmaster combine, automatic operation . 10 wa H 38 — Hillmaster combine, manual operation peeet0) wa H39 —Hillmaster combine, end stop . 10 wa H 40 — Hydraulic oil level indicator light 10 wa H41 — Tum signal light, header, leftthand .. 02... sees e eee B wae Z Series Combines PNAS “Tw4505 (06DEC00) 240-11Functional Schematics & Hameess Diagrams, from Ser.No. 062722/Component Survey H 42. — Tum signal light, header, right-hand ae cereal H 43. — Stop light, left-hand . 2... eee 219 H 44 — Stop light, right-hand... 2... Beene ea: 1 — Starting motor relay 2 — Basic relay : 3 — Basic relay 4 — Buzzer timer relay 5 —Flasher 6 — Relay, straw warning device 7 8 8 0 4 — Relay, work lights . — Float control relay . — Hillmaster leveling relay — Relay, fan speed alarm... — Relay, cylinder speed alarm - K 12 — Relay, field operation — road travel . K 13. — Relay, lower header quickly . K 14 — Relay, lower header slowly . K 15 — Relay, raise header quickly K 16 — Relay, raise header slowly K 17 — Relay, lower reel K 18 — Relay, raise reel... K 19 — Relay, move reel to the rear . K 20 — Relay, move reel to the front K 21 — Relay, separator clutch K 22 — Relay, straw warning device K 23 — Safety relay, header drive K 24 — Safely relay, unloading auger drive. K 25 — Timer relay, unloading auger swing . . K 26 — Relay, increasing concave gap K 27 — Relay, reducing concave gap. - K 28 — Relay, adjust feeder house speed K 29 — Relay, adjust feeder house speed .. K 30 — Relay, cylinder faster . . K 31 — Relay, cylinder slower K 32 — Relay, adjust reel speed K 33 — Relay, adjust reel speed K 35 — Timer ‘relay, header drive . K 36 — Relay, adjust fan speed . K 37 — Relay, adjust fan speed . K 38 — Relay, increasing fan speed . K 39 — Relay, decreasing fan speed K 42 — Relay, header el-clutch (moving motor) K 45 — Relay, D+ (moving motor) . K 46. — Separator timer relay . M1 — Starting motor... . M 2 —Reel speed adjusting motor. M_ 3 — Windshield wiper motor M 4 —Cab fan RARARARARRR ‘Wiring Harness ws2 W 20 w 20 Ww 12; W 13 AMS AMS Au Aw At AS ats Ata Ata wi AtS AM Au A’ A’ Att ats Ata At At5 At A’ Att At A 11 integrated A 41 integrated Ata At4 A141 Integrated A 11 integrated Au At Att wo we A114 integrated A11 integrated W 12; W 13, Ww 22 w2 we ‘TM4505 (05DEC00) 240-11-7 Z Series Combines PNeassFunctional Schematics & Hames Diagrams, from Ser.No. 062722/Component Survey Section Wiring Harness M 5 — Seat compressor... . 4 ws M_ 8 — Concave adjusting motor . 25 w7 M_9 —Fen speed adjusting motor 25 wa M11 — Windshield washer pump o7 wa M12 — Radiator cleaner motor 24 Ww 12; W413, M13. — Distributor adjusting motor 08 Ww 25 M14 — Reel variator (US header) = M45 —Miror .. . 5 ‘M16 — Mirror : - © 1 Saoant temperature gauge cess Hopobonsal-| w4 P 2 —Fusl gauge ..... : 05 wa P 3 —Header height gauge - 05 wa P 5 — Grain loss indicator 05 wa P 6 ~ P 7 —Clock ... 08 w2 P 8 —Distibutor gauge” 08 wa R 1 —Fan resistor ....... . 15 we R 2 —Potentiometer, concave adjustment 25 w7 R 3 —Potentiometer, header height . 26 wt4 R_ 4 — Sending unit, header height 26 w7 R 5 —Potentiometer, ree! height . 26 wi4 R 6 —Sending unit, reel height 26 w 22 R 7 —Potentiometer, reel horizontal position. 26 wis R 8 — Sending unit, reet horizontal position 26 we R 9 —Resistor, LED fuse tester : 04 ANB R13 — Potentiometer, header float 26 w 14 R14 — Potentiometer, distributor axjustment ‘i 06 w25 R16 — Glow-ype starting aid ........ S 1 —Starter switch ........... ot we S 2 — Hydrostatic safety’ switch ee een ot ws S 3 —Cold weather starting aid switch eee en o2B WB. S 4 — Indicator light test switch ee eect w2 S$ 5 — Parking brake control switch eee 2509 w7 S 6 —Header fioat switch ...... 30 ws $7 — Stop light switch 19 w7 S 8 —Hom button 18 we S 9 — Poteritiometer, reel speed 17 wt4 S 10 — Reel speed switch 7 ws $11. — Hazard warning sant switch B w2 $12 — Tum signal switch . 18 we S13. — Light switch pial w2 8 14 — Grain tank lighting switch :07 w2 $ 15 — Switch,straw warning device (cross shaker) |... sss... 015018 wo $16 — Switch, straw waming device (walkers)... 2s. eee WB w 20 si traw warning device (chopper) oo 18 w 20 $18 — Revolving hazard warning light switch 4 w2 erwvaono4s 9.108 ‘TM4505 (05DECO0) 240-11-8 Z Series Combines PNAS* Functional Schematics & Hames Diagrams, from Ser.No. 062722/Component Survey Section Wiring Harness $19 — Switch for cab roof work lights”... ae 7 we 'S 20 — Windshield wiper switch ee reer w2 S21 — Windshield washer switch |. | : 07 w2 $22 —Fan switch 15 we $23 —DIALAMATIC™ switch... 20 wa '$ 24 — Speed monitoring switch, chopper. 122 W 25 | S25 — Air conditioning switch we S27 — Switch, raise/lower header. ws S 28 — Automatic function switch ws S 29 — Switch, reel height adjustment ws S 30 — Switch, reel horizontal adjustment ws S31 —Road safety switch . we 32 — Switch, header control . wis S33 — Separator drive switch w3 S 34 — Header drive switch wW3 $35 — Unloading auger drive switch || ws S36 — Switch, concave adjustment ws S 38._— Switch, combine data center | wa S39 — Switch, unloading auger swing ws $40. — Switch, cylinder speed adjustment ws $41 — Switch, fan speed adjustment . . ws S42 — Parking brake switch .. ws S 44 — Fourswheel drive switch . w7 § 47 — Emergency cut-off switch ws S48 — Work light switch... .. we $49 — Fultbeam headlight switch wa S50 — Manuel leveling control switch. | wa § 51 — Leveling control switch automaticimanual ... .. 24 ws $52 — Demoisturizer switch (air conditioning) 18 w3 S53 — Switch, header variable drive wes § 54 — Switch, distributor adjustment S55 — Reverse travel switch $59 — End switch, leveling to the left $60 — End switch, leveling to the right § 62 — Suich, header hozonal adjustment « S63 — Battery switch : S 64 — Miror adjusting switch S65 — Mirror heater switch . |. S 66 — Switch, header lateral tit S69 — Reverse drive alarm switch V 1 —Fase tester .. At8 V 2 —Diode, pressure switch . At V3 — Diode, raising header : At4 V 4 —Diode, increasing feeder house speed. Aw V_5 — Diode, reel raising function . Ata V 6 —Diode, reel back function AN V_7 —Diode, reel forward function : At V8 —Diode, swinging unloading auger in’. AM ‘T4505 (05DEC00) 240-11-9 Z Series Combines NaasFunctional Schematics & Harness Diagrams, from Ser.No. 062722/Component Survey Section Witing Hames V_9 — Diode, swinging unloading auger out 26 At V 10 — Diode, increasing cylinder speed 26 Ata V 11. — Diode, concave gauge 26 Ata V 42 — Diode, concave gauge - V 13 — Diode ¥ 6 26 At | V 14 —Diode ¥ 4 26 AU V15 —Diode ¥2 2.0.0... 26 At V16 — Diodes ¥ 3 andY 5 = 26 At V17 —Diode ¥ 18 26 Ata V 18 — Diode ¥ 19 - ‘i 26 Ata V19 —Diode Y 18 ee ee ee 26 Ata V.20 —Diode ¥ 17. 26 Ata V 21 — Diodes Y 22 and Y 23” 22 At V 22 —Diode ¥ 28 - V 23 —Diode ¥ 29 - = 2 A V 24 — Diodes Y 26 and ¥ 27° V 25 — Diode ¥ 10 Att V 26 — Diode ¥ 11 Ata V 27 —Diode Y 34 . Ata ie Y 31 A146 V 29 — Diode Y 30 A14 jode Y 12. Aw V 31 —Diode ¥ 13... A’ v.32 — Diode K 13. Aw V 33 — Diode K 14 At V 34 —Diode K 15 Ata V.35 — Diode K 16 Ata V 38 — Diode K 17 Ata V 37 — Diode K 18 Ata v.38 — Diode K 19 A14 V.39 — Diode K 20 AU V 40 — Diode K 28 Au V 41 —Diode K 29 Ata V 42 — Diode, raise header Ald V 43 — Diode, lower header rer V 44 — Diode, header horizontal adjustme At V 45 — Diode, header horizontal adjustment At \V 46. — Diode, leveling to the left Au V 47 — Diode, leveling to the right A’ V 48 — Diode, header float control. A’ V 51 — Diode k8 . ac At V 52 — Diode K9 || ; Aid V 53 —Diode 14 A14 V 54 — Diode 15 AN V 55 — Diode Y13 . V 56 — Diode Y6 . V 57 -— Diode Y6 . : Bes eee V 58 — Diode DIAL‘A-MATIC™ - : ees V59 —Diode Ké3 0.0.0... or V 60 — Diode Kat. V 61 — Diode K40 ee V 62 — Zener diode 1N53443 Twa605 (05DECO0) 7240-11-10 Z Series Combines ooFunctional Schematics & Hamess Diagrams, from Ser.No. 062722/Component Survey Section Wiring Harness V 63 — Zener diode 1N5344B = V 64 — Zener diode 1N54448 X 0 — Ground connection, cab wiring hamess a6 - we X- 4 — Ground connection, distribution hamess | wt X 2 —Disconnect point, radio (USA) . : ne we X 3 —Disconnect point, Citizens’ Band radio Gbouco0sos X 4 — Disconnect point, header DIAL-A-MATIC™ swith oe. e eee ; - X 5 — Fuse tester socket os A15 X 6 — Connection, relay board - wa X 7 — Connection, relay board wa X 8 — Connection, relay board we X 9 —Connection, relay board... soe w2 X10 — Connection, relay board . |: eer we X 11 — Connection, relay board - wa X 12 — Connection, relay board - - w2 X13 — Connection, relay board * - wa X 14 — Connection, relay board - wa X15 —Traller socket .... - we X16 — Terminal, fuse board... | W 24; W 12 X47 — Connection, fuse board, In. wt X18 — Connection, fuse board, rh... - wt X 19. — Plug for warning light block ce 5 ne X 20 — Plug for alarm light block... toe X 21 — Disconnect point, header wiring harness . ile W 10; W 22 X 22 — Disconnect point, chopper wiring harness. - Ws; W 25 X 23 — Disconnect point, cab - wriw2 X 24 — Disconnect point, solenoid vaive block, basic hydraulics we X 25 — Disconnect point, cab - wisw2 X 26 — Disconnect point, cab ~ wiwe X 27 — Disconnect point, c2b : - wisw2 X 28 — Disconnect point, cab 5 foe wiw2 X29 — Splice 071 mo Nile we X 30. — Electronic ground adjusting potentiometers. = X 31 — Programming window flasher eereeneeeneeeenees Wats X 32 — Plug for solenoid block 2... : w22 X 33. — Ground distributor, hydraulic block 1 ree : we X 34 — Ground distributor, hydraulic block 2... = we X35 — 37-erminal armrest plug... pong0e0090—) w2;ws X 36. — Plug for forwardireverse lever . ws X 37 — Plug for dashboard 1 . ww X 38. — Plug for dashboard 2 W2; W 14 X 39 — 18-4orm. plug on data center relay board | wi X 40 — Cross-shaker switch plug . : we X 41 — Straw chopper plug . . : w20 X 42 — Data center control board plug wt X 43 — Straw hood wiring hamess plug W 20; W 9 ‘TM4505 (05DECOO) 240-11-11 Z Series Combines PN=asoFunctional Schematics & Hames Diagrams, from Ser.No. 062722/Component Survey Section Wiring Harness X 44 — Plug for basic harness, rh... ee w2,we X 45. — Plug for basic harness, Ih oe te w2,wo X 48 — Plug for platform wiring hares... ; wr.we X 47 — Plug for Hilmaster harness W 29; W 4 X 48. — Plug for grain tank hamess w 15; ws | X 49. — Plug for comer post harness w2,W4 X 50 — Plug for electronic box of speed monitoring system . .. wi X 51 — Plug for header control... wi X 52. — Plug for DIAL-AMATIC™ electronic box - wi X 83 — Spare plug wi X 54 — Ground connection, engine wiring hamess me W 12, W 13 X 85 — Plug for combine data center cee W 2; W 23 X 56 — Plug for reel speed control... 02s... coe wi X 57 — Plug for electronic row guidance. : X 58 — Plug for flex. cable on chaffer . . 5 cee X 59 — Plug for flex. cable on sieve . .. : 5 X 60 — Plug for flex. cable on chaffer extension X 61 — Plug for revolving beacon light . X 62 — Plug for engine wiring harness... w 12; W413 X 63. — Plug (according to local requirements) X 64 — Ground connection, basic harness, Lh wt X 65 — Plug for steering column hamess Wrwe X 66 — Plug for air conditioning harness w2we X67 — Socket, rear ayle ... 22... we X68 — Socket, engine . : - X 69 — Plug for battery + clock; radio; CB-radio : eo X71 — Plug for chaff spreader hamess ...... 5 ie W 25; W 26 X 72 — Plug for data center relay board ...... no wt X 73. — Plug for 16-terminal hydraulic block - w10 X 74 — Plug for Hillmaster solenoid block... .. - w29 X 75 — Connection, leveling control box - w29 X 76 — Plug for comer post harness - wW2;w4 X77 — Plug for feeder house hamess Ww 7; W 10 X78 — Splice 245 . w2 X79 — Splice 075 . . 5 wi X 80 — Splice 1, ground for electronics . - wi X81 — Splice 2, ground for electronics . wi X 82 — Plug for ultrasonic sensors w7swt X83 — Splice 256 wi X84 — Splice 327 X85 — Splice 050 X88 — Splice 147 . w 20 X87 — Splice 148... w 20 X 88 — Dashboard plug’. W2W3 X89 — Splice 151...... 5 Ww 20 X90 — Ground connection, straw hood . Ww 20 X91 — Plug for walker sensor, Lh. . ; : w 20 X 82. — Plug for walker sensor, rh oererrrre - w.20 Twa505 (O5DECOO) 2240-11-12 Z Series Combines PN=t5LL Functional Schematics & Harness Diagrams, from Ser.No. 062722/Component Survey Section Wiring Haress X93. — Plug for sieve sensor we X 94 — Plug for straw hood fighting w 20 X 95 — S+erminal plug for ultrasonic sensors . - w22 X 86 — Bosch plug for float control . : w3 X 97 — Plug for electrical mirror adjustment . - Ww 2; 39 X98 — Ground connection, electrical mirror adjustment... - - w3 X99 — 2-terminal plug, 4-wheel drive solenoid valve we ce X 100 — Ground connection hydraulic block 3 baae - w 10 X 101 — Plug for header lighting . . pagoosen W 22; W 32 X 102 — Plug for undersiung chopper X 103 — Float control bridging plug .. - X 104 — Plug for seat compressor . - X 105 — Plug for data bus ne = we X 117 — Sterminal plug for 1h. Power Board - wi X 418 — Sterminal plug for r.h. Power Board - wi X 119 — Service plug for ECU. = X 120 — Service plug for ECU X 121 — Service plug for ECU - X 122 — Splice for ECU hamess .. 0 ee eece eee es anes X 123 — Splice for ECU hamess ..-.. fees X 159 — Plug for Hillmaster end switch erererree w29 - Ww 29 X 160 — Plug for Hillmaster end switch. X 161 — 6-terminal plug, header electrical clutch |... | coo X 162 — 2+terminal plug, reverse drive alarm... le X 163 — 2-terminal plug, grain tank switch Y 1 —Main valve, solenoid control block we Y 2 —Header solenoid valve ....... wa Y 3 — Solenoid, raise header wo Y 4 — Solenoid, lower header we Y 5 — Solenoid, raise header . wo Y 6 —Solenoid, lower header wa Y 8 — Solenoid, ether starting aid w13 Y 9 — Solenoid, shut off engine . : wi2 Y 10 — Solenoid, swing in unloading auger” we Y 11 — Solenoid, swing out unloading auger wo Y 12 — Solenoid, leveling to the left 224 w29 Y 13 — Solenoid, leveling to the right 24 wo Y 14 — Solenoid, header horizontal position, left-hand... . 29 W 10; W411 Y 15 — Solenoid, header horizontal position, right-hand feet ee cece eee W 10; W414 Y 48 — Solenoid, move reel to the front oo. Ww 11; W 22 ‘TM4505 (05DECO0) 240-11-13 2 Series Combines PN=460» Functional Schematics & Hamess Diagrams, from Ser.No. 062722/Component Survey Section Wiring Harness Y 17 — Solenoid, move reel to the reat... : 26 Ww 44; W 22 Y¥ 18 — Solenoid, lower reel : 26 W 14; W 22 ¥ 19 — Solenoid, raise reel . - +26 Ww 14; W 22 Y¥ 20 — Solenoid, lower combine 24 Ww 29 Y 22 — Solenoid, engage separator... Bbsonoen eel wo ¥. 23 — Solenoid, engage separator 2 we Y 26 — Solenoid, unloading grain . . 27 we Y 27 — Solenoid, unloading grain . 27 wo Y 28 — Solenoid, reduce cylinder speed +25 wa Y 29 — Solenoid, increase cylinder speed 25 wo Y 30 — Solenoid, reduce feeder house speed. . 26 wo Y 31 — Solenoid, increase feeder house speed 26 w10 Y 32. — Solenoid, four-wheel drive 228 wa Y 33 — Compressor clutch 218 W 13; W 12 Y 34 — Header clutch pees 22 w7 Y 35 — Engine shut-off solenoid... 1.2 : 66 = 034, wi3 Y 36 — Solenoid, undersiung chopper... .. ‘i seer ‘TM4505 (0SDECOO) 240-11-14 Z Series Combines PNsastSiLb-ove. {00030800 soser O18 SNIONS. lv suvis: YOLOW ONILUVIS/ ATddNS HAMOd seme “Les zas 138 5 ae ous sea ols ‘8 GNY ve ‘ZF SNOLOAS ‘OUYIWSHOS TNOLLONNS ae Die We eT BRINE SIRES MNELIESD GVA Way CURENG SOU B ERRURTAS RUNINGall Sitico saves 2 ob-bb-007. (003090) sie SNIESIS, SINSWNWASNE Sd ANBWOYNYW SINOWIOSTS SNIONS. yeas 538, +38, 63S Vo GNY $ 'y ‘9 SNOLLOS ‘SLVWSHOS TNOLONNS Vo pie se BcnIRAS SINUS URRUNSZIEDD GVIRS Uy SURE SALI FERRITES UIA8 GNV Z'g9 SNOLLOAS ‘OLWSHOS WI 2 Bun Zo SuaIDNS GRE HURIFUNAEZIZOD BVIAG Waly SURTOG RUA FRR MATINFunctional Schematics & Hamess Diagrams, from Ser.No. 062722/Functional Schematio, Section 9 FUNCTIONAL SCHEMATIC, SECTION 9 a6 i 3 3 ses {LARRINTODUL ~ STOP-FUNKTIONEN ‘zx008208 ‘TM4505 (05DECO0) 240-11-18 Z Series Combines Pues* Functional Schematics & Hamess Diagrams, from Ser.No. 062722/Functional Schematic, Section 9A FUNCTIONAL SCHEMATIC, SECTION 9A ben fae 1 i i , q 4 eS on a - of - L 3 SER ‘ACRRRRTOOUL- STOR FUNRTIONEN aaa ‘TM4505 (05DECO0) 240-11-19 Z Series Combines PN=A8SFetqwog seus 2 oz-L1-092. (0023060) soso, Severe 02°02 _(qnosst) sperm TNGOWNEYM vols Vol NOLLO3S ‘SLLWNHOS TyNOWONAS Yor LonDes SHES BUOISUNEeEZEDO ONTAS Wy TURAED SUEY ¥ ORSUBAS USURGFunctional Schematics & Hamess Diagrams, from Ser.No. 062722/Functional Schematic, Section 108 FUNCTIONAL SCHEMATIC, SECTION 10B af a Ql 3 ‘SE108 4 WARNMODUL zxo08210 i ‘TM4505 (05DECO0) 240-11-21 Z Series Combines PNsde8EStcweo coves 2 ze-Li-ove NOWONA IHEN SUSIOOS /WSINON LIBuVOD_| z3s Has gh i x 19K Zb GNY +1 SNOLLOJS ‘OUVINSHOS TyNOLONAS 2 aISOS SURES IUAPUNTEEIESD GIS Way WUREEG SUR W SRURAS RONFunctional Schematics & Harness Diagrams, from Ser.No. 062722/Functional Schematic, Section 13. FUNCTIONAL SCHEMATIC, SECTION 13 F34 F20 HIT Hat sums neon su aom 115 cove Traten SE13 5 FLASHER FUNCTION g a i ‘TM4505 (05DECO0) 240-11-23 Z Series Combines PNsaTOang so105 2 verbb-ove NOLLIGNOS Iv ‘SLHOM SNIATONSE sias. vias Sb GNY PL SNOLLD3S ‘OUVINaHOS TWNOUONA GE Be Br CEO FIRING UPDATER ONS Wy SURO COURT EREURS USINGFunctional Schematics & Harness Diagrams, from Ser.No. 062722/Functional Schematic, Section 16 FUNCTIONAL SCHEMATIC, SECTION 16 Fa7 REAR VW wRAOR EAR VIEW 1ARROR err ricer SE16 REAR VIEW MIRROR ADJUSTMENT 8 8 4 _zxo0e6ea ‘M4505 (05DECOO) 240-11-25 Z Series Combines enea72Functional Schematics & Hames Diagrams, from Ser.No. 062722/Functional Schematic, Section 17 FUNCTIONAL SCHEMATIC, SECTION 17 es a ® = q : 7 WORRUGHTS i a 4 “T4505 (05DEC00) 240-11-26 2 Series Combines PN=t73Functional Schematics & Harness Diagrams, from Ser.No. 062722/Functional Schematic, Section 18 FUNCTIONAL SCHEMATIC, SECTION 18 Ft Far q| B12 a CJ Ee q K22 K6 RELAY HOR _ 88 a st aie 316 wasn 4 ST src een oe a0 3 SEIB i STRAW WARNING DEVICE e ones i ‘TM4505 (05DECO0) 240-11-27 Z Series Combines pNeateez-14-092. ANaWISNraY G33ds T33u ! SLHOM dO1s evo 613s 6b NoUO3S ‘OUYWHOS TyNOLLONNS GF WaaS SIRUSS UGUTUERIERD OVINE Uy SR THN F SHRURAS MOSTARFunctional Schematics & Hamess Diagrams, from Ser.No. 062722/Functional Schematic, Section 20 FUNCTIONAL SCHEMATIC, SECTION 20 2 = ee i ‘TM4505 (0SDECO0) 240-11-29 Z Series Combines pN=t76Eetqwog save 2 oe-L4-0¥2. (0003050) sone. YOLOW USNV310 HOLYIOWY ° HOLD HSGVSH ' HOLWH3E3S: eas 12 NOULDS ‘OUYW3HOS WNOLLONAS 12 Was SIRNAS RUNDUREZIERD OHTRS Uy BURGE HELEN F PCUOIAS SURGBaaueg sou 2 Leb t-0v7 (003080) som. WGISAS ENIEOLINON G3356 UOLNON 9¥HIO-NI 2238 ce a on Te non a = o] Efe Ke fe Ek ke = er + - 5 sz} = ences 628 = || : es sf} la} alelalsfalla 2% NOILO3S ‘OUYBHOS WNOLLONNS Fz WIIG SiRURIRS RUNIRTIEELERO ONS Way TaREG SLID NOUNS IATBini ze-ni-oe eros sev HOLINOW SONYIUOSUad ISBAUVH WSISAS ONTSAST UBISYWTIH ees 2 GNY £2 SNOLLOAS ‘OLLYWZHOS TYNOLONNd Fe BUR Be SunOS HOURS MUTTIEELERD GARG Way TURE SOUR PESOS UTISuva sams 2 senor (coon sos AINSWUSNrY NYS" 3AVONOO " UBONMAD. seas ‘Voz NOUDAS ‘OLLYWSHOS WNOLLONNS VEE WaImaS SISUDIES BRINIEZIEID HIRE Wy BUH SURI p EPRI UNIT* Functional Schematics & Hamess Diagrams, from Ser.No. 062722/Functional Schematle, Section 258 FUNCTIONAL SCHEMATIC, SECTION 25B TMi4505 (05DECOO) 240-11-34 ep 3 q a . mod Fj H |» J xs exe |g of; ) 4 3 i] gal = ; : TERE 3 CYLINDER, CONCAVE, FAN ADJUSTWENT ; Doom i Z Series Combines pnetatFunctional Schematics & Hamess Diagrams, from Ser.No. 062722/Functional Schematic, Section 2581 FUNCTIONAL SCHEMATIC, SECTION 2581 fe ea | est sat wf a 5 = : oars i ‘TM4505 (05DECO0) 240-11-35 Z Series Combines PN=a82Functional Schematics & Hamess Diagrams, from Ser.No. 062722/Functional Schematic, Section 2582 FUNCTIONAL SCHEMATIC, SECTION 2552 | | dud 3 owes] 8 wr SeasBe CYLINDER , CONCAVE , FAN ADJUSTMENT races 545085 (95DEC00) 7240-11-36 Z Series Combines PNstaFunctional Schematics & Hamess Diagrams, from Ser.No. 062722/Functional Schematic, Section 26A FUNCTIONAL SCHEMATIC, SECTION 264 P| a sa wey ve wo fhe. | = ee qe ‘SE2GA HEADER ADJUSTMENT (CUTTING HEIGHT; REEL; FLOAT) 2xo08224 ‘TM4505 (05DECOO) 240-11-37 Z Series Combinesina sone z ____ setae (onc toes (vors "7334 'LHOISH ONLLINO) INaWUSNPGY HIGVSH 99238 3A ‘892 NOLLOAS ‘OILYWSHOS WNOLLONNS BSE WISE SILAS URIDUNICELERO CNG Wy SUEDE OLA B HRUATD RUBINGFico sz so-tore (coon stone (1vO1- "7334 SIHOISH ONILLNO) LNBHUSNraY waGVaH 2923s afslalelele ‘992 NOLLO3S ‘OLLWINaHOS TwNOLLONNS 5 URS BICONE UGRUNIGZLEND OHTIRS Woy SURBRG SSL B RWURS RUGIRRTeee __orsiovz toes sam WALSAS ONIGVOTNN YNVL NIVEO) 38. 22 NOULDAS ‘OUWWSHOS TWNOLLONA Ze CaRaS RUS RUPEE NAS TURES SALI B PTS OMNESFunctional Schematics & Hames Diagrams, fram Ser.No. 062722/Functional Schematic, Section 28 FUNCTIONAL SCHEMATIC, SECTION 28 F380 3 SE28 FOUR WEEL DRIVE ‘zxo0e228 ‘TM4505 (05DECO0) 240-11-41 Z Series Combines PNsiasFunctional Schematics & Hamess Diagrams, from Ser.No. 062722/Functional Schematic, Section 29 FUNCTIONAL SCHEMATIC, SECTION 29 SE29 HEADER TILT zxoos240| ‘TM4505 (05DECO0) 240-11-42 Z Series Combineser-bt-ove (oopaas0) sosvan BMLVTV an Ove TOwINOD 1vOT 1238 083s. set a4 be GNY 0¢ SNOLLOAS ‘OLLVINSHOS TyNOLLONN TE uO SURES BIEURIOS RUGRINIERLESD GING tay WURHG SOUR RUNS RNINFunctional Schematics & Harness Diagrams, from Ser.No. 062722/Functional Schematic, Section 32 FUNCTIONAL SCHEMATIC, SECTION 32 one 312 iron =a A kas, TIMER RELAY wf ibe fe 5 8 5 sect SEB Seat 310 SE32 i TIMER RELAY 4,5S MD 2054 g x008600 & ‘TM4505 (0SDECOO) 240-11-44 Z Series Combines NestFunctional Schematics & Harness Diagrams, from Ser.No. 062722/Functional Schematic, Section 32 ‘TM4505 (0SDECO0) 240-11-45 Z Series Combines PNstaaFunctional Schematics & Hamess Diagrams, from Ser.No. 062722/Wiring and Hamess Diagrams, Hamess Location WIRING AND HARNESS DIAGRAM OF MAIN DISTRIBUTION HARNESS, PART 1 8 mm THT TET g § slajalalayaysyela] lala} alalalalalalalaldla LE} E) 8) 8/818) 8) 8) F}5) 8) 8] §) 8) 818/818) 8) 5) zxo08608 xe x9 x80 xo ‘TM4505 (05DECOO) 240-11-46 Z Series Combines PN=493Functional Schematics & Harness Diagrams, from Ser.No. 062722/Wiring and Hamess Diagrams, Hamess Location ‘M4505 (0SDECO0) 240-11-47 Z Series Combines PnsaaeStiqw00 soves z Sb b-0rz 2 Uva “SSANNVH NOLLNGRUSIO NIV JO WYYOVIG SSaNUVH GNY ONRIM oaieoo7 Becta SURED Se Bue BaneETEAD CABS Way SURED SSL B RAIS RAIALOCATION OF [Functional Schematics & Hamess Diagrams, from Ser.No. 062722/Wiring and Harness Diagrams, Hamess Location MAIN DISTRIBUTION WIRING HARNESS W1 WITH COMPONENTS S x118 AIS zx004159 ‘TM4505 (05DECO0) 240-11-49 Z Series CombinesFunctional Schematics & Hamess Diagrams, from Ser.No. 062722/Wiring and Hamess Diagrams, Harness Location sia 1 x009611 ‘TM4505 (05DECOO) v2 240-11-50 WIRING AND HARNESS DIAGRAM OF REAR BASIC WIRING HARNESS W9, GRAIN TANK WIRING HARNESS W15, CHOPPER WIRING HARNESS W25 AND CHAFF SPREADER WIRING HARNESS W26, PART 1 vio vit yan y2a 26 Z Series Combines PNsaayFunctional Schematics & Hamess Diagrams, from Ser.No. 062722/Wiring and Hamess Diagrams, Hames Location ‘TM4505 (05DECO0) 240-11-51 Z Series Combines PNsies[Functional Schematics & Hamess Diagrams, from Ser.No. 062722/Wiring and Hamess Diagrams, Harness Location WIRING AND HARNESS DIAGRAM OF REAR BASIC WIRING HARNESS W9, GRAIN TANK WIRING HARNESS W15, CHOPPER WIRING HARNESS W25 AND CHAFF SPREADER WIRING HARNESS W26, PART 2 2x000612 ‘TW4505 (05DEC00) oy wom dg dg a “ ames] 8) a 240-11-52 Z Series Combines Nats* Functional Schematics & Hamess Diagrams, fram Ser.No. 062722/Wiring and Hamess Diagrams, Hamess Location ‘TM4505 (0SDECOO) 240-11-53 2 Series Combines PN=500Functional Schematics & Hamess Diagrams, from Ser.No. 062722/Wiring and Hamess Diagrams, Hamess Location ‘zxo08619 WIRING AND HARNESS DIAGRAM OF REAR BASIC WIRING HARNESS W9, GRAIN TANK WIRING HARNESS W15, CHOPPER WIRING HARNESS W25 AND CHAFF SPREADER WIRING HARNESS W26, PART 3 He Kr Ke ess tt mm 818 we ‘Twi4505 (05DECO0) 240-11-54 Z Series Combines NSOFunctional Schematics & Hamess Diagrams, from Ser.No. 062722/Wiring and Hamess Diagrams, Hames Location LOCATION OF REAR BASIC WIRING HARNESS W9, GRAIN TANK WIRING HARNESS W415, CHOPPER WIRING HARNESS W25 AND CHAFF SPREADER WIRING HARNESS wai ° y . N oS \ ~ M4505 (0SDECO0) 240-11-55 Z Series Combines puteaFotiqung eaves 2 9FbOrZ 002050) sor veieso7 eeeuiey Sueiing ssouy noe Boaezzz00 OR tay SURIRG BroLAH B EREURIAS jLUNy][Functional Schematics & Hamess Diagrams, from Ser.No. 062722/Wiring and Hamess Diagrams, Hamess Location TM4505 (05DECO0) 240-11-57 Z Series Combines 04Functional Schematics & Hamess Diagrams, from Ser.No. 062722/Wiring and Hamess Diagrams, Hames Location WIRING AND HARNESS DIAGRAM OF ENGINE WIRING HARNESSES W12 AND W13, ARI G2 Ba B20 B10 v9 YT Fst Kaa F52 286 15 ¢ Kas Fz Kae Keo 0 youn Kea a8 son 24a, KAS ean © amsat 868 X62 oeans? 2 sess? Kaa sta57 © as625? YO4 es sacs? °F sa258@ Ya G2 Ba B2 B10 a5 Yo F651 Kaa Fe mo. teases a ae mean [ese pea abla” — at TM4505 (05DECO0) 240-11-58 Z Series Combines PNS5OSFunctional Schematics & Harness Diagrams, from Ser.No. 062722/Wiring and Hamess Diagrams, Hamess Location ‘TM4505 (0SDECO0) 240-11-59 Z Series Combines PNESOSFricwo seve 2 09-14-082. (003080) sosviu [erRoo7 Seow SuRNG sssUR pue BanWrzaZe50 GNIS Way BoRERG SouRH F INAS IRIE][Functional Schematics & Hames Diagrams, from Ser.No. 062722/WVring and Harness Diagrams, Hames Location TM4505 (05DECO0) 240-11-61 Z Series Combines PN=508Functional Schematics & Hamess Diagrams, from Ser.No. 062722/Wiring and Hamess Diagrams, Hamess Location LOCATION OF ENGINE WIRING HARNESSES W12 AND W13 WITH COMPONENTS ‘TM4505 (05DECO0) 240-11-63 Z Series Combines PestoFunctional Schematics & Hamess Diagrams, from Ser.No. 062722/Wiring and Harness Diagrams, Hames Location i WIRING AND HARNESS DIAGRAM OF STRAW HOOD WIRING HARNESS W20, PART 1 B21 sie S17. x90 E22 HAS HIS E13 a2 Bas g : i ae i ‘TM4505 (0SDECOO) 240-11-64 Z Series Combines pNcstt[Functional Schematics & Hames Diagrams, from Ser.No. 062722/Wiring and Harness Diagrams, Hamess Location Twa605 (05DECO0) 240-11-65 2 Series Combines pNest2[Functional Schematics & Hamess Diagrams, from Ser.No. 062722/Wiring and Harness Diagrams, Hamess Location WIRING AND HARNESS DIAGRAM OF STRAW HOOD WIRING HARNESS W20, PART 2 Hagia E14 E17 xes X87 X89 a] 3 xs xan zx000617 ‘TM4505 (05DECO0) 240-11-66 Z Series Combines PNBSeton sop0s 2 L9-L1-0b2 (003080) sosyes SLNJNOdWOD HLM 02M SS3NUVH ONPLIM COOH AVULS 40 NOLYOOT [aHeso7 asouny Suetag Suh Rie RaNVEClERO OWA Way TUREEG SoURH F SARURIAS RUNNY][Functional Schematics & Hamess Diagrams, from Ser.No. 062722/Wiring and Hamess Diagrams, Hamess Location ‘TM4505 (05DECO0) 240-11-68 Z Series Combines PASICurrent Supply/Starting Motor to Ser.No. 062721 ~ Group 15A SPECIFICATIONS tom Measurement Alternator Capacity Batteries Number Batteries Voltage Battery Capacity Speciation 1200 a | rv 88 AH OPERATIONAL INFORMATION Clearance lights, hazard warning lights, work lights ‘and hom may be switched on regardless of starter ‘switch position. With starter switch in position (I), all electrical systems may be switched on, with the exception of gauges and indicator lights. These components are activated when starter switch is turned to position (Il), With hydrostatic ground speed drive lever in neutral position, starting motor may be operated by turing starter switch to positon (I) NOTE: Power is supplied to memory functions of clock, radio and citizen band from a point locatéd in front of the battery switch which may be installed. This ensures correct ‘operation of these components with battery switch in “OFF" positon. THEORY OF OPERATION ‘The negative battery terminal is connected to the ‘machine frame on all combine models. The positive battery terminal is connected to terminal (30) of starting motor and to the fuse board on which the fuses and basic relays (K2) and (K3) are located. ‘The starter switch is supplied with current via fuse (F40), Tho hydrostatic ground speed contro lever must be in neutral position when starting the engine. This will activate switch (82). zerwaccomoe 9.250182 ‘TM4505 (05DECO0) 240-15A-1 Z Series Combines. PNSiCurrent Supply/Starting Motor to Ser.No. 062721/Functional Schematic, Section 1 FUNCTIONAL SCHEMATIC OF SECTION 1 on ka SET POWER SUPPLY 7 STARTING MOTOR 7x003994 | x18 — Connection, X44 — Disconnect point, xe2 listribution harness cab hamess (W2}, rear basic hamess (W1) to fuse board fear basic harness wo), X25 — Disconnect point, (wa) engine harness (W13) distribution harness X45 — Disconnect point, X65 — Disconnect point, Ki — Stating motor relay wn, ‘cab harness (W2}, front basie harness K2 — Basie relay ‘cab harness (W2) rar basic hamess wn, K3 — Basie relay X27 — Disconnect point, steering column M1 — Starting motor distribution harness hharness (We) ‘81 — Starter switch wn, cab hamess (W2}, _X117— Connection, 82 — Hydrostatic safety cab hamess (W2) front basie harness Aistribution harness switch X38 — Disconnect point, wn (Wt) to fuse boara ‘$63 — Battery switeh cab harness (W2), X17 — Connection, armrest harness (W5) distribution harness (Wt) to fuse board ‘TM4505 (05DECOO) 240-15A-2 Z Series Combines PNesi7‘stiquog soos 2 e-vsL-ovz, (903050) gosta + NoWLoaS 40 OUYW3HOS SUSONSVIG 1 WGieS SRRES SROOUENGTELESO OWNS OR BEES KAASCurrent Supply/Starting Motor to Ser.No. 062721/Diagnostic Schematic, Section 1 ‘TM4505 (05DECOO) 240-15A-4 Z Series Combines* Group 16A Current Supply/Starting Motor from Ser.No. 062722 SPECIFICATIONS tom Measurement Specification Alternator Capacity 120 Batteries