Combine W440

Technical Manual

TECHNICAL MANUAL

Combine W440

TM5SR5145 Issue A1 (ENGLISH)

For complete service information also see:

Diesel Engine Technical Manual in English Language CTM5AP9873

Diesel Engine Technical Manual in German Language CTM5AP9906
Diesel Engine Technical Manual in Polish Language CTM5AP9916

John Deere GmbH & Co. KG

PRINTED IN GERMANY
 Introduction

Foreword

This manual is written for an experienced technician. Technical Manuals are concise guides for specific
Essential tools required in performing certain service machines. They are on-the-job guides containing only
work are identified in this manual and are recommended the vital information needed for diagnosis, analysis,
for use. testing and repair.

Live with safety: Read the safety messages in the Fundamental service information is available from other
introduction of this manual and the cautions presented sources covering basic theory of operation,
throughout the text of the manual. fundamentals of troubleshooting, general maintenance,
and basic type of failures and their causes.

This is the safety-alert symbol. When you see this Information about periodic maintenance work you will
symbol on the machine or in this manual, be alert to the find in the Operators Manual (OM).
potential for personal injury.
Recognize Safety Information
This is a safety-alert symbol. When you see this symbol
on your machine or in this manual, be alert to the potential
for personal injury.
Follow recommended precautions and safe operating

T81389 UN07DEC88
practices.

DX,ALERT -19-29SEP98-1/1

Handle Fluids SafelyAvoid Fires

When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.

TS227 UN23AUG88
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
spontaneously.

DX,FLAME -19-29SEP98-1/1

Prepare for Emergencies

Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.

TS291 UN23AUG88

DX,FIRE2 -19-03MAR93-1/1
 Safety

Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from
the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object
across the posts. Use a volt-meter or hydrometer.

TS204 UN23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16C (60F).

DX,SPARKS -19-03MAR93-1/1

Prevent Acid Burns

Sulfuric acid in battery electrolyte is poisonous. It is strong
enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 1530 minutes. Get
medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not

TS203 UN23AUG88
exceed 2 L (2 quarts).
3. Get medical attention immediately.

DX,POISON -19-21APR93-1/1
 Safety

Handle Chemical Products Safely

Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used with
John Deere equipment include such items as lubricants,
coolants, paints, and adhesives.

TS1132 UN26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
(See your John Deere dealer for MSDSs on chemical
products used with John Deere equipment.)
DX,MSDS,NA -19-03MAR93-1/1

Handle Starting Fluid Safely

Starting fluid is highly flammable.
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
To prevent accidental discharge when storing the

TS1356 UN18MAR92
pressurized can, keep the cap on the container, and store
in a cool, protected location.
Do not incinerate or puncture a starting fluid container.

DX,FIRE3 -19-16APR92-1/1

Avoid High-Pressure Fluids

Inspect hydraulic hoses periodically at least once
per year for leakage, kinking, cuts, cracks, abrasion,
blisters, corrosion, exposed wire braid or any other signs
of wear or damage.

X9811 UN23AUG88
Replace worn or damaged hose assemblies immediately
with John Deere approved replacement parts.
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.
with this type of injury should reference a knowledgeable
Search for leaks with a piece of cardboard. Protect hands medical source. Such information is available in
and body from high-pressure fluids. English from Deere & Company Medical Department in
Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1
If an accident occurs, see a doctor immediately. Any fluid 309-748-5636.
injected into the skin must be surgically removed within
a few hours or gangrene may result. Doctors unfamiliar
DX,FLUID -19-12OCT11-1/1
 Safety

Park Machine Safely

Before working on the machine:
Lower all equipment to the ground.
Stop the engine and remove the key.
Disconnect the battery ground strap.
Hang a "DO NOT OPERATE" tag in operator station.

TS230 UN24MAY89
DX,PARK -19-04JUN90-1/1

Support Machine Properly

Always lower the attachment or implement to the ground
before you work on the machine. If the work requires
that the machine or attachment be lifted, provide secure
support for them. If left in a raised position, hydraulically
supported devices can settle or leak down.

TS229 UN23AUG88
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
Follow recommended procedures in this manual.
When implements or attachments are used with a
machine, always follow safety precautions listed in the
implement or attachment operator's manual.
DX,LOWER -19-24FEB00-1/1

Wear Protective Clothing

Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause impairment
or loss of hearing.

TS206 UN23AUG88
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
DX,WEAR -19-10SEP90-1/1
 Safety

Protect Against Noise

Prolonged exposure to loud noise can cause impairment
or loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or

TS207 UN23AUG88
uncomfortable loud noises.

DX,NOISE -19-03MAR93-1/1

Work in Clean Area

Before starting a job:
Clean work area and machine.
Make sure you have all necessary tools to do your job.
Have the right parts on hand.

T6642EJ UN18OCT88
Read all instructions thoroughly; do not attempt
shortcuts.

DX,CLEAN -19-04JUN90-1/1

Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If
it is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an exhaust
pipe extension.

TS220 UN23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.

DX,AIR -19-17FEB99-1/1
 Safety

Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use
a portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.

TS223 UN23AUG88
DX,LIGHT -19-04JUN90-1/1

Service Machines Safely

Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.

TS228 UN23AUG88
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.

DX,LOOSE -19-04JUN90-1/1

Construct Dealer-Made Tools Safely

Faulty or broken tools can result in serious injury. When
constructing tools, use proper, quality materials, and good
workmanship.

LX1016749 UN01JUL97
Do not weld tools unless you have the proper equipment
and experience to perform the job.

DX,SAFE,TOOLS -19-10OCT97-1/1
 Safety

Service Cooling System Safely

Explosive release of fluids from pressurized cooling
system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop

TS281 UN23AUG88
to relieve pressure before removing completely.

DX,RCAP -19-04JUN90-1/1

Service Accumulator Systems Safely

Escaping fluid or gas from systems with pressurized
accumulators that are used in air conditioning, hydraulic,
and air brake systems can cause serious injury. Extreme
heat can cause the accumulator to burst, and pressurized
lines can be accidentally cut. Do not weld or use a torch

TS281 UN23AUG88
near a pressurized accumulator or pressurized line.
Relieve pressure from the pressurized system before
removing accumulator.
Relieve pressure from the hydraulic system before
removing accumulator. Never attempt to relieve hydraulic
system or accumulator pressure by loosening a fitting.
Accumulators cannot be repaired.
DX,WW,ACCLA2 -19-22AUG03-1/1

Wait Before Opening High-Pressure Fuel

System
High-pressure fluid remaining in fuel lines can cause
serious injury. Only technicians familiar with this type of
system should perform repairs. Before disconnecting fuel
lines, sensors, or any other components between the

TS1343 UN18MAR92
high-pressure fuel pump and nozzles on engines with
High Pressure Common Rail (HPCR) fuel system, wait a
minimum of 15 minutes after engine is stopped.

DX,WW,HPCR2 -19-07JAN03-1/1
 Safety

Replace Safety Signs

Replace missing or damaged safety signs. See the
machine operators manual for correct safety sign
placement.

TS201 UN23AUG88
DX,SIGNS1 -19-04JUN90-1/1

Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe
injury or machine damage.
Follow recommended procedure for removal and
installation of components in the manual.

TS226 UN23AUG88
DX,LIFT -19-04JUN90-1/1

Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
Remove paint before heating:

TS220 UN23AUG88
Remove paint a minimum of 100 mm (4 in.) from area
to be affected by heating. If paint cannot be removed,
wear an approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
Do all work in an area that is well ventilated to carry toxic
from area. Allow fumes to disperse at least 15 minutes
fumes and dust away.
before welding or heating.
Dispose of paint and solvent properly.
Do not use a chlorinated solvent in areas where welding
will take place.
DX,PAINT -19-24JUL02-1/1
 Safety

Avoid Heating Near Pressurized Fluid Lines

Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to yourself
and bystanders. Do not heat by welding, soldering,
or using a torch near pressurized fluid lines or other
flammable materials. Pressurized lines can accidentally

TS953 UN15MAY90
burst when heat goes beyond the immediate flame area.

DX,TORCH -19-10DEC04-1/1

Service Tires Safely

Explosive separation of a tire and rim parts can cause
serious injury or death.
Do not attempt to mount a tire unless you have the proper
equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate
the tires above the recommended pressure. Never weld
or heat a wheel and tire assembly. The heat can cause
an increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension
hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety
cage if available.
Check wheels for low pressure, cuts, bubbles, damaged
rims or missing lug bolts and nuts.

TS211 UN23AUG88
DX,RIM -19-24AUG90-1/1
 Safety

Avoid Harmful Asbestos Dust

Avoid breathing dust that may be generated when
handling components containing asbestos fibers. Inhaled
asbestos fibers may cause lung cancer.
Components in products that may contain asbestos

TS220 UN23AUG88
fibers are brake pads, brake band and lining assemblies,
clutch plates, and some gaskets. The asbestos used in
these components is usually found in a resin or sealed in
some way. Normal handling is not hazardous as long as
airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding material containing
asbestos. When servicing, wear an approved respirator.
A special vacuum cleaner is recommended to clean Keep bystanders away from the area.
asbestos. If not available, apply a mist of oil or water on
the material containing asbestos.
DX,DUST -19-15MAR91-1/1

Practice Safe Maintenance

Understand service procedure before doing work. Keep
area clean and dry.
Never lubricate, service, or adjust machine while it is
moving. Keep hands, feet , and clothing from power-driven
parts. Disengage all power and operate controls to relieve
pressure. Lower equipment to the ground. Stop the
engine. Remove the key. Allow machine to cool.
Securely support any machine elements that must be
raised for service work.
Keep all parts in good condition and properly installed.
Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground
cable (-) before making adjustments on electrical systems
or welding on machine.
On towed implements, disconnect wiring harnesses from
tractor before servicing electrical system components or
welding on machine.

TS218 UN23AUG88

DX,SERV -19-17FEB99-1/1
 Safety

Use Proper Tools

Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards.
Use power tools only to loosen threaded parts and
fasteners.

TS779 UN08NOV89
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches.
Use only service parts meeting John Deere specifications.

DX,REPAIR -19-17FEB99-1/1

Dispose of Waste Properly

Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.

TS1133 UN26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants escaping into the air can
damage the Earths atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN -19-03MAR93-1/1

Live With Safety

Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.

TS231 1907OCT88

DX,LIVE -19-25SEP92-1/1
SAFETY PRECAUTIONS
When servicing or repairing the combine, there is always a risk of injury! Before
undertaking any repair work, make sure you understand these safety precautions.
x All repair and maintenance work
must be done with the engine and
transmission off, the ignition key off
the ignition and the master switch in its
off position. All moving parts must be
kept steady, immobile and, if
necessary, locked.
x Do not undertake any repair work
that you are not familiar with.
x Choose a safe place for the repair
work.
x Keep the repair area clean and tidy.
x Do not use defective or unsuitable
tools.
x Remove all rings, bracelets and
watches before starting work.
x Wear proper protection when
working; eye protection when working
with pressurized air, grinding or
hammering.
x Use a trolley jack to lift and move
heavy components (over 20 kg).
Ensure the lifting hooks, chains, etc.
are in faultless condition.
x Never work beneath a combine
raised with a trolley jack or jack only.
Use heavy trestles to support the
combine. Always support the cutting
table and the pick-up reel.
x Beware of slipping or falling down
when walking on the combine.
x Do not start the combine engine with
any other means except the ignition
key.
x Ensure that loose clothing or long
hair do not get entangled in rotating
parts.
x Be very careful if the engine has to
be started before the service has been
completed.
x If the engine is started indoors, make
sure there is good ventilation.
x Do not touch the exhaust manifold,
the supercharger or other hot parts.
x Open the cap of an over-pressurized
radiator carefully when the engine is
hot.
Hot radiator liquid and lubrication oil
will scald your skin.
1-2
x Open fire and smoking are forbidden
near fuel and accumulators.
x Disconnect the accumulator minus (-
) cable when servicing or repairing the
electrical system.
x Ensure there is a fire extinguisher
handy. Keep fire watch after welding
and doing other spark jobs.
x Do not use unsuitable tools to
remove or replace the accumulator.
x Be very careful when working with
accumulator acids.
x Do not add coolant with the engine
running.
x Do not add air in the tyres without a
pressure gauge; there is a risk of
explosion.
x Do not add fuel with the engine
running.
x Do not smoke while filling up the fuel
tank.
x Do not increase the hydraulic
working pressure without a pressure
gauge; there is a risk of damage to the
hoses.
x When servicing the hydraulics, be
aware of the high pressure in the
system. Make sure there is no
pressure in the system or in the
pressure reservoir before
disconnecting the connectors.
x When doing repair work, do not spill
any oils or liquids in the soil.
x Do not use fuses stronger than the
original ones. Too strong fuses may
cause damage.
x When refitting a front/rear wheel,
tighten the fixing screws to the correct
torque.
x Tow the combine only from
designated points.
x Be very careful if using a high-
pressure water jet to clean the
combine. Do not direct the jet at
electrical or fuel systems, bearings or
the condenser.
TABLE OF CONTENTS

1. FOR THE USER

- safety precautions 4. GRAIN TRANSPORT SYSTEM
- type specification - return elevator
- general installation - grain elevator
instructions - grain tank
- technical specifications - unloading
- shaft speeds 5. TRANSMISSION
- measurements - engine
- special tools - front axle
2. CUTTING TABLE - gearbox
- knife wobble-box drive unit - final drive
- pick-up reel - brakes
- table auger - rear axle
- crop elevator - cab
3. THRESHING MECHANISM 6. HYDRAULICS
- changing of pre-cylinder/shaft - working hydraulics
- changing of pre-concave - traction hydraulics
- stone trap - four-wheel drive
- threshing cylinder - engagement hydraulics
- concave - rotation hydraulics
- rear beater - oil service unit
- straw walkers 7. ELECTRICAL SYSTEM
- CSP straw ruffler - general
- straw chopper - wiring diagrams
- grain pan
- shaker shoe
- fan

1-3
TYPE MARKING

You can find the serial number of the combine, cutting table and engine as shown below:

Combine type plate Cutting table type plate

Combine number

Engine number

Note! Left side of the combine = The side of the cab with the stairs
Right side of the combine = The side with the fuel tank

1-4
GENERAL INSTALLATION AND REPAIR INSTRUCTIONS
Comply with the following general installation instructions unless otherwise instructed in specific
instructions on the component.
REMOVING AND REFITTING OF COLLAR BEARING

Slacken grub screw A and use a mandrel to strike the locking

ring off hole B counter to shaft rotation to loosen the ring
eccentric.
Unscrew fixing nuts C of the bearing flanges, after which the
outer flange can be removed and the bearing pulled off the shaft.
Remove the inner flange.
Fitting of a new bearing in the opposite order. Check the correct
shaft position before tightening flange screws C. Use a mandrel
to lock the locking ring in the direction of shaft rotation. Tighten
grub screw A.
If the shaft does a reciprocating movement, tighten the locking
ring clockwise.

FITTING OF SPRING COTTER

Note the position of the cotter notch in relation to load P.

FITTING OF GIB KEY

Dimension A = 1/2...2 h. Dimension A refers to a key driven in.

For example, if key height h = 8 mm, dimension A is x82x8,
i.e. 4...16 mm. Lubricate the sliding surfaces of the key.

FITTING OF FLAT WASHER

Use a flat washer under the spring washer when fitting a screw
through a long hole.

1-5
FITTING OF DRIVE NUT

The mating surface of the drive nut (the surface against the
locking plate) must be greased to prevent the locking plate tab
from breaking.

ALIGNMENT OF V-BELT PULLEYS

Shaft distance Maximum misalignment allowed

a/mm e/mm

V-belts to be Normal
connected V-belts

500 2.5 5
1000 5 10
2000 20

ADJUSTMENT OF JOCKEY PULLEY

Adjust the jockey pulley so that the belt edge will not rub the
pulley flange when in operation.

V-BELT TENSIONING

Check by pressing the belt midway between the shafts with your
thumb.

Shaft distance Deflection

a/mm f/mm

under 500 20
5001000 30
10001500 50
15002000 70

1-6
 CHAIN SPROCKET ALIGNMENT

Shaft distance Max. misalignment

a/mm allowed
e/mm

300 4
500 4.5
800 6

CHAIN JOCKEY PULLEY

Must be aligned with the chain so that it will not rub the chain side
links.

SCREW TORQUE

The recommended torque is suitable for standard

metric thread screws of 8.8 strength value.
If combine screws, nuts or washers are changed, do
not use hardware of less torque value. Hexagon
screws are of 8.8 strength value, except for some
extremely demanding cases, where strength values of
10.9 or 12.9 are required.

Hexagon nuts are of 8 strength value.

Washers are of HB 200 hardness.

1-7
SH FRICTION COLLAR COUPLING
Fitting:
Ensure tightening screws A do not come out of the
rear of nut B.
Turn the nut onto inner bush C as far as possible.
Outer bush D is welded onto the end of the pre-
cylinder. Turn the assembly of the inner bush and
the nut inside the outer bush so that the nut will be
against the rim of the outer bush.
Note! Left-handed thread!
Turn the tightening screws loosely against the
outer bush D.
Fit the shaft.
Make sure the shaft position is correct.
Tighten the tightening screws in turns. Ensure the
screws are properly tightened by tightening all the
screws two more times.

Removing:
Loosen tightening screws A so that they will be off
outer bush D.
Turn nut B out a bit.
Strike the nut B (or outer bush) lightly so that the
tapered part C of the thread will slacken.

Taper Lock is a way of locking a belt pulley or

a chain sprocket onto the shaft.

Fitting:
Fit belt pulley or chain sprocket A onto the shaft.
Taper hub B, which is split lengthwise, is pushed
over the key as deep as possible.
Tighten Allen screws G into grooves C-E. Grooves
C are threaded and grooves E unthreaded, due to
which taper hub B will get pressed inwards against
the taper surfaces when moving around the shaft.

Loosening:
Slacken Allen screws G.
Turn one of the screws into grooves D-F. Groove F
is threaded and groove D unthreaded, due to
which taper hub B will come loose from pulley hub
A and the shaft.

1-8
WELDING
Periodic combine maintenance does not involve welding, but it may occasionally be necessary. A hot
work permit is required in order to do welding.
Welding presents a risk of fire. Clean the combine carefully before undertaking welding, and ensure
there is a fire extinguisher handy. Remember the importance of fire watch after welding.

The electrical system of the combine has a number of semi-conductive components that may get
damaged by voltage peaks in arc welding. The principle is that any structures that require welding are
removed from the combine. If fixed constructions need to be welded, the following precautions shall be
taken:
x Turn off the master switch or disconnect one of the battery cables.
x Disconnect connector A to the Comvision display, fig. Comvision, inside the instrument panel.
x Disconnect the feeder cable (the left-side cable) to the control unit of the Common-Rail engine.
First open the protective cover on the unit fixed to the engine (TORX TX20). Turn the connectors
locking arm up and pull the connector open. Fig. AWF

Comvision

AWF

1-9
TECHNICAL SPECIFICATIONS

W440 W440 PTC

Cutting table
Cutting width m 4.20...5.70 4.5...6.30
Knife speed strokes/min 1020 1020
Table reverse Hydraulic Hydraulic

Pick-up reel
Diameter m 1.05 1.05
Rpm r/min 0...50 0...50
Rpm adjustment Hydraulic Hydraulic
Fore/aft adjustment Hydraulic Hydraulic

TS cylinder
Width/diameter m 1.33/0.40
Speed r/min (peripheral speed 80% of the cylinder peripheral speed)
Concave area m 0.40

Threshing cylinder
Width/diameter m 1.33/0.50 1.33/0.50
No/type of rasp bars pcs 8/ replaceable 8/ replaceable
Rpm, cereal 600...1300 600...1300
Rpm, maize 400...1150 400...1150
Rpm adjustment Electric Electric

Concave
Area m 0.62 0.62
Angle of wrap 105 105
No of rasp bars pcs 9 9
Thresh. clearance range mm 6...42 6...42

Straw walkers
No pcs 6 6
Separating area m 6.30 6.30
CSP -separating cylinder standard standard

Shaker shoe
Chaffer m 2.30+0.40 2.30+0.40
Grain sieve m 1.80 1.80
Total area m 4.50 4.50
Fan rpm adjustment Electric Electric

Chopper
Swing knife chopper standard standard
High-speed chopper standard standard

Grain tank
Volume m 6.5 7.6 (closed unloading) 8.1
Unloading height m 4.00 4.40 (closed unloading) 4.00
Full alarm Electric

1-10
TECHNICAL SPECIFICATIONS
W440 W440 PTC

Engine/SisuDiesel 74AWF 74AWF

Output kW/hp 175/238 175/238

Rpm/cyl. r/min/pcs 2000/6T 2000/6T

Fuel tank volume l 450 450

Transmission, hydro
Speeds 1st gear km/h 0...6.6 0...6.6
2nd gear 0...10.7 0...10.7
3rd gear 0...25 0...25

Final drive Oil bath Oil bath

Wheels
Front 800/65R32 800/65R32
Optional 900/60R32 900/60R32
1050/50R32 1050/50R32

Rear 480/65R24 480/65R24

Optional 540/65R24 540/65R24

Filling quantities
Engine oil, l 26 26
Cooling system, l approx. 27 approx. 27
Hydraulics, change, l 25 25
Gearbox, l 7 7
Final drive, CIT, l 7.5 7.5
Knife drive, l 0.5 0.5
Return auger bevel gear, l 0.35 0.35
AC refrigerant, kg 1.3 1.3

Weight
Standard table and chopper, kg 12650 14070

1-11
Shaft rpm and pulley sizes

1-12
Shaft rpm and pulley sizes

r/min = Shaft rpm

A, B, C, 2B, 3B = Belt profile
e.g. 5/8Z10 = Roller chain size, no of sprocket teeth
e.g. 385 = Pulley outer diameter, mm.
HD = e.g. maize option
HSC = HD chopper

Ref. r/min Belt/pulley

1 5105 C245,2C450
2 4505 2D510
3 62010 Z29
4 90010 3/4B489,2C254,C225
5 120010 2B366
6 200010 2B220,4B220,2B220
7 1305 B300
8HSC 308050 2B280,2B200
8 297050 2B270,2B200
8HD 220050 2B200,2B280
9HSC 393050 2B212
9 348050 2B224
9HD 205050 2B212
10 51010 C276
11 2105 C460
12 51010 C187,C276
13 51010 C276
14 1549 5/8Z60
15 5/8Z10,B285
16 28010 C41
17 55010 C210,B140,2C366 Ref. r/min Belt/pulley
19HSC220050 2B280,2B200 31 600...1300 2B360
19 220050 2B270,2B200 400...1150 2B360
20 B140,B280 32 600...1300 2B360
21 C285,C163 400...1150 2B360
22 2105 C460 33 0...160 Z14
23 51010 C187,C276 34 0...50 Z45
24 200010 B200 (66CTA) 35 189010 B212,B163 (66CTA)
24 200010 B225 (74CTA) 35 237010 B190,B163 (74CTA)
25 62010 C355 36 189010 B163 (66CTA)
26 62010 C355 36 237010 B163 (74CTA)
27 120010 2Z13 37 120010 Z15
28 37010 2Z42 38 23010 C410
29 49010 2Z32 39 450 C208
30 90010 HI200,C245 40 28010 C335
41 500...100030 HI250
42 62010 Z29

1-13
Measurements of the combine

1-14
Measurements of the combine, mm
Tyres
650/65 800/65 900/60 1050/50
Measurement W440 W440 PTC R38 R32 R32 R32

A 395025 395025
B 381025 381025
C max1008 max1008
Da 48025 48025
Db 55025 55025
E 3010 3010
F 6510 6930
H 8640 9060
J 9835 10255
K 10485 10905
L 650 650
M 1195 1195
N 2130 2130
P 3500 3920
S 245 245
T 285 285
Y 3400 3700 3900 4300

Cutting tables
Width Width Width Width Width Width Width
U 4200 4500 4800 5100 5700 6300 6900

Tyres

650/65 V 400 550 700 850 1150 1450 2050

R38 X 400 550 700 850 1150 1450 1450

800/65 V 250 400 550 700 1000 1300 1900

R32 X 250 400 550 700 1000 1300 1300

900/60 V 150 300 450 600 900 1200 1800

R32 X 150 300 450 600 900 1200 1200

1050/50 V -50 100 250 400 700 1000 1600

R32 X -50 100 250 400 700 1000 1000

1-15
 SPECIAL TOOLS

All service tools can be ordered via Servicegard . The tool number in Servicegard has the
prefix 5SR in front of the numbers shown in this manual.

1-16
 SPECIAL TOOLS

1. Gearbox mounting support

2. Fitting tool for ratchet switch of air intake intermediate shaft

3. Extraction tool for table auger drive shaft

4. Straw walker fitting tool

5. Extractor for straw walker belt pulley

6. Disengaging plate for table clutch frame

7. Extractor flange with holes

8. Unloading pipe gauge

9. Curved key iron

10. Long, straight key iron

11. Key set, 3 pcs

12. Threshing clearance gauge

13. Threshing clearance gauge W440 PTC

14. Extractor for rotating screen

15. Hook wrench

1-17
COMBINE CUT-AWAY PICTURE

1.Pick-up reel 11.Grain elevator 21.Pre-concave

2.Knife 12.Auger housing 22.Unloading pipe
3.Table auger 13.Shaker shoe 23.Bottom augers
4.Crop elevator 14.Return elevator 24.Filling auger
5.Stone trap 15.Sieves 25.Grain tank
6.Threshing cylinder 16.Sieve extension 26.Engine
7.Concave 17.Straw walkers 27.CSP ruffler
8.Rear beater 18.Straw alarm
9.Fan 19.Straw chopper
10.Grain pan 20.Pre-cylinder

1-18
 2 . CUTTING TABLE

Instructions on fitting and removal of the knife, replacement of a knife plate, checking of knife
holders as well as other daily inspections are given in the combine manual.

The working widths are: 4.2 4.5 4.8 5.1 5.4 5,7 6.3 and 6.9 m.

WOBBLE-BOX KNIFE DRIVE UNIT

Removal from cutting table, fig. P1:

Remove drive belt K off belt pulley J.

x Unscrew belt pulley screws F and Allen screw G

and pull the belt pulley with the hub off the shaft.

Remove side screws M of upper support L.

Undo knife screws A, fig. P2, and screw B. Then

pull drive lever H off the main shaft.
Unscrew wobble box fixing screws C. Now the
whole drive unit can be lifted off.

Remove upper support L if necessary.

Refitting is done in the opposite order.

Note the following:

Washers D are of the special Nordlock type (must

always be replaced).

Screws C are of a special type (M18-2x45 10.9)

and they are coated with glue before refitting.
Tighten to 250 Nm.

Fit knife drive lever H onto the grooves with the

knife turning point correctly aligned. Note the
direction of hole X at the shaft end in relation to
knife drive lever Y, fig. P3.

Move the lever up and down with the knife plates

lightly brushing the counter surface of the knife
finger and tighten screw B.

Fit belt pulley J to the hub with the screws loose.

Push the hub onto the main shaft, check belt
alignment and tighten Allen screw G. Finally tighten
belt pulley screws F.

In case crown nut E of the knife joint has been

undone, tighten it to 55 Nm + enough for a cotter to
be fitted.

2-1
Repair of wobble box knife drive unit, figs P4 and P5
Depending on table widths, two different wobble boxes are used: 39-48 and 51-69.

Remove the wobble box from the cutting table as instructed above and drain the oil through
plug A.

Unscrew the screws on cover B and remove the cover.

Remove screws D of bearing housing C and remove the bearing housing.

Lift the assembly of fork shaft E and eccentric shaft F with the bearings out of the knife drive
casing in one piece.

Loosen drive nut G and remove locking plate H.

Use a plastic or lead mallet to hit eccentric shaft F with its bearings out of bearing housing J.

Remove tapered bearings K both from shaft F and housing J.

Unscrew locking screws L of bearing pivots M and remove the pivots either by pulling out (an
M8 thread at the end of the pivot) or striking inwards. If the pivots are struck in, remove spacer
ring N first (only the 39-48 unit).

Use a suitable mandrel ( 50 mm) to strike nail bearings P and shaft packing R out of
housing C.

Remove nail bearing S and shaft packing T of cover B as well as nail bearing U of the
wobble box.

Press out bronze bushings V of the fork.

Refitting is done in the opposite order. Note the following:

The 39-48 wobble box: Fit outer rings Z of the tapered bearings into housing J using a
suitable bushing. Note the correct fitting direction.

Fit bearing bushings V onto the fork shaft, place eccentric bearing housing J between the
forks and press pivots M into places. Lock the pivots with screws L. Note the correct direction
of mark X, fig. P3, in relation to knife drive lever Y.

The 39-48 wobble box: Use a suitable bushing to strike inner ring X of tapered roller
bearing K against shoulder Y of eccentric shaft F. Heat the bearing (max. +100oC), if
necessary.

The 51-69 wobble box: Heat tapered roller bearing K, max. +100oC, and strike with a
suitable bushing against shoulder Y of eccentric shaft F. When the bearing has cooled down,
strike it hard to ensure the right position.

The 39-48 wobble box: Push eccentric shaft F into bearing housing J. Fit the second inner
ring X, locking plate H and drive nut G.

The 51-69 wobble box: Push eccentric shaft F into bearing housing J. Fit the second
tapered bearing K, locking plate H and drive nut G. Note the correct direction of mark X, fig.
P3, in relation to knife drive lever Y.

2-2
2-3
 Rotate the shaft so that the bearings fit correctly in relation to the shaft. Tighten drive nut G
to 250 Nm. Re-loosen the nut and rotate the shaft several times back and forth. After this,
tighten drive nut G to 15020 Nm and lock the nut with the locking plate H.

Fit nail bearing U into the wobble box and other nail bearing S on cover B.

Fit nail bearings P of bearing housing C so that the upper bearing is flush with the upper rim
of the bearing housing. Set the lower bearing 12 mm inside the bottom rim. See the figure.

Refit the assembly of the fork and the eccentric shaft back into the wobble box. Ensure that
the inner end of the eccentric shaft fits into the nail bearing bushing of the wobble box.

Grease O-ring W and refit bearing housing C. Tighten screws D.

Refit box cover B. Check the cover O-ring and apply glue on the mating surfaces.

Before fitting the packing, check that the rotational resistance of the eccentric shaft is
2.55.0 Nm.

Grease packing R and T before they are fitted.

2-4
 Cutting table intermediate shaft

Removal:
Loosen both the knife drive and the table auger drive belts from belt pulley B.
Remove guard A, fig. P6.

Belt pulley B is fixed onto the shaft taper with key C and nut D.

Undo nut D and pull the belt pulley off the shaft with an extractor.

Undo the flange screws of bearing E at the left end.

Bearing F at the right end is locked to the shaft with two lock screws, which are loosened,
and the bearing is pulled off the shaft.

Push the shaft out to the left, mark the position of bearing E on the shaft, unlock the bearing
eccentric locking and remove it from the shaft.

Refitting is done in the opposite order. Pay attention to the following:

Bearing E is fitted onto the shaft in the marked position and locked with an eccentric ring, or
the measurements given in the figure are used. (Note! With the eccentric ring turned inwards.)

Push the shaft in from the left and tighten the flange screws of bearing E loosely by hand.

Apply a thin coat of oil at the right end of the shaft, fit bearing F with its flange and tighten the
flange screws loosely by hand.

Tighten the flange screws of bearing E to the right torque, fit key C and belt pulley B, and
tighten nut D to 280 Nm. Ensure belt pulley B is correctly aligned in relation to the counter and
jockey pulleys. If necessary, unlock bearing E and move the shaft in the desired direction.

Tighten the flange screws of bearing F to the right torque and finally lock the bearing to the
shaft with locking screws.

Fit guard A and the belts.

2-5
PICK-UP REEL

Left-side eccentric end

When replacing bearings C, note that

there are two curved plates B between the
base of shaft A and the bearing with the
convex side against the bearing. On the
other side of the bearing fit spring washer D
and spacer E before tightening nut F.

Make sure that the outer races of the

bearings can rotate freely after having been
tightened.

Adjust lower support roll G so that it

lightly brushes the surface of the end plate.

Replacement of hydraulic
motor/pick-up reel

Disconnect the hydraulic hoses from the

motor and plug both the connector ends
and the motor openings.