Number 2 Batteries Voltage tv Battery Capacity 88 AH OPERATIONAL INFORMATION Clearance lights, hazard warming lights, work lights NOTE: Power is supplied to memory functions of and hom may be switched on regardless of starter clock, radio and citizen band from a point switch position, located in front ofthe battery switch which may be installed. This ensures correct With starter switch in position (1, all electrical operation of these components with battery systems may be switched on, with the exception of switch in "OFF" poston. gauges and indicator lights. These components are activated when starter switch is turned to position (II). ‘With hydrostatic ground speed drive lever in neutral position, starting motor may be operated by turning Starter switch to position (Il). THEORY OF OPERATION On all combine models, the negative battery terminal is connected to the machine frame via the main battery switch (S63). The positive battery terminal is connected. to terminal (30) of starting motor and to the fuse board ‘on which the fuses and basic relays (K2) and (K3) are located ‘The starter switch is supplied with current via fuse (F40). ‘The hydrostatic ground speed control lever must be in neutral position when starting the engine. This will activate switch (S2) and change switch ($63) from a positive conductor to a negative one. ‘TM4505 (05DECOO) 240-16A-1 Z Series Combines PN520Current Supply/Starting Motor from Ser.No. 062722/Functional Schematic, Section 1 FUNCTIONAL SCHEMATIC OF SECTION 1 SEI POWER SUPPLY / STARTING MOTOR 2X003994 I 15 — Fuse board X18 — Connection, X44 — Disconnect point, X62 — Disconnect point 40 — Fuse, 30 amps. ‘distribution hamess ‘cab harness (W2}, rear basic harness F48 — Fuse, 7.5 amps. (Wt) to fuse board rear basle harness (wey, G1 — Batteries X25 — Disconneet point, (wo) engine harness (W13) dliatibution harness X45 — Disconnect point, X65 — Disconnect point, wn, ceab harness (W2}, front basie harness cab harness (wa) rar basic harness X27 — Disconnect point, wa) Mt — Starting motor distribution harness X48 — Disconnect point, ‘81 — Starter eviteh wn, cab hamess (Wa, X17 Connection, ‘$2 — Hydrostatic safety cab hamess (W2) front basie harness sletribution harness ‘ite X35 — Disconnect point, wn (Wt) to fuse board ‘$63 — Battery switch cab harness (W2}, X17 — Connection, armrest harness (W5) distribution harness {(W1) to fuse board ‘TMi4505 (05DECO0) 240-16A-2 Z Series Combines pussat240AGAS 505 (05DECD0)Current Supply/Starting Motor from Ser.No. 062722/Diagnostic Schematic, Section 1 ‘TM4505 (05DECO0) 240-16A-4 Z Series Combines N53Group 15B Cold Weather Starting Aid OPERATIONAL INFORMATION The cold weather starting aid injects ether fluid into the intake manifold while cranking engine by means of starting motor. Ether is highly flammable, The heat created in the combustion chamber is sufficient to ignite the injected ether. This in turn will ignite the fuel/air mixture, Operating cold weather starting aid: ‘Tur starter switch to position Ill. As soon as the engine is cranking, push ether starting aid button (A). After the engine has started, release starter switch and starting ald button THEORY OF OPERATION With starter switch in position Ill, voltage Is supplied to starting motor relay coil via hydrostatic safety switch. At the same time, voltage is supplied to starting ald switch (S3) via wire 295. Solenoid (¥8) is activated by actuating switch ($3), which will inject ether into the intake manifold. ‘TM4505 (05DECO0) 240-15B-1 Z Series Combines PNesadCold Weather Starting Aid/Functional Schematic, Section 2 FUNCTIONAL SCHEMATIC OF SECTION 2 s3 i Sea 3 1 STARTING AID. 2x005243, i ‘A1S—Fuso board X#4—Disconnect point X62_Disconnect point ‘YB —Solenold, ether starting F46—Fuse, 15 amps. ‘ab harness (W2}, tear basie harness a 153 —Ethor starting ald baste harness (W3) 9), switch x46—Disconnoct point, engine harness X17—Connecton, distribution cab haress (W2), (wiawis) harness (1) to fuse front basic harness _X65-Disconnect point, board cr ‘tont basle harness X25—Disconnect point, wn, dotribution harness string column wy), hhamess (W8) cab hamess (W2) ‘TM4505 (05DECO0) 240-15B-2 Z Series Combines PNssesCold Weather Starting Aid/Diagnostic Schematic, Section 2 DIAGNOSTIC SCHEMATIC OF SECTION 2 ‘TM4505 (05DECO0) 240-15B-3 Z Series Combines pNeae8Cold Weather Starting Aid/Diagnostlc Schematic, Section 2 TH4S05 (O5DECO0) 240-15B-4 2 Series Combines enerGroup 15C Engine Shut-Off Device OPERATIONAL INFORMATION When starter switch is moved back from position (II) to position (I), the engine is shut off electrically. On the 7.6 Liter engine, a shut-off lever is moved by interrupting current supply to the lever retaining solenoid. On the 6.8 Liter engine, the fuel supply is shut off by means of a solencid valve in the fuel pump. THEORY OF OPERATION 7.6 LITER ENGINE When moving starter switch from position (I) to Position (I), call of (¥2) is supplied with current via wire (288). In addition, the second coil of (Y2) is activated via wire (045) during the starting procedure, moving the shut-off lever at fuel injection pump. The engine is ready for starting. After starting procedure is completed, the second coil is again without current. ‘The engine shut-off lever is held in operating position by the retaining coll. For shutting off the engine current supply to the retaining coll is interrupted A return spring moves shut-off lever at fuel injection pump to the zero position, 68 LITER ENGINE Fuel supply at injection pump is interrupted by a solenoid. With engine running, solenoid coil is supplied with current, keeping solenoid valve open. ‘When current supply is interrupted, the valve is closed by spring force, NOTE: If fuse (F16) fails, the machine will stop. T4505 (05DECO0) 240-15C-1 Z Series Combines PNBEngine Shut-Off Device/Functional Schematic, Sections 3A and 38 FUNCTIONAL SCHEMATIC OF SECTIONS 3A AND 3B gp =—=——_—_— ———S———— ———— 16 F 16 ezrin 4 seal st! wai * : SESA SESB ENGINE STOP z 2x003998 a ‘15 —Fuse board X62—Disconnect poi, __—_-X118—Conneeton, 95 —Engine shutof P16 —Fuse, 7.8 amps, Tear batie hares ltt harness solenoid Xd —Disconnect point, (wo, (07) to fuse board ‘ab harness (W2), engine harness ‘Yo Engine shutort Basie narness (W2) wiawia) ‘solenoid 128 Disconnect pot atatbuton harness ow, fab harness (W2) ‘TM4505 (05DECOO) 240-15C-2 Z Series Combines PN=629* Engine Shut-Off Device/Diagnostic Schematic, Sections 3A and 38 Twi4505 (05DECO0) DIAGNOSTIC SCHEMATIC OF SECTIONS 3A AND 3B r | POWER oIsTIBUTON BARD | ! i 1 ' Fis | e222 | ' | I lees \ 3 1 L 2-4 x119| wi w x26 4 we we | spat xu ve a5 " we : xe2 aan wis ow SEL SESA 240-15C-3 | SESB 08 we x26 we a ow g_o1 & x44 4 ore -2x003999 Z Series Combines PN=630,Engine Shut-Off Device/Diagnostic Schematic, Sections 3A and 38 ‘TM4505 (0SDECOO) 240-15C-4 Z Series Combines NeatGroup 15E Instruments OPERATIONAL INFORMATION ‘The combine is equipped with analog gauges to display coolant temperature, fuel level, grain losses and header height. When certain limit values are reached, the coolant or fuel level sending units activate indicator lights and buzzer. THEORY OF OPERATION With starter switch in position (il), the gauges are supplied with current via fuse (F24). ‘The COOLANT TEMPERATURE GAUGE (P1) is ‘connected to sending unit (84) via wire (034). Sending unit (B4) is a variable resistor. ‘At a coolant temperature of 20°C (68°F) resistance is very high. The gauge shows a very low temperature, At a coolant temperature of 110°C (240°F) resistance is low. The gauge shows a high temperature, ‘The FUEL GAUGE (P2) is connected to sending Unit (B11) via wire (033). ‘Sending unit (B11) is a variable resistor. At a low fuel level in fuel tank, resistance is low. Gauge shows empty tank. . ‘Ata high fue! level in fuel tank, resistance is high. Gauge shows full tank. ‘The HEADER HEIGHT GAUGE receives signals from potentiometer (4) on feeder house. Display of GRAIN LOSS GAUGE is controlled by harvest performance monitor (A4). ‘TM4505 (05DECO0) 240-15E-1 Z Series Combines NeaInstruments/Functional Schematic, Section 5 84 —Coolant temperature sending unit Bt1—Fuol tank sending unit F24—Fuse, 75 amps. Pt —Coolant temperature ‘gouge FUNCTIONAL SCHEMATIC OF SECTION 5 ; ‘SES z INSTRUMENTS: ZX004027 § P2—Fuel gauge X62—Disconnoct point, 3 —Header height gauge ‘ar basic harness P5 —Grain loss indieator (wo), x44—Disconnect point, engine harness ‘cab harness (W2}, (wranvts) ‘ear basic hamess (W2) ‘T4505 (05DECO0) 240-15E-2 Z Series Combines PNss33Instruments/Diagnostic Schematic, Section § DIAGNOSTIC SCHEMATIC OF SECTION 5 BS Bu ost wi2/ts_4 X62__wa ose ox 14 035 035 031 031 g zx004028 ‘TM4506 (05DECO0) 240-15E-3 Z Series Combines PNssaaInstruments/Diagnostic Schematic, Section 5 ‘TM4505 (05DECO0) 240-15E-4 Z Series Combines PNSS35Chopper Distributor Adjustment Group 15F OPERATIONAL INFORMATION ‘With separator engaged, itis possible to distribute chopped material to the right or left by repositioning distributor plates. Gauge (B) shows direction of material distribution, ‘A—Chopper distributor switch Chopper distributor gauge THEORY OF OPERATION ‘Switch (S54) is supplied with current via wire (202) (depending on position of separator switch) and via fuse (F15). Ground connection is also established by means of switch (S54). Rotating direction of electric motor (M13) depends on position of switch (S54). An internal mechanical slip clutch prevents overloading of the system. Gauge (P8) is controlled by potentiometer (R14) integrated in electric motor. ‘TM4505 (05DECO0) 240-15F-1 Z Series Combines PNBChopper Distributor Adlustment/Functional Schematio, Section 6 FUNCTIONAL SCHEMATIC OF SECTION 6 SEG ; CHOPPER DISTRIBUTOR ADJ zxo04029 § 5 ats —Fuse X22 Disconnect point, X38 —Disconnect point, -—_‘X118--Connection, cab F15 Fuse, 18 amps. tear basi hemes ab harness (W2), Tarmess to fuse board 1419 —Distrbutor adjusting wo, Eten console mator Chopper harness ramess (W714) Po —Distrbutor gauge (w25) 149 —Diaconnect point, fia ~Petentometar x27 Disconnect point, cab harness (2) 854 Swit, aatibutor tatibution harees omer post hamess austen ws, a ‘cab harass (W2) ‘TM4505 (05DECOO) 240-15F-2 Z Series Combines pNsbe?Chopper Distributor Adlustment/Diagnostic Schematic, Section 6 DIAGNOSTIC SCHEMATIC OF SECTION 6 AIS POWER DISTRIBUTION BOARD 1 1 1 i FIs sea1z2_——° | 1 1 ' 1 lamecieaecninametnecal wa x27_wi ov lor? wie KBB wo: 316 we X45 wo sip wo X22 was 319 . sie 2 032 319 316 zx008134 _newwacom er sBouNoL ‘TM4505 (05DECO0) 240-15F-3 Z Series Combines PussChopper Distributor Adjustment/Diagnostic Schematic, Section 6 ‘TM4505 (05DECOO) 240-15F-4 Z Series Combines PN=539Windshield Wiper/Washer System » Group 15G OPERATIONAL INFORMATION With starter switch in position (I), windshield Wiper/washer may be switched on by actuating switches (A) or (8). Windshield wiper switch (A) is a tumbler/rocker switch, for one-cycle or continuous wiper operation, Windshield washer rocker switch (B) can be actuated regardless of position of switch (A). Cab, grain tank and straw hood lighting are located in the same circult. .s zx004081 a * THEORY OF OPERATION With starter switch in position (I), current is supplied to switches (520) and (S21) via fuse (F36). Windshield wiper will operate in wiper switch position ()) oF (ll). Position (I) is for one-cycle operation, position (Il) for continuous operation. After shutting off windshield wiper, wiper motor (M3) will automatically return it to "park" position. Switch ($21) activates the windshield washer pump. ‘TM4605 (05DECO0) 240-15G-1 Z Series Combines PNeSa0Windshield Wiper/Washer System/Functional Schematic, Section 7 FUNCTIONAL SCHEMATIC OF SECTION 7 cian 3 is _ ee 4 evo aaa 5 ie A i Ea a ad SE7 LIGHTING, WINDSHIELD WASHER ZX004016 i 15 Fuse board S14—Grain tank lighting _-—_-X25—Disconnect point, x44—Disconneet point, cab 10—Grain tank lighting ‘witch ‘istrbution hamess — harness — rear Basie E12—Ceb interior lighting —-§20—Windshield wiper ‘ab harness, harness, E47—Straw hood lighting ‘switch X43—Disconnect point rear X48-—Disconnect point, rear F3t_Fuse, 15 amps. 521Windshild washer basic hamess — base harness — 3—Windshield wiper motor ‘switch straw hood harness rain tank harness Mt—Windshield washer X18—Connection, fuse board pump ‘to distribution hamess ‘TM4505 (0SDEC00) 240-15G-2 Z Series Combines pNsbatSino oe 2 eosi-ore (ooo20s0 osein 4.NOLLO’S 40 OLLWWAHDS OUSONOVIG ZLORRS BIBURAS SHORTAGE HNOWindshield Wiper’Washer System/Diagnostic Schematic, Section 7 TM4505 (05DEC00) 240-15G-4 Z Series Combines PNSBISGroup 15H Radio, Interior Lighting to Ser.No. 062721 OPERATIONAL INFORMATION With starter switch in position (0, display of digital ec ght up. When parking lights are switched ‘on, display is dimmed by 0%. ‘At the same time the radio, citizen band or interior fight may be switched on with starter switch in position (I) erent 1920802 THEORY OF OPERATION With starter switch in positon (1), power is supplied to Mio (A12) and clizen band (ATS) via fuse (F22), allowing the operator to ‘switch on these components. Display of digital clock (P7) wil ght uP. When current is supplied to digital clock via wire (103) (with lights switched on), display Is dimmed by 50%. Digital clock, radio and citizen band are continuously supplied with current via fuse (F18). emczoonenae e250 ‘TMi4505 (05DECO0) 240-15H-1 Z Series Combines eNesdRadio, Interior Lighting to Ser.No. 062721/Functional Schematic, Section 8 FUNCTIONAL SCHEMATIC OF SECTION 8 FIs F22 mel | (ler m7 a W30 B39 B40 WS! Jano aseea wrote P7 ee AIS rita one] se —w_] Jog SES i RADIO, CITIZEN BAND, CLOCK 2xX004018 3 8 an-Radio F22—Fuse, 7.5 amps. X18—Connection, fuse board ‘2ciizen band Pr—igal clock {o alstebution harness ‘A15—Fuse board X2—Disconmoct point, radio _x25—Disconnect point, F1—Fuso, 75 amps. (usa lstrbution hamess — cab harness X117—Connection, fuse board to distribution hamess ‘TM4505 (0SDECOO) 240-15H-2 Z Series Combines edRadio, Interior Lighting to Ser.No. 062721/Diagnostic Schematic, Section 8 DIAGNOSTIC SCHEMATIC OF SECTION 8 r 4 is | rover osticnon som | ' Pr | rie rea _oare 7 on ies 8 ' ! 103 ! iS | 1 1 ' 1 vt es 4 xq] oF 103, sei1210 — s wt X25 we o7s ee 4 104 pe 3 | sy q zxo04018 ‘ zaniecerees e201 ‘TM4505 (05DECO0) 240-15H-3 Z Series Combines pNSes| Radio, Interior Lighting to Ser No. 062721/Diagnost Schematic, Section 6 Z Series Combines 7 240-15H-4 "TMA4506 (0SDECOO)Group 16H Radio, Interior Lighting from Ser.No. 062722 OPERATIONAL INFORMATION With starter switch in position (1), display of digital clock will ight up. When parking lights are switched con, display is dimmed by 50%. ‘At the same time the radio, citizen band or interior light may be switched on with starter switch in position (, THEORY OF OPERATION With starter switch in position (I), power is supplied to radio (A12) and citizen band (A13) via fuse (F22), allowing the operator to switch on these components. Display of digital clock (P7) will ight up. When current is supplied to digital clock via wire (103) (with lights switched on), display is dimmed by 50%. Digital clock, radio and citizen band are continuously supplied with current via fuse (F18). NOTE: Connection from line (075) to relay (K46) in Section 22 applies only in the case of the 2054 combine, TM4505 (05DECO0) 240-16H-1 Z Series Combines PNBRadio, Interior Lighting from Ser.No. 062722/Funetional Schematic, Section 8 A12-Radio ‘A13—Citizen band ‘A15—Fuse board FUNCTIONAL SCHEMATIC OF SECTION 8 Eee EEE e————e—ey FIs F22 ESD | [J FE2 a ” ie W30 B39 B40 WS! eece | | | Sees tne ares P7 I (0001| bart be me on SES RADIO, CITIZEN BAND, CLOCK F18—Fuse, 7.5 amps. F22—Fuse, 7.5 amps. P7—Digita clock x2—Disconnect point, radio X25—Disconnect point, (usa) ZX004018 X18—Connection, fuse board to distribution harness. dlstribution harness — ceab hamess X117_Connection, fuse board to distribution hhamess ‘TM4505 (0SDECO0) 240-16H-2 Z Series Combines PNABASRadio, Interior Lighting from Ser.No. 062722/Diagnostic Schematic, Section 8 DIAGNOSTIC SCHEMATIC OF SECTION 8 lad AIS. ~~ | powenoititaunowsoare | | 1 Pr | Flere I Ber ! ma SEO! I total, | {s I 2 oe =) eee sere 9 ——s] i wg 5 ve on = | ———| a se , a ee pe 3 iaese7s I . i ergot pun ‘TM4805 (05DECO0) 240-16H-3 Z Series Combines pusisoRadio, Interior Lighting from Ser.No. 062722/Diagnostic Schematic, Section 8 T4505 (05DECO0) 240-16H-4 Z Series Combines. pussstGroup 15L Cigarette Lighter, Seat Compressor OPERATIONAL INFORMATION The machine is equipped with sockets for auxiliary When the machine is equipped with an air-cushioned equipment which are powered with starter switch in seat, the seat compressor is connected to position (I). socket (X104) located inside cab. FUNCTIONAL SCHEMATIC OF SECTION 11 x67; ‘X104 4 q : a ar g ‘SET CIGARETT LIGHTER 7 SOOKETS g ‘7X004033 a AIS — Fuse board X35 — Disconnect point, cab harness (W2), £9 — Cigarette lighter armrest harness (W5) F4_ — Fuse 15 amps. X37 — Disconnect point, cab harness (W2), X18 — Connection, main distribution switch console hamess (W3) hhamess (Wi) to fuse board X48 — Disconnect point, cab hamess (W2), X25 — Disconnect point, main distribution rear baste wiring harness (V9) hhamess (WA), eab harness (W2) ‘TM4505 (05DECO0) 240-15L-1 Z Serles Combines pussCigarette Lighter, Seat Compressor/Diagnostic Schematic, Section 11 DIAGNOSTIC SCHEMATIC OF SECTION 11 AI © us x67 cn4 i tio zxo04034 ‘TM4505 (05DECOO) 240-15L-2 Z Series Combines PN=5SGroup 15M Lighting System OPERATIONAL INFORMATION In position (ll) of dual-stage, double contact switch (S13), parking lights are switched on and in position (II) full or low-beam headlights. Parking lights can be switched on regardless of starter switch position. To switch on full or low-beam headlights, starter switch must be in position (I) or (II). ‘When parking lights are switched on, switch and instrument lighting is also switched on. At the same time, Infotrak monitor and digital clock displays are dimmed. [Light functions off Parking lights, switeh and instrument lighting li-Low-beam headlights only with starter switch Positions () or (l) wavey 2x 000394 _zcmocrcononn 0250102 THEORY OF OPERATION Light switch (S13) is a dual-stage, double contact switch, ‘The first contact is used for parking lights and instrument lighting, the second contact for lowifull-beam headlights. The parking light system is divided into three circuits which are protected individually. One circuit is provided for left-hand parking lights, one for right-hand parking lights and another circuit for switch and instrument lighting. ‘The lowifull-beam headlight circuit is connected to the starter switch. In light switch position (Il), low or full-beam headlights are switched on, depending on position of lowffull-beam headlight switch, ‘TM4505 (05DECO0) 240-15M-1 Z Series Combines PNSBSS> Lighting System/Functional Schematic, Section 12 FUNCTIONAL SCHEMATIC OF SECTION 12 i E17 meal WES aa eis | |e fee] haw eis | | ele ror) Bere es eee cos | | Epa bases] later] — feasae Testes x15 santa oer SEI2 LIGHT FUNCTION 1 —Hoadtight, tn, £2. —Headight, rh. E43 —Tall ight, Uh E14 Tall ight, ch E15 —Clearance light, Lh. E16 —Clearance light, {E22 —Registration plate light E23 —Clearance light, header, Lh. E24 —Clearance light, header F25 —Fuse 7.5 amps, X17 —Connection, main distribution X18 —Connection, main distribution harness (W1) to fuse board X21 —Disconn. point, feeder house hharness (W10), header harness (waz) X25 —Disconn. point, main distribution harness (W1), cab hamess (W2) x26 —Disconn. point, mal hhamess (W1), cab harness (W2) X37—Disconn. point, cab harness (W2), ‘switch console harness (W3) X38 —Disconn. point, cab harness (W2), 2Zx004031 osc, X43 — Disconn. point, rear basic har- ss (Wo), straw hood ha X45 — Disconn. point, cab harness rear basi hi x46 — Disconn. front basic hares (W7) X85 — Disconn. point, front basic harness (Wn, steering column harness (WB) XIT —Disconn. point, front basic harness wi) x7 nection, main distribution har- ness (W1) to fuse board X118-— Connection, main distribution har- 133 —Full-beam indicator ight ‘optional equipment harness (W14) ress (W1) to fuse board 813 Light switen ‘TM4505 (05DECO0) 240-15M-2 Z Series Combines PN=SES—— waren en ates 8 N\ = pete stot Se a eta = a : = es —H 3 a : — ee eee bEEEER [ = z teal] | tol = ee fd Pon = “E - TH = a 3 & Zi NOWOAS 40 OLLWSHDS SUsONOVIG [eraser career Tag SisUNIRS SONNETS Ban |Lighting SystemDiagnostic Schematic, Section 12 ‘TM4505 (05DECOO) 240-15M-4 Z Series Combines pusssrGroup 15N Flasher Functions OPERATIONAL INFORMATION When driving on public roads, use turn signal switch to indicate direction of machine travel In emergency situations both turn signal lights can be switched on by:means of the hazard warning light switch regardless of starter switch position (hazard ‘warning light function. THEORY OF OPERATION ‘TURN SIGNAL LIGHTS Power is supplied to terminal (49) of flasher via fuse (F20) and hazard warning light switch (S11). Terminal (31) establishes ground connection. When actuating turn signal switch (S12), current flows to the right or left-hand turn signal lights. Flasher (KS) generates the required flashing frequency and activates the corresponding turn signal indicator light via terminal (C2) or (C3). HAZARD WARNING LIGHTS With hazard warning light switch (S11) in position (I), power is supplied to terminal (49) of flasher via fuse (F34) regardless of starter switch position. At the same time the turn signal lights on both sides of the machine are connected to terminal (49A) of flasher. This generates the required flashing frequency. ‘TM4505 (0SDECO0) 240-15N-1 Z Series Combines NASBFlasher Functions/Functional Schematio, Section 13 FUNCTIONAL SCHEMATIC OF SECTION 13 X15 bole rune soot | SEIS FLASHER FUNCTION Al4—Relay and diode board ‘AiS—Fuse board F20—Fuse 7.5 amps. F34—Fuse 15 amps. Hi9—Tum signal light, rear th Ht4—Turn signal light, rear the H1S—Tum signal light, front th H16—Turn signal tight, front th, H17—Ada turn eign tight, th. H1B—Add, turn signal light, th. Tiva605 (05DEC00) ZX004035, i Hot—Tum signal indicator X14—Connection, cab X31—Soldered connection on Tight 4, combine hhamness (W2) to relay board 1H35—Tum signal indicator and diode board x48—Disconn. point, rear light 2, taller X15—Trallor socket baste harness (W9), X17—Connoction, main straw hood hemess. distribution harness (w20) (1) to fuse board X45—Disconn, point, cab X21—Disconn. point, fender wy, ‘house harness (W10), harness (W) S11 Hazard warning ight hheader harness (W22)_X46—Disconn, point, cab ‘ewiteh X25—Disconn. point, main harness '512—Tum signal switen ‘istribution harness X12—Connection, cab (Wt), cab harness (W2) hharness (W2) to relay _X26—Disconn. point, main and diode board distribution hamess (Wt), cab hares (w2) 240-15N-2 Z Series Combines PNSESS(oooas0) sostin. £1 NoUaS 40 OUVNSHOS SUSONOVIC (gees aFlasher Functions/Diagnostic Schematic, Section 13 ‘TM4505 (05DECO0) 240-15N-4 Z Series Combines PNesétGroup 150 Revolving Hazard Warning Lights OPERATIONAL INFORMATION With starter switch in position (|) or (I!) the revolving hazard waming lights may be switched on by means Of switch (S18), _Dcmoconoiss 1.280182 THEORY OF OPERATION ‘With starter switch in position (I) or (I), switch (S18) current. The revolving motion is accomplished by is powered via fuse (F396). means of an electric motor. If switch (S18) is activated, revolving hazard warning lights (H21) and (H36) are directly supplied with zrwwaconeise- 1.281012 ‘TM4505 (05DEC00) 240-150-1 Z Series Combines PNS562Revolving Hazard Warning Lights/Functional Schematic, Section 14 ‘A15—Fuse board F35—Fuse 15 amps. FUNCTIONAL SCHEMATIC OF SECTION 14 —a I SEI4 REVOLVING LIGHTS. S18—Revolving hazard ‘warning light switen ZX004037 x25—Disconn. point, main dltribution X44—Disconn. point, cab harness (V2), basic H2i Revolving hazard x1T—Conneetion, mein hamess (W1), cab thames (WO) ‘warning light ‘dstributon harness harness (W2} H36Revolving hazard (Wit) to fuse board warning ight ‘TM4505 (05DEC00) 240-150-2 Z Series Combines NSSRevolving Hazard Waring Lights/Diagnostic Schematic, Section 14 DIAGNOSTIC SCHEMATIC OF SECTION 14 : =| | ' ue 240-150-3 2 Series Combines 714505 (05DECOO) pssstRevolving Hazard Waring Lights/Diagnastic Schematic, Section 14 ‘TM4505 (05DECOO) 240-150-4 Z Series Combines PN=SESL ~ Group 15P Fan, Air Conditioning System OPERATIONAL INFORMATION With starter switch in position () or (Il) fan may be ‘switched on by means of rotary switch (A). Fan can be adjusted to four speeds. With fan running, the air conditioning system can be adjusted to the desired temperature by means of rotary switch (B). Even if air conditioning system is switched off at rotary switch (B) (e.g. switch turned to heating position), bbe switched on to maximum output by means of swith (C). NOTE: The above combination is used, for example, to reduce moisture content of cab air when windows are misted. 2x000903 THEORY OF OPERATION With starter switch in position (1) or (Ii), switch (S22) is supplied with current via fuse (F42), Fan (Mé) can be adjusted to four speeds by means of resistor (Rt). ‘As soon as rotary switch (S22) Is turned to position (or further, switch (S25) is supplied with current. Either air conditioning system or heater can be switched on by means of switch (825). In neutral position or when heater is switched on, the contact of switch ($26) is in “O" position. Thus switch (S52) is supplied with current, making it possible to switch air conditioning system to maximum output, With air conditioning system switched on by means of switch (S26), electromagnetic clutch (Y33) is activated via thermostat (B9), low pressure switch (B14) and high pressure switch (815). If pressure in air conditioning system is too high, high Pressure switch (816) is activated and the corresponding indicator light in SE10 will glow. _zenwacomen 1925002 ‘TM4605 (05DECO0) 240-15P-1 Z Series Combines putsesFan, Air Conditioning System/Functional Schematic, Section 15 FUNCTIONAL SCHEMATIC OF SECTION 15 SEIS AIR CONDITION 2x004039 i ‘A15—Fuse board Fé2—Fuse 30 amps. X26—Disconn, point, main X62—Disconn. point, rear B9—Thermostat (protection Ml4—Cab fan alistrbution basic harness (W2), ‘against freezing) Ri—Fan resistor harness (W1), cab ‘engine harness B13—Temperature switch, alr 522—Fan switch hares (wiants) ‘conditioning '825—Alr conditioning switch _X37—Disconn. point, cab _-—_‘X66—Disconn. point, cab 814Low pressure switch, _$52—Demoisturizer switch harness (W2) harness (W: air conditioning X18—Connection, main switch console hamess air conditioning and fan B15High pressure switeh, distribution hamess (ws) harness (W6) air conditioning (V1) to fuse board ‘TM4505 (05DECO0) 240-15P-2 Z Series Combines Nese?Fieco mans 2 ator (go2cg0 som St NOLLOaS 40 OLLVIIZHOS OUISONOVIC Si aa sag SRB DoreatRTRRNS BaNRRELRS ay = #]Fan, Air Conditioning SystemvDiagnostic Schematic, Section 15 TM4505 (05DECO0) 240-15P-4 Z Series Combines PNSS6SGroup 15Q Electrical Mirror Adjustment OPERATIONAL INFORMATION a For miror adjustment starter switch must be tumed to postion (I) or further. = = Move mirrors upidown or to the rightleft according to SN Z| arrows on switch, ( IS) i -Adjusting Lh. outside mirror — * adjusting eh ousie mirror = =), axooaeee _pamnacononu seu Switching on mirror heater is only possible with starter ‘switch turned to position (I) or further. [Mirror heater off Mirror heater on THEORY OF OPERATION Mirror heater switch (S65) and mirror adjusting switch to the rightfeft or up/down. This will reposition switch (864) are powered via fuse (F37). mirror surface by activating electric motors integrated in mirror housing. ‘Tum mirror adjusting switch knob to select mirror to be adjusted. Mirror adjustment is carried out by titing TM4505 (05DECOO) 240-15Q-1 Z Series Combines pxss7aElectrical Mirror Adjustment/Functional Schematic, Section 16 FUNCTIONAL SCHEMATIC OF SECTION 16 iL © gay view vaanon a, SEI6 REAR VIEW MIRROR ADJUSTMENT. A15—Fuse boar FST—Fuse 7.5 ‘S64¢—Mirror adjusting switch ‘S65—Mirror heater switch ‘listrbuton har (Wi), cab harness (w2) Zx004041 X97—Disconn. point, cab harness (W2), harness for electrical ‘mirror agjustment (was) “TMa505 (0SDECO0) 240-150-2 Z Series Combines pNesrtElectrical Mirror AdjustmentDiagnastic Schematic, Section 16 DIAGNOSTIC SCHEMATIC OF SECTION 16 AS sp012i2__F37 ncuavns (3)2 woo 4X07 we cor wa “ (OF 103 Ls c= ne zxo4042 ‘TM4505 (05DECO0) 240-15Q-3 Z Series Combines PassaElectrical Mirror Adjustment/Diagnastic Schematic, Section 16 TM4505 (05DECO0) 240-150-4 Z Series Combines PNeerSGroup 15R Work Lights OPERATIONAL INFORMATION With parking lights on, the work lights on cab roof and unloading auger may be switched on by actuating switch ($19). With road safety switch in field position, work lights on mirror arms, straw hood and operator's platform may also be switched on, THEORY OF OPERATION With parking lights switched on, switch (S19) is supplied with current via wire (103). When switch (819) is activated, relay (K7) is also activated and thus cab roof and unloading auger work lights are switched on directly. Work lights on operator's platform, mirror arms and straw hood may be switched on in any starter switch Position by means of switch ($48), depending on Position of road safety switch, even if parking lights are not switched on, ‘TM4505 (05DECO0) 240-15R-1 Z Seties Combines pNeere* Work Lights/Functional Schematic, Section 17 FUNCTIONAL SCHEMATIC OF SECTION 17 sae Smarr q ‘0 "> — | E4 E25 Els ae 8 | or E26 EI9 -&- 8 —— ee a Bien] Ae 3 7 al 2 TSM ura EB =e a efor ' SEIT i WORK LIGHTS ‘A18—Fuse board ch. _X27—Disconn. point, matin h ‘istibution harness E3—Rear work light 19—Platform work light, E4—cab root 25—Work light, (Wt), cab hamess (W2) ‘bracket x20-Splice X46—Disconn. pont, cab £26—Work light, ior X43—Disconn, point, rear hamess (W2), bracket basic harness (WS), front basic harness £6—Cab roof work light, X18—Connection, main Straw hood harness wn) cuter Lh dlstibution harnoss (w20) x48—Disconn. point, rear E7—Cab roof work tight, (Wi) to fuse Board ——_X44—Disconn. point, cab basic hammess (WO), Inner Lh x25—Disconn. pont, main harmoss (W2), grain tank hares. £E8Unloading auger work distribution harness rear basic hares (WS) (wis) Wight (Wt), cab hares (Wa) ‘TM4505 (05DECO0) 240-15R-2 Z Series Combines PN=87SWork Lights/Diagnostic Schematic, Section 17 DIAGNOSTIC SCHEMATIC OF SECTION 17 a SE12 SE21 138__w2_9, X46 wr E18 on we ,X77 wio wo, x21 fe oni __we X29 we on wa a X27 wi on on E5 EB | = ort ov Wa 4, X44 wa_o7t 4 * ; z | ‘TM4505 (0SDECO0) 240-15R-3 Z Series Combines PNESIEWork Lights/Diagnostic Schematic, Section 17 ‘TM4505 (05DECO0) 240-15R-4 Z Series Combines pNesr?Group 15S Straw Warning Device OPERATIONAL INFORMATION ‘The straw waming device is provided to detect plugging of material in the entire straw walker area, The first sensor is located in front of the cross shaker, the second one behind the cross shaker nd the third one above the straw chopper. When plugging of material occurs, the "STOP" light of the indicator tight unit will glow. In addition the buzzer and horn will sound, THEORY OF OPERATION Hom (812) is continuously supplied with current via fuse (F27), When actuating switch (S8), the horn is connected to ground and the hom signal will be heard. With starter switch in position (I), relays (KB) and, (K22) are supplied with current via fuse (F'14). ‘Switches (S15), ($16) and (S17) are in “OFF” position (closed). This causes relay (K6) to open and relay (K22) to close, interrupting ground connection to horn, buzzer and indicator light, I one of the switches ($15), (S16) or (S17) is ‘actuated due to excessive straw accumulation in the straw hood, relay (K6) establishes ground connection to horn, buzzer and indicator light. ‘TM4505 (0SDECO0) 240-15S-1 Z Series Combines PNESTE‘Straw Warning Device/Functional Schematic, Section 18 FUNCTIONAL SCHEMATIC OF SECTION 18 ‘Ald—Rolay and diode board ‘A15—Fuse board BI2—Horn Fid—Fuse 7.5 amps. F27_Fuse 15 amps. K6—Relay, straw warning dovico K22—Relay, straw warning device ‘88—Horn button S18-Switeh, straw waning dovice (cross shaker) 816—Switeh, straw warning device (walkers) Hy 12 Ke, [Sh dss aoa UB “Cae fa sis {a ‘Sous abel] wre STR WARNING DEVICE DooAoHS i i 817—Swte, saw warning X25—Diaconn, pon, mn XAB—Discon. pol, cab Seven shoppe) itbutonhamess harness 2), x12—Gonnection cab (wiycadharene (2) Hot base Ramass armas (Wf relay X27—Disonn, ply man wn beara letrnion tomess. X49—Diaconn, pln, eab x17—Eomectin, man {wt cab hares 2) hams 2 sitbton 1ax_Diconn pty eat Commer post harness hamess (W1) to fuse basic hamess (WS), (wa) board Stew hood hamess—X65-Diecon. pol ont x10—Conmecon, main (wa basi harross 7), sitibuon x45 Dicom. pont, oa tering column harese to fas homese 2) harose Oo) board rear basic harness (W2) Derwent. 