Remove guards A and B, unlock chain

C and remove the chain.

Unscrew motor screws D, which will

loosen nut plate E, and the motor can be
pulled out straight off the stand.

Unscrew screw F, remove outer spacer

G and remove chain sprocket H off the
shaft. Use an extractor, if necessary.

Unlock Taper Lock K of chain sprocket

J, (see separate instructions) and remove
the chain sprocket off the shaft. Unscrew
the flange screws of bearing L.

2-6
 Correspondingly on the left side,
unscrew the flange screws of bearing M,
fig. P9, remove screen plate N, and the
pick-up reel can be lifted off.

Loosen bearings L and M off the shaft by

unlocking the eccentric locking rings.

Reassembly is done in the opposite order:

Center the pick-up reel between the

supporting arms before locking the
bearings onto the shaft.

Fit the hydraulic motor with chain

sprocket H attached to it. Tighten motor
fixing screws D to 85 Nm.

Align chain sprocket J with chain

sprocket H and lock onto the shaft.

2-7
 TABLE AUGER

Removal from cutting table, left end:

Remove the knife drive and the table

auger belts.

Remove screw E and pull the pulley off

the shaft (sliding fit).

Loosen the locking ring of bearing F,

remove screws G, slacken adjusting screw
H and remove bearing holder J with the
bearings. If necessary, first remove
bearing flanges K from the bearing holder.

Slacken the screws of locking plate L.

Shaft M is screwed to end N of the table

auger with left-handed threading and
taper surfaces.

To remove the shaft, use special tool

R709190, or place pulley D temporarily
back on the shaft. Use a wooden block to
prevent the table auger from rotating, and
turn the pulley clockwise to unscrew the
shaft.

Removal from cutting table, right end:

Unscrew screw A, fig. P11.

First remove screw C, after which lever

D is pulled off the shaft.

Loosen adjusting screw E and remove

screws F and trimming tab G. Remove the
bushing behind the tab.

Lift the table auger assembly out of the

chute by first turning its left end out.

Refitting is done in the opposite order.

2-8
 Replacement of overload clutch friction plates

Remove the table auger drive belt and loosen screw E, fig. P10.

Unscrew screws A of the spring plates, fig. P12, remove washer B, additional trimming tabs
C, adjustment bushing D, trimming tabs E and bushing F.

First remove 6 spring plates G, then moving flange H, friction plate J, pulley K and inner
friction plate J off the shaft.

In case bearings L need to be replaced, remove all the pulleys off the shaft and unlock nuts
M in the rear, after which the bearings can be removed from shaft N.

Reassembly is done in the opposite order.

Fit the new bearings against the shoulder of shaft N. Fit bushing P onto the shaft between
the bearings and pulley frame T and tighten nut M to 200 Nm.

Before refitting all the pulleys onto the middle shaft, ensure latch bolt R behind the pulleys is
not stuck, but can be moved down to notch S by the spring, when necessary.

Fit the inner friction plate, pulley, outer friction plate and flange H. Fit 6 spring plates G in the
order shown in the figure. Grease surfaces U lightly before refitting.

If new spring plates G are used, fit two trimming tabs between the bushing and adjustment
bushing D to achieve measurement 16.5 mm. Additional trimming tabs C, (max. 5 tabs), are
fitted under washer B, and screw A is tightened to torque 7880 Nm.

If necessary and if old spring plates are used, additional trimming tabs can be moved to the
other side of the adjustment bushing shoulder to increase the compression force of the spring
plates.

2-9
Components inside table auger, fig. P13

Crankshafts D, E and F and shaft G are attached together with screw H and pivoted with
identical bearing units K, L, M and N inside the casing. The crankshafts can be replaced
without removing the table auger from the table:

Open door A, guard plates C and remove fingers B.

In case crankshaft E needs to be replaced, unscrew the nuts of bearing unit K and screw H
next to units L and M.

Pull shaft D in the direction of the arrow to remove it off shaft E.

Undo bearing eccentric locking ring J next to bearing unit L and remove the whole bearing
unit (or its bearing flanges).

Pull shaft E in the direction of the arrow to remove it through the mid opening. To remove
crankshafts D and F, remove the bearing units in a similar way.

The left-hand end can be disassembled only if the table auger is first removed from the table.

Reassembly is done in the opposite order.

Apply glue on screw P to attach the triangular plate at the left-hand end to hub R.

Correct the position of shaft G before locking the bearing locks. The measurement is
114 mm from the shaft end to the surface of the end flange.

Apply anti-corrosion grease on the crankshaft ends before they are joined.

Note the correct fitting position of finger B in relation to the crankshaft.

2-10
CROP ELEVATOR

Replacement of lower shaft

Unlock the table quick coupling and

remove the table. Instructions in the user
manual.

Remove feeder opening guard plate F,

fig. P14.

Slacken the crop elevator chains and

unlock the chain links.

Push lower drum G off its fastening forks

H and remove it through the feeder
opening.

To replace the lower shaft bearings,

unlock the eccentric locking ring and
screws B of bearing A, fig. P15, after which
the bearing is removed from beneath
flange C.

Refit new bearings onto shaft D. Note

that washers E are of the Nordlock type.

Centre shaft D in the middle of the shaft

tube before the bearing eccentric rings are
locked.

Note the relative rotation direction of the

lower shaft when the bearings are locked.

Replacement and adjustment of chain:

Remove the lower shaft as described

above.

In case the old chain is replaced with a

new, assembled one, attach the new
chain to the old one with a connecting
loop. Note the running direction of the slat
/ chain, see the arrow in fig. P16.

Use the old chain to pull the new one to

its correct position from below. If
necessary, open door A of the upper
shaft, fig. P17.

2-11
 If the chains are replaced so that the old slats are attached to the new chains, spread the
chains on a level surface as shown in fig. P16.

Note the slat profiles and the chain rotation direction when attaching the slats to the chains.
Screw A is black passivated, M8x20, strength class 8.8. A zinc coated M8x20 must not be
used.

The nuts are tightened loosely, the assembled chain is refitted onto the crop elevator shafts
and locking thread D of the connecting link is bent as shown in fig. P17.

Tension the chains so that the chains rise approx. 7590 mm off the control rails when lifted
through door B.

Rotate the chains while tensioning them to ensure they run in the middle of the crop elevator.
After this tighten nuts C of the slats, fig. P16, to 25 Nm.

2-12
 Table tilt bar

Unscrew middle nut E of the tilt bar, fig.

P17-18, through the crop elevator front
door, spanner width 36 mm.

Remove top pins F of the tilt cylinders,

fig. P18, at both ends of bar J. Pull off
perch pin G. Remove trimming tabs H and
lift the bar off.

Strike bearing bushings K off with a

suitable tool.

Refitting is done in the opposite order.

Note:
Press new bearing bushings K back to
bar J and ensure surfaces N and P are in
level.

Pressure plate L is symmetrical, but pressure plate M must be turned so that its darker
side is against pressure plate L.

Adjust the table fore/aft tilt using trimming tabs H, no more than 2o downwards (30 mm)
from the standard position.

Intermediate shaft

The transmission intermediate shaft is

machined symmetrical and can be
removed either to the left or the right.

Remove the belt guard from the left side

and the reverse guard from the right side.

Remove key A, fig. P19, and belt pulley

B from the left side.

Hit open the eccentric ring of bearing C,

remove the screws of flanges D and pull
the bearing off the shaft.

Unscrew reverse motor G screws F to

remove reverse motor G from the right
side.

Remove key H, unscrew the screws of hub J and push tooth rim K off the hub. Next remove
the hub and the tooth rim off the shaft.

Remove bushing L and unscrew screws M and P of motor stand N. Now the intermediate
shaft can be pulled out to the right.

Unlock the bearing eccentric locking and remove the bearing and the inner flange off the
shaft.

2-13
 Reassembly in done in the opposite order. Note:
Turn tooth rim K so that the smallest bevels of the teeth are against the starting motor.

Fit the right-end bearing against the shaft shoulder, bushing L against the bearing and hub J
against the bushing before key H is struck closed.

Clearance between the starting motor gearwheel and the tooth rim is 3 mm, adjusted with
spacers S.

Fit bushing R, spacer E and bearing C with its flanges D on the left hand side.

Align belt pulley B with the upper shaft pulley and lock with a key.

Table reverse with hydro motor

The piston of hydraulic cylinder A pushes

motor stand B in the direction of the arrow
and connects gearwheel D of hydro motor C
to gearwheel E of the intermediate shaft. Oil
channel F in the cylinder opens, and the
hydro motor starts to rotate the intermediate
shaft in the opposite direction. Spring G
returns the hydro motor back to its initial
position when the operation has been
completed.

Replacement of parts

To remove the motor stand, undo screw H

of spring G and open the hydraulic hoses.

Remove locking ring J and pull the stand

with the motor off the shaft.

To remove motor C, undo screws K.

Screw plate L functions as a nut.

To remove gearwheel D, undo screw M at

the end of the motor shaft.

To remove gearwheel E of the intermediate shaft, undo the key locking screw and pull the
gearwheel off the shaft.

Refitting is done in the opposite order.

Note that the spring measurement is 132 mm and the cylinder piston measurement is 20 mm.

2-14
Removal of crop elevator from combine

Drive the combine on hard, level ground

and set table trestle R634266 or a similar
20 - 30 cm high support under the table.
Support the top of the crop elevator
separately.

Lower the table onto the support and the

pick-up reel in its bottom position. Release
hydraulic oil pressure from the table and
pick-up reel cylinders.

On the right side of the crop elevator

loosen all the fasteners for electric cables
and hydraulic hoses, fig. P21.

Disconnect all cable ends.

Disconnect the hydraulic hoses in tilting as

shown in fig. P22.

On the left side of the crop elevator

remove belt guard D, fig. P23, and table
engagement belts C.

Remove stubble height indicator E.

To loosen the pistons of the table lifting

cylinders at their front ends, strike off pins B,
fig. P22.
Remove the table support.

On both sides of the combine open pins A

of the crop elevator blanking adapters, fig.
P21, and remove the pins and the locking
pieces.

Reverse the combine carefully. Monitor

that the table and the crop elevator stay in
their supported positions.

Refitting is done in the opposite order.

2-15
Crop elevator upper shaft

To be able to remove the upper shaft, the crop

elevator must be off the combine.

Remove door A fig. P17, at the top of the

crop elevator, and unlock the chains next to
the upper shaft.

Remove upper shaft anti-wrap guards A, fig.

P24, by undoing screws B.

Unscrew drive nuts D, fig. P25, and remove plate M and spring pack N. Next remove outer
friction flange E, key F, belt pulleys H with their friction plates G, inner friction flange J, other
key F and bushing K.

2-16
 On both sides remove fork bearing A and bearing flanges Ba and Bb by unscrewing their
screws C, fig. P26.

Unlock the eccentric locking rings of bearings D and E.

At the right end of the shaft turn a left-handedly threaded M8x16 screw F and with shaft slider
G push the shaft to the left through bearing E.

Clean the whole left end of the shaft with an abrasive band and pull bearing D off the shaft.

Remove the upper shaft through the crop elevator top opening by turning its right end out
first.

Use a suitable mandrel to strike keys H of the sprockets loose and remove the sprockets.

Refitting:

Fit sprockets J onto the shaft, turned as shown in the figure.

Note the sprocket measurements for different models according to the figure.

The starting point for the measurements is shaft shoulder K.

Strike keys H to the positions shown in the figure.

Refit the shaft to the crop elevator, push bearing D against shoulder K and lock the bearing
eccentric ring in this position.

Tighten left flange Ba to the correct torque.

Fit right-side bearing E. Press it lightly against fixed bearing flange L and lock the bearing
eccentric ring.

Fit flange Bb.

Fit anti-wrap guards A as shown in fig. P24.

Fit left fork bearing A in place before fitting the pulleys. Before this is done, replace pressure
and sliding bearings L, S and Z of the pulleys, fig. P25, if necessary.

Pull the assembly of the pulleys and bushing K or X firmly against the bearing with drive nut
D.

Note the positions and tensioning measurements of spring packs N or P as shown in fig.
P25.

2-17
2-18
 3 THRESHING MECHANISM

CHANGING OF PRE-CYLINDER / SHAFT

NOTE! The pre-cylinder is heavy and inconvenient to handle. Beware of injury!

Disassembly, fig. K1:

Remove the cutting table and the crop
elevator from the combine as instructed
previously.

Support the pre-cylinder with suitable

wooden blocks against the pre-concave.

Lift the combine from beneath the front

axle, support securely and remove the right-
side front wheel.

Open the service door of the right-side

front mudguard.

Remove the pre-cylinder drive belt and unlock Taper Lock A of pulley B onto the shaft and
remove the pulley. See instructions under General Installation Instructions.

Undo the eccentric locking ring of bearing C and the nuts of flanges D, and pull the bearing off
the shaft.

Remove the mudguard on the left side of the combine. Unlock the eccentric locking of the
bearing. Remove the nuts from the bearing flanges and pull the bearing off the shaft.

Open pre-cylinder SH friction bushing joint E and E1 on both sides. See instructions under
General Installation Instructions.

Pull the shaft out to the right and remove the pre-cylinder.

Reassembly is done in the opposite order.

Make sure the shaft distance from the flange is 67 mm before the SH joints are tightened.

It is important to tighten SH joint E1 at the end of the pulley all the way as instructed before
SH joint E at the other end is tightened.

Tightening torque for the hexagonal screws is 18 Nm.

Centre the pre-cylinder in the middle of the housing before tightening the eccentric lockings of
the bearings.

Check that the pulley is aligned with the cylinder variator pulley before locking its Taper Lock.
Screw torque is 90 Nm.

3-1
CHANGING OF PRE-CONCAVE

Disassembly, fig. K2
Remove the cutting table and the crop
elevator from the combine as instructed
previously.

Adjust the pre-concave in its bottom position

using electric motor A.

Undo support screws B on both sides. The

nuts are welded onto the concave ends.

Remove hinge plate C, after which the pre-

concave can be pulled out of the combine.

To remove the adjustment devices of the pre-

concave, unlock cotters F of support rods E,
bearing G and adjustment device H.

Unplug the cable to electric motor A.

Reassembly is done in the opposite order.

Ensure that rear edge D of the pre-concave will rest on top of the front edge of the main concave.

Fit hinge plate C before fitting foremost support screws B.

Basic setting of the pre-concave adjustment device

is done as shown in fig. K3:

Push adjusting shaft R from the cab side through

holder N and fit bearing L onto the shaft. Fit nuts S
and continue turning the shaft through threaded
bushing P.

Lock nuts S against bearing L with 0.1 mm

clearance, when the shaft shoulder touches holder
N.

Use electric motor A to adjust measurement 117

mm as shown in the figure, and lock limiter nuts J
against threaded bushing P.

Adjust the length of support rods E so that

clearance between the pre-cylinder and the pre-
concave is 10 mm when measured at the second
rasp bar. Measurement 29 mm is a theoretical
measurement.

3-2
STONE TRAP

If the stone trap has been removed, note the

following when refitting it:

Make sure slide plate A will stay inside the

stone trap when rear wall G is attached.

The stone trap closing device is attached

and adjusted with screws B so that hinge
door C is tight against beam D when closing
handle F is in its bottom position (closed).

To adjust the closed position of the closing

handle, undo screws E and move support H
so that lever J goes approx. 10 mm beyond
its dead point in its closed position.

3-3
THRESHING CYLINDER
CHANGING OF RASP BARS

The cylinder rasp bars are replaceable. A damaged rasp bar can be replaced when the
corresponding rasp bar on the opposite side is replaced as well to maintain the balance. At the
factory the rasp bars are weighed and sorted into four weight categories. All the rasp bars in an
assembled threshing cylinder have the same weigh class. Spare rasp bars are always supplied in
pairs and they are of the same weight category. If the patterns on the rasp bars are so worn that
groove depth is only approx. 4 mm, all the rasp bars must be replaced. Do not use badly worn and
new rasp bars together.

To remove damaged rasp bar F, fig. K5, remove screws G and rasp bar M on its opposite side.

Clean the fixing zones and the screw threads.

Fit new rasp bars. Note the groove direction. Always use new fixing screws and glue (Locktite
242). First tighten all the screws by hand and after that to 110 Nm.

If all the rasp bars need replacing, replace them in pairs and tighten a replaced pair before the
next pair is loosened. It is advisable to balance the threshing cylinder if all the rasp bars are
replaced at the same time.

3-4
CHANGING OF THRESHING CYLINDER

NOTE! The threshing cylinder is heavy and difficult to handle. Risk of injury!
Two people are needed to do the job!

Remove the cutting table and the crop elevator as instructed previously.

If there is a pre-cylinder, remove it as instructed.

At the left end of the cylinder shaft remove fixing plate J of the revcounter sensor, fig. K5, pulse
plate K and bearing eccentric locking ring L.

Remove two cylinder gib keys E, fig. K5, with

a suitable key iron.

Remove the right-hand front mudguard.

Lift the combine from beneath the front axle

on the right-hand side, support with trestles,
and remove the front wheel.

Slacken the drive belt at nut A, fig. K6, and

remove variator adjusting arms B.

Remove locking plate C and hub nut D off

the cylinder variator pulley.

Remove the variator pulley off the shaft by

pulling moving variator pulley B, fig. K5, with
sharp strikes against fixed variator pulley A. If
necessary, use an extractor.

3-5
xSet the concave in its top position and support the threshing cylinder with suitable wooden
blocks.

xUnscrew the nuts in bearing housing P, fig. K5.

With a brass mandrel strike the shaft out to the right. If necessary, the left-hand end of the shaft
can be pressed with a special tool as shown in fig. K7.

NOTE! Ensure the cylinder will not fall down when the shaft is removed!

xPlace two suitable planks (2.53 m) from the stone trap onto the floor and lower the cylinder
carefully.
Two people are needed to do this job!

xPull bearing housing P, fig. K5, with its bearing N off the shaft.

Reassembly is done in the opposite order.

A shaft is always supplied together with a new cylinder, since they are fitted and balanced
together. The gib keys and the gib grooves have been marked with a centre punch, and they must
not be exchanged.

xLift the threshing cylinder into the cylinder housing and ensure it is steady.

xCheck that bearing N, fig. K5, and dust packing C are intact and press the bearing securely onto
the shaft against shoulder D.

xPush the shaft from the right side of the housing through the cylinder. Fit left-side bearing H, but
do not tighten its locking ring L yet.

Tighten the nuts of right-side bearing housing P. Ensure that the inner ring of bearing N is
against shaft shoulder D.

Check that the outer surface of bush R is smooth and unscratched before refitting.

Fit variator pulleys A-B, tighten hub nut D, fig. K6, and lock the nut with locking plate C.

Adjust the cylinder variator belt as instructed so that its spring

pack tension measurement is 212 mm. Rotate the threshing
cylinder during the adjustment.

Now lock locking ring L, fig. K5, of the left-hand bearing. This
will ensure that the whole axial load produced by the belt tension
will lay on the right-hand bearing.

Centre the cylinder in the middle of the housing so that

measurements X are equal on both sides of the cylinder, after
which gib keys E are struck closed.

After the gib keys have been fitted, strike a mark on the key
groove to prevent the key from loosening.

Fit the front beam, the support plate, the pulse plate and its holder.

Check that the position of the revcounter sensor is as shown in fig. K8.

3-6
THRESING CYLINDER BELT VARIATOR

The variator pulleys are guided by three slide

pins. The slide surfaces of both the hub and the
pins are equipped with replaceable bronze
bushings.

Remove the variator pulleys as instructed off

the shaft and pull moving pulley A, fig. K9, off
the hub of fixed pulley B.

Press out bushings D of slide pins C after

locking ring E of the bushing has been
removed. Use a sharp screwdriver to lever the
cut end of the locking ring out of the groove.

Replace slide pins C if measurement X is less

than 21 mm. If a pin is broken, its stuck end can
be removed from pulley A by turning a M8
screw into hole F.

Bronze bushings G of moving variator pulley

A are removed in the same way as the slide pin
bushings.

Note the following in reassembly:

Apply Locktite 270 on the slide pin threads.

First centre the pins in the bushings of fixed
pulley B, then tighten to 100 Nm.

With a suitable tool press bronze bushings D and G into place and lock with the locking rings.
NOTE! Bushings G have packing H only at the outer ends. Remove the packing in the middle
before assembly if the bushing comes with packing.

Fill the hole surfaces of the bronze bearing bushings with grease after their housing has been
fitted.

Fit thrust bearing J into housing K so that the protected side of the bearing faces outwards.

3-7
CHANGING OF CYLINDER VARIATOR BELT

Remove grain elevator belt A, fig. K10, from

pulley B of the rear beater shaft.

Slacken the nuts of belt fixing screw K near

upper pulley D. Remove adjusting arms E of
the pulley.

Open the upper pulley enough to be able to

remove the belt from cylinder pulley F.

Reassembly is done in the opposite order.

Rotate the cylinder during tensioning. Ensure
the belt basic adjustment complies with the
instructions. The instructions on how to break in
a variator belt must be followed. A new belt
must be tensioned after a few operating hours.

CYLINDER VARIATOR ADJUSTMENT

Adjusting of the cylinder variator is positively

driven. The adjusting is done by electrically
rotated screw H, fig. K10, which moves the
levers in the D pulleys. Since the leverages are
connected to each other with connecting screw
G, both pulleys move at the same time. The
other ends of the leverages are connected to
the body of the combine with coach screws.
The leverage coach screw on the side of the
cylinder is equipped with a spring leaf pack,
which compensates for natural wear of the belt,
and provides additional flexibility in case of
overloading.

Basic adjustment of the leverages must be

made when the whole variator has been
disassembled or a belt has been replaced. The
adjustment must be made in such a way that
the full operating range of the variator will be
used, i.e. the belt can be adjusted on the pulleys in the extreme positions without the levers
touching the pulley rims.

Basic setting for a new belt: distance X between the cross pin centres of connecting screw G is
the following with different variators:

Variator (grain) Variator (maize)

600 - 1300 rpm 400 - 1150 rpm
~179 mm ~183 mm

The measurement is less when using a worn belt.

Before tensioning the belt, electric adjustment H should be in the centre of its adjustment range.
This can be measured from the adjusting screw.

3-8
 Tighten coach screws J and K until belt tension is correct. During adjustment rotate the variator
once in a while to ensure that the belt will set in its correct revolution diameter.

Tension so that the belt sets in the middle of its adjustment range on both pulleys. The adjusting
arms must be parallel with the side of the pulley.
Belt tension is correct when spring pack L measurement is 21+2 mm.

After this adjust the variator with the adjustment motor running and check that the adjustment
goes to the extreme positions without the adjusting arms touching the pulley.

On both pulleys the belt must rise to be flush with the outer races of the pulleys (except with the
400-1150 rpm variator where the belt must be 5-7 mm above the top of the outer race of the
cylinder pulley) without the adjusting arms touching the pulleys. If necessary, adjust coach screws
K and J. Belt tension will remain unchanged when one screw is slackened as much as the other is
tightened. It may also be necessary to adjust the connecting screw G.

Once the correct adjustment range has been found, limit it with nuts M so that the belt cannot go
outside the range.

Retightening as follows:

Always tighten coach screws K and J equally much and connecting screw G as much as the
coach screws together. E.g. if you tighten each coach screw one turn, you should tighten the
connecting screw two turns. This will maintain the basic setting of the leverage.

3-9
CHANGING OF CONCAVE

Two people are needed to do this job!

Remove the cutting table and the crop elevator as instructed previously.

If there is a pre-concave, remove it as instructed.

Lower the concave to its down position.

Remove the sieves, the grain pan cassettes and the two middle straw walkers.

Unscrew fixing nuts E (tacked screws) of concave extension D, fig. K11, and lift the extension on
top of the straw walkers.

Lift the right-side front wheel up from beneath the front axle, support with trestles and remove the
wheel and the mudguard.

Unscrew 4 locking screws G of support bushings F.

Pull support bushings F off support shaft H and slide shaft H out to the right.

Strike rearmost supports J in on both sides, fig. K11a, while another person is supporting the
concave inside the combine. The HD (maize) concave has a single rear support, which is pulled
out to the right.
Pull the concave out through the front.
3-10
When reassembling, note that foremost supporting shaft H is pushed through hinge plate K of the
stone trap. Rearmost supports J are struck out from the inside on both sides, fig. K11b.
Lock protective plate M against the housing with eccentric plate L, fig. K11c. Readjust the concave.

BASIC CONCAVE ADJUSTMENT

In the cab turn the concave adjusting to reading

6. Now clearance C, fig. K12, between the first
concave rasp bar and any rasp bar on the
cylinder, must be 6 mm.

Correspondingly, clearance D between the last

rasp bar and a cylinder rasp must be 3 mm.

Alignment at the front 1 mm and at the rear

0.5 mm.

Lock nuts S against bearing L with 0.1 mm

clearance, when the shaft shoulder touches
holder O fig. K12b.

Use electric motor A to adjust measurement

121 mm as shown in the figure, and lock limiter
nuts J against threaded bushing M

If there is a deviation, readjust the clearance with

nuts P at the lower end of adjustment rod N in the
concave, fig. K11. The clearance must be checked from
every corner of the concave. Use tool R152308.

3-11
CHANGING OF REAR BEATER AND ITS SHAFT

On the left side of the combine:

Remove the hydraulic hose to the table clutch and plug the hose and the nipple with tape.

Remove the shaker shoe, cutting table and threshing mechanism belts as well as the threshing
mechanism belt arc off the pulleys of the rear beater shaft.

Disassembly of the table clutch off the rear beater shaft, see the separate instructions below.

Loosen the screws to lower the mudguard enough to be able to pull polygroove pulley A, fig. K13,
off the shaft. On TS models with a closed unloading system the pulley is first removed off hub D,
after which the hub is pulled off the shaft.

Unlock eccentric locking C of bearing B.

On the right side of the combine:

Remove the grain elevator drive belt.

Remove belt pulley F by undoing screw G, after which counter surfaces H, friction plates J and
pulley F are pulled off the shaft grooves. Remove bush K.

Remove or lower the mudguard.

Loosen the cylinder belt at screw K, fig. K10, and remove adjusting arms E.

Remove moving variator pulley L, fig. K13, the cylinder variator belt and fixed variator pulley M. If
necessary, use an extractor.

Remove bush N, fan pulley P and bushes R and Q.

3-12
 Undo all bearing housing S nuts.

Open protective plates T on the surface of the rear beater housing (access through the straw
walker compartment) and loosen locking screws U of keys V.

Support the rear beater from below with a suitable wooden block through the front door.

Check that the position of locking screws U is straight upward before pushing the shaft out. This
ensures that keys V will remain in their grooves and not fall inside the rear beater.

Push the rear beater shaft out to the right. If necessary, attach an extractor plate and use a long-
forked extractor to push the shaft to the right.

Remove the left-hand bearing housing with its bearing.

If the right-side bearing or its housing is replaced, pull the housing with its bearing off the shaft.

Rotate the rear beater backwards on top of the straw walkers and remove it through the side
door.

When reassembling, note that the rear beater is turned inside the combine as shown in fig. K14.

Check also that the key grooves point straight up.

Fit right-side bearing housing S, fig. K13, with its bearing on the
shaft so that the inner bearing race will be against shoulder W.

Push the shaft from the right through the rear beater so that the
keys fall into the grooves of the rear beater hubs.

Ensure that the right hub of the rear beater is firmly against shaft
shoulder X.

Tighten the nuts of right-side bearing housing S.

On the left side fit rubber bush Y and support plate Z on the shaft. Fit bearing B with its housing.

Tighten the bearing housing nuts, but do not lock locking ring C. The rubber bushing shall shrink
approx. 2 mm.

Ensure the rear beater is in the middle of the housing. If necessary, set spacers either between
bearing housing S and the wall or between the bearing and shoulder W. If necessary, shims can
also be set between the rear beater hub and shoulder X.

Tighten locking screws U of keys V inside the rear beater. Fit cover plates T.

On the right side fit bush Q (with the bevelled end inward), bush R, pulley P, bush N, variator
pulleys L-M, bush K and pulley F with all the parts.

Tighten screw G. Adjust spring pack E to measurement 23 mm.

Set the fan variator belt and adjust / tension the cylinder variator belt as instructed. Rotate the
variator while tensioning.

Lock eccentric ring C of bearing B on the left side of the combine. This ensures that the axial
load produced by the variator belt will be on the right-hand bearing.

Fit polygroove pulley A against the shaft shoulder and the table clutch as instructed.

3-13
 Attach all loosened belt guards and belts.

CUTTING TABLE CLUTCH

Disassembly and reassembly in connection with the changing of the rear beater.

Open rotating connector body A, fig. K15, drive nuts B and shim C.

Lever hydraulic unit D off pipe shaft E with two screwdrivers against pulley H.

Remove spring plates F, undo screws G and remove pipe shaft E and pulley H.

Remove moving shackle of coupling M, springs N and friction pieces P. Note! If the same friction
pieces are refitted, they must be numbered to maintain the original order. New friction pieces are
numbered.

Note! Remove the plate, the friction segments

and springs very carefully in order not to drop
them. Use insulator tape to hold the segments
together. The segments shall always be
numbered and fitted in the given order.
Undo screw J, remove bush K and turn screw J
back onto the shaft.

Fit extractor plate T696730 as shown in fig. K16

with screws G and pull clutch body Y off the shaft
with a two- or three-forked extractor.

Remove inner tapered ring L and key V off the

shaft and pull pulley R off the shaft.

3-14
Reassembly is done in the opposite order.

Clean the shaft. Grease lightly the shaft, the inner surface of clutch body Y, tapers L and pipe
shaft E.

Set pulley R with its bearings against polygroove pulley X.

Fit key V, inner tapered bush L, clutch body Y, outer tapered bush L and bush K and tighten
screw J to 180 Nm.

Undo screw J again and ensure that the outer rim of the tapered bush goes at least 0.8 mm over
the shaft end. Retighten screw J to 180 Nm.

Fit the friction pieces in the correct order behind locking wire S. Use tape to hold the pieces in
place until springs N and moving clutch ring M have been fitted. Make sure the springs and guide
pins Z fall into the clutch ring holes.

Fit pulley H and pipe shaft E and tighten screws G crosswise.

Note the positions of spring plates F as shown in the figure before fitting them.

Check the condition of packing T of the hydraulic unit and replace, if necessary.

Ensure that the sharp rims of the pipe shaft do not damage packing T when the hydraulic unit is
carefully fitted onto the pipe shaft.

Fit shim C and tighten inner drive nut B all the way before locking it with another nut.

Check the O-ring of connector body A before fitting.

3-15
STRAW WALKERS

REMOVAL OF PULLEY

The straw walker pulley is attached onto the shaft with

locking ring B, fig. K21 and key C, which is locked with screw
A.

Remove the straw walker drive belt.

Undo and remove screw A and loosen locking ring B at the

end of the shaft.

Fit extractor tool R705652 as shown in the figure and pull

the pulley off the shaft.

When refitting, push the pulley onto the shaft only far enough
to be able to fit the locking ring.

CHANGING OF HOUSING BEARINGS

The straw walker shafts are bearing-mounted onto the

combine housing with long-necked ball bearings with breech
screw locking. Inner bearing flange D, fig. K22, is machined
and the screw holes have an M12 thread for extracting. Near
the rear shaft there is spacer F between flange D and the
wall.

Undo flange nuts A and remove the screws. Remove

flange B.

Undo locking screw C and turn flange D in the direction of

the arrow until the screw holes are out of alignment.

Screw three M12 screws E into flange D. Tighten them

evenly in turns and pull the bearing off the shaft.

When refitting, make sure the straw walkers are in the middle
of the housing before locking screws C are tightened.

3-16
CHANGING OF STRAW WALKERS

Remove the chaffer and grain sieve and the

straw walker drive belt.

Loosen all fixing nuts A, of the ball bearings of

the straw walkers about 5 mm (8 nuts/straw
walker) and knock the screws up.

Push the straw walker forward in the direction of

arrow B (about 20 mm) until the screw locking
heads align with the fitting holes.

Lift the straw walker straight up and out through

the rear door.

Reassembly is done in the opposite order:

Follow the instruction on the reassembly of straw
walkers given in chapter Changing of straw walker shaft ball bearings.

CHANGING OF STRAW WALKER SHAFT BALL BEARINGS

The ball bearing units are fitted onto the straw

walker shaft cranks through the shaft end.
Therefore the bearing(s) furthest out on the side
also have to be disassembled, if the centremost
bearing(s) is defective and needs replacing. New
locking plates are needed for these bearings
when refitting is done.
The necessary tools and materials include, fig.
K24:
A- Cleaning agent, Loctite 7063
B- Fixing agent, Loctite 603
C- Abrasive band
D- Screw driver
E- Tool R708251 to undo clip nut
F- Torque wrench
G- Spanner for final tightening

Remove the straw walker shaft with its bearings

off the combine by undoing all nuts A of the
bearing units, fig. K23.

Remove the drive pulley from the foremost

shaft.

Support the straw walkers so that the whole shaft can be removed from the combine after screws
A of the flange bearings, fig. K22, on the wall and locking screw C outside have been undone.

Clean the exterior of the shafts with their bearings.

3-17
 Remove cover plate A, felt ring B and protective
cover C, fig. K25, from the back of the bearing unit
to be replaced.

Mark the position of tapered ring K, fig. K26, on

the shaft with a centre punch to ensure the
bearing will be refitted in the correct position.

Lever latch A, fig. K27, open at the front of the

bearing unit using screw driver B.

Use tool R708251 to undo clip nut C.

Remove protective plate D and the locking plate

under it.

Knock the inner race of the bearing in the

direction of the arrows with a suitable mandrel,
fig. K28, to loosen the bearing unit off the tapered
bush halves K glued onto the shaft.

Remove the bearing unit off the shaft and

knock the tapered halves off the shaft with a
hammer.

Undo 4 screws R in the bearing unit.

3-18
 Knock the old bearing off the plastic bearing
housing with a suitable mandrel ( 79 mm).

Fit a new ball bearing in the same way, fig. K29.

The bearing unit is assembled so that screw

heads A and welded nuts B aree on the same side
as mark K on the inner ring of the bearing, fig.
K30.

Torque for the screws is approx. 25 Nm

Remove old glue off the shaft neck and the

tapered halves with an abrasive band, fig. K31.

Clean both shaft neck A and tapered halves B

by spraying cleaning agent on the surfaces, fig.
K32.

Wipe any excessive agent off before it dries.

3-19
 Apply Loctite 603 glue on the inner surfaces of
the tapered halves, fig. K33.

Fit tapered halves K on the shaft, rotate with a

finger back and forth to spread the glue evenly
round the shaft, fig. K34.

Place the halves next to the position mark and fit

the bearing unit on top of the taper with the back
side first.

Ensure that rims R are aligned.

If there are no position marks (a new shaft), use the measurements given in fig. K35.

Fit locking plate A onto the shaft at the front of

the bearing unit, fig. K36, with its latch falling into
the opening between the tapered halves.

Now turn protective plate D and clip nut C into

the threads of the tapered halves.

3-20
 Use spanner wrench H, fig. K37, to tighten the
nut to 35 Nm. After this tighten the nut two more
notches and more, if necessary, to be able to lock
latch A into the nut notch.

Fit protective plate C, fig. K25, felt ring B dipped

into oil, and cover plate A on the back side.

Lift the assembled straw walker shafts back in

place and fasten the straw walkers with the screws
loose.

Make sure the screw locking heads fall into their

locking grooves properly. Use tool R708255, fig.
K38, to facilitate the job.

Equalize the spacing between the walkers next

to the foremost crankshaft crossways (adjusting
holes in the bearing plates) and tighten the fixing
nuts to the final torque of 25 Nm.

Equalize the spacing between the walkers

sideways next to the rearmost crankshaft, too.

Rotate the shafts a few turns on the pulley until the left-side walker remains in the rearmost
position. Tighten the nuts to the final torque of 25 Nm.

Rotate the walkers a few turns and tighten the right-side walker the same way, and after that the
other walkers crossways.

When all the walkers have been tightened to their final torque, slowly rotate the shafts on the
pulley to make sure that all the walkers turn smoothly.

3-21
CSP STRAW RUFFLER

Only the CSP fingers and finger guides can be replaced without removing the CSP off the
combine.

To replace a finger, remove the CSP drive belt and open service doors L, fig. K41, after which the
fingers, the finger bearings and the finger guides can be replaced.There are 24 fingers and they
are identical with the table auger fingers of the cutting table.

3-22
REMOVAL FROM AND REFITTING TO THE COMBINE

Support the CSP inside the housing with suitable planks to prevent it from falling down after it
has been loosened.

Remove the CSP drive belt and pulley A, fig. K41, from the shaft on the left side of the combine.
Use an extractor, if necessary.

Remove revcounter pulse wheel B and sensor C and undo bearing flange screws D (nut threads
on the housing collar).

Pull the bearing off the shaft, after which the screws of flange shaft E can be removed.

On the right side remove adjusting lever F and fastener G, after which screws J of flange shaft H
are undone.

Lift the CPS ruffler out of the combine.

Refitting is done in the opposite order.

Lift the CSP ruffler back into the combine. Note the correct mounting direction.

First fix right-side flange shaft H with marker holes K in alignment. Fit fasterner G and adjusting
lever F.

Fit flange shaft E with bearing and make sure the ruffler rotates without wobbling inside the
housing.

Fit and lock pulse wheel B against the bearing. Adjust the distance from sensor C to the pulse
wheel nose to be 0.5...1.0 mm as shown in the figure.

Fit pulley A and align it with the driving pulley.

3-23
DISASSEMBLY AND REASSEMBLY OF CSP STRAW RUFFLER

Remove finger casing M, fig. K41, under which service doors L are, and open the service doors.

Loosen and remove all fingers A, fig. K42, off eccentric shaft B through the service doors.

Undo nut C, remove washer D and knock locking ring F of bearing E open at the shaft end.

Undo screws H of right-side end flange G and pull the flange out, which will loosen shaft B either
off hub J or end K or both.

Push hub J off bearing L. Undo the bearing flange screws to replace the bearing.

3-24
Reassembly is done in the opposite order.
If left end K has been removed, align its flange edges carefully with the edge of the ruffler
housing before tightening the screws.

Fit bearing E with its flanges at the left end of shaft B with loose flange nuts. Fit shaft B with
bearing E into the hub of end K against the shoulder.

Fix bearing L with loose flange nuts to end G and push hub J through the bearing.

Fit washer M against the bearing, after which hub J at end G is fitted through the corresponding
hole of shaft B. Fit washer D and tighten nut C lightly.

Align the outer edges of end G carefully with the edge of the ruffler housing before tightening
screw H.

Tighten nut C to its final torque, tighten the flange nuts of bearings E and L, and finally lock
eccentric locking ring F of bearing E.

Fit fingers A with their guides, the service doors and the finger casing.

3-25
CHOPPER

Beware of the rotating chopper knife!

Never adjust or clean the chopper while the engine is running.
Always wear protective leather gloves when changing chopper knives!

Changing of rotor knife, fig. K45.

Remove damaged knife A. Clean and grease.

Fit new knife B and tighten the nut to 65 Nm.

NOTE! The chopper rotor is carefully balanced

and therefore it is of great importance always to
use swinging knives of the same weight and
always replace the nearest two counter knives,
too.

Changing of counter knives, heavy-duty

chopper, fig. K47.

Slacken the three screws of protective case A

by 2-3 turns.

Remove the case and pull out damaged knife

B.

Fit a new knife and then the protective case.

The rotor shaft is mounted with ball bearings in

cast housings. To replace, strike the eccentric
ring open and pull the bearing and the housing
off the shaft. The drive belt pulley is attached
onto the shaft with Taper Lock. See the separate
instructions.

3-26
CLEANING ELEMENTS

CHANGING OF GRAIN PAN FRAME

CHANGING OF TOP SIEVE FRAME
CHANGING OF SLIDING SHAFT

Raise and lock the cutting table in its top position.

Undo rubber bushing screws A of the front of the

grain pan under the stone trap, fig. K51.

Undo screws C to remove front packing B of the grain

pan.

Remove the top and bottom sieves.

Remove the detachable sections of the grain pan.

To loosen the rearmost fastening of the top sieve

frame, remove cotters A, fig. K52, and locking rings B of
the bearings and loosen flange screw C, if necessary,
after which support levers D are pulled off on both
sides.

To loosen the foremost fastening of the top sieve

frame, open halves J of the rubber bearings, fig. K53,
and remove the top sieve frame from inside the
combine.

Sliding shaft Da and Db of the grain pan has two parts connected in the middle with right-hand
threading, fig. K53.

On the left side of the combine loosen the attachments of the rocker arm and the connecting rod
to the sliding shaft by undoing screws C, fig. K53a. Turn the screws into the holes as shown in fig.
K53b to release the locking round the shaft.

Support the rear of the grain pan in a suitable way.

Inside the combine, on the left side, loosen the screws of locking half G enough to release the
shaft. Open casing K only if a locking half needs replacing, or it has been opened all the way by
accident, or it has fallen down.

3-27
 To unlock locking E on the left edge, remove screws F and after that turn one of the screws into
the hole pointed at by the arrow deep enough to undo the locking and release the shaft.

Sliding shaft half Db is now loose and its middle joint can be opened by loosening screw H (the
screw has left-handed thread). Remove the shaft from the combine.

Loosen and remove right-side shaft half Da in a similar way.

Pull the grain pan frame out through the rear.

Reassembly:
Replace the side packing if worn or hardened.

If rubber bearings L of the sliding shaft need replacing, note the mounting measurements given
in the figure. The bearings have been fitted onto the shaft to press fit. No grease must be used
when fitting.

Fit the grain pan frame back to the combine, fix the front packing and nuts A of the screws in the
front rubber bushes, fig. K51, loosely.

Push sliding shaft half Db, fig. K53, from the left through the connecting rod and the rocker arm
and inside the combine through left-side fasteners E and G. Temporarily tighten fasteners E and G
to prevent the shaft from rotating.

Correspondingly, push shalf half Da into the combine from the right-hand side and turn it into the
other shaft. Tighten at right-threaded screw M.

Undo temporarily fastened fasteners E and G, centre the sliding shaft sideways so that bearings
L are in the middle in the connecting rod and rocker arm housings on both sides of the combine.

Centre the grain pan frame inside the combine and tighten all fasteners E and G

3-28
 Rotate the threshing mechanism until the grain pan stops midway in its moving range and tighten
both the screws of the rocker arm rubber bearings and the nuts of the front rubber bearings to the
right torque. Now rotate the threshing mechanism to move the grain pan either to its front or rear
extreme position, and tighten the screws of the connecting rod rubber bearings in this position.

Refit the top sieve frame. Note that rubber bearing halves J are asymmetrical. Set the bigger
screw hole upwards, see fig. K53. Lock locking ring B of the bearing clockwise, fig. K52.

CHANGING OF SHAKER SHOE

Remove the top and the bottom sieves.

Remove the top sieve frame as instructed previously.

Unscrew foremost rubber bush screws A of the shaker shoe, fig. K54, (access through the
shaker shoe).

At the rear unscrew rubber bush screws B below the shaker shoe. Remove the shaker shoe
from the rear (the rearmost levers will stay in place).

When reassembling, note the refitting instructions on the rubber bushes and the condition of the
side packing.

CHANGING OF CRANKSHAFT IN SHAKER SHOE / GRAIN PAN, fig. K55

Rotate the threshing mechanism by hand to move the grain pan to its foremost extreme position.

On both sides of the combine undo the flange screws of bearing B at the end of connecting rod
A. Undo fixing screw C of the rubber bearing housing at the other end of the connecting rod and
move it to the next hole and tighten to release the bearing housing. Now the connecting rod can be
removed. To remove the connecting rod on the right side of the combine, move the grain elevator
slightly backward or cut a section off the edge of the elevator casing, fig. K55a.

Loosen pulley D, eccentric hub E and remove key F.

3-29
 On the right-hand side of the combine strike the eccentric locking ring of bearing G open and on
the left-hand side undo the screws of bearing housing H.

Disconnect grease hose K, fig. K55b, from bearing housing G and H.

Push or strike out crankshaft J to the left through bearing housing G. When the shaft is loose,
bearing H can be pulled off the shaft with a suitable extractor.

Refitting is done in the opposite order

The lateral crankshaft position is determined when bearings G and H are pushed against the
shaft shoulder and the eccentric rings are locked.

Eccentric hubs E are pushed against the next shoulder and locked to the final torque before
pulleys D are attached.

The screws of the connecting rod rubber bearings are tightened when the grain pan in its
foremost or rearmost extreme position.

CHANGING OF MIDDLE SHAFT AND BEARING IN SHAKER SHOE

Connecting rods A, fig. K55, are removed as instructed above.

3-30
 Screws M of the top bearing housings of rocker arms L are undone and moved to the next hole
and tightened to release the bearing housing.

Remove the top and bottom sieves and after that remove bottom rubber bushes A of the rocker
arms at the bottom front corners, fig. K54. Support sliding shaft S, fig. K55, next to the holes on the
combine housing to keep the grain pan and the top sieve frames in place when the rocker arms
are removed. Support the shaker shoe from below, too.

Undo screws P of middle shaft N in the rocker arms, fig. K55.

Fix extractor plate R700966 and extractor with two M12x50 screws and pull the rocker arms off
the shaft taper, fig. K55c.

Undo the eccentric locking rings and flange screws of flange bearings R.

Pull the bearings off the shaft. Remove the shaft.

When refitting, centre the shaft in the middle of the casing. Note the tightening instructions on the
rubber bearings.

FITTING OF RUBBER BUSHES

The position of the rubber bush in relation to the

lever is shown in fig. K56.

Any grease and dirt must absolutely be wiped off

the lever and shaft ends before the rubber bushes are
fitted onto a shaft.

The diameter of the bush hole is approx. 25%

smaller than the corresponding lever or shaft.

No grease must be used to facilitate fitting!

Before the rubber housings are tightened, push the

shaft or lever end approx. 10 mm over the rubber, see
the figure.

Fit the housing halves of the rubber bushes as

shown in the figure, i.e. point a (groove) on the side
with the lever end.

All the rubber bushes are tightened into the housing

with every lever in its mid position.

3-31
CHANGING OF FAN CASING / AUGER HOUSING

Two people are needed to do the job!

Drive all the combine wheels on a 10-cm platform to be able to remove the auger housing from
under the combine safely.

Remove the top and bottom sieves. Remove the shaker shoe as instructed above.

Remove the rocker arms and the middle shaft of the shaker shoe as instructed.

On the left side of the combine loosen the fan revcounter sensor and undo the bottom cover
screws near the fan casing. Loosen also the adjusting rods for the air direction plates.

On the right side loosen the fan drive belt and the bottom covers.

To remove bottom return auger C, undo nut A, fig. K57, and the overload clutch parts under it as
well as the pulley. Unlock bearing B locking and remove the bearing off the shaft.

On the left side loosen the flanges of bearing D. Open joint K.

To remove lower auger P of the grain elevator, fig. K58,

unlock bearing R and the elevator chain and strike off the
cotter of sprocket S.

On the left side of the combine remove the revcounter

sensor and loosen bearing flanges F of the lower auger,
fig. K57 and rack G, after which lower auger P is turned out
to the left through opening H far enough to be able to open
joint T, fig. K58, between the grain elevator and the auger
housing. If necessary, remove the toolbox casing.

Support the fan/auger housing casing from below. Unlock

its top fixing screws J, lower the casing and pull it off from
under the combine. Remove the fan wings. See the
instructions in the next chapter.

Reassembly is done in the opposite order.

3-32
CHANGING OF FAN WINGS / SHAFT

Remove the drive belt pulley off the fan shaft and the revcounter sensor at the other end.

The fan wings are removed from inside the casing. Loosen wings E and arms F, fig. K59.
Access through the bottom door on the middle arm.

To open bearings M of the shaft, remove supports L, fig. K57, and remove the shaft off the
casing.

To remove hubs G off the shaft, undo locking nut D, fig. K59, after which locking screws C locked
with glue are unscrewed. Heat, if necessary.

When reassembling, first attach hubs G onto the shaft. Check the right direction in fig. K59.

Apply Loctite 243 or similar glue on locking screw C and turn it in the shaft holes, after which
locking nut D is tightened.

Fit the shaft in the casing and attach the bearings, but leave the eccentric rings loose.

Fit the arms as shown in the figure. Note that the fixing holes are asymmetrical, Note points A
and B, when wings E are fastened to the arms. Check also the correct positions of the washes in
fig. K59a.

Centre the wings in the middle of the casing and lock the eccentric rings of the bearings onto the
shaft.

Lock the pulley with a key, noting the correct alignment in relation to the belt variator. At the other
end of the shaft attach the revcounter sensor noting the measurements given in fig. K59.

3-33
REPAIR OF FAN VARIATOR

Loosen the fan variator belts.

Remove centre screw A of the variator pulleys and lift the pulleys off.

Strike shaft D out (a loose fit).

Loosen the locking nuts of binding bolts E and remove moving variator pulleys H off the hub.

Strike ball bearings J out with a suitable mandrel.

Press or strike out bearing bushings M of the moving variator pulleys.

Reassembly is done in the opposite order.

Clean the hub carefully before refitting the ball bearings.

Grease the moving variator pulleys and the outer surface of the hub with graphite grease.

Washer G fitted between fixing fork F and bearing J must not touch anything else but the inner
ring of the bearing.

3-34
 4 GRAIN TRANSPORT SYSTEM

RETURN ELEVATOR

Changing of upper auger

x Remove cover plates A and B fig. V1.

x Unlock the chain lock and remove chain C.

x Undo 8 pcs screws D of horizontal auger and one nut E on the right side of the combine fig. V2.
x Undo 6 pcs screws F.
x Lift the top of the elevator about 10 cm up, and lock it with the extra support.
x Pull the whole horizontal auger out of the combine to the left.

4-1
CHANGING OF LOWER AUGER IN RETURN ELEVATOR

Please see Changing of lower auger in grain elevator, same principle.

CHANGING OF CHAIN IN RETURN ELEVATOR

Please see Changing of chain in grain elevator, same principle.

NOTE:
In case of broken chain, open the cover plate A fig. V3. Through that hole you are able to
feed the new chain.

4-2
CHANGING OF LOWER AUGER IN GRAIN ELEVATOR

x Remove the elevator drive belt.

x Unlock the elevator chain through the elevator bottom

door and strike the pin of sprocket S loose, fig. V6.

x Unlock the eccentric locking of bearing R at the lower

end of the elevator.

x Open both the bottom doors on the left side of the

combine and remove the screws of bearing flanges L in
the lower auger, fig. V7. Remove the low speed sensor
and the outer bearing flange.

x Strike at the right end of lower auger P to move the

auger 10-20 mm to the left. Check from the left that the
end of the auger is in alignment with runner H of the
auger housing. Strike again at the right-hand end of the
shaft to push it out through the bearing opening.

x Turn the lower auger counter-clockwise while pulling it

to the left so that the auger turns via the runner on the
wall of the auger housing until the sprocket has reached
the bottom door of the auger housing.

x Through the bottom door strike the sprocket off the

end of the shaft.

x Inside the auger housing raise the end of the lower

auger high enough to be able to fit its left end under the
side cover of the combine and pull the lower auger out
that way.

Reassembly is done in the opposite order.

x The axial position of the lower auger is correct when
the sprocket of the elevator chain is in the middle of the
elevator casing.

CHANGING OF CHAIN IN GRAIN ELEVATOR

x Remove the drive belt and turn the elevator chain so

that connecting link A, fig. V8, is next to the bottom door,
after which it is unlocked. Connect the old and the new
chain with a connecting link.

x Pull the old chain out through the bottom to replace it with a new chain. In case no new chain is
fitted to the combine, but the old one is refitted, tie a rope to the end of the chain. Now you can pull
the chain out and set it back through the bottom door.

x Half loop B has been added to the elevator chain to even out the running so that when the chain
is tight in the down section (point D), it is loose in the top section (point C). Therefore half loop B
alone must not be removed if there is no more tensioning tolerance left.

x If all the tensioning tolerance is first used up, two loops can be removed.

4-3
GRAIN ELEVATOR UPPER SHAFT

x Drive belt pulley T is

attached to the shaft with
thread and taper, fig. V9.

x Remove the pulley by

turning it counter-clockwise.

x Use a suitable tool to

prevent shaft rotation. The
shaft has a 24 mm grip zone
to facilitate holding.

x Slacken the elevator chain

as much as the tensioning
device allows.

x Unlock the eccentric

locking ring of bearing B,
and flanges C, and remove
outer side plate D together
with the bearing.

x Unlock the eccentric

locking ring of inner bearing
A and the flange screws,
and remove side plate E
together with the bearing.

x Use a suitable tool to lever the elevator chain up and off sprocket G through opening F.

x Unlock the chain in its bottom position if the chain does not rise high enough.

x Pull the upper shaft out of opening F while preventing the elevator chain from falling down (use a
suitable rod).

x Alternatively, the elevator chain can be unlocked in its bottom position. Attach a string or rope to
the chain link and pull the whole chain out.

Refitting is done in the opposite order.

x Push bearings A and B against the shaft shoulders

x If the chain has been off, pull it back with a rope and lift it on the teeth before positioning the shaft
with the bearings.

x Chain tension is correct when the chain moves sideways on the sprocket in the bottom position,
but does not move up and down.

4-4
CHANGING OF GRAIN ELEVATOR CASING

Remove elevator drive belt and pulley A off the elevator upper
shaft, see the previous chapter.

Remove jockey pulley stand D.

Unlock the elevator chain through the bottom door, remove

bearing B and pull lower auger C out to the left until its right
end is no longer inside the elevator casing. See chapter
CHANGING OF LOWER AUGER IN GRAIN ELEVATOR.

Undo all the elevator casing top, bottom and side attachments
(arrows), after which the casing is lifted off.

Refitting is done in the opposite order.

Grain tank filling auger

Auger C is taken out upwards, fig. V11.

x Unlock screws B of bearing holders A and pull the auger out

of the pipe (not locked at the bottom).

x Remove bearing protection D, unlock the

eccentric locking ring of bearing E and pull the
bearing off the shaft.

Refitting is done in the opposite order.

x Fill the bottom hex socket of auger C with
graphite grease before fitting.

x The position of auger C is correct when its

bottom end lies against catch nut F.

x Fit bearing E and the holders.

x Make sure auger C lies against the catch nut

and lock the eccentric ring of the bearing.

x If bevel gear G is replaced, undo screw H and

pull pulley J off the shaft.

x Use an extractor, if necessary.

x Remove the bevel gear screws and lift the

bevel gear off.

4-5
FILLING AUGER BEVEL GEAR (Walterscheid)
Replacement of the inner components and the bearing, fig. V12.
x Remove the bevel gear from the combine as shown in fig. V11.
x Remove hexagonal nut A, after which end piece B and dust packing C can be removed.
x Use a ball bearing extractor to pull bearing D off the shaft and remove bushing E.
x Remove locking ring F of the bearing and spacers G under it and pull shaft H with bearing J out
of the casing. Remove bearing J off the shaft.
x Hit a hole into shaft packing K with a sharp mandrel and lever the packing off with a suitable tool.

x Unlock locking ring L and spacers N behind it.

x Use a soft mandrel to hit shaft R with its bearings out of the casing to the position pointed by the
arrow.
x Remove locking ring M, spacers P behind it, bearings S and V as well as bushing U and spacers
T under the outer race of the bearing.

Points to note in reassembly:

x First fit shaft H and bearing J. Fit enough spacers G to have no axial clearance of the shaft when
locking ring F has been fitted.
x Fill the casing with 0.25kg of Lithium GLP 00 G grease.
x Fit shaft R with its bearing. Find the right tooth contact with spacers T.
x There must not be any backlash when rotating the shafts by hand at both ends. However, the
shafts shall rotate freely.
x Fit enough shims M and P under the locking rings to have no axial clearance of shaft R.
Fit new shaft packing K.
x Check the condition of rubber plate X and the operability of breather Y before refitting them to the
combine.

4-6
 GRAIN TANK (open unloading)
CHANGING OF TRANSMISSION SHAFT IN UNLOADING, fig. V13

x On the left side of the combine, remove gib

key A and pull pulley B off the shaft.

x Unlock the locking ring of bearing C and pull

the bearing off the shaft.

x Remove support bearing D of the transmission

shaft from inside the grain tank.

x Inside the grain tank, unlock locking ring J of

right-side bearing H and the bearing flange nuts.

x On the right side of the combine, unlock roller

chain E and nut F, after which pull sprocket G off
the shaft.

x Remove the bearing and pull the shaft out to the left.

Refitting is done in the opposite order.

x Fit eccentric ring J, bearing cup K, bearing J and the bearing outer flange onto the shaft.

x Fit key L, sprocket G and the washers onto the drive shaft and tighten nut F.

x Press the back of the sprocket against the bearing journal before locking eccentric ring J.

x Tighten the screws of the bearing flange, which determines the axial position of the shaft.

x Align pulley B with the upper pulley before locking it with a key.

x Fit the support bearing inside the grain tank so that the shaft does not bend in any direction.

4-7
CHANGING OF BEARINGS AND DRIVE SHAFTS OF LOWER SIDE AUGERS, fig. V14

x Remove end plate A by undoing bearing flanges B, the chain jockey pulley, the support bar and
the plate screws.

x Unlock and remove the chain.

x Strike open eccentric rings D of bearings C.

x Undo nuts E and remove the bearings and the end plate.

x Pull sprockets F off shafts G.

x Pull out lower side augers J.

x Inside the grain tank undo the flange screws of bearings H and pull out drive shafts G through the
keyhole.

x Unlock bearing H and remove it.

x In reassembly note that bearing flange K of bearing H is machined.

x Turn nut E to tighten bearing D, shim L, sprocket F and bearing H against the shoulder of shaft
G.

Adjust the lengths of the side augers in the grain tank by fitting enough spacers M between
bearing N and auger J at the left end. The augers must be short enough not to prevent the
bearing door from closing properly.

4-8
CHANGING OF SHORT LOWER AUGER, fig. V15

x To replace innermost slide bearing bush A of the lower auger at the right-hand end of the grain
tank, fig. V15, remove the intermediate unloading auger and deflector B of the lower auger.

x After that remove head capstan C (right-handed thread attachment) and bearing rack D of the
lower auger.

x Strike the old bearing bush off with a suitable pipe and with the same tool strike in a new bearing
bush. Note to the direction of the greasing hole.

x Lower auger E, fig. V15, is changed in the following way:

x To slacken drive chain A, undo jockey pulley D,

fig. V16, and the chain lock and remove the
chain.

x To remove end plate B, undo the screws of

bottom auger bearing flanges C, chain jockey
pulley D, rear support E and the end plate fixing
screws.

x Undo nut G of lower auger sprocket F, fig. V15,

and pull the sprocket off the shaft. Remove
bushing L.

x Pull the intermediate unloading auger out of

the grain tank.

4-9
x From inside the grain tank remove deflector B and unscrew head capstan C of the lower auger.
Remove bearing rack D.
x Pull the lower auger horizontally out of bearing housing H.
x If bearing K needs replacing, undo screws J of the housing outside the grain tank.
x Remove locking ring M and protective plate N, after which the bearing can be replaced.

Reassembly is done in the opposite order.

x The axial position of the lower auger is correct when the bearing is against the shaft shoulder.

x Fit bushing L between the bearing and the sprocket with the sprocket against the shaft shoulder.

x Tighten all the parts together with nut G.

GRAIN TANK INTERMEDIATE AUGER

x To replace bearing bush A at the top of the

intermediate auger, fig. V17, remove ball head B
(right-handed thread attachment).

x Remove shim(s) D and support plate E.

x Remove bearing rack C. Use a suitable pipe to

strike the bearing bush off.

x Press a new bearing bush in place. Note the

direction of the grease hole in relation to the
grease nipple.

x The axial position of the grain tank

intermediate auger is adjusted as shown in
figures V17 and V18.

x After support plate E, fig. V17, fit enough shims

to reach the measurement of 32 1 mm, fig.
V18.

x The end of the intermediate auger lies against

the ball head of the lower auger, which means
that the axial load is carried by the lower auger
ball bearing.

4-10
UNLOADING PIPE

x To remove the unloading auger from the pipe,

remove the rubber guide at the top and undo the
screws of bearing housing A at the top, fig. V19,
and remove support B underneath.

x Turn the auger out through keyhole C at the

top.

x In reassembly, note the correct axial position of

the auger as shown in fig. V20.

x Fit spacer D and, if necessary, shims E between

the auger and the bearing. Fig. V19.

x Lift the unloading pipe out of the combine by

loosening the piston head of the swing cylinder off
the pipe casing.

x Remove the hinge pin cotter and pull the pin up

through the top hinge.

x The lower hinge pin, fig. V20, has been welded

onto the pipe fixing flange. Use a suitable trolley
jack to lift the pipe first straight upward and then to
the side.

x In the unloading position, the pipe hinge flanges

must close securely.

x Make the adjustment with the pipe in its

unloading position and the cylinder piston at the
extreme of its stroke.

x Undo locking nut A, fig. V21, and turn piston B

so long that the hinge flanges close properly. Lock
with locking nuts.

4-11
GRAIN TANK (closed unloading)

Changing of transmission shaft in unloading, see the previous chapter, fig. V13

CHANGING OF GRAIN TANK LOWER AUGER AND VERTICAL UNLOADING AUGER, fig. V22

x On the right side of the combine, unlock drive chain A and remove the chain off the lower auger
sprocket.

x Unlock locking screw C of sprocket B and locking ring D and pull the sprocket off the shaft.
Remove key E and unlock the eccentric ring of bearing F.

x Remove the front mudguard on the left side of the combine.

x Unlock and remove chain G.

x Through the cleaning door rotate vertical auger H to the position shown in the figure. Make sure it
will not fall down when the nuts of bevel gear J are slackened and the gear is removed. Rotate
auger H so that its auger head is in alignment with the opening pointed at by arrow K. Remove the
auger from below.

x Undo the screws of left bearing plate M of lower auger L, after which the auger can be pulled out
to the left. Remove sprocket N, unlock the eccentric locking ring of bearing P and pull the bearing
off the shaft.

4-12
Refitting is done in the opposite order.
x Make sure bushing R sits firmly between the bearing and the shoulder when lower auger L is
pushed back.

x Lock the bearing with an eccentric ring. Align sprocket B with spacers S to the correct position
before locking ring D is fitted.

x Press bearing P against the shaft shoulder and lock it. Align sprocket N with the sprocket of bevel
gear J with spacers V, after which the locking ring is fitted.

Push vertical auger H back. The cross runner at the top end of the auger is asymmetrical just like
cross pin U of bevel gear T. Rotate the auger to find the only position in which the runner and the
pin fall together.

x Fit bevel gear J. Make sure its cross pin falls into the runner of the vertical auger.

Changing of unloading auger and unloading pipe

Note! This job requires a trolley jack and two people.

x Remove grain guide A, fig. V23, at the end of the unloading pipe, unlock the eccentric locking
ring of bearing B and remove the whole bearing rack.

x Pull unloading auger C approx. 80 mm out of pipe D.

x Fit suitable support bands round the pipe (the pipe balance point is approx. 2120 mm from flange
E) and lift slightly with a trolley jack. Undo the screws of pipe flange E and lift the pipe off the
combine.

x When refitting, note that screw runner F is asymmetrical just like cross pin of the bevel gear G.

4-13
x Fit auger C inside the pipe with runner head F approx. 15...20 cm outside pipe flange E.

x Lift the pipe back and rotate it by hand to find the only position in which the runner and the pin fall
together. Then push the pipe and the elbow flanges together and fit the flange screws.

x Rotate to check that the auger heads of the vertical auger and the unloading auger touch each
other.

Changing of elbow and bevel gear

Note! This job requires a trolley jack and two people.

x Remove vertical auger H, fig. V22, as instructed above.

x Remove unloading pipe D, fig. V23, as instructed above.

x The screws in bevel gear G (2 screws outside and 1 inside) are undone and the bevel gear is
removed off the elbow.

x To remove elbow H, loosen attachment K of turning cylinder J, lift support bearing rail L up from
dummy M and undo screws N of the elbow.

x Undo screws R of connecting pipe P to remove pipe P.