1 9UNvE9 ‘TM4505 (05DEC00) 240-15S-2 Z Series Combines PNssioStraw Waring Device/Diagnostic Schematic, Section 18 DIAGNOSTIC SCHEMATIC OF SECTION 18 r ae ats i 1 ' ' i i 1 1 1 ' 2304048 ® Co ‘TM4505 (05DECO0) 240-15S-3 Z Series Combines PN=880‘Straw Warning Device/Diagnostic Schematic, Section 18 ‘TM4505 (05DECO0) 240-15S-4 Z Series Combines PNesatGroup 15T Reel Speed Adjustment to Ser.No. 062721 OPERATIONAL INFORMATION Reel height, reel horizontal position and reel speed may be adjusted for best performance according to harvesting conditions. A variable drive controlled by an electric motor permits infinite reel speed adjustment within a certain range, ‘The reel speed adjusting motor can be activated by @ switch in the cab or by the reel speed control system. ze mwzcoonsinter06c82 Depending on position of double sprocket (C), reel speed may be adjusted within a range of 14—30 rpm [this equals 3.2—6.8 kmih (2—4.2 mph] or 2360 rpm [5210.8 kmih (3.2—6.7 mph. ‘The reel speed control system activates the electric ‘motor which controls variable reel drive. In this case the following adjusting ranges are also obtained: 14—30 rpm [this equals 3.2—6.8 km/h (2—4.2 mph)] or 22—50 rpm [5.2—10.8 kmih (3.2—6.7 mph]. NOTE: The reel speed control system will only operate within @ ground speed range from 1.2 kmh (0.75 mph) to 10 km/h (6 mph). THEORY OF OPERATION With starter switch in position (I) or (i), current is supplied to switch ($10) and reel speed control system (At). Stop light switch (S7) is also supplied with current. ‘When actuating switch (S10), relay (K32) or (K33) is activated. This will increase or reduce reel speed. zerwarooonsss901080%2 ‘TM4505 (05DEC00) 240-15T-1 Z Series Combines PNS582Reel Speed Adjustment to Ser.No. 062721/Diagnostic Mode With header running (wire 289 powered), a diagnostic = —~ mode is activated when tuming speed ratio switch (otentiometer) ($9) to first position. The other switch positions will provide various reel speed ratios. The speed ratio switch (S9) is connected to reel speed ‘control system (A1) by means of four wires, providing 13 possible switch positions. i : 8 POSITIONS OF SPEED RATIO SWITCH S9 ar | OFF | Test | cao | 100 ] 410 | 148 | 120 | 125 | 120 | 180 ] 180 | 200 | 220 1 fofxfofxfofxfofx]ofx]o],x]o 2[o[x |x ]fofofx]fxfofofx]xfofo afofx]xfx fx fofofofo|x|xfx|x a[o[x]x]fxfxfx][xf[xfxfofofofo NOTE: (X) means that the corresponding switch connection Is grounded. DIAGNOSTIC MODE The program of the reel speed control system 4, Drive combine with a speed of §.6 km/h provides a diagnostic mode. In this mode input and (3.5 mph). ‘output signals of the system are tested. 5. Ata ground speed of 5.5 km/h (3.5 mph) move Diagnostic Procedure: speed ratio switch (S8) to test postion. 41. Move micro switch 1 to “ON” position (switches 2 6. Continue to drive combine with an exact speed of to 5 are already "ON’). 5.5 kmlh (3.5 mph) for 30 seconds. 2, Move speed ratio switch (S9) to “OFF* position. 7. Stop combine. Keep separator and header running. Read error displays at LED's. 3. Start engine; engage separator and header. ‘TM4505 (0SDECOO) 240-15T-2 Z Series Combines PNSSeSReel Speed Adjustment to Ser.No. 062721/Error Codes 0 —LED off X— LED on ERROR CODE DISPLAY Error Code Problem Solution No voltage (Check fuse (F12) No ground speed signal Check sending unit on 3-speed transmission Ground speed signal not within operating range ‘See “Operating Range of Reel Speed Control ‘System’ in "Controls and Instruments™ Section of Operator's Manual No reel speed signal Check sending unit at cutting platform Reel speed signal not within operating range ‘See “Operating Range of Reel Speed Control ‘System in "Controls and Instruments* Section of Operator's Manual AX BO cx D0 Error “Bit 1” at reel speed control switch AO Bx cx D0 Error "Bit 2° at reel speed control switch AX BX cx D—0 Error “Bit 3° at reel speed control switch AO BO co ox Error “Bit 4° at reel speed control switch ‘TWA505 (0SDECO0) 240-15T-3 Z Series Combines PassesReel Speed Adjustment to Ser.No. 062721/Etror Codes 0 — LED off X — LED on ERROR CODE DISPLAY (CONTINUED) Error Code Problem Solution AX Bo co px Option A, output 1 shorted to ground A0 Bx co px Option A, oulput 2 shorted to ground ax Bx co ox Reel does not accelerate AO BO cx ox Reel does not slow down = Bo cx Reel speed control switch not in diagnostic position ‘See “Reel Speed Control Switch” in “Controls and Instruments" Section of Operator's Manual Fault not found ‘All contacts to reel speed control switch open imwaconastsse0r0Eom ‘TM4505 (05DECOO) 240-15T-4 Z Series Combines N88OPERATING ADJUSTMENT OF MICRO SWITCHES During normal operation, micro switch 1 on board of ree} speed control system is in “OFF” position, while switches 2 to 6 are in “ON" position, 2 ‘zxoo4060.§ | ‘TM4505 (05DECO0) 240-15T-5 Z Series Combines PN=beReel Speed Adjustment to Ser.No. 062721/Functional Schematic, Section 19 FUNCTIONAL SCHEMATIC OF SECTION 19 — te tie ie ‘At—Reel speed control ‘Al4-Relay and diode board ‘A15—Fuse board 'B5—Sending unit, roel speed F12—Fuse 15 amps. 1H49—Stop light, Ln. Hed—stop iat, Ka2—Relay, adjust reet speed K33—-Relay, adjust reat speed (M2—Rool speed adjusting motor S7—Stop light switch '39—Potontiomater, reel speed i SEI9 5 STOP LIGHTS , REEL SPEED ADJUSTMENT a 2x004054 g 5 ‘S10—Reol speed switch x10—Connection, cab harness (W2) tor board Xt1—Connestion, ead hhemess (W2) to relay board X17—Connection, main ‘listribution hamess (Wt) to fuse boars x21—Disconn. point, house harness (W10), header harness (W22} X23—Disconn. point, cab harness (W2}, {ont basie harness wn a X25—Disconn. point, main slistribution harness (W1), cab harness (W2) x28—Disconn. point, main distribution (Wt), cab hamess (W2) X35—Disconn, point, cab hharness (W2), armrest harness (WS) X38—Disconn. point, cab harness (W2), ‘optional equipment harness (W14) ‘TM4505 (0SDECO0) 240-15T-6 Z Series Combines PINES?61 NODS JO OLLYW3HOS SUSONOVI GF BOERS SEUSS BRIERE GVIAS G HOLNBY PS FyReel Speed Adjustment to Ser.No. 062721/Diagnostic Schematic, Section 19 ‘M4605 (05DECO0) 240-15T-8 Z Series Combines PSSGroup 16T Reel Speed Adjustment from Ser.No. 062722 OPERATIONAL INFORMATION Reel height, reel horizontal position and reel speed may be adjusted for best performance according to harvesting Conditions. A variable drive controlled by an electric motor permits infinite reel speed adjustment within a certain range, ‘The reel speed adjusting motor can be activated by a ‘switch in the cab or by the reel speed control system. NOTE: Diodes (V62) and (V63) are installed only in conjunction with motor (M14). Depending on position of double sprocket (C), ree! speed ‘may be adjusted within a range of 14—30 rpm [this equals 3.26.8 kmih (2—4.2 mph)] or 2350 rpm (5.2108 kmh (3.26.7 mph)]. The reel speed control system activates the electric NOTE: The reel speed control system will only motor which controls variable reel drive. In this case ‘operate within a ground speed range from the following adjusting ranges are also obtained: 1.2 kmh (0.75 mph) to 10 km/h (6 mph). 14—30 rpm [this equals 3.2—6.8 kmih (2—4.2 mph) ‘or 22—60 rpm [5.2—10.8 km/h (3.2—6.7 mph)]. ‘T4505 (0SDEC00) 240-16T-1 Z Series Combines. PN=880Reel Speed Adjustment from Ser.No. 062722/Speed Ratio Switch $9 THEORY OF OPERATION With starter switch in position (I) or (Il), current is Stop light switch (S7) is also supplied with current. supplied to switch (S10) and ree! speed control system (At). When actuating switch (S10), relay (K32) or (K33) is activated. This will increase or reduce reel speed. With header running (wire 289 powered), a diagnostic mode is activated when turing speed ratio switch (potentiometer) (S9) to first position. The other switch positions will provide various reel speed ratios. The speed ratio switch (S9) is connected to reel speed control system (A1) by means of four wires, providing 13 possible switch positions. POSITIONS OF SPEED RATIO SWITCH S9 er | or [test | oa | 100 | 110 | 145 | 120 | 128 | 430 | 150 | 180°] 200 | 220 1 0 x 0 x 0 x 0 x 0 x 0 x 0 2 0 x x 0 0 x x oO 0 x x 0 0 3 0 x x | x |] x 0 0 0 0 x | x x x 4 0 x x x [x |x [x] x fx 0 0 0 0 NOTE: (X) means that the corresponding switch connection is grounded. ‘TM4505 (05DECOO) 240-16T-2 Z Series Combines: PNssotReel Speed Adjustment from Ser.No. 062722/Diagnostic Mode DIAGNOSTIC MODE ‘The program of the reel speed control system Provides a diagnostic mode. In this mode input and output signals of the system are tested. Diagnostic Procedure: 1. Move micro switch 1 to "ON" position (switches 2 to 5 are already "ON"). 2. Move speed ratio switch (S9) to “OFF” position, 3. Start engine; engage separator and header. 4. Drive combine with a speed of 5.5 km/h (3.5 moh), 5. At a ground speed of 5.5 km/h (3.5 mph) move speed ratio switch (S9) to test position. 6. Continue to drive combine with an exact speed of 5.5 kmih (3.5 mph) for 30 seconds. 7. Stop combine. Keep separator and header running. | Read error displays at LED's. ‘TM4505 (05DEC00) 240-16T-3 Z Series Combines PNss92Reel Speed Adjustment from Ser.No. 062722/€rror Codes ERROR CODE DISPLAY 0 —LED off X= LED on Error Code | Problem Solution A-0 | No voltage Check fuse (F12) a0 co D0 ‘=X | No ground speed signal ‘Check sending unit on 3-speed transmission Bo co Do ‘A—0 | Ground speed signal not within See “Operating Range of Reel Speed Control B-X | operating range System in "Controls and Instruments" co Section of Operator's Manual D-0 A-X | No reel speed signal ‘Check sending unit at cutting platform Bx co D-o ‘A—0 | Reel speed signal not within operating See “Operating Range of Reel Speed Control B-0 | range System” in “Controls end Instruments" c-x Section of Operator's Manual D0 A-X | Emror “Bit 1” at reel speed control 8-0 | switch cx D-0 A-0 | Error “Bit 2" at reel speed control B-x | switch cx D0 A-X | Error “Bit 3" at reel speed control BX | switch cx D-0 A-0 | Error “Bit 4” at reel speed control B40 | switch co D-x ‘TM4506 (05DECOO) 240-16T-4 Z Series Combines Ph 93Reel Speed Adjustment from Ser.No. 062722/Error Codes ERROR CODE DISPLAY (CONTINUED) 0 — LED off X —LED on Error Code | Problem Solution ‘Ax | Option A, output 1 shorted to ground BO c~0 Dx AO Option A, output 2 shorted to ground Bx co bx A-X | Reel does not accelerate Bx co ox AO Reel does not slow down AX Reel speed control switch not in ‘See “Reel Speed Control Switch” in BO diagnostic position “Controls and Instruments’ Section cx of Operator's Manual a0 Fault not found A-X | All contacts to real speed control B-X | switch open ‘TM4505 (05DECO0) 240-16T-5 Z Series Combines pyssod» OPERATING ADJUSTMENT OF MICRO SWITCHES During normal operation, micro switch 1 on board of reel speed control system is in "OFF" position, while switches 2 to 6 are in “ON” position. ‘TM4605 (0SDECO0) 240-16T-6 Z Series Combines PN=SiSReel Speed Adjustment from Ser.No. 062722/Functional Schematic, Section 19 FUNCTIONAL SCHEMATIC, SECTION 19 i: © oP SEIS STOP LIGHTS , REEL SPEED ADJUSTMENT 'S0—Potentiometer, X23—Disconn. point, cab ZX004054 X48—Disconn. point, rear ‘speed harness (W2), baste hamess (WS), ‘A18_Fuse board $10—Reol speed switch ‘front basic harness straw hood harness B5—Sending unit, eel speed X10—Connection, cab wn (wan) F12—Fuse 15 amps. Iharness (W2) to relay _X25—-Disconn. point, main __X45--Dieconn. point, cab H&S—Stop ight, board ‘distribution hamess hharnoss (W2), H44—Stop tight, X11—Connection, cab (WN), cab harness (W2) basic hares (W9) Ks2—Relay, adjust reel harness (W2) to relay —_X28—Disconn. pe x46—Disconn. point, eab speed board dist mess (W2), K33_-Relay, adjust reet X17—Connection, main (W1), cab harness (W2) front basic harness speed distribution hamess _‘X38—Disconn. point, cab way speed adjusting (W1) to fuse board ‘V62—Diode motor x21—Disconn. point, feeder V63—Diode house harness (W10), _X38—Disconn. point, cab header hamess (W22} hhamess (W2), ‘optional equipment harness (W14) crwwaconsterse. sis ‘TM4505 (05DECO0) 240-16T-7 Z Series Combines PNESOSHeo sae z suol-ov2 (oss sos 61 NOLLOaS ‘OWLVINSHOS OULSONOVIA Br canons SrRURIRS BISSUBEZIzOO NTRS Way HALEN POOAS aNGroup 15U I-A-Matic OPERATIONAL INFORMATION ‘The ground pressure once adjusted by the operator fon 900 Series cutting platforms will be kept constant by the DIAL-A-MATIC™. Three different ground pressures can be preselected by means of the rotary switch on switch console. By raising cutting platform manually the DIAL-A-MATIC™ is switched off. It is actuated again by lowering the platform manually (even for a short Period of time only), za ruacoonsn ‘esau THEORY OF OPERATION Rotary switch (S23) in switch console is supplied with ‘current via fuse (F43). By moving switch (S23) to positions 1, 2 or 3, electronic box (A2) and sending unit at cutting platform (S66) are supplied with current. ‘This preselection via switch determines which of the three center contacts in sending unit (S66) is without connection to electronic box (A2). The contact revolving in retation to cutting platform ‘ground pressure transmits a signal to the electronic control box (A2) until the revolving contact reaches the stationary contact without connection to electronic control box (A2). ‘The input signal is converted in the electronic control box (A2) and used for raising and lowering cutting platform (via wires 238 and 239), M4505 (05DECOO) 240-15U-1 Z Series Combines NASBDial-A-Matic/Testing the Dial-A-Matio TESTING THE DIAL-A-MATIC DIAL-A-MATIC test can be carried out by bridging CAUTION: It is possible during various terminals at connection (X4) to cutting DIAL-A-MATIC test that feeder house moves platform. Proceed as follows: up or down. DANGER OF ACCIDENTS. 1. Run engine at fast idle 3, Move rotary switch (S23) in switch console to position 1,2 or 3 and press switch for a short period 2. Move road safety switch to field postion. Engage _of time to lower cutting platform, Separator drive. 4. Check according to the following chart by bridging ‘connection terminals. ‘CONNECTION x4 ‘SWITCH POSTION FEEDER HOUSE 1 2 3 Bridge contacts 5 45,6 | 45,61 Feeder house rising Bridge contacts +6 ot 42 Feeder house not moving Bridge contacts 4123 | 423 3 Feeder house lowering ‘TM4505 (05DECO0) 240-15U-2 Z Series Combines PN=Sao* Dial-A-Matic/Functional Schematic, Section 20 FUNCTIONAL SCHEMATIC OF SECTION 20 Fas SS NER a aa a2. tS 26 e SE20 : DIAL_=A- MATIC : 2x004056 i ‘A2Electrone box X21—Disconnect point feeder _X27—Disconnect point main _X52-—Connection main DIALAMATIC house harness (Wi0), distribution hemes distribution harnes AIS—Fuse board cuting platform (Wi}cab wiring (Wi) tectonic box Fa3—Fuse 758, hhamess (w22} hhamess (W2) DIALAMATIC S2I—DIALAMATIC switch _X23-Disconnect point front X38—Disconnect point cab S65—DIALAMATIC sending sie wiring harmo unit (W7)-cab witing X18—Conneetion main hamess (W2) wiring harness (W14) distribution harness (01 to fuze boara ‘TM4505 (05DECOO) 240-15U-3 Z Series Combines PN=60002 NOUDAS 40 OLLVWaHOS SUSONOWIC (2 WaOG BSURIS HOOGATOA VETSeparator, Harvesting Unit to Ser.No. 062721 Group 15V OPERATIONAL INFORMATION By moving road safety switch to field position all hydraulic functions (including all hillmaster functions) ccan be used, At the same time fan in front of radiator is rotating Now separator and rear work lights can be switched on as well AA safety device prevents the separator from being switched on when road safety switch is moved to field position. With separator engaged, harvesting unit can be engaged as well A similar safety device prevents that the harvesting Unit is engaged at the same time separator switched on. THEORY OF OPERATION supplied with current from terminal (D+) of alternator via fuse (F48). When switching to field position, relay (K12) is activated and wire (222) is supplied with current, With switch ($33) in neutral position, relay (K21) has been activated. When separator drive is engaged, relay (K21) is kept in position and wire (202) is supplied with current. Solenoids (¥22) and (¥23) are now supplied with current via fuse (F23). The hydraulic cylinder activated by the solenoids tensions the separator drive V-belt. Harvesting unit is basically engaged in the same way as the separator. ‘The time delay relay integrated in the circuit is not used. Harvesting unit is directly engaged and disengaged via switch (S34). ‘Actuating emergency cut-off switch interrupts the input signal of wire (198) to time delay relay. Wire (289) is without current supply and harvesting unit drive is interrupted by the electromagnetic clutch. NOTE: Interruption of wire 259 or connection of ferminal (S) to ground causes harvesting unit to be disengaged 5 seconds after engagement. zacrwaconorrs sos ‘TM4505 (0SDECOO) 240-15V-1 Z Series Combines NabeSeparator, Harvesting Unit to Ser.No. 062721/Functional Schematic, Section 21 FUNCTIONAL SCHEMATIC OF SECTION 24 BRRRE ve Yes ast i i = ol ! =a i SEPERATOR , HEADER CLUTCH RADIATOR CLEANER MOTOR anes At4 —Relay and diode board V2. —Diode, pressure switch X24 ~Conn.solenotd valve block X37 —0i ‘R15 —Fuso board X10 —Connection eab harass rear basic harness (W8) F19 —Fuse 30a (W2}-lay board X25 ~Disconnect point main Fai —Fuse 154 X11 Connection cab hamess distribution harness (WI) X44 —Disconnect point cab har- F23 —Fuso 15A (W2}-clay board scab harness (W2) ness (W2)-rar basic, #2 Rely, field operation. X12 —Connection cab harness X26 —Disconn. point main dis- harness (W9) road travel (W2}relay board tribution hamess (Wf)- X45 —Disconnect point cab har- 21 —Relay, separator clutch X17 Connection main dist cab hamess (W2) ‘ness (W2)-ear basi har- K35 —Time delay relay, bation harness (W}-- X28 Disconnect point main ness (W9) eutting platform sive fuse board distribution harness (Wt) X62 —Disconnect point rear ba- ‘12 —Radlator cleaner motor X18 —Connection main distr- se harness (W3)-angine ‘831 —Road safety suiten bution harness (Wt) hhamess (#12013) ‘833 —Separator drive switch fuse board X117 Conn, main dation S34 “Harvesting unit dive X23 ~Disconnect point cab hamess (W1)use board sivitch hhamess (W2}front- X36 —Conn. mastor control le- 22 —Solenoidengage seperator 847 —Emergency cutoff switch bate harness (7) hhamess (WS) Y23 —Solenoid.engage separator Y36 Harvesting unit clutoh ‘TM4505 (05DECO0) 240-15V-2 Z Series Combines ed¥2 NOLLOaS 4 OUYWaHDS OUSONOVIG Te Wises SIEUOLOS SIROUERTTELEO CNRS OI Bae IRSSeparator, Harvesting Unit to Ser.No. 062721/Diagnostic Schematic, Section 21 “Twas05 (05DEC00) 240-15V-4 Z Series Combines PN=608Group 16V Separator, Harvesting Unit, from Ser.No. 062722 OPERATIONAL INFORMATION By moving road safety switch to field position all With separator engaged, harvesting unit can be hydraulic functions (including all hillmaster functions) engaged as well ‘can be used. At the same time fan in front of radiator is rotating. A similar safety device prevents that the harvesting unit is engaged at the same time separator is Now separator and rear work lights can be switched switched on. on as well A safety device prevents the separator from being ‘switched on when road safety switch is moved to field position. ‘TM4505 (05DECO0) 240-16V-1 Z Series Combines PN=60SSeparator, Harvesting Unit, from Ser.No. 062722/Theory of Operation THEORY OF OPERATION With engine running, the road safety switch is supplied with current from terminal (0+) of alternator via fuse (F48). When switching to field position, relay (K12) is activated and wire (222) is supplied with current, With switch ($33) in neutral position, relay (K21) has been activated. When separator drive Is engaged, relay (K21) is kept in position and wire (202) is supplied with current. Solenoids (¥22) and (¥23) are now supplied with current via fuse (F23). The hydraulic cylinder activated by the solenoids tensions the separator drive V-belt. Harvesting unit is basically engaged in the same way as the separator. ‘The time delay relay integrated in the circuit is not used. Harvesting unit is directly engaged and disengaged via switch (S34). Actuating emergency cut-off switch interrupts the input signal of wire (198) to time delay relay. Wire (288) is without current supply and harvesting unit drive is interrupted by the electromagnetic clutch. NOTE: Interruption of wire 259 or connection of terminal (S) to ground causes harvesting unit to be disengaged 5 seconds after ‘engagement. ‘TM4505 (05DECOO) 240-16V-2 Z Series Combines pd‘Separator, Harvesting Unit, from Ser.No, 062722/Functional Schematic, Section 21 FUNCTIONAL SCHEMATIC OF SECTION 21 ! 4 Sa si ke ae | a | S| Ea 2 a a SE2T 5 SEPERATOR , HEADER CLUTCH , RADIATOR CLEANER MOTOR 7X004058 A14 —Relay and diode board V2. —Dlode, pressure switch X24 —Conn.solenoid valve block X37 —Disconn. point cab he ‘A1S —Fuse board X10 —Connection cab harness -rear basic harness (WS) ness (W2)-switch console F19 —Fuse 30 (W2}relay board X25 —Disconnect point main ‘hares (W3) F21 —Fuse 154, X41 Connection cab hamess distribution hamess (W1) X44 —Disconnect point cab har- F23 —Fuse 15 (W2}-relay board scab hamess (W2) ‘ness (W2)-rear basic 12 —Rolay, field operation- X12 Connection cab hamess. X28 —Disconn. point main dis- hharness (W9) road travel (W2)-relay board tribution hamess (W1)- X45. —Diseonnect point cab har- 21 —Relay, separator clutch X17 —Connection main distri- ‘cab harness (W2) ness (W2}rear basic har- 35 —Time delay relay, bution harness (W1)- X28 —Disconnect point main ness (W9) ‘cutting platform drive fuse beard distribution harness (W1) X62 —Disconnect point rear b 12 —Radiator cleaner moter X18 Connection main distri- scab harness (W2) sie harness (W9)-engine ‘831 —Road safety switch bution harness (W1)- X35 —Disconnect point cab hhamess (W12IW13) ‘833 —Separator drive switch fuse board harness (Wa X417 —Conn, main distribution ‘834 —Harvesting unit drive X23 ~Disconnect point cab hhamess (WS) switch harness (W2}front X36 Conn, master control le- 22 —Solenoid,engage sey ‘S47 —Emergoncy cut-off switeh basic harness (W7) ver-armrest harness (WS) Y23- —Solenoid,engage sep: ‘Y84 Harvesting unit clutch ‘TM4505 (05DECOO) 240-16V-3 Z Series Combines PN=608Wz Nouoas ‘oUWWaHOS OUsONOvIG Fe Woes SHEURAS SISSLBBOCELEDD ONIRS Way Ta BUIEOAEH VOTING* . Group 15W Infotrak Monitor, Speed Monitoring System 47 OPERATIONAL INFORMATION, INFOTRAK-MONITOR - With starter switch in position (|) the infotrak monitor _All important separator drives are monitored by the is ready for operation. Speed monitoring system for decreasing of speed. An optical and an acoustical signal indicate the operator ‘The infotrak monitor is identical with the ones in other if the speed drops below a cortain level John Deere products, By the input of certain specific machine data the infotrak monitor is adjusted to the combine's needs. ‘TM4505 (0SDECOO) 240-15W-1 Z Series Combines PNS6iOInfotrak Monitor, Speed Monitoring System/Specific Machine Data INPUT OF SPECI IC MACHINE DATA IMPORTANT: Each time different size drive wheels are installed or tire radius changes due to wear, the infotrak monitor must be calibrated accordingly. This will also ensure correct area counter operation. Activate Input Status Press key combination (C + D) and simultaneously turn starter switch from position (0) to position (I). The position indicator wil move to upper left-hand position. Data Input Press key (C): displayed value will increase. Press key (E): displayed value will decrease. Data Storage Press key combination (D + F). At the same time the Position indicator will move to another field (upper right-hand, lower right-hand, lower left-hand field). Deactivate Input Status After input and storage of all data, turn starter switch to position (0). A y 3 a ‘A-Position indicator Display pane! ‘G—Key for ground speed display D—Key for cylinder speed display E_Key for engine speed display Fey for fan speed display MACHINE CODE Input code for mph: 03 — Combine Input code for kin: -, {2 23 — Combine | tT) 48 att |e zxo024ss j ‘M4505 (05DEC00) 240-15W-2 Z Series Combines pNeettInfotrak Monitor, Speed Monitoring System/Specific Machine Data TRANSMISSION SPEED RATIO CODE (00 — Final drive (85/11) 212231 (I) 01 — Final drive (97/11) 212282 (il) 02 — Planetary final drive Final deve 28/14 Final deve 9744 2x 000 843, TIRE RADIUS CODE For-input of tire radius code, use actual tire radius. On machines with machine code 03 the radius must be keyed in in inches. On machines with machine code 23 the radius must be keyed in in millimeters. NOTE: Refer to the tire chart in the operator's manual (Section “Wheels and Axles’) for tie radius. Radius can also be determined by proceeding according to the following instructions. 2x 000 532 _Dcroezoonsrea 0 nse ‘TM4505 (0SDECO0) 240-15W-3 Z Series Combines PNeet2Infotrak Monitor, Speed Monitoring System/Specific Machine Data DETERMINING TIRE RADIUS Requirements: + Combine on solid ground * Correct tire pressures * Combine steering wheels in straight-ahead position Mark tire and ground with dashes. Drive combine until marked tire has completed one revolution, ‘Transfer tite mark to ground, Measure distance (x) between ground marks. Divide measured distance (x) by 6.28. The value obtained is the tire radius for infotrak monitor input. en ENGINE IMPULSE CODE 24 — 2054 combine 27 — 2056-2066 combines om ‘TM4505 (05DECOO) 240-15W-4 Z Series Combines eNest3Infotrak Monitor, Speed Monitoring System/Error Codes ERROR CODES, INFOTRAK-MONITOR ‘The cause of a machine matfunction may be a broken wire etc. As soon as the infotrak monitor displays a three digit ‘umber followed by an “E* a malfunction or error of the operator is indicated. Error code Problem Solution OIE | Counter of engine operating hours in Replace infotrak monitor infotrak monitor is defective 102 — | Counter of working hours in Replace infotrak monitor infotrak monitor is defective 422E | Concave adjustment impossible, Voltage between pin 4 and 9 on infotrak monk Sensor signal in wrong range (too low) | tor not between 1 aind 4 Volts, wire on potentio- meter (R2) may not be correctly connected 123E | Concave adjustment impossible, Voltage between pin 4 and 9 on infotrak moni Sensor signal in wrong range (too high) | tor not between 1 and 4 Volts, wire on potentio- eter (R2) may not be correctly connected 428E | No reaction from infotrak monitor Check data lines 268 and 260 for correct connection, malfunction of infotrak monitor possible 429 | No reaction from control board Check data lines 268 and 269 for correct connection, possibly control board of machine ‘computer defective 130 | Adjusting motor can not reduce fan speed | Check fuses FS, F25 to the desired pm 131E | Variator can not reduce cylinder speed | Check fuse F3 to the desired mpm 1326 | Adjusting motor can not reduce concave | Check fuse F471 clearance to desired gap 135 | Adjusting motor can not increase fan speed Check fuses F3, F25 to the desired rpm 136E | Variator can not increase cylinder speed | Check fuse F3 to the desired rpm 137E | Adjusting motor can not increase concave | Check fuse Fat Clearance to desired gap 240-15W-5 Z Series Combines Passe ‘TM4505 (05DECO0)Infotrak Monitor, Speed Monitoring System/Operational Information, Speed Monitoring System 2 OPERATIONAL INFORMATION, SPEED MONITORING SYSTEM For better monitoring of drive systems the machines are equipped with a speed monitoring system. The following speeds are monitored: “Cylinder speed + Fan speed * Clean grain elevator + Tailings elevator * Cross shaker + Straw chopper + Chaff spreader NOTE: Cylinder and fan speeds are monitored via infotrak monitor, THEORY OF OPERATION Impulse pick-up units are installed at tailings elevator, clean grain elevator, cross shaker, straw chopper and chaff spreader shafts. On the shafts magnet rings are attached which influence the impulse pick-up units. If speed of one shaft drops to below 65% of rated shaft speed, the corresponding indicator light is ‘connected to ground and the buzzer sounds. If shaft speed exceeds 85% of the rated speed, the corresponding alarm is switched off again. Shaft alarm speeds are: Clean grain elevator 370 rpm Tailings elevator 300 rpm Cross shaker 240 rpm Straw chopper 1730 rpm Chaff spreader 130 rpm NOTE: If straw chopper or chaff spreader are disengaged, the additional switch (S24) or (S26) switches off the speed monitoring system for the shaft concerned. ‘TM4505 (0SDECOO) 240-15W-6 Z Series Combines PNETInfotrak Monitor, Speed Monitoring System/Functional Schematic, Section 22 FUNCTIONAL SCHEMATIC OF SECTION 22 bee FSI | ae + itd SEaD TNFOTRAK MONITOR. SPEED MONITORING SYSTEM ‘A-Eloctronie speed .B30—Fan speed sending unit ‘monitoring syetem K10—Relay, fan speed alarm At4—Relay and diode board _K11—Rolay, cylinder speed ‘A15—Fuse board ‘alarm ‘A18—Infotrak monitor $24—Speed monitoring B6—Ground speed sending ‘switch, straw chopper unit x12—Connection eab har- B16—-Straw chopper speed ness (W2)relay and diode board X13—Connection cab hare ‘sending unit ness (W2}-relay and '818—Cross shaker speed ‘lode board sending unit X18—Connection m: B18Clean grain elevator distribution harness ‘peed sonding unit B20—Chaff spreader speed x28—Disconnect point main distribution hare ness (W1}cab har- ness (W2) x27—Disconnect point main dlstrbution har. ress (W1}-cab hare ness (W2) 28—Disconnect point main distribution har ess (W1)-eab har- ness (W2) Xt4—Disconnect point cab hhamess (W2)-ear basic harness (WS) x45—Disconnect point cab ‘zx004069 X49—Disconnect point cab hhamess (W2}-comer post hamess (WA) X50—Connection main alstribution har- ness(Wi}-electronic ‘speed monitoring system x62—Disconnect point rear basie hamess (W9)-2n- gine harness (wants) Xr1—Disconnect point rear ‘sending unit basle harness (W9)- hhamess (Wv2)rear B28—Engine speed sending chopper harness (W25) basic harness (WO) unit x23—Disconnect point cab X46—Disconnect point cab 1B20Cylinder speed sending hharnoss (W2}ront hhamess (W2)-ront wit basic harness (W7) basle hamess (W7) ‘TM4505 (0SDECO0) 240-15W-7 Z Series Combines PNBBuco spo 2 SMGL-OFZ (coo3as0) sosvnu 2 NOUS JO OUWWSHDS DULSONOVIG 22 WaoG BIOUSIAS SFOIERGUSTS Baan Baas TOO AATGroup 15X Harvest Performance Monitor OPERATIONAL INFORMATION ‘Sensors are located at the end of the cleaning shoe and straw walkers which record the amount of grains falling on the sensor surface, Ground speed is measured by sensor (F) and light conditions (day/night) and moisture by sensor (C).. ‘Once these factors have been taken into account, the loss rate is shown at display unit (D). Display unit (D) indicates the loss level in relation to the level that is acceptable to the user. ‘The performance monitor enables the operator to use ‘maximum combine capacity within the performance range selected by him. After the operator has adjusted the combine and cutting platform to suit the harvesting conditions, he must set the monitor to | these conditions by means of the adjusting/selecting unit (E). ‘TM4505 (05DECO0) 240-15X-1 Z Series Combines PeeteHarvest Performance Monitor/Operational Information HARVEST PERFORMANCE MONITOR Ae ; ; ee ; i ee ee tee ees pei | Feral _zxownzcoomsrs. 9813402 ‘TM4506 (05DECO0) 240-15X-2 Z Series Combines. pNsei9‘ Harvest Performance Monitor/Operational Adjustment OPERATIONAL ADJUSTMENT OF HARVEST PERFORMANCE MONITOR While threshing, adjust potentiometers (A) and (B) so that needle of display unit (C) moves to the center of the green sector (X) at a given, accepted loss level. | Set potentiometer for straw walker losses: + Move selector switch (D) to position (Il) + Use potentiometer (A) to bring the needle into the green sector (X). l— Set potentiometer for cleaning shoe losses: + Move selector switch (D) to position (Il). + Use potentiometer (B) to bring the needle into the green sector (x). ‘A—Potentiometer, straw walker sensitivity ‘B_Potentiometer, cleaning shoe sensitivity (c—Display unit Selector switeh X-Green sector 5 5 a zx 002872 ‘TM4505 (0SDECO0) 240-15X-3 Z Series Combines PNE620Harvest Performance Monitor/Operational Adjustment SETTING SENSOR SENSITIVITY A-Switch for grain size Setting at straw walker ° e|o@. x Y Z BSwitch for grain size X-Highor sensor sensitivity ‘Setting at cleaning shoo for fine grain crops sensor ‘Y_Medium sensor sensitivity for medium grain crops. Z-Lowor sensor sensitivity for coarse grain crops, ‘TM4505 (05DECO0) 240-15X-4 Z Series Combines paceztHarvest Performance Monitor/Operational Check OPERATIONAL CHECK OF HARVEST PERFORMANCE MONITOR A CAUTION: Before carrying out the operational check, remove fuse F23. This prevents the separator from being engaged while at the same time ensuring that the harvest performance mor supplied with power. Start the engine. Put road safety switch in field position. Move separator switch to ON position. — Check straw walker sensors: + Tum potentiometer (A) clockwise as far as it will go. + Set selector switch (B) to position (Il) (straw walkers). + Rotary switch (C) should be in the medium position at both sides. + Actuate the left and right straw walker sensors by tapping them lightly with a hard object or by dropping kernels on them. A second person is required to observe the needle at the display. The needle must be seen to move. Il — Check cleaning shoe sensor: + Tum potentiometer (D) clockwise as far as it will go. + Set selector switch (B) to position (Ill) (cleaning shoe). + Tumbler switch (E) should be in the middle position, + Check cleaning shoe sensor in the same way as the straw walker sensors. * Switch on the parking light and check whether the display light is on. + Switch off the parking light. Disengage the separator and remove the switch key. + if fault occurs during the check described above, rectify the fault as necessary. NOTE: Once the operational check is completed, put fuse F23 back in place. eter, straw walker sensitivity, ‘switch C—Rotary switch D-Potentiometer, cleaning shoe sensitivity Tumbler ewiteh ‘TM4505 (05DECO0) 240-15X-5 Z Series Combines PNs622Harvest Performance Monitor/Functional Schematic, Section 23 st performance F38—Fuse, 7.5 amps. 'B3 —Light sensor B21—Straw walker sensor, fight 522—Siraw walker sensor, '823Cleaning shoe sensor (6 walkors) FUNCTIONAL SCHEMATIC OF SECTION 23 F38 522 823/824 x87—Splice walker sensor, right X98—Connection, cleaning ‘shoe sensor TM4505 (05DECO0) SEBS HARVEST PERFORMANCE MONITOR ‘2x004071 '824—Cleaning shoe sensor _X43Disconnect point, (6 walkers) rear basic harness, X18—Connection, distribution (wi), hhamess (W1) to fuse straw hood harness board (wo) X25—Disconnoct point, X44—Disconnect point, distribution harness ‘cab harness (W2}, wa, rear basic harness (W9) ‘cab harness (W2) x86—Splice 240-15X-6 Z Series Combines fdFetiques saves 2 EXSL-0ve. (093080) sosen za tea ya /sae ex zor bb cox 503s 220s HU, ' 1 v | g—ertess 1 ' i §&% NOUS 4O OULVWSHOS SUSONOvIA _E uaiag SIRENS SOLER AIA SURURRAGHarvest Performance Monitor/Diagnostic Schematic, Section 23, ‘TM4505 (05DECO0) 240-15X-8 Z Series Combines... Group 15Y Hillmaster Leveling System OPERATIONAL INFORMATION ‘Two switches for Hillmaster leveling system operation are provided in the switch console. Switch (B) is used as selector switch. Depending on switch position, the system operates manually, automatically or the combine may be lowered for driving on public roads. ‘Switch (A) is used to tit the machine manually to the right or left. With selector switch (B) in position (II), hydraulic oil from the retracting cylinder is routed to the hydraulic oil reservoir when tilting combine to the right or left. Dereaccreote 6 Tt THEORY OF OPERATION With road safety switch in field position and engine running, power is supplied to switches ($50) and (S51) via fuse (F29). When actuating switch (S50), solenoids (Y12) or (Y13) are activated. Pressure valve (Y7) is also activated via relay (K9). In addition, solenoid (Y20) Is activated with selector switch (S51) in position (T) to lower the combine. With selector switch (S51) in position (M), leveling control box (A8) is supplied with power. The output signals of the leveling control box also activate solenoids (Y'12) and (Y13) and pressure valve (Y7). When maximum tit is reached, end switch (S59) or (860) changes position and the indicator light in the cab will glow. ‘TM4505 (05DECOO) 240-15Y-1 Z Series Combines PNs6esHillmaster Leveling Syster/Functional Schematic, Section 24 FUNCTIONAL SCHEMATIC OF SECTION 24 $60 Oe va7 i Lewifis me q va6. a Teh ld ysl ys0 bald a2, | fro [rs | vie "7 SH |p t ot rt t 4 aa wee [ieee | ge ie : ‘SEDa i HILLMASTER LEVELING SYSTEM ° 7x005249 0g g & ‘AB —Loveing contol box V2 —Diode X37 —Disconnect point, X76 —Dieonnect point, ‘A14—Rolay and diode board VSS —Dlode ab harness (W2), cab hamess (2), 1815 —Fuze board ¥55 —Dioee ‘witch cons omer post harness F29 Fuse, 16 amps. X8 Connection, oab hhamess (¥3) ws). 550 —Manal leveling hhamess (W2) to relay X47 —Disconnect point, X88 Disconnect point, control switch and dlode board distribution harness cab harness (2), 851 —Leveling control X10 “Connection, cab wn, Switch console ‘wit, harness (W2) to rolay Hitmaster hamess harness (3) ‘utomaticrmanual and diode board 29) X159—Connection, Hilmastor S59 —End switch, leveling to X11 —Connection, cab X14 —Connecton, Hilmastor hhamess (Wz) to the tot thames (W2) to ralay hammess (W25) to Toft ond itch S60 —End switch, leveling to and diode board solenoid valve block X160—Connection, Hillmastar the ght x18 —Connection, X15 ~Connecton, ilmastor hares (W720) to Vt Diode distribution harness hhamoss (W129) to fight end switch 46 —Diods (Wt) to fuse board Iovaling control box a7 —biods x27 —Disconnoct point, dlotibution harness ow, ab harness (W2) ‘TM4505 (05DECO0) 240-15Y-2 Z Series Combines PNssa7tr sos 2 Sast-ove (¢203050 soo #2 NOUDAS JO OUVWSHOS SUSONOVIC FE CaaS SIRNAS BROOEOTOONTS BapaT CNHillmaster Leveling System/Diagnostic Schematic, Section 24 ‘TM4505 (05DEC0O) 240-15Y-4 Z Series Combines PN=629» Group 152 Separator Adjustment to Ser.No. 062721 OPERATIONAL INFORMATION ‘The concave and threshing cylinderifan speeds may be adjusted by means of rocker switches in the cab, Current cylinder speed may be displayed at the Infotrak monitor. When adjusting concave spacing, the corresponding value is also displayed at the Infotrak monitor. NOTE: Separator must be running when adjusting oylinder and fan speeds. THEORY OF OPERATION Adjusting threshing cylinder speed: With separator engaged, power is supplied to switch (S40) via fuse (F8). When actuating the switch, relays on board (A11) are activated, which in turn activate solenoids (28) or (Y29) and provide hydraulic adjustment of cylinder variable drive, ‘Adjusting fan speed: With separator engaged, power is supplied to switch (S41) via fuse (F8). When actuating the switch, relays on board (A11) are activated which in turn activate relay (36) or (K37). Motor (M9) will then adjust variable fan speed drive. ‘Adjusting concave: With starter switch in position (1), power is supplied to switch (S36) via fuse (F41). When actuating the switch, motor (MB) is activated via relays on board (A11). Motor (MB) is used for concave adjustment. Potentiometer (R2) integrated in motor (MB) will transmit the concave spacing value to the Infotrak monitor. ‘TM4505 (0SDECO0) 240-152-1 Z Series Combines PN=630‘Separator Adjustment to Ser.No. 062721/Functional Schematic, Section 264 FUNCTIONAL SCHEMATIC OF SECTION 254 peel Bret ‘SEDEA CYLINDER CONCAVE FAN ADJUSTMENT ‘Att Relay board, combine data center ‘At4 Relay and diode board ‘A15 —Fuse board F8 —Fuse, 7.5 amy F11 —Fuso, 30 amps. F20—Fuse, 7.5 amps. Fat —Fuse, 15 amps. K96 —Relay, adjust fan ‘S41 —Switeh, fan speed adjustment vi0 Diode 9 —Connoction, cab ‘harness (WW2} to relay ‘and diode board X17 Connection, “distribution hamess (Wt) to fuse board (Wt), cab harness (wy ‘x21 —Disconneet point, tistrbution harness (W1), cab harness x28 7x005250 x40 —Connection, °—O >—O) ‘TM4505 (05DECOO) 240-15AA-10 Z Series Combines PNesa7Separator Adjustment, Combine Data Center to Ser.No. 062721/Setting Combine Data Center and Area Counter SELECTING COMBINE DATA CENTER UNITS + Turn starter switch to position (1). Combine data center will switch to area counter (X). + Press "PAGE" key. Combine data center will switch to display (Y). + Press "PAGE" key. Combine data center will switch to setting unit (Z). zxo0n028 Romo semuase [TMa505 (0SDECO0) 240-15AA-11 Z Series Combines PNeaS‘Separator Adjustment, Combine Data Center to Ser.No. 062721/Setting Combine Data Center and Area Counter SELECTING AREA COUNTER FUNCTIONS + Select “Area Counter" unit. Light of “Area function will glow. ‘The harvesting area (for each day) is displayed. + Press “Down” key. Light of “Total Area” function will glow. The total harvesting area is displayed. + Press "Down" key. Light of "Header Width" function will glow. Header width (cutting width) is displayed. NOTE: Running through the various crop displays or setting unit functions is done in a similar way as dascrived above. 3 002519 2 Peouuzcontosssanuse ‘TM4505 (05DECO0) 240-15AA-12 Z Series Combines a9* ‘Separator Adjustment, Combine Data Center to Ser.No. 062721/Setting Combine Data Center and Area Counter CLEARING “AREA” DISPLAY + Select ‘Area Counter” unit * Select “Area” function. x The harvesting area for the day will be displayed. + Press key (C) ("Clear"). ha) Display will change to “zero” {2} s 8 8 S 3 s ‘TM4505 (05DECO0) 240-15AA-13 Z Series Combines PN=850‘Separator Adjustment, Combine Data Center to Ser.No. 062721/Setting Combine Data Canter and Area Counter CHANGING HEADER WIDTH + Select “Area Counter” unit + Select "Header Width function. ‘The current header width (cutting width) will be displayed, + Press “Modify” key (M). ‘An °M" will appear at the left of the display. + Press "Up" or “Down* key. * Press key (M) again. The displayed setting is saved; the *M" at the left of the display will disappear. NOTE: After pressing the °M" key, it always possible (M4 to interrupt the setting of the new header width by pressing “Cancel” key (C). The previous ‘hoader wiath will be displayed once again. o ‘The changed header width will be displayed Prowwzcoonnese 200082 TMA505 (050EC00) 240-15AA-14 Z Series Combines PN=tst‘Separator Adjustment, Combine Data Center to Ser.No. 062721/Setting Combine Data Center and Area Counter SETTING PARTIAL HEADER WIDTH + Select "Area Counter" unit. + Select "Header Width" function. ‘The current header width will be displayed. + Press "Calibrate" key (C). "3/4" will be displayed = 3/4 of the previous header width (cutting width). + Press “Calibrate” key (C). "1/2" will be displayed = 1/2 of the previous header width (cutting width). + Press "Calibrate" key (C). “1/4” will be displayed = 1/4 of the previous header width (cutting wiath).. + Press “Calibrate” key (C). The cutting width saved previously will be displayed. ‘zx 002522 THa605 (05DECOO) 240-15AA-15 prouarzcoones 8204182 Z Series Combines PN=Bs2Separator Adjustment, Combine Data Center to Ser.No. 062721/Setting Combine Data Center and Area Counter ‘SELECTING LANGUAGE + Press “Page” key while turning starter switch to position (I). The language saved previously will be displayed, + Press "Up" or “Down” key until desired language is displayed. + Press “Memory” key (M), + Tum starter switch to position (0) The desired language is saved. 2x 002523, ‘TM4505 (05DECO0) 240-15AA-16 Z Series Combines nessSeparator Adjustment, Combine Data Center to Ser.No. 062721/Setting Combine Data Center and Area Counter SELECTING CROP NOTE: This procedure is required to start automatic settings and to change to a different crop. + Select "Display" unit. The crop selected previously will be displayed. + Press "Up" or “Down key until desired crop is displayed, + Press “Modify” key (M). A flashing “MP will appear at the left of the display. + Press key (M) again. The selected crop is saved; the “M" atthe left of the display will disappear. NOTE: After pressing the “M" key, it is possible to Interrupt crop selecting procedure by pressing “Cancel” key (C). ‘zx 002528 zxouvzcomnots. 820042 ‘TM4505 (05DECO0) 240-15AA-17 Z Series Combines Psese‘Separator Adjustment, Combine Data Center to Ser.No. 062721/Setting Combine Data Center and Area Counter * AUTOMATIC MACHINE SETTING ACCORDING TO CROP SELECTED + Separator must be engaged. + Switch on function “Automatic Machine Adjustments” + Select “Display” unit ‘The selected crop will be displayed + Press "AUTO" key. Lights of functions — Cylinder speed — Fan speed — Concave spacing and — Automatic operation ("AUTO") will glow until the corresponing setting is completed. After setting procedure for all functions is completed, the “AUTO" light will go out. NOTE: It is possible to interrupt setting procedure by pressing "Cancel" key (C). 2x 002525, re a COR zounzo0en en 820482 TM4505 (05DECO0) 240-15AA-18 Z Series Combines PNS88SSeparator Adjustment, Combine Data Center to Ser.No. 062721/Setting Combine Data Center and Area Counter CLEARING CROPS CREATED BY THE OPERATOR: * Select “Display” unit. + Select crop to be cleared (ending with a number "2 or named “CROP2'—"CROPS"), + Press “Clear” key (C) for 2 seconds. For 2 seconds, a °C" will appear at the left of the display. Display will change to crop version ending with a number “1”. CCORN2) | i ] i i ‘TM4505 (05DECO0) 240-15AA-19 Z Series Combines edSeparator Adjustment, Combine Data Center to Ser.No. 062721/Setting Combine Data Center and Area Counter READING SETTINGS FOR SELECTED CROP + Select “Display" unit. The previously selected crop will be displayed | + Select “Setting Unit” function. + Select "Cylinder Speed” function. The cylinder speed for the selected crop is displayed. + Select “Fan Speed" function. The fan speed for the selected crop is displayed. NOTE: The remaining settings may be displayed in the same way. { N 8 g § ‘TM4505 (05DECO0) 240-15AA-20 Z Series Combines Nao?Separator Adjustment, Combine Data Center to Ser.No. 062721/Setting Combine Data Center and Area Counter CHANGING CROP SETTINGS (Crops Created by the Operator) + Select “Display” unit The previously selected crop will be displayed. + Select “Setting Unit’ function + Select “Cylinder Speed” function. ‘The cylinder speed for the selected crop is displayed. + Press "Modify" key (M). ‘An."M" will appear at the left of the display. NOTE: At this time itis possible to interrupt changing procedure by pressing “Cancel” key (C). + Press key (M) again. The crop created by the operator is saved (Indicated by ‘2 behind the crop name); the “M” at the left of the display will disappear. NOTE: The values for the remaining functions are ‘changed in the same way. + Press “Up” or “Down” key until desired display appears. 2x 002528, :TM4505 (0SDECOO) 240-15AA-21 Z Series Combines NESE.‘Separator Adjustment, Combine ‘Data Center to Ser.No. 062721/Setting Combine Data Center and Area Counter INDIVIDUAL SETTING OF CHANGED VALUES (AUTOMATIC SETTING) + Separator must be engaged + Switch on function “Automatic Machine Adjustments" + Select “Setting Unit" function. + Select “Cylinder Speed" function. The corresponding value is displayed. + Press “AUTO key. ‘The light of the selected function and the “AUTO” light will glow during automatic setting procedure. Nort is possible to interrupt setting procedure by pressing “Cancel” key (0). 2x 002520 icunacccntees ozone M4505 (0SDECO0) 240-15AA-22 Z Series Combines PN=BES‘Separator Adjustment, Combine Data Center to Ser.No. 062721/Theory of Operation THEORY OF OPERATION Manual adjustments of cylinder speed, fan speed and ‘concave spacing are identical with the procedures described in Group 240-152. These adjustments may be performed automatically by means of the combine data center. ‘The relays on the relay board are activated by control board (A8) via connecting wires. Control board (A9) land combine data center (A5) are connected to the Infotrak monitor via data transfer wires (268) and (269). Wire 038 transmits the signal from the header height sending unit to the combine data center. Wire 304 transmits a signal from switch (S55) during reverse travel to switch off the area counter. NOTE: The infotrak monitor displays error codes in case of combine data center malfunctions. zerwsatcones tos7086 ‘TM4505 (05DECOO) 240-15AA-23 Z Series Combines PN=Be0{oco2aso) Sosy ‘9z NODS 40 OLLYWAHOS TWNOILONNS "BEE URS BIEURINS URIPUNAZZEBD CNRS GRD PEO BUFORD TOUIETDY THEEISSeparator Adjustment, Combine Data Center to Ser.No. 062721/Diagnostic Schematic, Section 258 ‘TM4506 (05DECO0) 240-15AA-26 Z Series Combines PNte83Separator Adjustment, Combine Data Center from Ser.No. 062722 Group 16AA OPERATIONAL INFORMATION ‘The combine data center integrated in the righthand armrest essentially consists of an area counter and a system for automatic separator adjustments. ‘Area counting is based on travel distance during harvesting and cutting width. Automatic settings are performed depending on the type of crop selected on the combine data center, AA data or signal transfer takes place between the mentioned components. Actual settings (speeds, clearances) and error codes (in case of malfunctions) are displayed on the Infotrak monitor. ‘TM4505 (05DECOO) 240-16AA-1 Z Series Combines PNaBes* ‘Separator Adjustment, Combine Data Center from Ser.No. 062722/System Components x 002087 ‘A—Combine data center BoInfotrak monitor adjustments only) ‘TM4505 (0SDECOO) ESTO RTT A oF TTT D-Relay board E—Combine (sensors, ‘Switches, solenoids, motors) 240-16AA-2 SYSTEM COMPONENTS (“AREA COUNTER” AND “AUTOMATIC SEPARATOR ADJUSTMENTS”) Z Series Combines PN=BeS anaesSeparator Adjustment, Combine Data Center from Ser.No. 062722/Combine Data Center COMBINE DATA CENTER With starter switch in postion (), the combine data | center is ready for operation Functions: ‘A-Gontrots (6 keys) XeArea counter Y—Display (6 cigs) Z-Setting unit CONTROL KEYS + Cancel Automatic function (AUTO) E-Page change ram 2x 002404 M Keys A and B These keys are used to run through the various A functions of area counter, display panel or setting unit. If “Modify” mode is activated by pressing key (M), displayed values may be increased or decreased at given inorements by pressing these keys. VV B zx002513 Diowaconsensezannse ‘TM4505 (05DECO0) 240-16AA-3 Z Series Combines P86» Separator Adjustment, Combine Data Center from Ser.No. 062722/Combine Data Center Key c This key is used to-set data center displays to “zero” (e.g. area, header width) and to clear crop settings created by the operator. This key is also used to interrupt automatic settings, to leave the automatic or modify mode and for input of partial header width. o= a i zx002516 _zaownznomnst 1820092 Key D ‘This key is used to activate automatic functions for setting combine components according to the values of the previously selected crop (cylinder speed, fan speed and concave spacing). During the setting procedure, the "AUTO" light of the setting unit will glow. The light will go ‘out as soon as the setting procedure is completed. NOTE: During the setting procedure, the automatic mode may be left by pressing key (C). AUTO) ° 7002517 zx002516 a Key E ‘This key is used to “jump" from one unit of combine data center fo another: + From area counter to display + From display to setting unit + From setting unit back fo area counter This key is also used for the "Select Language” mode. (T] ‘TM4505 (05DECO0) 240-16AA-4 Z Series Combines pwcestSeparator Adjustment, Combine Data Center from Ser.No, 06272/Combine Data Center Key M If a certain setting (e.g. fan speed for a crop version created by the operator or header width) is to be u changed, select the corresponding function and press key (M). Now the setting can be changed, using the “arrow” keys. The new setting is saved by pressing key (M) once again, 2002515 § ‘TM4505 (05DECO0) 240-16AA-5 Z Series Combines pNebesSeparator Adjustment, Combine Data Center from Ser.No. 062722/Area Counter AREA COUNTER oo A @ ha + Starter switch in position (I) or (It). + Infotrak monitor correctly programmed B 3 Ede ear a ae eae @xha |i necessary for reading display only). a Setting Instructions c yO @ rhe : euaaon ‘Area values can only be cleared, but not changed. Total area values can neither be cleared nor changed. ‘Area function ight ‘2 Total area function light (C—Header width function light ‘The smallest area that can be displayed is 0.1 hectare oF 0.1 acre. ‘The smallest setting increment for header width is 0.1 m oF 05 f When full width of header is not used during operation, Partial width may be set in 1/4 increments. Header width will return to the previously saved value if header moves out of range of header height gauge. NOTE: The alsplayed measurement units for width and area are determined by infotrak monitor programming (see this Section). ‘M4505 (0SDECO0) 240-16AA-6 Z Series Combines‘Separator Adjustment, Combine Data Center from Ser.No. 062722/Setting Combine Data Center and Area Counter DISPLAY With ignition turned on, the following data are displayed: + Preloaded settings for various crops + Area counter data (area, total area, header width) + Preloaded crops (9), crops created by the operator (14) + Languages available: Gorman DEUTSC Fronch FRANCA, ‘Spanish —-ESPANT itlan TALIA Dutch = NEDERL. Danish DANSK Swedish SVENSK. English ENGLIS Factory-Loaded Crops + Barley + Com: + Beans + Peas + Wheat + Rye + Sunflowers + Oats + Rape NOTE: The names of the factory-loaded (permanent memory) crops end with a number 1. TM4505 (05DECO0) 240-16AA-7 Z Series Combines PNssz0‘Separator Adjustment, Combine Data Center from Ser.No. 062722/Setting Combine Data Center and Area Counter Crop Codes Created by the Operator For each of the previously mentioned crops (all of which are entered into the memory at the factory), the operator may enter one modified orop into the data center memory, including all necessary settings according to harvesting conditions. The names of these crop versions, created by the operator, end with a number 2. NOTE: The crops entered into data center memory by the operator may be recorded on the bottom of right-hand armrest. Special Crops ‘The operator may enter five additional special crops into the data center memory. These crops are named CROP2, CROP3—CROPE, NOTE: The crops entered into data center memory by the operator may be recorded on the bottom of right-hand armrest. ‘TM4505 (05DECO0) 240-16AA-8 Z Series Combines PNsertSeparator Adjustment, Combine Data Center from Ser.No. * 062722/Setting Combine Data Center and Area Counter SETTING UNIT Requirements: To start automatic setting of functions (A, 8 and C): + Engine must be running (throttle lever pushed all the way forward) + Soparator must be engaged + Switch for automatic machine adjustments must be ON Setting Instructions Values of functions (A—F) for the previously selected crop are displayed and may be changed as follows: Function Increments ‘Setting range a 10 rpm ‘92560 rpm 8 10 1pm (02550 rpm c 4 mm (118 in) (0—80 mm (09-48 in) o 4mm (118 in) (060 mm (09-48 in) E 4mm (118 in) (080 mm (0—-2-418 in) F 1mm (116 in) (080 mm (09-48 in) Values of functions (A—F) for crops ending with a number "1" (e.g. "CORN1") are factory loaded (permanent memory) and cannot be changed. Values of functions (A—F) for crops ending with a number "2" (e.g. "CORN2") may be cleared or changed. Values of functions (A—F) for “CROP2" to "CROPG" may also be cleared or changed. Functions (A—C) are set automatically by pressing the "AUTO’ key (if the above requirements are met). Values of functions (O—F) are only displayed. Setting ‘must be carried out manually Lights (A—C) and (G) will glow during automatic setting procedure. g@: e ne B c D E | F 3 AUTO @ a i zxo02se3 ‘A~Oylinder speed function ight 'B—Fan speed function light (C—Concave spacing function light ‘D—Chaffer function light E-Siove function light FChaffer extension function light (G—Automatic function light ‘TM4505 (0SDECOO) 240-16AA-9 Z Series Combines PuesreSeparator Adjustment, Combine Data Center from Ser.No. 062722/Setting Combine Data Center and Area Counter OPERATIONAL DIAGRAMS A Explanation -of Symbols: ‘A-Suitch on automatic machine adjustments B—Shows the combine data center unt to be + Setting unit (¢Shows individual functions of yuntarfsating unit ight) D-Shows the key to be pressed {bold enclosure) Display information F_Shows possible choices G—Shows time required for individual procedure F i 3 , 3 ai i i ronsre | ‘Tuas0s (0S0EC00) 240-GAA-10 7 Series Combines PN‘Separator Adjustment, Combine Data Center from Ser.No. 062722/Setting Combine Data Center and Area Counter SELECTING COMBINE DATA CENTER UNITS + Turn starter switch to position (1). Combine data center will switch to area counter (X). + Press "PAGE" key. 7 Combine data center will switch to display (Y). + ross "PAGE" ky. @ Combine deta center wil svich to seting unt (2) | . | 2x 002528 ‘TM4505 (05DECO0) 240-16AA-11 Z Series Combines Pusere‘Separator Adjustment, Combine Data Center trom Ser.No. 062722/Setting Combine Data Center and Area Counter SELECTING AREA COUNTER FUNCTIONS + Select “Area Counter” unit. Light of "Area" function will glow. ‘The harvesting area (for each day) is displayed, + Press "Down" key. Light of *Total Area” function will glow. ‘The total harvesting area is displayed. + Press “Down” key. Light of "Header Width" function will glow. Header width (cutting width) is displayed, ‘NOTE: Running through the various crop displays or setting unit functions is done in a similar way as described above. é 3S a] ( 2x 002519 TM4505 (0SDECO0) 240-16AA-12 Z Series Combines PN=B7S‘Separator Adjustment, Combine Data Center from Ser.No. 062722/Setting Combine Data Center and Area Counter CLEARING “AREA” DISPLAY + Select "Area Counter" unit, | «Salt Are unto, <> Te harvsng area for the dy wil be dpe «Prose tay (©) (lea ) Display will change to “zero’. 