Reassembly is done in the opposite order.

x Grease the surfaces of the bottom flange of connecting pipe P and fixing rings S. After the
screws have been tightened, make sure that the pipe turns freely inside the rings.

x Screw the bottom joint of elbow H.

x The position of dummy M shall be in the midpoint of the rotary motion of the vertical pipe. To
ensure the correct position, measure the pin position from a checkpoint while rotating the pipe
between the extremes of its rotary range. Acceptable deviation 0.5 mm.

x Attach support bearing rail L with its bearings. Note the correct position of the dummy.

x Fit the turning cylinder to the elbow and fit vertical auger H, fig. V22, as instructed.

x Finally, fit the unloading pipe to the elbow as instructed.

4-14
 5 TRANSMISSION

REMOVAL OF ENGINE FROM THE COMBINE

This job requires two people and a suitable trolley jack.

There must be a minimum of 2 m of open space above the engine.

x Turn the master switch to the off position or disconnect the battery minus cable.

x Remove the optional engine compartment cover. Remove the engine compartment left-
side top cover.

x It may be helpful to turn the unloading pipe to the open position or lift it off.

x Drain the cooling system, (see instructions in the manual), disconnect top and bottom
water hoses B, fig. M1, next to the engine. Disconnect the cab heating cell hoses and plug
any openings.

5-1
x Disconnect and plug the fuel hoses next to the engine.

x Drain the engine oil sump through the discharge pipe and loosen the fasteners for the
outlet hose on the right side of the combine.

x Disconnect intercooler hoses C at the engine end.

x Disconnect engine suction air hose D next to the supercharger and cover both the open
ends with tape.

x Remove Selective catalytic reduction (SCR) system E with the supports and cover the
supercharger connection opening.

x Remove the belt drive at the front of the engine.

x Remove the AC compressor (if any) from the stand without disconnecting the refrigerant
hoses.

x Disconnect all the electric cables to the engine. Open the service doors on the grain tank
wall when disconnecting the cables between the engine and the grain tank. Mark the
cables for reassembly.

x Remove all the drive pump hoses and plug all hose ends and openings properly.

x Disconnect and plug the hoses to the belt drive cylinders. Disconnect the drive pump
control cable from the pump and the stand.

x Loosen the fasteners for oil drain hose F of the engine split gear on the side of the
combine, but do not drain the oil.

x Remove all belt drives next to pulley G.

x Unscrew the four centre screws of engine

brackets H.

x The only safe way to lift the engine is to

use a trolley jack that directs the hoisting
capacity vertically at the hoist bracket, fig.
M2.

x Fit a suitable cover plate in front of the

cooler to protect the cells during lifting.

x During lifting make sure that all the hoses

and cable are disconnected.

x Once the engine has been lowered down,

remove the engine split gear with its pumps
by unscrewing screws J.

x Loosen screws A of the baffler plate, fig. M3, and remove the plate.

5-2
 Reassembly is done in the opposite order.

x Fix the baffler plate; tighten screws A to 50

Nm.

x Clean groove hub B and apply Weicon

Anti-Seize or similar on the grooves.

x Fix the engine split gear with its pumps

and tighten screws J, fig. M1, to 45 Nm.

x Check the condition of the engine rubber

pads. Replace if necessary.

x When the engine has been refitted, fill the drained systems: approx. 26 l of oil in the
engine (see the manual for the filling amount and viscosity class) and 27 l of anti-freeze
(40...50% ethylene glycol) in the radiator.

x If there is an accelerator cable, adjust the injection pump lever to go against the restrictor
when the engine is running at full revolutions.

Engine repairs are done in compliance with the engine manual.

5-3
REMOVAL/REFITTING OF ENGINE SPLIT GEAR

This job requires two people and a suitable trolley jack.

There must be a minimum of 2 m of open space above the engine.

x Remove the left-side top cover from the engine compartment.

x Turn the unloading pipe to the unloading position.

x Drain the oil out of the engine split gear. See the instructions in the manual.

x Remove all the belts from pulley A, fig. M4.

x Disconnect and plug the hoses of

connecting cylinders B.

x Disconnect the drive pump control cable

from pump lever G and stand H.

x Unscrew the screws of connecting lever

stand C and mid shaft locking screw D, after
which the levers can be removed.

x Disconnect and plug the hoses of hydraulic

pump unit E.

x Tie a hoist sling around the pump unit and the engine split gear, lift slightly with a trolley
jack, unscrew screws F of the engine split gear, pull out sideways and lower on the
ground. Next unscrew the four screws of the pump unit and pull the pump unit off the
engine split gear.

x Alternatively, the pump unit can be disconnected and lowered first, and after that the
engine split gear is disconnected from the engine.

Reassembly is done in the opposite order.

x Tighten screws F of the engine split gear to 45 Nm.

x Tighten four screws e, fig. M6, of the drive pump to 80 Nm.

x Fill the engine split gear with 4 litres of oil; API GL-5, 80W90.

5-4
REPAIR OF ENGINE SPLIT GEAR

x Clean the exterior of the engine split gear

before opening it.

x Remove cotter A, fig. M5.

x Undo locking nut B. Sleeve size is 55 mm

and shaft thread is M36x1.5.

x Pull the pulley off the main shaft using a

suitable extractor, e.g. extractor flange
R700996, with 120 mm spacing. Remove
the shaft key.

x On the other side of the engine split gear undo screws A, fig. M6, and remove casing B.

x Pull drive shaft D with its bearings and gearwheel F out of the casing.
Remove the inner races of bearings E and U and gearwheel F from the shaft with an
extractor.

x Remove cover M of side gearwheel L, and lift the gearwheel with its bearings out.
With an extractor remove the inner races of bearings N from the gearwheel.

5-5
x Turn open bearing flange T, which contains the outer race of bearing N, with special
wrench B2 with 105 mm pin spacing and 6 mm pin . Press the bearing race out of the
flange.

x Undo clip nut S of mid shaft H and strike the shaft out in the direction of the arrow with a
soft mandrel. Next remove intermediate gearwheel K with its bearings from the casing.

Reassembly is done in the opposite order. Ensure all the parts are undamaged and clean.

x First fit locking rings Z inside intermediate gearwheel K.

x Press the outer races of bearings J inside the gearwheel and after that the bearings.

x Fit the assembled intermediate gearwheel inside the casing.

x Oil packing G and R and fit them into the grooves on mid shaft H, after which fit the shaft
by striking it with a soft hammer through the bearings of the intermediate gearwheel.

x Fit clip washer and clip nut S and tighten the nut enough to have no clearance in
bearings J. Loosen and tighten the clip nut back and forth while ensuring the gearwheel
moves freely, although there is no clearance. Lock the clip nut with a lock washer.

x Press the outer races of bearings N to cover M and flange T. The inner races of bearings
N are pressed to side gearwheel L.

x Fit preassembled side gearwheel L into the casing, turned in the correct direction. Fit
packing Q and cover M. Apply heat-resistant glue on cover screws P and tighten
crossways to 45 Nm.

x Fit bearing flange T. Tighten and loosen the flange in turns to produce 0...0.1 mm
bearing clearance while ensuring the gearwheel moves freely. Apply grease in the
gearwheel grooves.

x Press the outer race of bearing U into the engine split gear casing.

x Fit the inner race of bearing U, gearwheel F, spacer ring Y and bearing E (inner race)
onto main shaft D. Lift the preassembled main shaft into the gear casing.

x Fit the outer race of bearing E into casing B. Apply glue on the contact surfaces of
packing a, and fit casing B to the gear casing with screws A (glue on the screws!). Torque
45 Nm.

x Turn clamp ring V closed against the outer race of bearing U. Turn it in turns back and
forth to produce 0,07...0.1 mm clearance for both bearings E and U, while ensuring the
shaft rotates freely.

x Fill shaft packing C and W with grease and fit them in place using a suitable installation
pipe.

x Clean the taper surface of the main shaft, fit key b and pulley d. Tighten nut B of the
pulley, fig. M5, to 520+80 Nm and lock with pin A.

5-6
ENGINE COOLING SYSTEM

On all the engine models the fan is rotated by

two belts and a two-part intermediate shaft at
the front of the cooler inside the air intake
screen. The structure also houses a vacuum
cleaner that sucks any debris off the outer
surface of the air intake screen.

Removal and refitting of intermediate shaft

x Remove nozzle A of the vacuum cleaner

A, fig. M7, (welded screws inside).

x Remove covers C inside the engine

compartment.

x Loosen nuts D of guide E. Next remove

vacuum cleaner casing B.

x Undo screw L of wing unit K, fig. M8, and remove the wing unit off the shaft.

x Remove the belt from pulley X, loosen the screws of bearing housing Y and remove
assembled shaft half V from the cover of the cooler casing.

x Unlock the locking ring of bearing Z and pull the bearing with its housing off the shaft.

x Undo locking screws J and H of clutch half G and pulley X, after which these parts are
pulled off the shaft.

x Press bearings Z and U out of their housings.

x With pressing tool TT698004 (or similar) press spring S on the shaft half short enough to
be able to remove locking ring T. Remove clutch half F, spring S and the parts behind it off
the shaft.
5-7
x Remove pulley M (Taper Lock attachment, see separate instructions).

x Undo the flange screws of bearings N and P and remove the shaft from the cooler casing
in the direction indicated by the arrow. Pull bearings N and P off the shaft after unlocking
their eccentric locking rings.

Reassembly is done in the opposite order.

x Fit bearing P against the shoulder of shaft R and tighten the bearing locking ring.

x Fit bearing N and the flanges of both the bearings onto the shaft, and fit the parts in the
cooler casing with the flanges on the left side of the fixing wall and the nuts of the flange
screws on the left as well. See the figure.

x Tighten the flange screws loosely. Do not lock the locking ring of bearing N yet.

x Apply grease in the grooves of shaft R. Assemble spring S + the parts, press clutch half
F with the special tool to be able to fit locking ring T.

x Fit pulley X against the shoulder of shaft half V and lock screw J.

x Push clutch half G against the shaft shoulder and lock with screw H. Press bearing U into
place.

x Push bearing Z with its housing from the opposite side against the shaft shoulder and
lock with its eccentric locking ring.

x Fit assembled shaft V onto the cover of the cooler casing. Tighten the screws of bearing
housing Y.

x Fit wing unit K against the shaft shoulder and tighten locking screw L. Fit vacuum cleaner
casing B, fig. M7, and fit guide E with the screws loose over the shaft end.

x Close cover Q while ensuring the clutch halves fit together and the end of shaft R falls
into bearing U. Rotate the shafts to ensure the clutch halves centre in relation to each
other and that there is no wobbling at shaft ends.

x Now tighten the flange screws of bearings N and P and the locking ring of bearing N.

x Fit pulley M in alignment with the engine drive pulley.

x Fit and tension the belts of both the pulleys to the correct tightness. Re-close cover Q.
Adjust guide E so that the inner rims of its hole do not touch the shaft surface. Tighten
screws D.

x Apply Weicon Anti-Seize or similar on the surfaces of the clutch halves.

x Fit covers C and vacuum cleaner nozzle A as close to the rotating air intake screen as
possible, but not touching it.

5-8
Disassembly of rotating air intake screen/fan

x Undo nut A, fig. M9, and pull the

whole rotating air intake screen off
the shaft. If necessary, fit M8 screws
to thread holes B for an extractor.

x To change bearings C, remove

locking rings D and pull the bearings
out of the hub.

x Bearings F of middle wings E are

not separately replaceable. If
necessary, replace the whole rotating
air intake screen.

Reassembly is done in the opposite

order.

The bearings of the cooler fan are

mounted on the same shaft as the
rotating air intake screen. The
bearings can be replaced when the
screen is first removed.

x Remove the drive belt off pulley H,

fig. M10.

x Remove wings J and bearing cap K

and after that locking ring M of
bearings L.

x Pull pulley H off the shaft. To

facilitate the job, screw two M10
screws into holes N and push the
pulley off the shaft.

Reassembly is done in the opposite order.

5-9
Changing of radiator fig.M11

x Drain the engine radiator through tap K. (See further instructions in the manual.)
Disconnect top and bottom water hoses L next to the radiator. Disconnect hoses D.

x Undo screws N and lift the radiator straight upward out of the engine compartment. Fit a
suitable protective plate between the radiator and the engine to protect the cells while
lifting.

x Loosen the hydraulic hoses of oil cooler from connectors B and C.

Reassembly is done in the opposite order.

AC condenser

x To replace AC condenser C, first disconnect

their hoses and after that the fixing screws.

Reassembly is done in the opposite order.

Note! The AC device shall be property filled

after changing of the condenser.

5-10
REPLACEMENT AND ADJUSTMENT OF THRESHING MECHANISM ENGAGING
BELT, fig. M14

x Remove the chopper engaging belt with its guide arc.

x Disconnect and plug the table clutch hose at the end of the rear beater shaft.

x Remove the shaker shoe and the table drive drive belts.

x To remove the threshing mechanism engaging belt, undo screw B of upper guide A, and
the screws of lower guide C.

x Fit a new belt and retighten the belt arcs.

x Start the engine, start running the threshing mechanism and check the positions of the
belt arcs in relation to the belt visually. Gaps D shall be 4...8 mm and gaps E 6...10 mm
with the belt engaged.

Tension adjustment
Check visually from behind the engine compartment with the engine running.

3-groove belt:

5-11
x The end of measuring plate F shall be flush with the front edge of the hexagonal part of
the adjuster sleeve when the threshing mechanism is running at standard speed without
load.

x To adjust, stop the engine, loosen locking nut G and turn adjuster sleeve H in the desired
direction as much as needed. Check and readjust, if necessary. Finally, lock locking nut G.

4-groove belt:
x There shall be a minimum of 8 mm gap J between the edge of the restrictor bush and the
cross arm lever.

x There is no actual adjustment since the length of coil spring K is always sufficient to
maintain the correct tension.

4-groove engaging cylinder

To disassemble, unlock locking nut L and loosen threaded sleeve M enough to be able to
remove spring K.

x Remove adjustment part P off cylinder R by striking double pin S off.

Reassembly is done in the opposite order. Note the correct fitting direction of the double
pin.

REPLACEMENT AND ADJUSTMENT OF UNLOADING ENGAGING BELT

x Remove the chopper engaging belt with its guide arc.

x Loosen screw F under the jockey pulley of the unloading belt, fig. M15, and remove the
belt off the lower pulley. Undo limiter A and belt support B, if necessary.

5-12
x Loosen the arc C, fig M14, remove the threshing mechanism engaging belt from the rear
beater pulley. Push the belt upward until there is a wide enough gap between the belt and
the engine pulley to remove the unloading belt through this gap.

x Fit a new unloading belt. Refit the other loosened belts and belt arcs.

x Start the engine, engage unloading and visually check the positions of the belt arc and
the limiter in relation to the belt. Limiter A measurement is 5...8 mm and support B
measurement is 3...5 mm with the belt engaged.

Tension adjustment
Check visually from behind the engine compartment with the engine running.

x The end of measuring plate D shall be flush with the front edge of the hexagonal part of
adjuster sleeve C when unloading is running at standard speed without load.

x To adjust, stop the engine, loosen locking nut E and turn adjuster sleeve C in the desired
direction as much as needed. Check and readjust, if necessary. Finally, lock locking nut E.

REPLACEMENT AND ADJUSTMENT OF CHOPPER ENGAGING BELT

x To remove belt guides A, fig. M16, undo

screws B and brake bolt C on the jockey
pulley arm.

x Remove the belt, refit a new belt and

refasten the belt guides.

x Start the engine, engage the threshing

mechanism/chopper and check visually
that bottom gap D between the belt arc
and the belt is 2...3 mm.

Tension adjustment

Check visually from behind the engine

compartment with the engine running.

x The end of measuring plate E shall be

flush with the front of the hexagonal edge
of adjuster sleeve F when the threshing
mechanism is running at standard speed
without load.

x To adjust, stop the engine, loosen locking nut G and turn adjuster sleeve F in the desired
direction as much as needed. Check and readjust, if necessary. Finally, lock locking nut G.

5-13
BEARINGS MOUNTED ON JOCKEY PULLEYS AND IDLE WHEELS

x Loosen centre bolt E of the jockey pulley,

fig. M17 and remove the pulley.

x Press out old bearings B in turns by

means of the shoulder of mid shaft D,
stage 1.

x Check that locking rings A are

undamaged and properly in their grooves.

x Fit new bearing B with the compression

force only directed at the outer race of the
bearing, stage 2.

x Turn the pulley half a turn and fit shaft D,

stage 3.

x Fit other bearing B so that the

compression force is directed at both
bearing races, stage 4.
Be careful not to break the bearing
packing during installation!

x Fit spacers or sleeves C at shaft ends

before refitting.

Chopper idle wheels

x Undo nut K, fig. M18a, remove bush L,

fasten extractor jaws M as shown in the
figure and pull the wheels off the shaft.

x Remove locking ring N, after which press

bearings P and bushing R off the wheels
as shown in fig M18b.

x Fit new bearing P with the compression

force directed only at the outer race of the
bearing, fig. M18c.

x Fit bushing R, second bearing P and

locking ring N.

x Push the wheels with their bearings back

onto the shaft so that the compression
force is directed only at the inner races of
the bearings, fig. M18d.

x Fit bush L and lock locking nut K to

250...300 Nm.

5-14
FRONT AXLE

Replacement of final drives (CIT) and gearbox (CIT)

The job requires two people, a trolley jack and gearbox lifting tool R709993.
The final drives weigh approx. 210 kg and the gearbox approx. 180 kg.
If the work must be done out in the field, park the combine on hard, level ground.

x Remove the cutting table, lift the crop elevator in its top position and lock the table
support.

x Lift the combine up from beneath the front axle, support with trestles and remove the
front wheels.

x Clean the whole axle carefully with compressed air before starting work.

x Attach a suitable lifting device to the final drive of wheel A, fig. M21, loosen screws B and
remove the final drives. Note centering cotter C between the shaft flange and the final
drives. Drain the oil from the final drives only if they are to be repaired.

x Unlock the screws of brake calipers D and turn the brake calipers carefully off brake
discs S without removing the pipes.

x Drain the oil from gearbox E. Pull drive shaft F out of the gearbox with its brake discs.

x Remove hydro motor G from the gearbox (do not disconnect the hoses).

x Disconnect and plug hose H of the gear releaser. Loosen connection X of the gearshift
lever.

x Disconnect the electric cables of drive speed sensor J and gear indicator K.

5-15
x Loosen hand brake cable M, fig. M22, and fasten lifting tool R709993 to the gearbox and
the trolley jack as shown in the figure.

x Strike off four centering pins P, fig M21, and remove the screws of side flanges R next to
the axle. Use a trolley jack to pull the gearbox backward until it comes off the axle, and
lower it on the ground.

x Remove the side flanges and fixing

flange U of the hydro motor if the
gearbox is changed.

Reassembly is done in the opposite

order.

x Fit side flanges R to the gearbox.

Tighten the screws to 78 Nm.

x Use a trolley jack to lift the gearbox up

and push it forward to fit the side flanges
to the axle. Do not tighten the screws yet.
Let the trolley jack bear the weight of the
gearbox.

x Push the drive shafts back to the gearbox. Be careful not to damage the shaft packing. If
the brake disc has been off the drive shaft, do not tighten its gib key yet.

x Fit the brake calipers, the gear releaser hose, the gearshift lever connection, the hand
brake cable and both the electric cables.

x Fit grooved bushes T at the ends of the drive shafts, after which the final drives are lifted
back in place while directing the final drive shaft end into the grooved bush. Ensure that
the contact surfaces of both the final drive and the flange are clean. Tighten screws B
crossways in turns to 370 Nm.

x Turn the hand brake wheel, e.g., to rotate the whole transmission mechanism. Lift and
lower the trolley jack to find a position in which the gearbox mechanism runs lightly and
smoothly. Now tighten the side flange screws to 78 Nm. Strike centering pins P closed
again. If the pin holes are not aligned, drill new 8 mm holes next to the old ones and fit
new pins.

x Centre the drive shaft brake disc in the middle of the brake caliper and fit with keys.

x Fit fixing flange U of the hydro motor and the grooved bush between the gearbox and the
engine. Check the condition of the fixing flange O-ring and replace, if necessary, before
the hydro motor is mounted. Tighten the flange and motor screws to 80 Nm.

x Fit the front wheels, lower the combine and tighten the wheel nuts to 700 Nm. Note!
Retightening after approx. 20...30 operating hours.

x Fill the gearbox with 7 litres of oil, API-GL-5, SAE-80W90.

x Test the function of the gear releaser and bleed air off the system at nipple V, if
necessary.
5-16
GEAR DIAGRAM FOR CIT GEARBOX

5-17
DISASSEMBLY AND REASSEMBLY OF CIT GEARBOX

x Remove the gearbox from the combine

as instructed.

x Clean the exterior of the gearbox.

x Open gearbox cover A, fig. M24, remove

springs B and lift lock balls C from their
holes with a magnet.

x Remove fixing flange P of the hydro

motor.

x Strike gib key G of hand brake wheel F

off and pull the wheel off the intermediate
shaft with an extractor.

x To remove shift fork H off its shaft, strike

off spring cotter J, after which the shaft
can be pulled off to the right, in the
direction of the arrow. Now remove shift
fork R in the same way.

x Strike spring cotter E off to remove gear

shifter D off its shaft, after which the shaft
can be pulled off to the right, in the direction of the arrow.

x Remove gear guide K from the gearbox.

x If packing M of pistons L of the gear releaser needs replacing, open cover N.

x To remove shaft A rotated by the hydro

motor, fig. M25, open side cover B and
the outer race of roller bearing E.

x Push the shaft to the left (arrow 1) far

enough to be able to remove bearing C
with an extractor. Remove locking ring D.

x Pull the shaft to the right (arrow 2) out of

the gearbox while holding onto gear F and
sliding it off along the shaft grooves.

x Remove locking ring G and the inner race of bearing E (with an extractor).

5-18
 x To remove mid shaft H, fig. M26, push
the shaft first to the left (arrow 1), after
which the outer race of roller bearing J is
removed.

x Now push the shaft to the right (arrow 2)

and first remove the outer race of roller
bearing K. Use an extractor to remove the
inner race of the bearing and pressure
plate L.

x Unlock locking ring M. Slide it along the

grooves to the right while pulling the shaft
to the left far enough to be able to remove gear N off the shaft.

x Remove locking rings M and P and pull the shaft out to the left while removing
gearwheels R and S off the shaft.

x Use an extractor to remove the inner race of bearing J. Remove pressure plate T.

To remove the differential, first remove

the mid shaft with its pulleys.

x Loosen the screws of long-necked brake

flange A, fig. M27, and pull the flange
straight to the side.

x Tie a hoist sling around differential C and

lift it slightly with a suitable lifting device.

x Remove short-necked brake flange B.

Knock the differential off its bearing race
with a lead mallet and lift out of the
gearbox.

x Remove packing E of the drive shafts

from the brake flanges.

5-19
Disassembly and reassembly of differential

x Pull bearing A off with an extractor, fig.

M28.

x To remove cover plate B, unlock screws

C, lift off side gearwheel D, and knock
crown wheel E off the casing with a plastic
hammer. Strike aligning studs F off with a
mandrel.

x Remove bearing G with an extractor.

x Strike off double pin J of perch bolt H

with a mandrel and on the opposite side
strike the bolt off with a soft mandrel in the
direction of the arrow. Remove small
gearwheels K of the perch bolt and
bushing L.

x Lift side gearwheel P out of the casing.

x Replace bearing bushes M of small

gearwheels K, if necessary.

Reassembly

x Grease the surfaces pointed by the arrows with Molycote.

x Check that locking rings N of side gearwheels P and D are properly in their grooves.

x Fit side gearwheel P, push perch bolt H into the casing through gearwheel K, bushing L
and other gearwheel K. Lock the bolt with new spring cotters J.

x Heat the inner race of ball bearing G to approx. +100C and fit into place. When the
bearing has cooled off, ensure its correct position by striking it with a plastic hammer.

x Fit crown wheel E and strike aligning studs F back into place.

x Fit cover plate B with screws C. Tighten the nuts crosswise to 100 Nm.

x Heat the inner race of ball bearing A to approx. +100C and fit into place. When the
bearing has cooled off, ensure its correct position by striking it with a plastic hammer.

x Check that all the moving parts of the differential rotate freely.

5-20
Reassembly of gearbox

x Fit new drive shaft packing E, fig. M27, onto both brake flanges A and B, and new
packing D.

x Lower the assembled differential back into the casing. First connect brake flange B and
differential bearing G. Fit brake flange A and tighten the flange screws to 78 Nm.

x Check the axial clearance of the differential. It must be 0.30...1.40 mm.

Fitting of mid shaft is done in the opposite order to what was explained in fig. M26.

x Heat the inner races of bearings J and K

to approx. 100C before fitting them.

x Fit new shaft packing C, fig. M29, with

the outer surface of the packing flush with
the surface of cover D.

x Fit side cover D with its packing and

apply joint paste on the screws. Note!
Screw P is a centering screw; screws A
are M10x25 and screws B M10x30.

Fitting of the shaft rotated by the hydro motor is done in the opposite order to what
was explained in fig. M25.

x Heat the inner race of bearing C to

approx. +100C before fitting it onto the
shaft, fig. M30.

x Fit side cover A and the packing under it.

Apply joint paste on screws B.

x Check the axial clearances of both the

shafts after both the side covers have been
tightened.

x Axial clearance of the intermediate shaft

shall be 0.1...1.04 mm.
Measure from the shaft end of the hand
brake wheel, e.g.

x Axial clearance of the shaft rotated by the

hydro motor shall be 0.20...1.16 mm.
Measure from the end of shaft D, e.g.

5-21
Fitting of gear shift mechanism

x Always replace O-rings A, fig. M31, of the

gear shift shafts.

x Fit gear guide B. Apply joint paste on the

screws.

x Push shift fork shaft C of the 2nd and 3rd

gears into the casing, through
corresponding fork D. Note! The fork turned
the correct way! Join the fork and the shaft
with new cotter E.

x Fit 1st gear fork F and shaft G the same

way.

x Fit gear shifter H the same way.

x Check that all the gears and the neutral

can be found when turning by hand.

x Fit locking balls J, springs K, and cover L with new packing M.

x First turn speedometer sensor N against a tooth on the differential gear and then
approx. turn up to have 0.5...1.0 mm distance between the tooth and the sensor.

Fitting of hand brake

x First fit springs C of hand brake shoes A.

Next lift the shoes into place.

x Push the brake drum onto the mid shaft

far enough to have a measurement of
approx. 2...4 mm between the brake lever
and the drum.

x Lock the brake drum with keys to this

position.

x Test the brake function.

5-22
FINAL DRIVE, CIT
Disassembly of final drive

x Drain the oil and remove the final drive from the combine as instructed previously.

x Strike protective cup A, fig. M33, off with a mandrel. Remove locking pin B and unlock
crown nut C.

x Remove mid shaft K from the casing by knocking the shaft end lightly with a mallet.

x Unlock the screws on casing cover E, remove the cover and lift out center wheel F.

x Remove V ring G and locking ring H. Now strike out the outer race of the taper roller
bearing P with a suitable tool.

5-23
x Open bearing cover J of input shaft L and remove the shaft with the bearings through the
inside of the casing.

Reassembly is done in the opposite order.

x Clean all the inside parts of the final drive. Apply oil on all the bearing and packing
surfaces.

x Fit input shaft L with the bearings and spacer M into the casing. Lift centre wheel F back
into the casing.

x Fit packing R of mid shaft K, spacer S, bearing N and locking ring T on casing cover E.
Push the shaft through the casing cover. Be careful not to damage shaft packing R when
fitting the shaft. Fit locking ring U onto the shaft.

x Apply glue on the packing surfaces of the casing E. Fit the cover with its shafts and
attach the halves with screws.

x Turn the final drive to have wheel flange V under the casing and fit taper bush G.

x Ensure there is no clearance between the mid shaft, bearing N and wheel F. Now take
measurement D from the outer surface of the casing to the taper bush surface.

x If measurement D is more than 46.9 mm, add spacers X.

x Fit locking ring H, bearing P, spacer Y and crown nut C.

x Tighten the crown nut while rotating the mid shaft back and forth to remove all clearance.
Now tighten the crown nut to 300...500 Nm and lock with cotter B.

x Press the bearings of input shaft L to remove any axial clearance. Select suitable spacer
Z to achieve 0.1...0.2 mm pre-tightening of the bearings with cover J attached with screws.
Apply packing glue on the cover packing surface before fitting.

x Fit shaft packing W.

x Fit new protective cup A, apply packing glue on its contact surface.

x When the final drive has been repaired, its rotational resistance shall be 2.5...5 Nm when
measured at the end of input shaft L.

x Fill the final drive with approx. 7.5 litres of oil; GL-5, SAE 80W90.

x Tighten the front wheel rim nuts to 700 Nm. Retightening after approx. 20...40 operating
hours.

5-24
CHANGING OF BRAKE PADS

x Lever off protective cover A of the brake

caliper, fig. M34, with a screwdriver.

x Strike locking pins B of the brake pads

off with a mandrel in the direction of the
arrow.

x Remove holder C, after which brake

pads D can be removed.

x Fit the new brake pads in the opposite

order. The brake caliper pistons may have
to be pressed inwards with a suitable tool
to fit the new pads.

REAR AXLE

Rear axle A, fig. M35, is bearing mounted on rear beam B with perch bolt C. If necessary,
bearing bushes D can be replaced when crown nut E and screws F on the other side are
unlocked. Pull the perch bolt off, after which the old bushes are pressed out and replaced
with new ones.
After refitting of the perch bolt, tighten nut E lightly and lock with a cotter.

5-25
Changing of stub axle and wheel bearing, fig. M35.

x Lift the combine up from beneath the rear axle, support and remove the rear wheels.

x Remove steering cylinder joint G from stub axle H lever with a suitable extractor.
Remove the connecting tie rod J joints the same way.

x To remove the bearings of hub K, open dust cover M, strike cotter N off and unlock
crown nut P. Next pull hub K off the stub axle by hand or with an extractor.

x Strike out outer races R of the bearings inside the hub with a suitable mandrel.

x Use a suitable tool to lever the race of rearmost bearing L outward far enough to remove
the race off the stub axle with an extractor. Be careful not to break the packing unit behind!

x Pull packing unit S-V off the axle bar with an extractor.

x To remove stub axles H, unlock screws T and pull the axles out through the bottom.

x Strike out slide bearings U of the axle bars with a suitable tool.

Reassembly is done in the opposite order.

x Press new slide bearings U into place and spread enough bearing grease by hand to fill
the holes of the bearing surfaces throughout.

x Apply grease on the surfaces of thrust bearing plates X before fitting them onto the stub
axle.

x Lift the stub axle into place, fit washers Y in their holes and tighten screw T.

x Fit jar rings V to adapter plate S and the whole packing unit, turned in the correct
direction, to the bottom of the stub axle.

x Apply a thin coat of oil on all the bearing surfaces. Press new bearing outer races R to
hub K.

x Fit the race of bearing L against the packing unit and lift hub K back into place.

x Fit outer bearing race Z, the washer and nut P.

x Tighten crown nut P until there is no bearing clearance when the hub is rotated in both
directions. Slacken the nut by two notches and lock with cotter N (torque 1.5...5.5 Nm).

x Refit dust cover M and the O-ring.

x Fill the hub with grease through the grease nipple.

x Tighten wheel bolts W to 400 Nm, on 4WD to 500 Nm. Retightening after approx. 20...40
operating hours.

5-26
Adjustments of the steering cylinder and the track rod, fig. M36

If the track rod and/or the steering cylinder are replaced, check their adjustments when
refitting.
xFit track rod A and lock the ball joint nuts as instructed.
xRaise the rear wheels clear off the ground.
xAt the front of both the tyres at hub height make a mark with chalk on the inner edge of the
tyres and measure dimension X between the marks.
xTurn the chalk marks on the tyres to the rear at hub height and measure dimension Y.
xThe adjustment is correct, when dimension Y is 35 mm longer than dimension X.
xIf hard level ground is available, the toe-in can be measured without raising the rear.
Instead, move the combine forward or backwards until the mark on the tyre turns from the
front of the tyre to the rear of it.
If any adjustment is necessary, proceed as follows:
xSlacken locking nuts E on track rod A and turn the track rod from grip zone F until the
required dimension is achieved, after which the locking nuts are tightened.
xNOTE! The left-side ball joint is left-threaded and the right side ball joint is right-threaded.

Adjustment of the steering cylinder, the rear wheels off the ground.

xFit the steering cylinder, leave the hydraulic hoses disconnected.

xTurn the wheels by hand from one extreme to the other and check that dimension B is
equal at both wheel extremes (the steering cylinder piston determines and limits the stroke).
xDimension B is measured from the mid of the ball joint to the surface of the rear axle.
xTo adjust, unlock locking C on the steering joint and turn the piston in the required direction
at grip zone D until dimensions B are equal at both extremes.
xAfter adjustment, ensure that the wheels turn easily from one extreme to the other.
xConnect the hydraulic hoses, start the engine and turn the steering wheel from one extreme
to the other to bleed the air out of the steering cylinder before the rear wheels are lowered.

5-27
CAB

AIR CONDITIONING DEVICE

Operation
The refrigerant circulating in the AC closed circuit is HFC134a. The substance circulates
through the components in the following order, fig. C1:
A. Compressor
B. Condenser
C. Drier
D. Expansion valve
E. Evaporater

The compressor takes in the refrigerant in a gaseous form in low pressure from the suction
side. Next it compresses the gas and pushes it out in a gaseous form in high pressure and
high temperature to the condenser.

The air in the diesel engine cooler compartment circulating through the condenser
removes heat from the refrigerant, which causes liquefaction of the gas in high pressure.
The liquefied refrigerant flows into the drier, which absorbs moisture in the system and
filters off mechanical impurities. The drier also functions as a reservoir that evens out heat
expansion in liquid and always provides the expansion valve with only liquid without any
bubbles.
The liquid further flows under high pressure to the expansion valve. The pressure rapidly
drops in the valve nozzle, which makes the liquid boil and evaporate.
Warm cab air is blown through the evaporator with blower G. Since the refrigerant
temperature in the evaporator is lower than the air flowing through its lamellas, it absorbs
heat from the air and at the same time the air cools down as it passes the evaporator cell.
The moisture in the air condensates into water drops on the lamella surfaces of the
evaporator, and it is taken out to the AC drain pan through hoses H.

5-28
Now the refrigerant has circulated a full circle coming back to the compressor suction side
in low pressure.

Use and adjustment

Start-up of the AC compressor requires the following:
- cab air is warm enough
- the combine diesel engine is running
- cab fan G is on
- piping pressure of the system is not too high or low

The system gets its drive current from cab fan switch J. Thermostat switch K switches the
system on, and the temperature is controlled by turning the knob. Pressure switch M
monitors the pressure in the piping and stops the compressor, if necessary. The magnetic
switch on pulley N switches on the compressor periodically as regulated by the thermostat.

Trouble shooting

With the AC on, the diesel engine running, the thermostat switch and the fan in their
maximum positions, the temperature of the air blowing from the blower nozzle should be
+10C or below (outside temperature approx. +20C). If this is not the case, check the
following:

Is the compressor rotating?

If not, check that the magnetic plate switch gets both electricity and earth connection.
If there is no electricity, check the pressure switch cables near the drier. Connect them
(the violet and the black ones) and if the compressor now starts running, the system is
probably not full enough (or the pressure is too high).
The system must be sufficiently full, as running periods are long, which increases the risk
of damage to the compressor.

Inefficient AC
- is the heater tap properly turned off
- is the thermostat operating correctly
- is the cab suction filter blocked
- is the condenser blocked
- check the tension and condition of the compressor drive belt

If the system must be opened for repairs such as replacing of the compressor or refilling of
the system, remember that:

Only an authorized mechanic is allowed to drain and refill the AC device.

Draining:
The combine must be in a warm place.
Clean the exteriors of the replaceable components and hose connections.
Connect the service device connectors to the combines low- and high-pressure-side
connectors, turn on the system valves and start the draining function.
Continue the draining function until the pressure gauge indicates 0, and there is no more
refrigerant to drain. Turn off the draining function.
Check how much compressor oil was drained with the refrigerant (usually approx. 10...20
ml).

5-29
Drier
An advisable replacement interval, depending on use, is 1...2 years.
If the system has been empty for over 15 min. due to a component breakage, and the drier
has not been plugged, the drier must always be replaced.

Evacuation
Start the service device evacuation function. The minimum evacuation time is 20 min.
The main purpose of evacuation is to remove any moisture and air from the system (low
pressure evaporates water and it can be sucked out).
NOTE! However, evacuation does not remove the water in the drier absorbed by the
dehydrating agent!
When the evacuation time is up, close the valve of the low-pressure pump and stop the
pump.
Monitor the gauge. Low pressure must not drop for the next 5 minutes.

Refill
Fill 1300 g of refrigerant in the service device.
Start the refill function. After the whole amount has been fed into the system, turn off the
high pressure valve of the refill hose, switch on the AC device and let it run until the gauge
indicates 1...2 bar. Turn off the valve on the low-pressure side.

Add the same amount of compressor oil into the system through the low-pressure
connector as was drained. If components have been replaced, add the amounts of oil
recommended by the manufacturer, e.g. the condenser 30 ml, the evaporator 50 ml, the
drier 10 ml and a hose 10 ml. The type of compressor oil must comply with the
manufacturers recommendations, which is PAG 500 SUS. Initial fill 1.8 dl.

Finally it is advisable to add approx. 10 ml of leak detector colour through the low-pressure
connector. This will later facilitate leak detection with a UV lamp.

Disconnect the service hoses and check that the needle valves of the service connectors
do not leak. Attach the protective hoods into place.

Do not use compressed air to check for leaks!!

The mixture of compressed air and R134a may explode in certain conditions.

5-30
 Replacement of cab windscreen

The windscreens of cabs are glued to

the cab frame. The window on the door
to the cab is also glued, but all the other
windows are attached with conventional
rubber frames and wedge strips.
Toughened glass is used for all the
windows except for the windscreen of
the cab, which is laminated.

If the windscreen breaks, it is advisable

to contact a glazier as the job is
demanding and requires special tools.
Temperature in the working area must
be +15...25C, and air relative humidity
50...60%.
The job requires two people.

x First remove all the strips and

fastenings round the window both
inside and outside the cab.

x The old glue surface between the

window and the cab is cut using a
suitable tool. Remove the window and
clean and trim the old glue surface in
the cab. All the old glue surface does
not need to be removed.

x Wipe the edges of the front window

with a lint-free paper towel moistened with SIKA
Aktivator 0981316, or similar. Use the same cleaning
agent to wipe all the cab surfaces on which glue is
applied as well as the glue strips to be attached with
screws.

x Allow the cleaning agent to dry for a minimum of 10

min. (max. 2 h).

x Spread an approx. 8...10 mm thick coat of glue, e.g.

SIKA TRACK DRIVE 0981315 on the upper and lower
cab edges, fig. C2.

x Fit 18 rubber pads of the same thickness (approx.4

mm) at even intervals on the glued surface as indicated
by the arrows, fig. C3, (6 pads up-down, 6 on the sides).
Place two rubber pads on the windscreen support strip in
the position indicated by arrow A.

x Fit the window into place with the bottom edge first on
the rubber pads on the support strip and adjust the

5-31
window to have equally wide glue gap all around. NOTE! The window must not touch the
cab metal surfaces.

x Use hoist slings to support the windscreen in the right position.

x Spread glue on the sides of the window from inside the cab, e.g. two 8 mm thick layers
on top of one another.

x Fit the glue strips into place with screws (M8x20). Stick adhesive covering strips into
place.

x Finish the cab glue joints by adding or removing glue as necessary.

x Allow to dry for a minimum of 8 hours. Drying time depends on air humidity. Humid air
speeds up drying and vice versa.

5-32
 6 HYDRAULICS

General instructions on hydraulic assembles

In principle, hydraulic systems are extremely reliable and dependable. Certain regulations must,
however, be followed in their assembly and service:

1. If in doubt about your mechanical skills, get help before undertaking any work.

2. Make sure you have all the necessary clean tools and other equipment such as
protective plugs, etc. available (also clean hands and uniform).

3. Clean the working area carefully before disassembly.

4. Plug every disassembled joint in order to stop any impurities from getting into the
system. (Cotton cleaning waste must not be used as a plug.)

5. Mark every disassembled component:

- which combine (type and serial number) it belongs to, date and name
- the condition of the component (damaged, working, working hours, etc.)

6. If a component is so badly damaged that there is metal dust in the system, clean the
whole system.

7. Use only clean, undamaged components. All the tubes, pipes and clamps must be in
good condition. If a cover is missing from a component, consider it soiled, and clean
and cover it properly.

8. Fill the system with clean oil. Even brand-new oil has impurities that may damage a
modern hydraulic system, due to which the use of a filling-up filter with a filtering
degree of 10 microns is recommended. Out in the field the oil can be filtered using the
built-in filters in the system and allowing the oil to circulate through the filters for 10...15
minutes after the first start-up before any valve functions are switched on. (This is
applicable only to a continuously circulating circuit.)

9. Start the system in compliance with the special instructions. Bleed the system if
necessary. Next check the oil level. Check the connections for leaks. Test run as
instructed.

Compliance with these principles guarantees that the hydraulic system will be properly assembled
and thus function faultlessly to the complete satisfaction of the customer.

6 -1
 COMBINE HYDRAULIC SYSTEM
The hydraulic system consists of the following functions:

Working hydraulics:
- steering
- cutting table lifting and lowering
- cutting table side tilt
- cutting table reverse
- pick-up reel lifting and lowering
- pick-up reel fore/aft adjustment
- unloading pipe turning
Traction hydraulics:
- traction pump
- traction motor and 3-gear gearbox
- 4WD
Engagement hydraulics:
- threshing mechanism
- chopper
- cutting table
- grain tank unloading
- gear lock release
Rotation hydraulics:
- pick-up reel rotation
- chaff spreader rotation
Oil unit:
- two pumps
- oil filter
- oil cooler
- oil tank

Description of the working hydraulic system

The system is a so-called round circulating working hydraulic system. Two gear pumps and
the traction pump feeder pump run the above-mentioned operations. The gear pumps are
attached in a row to the end of the drive pump and are powered by the traction pump mid
shaft. So they always rotate when the engine is running.

Steering, figs. H1, H2 and H3

Steering and working hydraulics get their oil from the first pump, from which the oil is first
directed to the Orbitrol control valve equipped with a priority valve, and it takes as much oil
for steering from the oil flow as needed. The rest of the time the pump output can be used for
other functions. Steering and other working hydraulics are thus connected parallel after the
priority valve.

The whole oil flow produced by the pump comes into the OLSA priority valve fitted
together with the steering valve. The function of the priority valve is to ensure that the
amount of oil needed for steering is always available. The rest of the oil flow goes over to
working hydraulics, line C. The steering valve is of the LS (Load Sensing) type. When
driving straight along, it is closed, case A. The channels leading to the steering cylinder as
well as the valve pump- and the tank line are closed.

6 -2
When starting to turn the steering wheel, distributor gear D tries to push oil into the steering
cylinder. At the same time the valve section starts to open the channel between the pump
and the pressure side of the steering cylinder and from the return flow side of the steering
cylinder to the tank line. The pressure signal going along the LS channel of the control valve
changes the balance in the priority valve so that it restricts the flow going into working
hydraulics, case B. The pressure and the amount of oil needed in steering are obtained this
way. The amount of oil defined by the distributor gear goes into the cylinder and turns the
rear wheels precisely as much as the steering wheel is turned. The oil from the cylinder goes
into a separate tank line of the control valve. The rear wheels turn right and left at a slightly
different speed. This is due to the difference in area in the steering cylinder caused by the
piston rod. It also makes the steering wheel knob move along the steering wheel in the mid
position. Due to the difference in volume, the number of steering wheel rotations from one
extreme to the other is different from left to right from the number of rotations from right to
left.
The amount of oil going into working hydraulics varies depending on how fast the steering
wheel is turned. In fast steering the slowing-down is approx. 30 %.

Steering is also possible when the hydraulic pump is not running, but it is, of course, much
heavier then. The system is built so that steering works even if the pressure line in the
hydraulic pump fails, and the pump sucks the oil out of the tank; the return oil pipe is
positioned lower than the suction pipe. In case of breakdown, the necessary additional oil for
steering can be obtained this way.

6 -3
Operating diagram for the steering system, fig. H2 and H3

Steering cylinder
The diameter of the steering cylinder piston is 63
mm, the piston rod is 25 mm and the stroke is 250
mm long.

Distributor gear
Rotation volume of the distributor gear is 160
cm/r.

Check valve
prevents the steering wheel from turning counter
to the steering movement in case external force
counter to the steering movement exceeding the
maximum steering force of 225 bar is directed at
the rear wheels.

Pressure restricting valve

restricts the working pressure in the system and
at the same time it restricts the steering force to
the required maximum, 175 bar.

Valve positioning is shown in fig. H3.

6 -4
OSPC steering valve, fig. H4

Repair of a steering valve is not advisable out in the field. In case of breakage, the whole unit
should be replaced. Leaks can be repaired with packing set 0493980, which contains all the
O-rings and other packing for the OSPC and OSLA valves. A special tool obtainable from
Sauer-Danfoss is required in the replacement of dust seal ring 1.

1. Dust seal ring 14. Spacer 30. Relief valve

2. Housing, spool and sleeve 15. O-ring 31. Spring
3. Ball 8.5 mm 16. Distributor plate 32. Check valve ass.
4. Thread bushing 17. Gearwheel set 33. Ball, 3 mm
5. Double seal 18. O-ring 34. Valve pin
7. Bearing 19. End cover 35. LS valve, pin
10. Ring 20. Washer 36. LS valve, ball, 3 mm
11. Cross pin 22. Special screw 37. Valve
12. Set of springs 23. Screw 38. Spring
13. Cardan shaft 24. Name plate
6 -5
OLSA priority valve, fig. H5

If necessary, the valve can be disassembled and cleaned.

x Unplug plug A and remove spring B.

x Unplug plug D and push valve spindle C out of the casing.

x Check the condition of the components before refitting.

In case of damage, the whole OSLA unit needs to be replaced.

6-6
Diagram, working hydraulics, fig. H6

6-7
Working hydraulics is controlled by double-section CIT valves. Main section A houses free
flow valve B, relief valve C, table lifting valve D, lifting check valve O, table lowering valve E
and table lowering speed adjusting valve F.

Additional section G houses reel lifting H and lowering J valves, reel fore/aft valve K,
unloading pipe turning valve and L, table tilt valve M and table reverse valve N.
All the valves are directly controlled solenoid valves, except for the table lowering valve,
which is pilot-controlled.
Due to the separate lifting and lowering valves the different functions of the system are not
interdependent, and several functions can be operated at the same time.

Outside the main section there is table pressure gauge P, or pressure switch S16, hydraulic
accumulators R and single-acting table lifting cylinders S.

Outside the additional section there are fixed restrictors Q, one-way restrictor T, hose quick-
coupling U, single-acting reel lifting cylinders V, double-acting reel fore/aft cylinders W,
double-acting unloading turning cylinder X, single-acting table tilt cylinders Y, table reverse
engaging cylinder Z and table reverse hydro motor Aa.
The oil return line has filter Bb, pressure switch S14 and oil tank Dd.

Positions of the CIT main section valves and connectors, fig. H7

A Free flow valve

B Relief valve
C Table lift valve
D Check valve
E Pilot control for table lowering
G Lowering speed adjustment
1 Pressure in from the pump
2 Return to the tank
3 Pressure to the lifting cylinders
4 Pressure to the additional section
5 Pressure measuring point

6-8
Operation mode of the CIT main section, free flow, fig. H8

At standstill when the engine is off and no functions are used, all the valve solenoids are de-
energized. The free flow valve is open and the table lifting and lowering valves are closed. If the
cutting table has been raised off the ground, there is pressure in working line 3 varying between
80100 bar (blue line) depending on the table weight.
When the engine is started, the oil produced by the pump in working hydraulics starts circulating in
the system. The oil comes first into the OSLA section. There the priority valve distributes the oil to
steering and working hydraulics. Steering always gets the oil it needs first, and the rest of the oil
goes to working hydraulics. The oil can flow through the main section (green line), as free flow
valve A is open. The oil from connector 2 returns back to the tank through the oil filter.

6-9
Operation mode of the CIT main section, table lift, fig. H9

When the table is lifted, electric current is conducted both to free flow valve A and table lift valve C.
This will close free flow and open the lift valve and the oil will force open check valve D and flow
through gate 3 into the table lift cylinders.
The oil flow is not restricted during table lift, means that the whole pump output is used.
If lifting continues until the cylinder pistons have reached their extreme position, oil pressure will
rise so that relief valve B will open and oil will flow to the return sides through gate 2.
When lifting is completed, valve C will close and valve A open. Table weight will produce counter-
pressure in channel 3, which will close check valve D.

6-10
Operation mode of the CIT main section, table lowering, fig. H10

When the table is lowered, electric current is conducted to pilot pressure section E of the table-
lowering valve. The pilot pressure pin will open table channel 3, and the pressure in the channel
will open drain valve F. The oil in the table channel will flow through lowering-speed adjusting valve
G to return channel 2 through the open free flow valve.

6-11
Operation mode of the CIT main section, additional section functions, fig. H11

When any of the functions in the additional section is activated, free flow valve A of the main
section closes. At the same time the corresponding valve of the same function opens in the
additional section.
All the functions of the additional section, except for table reverse, are restricted, so some of the oil
is forced through relief valve B to the return side. Now the pump operates counter to the relief
valve pressure although a function may not require it. There is no function in the main section
when lowering any functions in the additional section.

6-12
Operation mode of the CIT additional section, pick-up reel, no functions, fig. H12.

Lifting and lowering of the reel are controlled

by two similar solenoid valves A and B of the
directly operated type. At standstill they are
de-energized and their check valves C and D
are closed. Check valve C prevents the oil in
the reel cylinder line from flowing into tank line
T. If some other functions are being used
(table up, e.g.), line P will be pressurized, but
check valve D will prevent the oil from flowing
into the cylinder line.

CIT pick-up reel lifting, fig. H13.

When the electric switch for reel lifting is

pressed, the free flow valve in the main section
will close and valve B in the additional section
will open its check valve D.
Pressurized oil will flow through the section,
and it will open check valve C on the way to
the cylinders. Restrictor E (1.5 mm)
determines lifting speed, and some of the oil
will flow into the tank line through the relief
valve.

CIT pick-up reel lowering, fig. H14.

When the electric switch for reel lowering is

pressed, valve A in the additional section will
open its check valve C. Oil can flow at a rate
determined by restrictor E through both valves
A and B into the tank line. If another function is
used at the same time that requires the free
flow to be closed, check valve D will prevent
pressurized oil from flowing into the reel circuit.

6-13
Operation mode of the CIT additional section, unloading pipe, no functions, fig. H15

Functioning of the unloading pipe is controlled

by two similar solenoid valves A and B of the
directly operated type. At standstill they are de-
energized and their check valves C and D are
closed. Check valve C prevents the oil in the
cylinder line of the unloading pipe from flowing
into tank line T when the pipe is up. If some
other functions are being used (table lifting,
e.g.), line P will be pressurized, but check valves
E and F will prevent the oil from flowing into the
cylinder lines.

CIT unloading pipe lifting, fig. H16.

When the electric switch for unloading pipe lifting

is pressed, the free flow valve in the main
section will close and valve A in the additional
section will open its check valve E. Pressurized
oil will flow through the section, and it will open
check valve C on the way to the piston side of
the cylinder. Because of the oil pressure, piston
K will move in the direction of the arrow and
open check valve D so that the oil will flow from
the piston rod side of the cylinder back to the
tank line. Restrictor G (0.9 mm) on the pressure
side and one-way nozzle H (0.44 mm) on the
return side determine the speed of turning.
During turning some of the oil will flow through
the relief valve into the tank line.

CIT unloading pipe lowering, fig. H17.

When the electric switch for unloading pipe

lowering is pressed, the free flow valve in the
main section will close and valve B in the
additional section will open its check valve F.
Pressurized oil will flow through the section, and
it will open check valve D on the way to the
piston rod side of the cylinder. Because of the oil
pressure piston K will move in the direction of
the arrow and open check valve C so that the oil
will flow from the piston side of the cylinder back
to the tank line. Restrictor G on the return side
determines the speed of turning. During turning
some of the oil will flow through the relief valve
into the tank line.

6-14
 CIT pick-up reel fore/aft adjustment
and cutting table tilt adjustment, fig.
H18.

Functionally similar to turning of the

unloading pipe.
All the working lines have fixed 0.6 mm
restrictors.

Cutting table reverse, fig. H19.

When the electric switch for the table

reverse is pressed, the free flow valve in the
main section will close and a solenoid-
controlled valve in a separate section will
open a channel to table reverse engaging
cylinder K.
The piston of the engaging cylinder will open
a channel to the hydraulic motor, which
reverses the cutting table.

6-15
Turning cylinder of unloading pipe

The cylinder is double acting and of a closed welded type. In case of oil leakage or
other malfunction, the whole cylinder is replaced.

Cutting table lifting- and tilt cylinders, fig. H20.

The cylinder is single acting and its rear end G is threaded into the cylinder liner. The piston
diameter is 50 mm. The stroke is 535 mm long. Cut locking ring E prevents the piston from coming
out at the outer extreme. Dust seal A is of scraper ring type. Packing includes profile rings C and
D. The piston is guided by two cut support rings B.

Replacing of packing or/and piston

Remove the cylinder from the combine. Plug the oil hose.

Fix the cylinder to a bench vice and turn rear end G open (locked with Loctite 242).
Pull the piston out and remove the old packing.

Clean the cylinder carefully, particularly the packing grooves. Ensure the groove
edges are not sharp, as that would damage the packing during assembly.

Fit new oiled packing and support rings. Note the correct fitting directions of the
profile packing.

Check that the chrome surface of the piston is intact and unscratched. Replace the
piston if necessary, and fit new locking ring E.

Push the piston back with extreme care to avoid damage to the packing.

Clean the threading of rear end G carefully and fit new packing ring F.

Apply Loctite 242 on the threading and turn the end closed.

6-16
Pick-up reel lifting and fore/aft adjustment cylinders, fig. H21

Function

Left-side lifting cylinder L of the pick-up

reel and both of the fore/aft adjustment
cylinders are double acting. Right-side
lifting cylinder R of the pick-up reel is
single acting.
All the double-acting cylinders are
functionally identical, i.e. of the series-
connected master/slave type.
At the bottom of the pistons there are
compensation valves A, which even
out the cylinder motion ranges at the
piston extremes.
Oil is supplied in through connector B,
which pushes piston C upwards.
Similarly, the oil above piston C
pushes out the piston of cylinder R at
the same speed as the piston of
cylinder L, since the pistons have
equal areas.

Replacement of packing

x Clean the cylinder thoroughly before removing it.

x Remove the cylinder from the combine and plug the disconnected connectors.

x Fix the rear of the cylinder to a bench vice.

x Turn the cylinder end with a 36 mm spanner wrench in the direction of the arrow until locking wire
E unthreads off its groove.

x Pull end D straight out of the cylinder liner, after which the piston is removed.

x Remove old packing, clean and check all the parts.

x Fit new packing. Every cylinder has its own packing set.

x Apply oil on the packing and push the piston carefully back into the cylinder liner.

x Push the end all the way back to the bottom and thread the locking wire back into the groove.

x Pre-fill the cylinders with oil before refitting them to the combine.
Note! The left and right cylinder must not be exchanged!

Start the engine and run the hydro functions until all air is bled from the cylinders either through
the connectors or bleeder screw F.

6-17
Steering cylinder is double acting

Replacement of packing
Remove the cylinder from the combine and plug the hydraulic hoses. Use an extractor to remove
ball joint A from the steering lever.

Mark the position of the ball joint, unscrew screw B and turn the joint off the piston rod.

Unlock locking screw D at rear end C and turn the end off the cylinder liner.

Pull piston E with its rod out of the cylinder. If the piston must be removed from its rod F, unlock
locking screw G and turn the piston off.

Remove old packing, clean and check all the parts.

Apply Loctite 638 on the threading of piston rod F before tightening piston E and locking it with
screw G.

Fit new packing rings H, scraper ring J and support rings K.

Apply oil on the packing and push the piston with its rod carefully back into the cylinder.

Turn rear end C back far enough to be able to lock locking screw D.

Fit ball joint A in the marked position and lock with screw B.

Fit the cylinder back to the combine, connect the hoses and tighten crown nut L of the ball joint to
200 Nm and lock with a cotter.

6-18
Table reverse engaging cylinder is single acting

Replacement of packing

Remove the cylinder from the combine and plug the hoses and connectors.

Open end plate A, which is threaded to cylinder body B (spanner width 36mm)

Remove locking ring C off the groove of piston D, and pull the piston off the end cover.

Remove old packing, clean and check all the parts.

Fit locking ring C to the piston.

Fit groove ring packing E to the end cover with the groove (see the arrow) turned against the
cylinder body.

Fit scraper ring F and grease the inside of the cylinder end cover with KLUEBER
STABURAGS NBU 30K or similar.

Fit O-ring G. Push the piston carefully through the end cover.

Turn the end cover and the piston tightly back to the cylinder body.

Ensure the measurement of piston adjusting screw H is 20mm.

6-19
Service and troubleshooting

Working hydraulic functions have two sides: the electric and the hydraulic.
The electric side is controlled by a safety relay, which does not allow the use of working hydraulics
until the diesel engine of the combine has been started. The engine oil pressure sensor controls
this function. When the oil pressure light goes off, the safety relay connects the current to working
hydraulics.
The combine also has a yellow safety switch in the cab. When it is pressed down, it will disconnect
electricity supply to working hydraulics. This function is used when driving on the road to prevent
unintentional turning of the unloading pipe.

A previous description explains which valve cartridge should be working in different situations. The
transparent connector in the solenoid coil has a LED light, which will glow when electric connection
to the coil is intact. This does not necessarily mean that the solenoid coil is intact. An undamaged
coil becomes magnetized, which is easy to check by touching the solenoid surface with a small
screwdriver.
The easiest way to do the test is to disconnect the cable to the engine oil pressure switch, in which
case the system will work although the engine is not running.

Note! Lower the table and the reel before disconnecting the cable!

For testing purposes the valves can be controlled without electricity. When you press into the hole
at the end of the solenoid with a thin rod ( = approx. 3 mm), the valve will either open or close,
depending on its function.

The relief valve pressure in working hydraulics is set at

180 bar. Check the pressure level at the table pressure
gauge, or with a separat gauge (connected to the
measuring point, see fig. H7). Lift the table to its top
extreme and keep it there for a few seconds. The relief
valve is located in the main section; see fig. H7, point 2.
To increase pressure, unplug plug A, fig. H25, and add
shims B above the spring.

Seat C of the relief valve, which contains spindle D, is

threaded into the valve section and can be detached for
cleaning or replacing, if necessary.

When supplied as a spare part, spindle D and seat C

come as one part.

6-20
Internal valve leaking shows as a fault function; mostly so that a cylinder piston pushed out will
gradually go back in.

If the cutting table tends to descend little by little without any visible oil leak, the reason is leaking
check valve A, fig. H26, or lowering valve B.

Unplug plug C and remove check valve A.

Check the bottom surface of the packing for metal dust
or other dirt. Replace the valve if necessary.
Re-plug. No adjustments are necessary.

Another alternative reason for unintentional table

lowering can be leaking or stuck spindle B in the drain
valve.
Remove the pilot control unit and pull out seat D with
the spindle (pressed together, not threaded).
Clean the contact surfaces of the spindle and the seat
and ensure that the spindle moves easily in the seat.
Replace the assembly of the spindle and seat, if
necessary. No adjustments are necessary after
refitting.

If the reel tends to descend little by little without any

visible oil leak, the reason is leaking check valve C,
fig. H12.
Remove coil A, after which solenoid F can be
unscrewed. Now pull out valve seat G with pin H by
hand. Ball C, which prevents oil from flowing into the
tank line, is pressed to place and cannot be replaced
separately. If necessary, replace whole valve G. No
adjustments are required after refitting.

If the reel rises without its electric switch being activated while some other function is being used,
e.g. the table lift, it means that check valve D leaks. The repair procedure is the same as above, as
sections A and B are identical.

If the unloading pipe tends to descend little by little without any visible oil leak, the reason is
leaking check valve C, fig. H15. The repair procedure is the same as with the reel.

A leak in the center packing of the unloading pipe turning cylinder can be detected with the
following test: Try to push the unloading pipe up from its transport position manually. If the pipe can
be moved manually, the piston packing leaks oil from the piston rod side to the piston side. The
whole cylinder shall be changed.

6-21
TRACTION HYDRAULICS

General

Traction hydraulics in the combine is implemented with closed circuit hydraulics. The system
comprises a servo-controlled variable displacement axial piston pump, which adjusts into its full
output in both directions, a fixed displacement high-speed axial piston motor, an oil cooler, an oil
tank, a suction filter and necessary pipelines.
The filter and the oil tank are used jointly with rotation hydraulics.

The pump is powered by the diesel engine through gear transmission. The hydraulic motor is
located in connection with the gear box, and it rotates the input shaft of the gear box through a
connecting bush. The pump takes the oil into the charge circuit from the tank through a suction
filter. The charge pump sees to the replacement of any leaks and the bleeding oil in the system.
The charge oil is also used for controlling the pump servo and for engagement hydraulics.

The oil cooler is positioned below the diesel radiator and it is connected to the return oil circuit.
through a thermostat.

The traction hydraulics is controlled with the traction lever in the cab, from where the commands
are transmitted to the pump servo by means of a cable.

6-22
Technical specifications

Pump
Type DanFoss 90R100
Rotation volume
- Charge pump 20 cm/rev
- Main pump 100 cm /rev
Speed 2410r/min
Output max. 241 l/min
Max. pressure 420 Bar
Charge pressure 24 Bar

Hydraulic motor DanFoss

Type 90M100
Rotation volume 100 cm
Speed max. 2400r/min

Suction/return filter
Type Replaceable cartridge
Filtering degree 15 m
Nominal size 100 l/min

Oil
Type Shell Tellus S4 VX 32 in initial fill-up
Viscosity requirement
- Cold under 1000 cSt
- Hot over 10 cSt
Volume 2 l

Four-wheel drive

Hydraulic motor Sampo Hydraulics

Type BBC 02
Rotation volume 783 cm

6-23
Introduction

Sauer-Danfoss Series 90 closed circuit piston pumps convert input torque into hydraulic power.
The input shaft transmits rotational force to the cylinder block. Bearings support the input shaft at
the front and rear of the pump. The shaft is splined into the cylinder block. A lip-seal at the front
end of the pump prevents leakage where the shaft exits the pump housing. The spinning cylinder
block contains nine reciprocating pistons. A ball joint at one end connects each piston to a brass
slipper. Fixed-clearance hold-down brackets keep the slippers in contact with the swashplate. The
reciprocating movement of the pistons occurs as the slippers slide against the inclined swashplate
during rotation. The valve plate connects one half of the cylinder block to low pressure and the
other half to high pressure. As each piston cycles in and out of its bore, fluid is drawn from the inlet
and displaced to the outlet thereby imparting hydraulic power into the system. A small amount of
fluid flows from the cylinder block/valve plate and slipper/swashplate interfaces for lubrication and
cooling. Case drain ports return this fluid to the reservoir.

The angle of the swashplate controls the volume of fluid displaced into the system. The servo
piston forces the swashplate into an inclined position. The pump control, acting on input from the
operator, by modulating pressure balance across the servo piston, sets displacement in the system
circuit.

6-24
REPAIRS

It is advisable not to repair hydraulic components, pumps and motors out in the field or in
unauthorized service shops. Disassembly and repair of a component require professional skill and
well-equipped premises, which are to be as clean and dustless as a hospital. After every repair the
component must be test-run, which requires a test bench or similar. It is also important to have
access to all the adjustments and settings of the components.

As there is usually no time to send components to be repaired during the harvesting season, the
quickest solution is to install a so-called replacement component, which can be ordered from the
factory.

Any other repairs, except for the replacement of the main shaft and / or bearing explained below,
should be carried out by authorized repair mechanics working for the factory, the import dealer or
authorized repair shops.

A lifting device is needed to lift the traction pump out of the combine. Clean carefully around the
pump. Disconnect all suction and pressure hoses both from the drive pump and the working
hydraulic pump and plug them well. Any openings in the pumps must immediately be plugged
properly.

Disconnect the working hydraulic pumps from the drive pump, see chapter Working hydraulic
pumps, fig. H61.