3} ‘TM4505 (05DEC00) 240-16AA-13 Z Series Combines pases‘Separator Adjustment, Combine Data Center from Ser.No. 062722/Setting Combine Data Center and Area Counter’ CHANGING HEADER WIDTH + Select “Area Counter” unit + Select "Header Width* function. ‘The current header width (cutting width) will be displayed. + Press "Modify" key (M). ‘An “MF will appear at the left of the display. + Press “Up” or “Down” key. The changed header width will be displayed. + Prass key (M) again. The displayed setting is saved; the "M” at the left of the display will disappear. NOTE: After pressing the "M" key, it is always possible fo interrupt the setting of the new header width by pressing “Cancel” key (C). The previous header width will be displayed once again. _— fy £ Tiwas05 (G5DEC0) 240-16AA-14 Z Series Combines pxo7T‘Separator Adjustment, Combine Data Center from Ser.No. 062722/Setting Combine Data Center and Area Counter SETTING PARTIAL HEADER WIDTH + Select “Area Counter" unit. + Select "Header Width” function. The current header width willbe displayed. + Press “Calibrate” key (C). "3/4" will be displayed = 3/4 of the previous header width (cutting width). + Press “Calibrate” key (C), 1/2" will be displayed = 1/2 of the previous header width (cutting width). + Press *Calibrate’ key (C). “1/4" will be displayed = 1/4 of the previous header width (cutting wiath).. + Press "Calibrate" key (C). ‘The cutting width saved previously will be displayed. 2x 002522 : n Ss (| ayy &) ve ‘TM4805 (05DECO0) 240-16AA-15, Z Series Combines PNsers,Separator Adjustment, Combine Data Center from Ser.No, 062722/Setting Combine Data Center and Area Counter ‘SELECTING LANGUAGE + Press "Page" key while turning starter switch to position (\). | The language saved previously will be displayed. + Press "Up" or “Down” key until desired language is, displayed. + Press “Memory" key (M). ENG' + Tum starter switch to position (0). The desired language is saved. ‘TM4505 (05DECO0) 240-16AA-16 Z Series Combines pNssraSeparator Adjustment, Combine Data Center from Ser.No. 062722/Setting Combine Data Center and Area Counter SELECTING CROP NOTE: This procedure is required to start automatic settings and to change to a different crop. + Select "Display" unit. ‘The crop selected previously will be displayed. + Press "Up" or “Down” key until desired crop is displayed. + Press "Modify" key (M). AA flashing *“M" will appear at the left of the display. + Press key (M) again. ‘The selected crop is saved; the ” display will disappear. at the left of the NOTE: After pressing the "M" key, it is possible to interrupt crop selecting procedure by pressing = “Cancel” key (C). CORN 1 MCORN 4 CORN 4 zxoorses | A ‘TM4505 (05DECO0) 240-16AA-17 Z Series Combines PNs680Separator Adjustment, Combine Data Center from Ser.No. 062722/Setting Combine Data Center and Area Counter AUTOMATIC MACHINE SETTING ACCORDING TO CROP SELECTED + Separator must be engaged. + Switch on function "Automatic Machine Adjustments". + Select ‘The selected crop will be displayed. + Press *AUTO" key. Lights of functions, — Cylinder speed — Fan speed — Concave spacing and — Automatic operation ("AUTO") will glow until the corresponing setting is completed. After setting procedure for all functions is completed, the "AUTO light will go out. Nort is possible to interrupt setting procedure by pressing “Cancel” key (C). 2x 002525 ‘TM4505 (05DEC00) 240-16AA-18 Z Series Combines Nees‘Separator Adjustment, Combine Data Center from Ser.No. 062722/Setting Combine Data Center and Area Counter: > CLEARING CROPS CREATED BY THE OPERATOR + Select "Display" unit. + Select crop to be cleared (ending with a number named “CROP2"—"CROP6"). + Press “Clear” key (C) for 2 seconds. For 2 seconds, a "C* will appear at the left of the display. Display will change to crop version ending with a umber “1”, ‘zx 002528 ‘TM4505 (05DECO0) 240-16AA-19 Z Series Combines Nasa‘Separator Adjustment, Combine Data Center from Ser.No. 062722/Setting Combine Data Center and Area Counter READING SETTINGS FOR SELECTED CROP { + Select “Display” unit ‘The previously selected crop will be displayed. + Select “Setting Unit" function CORN 4 + Select “Cylinder Spoed” function, ‘The cylinder speed for the selected crop is displayed. @ + Select “Fan Speed” function. The fan speed for the selected crop is displayed. Zz NOTE: The remaining settings may be displayed in the same way. -————+ zx002827 zourzcowness 19 542 ‘TM4505 (05DECO0) 240-16AA-20 Z Series Combines:‘Separator Adjustment, Combine Data Center from Ser.No. 062722/Setting Combine Data Center and Area Counter CHANGING CROP SETTINGS (Crops Created by the Operator) + Select “Display” unit ‘The previously selected crop will be displayed. + Select “Setting Unit’ function. + Select " inder Speed’ function. The cylinder speed for the selected crop is displayed. + Press "Modify" key (M). ‘An "M" will appear at the left of the display. + Press “Up” or "Down" key until desired display appears. NOTE: At this time it is possible to interrupt changing procedure by pressing “Cancel” key (C). + Press key (M) again. The crop created by the operator is saved (indicated by °2" behind the crop name); the "MI" at the left of the display will disappear. NOTE: The values for the remaining functions are changed in the same way. TMi4505 (05DECO0) 240-16AA-21 CORN 4 e zx 002528 Z Series Combines puso[ Separator Adjustment, Combine Data Center from Ser.No. 062722/Setting Combine Data Center and Area Counter INDIVIDUAL SETTING OF CHANGED VALUES (AUTOMATIC SETTING) + Separator must be engaged. + Switch on function “Automatic Machine Adjustments’. + Selec “Seting Uni function. * Select “Cylinder Speed” function. ‘The corresponding value is displayed. + Press “AUTO” key. ‘The light of the selected function and the “AUTO” light will glow during automatic setting procedure. NOTE: It is possible to interrupt setting procedure by pressing “Cancel” key (C). 2x 002828 ‘TM4505 (05DECO0) 240-16AA-22 Z Series Combines PNE8BS‘Separator Adjustment, Combine Data Center from Ser.No. 062722/Theory of Operation THEORY OF OPERATION Manual adjustments of cylinder speed, fan speed and concave spacing are identical with the procedures described in Group 240-152. ‘These adjustments may be performed automatically by means of the combine data center. The relays on the relay board are activated by control board (AS) via connecting wires. Control board (A9) ‘and combine data center (A5) are connected to the Infotrak monitor via data transfer wires (268) and (269), Wire 038 transmits the signal from the header height. sending unit to the combine data center. Wire 304 transmits a signal from switch (S55) during reverse travel to switch off the area counter. NOTE: The infotrak monitor displays error codes in case of combine data center malfunctions. ‘TM4505 (05DECO0) 240-16AA-23 Z Series Combines PN=86‘Separator Adjustment, Combine Data Center from Ser.No. 06272/Functional Schematic, Section 25 FUNCTIONAL SCHEMATIC, SECTION 25B ae) st yl) LD a SEES ‘CYLINDER , CONGAVE , FAN ADJUSTMENT 1008222 emecoossss0 54K ‘TM4505 (05DEC00) 240-16AA-24 Z Series Combines ences?Separator Adjustment, Combine Data Center from Ser.No. 062722/Functional Schematic, Section 25 AS — Combine data center FUNCTIONAL SCHEMATIC, SECTION 258 R2 — Potentiomoter, concave X27 — Disconnect point, x42 — Connection, 9 — Control board, sajustment dlstebution hamess Aistouton namoss combine data center V10 — Diode {Wi cab namess (0) te data comer Att —Relay boar, combine X9— Connection, ead (wa) contol board datacenter harness (W2) to relay X28 — Disconnect point, x44 — Disconnect polnt, cab ‘At — Relay and code and slode board distbution hare harness (W2), rear board x17 — Connection, (Wi), cab hamese Baste harness (8) ‘A15 — Fuse board Separator Adjustment, Combine Data Center from Ser.No. 062722/Functional Schematic, Section 25 AS — Combine data center ‘89 — Control board, Combine data center Att — Relay board, combine data center Aid — Relay and diode board 15 — Fuse board FB — Fuse, 7.5 amps. At — Fuse, 30 amps F28 — Fuse, 7.5 amps. FUNCTIONAL SCHEMATIC, SECTION 2582 R2 — Potentiometer, concave adjustment vi0 — Diode X9— Connection, cab harness (W2) to rolay ‘and diode board X17 — Connection, Aletribution harness (Wi) to fuse board X23 — Disconnect point, cab harness (W2), front X27 — Disconnect point, distribution hare (Wt), cab harness (wa) X28 — Disconnect point, ‘distribution harness (W1), cab hamess (way X85 — Disconnect point, cab hhamess (W2), armrest hamess (WS) x42 — Connection, distribution herness (01) to data center ‘contro! board X44 — Disconnect point, cob harness (W2), re basic hamess (W9) X45 — Disconnect point, cab harness (W2), rear basle harness (WO) X85 — Disconnect point, cab Fat — Fuse, 15 amps. basic hamess (W7) X38 — Disconnect point, cab harness (W2), daia 36 — Relay, aust fan X24 — Connection, rear hhamess (W2), harness (W23) pee bale hamess (W8) to cptional harness x70 — Spi a7 — Relay, adjust fan solenoid valve block ws) -— Connection, speed X25 — Disconnect point, X39 — Connection, distribution harness Ms — Concave adjusting distribution han distribution harness (Wit) to fuse board motor (Wt, cab harne (Wt) to data center {Mo — Fan speed adjusting (way relay board | motor X26 — Disconnect point, distribution harness (W), cab harness way ‘TM4505 (0SDECO0) 240-16AA-29 Z Series Combines edFico eee 2 oe-vvat-ove (conan ce ut ‘vst NOUOAS ‘OLWWSHDS DLSONOVIG 132 UaNDOS BARURIRS SISOUBEAEZL RO NING Wy HD BD BURIED TAINIBY IREEAS—— Lewwor-orz (0003050 sos eT — os = ales “a = S — Va = = = = ee le = = = 5 an is | “ ie ja |e le le le PT Eeccat |] Gear t ecco = a tt ul. “ct. ‘US ‘882 NOLLO3S ‘DLLVINaHOS OSONOWIC ‘3 WOHPRS SHBURISS BPUTREIRELEBD GVIRG Oy UND BING SURINND TOSUISADY ORAS(Go03080) sosm. zaS2 GNV 1852 SNOLLOAS ‘DLVHZHOS SUSONOVIG ‘ WaIEOS SISUNIAS BRSHDRTEZTERD GINS Way RIIRD RG BINUD TSUDY RESHeader Adjustments to Ser.No. 062721 Group 15AB OPERATIONAL INFORMATION All header settings such as header lif, ree! lift and horizontal reel adjustment are carried out hydraulically and are controlled electrically ‘The basic adjustment preset by the operator can be obtained automatically at any time by pressing a button, NOTE: For safety reasons, header or reel can only be adjusted with engine running and road safety switch in “field” position. | _Dererccrerer 16 uot THEORY OF OPERATION ‘As switches (S27, $29 and $30) are not designed for high current draw, a relay is located in front of each hydraulic function solenoid of this Section. ‘All switches and header control (AB) are protected by fuse (F26). Operating current for solenoids used for reising/lowering header is supplied via fuse (F33). Operating current for solenoids of reel functions and variable feeder house drive is supplied via fuse (F45). Depending on position of selector siwitch (S53), switch (829) activates the solenoids for raising or lowering reel or the solenoids for increasing or decreasing header speed. Potentiometers (R4,R6 and R8) indicate reel position (height and horizontal position) and header height (needed for electronic control). Potentiometers (R3, RS and R7) in the switch console can be used to select desired settings. When actuating switch (S28), the header is automatically set according to the selected values. NOTE: Manual control functions will override automatic control functions. ‘TM4505 (05DECO0) 240-15AB-1 Z Series Combines PN=6o8SSSHeader Adjustments to Ser.No. 062721/Diagnostic Schematic, Section 26 ‘TM4505 (05DECOO) 240-15AB-4 Z Series Combines pyss9aHeader Adjustments from Ser.No. 062722 Group 16AB OPERATIONAL INFORMATION All header settings such as header lift, reel lift and horizontal reel adjustment are carried out hydraulically and are controlled electrically. ‘The basic adjustment preset by the operator can be obtained automatically at any time by pressing a button, NOTE: For safety reasons, header or reel can only be adjusted with engine running and road safety switch in “field” position. THEORY OF OPERATION AAs switches (S27, S29 and $30) are not designed for high current draw, a relay is located in front of each ‘hydraulic function solenoid of this Section. All switches and header control (A6) are protected by fuse (F26). Operating current for solenoids used for raising/lowering header is supplied via fuse (F33). ‘Operating current for solenoids of reel functions and variable feeder house drive is supplied via fuse (F46). Depending on position of selector switch (S53), switch (629) activates the solenoids for raising or lowering reel or the solenoids for increasing or decreasing header speed. Potentiometers (R4,R6 and R8) indicate reel postion {height and horizontal position) and header height (needed for electronic control). Potentiometers (R3, 5 and R7) in the switch console can be used to select desired settings. When actuating switch (S28), the header is automaticaly set according to the selected values. NOTE: Manual contro! functions will override automatic control functions. ‘M4505 (05DECO0) 240-16AB-1 Z Series CombinesHeader Adjustments from Ser.No. 062722/Functional Schematic, Section 26 FUNCTIONAL SCHEMATIC, SECTION 26A 33 wey ve ae | pe m2 R16 | 2 Sin i a “aye [=e ea 4 i 30 on “we | ‘| SERA HEADER ADJUSTMENT (CUTTING HEIGHT; REEL; FLOAT) zxoos224 240-16AB-2 Z Series Combines ‘TM4505 (05DECOO) pN=rOtHeader Adjustments from Ser.No. 062722/Functional Schematic, Section 26 ‘AS —Automatle header FUNCTIONAL SCHEMATIC, SECTION 264 K18 Relay, raise reel, 3 —Potentiometer, header 82 —Suiteh, raise ‘control 19 Relay, move reel to height resume ‘530 —Suwiteh, root horizontal the rear 4 —Sending unit, header ‘adjustment K20 —Relay, move reel to height $832 —Switeh, resume FAS —Fuse, 15 amp the front RS —Potentiometer, real ‘controle 413.—Relay, lower header —_K28 —Relay, variable header height ‘853 Selector switch, raise quickly ‘ive (slow) R6 —Sending unit, reo! reelariable K14—Relay, lower header 29 —Relay, variable header hight header drive slowly five (last) RT —Potentiometer, roel ‘866 —Selector switch, K15 Relay, ralso header —_K40 —Relay, tilting header to position horizontal root quickly the loft RB —Sending unit, reet adjustmentheader K16 Relay, race header ——_K#1 —Relay,titing header to lateral eit slowly the right K17 Relay, lower rel ‘TM4505 (05DECO0) 240-16AB-3 Z Series Combines PI 02Sino eave z ravor-ovz (oxososo saves (yo7s '733Y 'LHOISH ONILINO) INSWISArOY UIGVaH ‘gszas qe a @ 29s {892 NOLLDSS ‘SLLWHSHOS TwNOLLONAS {BE UaiNG BIRUNS MGTEEESD NIRS Way HUBLIEMBY BHHeader Adjustments from Ser.No. 062722/Functional Schematic, Section 26 ‘AS —Automatie header F45 —Fuse, 18 amps. K13 —Rolay, lower header ‘quickly 14 —Rolay, lower heador slowly Ki5 3, false heador quickly K16 Relay, ralse header ‘slowly Kt7 —Relay, lower reel FUNCTIONAL SCHEMATIC, SECTION 26B K18 —Rolay, raise reet K18 Relay, move real to the rear 20 —Relay, move reel to the front 28 —Relay, variable header ‘rive (stow) 29 —Relay, variable hoador ‘rive (fast) 40 —Relay,titing header to the fete 41 Relay, titing header to the right RS —Potentiometer, header height resume Ra —Sending unit, header height 5 —Potentiometer, reel, height R6 —Sending uni, reel height RT —Potentiometer, reel 829 —Suiteh, raise root ‘830 —Suitch, roel horizontal ‘adjustment 882 —Suitch, resume ‘controls, $55 —Soloctor ewite ‘eellvarab header drive 866 —Selector swith, horizontal ree! adjustmentheader tater tit _nencensest 0 suaRa8 ‘TM4505 (0SDECOO) 240-16AB-5 Z Series Combinesona se 2 e-aval-ove coacuo o, (1y074 "733" LHOISH ONILLND) INBWUSNPaY H3OVSH 99238 ‘992 NOLLOJS ‘OLLVINJHOS TYNOLLONNS BE URIS WHBURIES RUSSUNIEELEOD ONS WH GOREN FPOHeader Adjustments from Ser.No. 062722/Functional Schematic, Section 26 ‘AS —Automatic header ‘contol F26—Fuse, 7.5 amps. F33 Fuse, 15 amps. 45 —Fuso, 15 amps. 13 —Rolay, lowor header ‘quickly 14 —Rolay, lower header slowly 15 —Relay, rise header ‘quickly k16 Relay, slowly, 17 Relay, tower root Ise header FUNCTIONAL SCHEMATIC, SECTION 26C 20 —Rolay, move roel to the front x28 —Relay, variable header drive (slow) 29 —Relay, va ble header fave (tas) K40 —Relay, tilting header to the loft Kat —Rolay, titing header to the right R3—Potentiometer, header $29 —Suitch, raise reel height resume ‘330 —Suwitch, reel horizontal 4 —Sending uni, header ‘adjustment height ‘832 Switch, resume 5 —Potentiomote, reel ‘controls height 853 —Solector switch, 6 —Sending unt, root ‘ellvariable height header dive 7 —Potentiometer, reel $06 —Selector switch, position horizontal reel RB —Sonding unt, rool adjuetmentheader position Tatoral tit 827 —Suwitch, raisetower header ‘TM4508 (05DECO0) 240-16AB-7 Z Series Combines. Ph 708Fee wun 2 saverore et ‘992 GNY g8z ‘YBz SNOLLOS ‘OLLYHaHOS SUSsONOVIG ‘BE UaIoG BIOURIAS STOLERIEELERG OVINE Way BUBLUABY EAH‘992 ONY asz ‘vez SNOLLORS ‘SILVWAHDS SUSONOVIO ‘ UainaS BIOURIOS SHSSDEGCZTERD GNIRG Wy GRUB JPETHeader Adjustments from Ser.No. 062722/Diagnostic Schematic, Section 26 ‘TM4505 (05DEC00) 240-16AB-10 Z Series Combines pnsioaGroup 15AC Grain Tank Unloading System OPERATIONAL INFORMATION ‘Switch (A) is used to swing unloading auger in or out. NOTE: A timer relay interrupts current supply to electromagnetic control valve after 22 seconds to Prevent overheating of the hydraulic system. Switch (B) is used to engage unloading auger drive. A switch lock is provided to avoid unintentional ‘engagement of unloading auger drive, ‘A—Suiteh, swing unloading auger in or out ‘B-Unloading augor drive switch (C-Suiteh lock THEORY OF OPERATION With road safely switch in “field” position and engine running, power is supplied to switches (S35) and ($39), pressure switch (B31) and timer relay (K25) via fuse (F36). With switch ($35) in noutral position, relay (K24) is ‘activated. When engaging unloading auger drive, relay (K24) is held in position. Solenoids (Y26) and (¥27) are activated. The pressure valve is activated by pressure switch (B31), depending on pressure. ‘TMA505 (05DECO0) 240-15AC-1 When swinging unloading auger in or out, double contact switch (S38) connects terminal (S) of timer relay (K25) to ground. Thus terminal (87) of timer relay is supplied with power. The second contact of double contact switch (S39) activates the solenoid for swinging unloading auger in oF out. The timer relay powers terminal (87) for 22 seconds Z Series Combines eneroGrain Tank Unloading System/Functional Schematic, Section 27 FUNCTIONAL SCHEMATIC OF SECTION 27 Heide $ 4 ly26 \v27. pone |utaone erase. SEaT (GRAIN TANK UNLOADING SYSTEM Ald —Relay and diode board v9 —Diode ‘A15 —Fuse board 24 —Diode 831 —Pressure switch, main V25 —Die clutch v26 —0i F39—Fuso, 15 amps. XB —Connection, cab 24 —Safety relay, unloading ‘harnoss (W2) to relay auger drive and diodo board 25 —Timer rolay, unloading x9 —Connection, cab ‘auger swing harness (W2) to relay {835 —Unloading auger drive and diode board sth X10 —Connection, cab 899 —Switch, unloading ‘harness (W2) to relay ‘auger Swing and diode board v2 —Diode X17 —Connection, V8 —Diode distribution harness (W1) to fuse board X24 Connection, rear basic harness (Wo) to eolenold valve block X26 —Disconnect point, distribution harness wn, cab harness (W2) X37 —Disconnect point, ‘cab harness (W2}, ‘switeh console harness (W3) X45 —Disconnect point, ‘cab hamess (W2}, ie harness ‘TM4505 (05DEC00) 240-15AC-2 Zx005246 x49 —Disconnect point, ab harness (W2), ‘corner post hares way Yt —Preeeure valve 4 Y10 Solenoid, swing in unloading auger Y41 Solenoid, swing out unloading auger 26 —Solenold, unloading ‘grain tank ‘Ye? —Solencid, untoading Z Series Combines pNerit42 NOUS 40 SUVHIAHDS OUSONOVIG Ze RS SLRS HSE GRATIS BIEHRN WORLDGrain Tank Unloading System/Diagnostic Schematic, Section 27 ‘TM4505 (05DECO0) 240-15AC-4 Z Series Combines PNeTi3Group 15AD Four-Wheel Drive OPERATIONAL INFORMATION With starter switch in position (II), hydraulic fourswheel drive may be engaged by means of switch (S44). ‘An indicator light shows that four-wheel drive is engaged. THEORY OF OPERATION With starter switch in position (I), power is supplied to switch (S44) via fuse (F30), ‘When actuating switch (S44), solenoid (Y32) is activated and a certain amount of hydrostatic oll low is directed to the rear axle, At the same time an indicator light in Section 10 will glow. ‘TM4505 (0SDECO0) 240-15AD-1 Z Series Combines puraFour-Whee! Drive/Functional Schematic, Section 28 FUNCTIONAL SCHEMATIC OF SECTION 28 a Y32 ee 4 seo | i SE28 5 FOUR WEEL DRIVE 7 7x004047 sg [AIS Fuse board 27—Diaconnect point, X48 Disconnect point, X40 Disconnect pln F30— Fuse distribution harness cab hamess (W2), cab hamess (2), Set Fours! ive wn, tow bate hares corner post Nemeas ‘switch ‘cab harness (W2) (wa) (way Yaz Fournhel ive X37—Disconmoct ptt Sstenla ab hares 5, Stn console iamess 3) ‘TMA5O5 (0SDECOO) 240-45AD-2 Z Series Combines PNETFour-Whee! Drive/Diagnostic Schematic, Section 28 DIAGNOSTIC SCHEMATIC OF SECTION 28 Le +++ ete el ee my we | eT Fa at, ‘TM4505 (05DECO0) 240-15AD-3 Z Series Combines pusriFour-Wheel Drive/Diagnostic Schematic, Section 28 ‘TM4505 (05DEC00) 240-15AD-4 Z Series Combines pari?.. Group 15AE Header Lateral Tilt Function OPERATIONAL INFORMATION ‘This function-is provided to tit the header laterally, e.g, when working on slopes. It will provide a uniform cutting, height over the entire header width. Without the lateral tilt function, cutting height on the uphill side would be higher than on the downhill side due to combine weight distribution. THEORY OF OPERATION With road safety switch in “field” position and engine running, power is supplied to switch (S22) via fuse (F26). ‘When titing header to the left or right, solenoid (Y14) or (¥15) is activated. Pressure valve (V1) in Section 27 is also activated via diode (V44) or (V45). NOTE: Switch (S62) is normally not installed, because Section 26 is used fo control the function. Field Installation of the switch is possible. ‘TM4505 (05DECO0) 240-15AE-1 Z Series CombinesHeader Lateral Tit Function/Functional Schematic, Section 29 [ FUNCTIONAL SCHEMATIC OF SECTION 29 _ wae 3 ee vee 4 A, seis cs EBM g Z SEBS i HEADER TILT 2x008248 = i a X25 —Disconnect point, X73 Connection, feeder X82—Diseonnet pont, strbuion harmess house hamess (10) aistbuton harness wn, to solenold valve, ow, ab harness (W2) Bock front baste harness hamess (Wz) o relay XS7—Disconnect point, X77 —Disconnect point, wn and diode board cab harness (W2), front baste harness X12 —Connaction, ead Switch console. wn, harness (W2) to relay harness (3) feeder house harness and diode board wi mazes 8.304 ‘TMA505 (05DECO0) 240-15AE-2 Z Series Combines eneridHeader Lateral Tilt Function/Diagnostic Schematic, Section 29 DIAGNOSTIC SCHEMATIC OF SECTION 29 RELAY-DIODES BOARD i 1 1 i \ I 288 spor | 288 sear 1 ' se2p 8, | gva5 vase vo i see6 248} ! 53 1 sete 10 ' i i \ i ' u xs7_ws sas m Eze! 178 e052 —/ s Bw yas ws X82 w7 3 fi 3 vid Ine i pa X73_wio ge _wio «X77 _wr sul | § fe sas 33 us| § 5 : 2x004127 5 PenwacoromesnsrauBe ‘TM4505 (05DECO0) 240-15AE-3 Z Series Combines 2‘M4505 (05DEC00) 240-15AE-4 Z Series Combines Neri- Group 15AF Header Float Control OPERATIONAL INFORMATION A preset float is selected by pressing button (C). Float is obtained by activating hydraulics of header lift system, Use potentiometer (B) to adjust desired header float. IMPORTANT: Do not operate float control for more than one minute without interruption to avoid overheating of the hydraulic oil. THEORY OF OPERATION Float control system (A10) is powered via wire 184. ‘When switch ($6) is actuated, header contro! system (A6) in Section 26 is switched off. The function “raise header slowly" is activated via diode (V48) and wire 238. At the same time, coil of solenoid (¥6) is supplied with voltage via wires 101 and 102. Dornier sia, fst cane | electronics will provide a current between 350 and 900 mA to the solenoid coil. This in turn will provide | a lower or higher hydraulic system pressure. Derwpacooars ses74N8e “T4505 (05DECOO) 240-15AF-1 Z Series Combines pueraaHeader Float Control/Functional Schematic, Section 30 FUNCTIONAL SCHEMATIC OF SECTION 30 ae 3 SESO j FLOAT CONTROL ‘zx008264 i ‘A10 —Float control X35 —Disconnect point, X88 —Disconnect point, x103—Connection, switch ‘Ad —Rolay and diode board ‘cab hamess (W2), ‘cab harness (W2}, console harness k8 —Relay ‘armrest hamoss (WS) ‘switch console to float control system R13 —Potentiometer X36 —Connection, armrest hharnoss (W3) 86 —Header float switch harness (WS) X98 —Disconnect point, X10 —Connection, cab to multifunction lever ‘ground to relay and ‘TM4505 (05DECO0) 240-15AF-2 Z Series Combines pNsTe3Header Float Contro/Diagnastic Schematic, Section 30 DIAGNOSTIC SCHEMATIC OF SECTION 30 88 Ka Ris fe 17a ule So es eee RELAY-DIODES 90ARD ae ' | v2. -ioar contro. 225 225 uy it . 