6-25
Replacing of traction hydraulic motor

In case of breakage, the traction hydraulic motor is always replaced either with a new one or out in
the field with a so-called replacement motor.

Motor A, fig. H43, is fixed to flange C of the gearbox.

Disconnect the traction hydraulic motor hoses and plug both the hoses and the motor openings.
Disconnect the motor temperature sensor as well.
Unscrew motor screws E, pull the motor straight out and remove connecting bush F.

Clean the surface of the flange carefully before mounting the new motor.
Apply Loctite 5922 joint paste or similar on the contact surfaces of both the flange and the motor.
Check the condition of connecting bush F and the shaft end of the gearing. Apply grease that
contains Mo2S on the grooves.
Attach the motor. Tighten screws E crossways to 120 Nm.
Fill the motor casing with clean oil, connect the hoses and the temperature sensor.
Start the engine and ensure the charge pressure starts to rise just like when refitting the pump.

Before starting to run the hydraulic motor, the motor must be pressurized to press its cylinder block
and shaft into their correct positions:
- Change into 3rd gear
- Lock the brakes
- Start up the engine and drive the combine using the traction lever for a short
moment
- The relief valve must open (can be heard)

6-26
 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

0RESSUREMEASUREMENT

REQUIRED TOOLS 9OUCANPERFORMTHESERVICEPROCEDURESDESCRIBEDINTHISMANUALUSINGCOMMON

MECHANICSTOOLS3PECIALTOOLSIFREQUIREDARESHOWN5SECALIBRATEDPRESSUREGAUGESTO
ENSUREACCURACY5SESNUBBERSTOPROTECTPRESSUREGAUGES

PORT LOCATIONS AND 4HEFOLLOWINGSECTIONSLISTTHEPORTSFOREACHTYPEOFHYDRAULICUNIT4HElTTINGSIZEAND

GAUGE INSTALLATION RECOMMENDEDPRESSUREGAUGEAREALSOSPECIlED

4HEFOLLOWINGTABLEANDDRAWINGSSHOWTHEPORTLOCATIONSANDGAUGESIZESNEEDED

Port information
Port identier Pressure obtained Gauge size Port size
M1, M2 3YSTEMPRESSURE BAR;PSI=  
M3 (M6) #HARGEPRESSURE BAR;PSI=  
M4, M5 3ERVOPRESSURE BAR;PSI=  
L1, L2 #ASEPRESSURE BAR;PSI=    
    
   
    
X1, X2 ($#%$#CONTROLPRESSURE BAR;PSI=  OR 
X3 %XTERNALCONTROLPRESSURE BAR;PSI=  
S #HARGEPUMPINLET 6ACUUMGAUGE     
4EEINTOINLETLINE     
    
  3!% SPLITmANGE


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

0RESSUREMEASUREMENT

PORT LOCATIONS AND

GAUGE INSTALLATION
(continued)

Pump with side port end cap and manual displacement control

Case drain Servo / displacement

port L1 cylinder pressure
gauge port M4

Servo / displacement
System pressure cylinder pressure
port B gauge port M5
External control pressure
System pressure supply port X3
gauge port M2
Speed sensor

Charge inlet pressure

(vacuum)

System pressure
gauge port M1

Carge pump
inlet port S System pressure
port A Case drain port L2 Charge pressure
gauge port M3 P106 158E


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

0RESSUREMEASUREMENT

PORT LOCATIONS AND

GAUGE INSTALLATION
(continued)

Pump with twin port end cap and manual displacement control
Servo / displacement
cylinder pressure
gauge port M4
Case drain
port L1

Servo / displacement
cylinder pressure
gauge port M5

System pressure
gauge port M2

System pressure
port B

Charge pump inlet

port S

System pressure
port A
System pressure
gauge port M1
Case drain port L2

P106 160E

Pump with side port end cap and remote pressure ltration Pump with side port end cap and integral pressure
ltration

Charge pressure
gauge port M6 Port E
(before the filter) (from filter)

Port D
(to filter)

Charge pressure
gauge port M3
Charge pressure (back side-after
gauge port M3 the filter)
(after the filter)

P106 163E


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

4ROUBLESHOOTING

OVERVIEW 4HISSECTIONPROVIDESGENERALSTEPSTOFOLLOWIFCERTAINUNDESIRABLESYSTEMCONDITIONS
OCCUR&OLLOWTHESTEPSINASECTIONUNTILYOUSOLVETHEPROBLEM3OMEOFTHEITEMS
ARESYSTEMSPECIlC&ORAREASCOVEREDINTHISMANUALWEREFERENCETHESECTION!LWAYS
OBSERVETHESAFETYPRECAUTIONSLISTEDINTHEIntroductionSECTIONPAGE ANDTHOSE
RELATINGTOYOURSPECIlCEQUIPMENT

NEUTRAL DIFFICULT OR
IMPOSSIBLE TO FIND

Item Description Action

)NPUTTOPUMPCONTROL )NPUTTOCONTROLMODULEISOPERATINGIMPROPERLY #HECKCONTROLINPUTANDREPAIRORREPLACEASNECESSARY
0UMPDISPLACEMENTCONTROL #ONTROLLINAGESARENOTSECURECONTROLORIlCESARE !DJUSTREPAIRORREPLACECONTROLMODULEASNECESSARY
BLOCKED
-ULTIFUNCTIONVALVE -ULTIFUNCTIONVALVEISLEAKING 3WAPMULTIFUNCTIONVALVES)FSYSTEMCHANGESDIRECTION
REPLACEDEFECTIVEVALVE

SYSTEM OPERATING HOT

Item Description Action

/ILLEVELINRESERVOIR )NSUFlCIENTHYDRAULICmUIDWILLNOTMEETCOOLING &ILLRESERVOIRTOPROPERLEVEL
DEMANDSOFSYSTEM
(EATEXCHANGER (EATEXCHANGERISNOTSUFlCIENTLYCOOLINGTHE #HECKAIRmOWANDINPUTAIRTEMPERATUREFORHEAT
SYSTEM EXCHANGER#LEANREPAIRORREPLACEHEATEXCHANGER
#HARGEPRESSURE ,OWCHARGEPRESSUREWILLOVERWORKSYSTEM -EASURECHARGEPRESSURE)NSPECTANDADJUSTORREPLACE
CHARGERELIEFVALVEORREPAIRLEAKYCHARGEPUMP
#HARGEPUMPINLETVACUUM (IGHINLETVACUUMWILLOVERWORKSYSTEM!DIRTY #HECKCHARGEINLETVACUUM)FHIGHINSPECTINLETlLTERAND
lLTERWILLINCREASETHEINLETVACUUM)NADEQUATELINE REPLACEASNECESSARY#HECKFORADEQUATELINESIZELENGTH
SIZEWILLRESTRICTmOW OROTHERRESTRICTIONS
3YSTEMRELIEFPRESSURESETTINGS
FUNCTIONVALVES
&ORINTERNALLEAKAGEINMOTOR
)FTHESYSTEMRELIEFSETTINGSARETOOLOWTHERELIEF 6ERIFYSETTINGSOFPRESSURELIMITERSANDHIGHPRESSURE
VALVESWILLBEOVERWORKED RELIEFVALVESANDADJUSTORREPLACEMULTI
ASNECESSARY
,EAKAGEWILLREDUCELOWSIDESYSTEMPRESSUREAND -ONITORMOTORCASEmOWWITHOUTLOOPmUSHINGINTHE
OVERWORKTHESYSTEM CIRCUITUSEDEFEATSPOOL )FmOWISEXCESSIVEREPLACE
MOTOR
3YSTEMPRESSURE (IGHSYSTEMPRESSUREWILLOVERHEATSYSTEM -EASURESYSTEMPRESSURE)FPRESSUREISHIGHREDUCELOADS


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

4ROUBLESHOOTING

TRANSMISSION
OPERATES NORMALLY IN
ONE DIRECTION ONLY

Item Description Action

)NPUTTOPUMPCONTROL )NPUTTOCONTROLMODULEISOPERATINGIMPROPERLY #HECKCONTROLINPUTANDREPAIRORREPLACEASNECESSARY
0UMPDISPLACEMENTCONTROL #ONTROLLINKAGESARENOTSECURECONTROLORIlCESARE 2EPAIRORREPLACECONTROLMODULEASNECESSARY
BLOCKED
3YSTEMPRESSURELIMITERSHIGH )NTERCHANGINGTHEMULTI FUNCTIONVALVESWILLSHOW )NTERCHANGEMULTI FUNCTIONVALVES)FTHEPROBLEM
PRESSURERELIEFVALVESORSYSTEM IFTHEPROBLEMISRELATEDTOTHEVALVEFUNCTIONS CHANGESDIRECTIONREPAIRORREPLACETHEVALVEONTHESIDE
CHECKVALVES CONTAINEDINTHEMULTI FUNCTIONVALVES THATDOESNOTOPERATE
#HARGEPRESSURE )FCHARGEPRESSUREDECAYSINONEDIRECTIONTHELOOP -EASURECHARGEPRESSUREINFORWARDANDREVERSE)F
mUSHINGVALVEMAYBESTICKINGINONEDIRECTION PRESSUREDECAYSINONEDIRECTIONINSPECTANDREPAIRTHE
MOTORLOOPmUSHINGVALVE

SYSTEM WILL NOT

OPERATE IN EITHER
DIRECTION

Item Description Action

/ILLEVELINRESERVOIR )NSUFlCIENTHYDRAULICmUIDTOSUPPLYSYSTEMLOOP &ILLRESERVOIRTOPROPERLEVEL
)NPUTTOPUMPCONTROL )NPUTTOCONTROLMODULEISOPERATINGIMPROPERLY #HECKCONTROLINPUTANDREPAIRREPLACEASNECESSARY
0UMPDISPLACEMENTCONTROL #ONTROLLINKAGEISNOTSECURECONTROLORIlCESARE 2EPAIRORREPLACECONTROLMODULEASNECESSARY
BLOCKEDETC
"YPASSVALVES OPEN )FBYPASSVALVES AREOPENTHESYSTEMLOOPWILLBE #LOSEBYPASSVALVES2EPLACEMULTI FUNCTIONVALVEIF
DEPRESSURIZED DEFECTIVE
#HARGEPRESSUREWITHPUMPIN ,OWCHARGEPRESSUREISINSUFlCIENTTORECHARGE -EASURECHARGEPRESSUREWITHTHEPUMPINNEUTRAL)F
NEUTRAL SYSTEMLOOP PRESSUREISLOWGOTOPump charge relief valveOTHERWISE
CONTINUEWITHCharge pressure with pump in stroke.
#HARGEPRESSUREWITHPUMPIN ,OWCHARGEPRESSUREWITHTHEPUMPINSTROKE -EASURECHARGEPRESSUREWITHPUMPINSTROKE)FPRESSURE
STROKE INDICATESAMOTORCHARGERELIEFVALVEORSYSTEM ISLOWADJUSTORREPLACEMOTORCHARGERELIEFVALVE
PRESSURERELIEFVALVEMAYBEIMPROPERLYSET OTHERWISEGOTOCharge pumps.
0UMPCHARGERELIEFVALVE !PUMPCHARGERELIEFVALVETHATISLEAKYORSETTOOLOW !DJUSTORREPLACEPUMPCHARGERELIEFVALVEASNECESSARY
WILLDEPRESSURIZETHESYSTEM
#HARGEPUMPINLETlLTER !CLOGGEDlLTERWILLUNDERSUPPLYSYSTEMLOOP )NSPECTlLTERANDREPLACEIFNECESSARY
#HARGEPUMPS !MALFUNCTIONINGCHARGEPUMPWILLPROVIDE 2EPAIRORREPLACETHECHARGEPUMP
INSUFlCIENTCHARGEmOW
0UMPDISPLACEMENTCONTROL #ONTROLLINKAGESARENOTSECURECONTROLORIlCESARE 2EPAIRORREPLACECONTROLMODULEASNECESSARY
BLOCKED
3YSTEMPRESSURE ,OWSYSTEMPRESSUREWILLNOTPROVIDEPOWER -EASURESYSTEMPRESSURE#ONTINUETONEXTSTEP
NECESSARYTOMOVELOAD
3YSTEMMULTI FUNCTIONVALVES $EFECTIVEMULTI FUNCTIONVALVESWILLCAUSESYSTEMTO 2EPAIRORREPLACEMULTI FUNCTIONVALVES 
PRESSURETOBELOW


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

4ROUBLESHOOTING

LOW MOTOR OUTPUT

TORQUE

Item Description Action

3YSTEMPRESSUREATMOTOR ,OWSYSTEMPRESSUREATTHEMOTORWILLREDUCETORQUE -EASURESYSTEMPRESSUREATMOTOR)FPRESSURELIMITER
SETTINGISLOWINCREASESETTING
6ARIABLEMOTORSTUCKAT -INIMUMMOTORDISPLACEMENTYIELDSLOWOUTPUT #HECKCONTROLSUPPLYPRESSUREORREPAIRDISPLACEMENT
MINIMUMDISPLACEMENT TORQUE CONTROL#HECKMOTORCONTROLORIlCES
)NTERNALLEAKAGE )NTERNALLEAKAGEWILLREDUCESYSTEMPRESSURE #HECKFORLEAKING/ RINGSGASKETSANDOTHERlTTINGS
2EPAIRUNITASREQUIREDORREPLACELEAKINGUNIT

IMPROPER MOTOR
OUTPUT SPEED

Item Description Action

/ILLEVELINRESERVOIR )NSUFlCIENTHYDRAULICmUIDWILLREDUCEMOTORSPEED
0UMPOUTPUTmOW )NCORRECTOUTmOWWILLAFFECTOUTPUTSPEED)NCORRECT
OUTPUTmOWINDICATESTHESWASHPLATEISOUTOF
POSITION
6ARIABLEMOTORDISPLACEMENT )FVARIABLEMOTORDISPLACEMENTCONTROLISNOT
&ILLOILTOPROPERLEVEL
-EASUREPUMPOUTPUTANDCHECKFORPROPERPUMPSPEED
%NSURETHEPUMPISINFULLSTROKE
3EEIFVARIABLEMOTORDISPLACEMENTCONTROLISRESPONDING
CONTROL FUNCTIONINGCORRECTLYVARIABLEMOTORSWASHPLATEMAY )FNOTREPAIRORREPLACECONTROL
BEINWRONGPOSITION
)NTERNALLEAKAGE )NTERNALLEAKAGEWILLREDUCESYSTEMPRESSURE #HECKFORLEAKING/
RINGSGASKETSANDOTHERlTTINGS
2EPAIRUNITASREQUIREDORREPLACELEAKYUNIT

SYSTEM NOISE OR
VIBRATION

Item Description Action

/ILINRESERVOIR )NSUFlCIENTHYDRAULICmUIDWILLLEADTOCAVITATION &ILLRESERVOIRTOPROPERLEVEL
!IRINSYSTEM !IRBUBBLESWILLLEADTOCAVITATION ,OOKFORFOAMINRESERVOIR#HECKFORLEAKSONINLETSIDE
SYSTEMLOOPANDREPAIR!FTERWARDSLETRESERVOIRSETTLE
UNTILFOAMDISSIPATES2UNSYSTEMATLOWSPEEDTOMOVE
SYSTEMmUIDTORESERVOIR2EPEAT
0UMPINLETVACUUM (IGHINLETVACUUMCAUSESNOISE!DIRTYlLTERWILL )NSPECTANDREPLACElLTERASNECESSARY#HECKFORPROPER
INCREASETHEINLETVACUUM SUCTIONLINESIZE
3HAFTCOUPLINGS !LOOSESHAFTCOUPLINGWILLCAUSEEXCESSIVENOISE 2EPLACELOOSESHAFTCOUPLINGORREPLACEPUMPORMOTOR
3HAFTALIGNMENT -ISALIGNEDSHAFTSCAUSENOISE !LIGNSHAFTS


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

4ROUBLESHOOTING

SYSTEM RESPONSE IS
SLUGGISH

Item Description Action

/ILLEVELINRESERVOIR )NSUFlCIENTHYDRAULICmUIDCAUSESSLUGGISHRESPONSE &ILLRESERVOIRTOPROPERLEVEL
-ULTI
FUNCTIONVALVESPRESSURE )NCORRECTPRESSURESETTINGSAFFECTSSYSTEMREACTION !DJUSTORREPLACEMULTI
FUNCTIONVALVES
SETTINGS TIME
0UMPINLETVACUUM
0RIMEMOVERSPEED
#HARGEANDCONTROLPRESSURES
3YSTEMINTERNALLEAKAGE
(IGHPUMPINLETVACUUMREDUCESSYSTEMPRESSURE -EASURECHARGEINLETVACUUM)FHIGHREPLACEINLETlLTER
,OWENGINESPEEDREDUCESSYSTEMPERFORMANCE !DJUSTENGINESPEED
)NCORRECTCHARGEORCONTROLPRESSURESAFFECTSSYSTEM -EASURECHARGEANDCONTROLPRESSURESANDCORRECTIF
PERFORMANCE NECESSARY
)NTERNALLEAKAGEREDUCESSYSTEMPRESSURE #HECKFORLEAKAGEIN/
RINGSGASKETSANDOTHERlTTINGS


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

!DJUSTMENTS

STANDARD
PROCEDURES, "EFOREWORKINGONTHEPUMPCLEANTHEOUTSIDEOFTHEPUMP
INSPECTIONS, AND
ADJUSTMENTS
CCaution
#ONTAMINATIONCANDAMAGEINTERNALCOMPONENTSANDVOIDYOURWARRANTY4AKE
PRECAUTIONSTOENSURESYSTEMCLEANLINESSWHENREMOVINGANDREINSTALLINGSYSTEMLINES

 7ITHTHEPRIMEMOVEROFFTHOROUGHLYCLEANTHEOUTSIDEOFTHEPUMP

 )FREMOVINGTHEPUMPTAGEACHHYDRAULICLINECONNECTEDTOTHEPUMP)FHYDRAULIC

LINESAREDISCONNECTEDPLUGEACHOPENPORTWITHACLEANPLUGTOENSURETHATDIRTAND
CONTAMINATIONDONOTGETINTOTHEPUMP

 %NSURETHESURROUNDINGAREASARECLEANANDFREEOFCONTAMINANTS

 )NSPECTTHESYSTEMFORCONTAMINATION

 6ISUALLYINSPECTTHEHYDRAULICmUIDFORSIGNSOFSYSTEMCONTAMINATIONmUID

DISCOLORATIONFOAMINTHEmUIDSLUDGEORSMALLMETALPARTICLES

 )FTHEREARESIGNSOFCONTAMINATIONINTHEHYDRAULICmUIDREPLACEALLlLTERSDRAINAND

mUSHTHEHYDRAULICSYSTEMANDlLLWITHTHECORRECTlLTEREDHYDRAULICmUID

 &LUSHTHELINESBEFOREREPLACINGTHEHYDRAULICmUID


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

!DJUSTMENTS

ADJUSTMENTS 4HISSECTIONOFFERSINSTRUCTIONONINSPECTIONANDADJUSTMENTOFPUMPCOMPONENTS2EAD
THROUGHTHEENTIRERELATEDSECTIONBEFOREBEGINNINGASERVICEACTIVITY2EFERTOPressure
measurementsPAGESANDFORLOCATIONOFGAUGEPORTSANDSUGGESTEDGAUGE
SIZES

CHARGE PRESSURE 4HEFOLLOWINGPROCEDUREEXPLAINSHOWTOCHECKANDADJUSTTHECHARGEPRESSURERELIEF

RELIEF VALVE VALVE
ADJUSTMENT
 )NSTALLABAR;PSI=PRESSUREGAUGEINTHEPUMPCHARGEPRESSUREGAUGEPORT
W Warning - )NSTALLABAR;PSI=GAUGETOMEASURECASEPRESSURETEEINTO,OR,OR
4HEFOLLOWINGPROCEDURE USESERVOGAUGEPORT-OR- /PERATETHESYSTEMWITHTHEPUMPINNEUTRALZERO
MAYREQUIRETHEVEHICLE DISPLACEMENT WHENMEASURINGPUMPCHARGEPRESSURE
MACHINETOBEDISABLED
WHEELSRAISEDOFFTHE  4HETABLESHOWSTHEACCEPTABLEPUMPCHARGEPRESSURERANGEFORSOMECHARGERELIEF
GROUNDWORKFUNCTION VALVESETTINGS4HESEPRESSURESASSUMEMINRPM ANDARESERVOIRTEMPERATURE
DISCONNECTEDETC INORDER OF#;&=ANDAREREFERENCEDTOCASEPRESSURE
TOPREVENTINJURYTOTHE
TECHNICIANANDBYSTANDERS
4AKENECESSARYSAFETY Charge pressure relief valve
Case drain port L1
PRECAUTIONSBEFOREMOVING
THEVEHICLEMACHINE M4 G 


)



(*!
K90 B 1 1/16-12
Adjusting screw t 
.%

$.t]
K10 M5
Lock nut

.%

$.t]

Charge pressure gauge port M3

G 


)



(*!
B 

t 
.%

$.t]


(()'()!+
+$
P106 162E

,ISTEDPRESSURESASSUMEAPUMPSPEED Charge pressure ranges

OFMIN-1RPM !THIGHERPUMP Model code Measured charge pressure*
INPUTSPEEDSWITHHIGHERCHARGEmOWS nBAR
20
THECHARGEPRESSUREWILLRISEOVERTHE ;nPSI=
RATEDSETTING nBAR

;nPSI=
nBAR

;nPSI=

4HISISTHEACTUALCHARGEPRESSUREPORTGAUGE
READINGMINUSTHECASEPRESSUREPORTGAUGE
READING


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

!DJUSTMENTS

CHARGE PRESSURE  %ARLIERPRODUCTION3ERIESPUMPSHAVEASHIMADJUSTABLECHARGEPRESSURERELIEF

RELIEF VALVE VALVE3HIMKITSAREAVAILABLEFROM3AUER $ANFOSS2EMOVETHEPLUGUSINGAINHEX
ADJUSTMENT WRENCHANDEXCHANGESHIMSBEHINDTHESPRINGTOADJUSTCHARGEPRESSURE4ORQUE
(continued) PLUGTO.sM;LBFsFT=

 ,ATERPRODUCTION3ERIESPUMPSHAVEANEXTERNALSCREW ADJUSTABLECHARGE

PRESSURERELIEFVALVE,OOSENLOCKNUT+ ANDTURNTHEADJUSTINGSCREW+ USINGA
SCREWDRIVERORINHEXWRENCHTOADJUSTCHARGEPRESSURESETTING

Lock nut wrench size

Frame size Wrench size
n  INCH
n  INCH

 #LOCKWISEROTATIONOFTHEPLUGINCREASESTHESETTINGANDCOUNTERCLOCKWISEROTATION
DECREASESTHESETTINGATARATEOFAPPROXIMATELYBAR;PSI=PERTURN 4ORQUE
LOCKNUTTO.sM;LBFsFT=

 /NCEYOUACHIEVETHEDESIREDCHARGEPRESSURESETTINGREMOVETHEGAUGESANDPLUG

THEPORTS


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

!DJUSTMENTS

MULTI-FUNCTION VALVE 9OUACCOMPLISHADJUSTMENTOFTHEPRESSURELIMITERSETTINGANDTHEHIGHPRESSURERELIEF

PRESSURE ADJUSTMENT VALVE(026 SETTINGSIMULTANEOUSLY4HE(026SETTINGISAUTOMATICALLYSETAPPROXIMATELY
BAR;PSI=ABOVETHEPRESSURELIMITERSETTING

W7ARNING ,OCKTHEMOTOROUTPUTSHAFTBYLOCKINGTHEVEHICLESBRAKESORRIGIDLYlXINGTHEWORK
4AKENECESSARYPRECAUTIONS FUNCTIONSOITCANNOTROTATEORCAPTHESYSTEMPORTSW
THATTHEMOTORSHAFT
REMAINSSTATIONARYDURING
THEADJUSTMENTPROCEDURE
Multi-function valve adjustment

Charge pressure gauge port M3

G 0 - 50 bar [0 - 1000 psi]
B 9/16-18
t 
1%

$1t]

I Adjusting screw
h Lo#
&-,
+%$$*
/
&-,
tLock nut torque 
((*'(*!,
,$

System pressure gauge port M2

G 0 - 1000 bar [0 - 10000 psi]
B 9/16-18
t

1%

$1t]
System pressure gauge port M1
G 0 - 1000 bar [0 - 10000 psi]
B 9/16-18
t

1%

$1t]
P106 168E

 )NSTALLTWOBARORPSI PRESSUREGAUGESINTHEHIGHPRESSUREGAUGE

PORTS-AND- )NSTALLABARORPSI PRESSUREGAUGEINTHEPUMPCHARGE
PRESSUREGAUGEPORT- 

 3TARTTHEPRIMEMOVERANDOPERATEATNORMALSPEED

 ,OOSENLOCKINGNUT

 )NSERTANINTERNALHEXWRENCHINTOTHEPRESSUREADJUSTINGSCREW

!PLASTICDUSTPLUGISINSTALLEDINTHEADJUSTINGSCREW


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

!DJUSTMENTS

MULTI-FUNCTION VALVE  4HEMODELCODESHOWSTHEFACTORYPRESETPRESSURELIMITERSETTING)TISREFERENCEDTO

PRESSURE ADJUSTMENT CHARGEPRESSURESOTHEPRESSURELIMITERSETTINGISTHEDIFFERENCEBETWEENTHEHIGH
(continued) ANDLOWPRESSURESIDESOFTHESYSTEMLOOP!CTIVATEORMOVETHECONTROLINPUTSO
THATPRESSUREINCREASESINTHEHIGHPRESSURESIDEOFTHECLOSEDCIRCUITTOTHEPRESSURE
LIMITERPRESSURESETTING4HEPRESSURELIMITERSETTINGISREACHEDWHENTHEPRESSURE
STOPSINCREASINGANDREMAINSSTEADYATAGIVENPRESSURELEVELASSHOWNONTHE
GAUGES 

 2ETURNTHEPUMPTOITSNEUTRALZEROmOW POSITIONANDADJUSTTHEPRESSURELIMITER

SETTINGBYROTATINGTHEPRESSUREADJUSTINGSCREWWITHANINTERNALHEXWRENCH

#LOCKWISEROTATIONOFTHEPRESSUREADJUSTMENTSCREWINCREASESTHEPRESSURESETTING
ANDCOUNTERCLOCKWISEROTATIONDECREASESTHEPRESSURESETTING%ACHCOMPLETE
ROTATIONOFTHEPRESSUREADJUSTINGSCREWCHANGESTHEPRESSUREASSHOWNINTHE
FOLLOWINGTABLE

Pressure limiter adjustment data

Frame size Lock nut wrench size and torque Adjusting Approximate pressure change
screw size per revolution of adjusting screw
EARLY  MM.sM;LBFsIN= MM BAR;PSI=
  MM.sM;LBFsFT= MM BAR;PSI=
EARLY MM.sM;LBFsFT= MM BAR;PSI=
  MM.sM;LBFsFT= MM BAR;PSI=

 4OVERIFYTHEACTUALPRESSURESETTINGACTUATEORMOVETHECONTROLINPUTSOTHATTHE

PUMPAGAINDEVELOPSPRESSUREINTHEHIGHPRESSURECIRCUITTOTHENEWLYADJUSTED
PRESSURELIMITERPRESSURESETTINGTHENREADTHEHIGHPRESSUREGAUGE!LLOWTHEPUMP
TORETURNTOITSNEUTRALPOSITION4HEPRESSUREINTHEHIGHPRESSURECIRCUITSHOULD
RETURNTOTHECHARGEPRESSURESETTING

 7HILEHOLDINGTHEPRESSUREADJUSTINGSCREWSTATIONARYTIGHTENTHEPRESSUREADJUSTING

SCREWLOCKNUT4ORQUEASSHOWNINTHETABLE

$ONOTOVERTORQUE

 3HUTDOWNTHEPRIMEMOVERREMOVETHEGAUGESANDINSTALLTHEGAUGEPORTPLUGS

2EPLACETHEPLASTICDUSTPLUGSIFUSED 

5SETHESAMEPROCEDUREFORSETTINGTHEPRESSURELIMITOFTHEOTHERMULTI FUNCTIONVALVE
-OVEORACTIVATETHECONTROLINPUTSIGNALINTHEOPPOSITEDIRECTIONSOTHATHIGHPRESSURE
DEVELOPSINTHEOPPOSITESIDEOFTHECLOSEDCIRCUIT


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

-INORREPAIR

STANDARD PROCEDURES Removing the pump

"EFOREWORKINGONTHEPUMPCLEANTHEOUTSIDEOFTHEPUMP)FTHEPUMPHASANAUXILIARY
PUMPATTACHEDREMOVEBOTHPUMPSASASINGLEUNIT4AGANDCAPALLHYDRAULICLINESAS
THEYAREDISCONNECTEDANDPLUGALLOPENPORTSTOENSURETHATCONTAMINATIONDOESNOT
ENTERTHESYSTEM

CCaution
#ONTAMINATIONCANDAMAGEINTERNALCOMPONENTSANDVOIDYOURWARRANTY4AKE
PRECAUTIONSTOENSURESYSTEMCLEANLINESSWHENREMOVINGANDREINSTALLINGSYSTEMLINES

Disassembly
 7ITHTHEPRIMEMOVEROFFTHOROUGHLYCLEANTHEOUTSIDEOFTHEPUMP

 4AGCAPANDDISCONNECTEACHHYDRAULICLINECONNECTEDTOTHEPUMP!SHYDRAULIC

LINESAREDISCONNECTEDPLUGEACHOPENPORTTOENSURETHATDIRTANDCONTAMINATION
DONOTENTERTHESYSTEM

 2EMOVETHEPUMPANDITSAUXILIARYPUMPIFAPPLICABLE ASASINGLEUNIT

Inspection
 %NSURETHEWORKSURFACEANDSURROUNDINGAREAARECLEANANDFREEOFCONTAMINANTS

 )NSPECTTHESYSTEMFORCONTAMINATION

 ,OOKATTHEHYDRAULICmUIDFORSIGNSOFSYSTEMCONTAMINATIONmUIDDISCOLORATION

FOAMSLUDGEORSMALLMETALPARTICLES

Reassembly
 "EFOREREPLACINGTHEPUMPONTHEMACHINEREPLACEALLlLTERSANDDRAINANDlLLTHE
HYDRAULICSYSTEMWITHTHECORRECTHYDRAULICmUID

 &LUSHTHELINESBEFOREREPLACINGTHEHYDRAULICmUID


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

-INORREPAIR

SHAFT SEAL AND SHAFT 9OUCANREPLACETHESHAFTANDSEALWITHOUTMAJORDISASSEMBLYOFTHEUNIT#LEANPUMP

REPLACEMENT ANDSURROUNDINGAREATHOROUGHLY$ISCONNECTANDREMOVETHEPUMPFROMTHEUNITAND
CLEANITTHOROUGHLYBEFORESTARTINGREPAIRS-ARKALLCONNECTIONSFORLATERREASSEMBLY

Shaft removal
 0OSITIONTHEPUMPWITHTHESHAFTFACINGUP

)FTHEUNITISPOSITIONEDHORIZONTALLYORMOVEDORJARREDWHILETHESHAFTISOUTTHECYLINDER

BLOCKCOULDMOVEOUTOFPLACEMAKINGSHAFTINSTALLATIONDIFlCULT

 2EMOVETHETHREEORFOURSCREWS, HOLDINGTHERETAINERPLATE, ANDSEAL

CARRIER, TOTHEHOUSINGUSINGAMMHEXWRENCHUNIT AMMINTERNAL
HEXWRENCHTHROUGHUNITS ORAMMINTERNALHEXWRENCHTHROUGH
UNITS 2EMOVETHERETAINERPLATE

#ERTAINEARLIERPRODUCTIONUNITSUSEA Shaft assembly

ONEPIECERETAINERPLATEANDSEALCARRIER
L70

 !FTERREMOVINGTHESCREWSTHE L60

SPRINGFORCEONTHESHAFTMAYMOVE
THESEALCARRIEROUTOFITSBOREBY
L30
APPROXIMATELYMM;INCH=)F
THESEALCARRIERDOESNOTMOVEFROM L40
ITSBOREPRYITFROMITSBOREANDOR
LIGHTLYTAPTHEENDOFTHESHAFTWITHA L50
SOFTMALLET L20

 2EMOVETHE/ RING, FROMTHE

SEALCARRIERANDDISCARD L10

 0LACESEALCARRIERANDSEALINANARBOR L100

PRESSANDPRESSOUTTHESEAL, 

 2EMOVESHAFT, ANDROLLER

BEARINGASSEMBLY, FROM
PUMP9OUCANTRANSFERTHEBEARING
ASSEMBLYTOTHENEWSHAFT

 5SINGSNAP RINGPLIERSREMOVETHE

RETAININGRING, THATSECURESTHE
ROLLERBEARINGASSEMBLY2EMOVETHE
ROLLERBEARINGASSEMBLY

P106 181E


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

-INORREPAIR

SHAFT SEAL AND SHAFT Inspection

REPLACEMENT  )NSPECTTHESEALCARRIERTHENEWSEALANDTHE/ RINGFORANYDAMAGEORNICKS
(continued)
 )NSPECTTHESHAFTANDBEARINGFORRUSTWEARORCONTAMINATION3PINTHEBEARINGIN
YOURHANDFEELINGFORROUGHNESS2EPLACEIFNECESSARY

Reassembly
 5SINGTHEARBORPRESSPRESSTHENEWSEAL, INTOSEALCARRIER, "ECAREFULNOTTO
DAMAGETHESEAL

)FTHESHAFTISNOTBEINGREPLACEDPROCEEDTOSTEP

 0LACEROLLERBEARINGASSEMBLYONNEWSHAFTANDSECUREWITHTHERETAININGRING

 )NSTALLANINSTALLATIONSLEEVEORWRAPSPLINEORKEYEDENDOFSHAFTWITHPLASTIClLMTO
PREVENTDAMAGETOTHESEALINGLIPONTHESEALDURINGINSTALLATION

 ,UBRICATEANDINSTALLANEW/ RING, ONTHESEALCARRIER,UBRICATETHESEALWITH

CLEANPETROLEUMJELLY

 !SSEMBLETHESEALCARRIERANDSEALOVERTHESHAFTANDINTOTHEHOUSINGBORE)NSTALL
THERETAINERPLATEIFUSED 

 )NSTALLTHESCREWSANDTORQUETOTHE Shaft retainer screw torque

APPROPRIATEVALUEINTHETABLETOTHE Frame size Torque
RIGHT n .sM;LBFsFT=
n .sM;LBFsFT=
4ORQUETHESCREWSINASEQUENCED n .sM;LBFsFT=
PATTERNTHENRECHECK


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

-INORREPAIR

DISPLACEMENT  2EMOVETHECONTROLASSEMBLYAS Underside of an MDC module showing

CONTROL ORIFICE DESCRIBEDINTHEINSTRUCTIONSFORTHE orice locations
CHECK VALVE SPECIlCDISPLACEMENTCONTROL
TA A B TB

 4HEORIlCECHECKVALVEISLOCATEDIN P

THECONTROLASSEMBLYATTHESURFACE
OFTHEPUMPHOUSINGFACE2EMOVE
THESPRINGRETAINERANDSPRINGFROM
Orifice plugs
THEORIlCECHECKVALVECAVITYAND
THENREMOVETHEORIlCECHECKVALVE
Orifice check valve
 #LEANANDINSTALLTHEORIlCECHECK E101 086E

VALVEINTHECAVITYANDTHENINSTALL
THESPRINGANDSPRINGRETAINERTOHOLDTHEORIlCECHECKVALVEINPOSITION

 !SSEMBLETHECONTROLONTOTHEPUMP2EFERTOTHEINSTRUCTIONSFORTHESPECIlCCONTROL


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

-INORREPAIR

MANUAL DISPLACEMENT Removal

CONTROL (MDC)  4HOROUGHLYCLEANEXTERNALSURFACESPRIORTOREMOVALOFCONTROL

 5SINGAMMINTERNALHEXWRENCHREMOVETHESIXCONTROLMOUNTINGSCREWS- 

2EMOVETHECONTROL- WITHORIlCECHECKVALVE4 ANDSPRING4 ANDCONTROL
GASKET- FROMTHEHOUSING$ISCARDTHEGASKET

)FNECESSARYREMOVETHECONTROLHANDLE- BYREMOVINGTHELOCKINGNUT- AND

WASHER- 

C#AUTION
0ROTECTEXPOSEDSURFACESANDCAVITIESFROMDAMAGEANDFOREIGNMATERIAL

Reassembly
 )NSTALLANEWGASKET- )NSPECTCONTROLTOASSURETHATTHECONTROLORIlCECHECK
VALVEANDSPRINGAREINTHEIRPROPERPOSITIONINTHECONTROL

 )NSTALLTHECONTROL%NGAGETHEPINONTHECONTROLLINKAGEINTOTHEMATINGHOLEINTHE
LINKATTACHEDTOTHESWASHPLATE

 7ITHTHECONTROLINPOSITIONMOVECONTROLLEVERBOTHDIRECTIONSTOCHECKPROPER

ENGAGEMENTOFCONTROLLINKAGEPIN)FPROPERLYASSEMBLEDLEVERWILLRETURNTO
CENTER)FLEVERDOESNOTRETURNTOCENTERREMOVETHECONTROLANDREPEATTHEABOVE
PROCEDURE

MDC removal/installation
M72
S40 M71 h 8 mm
h 1-1/8 in M70 
*"
 
!*']


*"


!*']

M90 (x6)
I 5 mm

*"


!*']

M11
Seal washer d
location (42, 180, 250 cc)
T

T30 T40

P106 185E


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

-INORREPAIR

MANUAL DISPLACEMENT )FREMOVEDINSTALLTHECONTROLHANDLE- ANDLOCKINGNUT- WITHWASHER- 

CONTROL (MDC) (OLDTHEPOSITIONOFTHEHANDLEANDTORQUETHELOCKINGNUTTO.sM;LBFsFT=USING
(continued) ANMMHEXWRENCH

 !LIGNTHECONTROLGASKETANDINSTALLTHESCREWS4ORQUETHESCREWSTO.sM
;LBFsFT=

W 7ARNING )NSTALLASEALINGWASHERUNDERTHEHEADOFMOUNTINGSCREWSTHATAREINSTALLEDINTO
4HENEUTRALSTARTSWITCH THROUGHHOLESINTHEHOUSING
NEUTRALMUSTBEREADJUSTED
AFTERREASSEMBLINGTHE
-$#MODULE


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

4ORQUECHART

FASTENER SIZE AND Item Fastener Frame size Wrench size Torque
TORQUE CHART B83 3PEEDSENSORLOCKNUT    INHEX .sM;LBFsFT=
E60 3IDECOVERSCREW   MMHEX .sM;LBFsFT=
"LINDHOLES   MMHEX .sM;LBFsFT=
  MMHEX .sM;LBFsFT=
E60 3IDECOVERSCREW   MMHEX .sM;LBFsFT=
4HRUHOLES   MMHEX .sM;LBFsFT=
  MMHEX .sM;LBFsFT=
& 3ERVOCYLINDERSCREW   MMHEX .sM;LBFsFT=
F211   MMHEX .sM;LBFsFT=
' %NDCAPSCREW   MMINTERNALHEX .sM;LBFsFT=
G97   MMINTERNALHEX .sM;LBFsFT=
 MMHEX .sM;LBFsFT=
  MMHEX .sM;LBFsFT=
H80 #HARGEPUMPRETAININGSCREW   MMHEX .sM;LBFsFT=
  MMHEX .sM;LBFsFT=
J80 %NDCAPSCREW  MMINTERNALHEX .sM;LBFsFT=
EARLY MMINTERNALHEX .sM;LBFsFT=
LATE MMINTERNALHEX .sM;LBFsFT=
 MMHEX .sM;LBFsFT=
  MMHEX .sM;LBFsFT=
  MMINTERNALHEX .sM;LBFsFT=
  MMINTERNALHEX .sM;LBFsFT=
K10 #HARGEPRESSUREVALVEPLUG   INHEX .!
K90 #HARGEPRESSURELOCKNUT    INHEX .sM;LBFsFT=
   INHEX .sM;LBFsFT=
L70 3HAFTRETAININGSCREW   MMHEX .sM;LBFsFT=
  MMINTERNALHEX .sM;LBFsFT=
  MMINTERNALHEX .sM;LBFsFT=
M72 -$#HANDLENUT   MM .sM;LBFsFT=
M78 $E STROKEVALVEMANIFOLDSCREW   MMINTERNALHEX .sM;LBFsFT=
M85 %CCENTRICPLUGLOCKNUT    INHEX .sM;LBFsFT=
M88 .EUTRALSTARTSWITCHLOCKNUT    INHEX .sM;LBFsFT=
M90 #ONTROLMOUNTINGSCREW   MMINTERNALHEX .sM;LBFsFT=
M92 3OLENOIDVALVEMOUNTINGSCREW   MMINTERNALHEX .sM;LBFsFT=
M98 0#0MOUNTINGSCREW   MMINTERNALHEX .sM;LBFsFT=
N10 &ILTERREDUCERASSEMBLY    INHEX .sM;LBFsFT=
   INHEX .sM;LBFsFT=
   INHEX .sM;LBFsFT=
N37 &ILTERPLUGASSEMBLY   ININTERNALHEX .sM;LBFsFT=
0" -ULTI FUNCTIONVALVE    INHEX .sM;LBFsFT=
P2A1    INHEX .sM;LBFsFT=


 3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS

4ORQUECHART

PLUG SIZE AND TORQUE )FANYPLUGSORlTTINGSAREREMOVEDFROMTHEPUMPDURINGSERVICINGINSTALLANDTORQUEAS

CHART INDICATEDINTHEACCOMPANYINGTABLEC

!LWAYSINSTALLNEW/ RINGSBEFOREREINSTALLINGTHEPLUGSORlTTINGS
C#AUTION
4ORQUEPLUGSORlTTINGS Item O-ring plug Wrench size Torque
INSTALLEDINTOALUMINUM B70, B72   INTERNALHEXWRENCH .sM;LBFsFT=
HOUSINGSTOTHELOWER B71   INTERNALHEXWRENCH .sM;LBFsFT=
VALUESSPECIlEDFOR B80    INTERNALHEXWRENCH .sM;LBFsFT=
INTERNALHEXPLUGSOFTHE B82, B83   INTERNALHEXWRENCH .sM;LBFsFT=
SAMESIZE G18   INTERNALHEXWRENCH .sM;LBFsFT=
G45-G50   INCHHEXWRENCH .sM;LBFsFT=
G52-G54   INTERNALHEXWRENCH .sM;LBFsFT=
H90 (not shown)    INTERNALHEXWRENCH .sM;LBFsFT=
N35, N36 (not shown)   INCHHEXWRENCH .sM;LBFsFT=
N37   INTERNALHEXWRENCH .sM;LBFsFT=

FASTENERS AND PLUGS

Fastener and plug locations

B70, B72 O-ring plug
9/16-18
J80 Auxilliary pad / G90 End cap screw
end cap screw M90 Control bolt

H80 Charge pump

retaining screw L70 Shaft seal
retaining screw

G53, G54 O-ring plug

9/16-18

K10 Charge pressure

relief valve plug M88 Neutral start switch
lock nut
M85 Eccentric plug
K90 Charge pressure lock nut
relief valve lock nut
B80 O-ring plug
1-1/16-12 P2B1 Multi-function valve

G97 End cap screw B71 O-ring plug

B82 O-ring plug
9/16-18
9/16-18
B83 Speed sensor /
G50 O-ring plug O-ring plug
9/16-18 9/16-18

G49 O-ring plug

9/16-18

G48 O-ring plug

9/16-18

N37 Filter plug assembly

F111 / F211 Servo cylinder screw E60 Side cover screw N10 Filter reducer assembly
P106 189E
P2A1 Multi-function valve


 +<'5267$7,&)285:+((/'5,9(
*HQHUDO

The hydrostatic four-wheel drive of the combine is implemented with radial piston motors C
positioned on the rear wheel hubs, fig. H44. The oil into the motors is taken from normal
hydrostatic traction transmission A of the combine. Thus the rear wheel motors are parallel
connected with the main traction.
Four-wheel drive is switched on by means of two electro-controlled valves. Valve B connects the
work lines of the motors onto the corresponding work lines of the main traction. Valve D controls
the dummy coupling of the motors. The return oil is directed to the cooler circuit from connector E.

The four-wheel drive control switch is a two-phase rocker arm switch on the instrument panel.

About 20 % of the main traction can be transferred onto the rear axle in four-wheel drive, and
driving speed will drop about 20 %. It does not actually push the combine, but produces
approximately the same amount of power as needed to keep the rear wheels moving.

7HFKQLFDO6SHFLILFDWLRQV
Hydraulic motor Sampo Hydraulics
Type BBC 01
Rotation Volume 783 cm3
Main Valve Rexroth 4WEH16
Second Valve Rexroth 4WE6

6-47
)XQFWLRQ

With four-wheel drive switched

off, fig. H45, valves B and D are
de-energized. Charge pressure
(dark blue line, approx. 30 bar)
from the traction pump is directed
into the hub motor casing and the
hub motor work circuit is directed
to the main traction drain line.
The charge pressure (light blue
line, 58 bar) that rises in the
casing will press all the work
pistons to the centre, off the cam
ring and will release the motor
(and the rear wheel) to rotate
freely. The oil pressed out of the
work circuit will flow into the drain
circuit. (green line, 13 bar).
In the valve connection, between
the base and the valve section,
there is a 1-mm restrictor to
prevent the charge pressure in the main traction from dropping suddenly when disconnected. (0.8 l
of oil will flow into motor casings.)

With four-wheel drive switched

on, fig. H46, valves B and D are
energized. Main valve B will
connect the work lines (red line,
0420 bar) and the hub motors
will get pressurized oil. Second
valve D will connect the hub
motor casing line to the drain
line in the main traction (green
line, 13 bar).

The motors are of the cam ring

type. The cylinder block is fixed
onto the motor body and the
cam ring rotates with the shaft.

A switch in the cab controls

four-wheel drive. When the
valves are de-energized, the
drive is switched off. When the
valves are energized, the drive
will be on. This can be done
with the combine moving.

6-48
5(3$,5$1'5(3/$&(0(172)+8%02725fig.H47

It is not advisable to repair 4WD hub motors in the field or in unauthorized service shops. All
service should be done at the factory or in authorized repair shops.

As there is usually no time to send the motor to be repaired during the harvesting season, the
quickest solution is to install a so-called replacement motor, which can be ordered from the factory.

Lift the combine up from

beneath the rear axle, support
securely and remove the rear
wheel.

Unscrew 6 hub motor screws

B, and lift the motor off its bolt
plate.

Remove the 3 O-rings.

Protect the oil channels in the

bolt plate if a new motor is not
fitted immediately.

Refitting is done in the opposite

order.

Check that the O-ring grooves

and the contact surfaces are
undamaged and clean.

Fit new O-rings and tighten them securely.

Remove the protective plugs of the new motor and refit the motor.

Tighten the fixing screws crossways in turns to 275 Nm.

Fit the rear wheel and tighten rim screws E to 515 Nm.

Note! Do not over-grease grease nipple F.

6-49
 (1*$*(0(17+<'5$8/,&6

The combine belt engagements, such as the threshing mechanism, the chopper, the cutting table,
the grain tank unloading and the gear lock are controlled by low-pressure hydraulics. The oil
obtained from charge circuit connector M3 of the traction hydraulic pump is directed through valves
A to working cylinders, which engage or disengage the belt drives.

M3

H51


)XQFWLRQ fig. H51
When the diesel engine has started, oil pressure in the charge circuit of the traction hydraulic pump rises to
approx. 24 bar and flows from connector M3 both to the valves and to the piston rod side of the cylinders.
The grain tank unloading and the gear lock function whether the other functions are on or off.

The threshing mechanism, the chopper and the cutting table are engaged in the following way:
When the threshing mechanism electric switch is pressed, chopper valve Y7 will open (if the chopper guide
plate in the straw hood is in the to the chopper position) and the chopper will start.
Pressure sensor S56 detects an increase in pressure in the cylinder line and opens valve Y9, which will start
the threshing mechanism.
If the chopper guide plate is in the not to the chopper position), its limit switch will pass pressure sensor
S56. The cutting table can be started when pressure sensor S52 detects that the threshing mechanism has
started. Pressure sensor S49 detects the table mode and allows engagement of the table reverse only if the
table is disengaged.

6-50

6HUYLFHDQGUHSDLU

The valves in engagement

hydraulics fig. H53.

Section contains pressure

connector P and tank connector T.

A valve 2 inside a section is not

repaired in case of breakage, but
the whole valve is replaced.











5HSODFHPHQWRIHQJDJHPHQWF\OLQGHUSDFNLQJ

End A of the double-acting cylinder, fig. H54, is threaded into the cylinder liner.
Remove the cylinder off the combine and plug open hoses.
Fasten the cylinder to a bench vice. Do not press too hard in the middle of the cylinder liner!
Use a pipe wrench to turn end A open, pull the piston out of the cylinder and the end off the piston.
Remove old packing rings and check that the grooves are undamaged and clean.
Fit new packing. The piston packing includes O-ring B and profile ring C. Fit ring packing D. Note
the correct fitting direction.
Fit O-ring E and oil all the packing with clean oil before tightening end A again.

6-51

5HSODFHPHQWRISDFNLQJLQFXWWLQJWDEOHFOXWFK


Clean around the clutch and disconnect the hydraulic hose from connector G and plug the hose.

Open rotating connector body A, fig. H55, drive nuts B and spacer C.

Lever hydraulic unit D off pipe shaft E with two screwdrivers against belt pulley H.

Push piston M out of the cylinder, after which piston packing K and scraper ring L can be replaced.
Grease the packing before fitting.

Replace packing T noting packing positions in the grooves.

Make sure that the sharp rims of the pipe shaft do not damage packing T when the hydraulic unit is
carefully refitted onto the pipe shaft.

Fit spacer C and tighten inner drive nut B all the way before locking it with another nut.

Check the O-ring of connector body A before fitting.

6-52
5RWDWLRQK\GUDXOLFV
The chaff spreader and the pick-up reel are rotated by series-connected hydraulic motors of the
gerotor type. Oil is obtained from the outermost working hydraulic pump. The chaff spreader is
engaged together with the threshing mechanism, and the pick-up reel is engaged from the cutting
table switch.

H56
C

B K
E
D

M
J
A


)XQFWLRQ

When the diesel engine has started, but the threshing mechanism is not running yet, oil circulates
from pump A, fig. H56, to valve section B of the chaff spreader through its free flow valve Y12 and
further on through valves K of the pick-up reel to the tank line.

Spring loaded check valve E controls that the pick-up reel does not run during free flow.

When the threshing mechanism switch is pressed, it also switches on valve Y12 of the chaff
spreader, which closes the free flow and forces the oil to rotate gerotor motors C.

In case of overload, relief valve D opens if oil pressure exceeds 125 bar. Maximum pressure can
be adjusted. The measurement is made quick connection of chaff spreader being uncoupled. One
turn of the adjusting screw corresponds to about 30 bar pressure change. Adjusting is carried out
through the port M. This port has a G" thread.

When the cutting table switch is pressed, it switches on proportional valve Y11 of the pick-up reel
at the set value.

The faster the speed is adjusted, the more valve Y11 is open. When reversing cutting table, also
pick-up reel is reversing. In reverse valve Y11 switches to the rear value and valve Y19 reverse the
direction of motor F.

6-53
In the relief valve J is the control line, which provides always the same differential pressure over
the valve Y11. This avoids the effect of the external load to rotation speed. When valve Y11 is
closed, the relief valve J operates as a free flow.

The maximum pick-up reel load is adjusted at relief valve J, whose preset pressure is approx. 75
bar. The pressure can be measured from the plug H next to the relief valve. Measuring port thread
is G". Measurement is carried out quick coupling of the table being uncoupled.

*HURWRUPRWRUVare not repaired out in the field, but a replacement component is fitted.

Chaff spreader UHOLHIYDOYHILJ+ is adjusted by unlocking locking nut N and turning adjusting
screw S.

Valvescontain a replaceable electric coil and valve cartridge.

6-54
 2,/6(59,&(81,7

:RUNLQJK\GUDXOLFSXPSV
are of a gearwheel type.

Rotation volume 11 cm
Output 26 l/min

Replacement of packing, fig. H61

Disconnect and plug pressure hoses A.

Disconnect suction hose B with its flange

and plug.

Unlock pump screws C.

The pumps are assembled with sections

joined with screws D. Mark the sections in a
suitable way before unlocking screws D.

Replace the O-ring packing between the

sections.

Ensure O-rings F in holder E are fitted

correctly.

Push shaft packing G out from the inside

of the flange.

Fit new shaft packing and lock with new

locking plate H.

Assemble the pump sections.

Fit new O-ring J, after which the pumps

are attached to the traction hydraulic pump.

Tighten screws C to 50 Nm.

6-55


2LOFKDQJH

The best time to change hydraulic oil is a

warm summer day after winter storage.
This will ensure that any condensed water
collected during the winter is drained from
the oil tank.

Do not start the engine, but drain the

hydraulic oil into a pan.

Open filter cover A, fig. H62, and remove

oil filter cartridge B.

Fit a new filter cartridge and fill the tank

with 22 litres of new oil, Tellus T46 (Shell),
Univis 46 (Esso), or similar.

Start the engine and idle for approx. 10

min.

Note!
No hydraulic functions must be used
during this time,

but allow the oil to circulate through the

new filter long enough to ensure the oil is
clean enough for the hydraulic system.

8VHGRLODQGILOWHUVDUHKD]DUGRXV
ZDVWHZKLFKPXVWEHGLVSRVHGRILQDQ
DSSURSULDWHPDQQHU

6-56
 7 ELECTRICAL SYSTEM

General Description

The combine has 12V voltage in the electrical system. The engine is equipped with a 200A
alternating-current generator. The battery is earthed to the body.

Do not turn the master switch to the 0 position with the engine running except as a
necessary precaution as this may damage the generator.

Fuses
The main fuses are housed in the electricity distribution centre on the left side of the combine
(cab 150A, rear distribution centre 40A), and there is one main fuse in the cab for the ignition
lock (30A).
Engines equipped with electric preheating have a 250A fuse on the heater supply cable in the
electricity distribution centre.
The cab fuses are on a circuit card and there are some fuses in the rear distribution centre.

On relays
A number of functions are controlled by contact relays. Most relays are housed on a circuit card
inside the instrument panel. Next to the cab fan there are some relays connected with the
fan/AC control.
The relays required for the diesel engine are housed in a safety casing in the regulator unit in
the electricity distribution centre.
The electricity distribution centre also has the start-up control relay and the relay for the
rearmost working lights.

Hydraulic control
The valves in working hydraulics are electrically controlled. To prevent unintentional use, the
control system is equipped with a safety function that does not allow control of a hydraulic valve
until the engine generator has started charging.

Electric reverse of cutting mechanism

The crop elevator has a hydraulic motor controlled with a switch on the instrument panel. This
device works when the engine is running and the cutting mechanism is disengaged.

Control of threshing mechanism

The valves of the threshing mechanism are electrically controlled. To prevent unintentional use,
the control system is equipped with a safety function that does not allow control of a hydraulic
valve until the engine is running, and the on/off knob of the threshing mechanism has been
pressed to its lower position.

7-1
Functioning hierarchy of electric controls
Switching on of electric controls is arranged in a way that guarantees safe combine operations.
The following specifies on which conditions the functions can be switched on.

Starting of engine:
The master switch is in its "on" position.
The traction lever is in its mid position.

Engaging of threshing mechanism:

The engine is running.
The safety switch is raised up.
The chopper comes on = the pressure sensor of the chopper engagement cylinder connects the
control current (if the straw guiding plate is turned to the chopper position).
If the yellow press switch is in its up position, press it down.

Engaging of chopper:
The chopper comes on when the threshing mechanism is turned on if the limit switches for the
straw guiding plate connect the control current.

Engaging of cutting table:

The threshing mechanism is running = the pressure sensor of the threshing mechanism
engagement cylinder connects the control current.
If the yellow press switch is in its up position, press it down.

Engaging of pick-up reel:

The pick-up reel comes on when the table is turned on.
Gets its control current from the cutting table electric control.

Engaging of vertical knife:

The vertical knife comes on when the table is turned on if the knife has been switched on from
the control switch.
The vertical knife gets its control current from the cutting table electric control.

Engaging of table reverse:

The engine is running.
The cutting mechanism has been stopped.

Engaging of unloading:
The engine is running.
The safety switch is raised up.

Turning of unloading pipe:

The engine is running.
The safety switch is raised up.

7-2
Cutting table lifting and lowering, pick-up reel lifting and lowering, pick-up reel fore/aft
and cutting table side tilt:
The engine is running.

Pick-up reel speed adjustment:

The cutting table is running.

Starting of chaff spreader:

The chaff spreader comes on when the threshing mechanism is started.

Rotating becon:
0, automatic and the on position.
On automatic the rotating beacon turns on when the grain tank is half full.

Symbols

A- Battery
B- Lamp
C- Relay
D- Valve
E- Fuse
F- Led

7-3
CABLING

1 9711520 Collects everything from the top part of the cab

2 9697589 Earths the cab
3 9711514 Lights of the light pontoon
4 9711515 Working lights
5 9711503 Cutting table valves
6 9710505 Under cabin
7 9711518 Instrument panel
8 9711505 AHC
9 9711517 LH connector

7-4
1 9711512 Threshing machine
2 9711519 Connects the cab and the rear distribution centre
3 9711509 Engine
4 9711510 Left flank from the electricity distribution centre rearward

7-5
 1 9711507 Adjustment motors
2 9701168 Charger - Start
3 9703576 Engine Earth
4 9697579 Battery
5 9707127 Battery
6 9697578 Battery (-)
7 9697589 Earths the centre
8 9711521 Main Switch
9 9710519 Rear lights
10 9711513 Back central
11 9707136 4WD
12 9707138 Straw blender motors

7-6
1 9710519 Rear lights
2 9707128 Grain tank light
3 9711511 Grain tank
4 9701174 Grain tank sensor
5 9707111 Arm rest

7-7
 Fuses and relays

E10

7-8
Fuses and relays

Fuses F1 F42 are housed on a circuit card, fig. E10, under the instrument panel. Fuses
F100 F116 are housed in the rear distribution centre, fig. E11, in a fuse box under the
left-side side guard.

The main fuses are also housed in the rear distribution centre under the left-side side
guard. Control relays for different functions are housed on a circuit card under the
instrument panel. The relay functions and positioning are shown on the instruction sticker
on the inside of the service door on the instrument panel.

CABLE KITT START-

CABLE KITT INTERMEDIATE CABLE

CABLE KITT ENGINE

CABLE KITT THRESHING MACHINE

CABLE KITT REAR

CABLE KITT REVERSE

CABLE KITT
BATTERY+/CENTER

E11

7-9
Fuses Relays
1F 150A Main fuse Relays PCB
2F K1 Relay, diesel running
3F 30A Main fuse K2 Relay, +15(preconcave adjustment), graintank cover
4F 150A Main fuse, vertical knife K3 Relay, cabin blower
5F 40A Main fuse,/ electrical box K4 Relay, gear lock
6F 250A Fuse, Grid heater K5 Relay,option
7F 50A Fuse, vertical knife K6 RPM guard relay, CSP drum
8F 50A Fuse, vertical knife K7 Relay, 4wd
K8 Relay, blinkers
Fuse PCB K9 Relay, AC compressor
F1 3A mirror K10 Relay, reverse
F2 10A A/C, K11 table off, seat
F3 20A Fuse, lightswitch K12 unloading off seat
F4 15A Hazard blinker K13 Relay, rotating beacon
F5 10A Air suspended seat., cabin light, K14 Relay, treshing unit on
F6 20A AC, fan K15 Relay, treshing machinery safety
F7 20A Windscreen motor K16 Relay, cuttingtable reset
F8 20A Reverse alarm, indicator and backlight, K17 Relay, Treshin unit reset
workinligts K18 Relay, unloading off
F9 7,5A +12V output in cabin K19 Relay, workinlight front
F10 5A LH, engine display, rear camera K20 Relay, Pick up reel back/forward
F11 10A Blinker K21 Relay, cuttingtable on
F12 3A Engine +12V ignition key +15 K22 Relay, treshing unit on
F13 15A Gauges K23 Relay, chopper on
F14 25A Gear lock, not used K24 Relay, unloading on
F15 MAX 25A option K25 Relay, workinlight front
F16 15A Treshing machinery K26 Relay, Pick up reel back/forward
F17 20A Workinlights, front K27 Relay, graintank full (LH 500)
F18 20A Workinlights, front K28 Relay, DHC cutting table down
F19 20A Rotating beacon K29 Relay, graintank 3/4 ( LH500)
F20 25A Treshing drum and fan speed K30 Relay, DHC cutting table up
F21 15A 4WD, diff.lock K31 Relay, DHC cutting table stop point
F22 20A Concave adjustment, graintank cover K32 Relay, pick-up reel --
(auto reset funktion) K33 Relay, DHC active
F23 25A AHC, COBO K34 Relay, pick-up reel+++
F24 5A S0,S50,S51,S53,S57,K7control
F25 5A K32,K34,H53 control Instrument panel
F26 25A AHC K35 RPM guard relay, return bottomauger
F27 7,5A K2,S37,S38 control K36 RPM guard relay, returnauger
F28 7,5A Radio K37 RPM guard relay, grainelevator
F29 7,5A Radio, R position K200 Controller joystick control
F30 10A Brakelights
F31 5A K21,K13,K27 control Cabin roof
F32 7,5A Blinker left K42 thermostate
F33 7,5A Blinker right K43 Relay, cabin blower
F34 7,5A Lowbeam left K44 Relay, AC blower
F35 7,5A Lowbeam right K45 Relay, cabin blower position 4
F36 7,5A Fuse, high beam left
F37 7,5A Fuse, high beam right Rear switchboard
F38 7,5A Parkinglight left, front and rear, K100 relay,chopper spreader adjustment
F39 7,5A Parkinglight right, front and rear, K101 relay,chopper spreader adjustment
F40 7,5A Glow plug (not used) K102 Relay, nox sensors, waste gate
F41 3A Start K103 Relay, workinglight rear straw room option
F42 10A Guard relays and DHC K104 Relay, urea main heater
Fuse Electr. box rear K105 Relay, workinglight rear left/right side,unloading
F100 20A Nox sensors, waste gate K106 Relay, start
F101 15A Workinglights optio K107 Relay, Diesel supply
F102 25A Straw spreader adjustment K108
F103 15A Workinglight, sieve area , K109 relay,chopper spreader adjustment
F104 25A Worklights, stairs,left side,unloading K110 relay,chopper spreader adjustment
F105 25A Start
F106 20A +12V machine back part, workinglight
sidecovers
F107 5A Diesel
F108
F109
F110
F112 25A Diesel
F113 10A Nox sensors engine
F114 10A Waste gate
F115 15A Radio, memory,main switch
F116 15A heater urea module

7-10
Engine
Fuses are located in fusebox of the rear switchboard (fig. E11) under left side guard.
The engine control unit is attached to the engine on the side of the grain tank.

Do not fit an oversized fuse, as it may damage the cables and the respective electrical devices.
If a fuse blows on
the same location repeatedly, find the reason for it and remedy it.

Sensors of electric gauges

The sensors of electric speed indicators (drive

speed and fan and cylinder revcounters) are
housed with the gears and at shaft ends. To
guarantee faultless sensor function, distance a
between the sensor and the pulse plate (or
gearwheel) is 1 0.5 mm. (Fig. E13) If
necessary, adjust at the sensor fixing nuts. In no
condition must the sensor touch the rotating
pulse plate. Max. torque 5 Nm.

7-11
Sensor testing

The condition of the drive speed, threshing cylinder and fan sensors can be tested, fig. 13a.

You need sensor A to be tested, testing device B, adapter cable C and suitable metal object D,
a paper clip, for example.

Check first that the tester batteries are intact by pressing tester switch E with a suitable spike. If
green light F comes on, and there is a beep, the tester is intact.

Connect adapter and sensor connectors G and H and the adapter cable ends to the tester so
that the blue cable is connected to the minus pole (-), the black cable to the IN pole and the
brown cable to the plus pole (+).
Touch the sensor end with a metal object. If the green light comes on, and there is a beep, the
sensor is intact.