382 362 af peoae | ‘TM4505 (05DECOO) 240-15AF-3 Z Series Combines pI 74Header Float ControvDiagnostic Schematic, Section 30 ‘M4505 (05DECO0) 240-15AF-4 Z Series Combines PNETSUV dn OVE TOUINOS LVOTS se38 cas ove |E le some be ONY of SNOLLO’S ‘OLLYWSHOS WNOLLONNS Zlza) “ONTOS WOH Wey 6atig BsIeNey VST dnoigReverse Drive Alarm from Ser.No. 062722/Diagnostic Schematic, Section 31 FUNCTIONAL SCHEMATIC, SECTIONS 30 AND 31 B43 —Reverse drive alarm —_K42 —Relay, el. clutch ‘alarm 45 —Relay D+ (moving ‘buzzer (moving motor) motor) FS1—Fuse, 7.8 amps., ‘Yo4 Electric clutch, header F52 —Fuso, 7.5 ampe. electric clutch for v2T —Diode ¥34 hheadr reverse drive header drive alarm DIAGNOSTIC SCHEMATIC, SECTION 31 a kez Fst Fea KAS 2 Bea 8 a seo es we wea ars i i ones | ‘TM4505 (05DECO0) 240-15AG-2 Z Serles Combines puerar« Group 15AH Separator Timer Relay from Ser.No. 062722 FUNCTIONAL SCHEMATIC, SECTION 32 ove, 318 302 aie 15 K46 TIMER RELAY mf be fe vos i 8 5 sear see Seat SE32 TIMER RELAY 4,58 MD 2054 x008600 anes sacres K46 —Timer relay, separator ‘V64 —Zener diode 1NS444B cmpaconost 16.158 ‘TM4505 (05DECO0) 240-15AH-1 Z Series Combines PNeTeSeparator Timer Relay from Ser.No. 062722/Diagnostic Schematic, Section 32 DIAGNOSTIC SCHEMATIC, SECTION 32 a3 V64 Alon i 5 8 § 3 SE21 SE08 ‘SE21 zroosses zxnageompen pus Ta605 (05DECD) 240-15AH-2 Z Series Combines PN=729Group 05 Accumulators SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARD™ Catalog or in the European Microfiche Tool Catalog (MTC). ‘Accumulator charging and testing device Feato4ce, 2x008221 CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. a Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. | ‘TM4505 (05DEC00) 70-05-1 Z Series Combines PNe2e2Accumulators/Main Drive Accumulator MAIN DRIVE/JUNLOADING SYSTEM ACCUMULATORS ‘The unloading system accumulators have a capacity of 0,36 L (0.09 US.gal.) and are precharged with nitrogen Under a pressure of 3800 kPa (38 bar) (550 psi). NOTE: Before connecting testing device FKM10448 to accumulator, silghtly loosen accumulator hex. socket screw. This will avoid damage fo the ‘esting device when accumulator is opened. For checking accumulator (A), connect testing device FKM10448 to accumulator (A). For checking accumulator (8), connect testing device FKM10448 to accumulator (B). AAccumulator, main drive BAccumulator, main drivelunloading system NOTE: Before checking accumulator (B), engage and disengage main clutch several times with engine shut off, starter switch in position I! and road safely switch in field position to relieve hydraulic pressure. Use a ratchet on testing device to open accumulator valve. ‘Accumulator charging pressure is indicated by the Pressure gauge. If charging pressure is too low, the accumulator must be charged with nitrogen, “Twa605 (05DECO0) 70-05-2 7 Series CombinesAccumulators/Header Float System Accumulator The accumulator may be charged by loosening knurled screw, If the accumulator is not connected to an extemal nitrogen source (under pressure), pressure is reduced by knurled screw. HEADER FLOAT SYSTEM ACCUMULATOR ‘The combines are equipped with one or two ‘accumulator(s). Accumulator capacity is 2 L (0.53 US.gal). ‘Accumulator charging pressure depends on weight of header and lit cylinder diameter. ‘A-Accumulator CHECKING HEADER FLOAT SYSTEM ACCUMULATOR(S) NOTE: Before connecting tésting device FKM10448 to accumulator, slighty loosen accumulator hex. socket screw. This will avoid damage to the testing device when accumulator is opened. For checking accumulator (A), connect testing device FKM10448 to accumulator (A). For checking accumulator (B), connect testing device FKM10448 to accumulator @). Relieve pressure in hydraulic line to header lift cylinders by actuating switch for lowering header. ‘TM4505 (05DECO0) 70-05-3 Z Series Combines pnctiaAccumulators/Header Float System Accumulator Use a ratchet on testing device to open accumulator valve. Accumulator charging pressure is indicated by the Pressure gauge. If charging pressure is too low, the accumulator must be charged with nitrogen, ‘The accumulator may be charged by loosening knurled ‘screw. If the accumulator is not connected to an external nitrogen source (under pressure), pressure is reduced by opening knurled screw. ‘Adjust charging pressure acco to the following table, il CHARGING PRESSURES OF HEADER FLOAT SYSTEM ACCUMULATOR(S) eee + 6000 kPa (60 bar; 870 psi) ee ee eee ee 6500 kPa (65 bar; 940 psi) 18 7000 kPa (70 bar; 1015 psi) 20... eee eee Oe eee +++ 8000 kPa (80 bar; 1160 psi) oo eee eee 9000 kPa (90 bar; 1300 psi) ‘The pressures given in the table apply to machines When cutting platforms with Hardox plates are used, with standard feeder house and standard cutting ‘add 1000 kPa (10 bar; 150 psi) to the values given. platforms with a lift cylinder diameter of 85 mm. When several of the points mentioned above apply to For machines equipped with 60 mm dia. lit cylinders, a certain machine, add or subtract the corresponding subtract 1000 kPa (10 bar; 150 psi) from the values valués as necessary. given. For machines with Hillmaster feeder house (header lateral tit, add 1000 kPa (10 bar; 150 psi) to the values given. ‘TM4505 (0SDECO0) 70-05-4, Z Series Combir AAccumulators/Header Accumulator HEADER ACCUMULATOR ‘An accumulator is integrated in the header hydraulic system lines. With header detached, it prevents an excessive pressure build-up caused by solar radiation. ‘Accumulator capacity is 75 cm? (4.6 cu.in.) and is precharged with a pressure of 500 kPa (5 bar; 70 psi). The accumulator is maintenance-free and cannot be repaired. IMPORTANT: Before removing accumulator, relieve Pressure in hydraulic system. ‘TM4505 (05DECO0) 70-05-5 Z Series Combines PN=266Accumulators/Header Accumulator ‘TM4505 (0SDECO0) 70-05-6 Z Series Combines PNe267Group 10 Triple Hydraulic Pump GENERAL REPAIR INFORMATION IMPORTANT: Prior to opening hydraulic components, thoroughly clean surrounding area, Observe the utmost cleanliness when repairing hydraulic components. REMOVING HYDRAULIC PUMP Disconnect suction and pressure lines from hydraulic pump. Immediately plug openings. Remove both attaching screws and lift off pump, NOTE: Replace complete pump if bushings, gears or housing are defective or worn. Itis only possible to replace unserviceable seals. ‘A—Hydraulie pump + Standard machine 35 Lin. (8.2 gpm) + Hillmaster 48 Littin. (14. gpm) BHydraulle pump 25 LiMn. (6.5 gpm) (steering) pump machine 15 LiMin. (3.9 gpm) + Hillmaster 36 Ltn. (8:2 gpm) 70-10-14 Z Series Combines ‘TM4505 (05DECO0) PN=268Triple Hydraulic Pump/Disassemble Hydraulic Pump MARKING HYDRAULIC PUMP IMPORTANT: Mark all pump parts prior to removal to ensure correct reinstallation. zxo008r0 4 DISASSEMBLING HYDRAULIC PUMP. NOTE: Two of the four cap screws are longer and hold together the hydraulic pump which consists of three pump units. To disassemble remove the two longer cap screws. Disassemble parts of pump which have to be repaired: Remove screws (A). Remove intermediate cover (B). Remove front bushings (C) and (0). ios TS zx 000: M4506 (05DECOO) 70-10-2 2 Series Combines pN=28Triple Hydraulic Pump/Disassemble Hydraulic Pump Press out gears with rear bushings. NOTE: Mark all parts prior to removal to ensure correct reinstallation A—Bushing Bushing ‘C—Drive gear D—Driven gear E—Gasket Gasket support REPLACE SHAFT SEAL Remove snap ring (A) and extract seal ring (B), taking care not to damage seal seat surface. When installing seal ring, make sure sealing lip faces toward the inside. 2108722. INSTALLING GASKET AND SUPPORT Install gasket (B) and support (A) in bushings, noting Position of support (A). A-Support Gasket (Suton eile D—Pressure side Bushing set ‘TM4505 (05DEC00) 70-10-3 Z Series Combines PNeeoTriple Hydraulic Pump/Disassemble Hydraulic Pump TRIPLE HYDRAULIC PUMP, EXPLODED VIEW 1~cover 9—Drive gear 17—Shaft seal 24 Intermediate plato 2Soal ring 10—Driven gear 18 Intermediate plate 25—Housi 3 —Back-up ting 4t—Bushing 19—Housing 26—Te bolt (4 used) ‘4Seal ring $2—Bushing 20—Drive gear 27—Driven gear ‘S-Housing 43 —Intermediate plate 2—Driven gear 28—Drive gear Bushing 14-O-ing 22—Intermediate plate 29—End plate Spring pin 15carior 23—O-ring '30—Snap ring Bushing 16—Washer _amiserones 1836.01 ‘TM4505 (05DECO0) 70-10-4 Z Series Combines pntTriple Hydraulic Pump/Assemble Hydraulle Pump ASSEMBLING HYDRAULIC PUMP ‘Assemble hydraulic pump, noting marks made before Coat all moving parts with clean hydraulic oil before disassembly. assembling. Use new gaskets. ‘TM4505 (0SDECO0) 70-10-5 Z Series Combines pNeer?a Triple Hydraulic Pump/Assemble Hydraullo Pump ‘TM4505 (0SDECOO) 70-10-6 Z Series Combines PNE2TS~ Group 15 L Electromagnetic Control Valve CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. | Avoid the hazard by relieving pressure before | disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard, a Protect hands and body from high pressure fluids, Hf an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. GENERAL REPAIR INFORMATION IMPORTANT: rior to opening hydraulic components, thoroughly clean surrounding area, Observe the utmost cleanliness when repairing hydraulic components. M4505 (05DECO0) ~ 70-15-1 2 Series Combines pneareElectromagnetic Control Valve/Solencid Valve Block, Basic Machine | REMOVE BASIC MACHINE SOLENOID VALVE BLOCK 1. Lower harvesting unit completely and adjust lowest threshing cylinder speed to relieve pressure in hydraulic lines. 2. Disconnect wiring hamess from solenoid valve block at disconnect point (A). 3. Mark hydraulic lines and disconnect at solenoid valve block. 4, Plug all openings immediately. 5. Loosen screws (B) and (C) and remove solenoid valve block. 2X004052 ‘TM4505 (05DECO0) 70-15-2 Z Series Combines PNezrsElectromagnetic Control Valve/Repaic Solenoid Valve REPAIRING SOLENOID VALVE PLATE ’SWINGING OUT UNLOADING AUGER’ B A T c im s i D ON E | as x 75 . 14 S 3 G R a r GN L Q : Hy zx 005198 P ON ML J 7 2 a A-Solenoia Control plunger M-Check vave contr ache vane So setonld —ol passage plunger Root pavsage enews valve prec alee Return ot pessape Sched valve sat Sneed valve sat Shressre ol conection O—Check vale seat Toned valve ESpring ieee vive seat provsure of comecton Disassemble solenoid vave plate. Once removed, seals must be replaced with new Check all bores, orifices and valve seats for restcton, Replace damaged parts ‘TM4505 (05DECO0) 70-15-3 Z Series Combines PNeeTeElectromagnetic Control Valve/Repair Solenoid Valve PRESSURE VALVE REPAIR L 2x 004118 G E~Control plunger Fooritice G—Controt plunger coat ‘C—Needle valve seat D—Pressure test port Disassemble solenoid valve plate. Check all bores, orifices and vaive seats for restriction, ‘TMa505 (0SDECOO) chock valve N—Pressure oll passage H-Hydraullc oll inlet ‘J-Roturn ot passage “Hydraulic oit outlet (to reservoir) Replace damaged parts. Once removed, seals must be replaced with new ones. ae 70-15-4, Z Series Combines par?Electromagnetic Control Valve/Repair Solenoid Valve REPAIRING PRESSURE VALVE WITH PRESSURE RELIEF VALVE q 4 a 2X 005196 A ‘A—Controlplung ‘DControt plunger seat H-Sotenoid 5 Spring Check valve plunger Plug ‘C—Plug with test connection Remove plugs (C) and (J). Replace damaged parts. ‘Screw out pressure relief valve (F) and solenoid (H). Once removed, seals must be replaced with new ones. Check all bores, orifices and valve seats for restriction, TM4505 (05DEC00) 70-15-5 Z Series Combines. pNse78Electromagnetic Control Valve/Repair Solenoid Valve REPAIRING SOLENOID VALVE PLATE 'RAISING/LOWERING HARVESTING UNIT’ M H t J K oO N A H c G F 5 og I B 4 q 2X 005188 E oD q ‘A-Contol plunger, rising Control plunger, lowering G—Plug Solenoid harvesting unt harvesting unit Hocheek valve Solenoid BSpring Spring JoNeedie Noonttee C—cap wth adlusting sore FCap with adjusting serew Noodle Ononiee for easing speed for lowering speed Disassemble solenoid valve plate. Replace damaged parts. Check all bores, orifices and valve seats for Once removed, seals must be replaced with new restriction, ones. ‘TM4505 (05DECOO) 70-15-6 Z Series Combines PNee73Electromagnetic Control Valve/Repair Solenoid Valve REPAIRING SOLENOID VALVE PLATE 'RAISING/LOWERING HARVESTING UNIT, FLOAT CONTROL’ P B H A N 7 c M i L E oO y, i zxooa1i9 KK J G F i A-Solenoid FConnecting passage to J-Pressure oll passage O—Connectng passage B—Solenold second solenoid valve _KContol plunge, owerlng Pod seron CoNeede vale ae toheck vate X—Adjustment, raising Sonics ‘2-Return of passage YCAghustment, towering E—Contot plunge, raising Pressure ol passage | N—Newdle valve Disassemble solenoid valve plate. Replace damaged parts. Check all bores, orifices and valve seats for Once removed, seals must be replaced with new restriction, ones. ‘TM4805 (05DECOO) 70-15-7 Z Series Combines PN=280Electromagnetic Control Valve/Repair Solenoid Velve REPAIRING SOLENOID VALVE PLATE 'CYLINDER SPEED ADJUSTMENT’ B A —_| yo " K J y H D ] =) i 3 2X 004120 L G F E ‘A-Soleoia DNeedlo valve seat Return oil passage K--Prossure ol passage Solenoid E—Pressure oll connection Needle valve seat Return passage to CoNeedle vate FProscure rll valve —_JNetle vale reservoir Disassemble solenoid valve plate. Replace damaged parts. Check all bores, orifices and valve seats for Once removed, seals must be replaced with new. restriction. ones. Perrasenoss 60.089 74505 (05DEC00) 70-15-8 Z Series Combines pNezetElectromagnetic Contro! Valve/Repair Solenoid Valve REPAIR PRESSURE REDUCTION UNIT E D A zx 004121 c B ‘A-Pressure reduction valve C—Passage for reduced E~Test connection B-Return oll passage ‘pressure oil Remove pressure reduction valve (A) from housing, Once removed, seals must be replaced by new ones. Remove test connection (E). NOTE: Pressure reduction valve (A) interrupts oil flow at 6500 kPa (65 bar) (950 psi). Replace Check bores in housing and in pressure reduction complete valve, if defective. valve (A) for restriction. _mcmvcaooratse 1 810189 ‘TM4505 (05DECOO) 70-15-9 Z Series Combines PNszea» Electromagnetic Control Valva/Repair Solenoid Valve REPAIR SOLENOID VALVE PLATE FOR ENGAGING/DISENGAGING MAIN DRIVE OR UNLOADING DRIVE iM D iB A B 3 2x 005192 q ‘AcNeedle valve seat Novae va Solenoid D-Solenola Disassemble solenoid valve plate. Replace damaged parts. Check all bores, orifices and needle valve seats for ‘Once removed, seals must be replaced by new ones. restriction, ‘TM4505 (05DECO0) 70-15-10 Z Series Combines PN=283Electromagnetic Control Valve/Repair Solenoid Valve REPAIR SOLENOID VALVE PLATE FOR HORIZONTAL REEL ADJUSTMENT 2X 005193 P ONML J K g a A-Solenoid Control plunger ‘Pressure oil connection Solenoid Goll passage Qcheck valve C—Neod valve RO passage ‘S—Needle valve seat 1 Thermal rele valve (O—Check valve seat Disassemble valve plate. Replace damaged parts. Check all bores, orffices and valve seats for (Once removed, seals must be replaced by new ones, restriction, ‘TM4505 (05DECO0) 70-15-11 Z Series Combines, pyabeElectromagnetic Control Valve/Repair Solenoid Valve REPAIR SOLENOID VALVE PLATE FOR REEL LIFT 2X 005194 F E J ‘A~Solencid DNeodle valve seat G-Noodle valve seat E_Pressure oll connection Needle valve FReturn oll passage Disassemble solenoid valve plete. Check needle valve seats for restriction, Replace damaged parts. ‘J—Accumulator connection Pressure oll passage _mceconons 9 sows ‘TM4505 (05DECO0) 70-15-12 Z Series Combines pNezesElectromagnetic Control Valve/Repair Solenoid Valve REPAIR SOLENOID VALVE PLATE FOR HEADER LATERAL TILT E E G R K F @ i Hi 3 2X 005195 P ON ML J a 8 A-Solenoid 6—0it passage check valve seat P—Prossure oil connection Solenoid Hocheck M—Chock valve control Q—Check valve CNeedte valve Pressure oll connection plunger R—Oil passage DoNeodle valve seat ‘Connection to pressure N—Retum oll passage ‘SNe valve seat E—Spring reli plate (O—Check valve seat ToNeeale vale F-Contl plunger Disassemble solenoid valve plate. Replace damaged parts. Check all bores, orifices and valve seats for Once removed, seals must be replaced by new ones. restriction, ‘TM4505 (05DECO0) 70-15-13 Z Series Combines PN=285Electromagnetic Control Valve/Repair Solenoid Valve 2X 005197 F H E A-Solenoid Pressure oil passage a ve E_Retur of passage CNet valve seat F—Controt plunger Disassemble solenoid vaive plate. Check all borés, orifices and valve seats for restriction. REPAIR SOLENOID VALVE PLATE FOR PRESSURE RELIEF (HEADER LATERAL TILT) YA sec xx ] E G F a Connection to hydraulic J-Check valve cylinder H—Gonnecton to hydrauite eylindar Replace damaged parts, Once removed, seals must be replaced by new ones. _Derzcoomo4s. 1.184019 ‘TM4505 (05DECO0) 70-15-14 Z Series Combines PNsaer> Electromagnetic Control Valve/Repair Solenoid Valve REPAIR SOLENOID VALVE PLATE FOR VARIABLE FEEDER HOUSE DRIVE NOTE: The solenoid valve plate for variable feeder plate for reel lift (refer to information given in house drive is identical with the solenoid valve this Group). REPAIR FLOW DIVIDER A B puss 2X 005200 Remove cap from housing. Take piston (A) and Check all bores for restriction, spring (B) out of valve plate. Replace damaged parts. ‘TMa505 (05DECOO) 70-15-15 Z Series Comtines PNe288Electromagnetic Control Valve/Repair Solenoid Valve REPAIR PRESSURE VALVE NOTE: The pressure valve of Hillmaster combines is almost identical with the pressure valve of standard combines. The only difference is that ro check valve is installed. When ordered as spare art, the valve plate is supplied with a check valve. ocrcoraots9snov 70-15-16 Z Series Combines. TM4605 (05DECOO) PNE286Electromagnetic Control Valve/Repair Solenoid Valve REPAIR SOLENOID VALVE PLATE FOR HILLMASTER CONTROL, D E od a ae . 4 ‘i O iS R F H 1 : : e i ZX 005201 P L J v | 2-0 passage ee oneck ae | Sheed vane Sceremur ol comestion —Precaurol somecton V—thesta at valve echo ae wether ae . Son pesane Feo unger Disassemble solenoid valve plate. Replace damaged parts. Check all bores, cries and vale seats for Once removed, seals must be replaced by new ones, restriction, ‘M4505 (05DECO0) 70-15-17 Z Series Combines pasoElectromagnetic Control Valve/Repair Solenoid Valve REPAIR RATE-OF-DROP SOLENOID VALVE PLATE A | __ H i x i $A E ZX 005199 D q ‘ASolenoid Needle valve saat H—Retecotdrop adjusting X Adjusting dimension BNectle vate D—Contrt plunger screw Disassemble solenoid valve plate, Replace damaged parts. Check all bores, orifices and needle valve seats for restriction ‘TM4505 (05DECO0) 70-15-18 Z Series Combines PNe2atGroup 20 Hydraulic Cylinders GENERAL INFORMATION ‘A. Damage to the Piston Rod Watch out for the following - Piston rods must not be subject to mechanical damage, such as dents. = Prevent ice from forming on the running surface, as ice can damage the wiper ring. = Piston rods must not be washed with acidic solutions or. cleaning solutions that adversely affect chrome, - Piston rods that are exposed to the elements when extended must be treated with non-corrosive grease If left inoperative for lengthy periods, + Sticky dirt such as clay etc. must be carefully removed before the cylinder is operated, Cylinders whose piston rods are extended but inaccessible must be actuated periodically. B. Damage to Cylinder Barrels - Never perform welding work on cylinder barrels. Gylinder barrels must never be subjected to thermal shocks (e.g. from welding rods etc:). = Oylinder barrels must never be subjected to mechanical damage. ©. Mis. igned Cylinders Cylinders that are installed off-center and have no ball-and-socket joints are subject to dangerous lateral forces, which cause wear on the piston rod and guides. (An exception to this is cylinders built to withstand lateral forces). ‘SPECIFICATIONS ftom Measurement Specification Nut in cylinder for swinging Torque 114.411. Nm ut the unloading auger (84% 8 Ib) Nat in cylinder that controls Torque 114 4 11.Nm the pivoting shield (84 8 If) ‘TM4505 (05DECO0) 70-20-1 Z Series Combines PNs2a2Hydraulic Cylinders/Disassembly and Changing the Seals DISASSEMBLY AND CHANGING THE SEALS Using @ blunt screwdriver, press axially against snap ring (A) and at the same time turn piston rod (B). It should take about one tum before the snap ring jumps off the piston rod. Turn the piston rod in the direction of the arrow. Use a blunt inscribing too! to extract grooved ring (C). Once the piston rod is removed, wiper ring (D) can be removed easily from the groove. Fold the new grooved ring (C) into a heart shape (E), leaving no sharp edges. Use snap ring pliers to hold the grooved ring together and push it in through bore (F). It will expand to fil the groove. Install new wiper ring (D) in the wiper ring groove. ‘ASSnap ring Piston rod ‘c—Grooved ring D—Wiper ring Grooved ring in “heart” shape F—Piston rod bore G—cylinder barrel, ‘TM4505 (05DECO0) 70-20-2 Z Series Combines pN=283Hydraulic Cylinders/Piston Assembly 90. groove, ASSEMBLING THE PISTON Look through disassembly hole to check that the snap ring is in its proper position, ‘A~oylinder BSnap ring (C—Piston rod Place snap ring (B) on piston rod (C) and slide the Piston rod into cylinder (A). AAs shown by the arrow, insert the piston as far as it will Place the end of the piston rod on a wooden surface and strike the end of the cylinder barrel once with a hammer. The blow should be brief but hard. This causes the snap ring to jump into the snap ring _ B. + g 3 oO} ; zivessea i ‘TM4505 (05DEC00) 70-20-3 Z Series Combines pNe2ehHydraulic Cylinders/Cylinder for Raising Header J CYLINDER FOR RAISING HEADER Bc D E G —_ = HA F J zxo09908 ‘A—Wiper ring D-Plug with O-ing G—Hose connection and H-Snap ring BGrooved ring ECylindor barrel ‘disassembly hole JCylinder base (o—Rod seal FPiston rod Disassembly and Changing the Seals Use-a blunt inscribing tool to remove all seals, and replace them with new ones. Use a blunt screwdriver to press snap ring (H) down towards cylinder base 4) IMPORTANT: Take care not to damage the base of the groove. Extract piston rod (F) from cylinder barre! (E). Assemble in reverse order. ‘TM4505 (05DECO0) 70-20-4 Z Series Combines pNeeeSHydraulic Cylinders/Cylinder for Swinging Out Unloading Auger CYLINDER FOR SWINGING OUT THE UNLOADING AUGER EF zx000085 A—Wipor ring 8 Retaining ving :—Grooved ring (G—Cylinder barrel D—Snap ring Disassembly and Changing the Seals Use assembly ples to remove retaining ring (8). Push back guide (F) until snap ring (0) is exposed. Use a blunt screwdriver to pry out snap ring (0) Pull out piston rod (H) and piston (K). Hf necessary, slacken nut (M) and take off piston (K). 1 I N K z i 5 Piston rod Lotye rng Jude bend tone iPiston NoBushing Use a blunt inscribing tool to remove all seals, and replace them with new ones. of IMPORTANT: Take care not to damage the ba: the groove. Assemble in reverse order. Tighten nut (M) to 114 + 11. Nem (84 + 8 Ib-) ‘TM4505 (05DECO0) 70-20-5 Z Series Combines edPIVOTING SHIELD CONTROL CYLINDER AB Cc L en = : - Le 3 5 G 5 DE F J K g ‘zx009387, i — re ‘TM4505 (05DECO0) 70-20-6 Z Series Combines puczerHydraulic Cylinders/Belt Tensioning Cylinder > BELT TENSIONING CYLINDER A-Piston rod ‘8 —Wiper ring Disassembly and Changing the Seals (c—Grooved ring D—cytinder barrel Pull piston rod (A) in the direction of the arrow until snap ring (G) becomes visible in disassembly hole ©. Insert a blunt screwdriver through disassembly hole {E) and press snap ring (G) down towards cylinder base (F), Disassembly hole Fooylinder base G—Snap ring Extract the piston rod from cylinder barrel (D). Use a blunt inscribing tool to remove ail sealing components. IMPORTANT: Take care not to damage the base of the groove. Assemble in reverse order. ‘TM4505 (05DECO0) 70-20-7 Z Series Combines PN=298Hydraulic Cylinders/Belt Tensioning Cylinder ‘TM4505 (05DECO0) 70-20-8 Z Series Combines PN=23Hillmaster Hydraulic Cylinder Group 21 MAKING A SPECIAL TOOL cy Too for disassomblng and essembing the vaive seat jo | and piston in the check valve. ‘A200 mm (7.9 in) 5100 mm (4.0 in) ‘C—Diameter 4 mm (0.16 in) Dod thread, 10 mm (04 in) A g 3 a ranes =O | ‘SPECIFICATIONS tom Measurement ‘Specification Nat in hillmaster hydraulic Torque 1400 # 140 Nem cylinders (1033 + 103 Ib-f) ‘Screw plug on check Torque 130 £ 13. Nm valve (96 + 10 Ib-f) 7 OTHER MATERIALS | Number Name Use Ty9371 Lootite 270 Securing the guide in the hillmaster hydraulic cylinder TM4505 (05DECO0) 70-21-1 Z Series Combines PNsa00L Hilimaster Hydraulic Cylinder/Components of Hillmaster Cylinder GENERAL INFORMATION CAUTION: Never work on the hillmaster cylinders unless the combine harvester has already been lowered. NOTE: Refer to Operator's Manual Hillmaster Levelling System “Operating With CAUTION: Danger! Hillmaster cylinders weigh approx. 55 kg (121 Ib). COMPONENTS OF HILLMASTER CYLINDER G Mo oB J oN OD c oa : . sy & Ez | P HK ELJ HA J 2 zxoososs 5 ‘A-cyinder bare, Compensating valve NC Spiral backup ring Fiaton Focheck valve O—Wper ring CoPiston roa ooNut P—Grooved rng Dou HoWasher —Gulde band Secure with Loctte Disassembly and Changing the Seals, IMPORTANT: Take care not to damage the base of the groove. Heat the area of the cylinder around the thread on guide (D) to a temperature of at least 300°C (572°F), Assemble the cylinder in reverse order, break the Locite seal and use assembly pliers to unscrew guide (D). Tighten nut (G) to 1400 140 Nm (1033 + 130 tb-t), Pull out piston rod (C) and piston (B). Apply Loctite 270 (TY9971) to the thread of guide (0) Remove nut (G), washers (H), piston (B) and guide _—_before inserting and tightening the guide. (0) from the piston rod. Use a blunt inscribing tool to remove all seals, and replace them with new ones, "TM405 (05DECO0) 70-21-2 Z Series Combines PN=aotHllmaster Hydraulle Cylinder/Check Valve Components CHECK VALVE COMPONENTS Removing the Check Valve Use a hex. socket wrench with a width across flats of 17 mm to take out screw plug (J). One after the oth valve cone (G). remove spring (E), sleeve (H) and A-oring e—Pteton ; Cushing ESpnng s—8 FoValve seat °—2 Valve cone tote Ls Screw plug D {_ e T L 16 z 33] —o— 4 of len oa 34] wo oe 22 yl y yf Be e ot re oi j 35 g 6 = 7 i EG zsh 5 7a hy, 1 8 [ (F; = ri 18 |!" 9] of LL. TM4505 (05DEC00) 270-05-4 Z Series Combines puerstGeneral Information/Explanation of Symbols ‘Mechanica (ol | aetustor | 2-Hydreutc actuator ‘3-Pneumatic actuator ‘electromagnetic (solenoid) actuator 5Solenoid pilot and hydraulic actuator ‘6-Pnoumatic pilot and ‘hydraulic actuator 7_Detent actuator 2—Springloaded roturn 9472 directional control ‘valve with solenoid Actuator and spring loaded return 10-42 valve with external hydraulic actuator and return 4442 valve with detent and ‘solenoid actuator ‘and return 12413 valve with solenoid actuator, spring centered head) 43-Pressure control valve, O-position normally blocked +4Pressure control valve, ‘O-position normally normally open | 16 —Pressure roll valve, fixed spring pressure 16—Adjustable prossure relief valve ‘17—Adjustable pressure re- Hef valve, remote con- ‘ol connection with ox ‘ternal pilot oll drain 18—Adjustable pressure re lef valve, ramote con- trol connection with in- ternal plot oll drain 49--Fixed pressure reduction valve, remote control ‘connection with external pilot oll drain 20Adjustable pressure tontrol valve, remote ‘operated with external pilot olf drain LEGEND — GRAPHIC SYMBOLS FOR HYDRAULICS 24—Adjustable pressure ‘control valve, remote 22Pressure relief valve, remote operated 2a-Preeure switch ‘24Onific, fixed restriction restriction 26—Vieeosity Influenced restietion 27—Adjustable flow control ‘valve with bypass ‘28-Fixed unidirectional low ‘control valve, 29Variable unidirectional ‘low control valve 1—Variable unidirectional flow control valve with bypass check valve ‘31—Threeeway flow contro valve 32Flow alvidor '32—Check valve without spring ‘34-Spring loaded chock valve 35—Check valve pilot- ‘operated to open with Internal oil drain 36—Check valve pilot ‘operated to open with fextomal olf drain ‘37—Pilot operated double ‘heck valve in detail '36—Same valve simplified 39—Hydraulle accumulator 40—Filter, strainer ‘41—Cooler 42--Reservolr (vented) ‘TM4505 (05DECO0) 270-05-5 Z Series Combines PNere2General Information/Hydraulic System Circuit Diagram EXPLANATION OF SYMBOLS A—Hydraulic pump H—Hydraulic cylinder, raise O—Cylinder, variable \V-Hydraulie chaff spreader ‘B—Hydraulle pump roel threshing eylinder drive drive (C—Hydraulic pump J-Accumulator PHTensioning cylinder, main W—Hydraulic oll reservoir ‘D—Solenoid valve block, K-Hydraulic cylinder, header drive X—-Return connection from ‘basic machine parallel adjustment Q—Tensioning eyinder, powered rear axle Solenoid valve block, L-Gylindor, variable feeder unloading drive Y—Suetion tine of ‘Teoder house hhouse drive R-Pressure switch hydrostatic ground drive Solenoid valve block, MAHydraulic cylinder, swing S—Accumulator Z-Return line of hydrostatic header ‘out unloading auger ‘T—Hydraulic ol filter ‘ground drive G—Hyarautie eylinder, N—Header tft cylinder U—Drain connection horizontal reel adjustment NOTE: Connections (X), (Y) and (Z) are continued in "Y" designations of solenoids are identical with hydrostatic system circuit diagram (refer to those in the electrical system diagrams. Section 250). ‘TM4505 (0SDECOO) 270-05-7 Z Series Combines PNeTOdGeneral Information/Hydraulic System Circuit Diagram B—Hydraulie pump (C—Hydrautle pump Solenoid valve block, ‘basic machine Solenoid valve block, feeder house F_Hoader quick coupler ‘G—Header quick coupler H-Solenoid valve block, Hilmastor ‘Section 260). NOTE: Connections (x), (Y) and (2) are continued in hydrostatic system circuit diagram (refer to EXPLANATION OF SYMBOLS lic eyinder, header N-—Header Ut cylinder adjustment (O—cylinder, variable (master cylinder at final threshing eylinder drive rive) PTensioning cylinder, main K-Hydraulc cylinder, header drive parallol adjustment ‘a—Tensioning eytinder, L-Cylinder, variable fooder unloading drive house drive Pressure switch MHydraulle eylinder, swing S—Accumulator ‘out unloading auger THydraulle ol itor "Y" designations of solenoids are identical with those in the electrical system diagrams. U-Drain connection ‘V—Hydraulle chaff spreader ‘rive WA Hydraulic olf reservoir X-Retuen connection from ‘powered rear axe ‘Y-Suction tine hydrostatic ground drive Z-Rotuen tine of hydrostatic ‘round drive Twi4505 (0SDECOO) 270-05-9 Z Series Combines PNSTESGeneral Information/Hydraulle System Circuit Diagram ‘TM4505 (05DECO0) 270-05-10 Z Series Combines NeverGroup 10 Solenoid Valves SOLENOID VALVES — BASIC MACHINE Zx004160 i Y 1— Pressure valve 4 Y 22 — Solenoid, switching on separator Y 2— Pressure valve 2 Y 23 — Solenoid, switching on separator Y 3 — Solenoid, raising header Y 26 — Solenoid, unloading grain tank Y 4 — Solenoid, lowering header Y 27 — Solenoid, unloading grain tank Y_ 5 — Solenoid, raising header Y 28 — Solenoid, reducing cylinder speed Y 6 — Solenoid, lowering header Y 29 — Solenoid, increasing cylinder speed Y 10 — Solenoid, swinging in unloading auger 'Y 30 — Solenoid, reducing feeder house Y 11 — Solenoid, swinging out unloading auger speed Y 14 — Solenoid, header leveling, left side Y 31 — Solenoid, increasing feeder house Y 15 — Solenoid, header leveling, right side speed Y 21 — Solenoid not allocated eruacosonerse 20s ‘TM4505 (05DECO0) 270-10-1 Z Series Combines enere8» Solenoid Valvos/Solenoid Valves Hilmaster SOLENOID VALVES — HILLMASTER q zxooatet | Y_ 7. Prossure valve 3 Y 13 — Solenoid, leveling system, right ¥ 12 — Solenoid lveling system, let YY 20 — Solencid, lowering combine Fiwa605 (0SDECO0) 270-10-2 Z Series Combines eN=TeSSolenoid Valves/Solenoid Valve Plates - Theory of Operation SOLENOID VALVE PLATE FOR HORIZONTAL REEL ADJUSTMENT, NEUTRAL POSITION A e u T N c TT s D ; E les NM cs R F H @ c NS P oONM EL J k . = i A-Solenoid control plunger check vate seat check vale e—Solnold Reta ol postage Piston ol pase HCoheck valve NoRetun valve seat, D—Noedle valve eet Somecton woking tine OWGheck vale seat E-Spring k—Thormal relief valve Connection, working line The solenoid valve plate for horizontal reel adjustment In neutral position, solenoids (A) and (B) are closed is a 3/4 directional control valve plate with integrated (without current). Orifices of contro! plunger (F) relieve check valves. pressure on both sides of plunger, moving it to center position. Both check valves are closed. TM4505 (05DECO0) 270-10-3 Z Series Combines pastSolenoid Valves/Solenoid Valve Plates - Theory of Operation SOLENOID VALVE PLATE FOR HORIZONTAL REEL ADJUSTMENT, WORKING POSITION B A u ic Ne Lf ce | im im Ss D E (= : E diese c R ra Fe H S 2 5 5 zmeaias P ONM EL J K : A-Solonoid check valve seat check vatve Solenoid Return ot passage RoRetum of passage CoNeede valve Scleedl valve seat D—Needle valve set Hecke valve e—Sprng Poconnection, working ine U—Pressro oll passage In working position, needle valve (C) or (T) is opened _via the check valve. Pressure moves piston (M) to electromagnetically. Control plunger (F) moves to the _the opposite side, opening return check valve. The right or left and routes pressure ail to the working line _reel is moved forward or rearward. zxnoaconon anion M4505 (08DECO0) 270-10-4 Z Seties Combines enerSolenoid Valves/Solenoid Valve Plates - Theory of Operation SOLENOID VALVE PLATE FOR REEL LIFT, NEUTRAL POSITION | A §B—_ Jd RAI i i H | hi c yo K\ mI . D G \ = a ; F E J 2 zxooss29 3| 5 A-Solanoid D-Needle valve soot Solenoid Cylinder connection $F Accumulator connection CoNeede valve AA hydraulic cylinder or a hydraulically adjustable When using solenoid valve plate on cutting platform, variable drive is connected to (E). an accumulator is connected to (J) to facilitate the coupling process. ‘TM4505 (05DECO0) 270-10-5 Z Series Combines PNETSolenoid Valves/Solenoid Valve Plates - Theory of Operation zxo0s140 a E ‘A-Solenoid ‘D-Nosdle valve seat Return ‘B-Solenoid E=Cylinder conneetion Needle C—Neodle valve Needle valve (C) is opened, routing pressure oil to connection (E). Needle valve (H) opened to lower reel. SOLENOID VALVE PLATE FOR REEL LIFT, ’RAISE’ POSITION H-Noodle valve Accumulator connection ‘TM4505 (05DECO0) 270-10-6 Z Series Combines PNerTs» Solenoid Valves/Solenoid Valve Plates - Theory of Operation SOLENOID VALVE PLATE FOR PRESSURE RELIEF (HEADER LATERAL TILT) D =x 5 “ J c i SEC KX oO) OF i ex 3 zxooetat F H E G F i ‘A-Solenoid (not installed) _-_‘D-Pressure oll passage G—Hyraule oylindor s-Check valve Return oil passage connection F—Controt plunger H-Hydraulle eyindor connection This solenoid valve plate is used on machines corresponding side of double-acting hydraulic cylinder. provided with header lateral tit function ‘The pressure relief valves installed on right and left-hand side limit pressure to 12500 kPa (125 bar; When the cutting platform is lowered and touches the 1800 psi, controlled by needle valve (B). ground on one side, high pressure is created on ‘TM4505 (05DECO0) 270-10-7 Z Series Combines pussSolenoid Valves/Solenold Valve Plates - Theory of Operation SOLENOID VALVE PLATE FOR HEADER LATERAL TILT, NEUTRAL POSITION B A u SS s T Cc i s D E i all E a G R K K 2 \ ‘ a 3 z ens P ONM L J 5 ‘A-Solenoia Return ot passage check vatve seat check vate | Solenoid HOGheck valve —Pston RoRetumn of passage CNeodle valve Connection working line N—Retum ol passage S—Needla valve seat Needle valve soat 1 Connecting passage 19" O—Check valve seat Needle valve E—Spring proceure rll plate. -P-—Connection, working Hine U—Pressuro cll passage F—Conto! plunger ‘The function of the solenoid valve plate for header ‘The only difference is that two connecting passages lateral tit corresponds to the function of the solenoid _—_(K) to the solenoid valve plate for pressure relief are valve plate for horizontal reel adjustment (refer to provided. information in this Group). ‘TM4505 (05DECO0) 270-10-8 Z Series Combines pnersSolenoid Valves/Solencid Valve Plates - Theory of Operation SOLENOID VALVE PLATE FOR HEADER LATERAL TILT, WORKING POSITION os B A T c | hg: U1 T s D E : alll G R r 2a F kK 1 K e i a! 2 aoe P ON ML J : AcSolenold ‘GRotum oll passage Lcheck valve seat, chock valve Solenoid Hocheck valve Piston Roum olf passage CoNeeao valve =Connaction, working tine N—Retur Seed valve set Needle valve sot Connecting passage to O—Check vl T Needle vave E-Spring Dresbure rele pate Connection, working tine U-Pressure oll passage FoContot plunger In working postion, needle valve (C) or (T) is opened _ ine via the check valve. Pressure moves piston (M) electromagnetically. Control plunger (F) Is moved to _to the opposite side, opening return check valve. The the right or left and directs pressure oil to the working _cuting platform is tited to the right or lef “Twas05 (05DECOO) 270-10-9 Z Series Combines NearsSolenoid Valves/Solenold Valve Plates - Theory of Operation SOLENOID VALVE PLATE FOR HARVESTING UNIT VARIABLE DRIVE NOTE: The solenoid valve plate for harvesting unit variable drive is identical with the solenoid valve plate for ree! lift. Refer to information given in this Group. * 270-10-10 Z Series Combines exert ‘TM4505 (0SDECOO)Solenoid Valves/Solenoid Valve Plates - Theory of Operation SOLENOID VALVE PLATE FOR SWINGING OUT UNLOADING AUGER, NEUTRAL POSITION B A Ty (| i c I im 8 D > E AAs = e arco Freee G R F iN N Q I H z came P ON ML J § ‘A-Solanold Control plunger Piston R-Return oll passa Solenoid NCReturn ofl passage S—Noodle valve seat Needle valve (O—Check valve seat F_Necale valve DoNeedle valve soat Connection, Poeonnection, working line U—Pressure oll passage Spring chock valve seat Check valve Pilot-operated check valves are located in front of the This makes it possible to hold the unloading auger connections to the double-acting hydraulic cylinder. securely in any position. ‘TM4505 (05DECO0) 270-10-11 Z Series Combines PNETTS.Solenoid Valves/Solenoid Valve Plates - Theory of Operation SOLENOID VALVE PLATE FOR SWINGING OUT UNLOADING AUGER, WORKING POSITION 3 \ 2 ee Pp ON ML J 5 A-Solenois Control plunger Piston Solenoid G—-Retum ol passage N—Return ofl pos C—Needle valve Hooheck valve O=Check valve seat, Needle valve seat ‘TTComnection, working line PoGennaction, working fine UPressure cll passage Spring i cheok valve coat Check valve Plunger (F) is pressurized on one side by opening (U) and line (J) or (P). The pressure buildup opens ‘one needle valve. This moves the plunger out of the check valve on the opposite side to provide a Center postion to right or lefthand end postion, retum oil connection providing a connection between pressure oil passage _zxmpgoowore-1 2810103 ‘TM4505 (05DECO0) 270-10-12 Z Series Combines PNTSolenoid Valves/Solenoid Valve Plates - Theory of Operation PRESSURE VALVE IN NEUTRAL POSITION ~\ L 2x 004146 JG ‘A-Solenotd B—Neoule valve ‘C—Neodle valve seat ‘D—Pressure test connection E—Control plunger orifice ‘G—Control plunger seat Connection, pressure oil ‘from hydrautie pump J-Return oi! paseage (with connection to the other valve plates) With pressure valve in neutral position, needle valve (8) Is open. Space behind control plunger (E) is pressure-free, because this space is connected to return oll passage and, via connection (L), to hydraulic oil reservoir. ‘TM4508 (05DECO0) 270-10-13 H FE E D N-Preseure oll passage ‘(with connection tothe ‘thar valve plates) L-Connection, return oil to hydraulic oll reservoir M—Check valve plunger ll from hydraulic pump entering at connection (H) pushes plunger (E) back and retums to hydraulic oft reservoir via connection (L). Z Series Combines pNere0Solenoid Valves/Solenoid Valve Plates - Theory of Operation PRESSURE VALVE IN WORKING POSITION pa SSA ic: Oy oo eae zx 004147 J ‘A-Sotonold B—Needle valve (C—Needle valve seat D—Pressure test connection Control plunger F—onitice {G—Control plunger seat H—Connection, pressure oll from hydraulic pump ‘J-Return oll passage (with connection to the ‘other valve plates) With pressure valve in working position, needle valve (B) is pressed on its seat (C) by solenoid (A). ‘There is no connection between space behind plunger (E) and return oil passage. Orifice (F) builds up pressure behind plunger. Due to the pressure buildup and spring force, control plunger (E) Is pressed on its seat (G). The connection to return oil passage is interrupted. ‘TM4505 (05DECO0) L-Connection, return oll to M—Check valve plunger 270-10-14 H F E 0 N-Pressure oil passage (with connection to the other vaive plates) hydrauile lt reservoir ‘The pressure oil pushes back plunger (M) of check valve and flows into pressure oil passage (N). Pressure oil can flow from pressure oil passage (N) to one of the control valve plates (arranged parallel) to perform any desired hydraulic function. Z Series Combines pNeratSolenoid Valves/Solenoid Valve Plates - Theory of Operation PRESSURE VALVE WITH PRESSURE RELIEF VALVE i L ui i iN ii zxo044s ‘B-Conneetion, return ol ‘A~Connection, pressure oll hydraulic ol reservoit from hydraulic pump to operation of pressure valve without relief valve, The only difference is a connecting bore between pressure oll passage and retum oll passage with Operation of pressure valve with relief valve is similar c-Pressure oll passage incorporated relief valve. Relief valve opening pressure is 22000 kPa (220 bar; 9200 psi). Pressure relief valve ‘TM4505 (0SDECOO) 270-10-15 Z Series Combines NeraSolenoid Valves/Solenoid Valve Plates - Theory of Operation B a i N M L zxo04149 kK J ASolenoi F—Connesting pa = ‘G—Return passa (C—Neodle valve HOPressure oll passage Boonies JConnecting passage Control plunger, raising In neutral position needle valves (C) and (N) are closed by spring pressure. Pressure can be buill up via orifices (M) and (D) in space behind control plungers (E) and (K) and both control plungers are pressed on their seats. Pressure oil passage (H) and return oil passage (G) are closed by lit cylinder connection, SOLENOID VALVE PLATE ‘RAISING HARVESTING UNIT’, NEUTRAL POSITION Gc oF 3 A Control plunger, lowering X—Dimension for ift rate L=Check valve adjustment N—Orifice Y_Dimension for NNecdle valve rate-of-drop adjustment When no hydraulic functions are operated and pressure oil passage is without pressure, check valve (L) prevents hydraulic oil from flowing back. This in turn prevents harvesting unit from lowering. ‘TM4506 (0SDECOO) 2270-10-16 Z Series Combines PN=7eSSolenoid Valves/Solenoid Valve Plates - Theory of Operation SOLENOID VALVE PLATE ’RAISING HARVESTING UNIT’, RAISING POSITION ZX 004150 K J ‘A-Solenoid Solenoid CNeedle valve HCPressue ol passage D—onifce Control plunger, raising J-Connecting passage To raise harvesting unit solenoid (A) is activated. Needle valve (C) opens and so connection between space behind control plunger (E) and passage to harvesting unit lift cylinder (blocked by control plunger, E) is open. G F X—Dimension for it rate adjustment mension for ratecoF-drop adjustment K-Control plunger, lowering L—Check valve orifice ¥ NNoodle valve ‘This causes pressure to drop in space behind control plunger (E), and. plunger (E) to open. Pressure oil flows past check valve (L) to harvesting unit lift cylinders. Derwacoones 19.2009 ‘TM4505 (05DECO0) 270-10-17 Z Series Combines:Solenoid Valves/Solenoid Valve Plates - Theory of Operation SOLENOID VALVE PLATE 'RAISING HARVESTING UNIT’, LOWERING POSITION 2X 004151 K J ‘A~Solenotd FConnecting passage B—Solenoid G—Retumn oll passa C—Neodle valve H—Pressure oll Doorifice Connecting passage Control plunger, ralsing To lower harvesting unit solenoid (A) is activated. Needle valve (C) opens and so connection between space behind control plunger (E) and return cil passage (G) is open. G F K-Control plunger, lowering X—Dimension for lift rate chock valve adjustme Hi—Onifice ‘Y—Dimension for NoNeedle valve rate-f-drop adjustment ‘This causes pressure to drop in space behind control plunger (E), and plunger (E) to open. Oil can now flow from harvesting unit lift cylinders to return cil passage (G). ‘TM4505 (05DECO0) 270-10-18 Z Series Combines eN=TeSSolenoid Valves/Solenoid Valve Plates - Theory of Operation SOLENOID VALVE PLATE ‘RAISING HARVESTING UNIT’, FLOAT POSITION zxoo4152 «KK J G F ‘A-Sotencid F—Connecting passage L-Check vatve Dimension for it rato BStee! core G—Retumn oil passage Morice adjustment C—Neodle valve HPressure oll passage NoNecdle valve Y—Dimension for D—oFifice Connection to lift cylinder O—Connecting bore rate-of-drop adjustment E—Control plunger, raising —_K—Control plunger, lowering P—Bloed screw To obtain float function, the solenoid valve plate is ‘current between 300 and 900 mA. Depending on equipped with @ special solenoid (B). For float current a certain needle valve (N) opening pressure function the solenoid is supplied with an electric is obtained which determines ground pressure. ‘TM4505 (05DEC00) 270-10-19 Z Series Combines PNETESSolenoid Valves/Solenoid Valve Plates - Theory of Operation 2X 004153, ‘A~Solenoid B-Solenoid C—Neodle valve DoNeodle valve seat drive oylinder. Threshing cylinder variable drive hydraulic cylinder is connected to connection (E) of solenoid valve plate. By activating solenoid (B) and opening needle valve (J) hydraulic oll is discharged from variable SOLENOID VALVE PLATE ‘CYLINDER VARIABLE DRIVE ADJUSTMENT’ g Lo oGF E i e-comecon tnd Geta ol pasnge ——KPresueopsaon sora te Scaceme cuca ER comectan rr (70 bar; 1015 psi). re ralief valve J Needle valve reservoir By activating a pressure valve and solenoid (A) hydraulic oil is directed to variable drive cylinder. Pressure rolief valve (F) limits pressure to 7000 KPa ‘TM4505 (05DEC00) 270-10-20 Z Series Combines pNera7Solenoid Valves/Solenoid Valve Plates - Theory of Operation SOLENOID VALVE PLATE ‘CYLINDER VARIABLE DRIVE ADJUSTMENT’, INCREASING | | B J H t i ZX 005230 L GF E 5 A~Solenoid Connection, eyinder -—»«GRetum ol passage K—Pressure oll passage Solenoid variable drive HNeedlo valve seat LTRetum connection to Needle valve Pressure relief valve JNecele valve resorvoi DNase valve seat One pressure valve and solenoid (A) are activated to 1018 psi). An additional orifice plate is located in increase threshing cylinder speed. The orifice in the connection (E). This ensures that cylinder variable pressure oil passage limits oll flow. Pressure relief ative adjustment is not carried out too rapidly. valve (F) limits pressure to 7000 kPa (70 bar, ervarcouten sone ‘TM4505 (05DECOO) 270-10-21 Z Series Combines pNeres> Solenoid Valves/Solenoid Valve Plates - Theory of Operation SOLENOID VALVE PLATE ‘CYLINDER VARIABLE DRIVE ADJUSTMENT’, DECREASING SER Le SN : : H 2 ee a o KK R SS . > oN . 2 j 3 GF E K-Prossure oll passage HoNecdle val L=Return connection to J-Needle val reservoir Solenoid (B) is activated to decrease threshing seat into the return oil passage and back to the cylinder speed. Hydraulic oil lows via needle valve hydraulic oil reservoir. ‘TM4505 (05DECO0) 270-10-22 Z Series Combines PNETESSolenoid Valves/Solenoid Valve Plates - Theory of Operation PRESSURE REDUCING VALVE E D A zxo0s202 c B i ‘A-Precsure reducing Insert B—Return oll passage c-Pressure oll passage to _D--Prossure oil passage from pressure valves ‘The purpose of pressure reducing valve is to limit oil (210 bar; 3050 psi) max. (when other hydraulic pressure which is necessary for main clutch operation functions are operated) to 6500 kPa (65 bar; to 6500 kPa (65 bar; 940 psi) max. ‘940 psi) max. in passage (C). ‘The pressure reducing insert (A) limits pressure from pressure valves in passage (D) of 21000 kPa _zxmmzcorone 62510109 ‘TM4505 (0SDECOO) 270-10-23 Z Series Combines PN=rs0Solenoid Valves/Solencid Valve Plates - Theory of Operation SOLENOID VALVE PLATE ‘ENGAGING SEPARATOR OR UNLOADING DRIVE’, NEUTRAL ISITION. B——__ | Sy H i) iv Cc —| NY Na + S DE 6 a = i 3 F E 3 zaoniss i ‘A-Solenoid Needle valve seat Return ot passage H—Nectle vale B—Solenoid Connection to main ‘G-Needle valve seat ‘Pressure oll passage Needle vale cute With solenoid valve plate in neutral position, solenoid connection (E) leading to main clutch, is connected to valve (A) is closed without current and solenoid relum ol passage. Main clutch is without pressure valve (B) open without current. In this position and thus disengaged. ‘TM4505 (0SDECO0) 270-10-24 Z Series Combines pNeT3tSolenoid Valves/Solenoid Valve Plates - Theory of Operation Ss a GS zxo04185 FE A-Solenoid Needle valve seat B-Solenoid Connection to main CoNeadle valve clutch With solenoid vaive in operating position solenoid valves (A) and (B) are activated, solencid valve (A) opens and provides @ connection between pressure «il passage and connection (E). MAIN CLUTCH SOLENOID VALVE PLATE IN OPERATING POSITION A J le’ c D 3 8 E A H-Needle valve Pressure oll passage Return oil passage G—Necdle valve seat Solenoid valve (B) interrupts connection to return oil passage. Via connection (E) pressure is built up in main clutch and main clutch is engaged. ‘TM4505 (05DECOO) 270-10-25 Z Series Combines pNeTa2Solenoid Valves/Solenoid Valve Plates - Theory of Operation FLOW DIVIDER (HILLMASTER) aie | My en / Se wnt a zxo04156 é b ‘A~Supply from pump cProssure oll passage ‘D-Return oll passage B-Spoot {primary system) E—Connection to main solenoid valve block The first module at hllmaster combine hydraulic valve (7 US gal/min) oil approx. The surplus amount of ofl block is the flow divider. It is supplied from hydraulic of 18 LImin (5 US gal/min) approx. flows via pump with 45 Limin (12 US gal/min) oil via connection (E) to secundary system, the combine connection (A). Hilmaster system is supplied with main valve block with pressure valve (Y4). priority via spool (B) and passage (C) with 27 Limin TMa605 (05DECO0) 270-10-26 Z Series Combines PNeT9Solenoid Valves/Solenoid Valve Plates - Theory of Operation PRESSURE VALVE, HILLMASTER Function of pressure: valve of hillmaster combine solenoid valve block is the same as function of pressure valve on basic machine. The difference is that on hillmaster combines no check valve is installed. Opening pressure of pressure relief valve is 22000 KPa (220 bar; 32000 psi ‘TM4505 (05DECO0) 270-10-27 Z Series Combines pacradSolenoid Valves/Solenoid Valve Plates - Theory of Operation SOLENOID VALVE PLATE ’HILLMASTER’, TILTING LATERALLY B A Ny Ye D > E pad 56 «Ha oN — LZAT G 5S i iG i H Q as : w RS 3 3 2X 004157 P ONML J Vv i A Solenoid N—Return oi pases ‘S-Neadle valve seat Solenoid O—check valve te FNeeso valo Soconnection work ine --Po-Connecton, working —«—-Uc-Pressure ell passage ‘DoNesae valve seat Chock valvo seat check valve ‘VThermal role valve E-Spring Plunger Return oll passage WoThermal rele valve Font plunger Function of solenoid valve plate shown is the same (W) is integrated in each connection for work line. as the function of solenoid valve plate for swinging This is to avoid pressure build-up caused by heating cut unloading auger. A difference is, that on up hydraulic oll by solar radiation. hillmaster combines a pressure relief valve (V) and zxrwacoovan 9 280 ‘TM4505 (0SDECO0) 270-10-28 Z Series Combines PNeTasSolenoid Valves/Solenoid Valve Plates - Theory of Operation SOLENOID VALVE PLATE 'LOWERING MACHINE’, NEUTRAL POSITION A G if B c H xf zx 005229 «-F E D i ‘A-Solenoid ‘D—Contro plunger F_Retum oll passage X-Dimension for adjustment BCNowde valve E=Conncction to piston side G—Passoge without function 20 mm (0.88 in) (C—Nwao valve soat of hillmastor hydraulic H—Adjusting screw eytinors In neutral positon, needle valve (B) is closed. ‘With needle valve (B) open, no pressure can build up Pressure from connection (E) also builds up behind behind plunger (D). This will open return oil passage plunger (0). This closes passage (F) and retum line and the oil can flow to the hydraulic oil reservoir. to hydraulic oll reservoir. ‘TM4505 (05DECOO) 270-10-29 Z Series Combines PNSTeSSolenoid Valves/Solenoid Valve Plates - Theory of Operation SOLENOID VALVE PLATE "LOWERING MACHINE’ G H x J) i e zx004158 F E D i ‘A—Solenoid Control plunger F-Return olf passage Adjusting screw Noodle vane E—Connection of pistonside G—Passage without function X—Dimension for adjustment ‘C—Noadle valve soat connacting ines (blocked) 720'mm (0.80 in) Connection (E) is connected to hydraulic fine solenoid (A) is activated. This prevents one hydraulic, connecting hillmaster cylinder piston sides. Oil owing cylinder from extending when the other one is during normal lateral ting from one hydraulic cylinder _retracted, and the machine is lowering to the other, is directed to return oil passage if, Dirxaconat 6.250183 [Tasos (050EC00) 270-10-30 Z Series Combines PNerorGroup 15 Hillmaster Leveling System GENERAL INFORMATION On combines with Hillmaster leveling system, final drives pivot on front axle. Final drive position is determined by hydraulic cylinders (one on each side of the combine). ‘The cutting platform pivats on feeder house. Cutting platform position in relation to slope angle is determined by a master cylinder on final drive and a slave cylinder ‘on pivoting shield of feeder house. ‘A—Pivoting final drive 'B-Final drive hydraulic cylinder ‘G—Pivoting shield hydraulc cylinder ‘TM4505 (05DECO0) 270-15-1 Z Series Combines PNeToEFetqwen sov0s Z Z-S4-022 ‘SLN3NOAWOD WAISAS ONMAT7 MLSVTTIH RANA ARPTS BOOT INETHillmaster Leveling System/Components HILLMASTER LEVELNG SYSTEM COMPONENTS ‘A—Final deve, right ltmastor hydraulic Flow divider Solenoid valve plate, BFinal drive, oft cylinder, lft G—Pressure valve oweting combine (C—Htmaster hydraulic E-Lovel sensing control box | H—Solenold valve plate, cylinder, right tilting to the rightett The final drives are bolted to two support plates, ‘A pendulum in the level sensing control box is used which can be pivoted around a horizontal axis relative __to sense slope angle. This box transmits a signal until to the axle. The plate is held in a certain position the pendulum is centered in the box and the combine relative to the axle or pivoted by a large hydraulic, is exactly level cylinder. ‘TM4505 (0SDEC00) 270-15-3 Z Series Combines. PN=800La Die ah gue 65199 2 perore ona anse) soci NOUWE3dO NOs WALSAS ONMTATT NALSYWTIH ONRIVETIdHilimaster Leveling System/Preparing for Operation PREPARING HILLMASTER LEVELING SYSTEM FOR OPERATION ‘ACHydraulic cylinder, right B_Hydraulic cylinder, left CoPilot-operated check valve D-Pilot-operated check valve E-Solenoid vaive plate, imaster control FSolenoid valve plat, lowering combine Bofore operating Hillmaster leveling system, itis necessary to move the machine from lowered position (for road travel) to higher position (for field operation). This is done by moving combine to maximum right or left-hand tit position by operating manual leveling control switch During the titing process, the solenoid valve directs hydraulic oll to the rod side of one hydraulic cylinder c—Reservoir Hydraulic of, high pressure Hydraulic ol, pressure-ree (return cil) K-Hydraulle of, trapped L-Hyaraute ol, rapped land, via the check valves in the piston, to the piston side of the opposite cylinder. The piston side of the hydraulic cylinder is filed with hydraulic oil, causing the cylinder fo extend. When the combine is moved back to center position, ail flows back from the piston side of the extended hydraulic cylinder. This means that both hydraulic cylinders are halfway extended with combine in center position (on level ground). ‘T4505 (05DECO0) 270-15-5 Z Series Combines PN=B02uD gore fone) son ruHillmaster Leveling System/Operation E-Solenoid valve plate, Hilimaster control F-Solenoid valve plate, Towering combine A—Hydraulle oylinder, right Hydraulic eyinder, left CPt operated check valve Pilot operated check valve NOTE: During leveling system operation, the machine fs held in position by pilot-operated check valves integrated in the hydraulic cylinders, e.g. if a hydraulic hose should burst. Hydraulic oil is trapped on the piston side of hydraulic oylinders. ‘When leveling to the right, the solenoid valve plate routes hydraulic oll to the right-hand hydraulic cylinder. Oil pressure is directed to the rod side of the hydraulic cylinder. At the same time the pilot-operated check valve in the hydraulic cylinder head is activated, allowing trapped oil to flow out of ‘TMi4505 (05DECOO) HILLMASTER LEVELING SYSTEM OPERATION, LEVELING TO THE RIGHT 270-15-7 G—Resorvoir Hydraulic ol, trapped Hydraulic of, high L-Hyarautie ol trapped pressure Hyrule ot, Dressure-ree (return oil) the piston side. The right-hand hydraulic cylinder is retracted. The oil flow from the right-hand cylinder is directed to the piston side of the left-hand cylinder. The left-hand cylinder is extended by the same distance as the right-hand cylinder is retracted, ‘The oil flowing out of the rod side of the lefthand hydraulic cylinder is directed to the return passage of the solenoid valve plate and returned to the hydraulic oil reservor. Z Series Combines PN=B04aHillmaster Leveling Syster/Operation Solenoid valve plate, lindo, oft Hillmaster control (©Pilot-operated check FSolenoid valve plate, valve towering combine D-Pilot-operated check valve NOTE: During leveling system operation, the machine Is held in position by pilot-operated check valves integrated in the hydraulic cylinders, eg. if a hydraulic hose should burst. Hydraulic ‘il is trapped on the piston side of hydraulic cylinders. When leveling to the left, the solenoid valve plate routes hydraulic oil to the left-hand hydraulic oylinder. Oil pressure is directed to the rod side of the hydraulic cylinder. At the same time the pilot-operated check valve in the hydraulic cylinder head is HILLMASTER LEVELING SYSTEM OPERATION, LEVELING TO THE LEFT G—Reservoi Hydra pressure sHyaraute ot, pressure-ree (return cil) Hydraulic of, trapped L Hydraulic ot, trapped oll, high activated, allowing trapped oil to flow out of the piston side. The left-hand hydraulic cylinder is retracted. The oll flow from the left-hand cylinder is directed to the piston side of the right-hand cylinder. The right-hand cylinder is extended by the same distance a8 the left-hand cylinder is retracted, The oil lowing out of the rod side of the right-hand hydraulic cylinder is directed to the return passage of the solenoid valve plate and returned to the hydraulic oil reservoir. : Dempercorssss ore ‘TMAB05 (05DECOO) 270-15-9 Z Series Combines PNS208nD Seo mins ov-si-o2z (cacao, NIGNOD ONINAMOT ‘NOLVuadO WSISAS ONTSATT YALSVATIHHilimaster Leveling System/Operation J HILLMASTER LEVELING SYSTEM OPERATION, LOWERING COMBINE NOTE: Before driving a Hillmaster combine on public roads, it must be moved to lowered position to ensure that the maximum permissible height of 4 m (13 fY is not exceeded. When lowering a Hillmaster combine, the solenoid valve Plate for lowering combine is activated as well as the lateral tit hydraulic function. In this case the oil displaced ‘rom the piston side does not flow to the opposite hydraulic cylinder, but to the hydraulic oll reservoir via the solenoid valve plate for lowering combine. NOTE: For more information on solenoid valve plate function, refer to Group 10 of this Section. Electrical system operation is described in Group 240-15Y. zemwaconnteseor64 ‘TM4505 (05DECO0) 270-15-11 Z Series Combines N80Hillmaster Leveling Systenv/Check Valve in Valve Block » Cc 2x 005225 ‘A—Connection to piston side _O—Connection to plston of hydraulle cylinder side of opposite ‘B-Connection to rod side of hydraulle cylinder hydraulic cytindar HHydraulie of, high (Connection to hydraulic Pressure ‘ll reservoir ‘When the solenoid valve plate of Hillmaster leveling system is activated, it will direct hydraulic oil to the rod side of the hydraulic cylinder to be rectracted. At the same time, hydraulic oil pressure opens pilot-operated check valve via connection (B). This, CHECK VALVE IN HILLMASTER HYDRAULIC VALVE BLOCK B | | K 3 L 4 i J-tyaaute ot Lycra of, eats wore fur separate ot torre allows oil from the piston side to flow to the opposite hydraulic cylinder via connections (A) and (0). Connection (C) to the hydraulic oll reservoir is always. Pressure-free. “TMaBDS (0SDECO0) 2270-15-12 Z Series Combines N80. Group 20 Hydraulic Tests SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICE-GARD™ Catalog-or in the European Microfiche Too! Catalog (MTC), Main clutch pressure Pressure switch Variable threshing cylinder drive pressure TMi4605 (08DECO0) Unworsal pressure test ht (A) Fxwtoo02 A z . 5 3 5 e ziosaork Quick coupler . - sT03264 SPECIFICATIONS Mem Measurement Specitiation Hydraulic pump 1 (standard) Delivery 35 LIMin. (8.2 gpm) Hydraulic pump | (Hilmaster) Delivery 45 UMin. (11 gpm) Hydraulic pump Ill (standard) Delivery 15 UMin. (4 gpm) Hydraulic pump til (Hilmaster) Delivery 35 UMin. (8.2 gpm) Pressure relief valve Setting 21 000 kPa (210 bar) (3050 psi) Pressure reduction unit, Setting 6500 kPa (65 bar) (940 psi) Minimum pressure ‘Shut-off pressure ‘Maximum pressure 270-20-1 5000 kPa (50 bar) (725 psi) 6000 kPa (60 bar) (870 psi) 7000 kPa (70 bar) (1020 psi) Z Series Combines PNSBIOHydraulic Tests/Checking Pressure Reduction Unit CHECKING PRESSURE RELIEF VALVE Connect a pressure gauge with a measuring range of (0-25 000 kPa (0—250 bar) (0—3600 psi) to test port (A). Rua engine at fast idle. Press switch for raising header. Read pressure at gauge. Pressure should be 21 000 kPa (210 bar) (3050 psi). If this pressure is not obtained, the cause may be a ‘maifuction of the pressure relief valve, the pressure valve cr the corresponding hydraulic pump section Connect a pressure gage with a measuring range of (0-25 000 kPa (0—250 bar) (0—3600 psi) to test port (B). Run engine at fast idle. Press switch for raising header. Read pressure at gauge. Pressure should be 21 000 kPa (210 bar) (3050 psi). If this pressure is not obtained, the cause may be 2 ‘malfuction of the pressure relief valve, the pressure valve or the corresponding hydraulic pump section. CHECKING PRESSURE REDUCTION UNIT 4. Connect a pressure gauge to test port (A). 2. Engage unloading drive with engine running ei 3. Swing in unloading auger against stop until pressure relief valve is activated, The gauge should show a pressure of 6500 kPa (65 bat) (040 psi). (2x005205) ‘Twa605 (05DEC0O) 270-20-2 Z Series Combines PnseitHydraulic Tests/Checking Pressure Relief Valve on Hillmaster Block CHECKING PRESSURE SWITCH 1. Referring to "Checking Pressure Reduction Unit’, Perform steps 1 and 3. 2. Temporarily disengage and reengage main clutch to discharge accumulator. When pressure has dropped to 5000 kPa (50 bar) (726 psi), it should increase again to 6000 kPa (60 bar) (8700 psi). ‘A~Tost port CHECKING THE PRESSURE RELIEF VALVE ON THE HILLMASTER BLOCK Connect pressure gauge to test port (B). ‘Swing out the hillmaster combine automatically. Maximum pressure should be no more than 21000 kPa (210 bar; 3050 psi). ‘Swing out the hillmaster combine manually as far as the stop. Maximum pressure should be approx. 15000 kPa (150 bar; 2180 psi) ‘TM4505 (0SDECO0) 270-20-3 Z Series Combines PuseteHydraulic Tests/Checking Pressure Rellef Valve (Chaff Spreader) CHECKING PRESSURE RELIEF VALVE OF CHAFF SPREADER DRIVE Disconnect quick coupler (A). Engage separator. Connect a pressure gauge to test port (C). Read pressure at gauge. ‘Maximum pressure should be 21000 kPa (210 bar; 3050 psi). ‘AQuick coupler (inlet flow) ‘Buick couper (return flow) C—Pressure test port ‘TM4505 (0SDECO0) 270-20-4Contents Group 05—Operational Tests Group 10A—Troubleshooting — Air Conditioning ‘System Safety at Work + 290-10A-1 Handling Refrigerant . bese: BOOMOAT ‘Storage of Refrigerant Containers . .. . . 290-10A-2 R14A Refrigerant pees ete + 2Q0M0A-3, ‘Special Tools : betes 290-1044 Leak Tester aor Diss 290-10A-4 Specifications... oes assess ss 2O0-10A:5 Troubleshooting ....... 290-10A-6 System Checks 0.6.5... 290-10A-7 Group 108—Troubleshooting — Ventilation and Heating Systems Group 10C—Troubleshooting — Operator's Seats Group 15 —Operation — Air Conditioning System Principle of Heat Exchange .......... 290-161 RI34A Refrigerant... 2... + + 200-15-2 Layout of Refrigerant Circuit 2 290-15-3 Description of Circuit Function + 290-154 Compressor + 290-156 Condenser . + 290-15-6 Recelver-Drier . .. 2 290-15-7 + 290-15-8 1 290-159 Expansion Valve. ‘Thermostat Switch Section 290 Operator’s Cab Evaporator... . * 290- 15-10 Temperate Gail, Compressor ‘Switch . . 290-15-10, Group 20 —Cab Ventilation “Twa505 (5DECO0) 280-1 Z Series Combines PN=88Contents ‘TM4505 (0SDECO0) 290-2 Z Series Combines: pusborGroup 05 Operational Tests TEST SEQUENCE Perform the operational checks in 290-06 first. In If the operational checks in 290-05 do not identify the many cases, this is sufficient to allow the cause of fault, perform the checks in 290-10A, 10B and 10C. the fault to be identified. ‘These lead the user to the cause of the fault one step at a time. OPERATIONAL CHECKS ON AIR CONDITIONING, HEATER AND OPERATOR'S SEAT NOTE: In the following preliminary checks, it is possible to identity a fault without using tools or a testing device, + Tests with the | OPEN cab coors. Sich on bower (0K: Proceed from Test eee Compressor switched E on. ‘The compressor clutch NOT Ok: See Section ‘must give an audible 240-18. Thermostat switched | cick. eas Lamson 201 2 Move blower switch | Blower not operating, OK: Proceed with Test from lowest seting to E highest setting. Remove and check fuse F42, NOT OK: One or both Of the blower motors is Reinstall fuse. defective, proceed wih Test 0. E Set blower switch to maximum Qk: Proceed with Test ‘output. A Set switch to direct alrflow in all NOT OK: Repair air possible directions, louvers and airflow direction switeh. ‘Check air louvers in all positions. Proceed with Test A. TM4505 (05DEC00) 290-05-1 Z Series Combines puestaOperational Tests nsina | 2 Run engine ot 2000 rpm. Check the folowing: | OX: Proceed with Test AL oat wt ona took for bubbles at | 8 b, Set blower switch fo maximum output Sohtgless on reboherae, Nor ox: Repair | ¢. Sel thermostat switch to maximum cootng | Compressor intake ne | ventlaton system. effect, should be cool or cold. | Proceed with Test U. ald aitfew fom ar 4. Keep cab doors closed fouvors aftr approx. 8 mines. 5 wong agen” | comer arpenan wen nepeaue pu Pooei wn roa | re ur outside side temperature in, eit, im tomperatire rocoed wih Test | Temperature test | somporature (in the 8 | shade). less thon 20 (75) 120 0) | NOT OK: Proceed with | switch on ai between 24—22°0 1e0 5%) Tet 0. | ondilonng system. e207) Walt 19 to 20'minves land measure owr sc (@r) 18 GOR) temperature at front air louver (see table). xastosnene se ores 0 check neater sit ‘Tum heater switch clockwise. After approx. 2 minutes, warm air should flow from the air louvers. ‘Tum heater switch counterclockwise. After a few minutes, cold air should flow from the air louvers. Ok: Proceed with Test a NOT OK: Replace heater switch. Proceed with Test U. 0 check Air Comfort Seat Start the engine and ‘actuate height ‘adjustment lever briefly. The seat should move automatically to the center postion, NOT OK: Fuse or Compressor defective Proceed with Test U. amos ssoree503 ‘TMAa505 (0SDECOO) 290-05-2 Z Series Combines PNEsiOperational Tests U RESULT OF FUNCTIONAL TESTS NOT OK: See Groups 10A, 108 and 10C. ‘TM4505 (05DECO0) 290-05-3 Z Series Combines puestaOperational Tests “TMa505 (0SDECOO) 290-05-4 Z Series Combines pwet?Troubleshooting — Air Conditioning System . Group 10A SAFETY AT WORK CAUTION: Certain basic safety regulations apply when dealing with air conditioning systems, and must be observed at all times. ‘They are backed up by legislation covering safety precautions for air conditioning systems, The following excerpts are Particularly important: 1. Air conditioning systems may be operated, serviced or repaired by authorized, trained personnel only. 2, Adolescents should not be allowed to ‘carry out service work on air conditioning systems involving the discharge of Category 2 or 3 refrigerants, unless trade training of adolescents over 16 years old requires such work. In this case, the adolescent must be supervised by a trained adult. 3. Before repairing components carrying refrigerant, remove refrigt necessary to ensure that the work can be carried out safely. 4. Refrigerant should be extracted by suction and re-used. When refrigerant is discharged into the air, there is the danger of asphyxiation, especially if work is being performed in an inspection pit, since refrigerant is heavier than air and concentrates at the lowest level. Moreover, refrigerant is odorless and colorless, so ‘small quantities emerging from a leak cannot be detected. In such a case, ensure that there is adequate ventilation at the place of work. 5. Smoking and naked flames are not permitted in enclosed spaces where refrigerant has been released. High temperatures cause chemical reactions in the refrigerant gas, and highly poisonous substances can form. If inhaled, these substances have serious effects on health. 6. High temperatures produced by welding and soldering cause very high pressures inside components of the air conditioning system, and these pressures may result in an explosion. HANDLING REFRIGERANT CAUTION: When handling refrigerant, always wear safety glasses and leather gloves. Contact with escaping refrigerant may result in serious frostbite, or even blindness if the refrigerant strikes the eye, Whenever there is the risk of refrigerant encountering high temperatures, wear a suitable breathing mask while working. However, a breathing mask provides no protection against asphyxiation if large quantities of refrigerant escape. 290-10A-1 Z Series Combines PNsid TM4505 (0SDECOO)Troubleshooting — Air Conditioning System/Storage of Retrigerant Containers IN AN EMERGENCY + Rinse eye with cold water; preferably use a1% boric acid solution. + Wash affected parts of the body with water, or preferably with a solution consisting of one part essence of vinegar and five parts water. + See a doctor as soon as first aid has been administered. SAFETY EQUIPMENT This equipment consists of safety glasses, safety gloves and, where approtiate, a breathing mask (i there is the risk of poisonous gases being released). Prepare a 1% boric acid solution for rinsing the eyes and a solution consisting of 1 part essence of vinegar and 5 parts water for washing affected parts of the body. Also provide a first aid kit STORAGE OF REFRIGERANT CONTAINERS CAUTION: Refrigerant containers are under Never store pressurized containers in the pressure, and this pressure increases vicinity of heat sources or in places rapidly when the temperature of the exposed to direct sunlight. Never open container rises. The thin-walled refill pressurized containers by force or damage containers are particularly at risk in this them in any way. respect. Refrigerant containers must never be exposed to temperatures over 52°C (120°F}, ‘TM4505 (05DECO0) 290-10A-2 Z Series Combines PNeBtSTroubleshooting — Air Conditioning System/R194A Refrigerant i) R134A REFRIGERANT IMPORTANT: The air conditioning system operates using R134a refrigerant (tetrafluorethane). This substance does not contain any chlorine atoms, so it does not have a detrimental effect on the ozone in the Earth's atmosphere, Even so, the refrigerant must never be discharged straight into the air, It must be trapped in a recycling unit. Refrigerant stored in a recycling unit may be re-used at any time. The recycling unit used to do this must be of a type suitable for handling Rida refrigerant. The boiling point of R134a is minus 26.5°C (minus 15.7°F) and its freezing Point is minus 101°C (minus 149.8°F). R134a has a corrosive effect on copper as well as various seals and ‘components used in the R12 system. For this reason, never use R134a refrigerant in a system that has previously used R12. Before replacing whether it is compatible with the type of refrigerant used. It is still essential to ensure that the correct refrigerant oil is used. R12 systems were lubricated with mineral oil, which is totally unsuitable for Rida systems. The latter require PAG oil, which mixes very well with the refrigerant and provides ideal lubrication throughout the system. ‘TM4505 (05DECO00) 290-10A-3 Z Series Combines PNse20Troubleshooting — Air Conditioning System/Leak Tester SPECIAL TOOLS ‘Service unt Fre04s Evacuating, filing, cleaning and checking the air ‘conditioning system. NOTE: All work performed with this unit must be carried out in accordance with the service unit operator's manual, IMPORTANT: Use only service units suitable for handling R134a refrigerant. zens Leni ester Fawo4ee Pinpointing a refrigerant leak. NOTE: Use only leak testers suitable for finding R134a leaks, ! i i 2 wm 7 ixoorer i ‘TM4505 (05DECO0) 290-10A-4 Z Series Combines PNsbatTroubleshooting — Air Conditioning System/Specifcations ‘SPECIFICATIONS ftom Air conditioning system Evacuating system ‘Air conditioning system with ‘compressor Compressor ‘Air conditioning system, pressure side (2200 rpm) Air conditioning system, suction side (2200 rpm) Compressor clutch coil ‘Temperature control switch set for + Contact points open (low limit) + Contact points closed (high fmt) ‘Temperature control switch set for min, cooling: * Contact points closed (high limit) Ice protection switch + Contact points open (low limit) + Contact points closed (high limit) Double radial fan (Installed) ‘Measurement Refrigerant quantity Vacuum at sea level Oil quantity Oil quantity Refrigerant pressure Refrigerant pressure Current draw (at 12 volts) ‘Temperature at capillary tube Temperature at capillary tube ‘Temperature at capillary tube ‘Temperature at capillary tube ‘Temperature at capillary tube Current draw (at 12 volts) Speciation 2400 9 (85 02) 4100 KPa (1 bar) (14.5 psi) 300 om? (18.3 cu in.) 460 om? (9.8 cu in) 4500-2000 kPa (1520 bar) (218290 psi) ‘80—200 kPa (0.8—2 bar) (11—29 psi) 2.2 amps. max. “1° to 1°C (30° to 34°F) 1.8" to 3.8°C (35° to 39°F) 18.6" to 17.6°C (56 to 64°F) 0-1 °C (26° to 30°F) 0.5" to 2.5°C (33° to 36°F) 143 amps. ‘TM4505 (0SDECOO) 290-10A-5 Z Series Combines adTroubleshooting — Air Conditioning System/Troubleshooting TROUBLESHOOTING ‘Symptom No cooling effect Inadequate cooling effect Intermittent or poor cooling effect Unusual noises when system is in operation Problem System not in operation Condenser severely contaminated, Evaporator severely contaminated. Actuating cables of temperature control switch not functioning, correctly. Insutficient tension at compressor drive belt. Coolant leak Thermostat switch not functioning correctly. Compressor not functioning correctly. System components iced up. Insufficient tension at compressor drive belt. Defective compressor Solution Switch on compressor switch. Turn temperature control switch counterclockwise. Switch on fan. If functioning, proceed to checks 4 Clean condenser. Clean evaporator. Check and adjust actuating cables. Replace drive belt or belt tensioner. See checks 3 ‘See checks 4A See checks 5 Evacuate refrigerant and refill with recycled or new refrigerant. Replace receiver-drer. Replace drive belt or belt tensioner. Replace compressor. ‘TM4505 (05DECO0) 290-10A-6 Z Series Combines 3Troubleshooting — Air Conditioning System/System Checks EXPLANATION OF CHECKS The checks on the following pages show how to find an existing fault and then rectify it. Visual checks are performed first, as this is the simplest way to eliminate possible causes of the fault. ‘The preliminary checks reveal whether individual ‘components of the air conditioning system are functioning correctly. Next, the leak tester is used to check if there is a leak at any point in the air conditioning circuit. Up to this stage, the checks are relatively straightforward and do not involve lots of tools. The subsequent tests, however, may involve repair work or the replacement of major components, depending on the results of the test. If the checks do not produce a clear result, observe the note below. NOTE: A frequent cause of faults in air conditioning systems is too much moisture in the refrigerant circuit, Moisture results in air conditioning components icing up from the inside and functioning incorrectly. Too much moisture can also produce acid, which destroys the air Conditioning system from within. If moisture is suspected, the air conditioning system must be evacuated, cleaned, bled and refilled with new or recycled refrigerant. The refrigerant oil contained in the compressor must be changed, It Is particularly important to replace the recelver-drier, as it gradually loses its ability to absorb moisture. Eventually, it loses this ability altogether. ‘cam store seonmanas ‘TM4505 (05DECO0) 290-10A-7 Z Series Combines PuaTroubleshooting — Air Conditioning System/System Checks AIR CONDITIONING SYSTEM, CHECKS _pcrpocroanr. 12802 3 VISUAL CHECKS 8. Check tension of compressor bel. b. Cab fters must be clean, . Air passages must be clear. 4d. Check for damaged ti . Hoses must not be deformed or trapped. {. Condenser and evaporator must not be contaminated. 9. All electrical tines ‘must be OK, Fi. Listen for unusual noises while the system is operating. A PRELIMINARY CHECKS ‘Switch on ignition and run the fan at each possible speed. NOT Ok: See Section 240-15, 0K: Proceed with checks. ‘TM4505 (05DECOO) 290-10A-8 Z Series Combines PNs825Troubleshooting — Air Conditioning System/System Checks B Switch on ignition and | NOT Ok: See Section run fan at lowest 240-15, possible speed. Set femperature contral | OK: Proceed with suiteh (A) fo operate | checks, the alr conditioning system, Note whether the licking of the magnetic clutch tan be heard at compressor (8). s zx004408 enuezeomsers ‘samo Cc Run engine at 2200 | NOT OK: The air ‘pm and set air conaltoning system Conditioning to ful | must be topped up. output. Observe refrigerant fowing past | ok: Proceed with the sight glass at checks. racever-dier. Zx008807 pera After some time, the bubbles inthe refrigerant should disappear completsy. T4505 (05DECOO) 290-10A-9 Z Series Combines PN=825Troubleshooting — Air Conditioning SystenvSystem Checks Instructions. txoor7e2 dA CAUTION: Keep away from moving engine parts at all times. Avoid accidents! Hold the feak tester at the alr outlets in the cab to test whether there is a leak in the evaporator housing D Run engine at 800 rpm | NOT OK: The and set temperature. | compressor or its ‘contol switch to max. | magnetic clutch thust ‘cooling positon. be repaired, See Section 90. {At the moment the ‘witch tnps, the engine | OK: Proceed with sound should change | checks. ae zenazcomaesses0989 BA Run the engine at 1000 rpm and switch on fan | NOT OK: If the leak an at condoning sytem, Uso FIeMIO444 leek | tse inca leak tester to check the entire refrigerant circuit for | while testing atthe air ee leaks. Comply with the manutaciurers outlets, proceed with B. Ia leak is found at another part of the system, the leak must be repaired or the leaking component must be replaced. See Section 90. Ok: Proceed with A _zrconoer0 Fes ‘Open evaporator B_ REFRIGERANT housing under NOT OK: Ifa leak is found at any part of LEK AT oe passenger seat. Run | the atm to ek svaroma rate at 1000p” | must be repre or fra swith on fon and_| the faking component Si conienng systom. | must be feplaca. Soe Seaton 8. Use oak tester FKM10444 to test (OK: Proceed with A. evaporator, expansion valve and otipeant thes for eek Tiwa505 (@5DEC00) 290-10A-10 Z Series Combines pasazrTroubleshooting — Air Conditioning System/System Checks A. component cece A Thermostat switch Open evaporator NOT OK: To correct housing under faults, soe Section 90, Passenger seat (0K: Proceed with Check that sensing | checks. bulb (A) is not damaged. Make sure that thermostat switch (B) is actuated correctly. Do this by actuating the temperature switch several times and ‘observing cable (C). Check all electrical contacts of the thermostat switch, contamination and ‘check for signs of damage. Bes pmtaaton Make sure that Nor Ok: To correct ‘switch capillary tube (A) is not | faults, see Section 90, damaged and inserted into evaperatr. of: Proceed wth checks. Chock all lectrical Contacts of the lob protection sifich, CC evaporator | Remove any NOT OK: Ifthe evaporator shows signs of damage, it must be replaced. See Section 90. A. CAUTION: Before removing the evaporator, first evacuate the refrigerant from the air ‘conditioning system. (0k: Proceed with checks. zcrnwacovon seanove D__ expansion vaive (Check that there are | NOT OK: Replace no signs of damage at | expansion vaive. thermal head (A). ‘Check all connections. evacuate refrigerant from tt conditioning system. 0K: Proceed with checks. zemoacoomi sesso ‘M4505 (05DECO0) 290-10A-11 Z Series Combines pNse28Troubleshooting — Air Conditioning System/System Checks © compressor, ACHigh pressure ‘connection 8—Low pressure ‘zxo0se1s connection Connect the pressure gauges of he service Unit fo the compressor. Run engine at 2200 rom, Switch on fan and sel temperature control switch to max. cooling positon. (On the high pressure side, the pressure reading must be 415002000 kPa (15—20 bar) (21-290 psi. (On the low pressure side, the pressure reading must be 80—200 kPa (0.82 bar) (11-29 pai, NOT OK: See pressure deviations. a masents 1 258012 ‘Twid505 (05DECOO) 290-10A-12 Z Series Combines PNs829Troubleshooting — Air Conditioning System/System Checks PRESSURE DEVIATIONS Symptom Low pressure and high pressure both too high Low pressure too low and high pressure too high Low pressure too high but high pressure normal Low pressure and high pressure are the same Low pressure too low but high pressure normal Low pressure and high pressure both too low Problem System has been over-filed, Condenser is contaminated or plugged. Condenser plugged. Recelver-drier plugged. Expansion valve not operating correctly, ‘Compressor not operating correctly. Compressor not operating. Not enough refrigerant in circuit. Expansion valve not operating correct. Evaporator contaminated or plugged. Not enough refrigerant in circuit. Recelver-drier plugged. Expansion valve not operating correctly. Solution Reduce amount of refrigerant in system. Clean or unplug condenser. Replace condenser, if necessary. Unplug condenser or replace, if necessary. Unplug receiver-drier or replace, if necessary. Replace expansion valve. Repair or replace compressor. Check drive belt. Check electrical wiring Change highilow pressure switch Check thermostat switch, see Section 240, Check magnetic clutch of compressor. Top up system. Replace expansion valve. Clean evaporator. Unplug evaporator or replace, if necessary. Top up system, Unplug receiver-drier or replace, if necessary. Replace expansion valve. Continued on next page ‘TM4505 (0SDECO0) 290-10A-13 Z Series Combines PN=830Troubleshooting — Air Conditioning System/System Checks Symptom Problem Solution Low pressure and high pressure Too much moisture in circuit, Evacuate system, replace both too low (Continued) causing components to ice up. recelver-drier and then refill system Compressor not operating correctly. | Repair compressor or replace, if necessary. ‘TM4505 (0SDECO0) 290-10A-14 Z Series Combines PNsestGroup 10B Troubleshooting — Ventilation and Heating Systems ‘Symptom Inadequate flow of fresh air Blower not working Blower operating too slowly or itregularly Inadequate heating effect Ice or misting on windows does not clear properly Problem Main filter or recirculating air fter clogged Air inlets clogged Blower motor defective Blower motor switch defective Loose wire connection Blower motor defective Blower motor switch defective Wire broken, or loose connection Electrical circuit interrupted Blower motor shaft is jamming Loose wire Blower motor switch defective Engine thermostat defective Foreign bodies in heating element or heater hoses Heater switch not operating correctly Blower not operating correctly Blockage at air inlets Air louvers not directed properly Solution Clean or replace fiters. See Section 90, Group 10 Clean air inlets Replace blower. See Section 90, Group 10 Replace switch Reconnect or replace wires. See Section 240, Group 10 Replace blower. See Section 90, Group 10 Replace switch Reconnect or replace wires. See Section 240, Group 10 Check circuit. See Section 240, Group 15 Replace blower. See Section 90, Group 10 Reconnect wire or replace connection. See Section 240, Group 10 Replace switch Replace thermostat. See Component Technical Manual "Engines" Clean heater element or heater hoses Check heater switch. Replace if necessary. See Section 90, Group 10 Clean blower. Replace if necessary Clean air inlets Direct the air louvers properly ‘Continued on next page ‘TM4505 (0SDECO0) 290-10B-1 Z Series Combines NSB?Troubleshooting — Ventilation and Heating Systems ‘Symptom Heater valve does not turn coolant flow off Problem Blower not operating correctly Heater switch not operating correctly Inlet and outlet hoses wrongly connected Heater switch defective Solution Clean blower. Replace if necessary. See Section 90, Group 10 Check heater switch. Replace if Necessary. See Section 90, Group 10 Connect inlet and outlet hoses correctly. See Section 90, Group 10 Replace heater switch. See Section 90, Group 10 ‘TM4505 (0SDECOO) 290-10B-2 Z Series Combines PN=BSSGroup 10C Troubleshooting — Operator’s Seats COMFORT SEATS Symptom Correct weight adjustment not possible Seat bounces Seat cannot be adjusted Problem Springs over-extended Spring broken ‘Shock absorber defective Loose screw connections Locking device defective sotution Replace springs See above Replace shock absorber. Tighten or replace screw connections. Replace locking device. Seat does not move to center position Seat bounces Seat cannot be adjusted ‘Seat shakes Wire not connected or loose Fuse defective Compressor defective Air spring defective Shock absorber defective Loose screw connections Locking device defective Loose screw connections Seat shakes Loose screw connections Tighten or replace screw connections. Liaanocmaan ores AIR COMFORT SEAT ‘Symptom Problem Solution Reconnect or replace wire. See Section 240, Group 10 Replace fuse Replace compressor Replace air spring Replace shook absorb Tighten or replace screw connections. Replace locking device Tighten screw connections ‘TM4505 (05DECO0) 290-10C-1 Z Series Combines 34Troubleshooting — Operator's Seats ‘TM4505 (05DECO0) 290-10C-2 Z Series Combines PN=835Operation — Air Conditioning System Group 15 PRINCIPLE OF HEAT EXCHANGE ART NOT FOUND Lxoo2148, ‘A—Liquid refrigerant under high pressure B_Gaseous refrigerant ‘under high pressure (C—Gacoous refrigerant ‘under low pressure ‘The simplified example set out below is intended to ‘show how heat is exchanged in an air conditioning system. Each explanation concludes with the part of the air conditioning system that corresponds to the principle involved. Fig. 4: Gaseous refrigerant is contained in a cylinder which has a certain reserve of energy (E) in the form of heat. (intake line of compressor) Fig. 2: A piston reduces the space in which the ‘gaseous refrigerant is trapped. This concentrates the heat (E) in a smaller space. This means that the temperature inside the cylinder is now higher than it was before. Heat is now exchanged, with the surrounding area absorbing the heat of the gas. Heat always moves from a hotter substance to @ colder one. (compressor to condenser) D-Exchango of heat E—Energy in the form of heat Fig. 3: The pressurized refrigerant condenses on the cylinder wall and becomes a liquid. The gas has transferred its heat through the cylinder wal to the surrounding area. (condenset) Fig. 4: The space inside the cylinder is increased. ‘This means that the pressure drops rapidly and the liquid refrigerant is free to expand. The refrigerant evaporates and returns to lis gaseous state. In consequence, the heat remaining in the gas is free to spread through a larger atea. The temperature inside the cylinder drops and heat is exchanged once again ‘This time the heat is absorbed from the surrounding area by the cold cylinder. (expansion valve and evaporator) ‘TM4505 (05DECO0) 290-15-1 Z Series Combines ocdOperation — Air Conditioning System/R134A Refrigerant R134A REFRIGERANT IMPORTANT: The air conditioning system operates using R134a refrigerant (tetrafluorethane). This substance does ot contain any chlorine atoms, so it does not have a detrimental effect on the ozone in the Earth's atmospher Even so, the refrigerant must never be discharged straight into the air. It must be trapped in a recycling unit. Refrigerant stored in a recycling unit may be re-used at any time, ‘The recycling unit used to do this must be of a type suitable for handling R134a refrigerant. The boiling point of R134a is minus 26.8°C (minus 15.7'F) and its freezing point is minus 101°C (minus 149.8°F). Rida has a corrosive effect on copper as well as various seals and components used in the R12 system, For this reason, never use R134a refrigerant in a system that has previously used R12. Before replacing any component, itis vital to check whether it is compatible with the type of refrigerant used. It is still essential to ensure that the correct refrigerant oil is used. R12 systems were lubricated with mineral oil, which is totally unsuitable for Rt34a systems. The latter require PAG oil, which mixes very well with the refrigerant and provides ideal lubrication thoughout the system. ‘TM4505 (05DECOO) 290-15-2 Z Series Combines PI 7Operation — Air Conditioning System/Layout of Refrigerant Circuit LAYOUT OF REFRIGERANT CIRCUIT ‘A—Temperature control D-Blower fan HAFlow of air into cab High-pressure tine ‘switch Thermostat switch J—Condensor NoReceiver

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