7-12
Speed sensor
Threshing monitor have speed sensors on a
number of different shafts. The sensors are of the
Hall type, which need a magnet attached to a
rotating shaft to operate. These sensors do not
require an exact installation distance. A suitable
distance is 3-8mm, fig. E14.

7-13
Navigation in the wiring diagram

.
All the pages of the wiring diagram are numbered (horizontal) and alphabetized (vertical).
This helps you to navigate from page to page as shown in the example above.

7-14
 ELECTRICAL PARTS
Comia 10/12
POSITION Description PAGE

B1 Temperature sensor, hydraulic oil 5

B2 Fuel level sensor 10
B3 Temperature sensor, diesel 10
B4 Sensor, return material amount 11
B5 Loss sensor, sieves left 11
B6 Loss sensor, sieves right 11
B7 Loss sensor, straw walkers left 11
B8 Loss sensor, staw walkers right 11
B9 Rotary position sensor, concave 10
B10 Rotary position sensor, pre-concave 10
B11 Potentiometer, skid left (AHC) 16,20
B12 Potentiometer, skid right (AHC) 16,20
B13 Potentiometer, feeder height (AHC) 16,20
B14 Pressuresensor, tablelifthydraulics (AHC) 16,20
B15 Potentiometer, presetheight (AHC) 16,20
B16 Potentiometer, contourheight (AHC) 16,20
B17 Grid heater 18
B18 Nox sensor, Downstream 18
B19 Nox sensor, Upstream 18
B20 Environmental temperature sensor 18
B21 Urea tank level and temperature sensor 18
B22 Exhaust gas temp, sensor,upstream 18
B23 Exhaust gas temp, sensor,downstream 18
B24 Exhaust gas temp, sensor, 18
B25

C1 Capacitor,
C2 100 nF Capacitor,
C3 100 F Capacitor,
C4 100 nF Capacitor,
C5 100 F Capacitor,
C6 10 F Capacitor, limitswitch of seat 14

E1 Glow plug ( Not used) 3

E2 Blinker, left front 4
E3 Blinker, left rear 4
E4 Blinker, left rear option 4
E5 Blinker, left tabletrailer 4
E6 Blinker, right tabletrailer 4
E7 Blinker, right rear option 4
E8 Blinker, right rear 4
E9 Blinker, right front 4
E10 Drivelight, left low beam 4
E11 Drivelight, right low beam 4
E12 Drivelight, left high beam 4
E13 Drivelight, right high beam 4
E14 Interior light, cabin 6
E15 Workinglight, graintank 8
E16 Workinglight, right side stairs 7
E17 Workinglight, unloading 7
E18 Workinglight, left side 7
E19 Workinglight, straw hood option 7
E20 Workinglight, right side option 6
E21 Workinglight, left side 7
E22 Workinglight,left 7
E23 Workinglight, right side 7

7-15
E24 Workinglight, right side 7
E25 Workinglight, left down 7
E26 Workinglight, right down 7
E27 Workinglight, sieve area 7
E28 Workinglight, LEFT option 6
E29 Rotating beacon, left front 7
E30 Rotating beacon, rear 7
E31 Rotating beacon,right front 7

E33 Brakelight, left 8

E34 Brakelight, left option 8
E35 Brakelight, left trailer 8
E36 Brakelight, tabletrailer right 8
E37 Brakelight, right option 8
E38 Brakelight, right 8
E39 Parkinglight, left front 8
E40 Rearlight, left 8
E41 Rearlight, left option 8
E42 Rearlight, tabletrailer left 8
E43 Rearlight,right tabletrailer 8
E44 Rearlight, right option 8
E45 Rearlight, right 8
E46 Light, vehicle tag 8
E47 Parkinglight, right front 8
E48 Working light, unloading 7
E49 Workinlight, 7
E50 workinglight 7

MAIN FUSE
1F 150A Main fuse 3
2F
3F 30A Main fuse 3
4F 150A Main fuse, vertical knife 3
5F 40A Main fuse,/ electrical box 3
6F 250A Fuse, Grid heater 3
7F 50A Fuse, vertical knife 20
8F 50A Fuse, vertical knife 20
Fuse PCB
F1 3A mirror 6
F2 10A A/C, 9
F3 20A Fuse, lightswitch 4
F4 15A Hazard blinker 4
F5 10A Air suspended seat., cabin light, 6
F6 20A AC, fan 9
F7 20A Windscreen motor 9
F8 20A Reverse alarm, indicator and backlight, workinligts 4
F9 7,5A +12V output in cabin 6
F10 5A LH, engine display, rear camera 11
F11 10A Blinker 4
F12 3A engine +12V ignition key +15 18
F13 15A Gauges 10
F14 25A Gear lock, not used 12
F15 MAX 25A option 17
F16 15A Treshing machinery 15
F17 20A Workinlights, front 7
F18 20A Workinlights, front 7
F19 20A Rotating beacon 7
F20 25A Treshing drum and fan speed 13
F21 15A 4WD, diff.lock 9
F22 25A Concave adjustment, graintank cover(auto reset funktion) 13
F23 25A AHC, COBO 12
F24 5A S0,S50,S51,S53,S57,K7control 12
F25 5A K32,K34,H53 control 12
F26 25A AHC 20

7-16
F27 7,5A K2,S37,S38 control 13
F28 7,5A Radio 3
F29 7,5A Radio, R position 3
F30 10A Brakelights 8
F31 5A K21,K13,K27 control 12
F32 7,5A Blinker left 4
F33 7,5A Blinker right 4
F34 7,5A Lowbeam left 4
F35 7,5A Lowbeam right 4
F36 7,5A Fuse, high beam left 4
F37 7,5A Fuse, high beam right 4
F38 7,5A Parkinglight left, front and rear, 8
F39 7,5A Parkinglight right, front and rear, 8
F40 7,5A Glow plug (not used) 3
F41 3A Start 3
F42 10A Guard relays and DHC 13

Fuse Rear central

F100 20A Nox sensors, waste gate 18
F101 15A Workinglights optio 7
F102 25A Straw spreader adjustment 17
F103 15A Workinglight, sieve area , 7
F104 25A Worklights, stairs,left side,unloading 7
F105 25A Start 3
F106 20A +12V machine back part, workinglight sidecovers 6
F107 5A Diesel 18
F108
F109
F110
F112 25A Diesel 18
F113 10A Nox sensors engine 18
F114 10A Waste gate 18
F115 15A Radio, memory,main switch 3
F116 15A heater urea module 18
F117

G1 Battery 3
G2 Alternator 3

H1 Backlight, reverse 15
H2 Indicator lamp, hazard flasher 4
H3 Indicator lamp, blinkers 4
H4 Signal lamp, high beam 4
H5 Horn 4
H6 Reverse beeper 4
H7 Backlight, throttle 4
H8 Backlight,LH Aut/Man 4
H9 Indicator lamp, charging (alternator) 5
H10 Alarm beeper 5
H11 Indicator lamp, unloading auger turning 5
H12 Indicator lamp, grainelevator alert(not used, if loss monitor) 5
H13 Indicator lamp, return bottomauger alert(not used, if loss monitor) 5
H14 Indicator lamp, returnauger alert(not used, if loss monitor) 5
H15 Indicator lamp, straw blockage 5
H16 Indicator lamp, graintank full 5
H17 Indicator lamp, oil pressure(Not used, 4F) 5
H18 Indicator lamp, diesel diagnostics 5
H19 Indicator lamp, diesel coolant temperature(not used, 4F) 5
H20 Indicator lamp, diesel aircleaner(not used, 4F) 5
H21 Indicator lamp, parkingbrake 5
H22 Indicator lamp, hydraulicfilter 5
H23 Indicator lamp, hydraulicoil temperature 5
H24 Indicator lamp, csp blockage (Not used) 5
H25 Indicator lamp, grid heater 5

7-17
H26 Indicator lamp, higher than 4m 5
H27 Indicator lamp, cuttingtable in earth 5
H28 Indicator lamp, graintank 1/2 5
H29 Indicator light, electrical mainswitch(front) 3
H30 Backlight, workinglights rear 7
H31 Backlight, workinglights front 7
H32 Backlight, rotating beacon 17
H33 Indicator lamp, differential lock 9
H34 Indicator light, electrical mainswitch 3
H35 backlight windscreen 6
H36 Backlight, AC panel 6
H37 Backlight, AC panel 6
H38 Indicator lamp, 4WD 9
H39 Backlight, 4WD 9
H40 Backlight, fuel level gauge 10
H41 Backlight, coolant temperature gauge 10

H43 Backlight, concave adjustment 7

H44 Backlight, preconcave adjustment 7
H45 Backlight ,straw spreader adjustment left 17
H46 Backlight ,straw spreader adjustment right 17
H47 Backlight, treshing unit rpm 4
H48 Backlight fan rpm 4
H49 Indicator lamp, chopper on 5
H50 Indicator lamp, chopper off not used 5
H51 Indicator lamp, unloading 14
H52 Backlight, graintank cover 13
H53 Backlight, AHC 16,20
H54 Backlight, dhc 17
H55 Backlight, dhc 17
H56 backlight, vertical knife left 19
H57 backlight, vertical knife right 19

PCB
K1 Relay, diesel running 12
K2 Relay, +15(preconcave adjustment), graintank cover 13
K3 Relay, cabin blower 9
K4 Relay, gear lock 12
K5 Relay,option 17
K6 RPM guard relay, CSP drum 13
K7 Relay, 4wd 9
K8 Relay, blinkers 4
K9 Relay, AC compressor 9
K10 Relay, reverse 15
K11 table off, seat 14
K12 unloading off seat 14
K13 Relay, rotating beacon 7,12
K14 Relay, treshing unit on 13
K15 Relay, treshing machinery safety 15,14
K16 Relay, cuttingtable reset 15,14
K17 Relay, Treshin unit reset 15,14
K18 Relay, unloading off 15,14
K19 Relay, workinlight front 7
K20 Relay, Pick up reel back/forward 17
K21 Relay, cuttingtable on 15,14
K22 Relay, treshing unit on 15,14
K23 Relay, chopper on 15,14
K24 Relay, unloading on 15,14
K25 Relay, workinlight front 7
K26 Relay, Pick up reel back/forward 17
K27 Relay, graintank full (LH 500) 11,12
K28 Relay, DHC cutting table down 17
K29 Relay, graintank 3/4 ( LH500) 11,12
K30 Relay, DHC cutting table up 17

7-18
K31 Relay, DHC cutting table stop point 17
K32 Relay, pick-up reel -- 17
K33 Relay, DHC active 17
K34 Relay, pick-up reel+++ 17
Instrument panel
K35 RPM guard relay, return bottomauger 13
K36 RPM guard relay, returnauger 13
K37 RPM guard relay, grainelevator 13

K200 Controller joystick control 16,17

Cabin roof
K42 thermostate 9
K43 Relay, cabin blower 9
K44 Relay, AC blower 9
K45 Relay, cabin blower position 4 9

Rear central

K100 relay,chopper spreader adjustment 17

K101 relay,chopper spreader adjustment 17
K102 Relay, nox sensors, waste gate 18
K103 Relay, workinglight rear straw room option 7
K104 Relay, urea main heater 18
K105 Relay, workinglight rear left/right side,unloading 7
K106 Relay, start 3
K107 Relay, Diesel supply 18
K108
K109 relay,chopper spreader adjustment 17
K110 relay,chopper spreader adjustment 17

k63 Solenoid, grid heater 18

K64 Solenoid, vertical knife left 19
K65 solenoid, vertical knife right 19

M1 Start motor 3
M2
M3 air seat 6
M4 Cabin blower 9
M5 Wndshield washer 9
M6 Windshield wiper 9
M7 Straw blender adjustment left 17
M8 Straw blender adjustment right 17
M9 Uppersieve 8
M10 Lowersieve 8
M11 Treshingdrum variator 13
M12 fan variator 13
M13 Concave adjustment 13
M14 Preconcave adjustment 13
M15 Craintank cover 13
M16 Craintank cover 13
M17
M18
M19 Vertical cnife, left 19
M20 Vertical knife, right 19
M21
M22

P1 Indicator panel 5
P2 Gauge, driving speed 10
P3 Gauge, fan/treshingdrum 10
P4 Gauge, fuel level 10

7-19
P5 Gauge, coolant temperature 10
P6 Treshing monitor 11
P7 Rear camera monitoring 10
P8 Display, diesel 10
P9 Display, sieve adjustment 8
P10 Gauge, concaves 10

Q1 Electric main switch 3

R1 Resistor 1k ohm (LH500) 11

R2 Resistor 1k ohm throttle 18
R3 Resistor 1k ohm throttle 18
R4 Resistor 1k ohm (LH 500) 11
R6 resistor 18

S0 Switch, road switch 14,16,20

S1 Igniton switch 3
S2 Switch, control for electric mainswitch rear 3
S3 Switch, control for electric mainswitch front 3
S4 Switch, avoid starting 3
S5 Switch, reverse 15
S6 Switch, emergency flasher 4
S7 Switch, light 4
S8 Switch, reverse beeper 4
S9 Switch, 4wd 9
S10 Limitswitch, unloadingauger in 5
S11 Limitswitch, strawhoodalert 5
S12 Switch, workinlight rear 7
S13 Switch, workinlight front 7
S14 Pressure switch,hydraulicoil filter 5
S15 Switch, rotating beacon 7
S16 Pressure switch, cutting table on the ground 5
S17 Levelswitch, graintank 3/4 12
S18 Levelswitch, graintank 1/1 12
S19 Switch, cabin light 6
S20 Switch, gearbox /lock/lightener 12
S21 Vacuum switch, diesel airfilter 18
S22 Limitswitch, parkingbrake 5
S23 Switch, differential lock(not used) 9
S24 Levelswitch, graintank over 4M 5
S25 Switch, brake lights 8
S26 Limit switch, unloadingauger out 5
S27 Pressureswitch, A/C 9
S28 Switch, AC 9
S29 Switch, fan 9
S30 Switch, windshieldwiper 9
S31 Inductive sensor, driving speed 10
S32 Inductive sensor, treshingdrum speed 10
S33 Inductive sensor, fan speed 10
S34 Hall sensor, chopper rpm 11
S35 Hall sensor, Traw walker rpm 11
S36 Switch, pick-up reel Auto/Man 11
S37 Switch, straw blender adjustment left 17
S38 Switch, straw blender adjustment right 17
S39 Hall sensor, bottomauger 11
S40 Hall sensor, returnauger 11
S41 Hall sensor, grainelevator 11
S42 Magneticswitch, header height 11
S43 Inductive sensor, pick-up reel speed 11
S44 Hall sensor, feeder elevator speed 11
S45 Namur-sensor, straw drum 13
S46 Namur-sensor, bottomauger 13
S47 Namur-sensor, returnauger 13
S48 Namur-sensor, grainelevator 13

7-20
S49 pressureswitch cutting table 11
S50 Limit switch, seat 14
S51 Switch, cuttingtable on/off 14
S52 Pressureswitch, treshing unit 14
S53 Switch, treshing unit on/off 14
S54 Limit switch, chopper 14
S55 Limit switch, chopper 14
S56 Limit switch, chopper 14
S57 Switch, unloading on/off 14
S58 Not used Limit switch, differential lock
S59 Switch, treshing drum speed 13
S60 Switch, fan speed 13

S62 Switch, concave adjustment 13

S63 Switch, pre-concave adjustment 13
S64 Graintank cover 13

S66 Switch, cuttingtable down 16,20

S67 Switch, cuttingtable up 16,20
S68 Switch, pickupreel down 16,20
S69 Switch, pickupreel up 16,20
S70 Switch, pickupreel forward 16,20
S71 Switch, pickupreel backward 16,20
S72 Switch, unloadingtube in 16,20
S73 Switch, unloadingtube out 16,20
S74 Switch, pickupreel speed adjustment++++ 16,20
S75 Switch, pickupreel speed adjustment ---- 16,20
S76 Switch, sift 16,20
S77 Not used Switch, DHC on/off and PWM
S78 Not used Magneticswitch, DHC activated
S79 Not used Magneticswitch, DHC stop
S80 Switch, AHC 16,20
S81 Switch, throttle 18

S84 switch, vertical knife left 19

S85 switch, vertical knife right 19
S86 Switch, mirror 6
S87 Hall Sensor, CSP 11

PCB
V1 diode, radio 3
V2 diode, radio 3
V3 diode, seat switch 14
V4 diode, seat switch 14
V5 not used 12
V6 diode, reverce control 15
V7 diode, table check 14
V8 diode, table grip 15
V9 diode, threshing grip 15
V10 diode, reverce control 15
V11 diode, DHC 17
V12 diode, threshing check 14
V13 diode, unloading grip 15
V14 diode, DHC 17
V15 diode, alternator D+ 3
V16 15
V17 15
V18 15
V19 diode, chopper switch 14
V20 diode, chopper pressure switch 14
V21 diode, threshing check 14
V22 diode, reverse freeflow valve 15
V23 diode, threshing check 14

7-21
V24 diode, chopper switch 14
V25 diode, straw compartment blockage 5

Cabin roof
V28 diode, fan 9
V29 diode, fan 9
V30 diode, fan 9
V31 diode, fan 9
V50 Diodi, presetheight (AHC) 16,20
V51 Diode, contourheight (AHC) 16,20
Rear
V32 diode, diesel diagnostic light 18
V33 diode, diesel diagnostic light 18
V34 diode, diesel 3B urea 18

Y1 Coil, freeflow valve 16,20

Y2.1 Coil, cuttingtablevalve up 16,20
Y2.2 Coil, cuttingtablevalve down 16,20
Y3.1 Coil, pickupreelvalve up 16,20
Y3.2 Coil, pickupreelvalve down 16,20
Y4.1 Coil, pickupreelvalve front 16,20
Y4.2 Coil, pickupreelvalve back 16,20
Y5.1 Coil, unloadingaugervalve in 16,20
Y5.2 Coil, unloadingaugervalve out 16,20
Y6.1 Coil, tabletiltvalve right 16,20
Y6.2 Coil, tabletiltvalve left 16,20
Y7 Coil, chopper 15
Y8 Coil, feedervalve/cuttingtable on 15
Y9 Coil, treshingunit on 15
Y10 Coil, unloadingvalve on 15
Y11 Coil, pickupreelvalve rpm 16,20
Y12 Coil, chaffspreadervalve on 15
Y13 Coil, reverse 15
Y14 Coil, A/C compressor on 9
Y15 Coil, 4wd valve on 9
Y16 Coil, 4wd valve on 9
Y17
Y18 gearbox lightener 12
Y19 Coil, pickupreel reverse 15

7-22
 ELECTRICAL PARTS
Comia 10/12
POSITION Description PAGE

Circuit card connectors

Xk1 Circuit card, current

Xk2 Circuit card, current +15

Xk3 Circuit card, ground

XK4 Circuit card, current

Xk5 Circuit card, current

Xk6 Circuit card, current +15

Xk7:1 Resistor R6 18
Xk7:2 F14, supply 12
Xk7:3 K4 87,gear lock 12
Xk7:4 Resistor 18
Xk7:5 K4 85, gnd 12
Xk7:6 F14, gear lock 12
Xk7:7 K4 30, gear lock 12
Xk7:8 K4 86 S20 12
Xk7:9 K4 87a 12

Xk8:1 K5 30 option 17
Xk8:2 F15 option 17
Xk8:3
Xk8:4 F15 option 17
Xk8:5 K5 86 option 17
Xk8:6 +12V
Xk8:7 K5 87a option 17
Xk8:8 K5 85 option 17
Xk8:9 K5 87a option 17

Xk9:1 Lightswitch 4
Xk9:2 Hazard blinker 4
Xk9:3 Air suspended seat. , cabin light 6
Xk9:4 A/C 9
Xk9:5
Xk9:6 Windscreen wiper/wash motors 9
Xk9:7 Mirror +12V 6
Xk9:8
Xk9:9 AC, fan 9

Xk10:1
Xk10:2 CAN LOW 10
Xk10:3
Xk10:7 CAN H 10
Xk10:9

Xk11:1 K150 +12V 12

Xk11:2
Xk11:3 AHC 20
Xk11:4 +15 K2:87 13
Xk11:5
Xk11:6 H53,K32,K34 control 12
Xk11:7

7-23
Xk11:8
Xk11:9 DHC, activating, alarm relay 13

Xk12:1 engine running, supply for switches 12

Xk12:2 sensors +12V 13
Xk12:3 Radio R 3
Xk12:4 Concave /precongave adj. Supply graintank cover 13
Xk12:5
Xk12:6 Radio supply 3
Xk12:7 Thresh. cylinder and fan adj. power supply 13
Xk12:8 12
Xk12:9 K7:87 4WD,differential lock 9

X13:1
X13:2 CAN LOW 10
X13:3 CAN H 10

Xk14:1 AC compressor 9
Xk14:2
Xk14:3 motor on 3B motor 12
Xk14:4 CSP drum 13
Xk14:5
Xk14:6
Xk14:7 CSP drum 13
Xk14:8
Xk14:9 Dropped rev relays, voltage supply, DHC 13

Xk15:1 Graintank full, relay LH 500 12

Xk15:2 Treshing mach. pressure switch(cutting table stop ) 14
Xk15:3 Brakelights
Xk15:4 Table off 14
Xk15:5 K13 GND 12
Xk15:6
Xk15:7 DHC stop limit 17
Xk15:8 DHC activating limit 17
Xk15:9 F31 12

Xk16:1 Beeper, working light control, workinglights 4

Xk16:2 +12V in cabin 6
Xk16:3 LH 500,engine display,rear camera 11
Xk16:4 Blinker, left 4
Xk16:5 Blinker, indicator lamp 4
Xk16:6
Xk16:7 Blinker, right 4
Xk16:8 Head lights, low 4
Xk16:9 Head lights, high 4

Xk17:1 Blinker 4
Xk17:2 AC compressor control 9
Xk17:3 Blinker relay 4
Xk17:4 Position light 8
Xk17:5 Reverse control
Xk17:6 Start, control 3
Xk17:7 not used Heater 3
Xk17:8 Diodi,D+ 3
Xk17:9 Start, control 3

Xk18:1 gauges,lightpanel,radio backlight 10

Xk18:2 Blinker relay 4
Xk18:3 Table reverse (electric) control solenoid 15
Xk18:4 Treshin mach. is off 15
Xk18:5 Table check control 14
Xk18:6 Tresh. mach. safety relay 14
Xk18:7 Table on 14

7-24
Xk18:8 Vertical knife, control 15
Xk18:9 Reverse (table off) 15

Xk19:1 Head light, low, right 4

Xk19:2 Head light, high , left 4
Xk19:3 Head light, high, right 4
Xk19:4 Head light, low, left 4
Xk19:5
Xk19:6 Parking light, left 8
Xk19:7 Blinker, left 4
Xk19:8 Blinker, right 4
Xk19:9 Parking light, right 8

Xk20:1 Blinker, left 8

Xk20:2 Engine IGN 18
Xk20:3 not used Glow 3
Xk20:4 Parkinglight, right
Xk20:5 D+, alternator
Xk20:6
Xk20:7 Blinker, right 4
Xk20:8 Blinker, left 4
Xk20:9

Xk21:1 Ground 14
Xk21:2 Thresh.mach./chaffspreader on valves 15
Xk21:3 15
Xk21:4 Table on valve 15
Xk21:5 chopper off 14
Xk21:6 Chopper coil 15
Xk21:7
Xk21:8 Chopper pressure switch 14
Xk21:9

Xk22:1 Thresh.mach.on 14
Xk22:2 Unloading off 14
Xk22:3 Unloading on 14
Xk22:4 Throttle (half rounds) 18
Xk22:5 unloading on 14
Xk22:6 Thresh.mach.off reset 14
Xk22:7 Seat limiter switch 14
Xk22:8 Clogged straw apartment 5
Xk22:9 Throttle signal 18

Xk23:1 Unloading on Y10 15

Xk23:2
Xk23:3 Rotating beacon 7
Xk23:4 Throttle signal 18
Xk23:5 Throttle gnd 18
Xk23:6 Clogged straw compartment 5
Xk23:7 Chopper on 14
Xk23:8 reel forward control 17
Xk23:9

Xk24:1 Working lights left front 7

Xk24:2 Rotating beacon 7
Xk24:3 Reel motors M21/M22 17
Xk24:4 Working lights 7
Xk24:5
Xk24:6
Xk24:7 Working lights, control 7
Xk24:8
Xk24:9 Reel motors 17

Xk25:1 Reel forward/back ground 17

7-25
Xk25:2 Reel forward/back F26 17
Xk25:3 Reel forward/back gnd 17
Xk25:4 Reel back control 17
Xk25:5
Xk25:6
Xk25:7
Xk25:8
Xk25:9 Reel forward/back F26 17

Xk26:1 LH 0V reference 11
Xk26:2 LH Graintank 1/2 and 1/1 11
Xk26:3 K34 control 17
Xk26:4 LH +5V reference 11
Xk26:5 DHC on/off 17
Xk26:6 K32 control 17
Xk26:7
Xk26:8
Xk26:9

Xk27:1 K32 11 reel rpm +/- 17

Xk27:2 K32 12 ground 17
Xk27:3 K33 12 ground 17
Xk27:4
Xk27:5 DHC table up 17
Xk27:6 K34 11 reel rpm +/- 17
Xk27:7 DHC table down 17
Xk27:8 K32 14 F26 17
Xk27:9 K34 14 F26 17

Modul connectors

Xcr p/n1:1 +12V 16,20

Xcr p/n1:2 GND 16,20
Xcr p/n1:3
Xcr p/n1:4
Xcr p/n1:5
Xcr p/n1:6

Xcr10:1 +12V 16
Xcr10:2 AHC on/Off 16,20
Xcr10:3
Xcr10:4 Road switch 16
Xcr10:5
Xcr10:6
Xcr10:7
Xcr10:8
Xcr10:9
Xcr10:10
Xcr10:11
Xcr10:12
Xcr10:13
Xcr10:14 AHC on/Off 16
Xcr10:15
Xcr10:16 reel RPM control - 16,20
Xcr10:17
Xcr10:18 reel RPM control + 16,20

Xcr11:1 AHC potentiometer 16

Xcr11:2 AHC potentiometer 16
Xcr11:3 Pressuresensor, tablelifthydraulics 16
Xcr11:4 Feeder height 16
Xcr11:5 +12V 16
Xcr11:6
Xcr11:7 Potentiometer, skid right (AHC) 16

7-26
Xcr11:8 Potentiometer, skid left (AHC) 16
Xcr11:9 Reverse 16
Xcr11:10 Joystick, shift 16

Xcr12:1 Joystick, +12V 16

Xcr12:2 Joystick, table down 16
Xcr12:3 Joystick, +12V 16
Xcr12:4 Joystick, table up 16
Xcr12:5 Joystick, +12V 16
Xcr12:6 Joystick, PU-reel, down 16,20
Xcr12:7
Xcr12:8 Joystick, PU-reel, up 16,20
Xcr12:9
Xcr12:10
Xcr12:11
Xcr12:12 Joystick, (PU-reel forward) 16
Xcr12:13 Joystick, +12V 16
Xcr12:14 Joystick, (PU-reel backward) 16
Xcr12:15
Xcr12:16 Joystick, unload. pipe out 16
Xcr12:17
Xcr12:18 Joystick, unload. pipe in 16

Xcr20:1 +12V 16
Xcr20:2 Pickupreelvalve up 16
Xcr20:3 +12V 16
Xcr20:4 Pickupreelvalve down 16
Xcr20:5 +12V 16
Xcr20:6 Pickupreelvalve front 16
Xcr20:7 +12V 16
Xcr20:8 Pickupreelvalve back 16
Xcr20:9 +12V 16
Xcr20:10
Xcr20:11 +12V 16
Xcr20:12
Xcr20:13 +12V 16
Xcr20:14 +10V 16
Xcr20:15 AHC led 16
Xcr20:16 AHC led 16
Xcr20:17
Xcr20:18

Xcr21:1 PU-reel rpm 16

Xcr21:2 Cuttingtablevalve up 16
Xcr21:3 Cuttingtablevalve down 16
Xcr21:4 Tabletiltvalve right 16
Xcr21:5 +12V 16
Xcr21:6 Tabletiltvalve left 16
Xcr21:7 Freeflow valve 16
Xcr21:8
Xcr21:9
Xcr21:10 +12V 16

Connectors in cables from instrument panel

X1:
X1:
X1:

X2:1
X2:2
X2:3

X3:1 Cabin lights, red ambient+ 6

X3:2 Cabin lights ambient - 6

7-27
X3:3 Cabin lights, gnd 6

X4:1 Sieve adj. +12V 8

X4:2 Fond light for sieve adj. 8
X4:3 Sieve adj. ground 8

X5:1 Blinker, 4
X5:2
X5:3 GND 4,8
X5:4 8

X6:1 Working light, 7

X6:2 Gnd 7

X7:1 Working light, 7

X7:2 Gnd 7

X8:A
X8:B
X8:C
X8:D
X8:E Sisu display,Can H 11
X8:F Sisu display,Can L 11
X8:G
X8:H

X9:1 Electrical reverce solenoid. Control

X9:2 reel forward/back 17
X9:3 reel forward/back 17
X9:4 PU-reel rpm
X9:5 Pu-reel rpm
X9:6 Vertical knife, right 19
X9:7 Vertical knife, left 19
X9:8 Sensors, +12V 16,20
X9:9 Sensors GND 16,20
X9:10 reel rpm signal 11
X9:11 Potentiometer, skid right (AHC) 16,20
X9:12 Potentiometer, skid left (AHC) 16,20
X9:13

X10:1 Reverse camera, +12V 10

X10:2 Reverse camera,ground 10

X11:1 Working light, unloading 7

X11:2 Working lights front right 7
X11:3 Rotating beacon cabin 7
X11:4 Windscreen wiper +12V 9
X11:5
X11:6 Radio 3
X11:7 Radio, memory 3
X11:8 Cab light 6
X11:9 Backlight(from ignition switch) 6
X11:10 Reverse camera, +12V 10
X11:11 AC compressor 9
X11:12 Windscreen water nozzle 9
X11:13 Electric sieves 10
X11:14 concave signal 10
X11:15 preconcave signal 10

X12:1 Working lights left front 7

X12:2 Fan 9

7-28
X13:1 Windscreen wiper, motor, head current 9
X13:2 Windscreen wiper, motor, return current 9
X13:3 Windscreen wiper,motor, switch contr 9
X13:4 Windscreen motor ground 9

X14:1 AC panel, backlight 6

X14:2 Fan, +12V 9
X14:3
X14:4 AC compressor, control

X15:1
X15:2
X15:3
X15:4 Radio memory 3
X15:5
X15:6 Radio, backlight 3
X15:7 Radio, +12V 3
X15:8 Radio, ground 3

X16:1
X16:2
X16:3 Right speaker+
X16:4 Right speaker -
X16:5 Left speaker+
X16:6 Left speaker -
X16:7
X16:8

X17:1 concave signal 10

X17:2 preconcave signal 10
X17:3 concave gauge- 10
X17:4 concave gauge + 10

X18:1 unloading pipe stop 20

X18:2 Reverse vave 15
X18:3 Table in ground signal 5
X18:4 Table in ground supply 5
X18:5 reel speed K32 + 17
X18:6 reel speed K34 - 17
X18:7
X18:8 AHC on/Off 16,20
X18:9 RPM M17
X18:10 RPM M17
X18:11 AHC led 16,20
X18:12 AHC potentiometer 16,20
X18:13 AHC potentiometer feed 16,20
X18:14 AHC led 16,20
X18:15 AHC potentiometer 16,20
X18:16
X18:17
X18:18 Feeder height 16,20
X18:19 Reel on control 16,20
X18:20 reel RPM control - 16,20
X18:21 reel RPM control + 16,20

X19:1 grainelevator rpm signal 11,13

X19:2 grain elevator rpm + 13
X19:3 return rpm signal 11,13
X19:4 return rpm + 13
X19:5 return down rpm signal 11,13
X19:6 return down rpm + 13
X19:7 chopper rpm signal 11

7-29
X19:8 alarm relay +12V 13
X19:9 bottom auger
X19:10 Return vertical auger indication light 5
X19:11 grain elevator indication light 5
X19:12

X20:1 sensors 12V front 11

X20:2 congave signal 10
X20:3 Preconcave signal 10
X20:4 drive speed 10
X20:5 LH +5V 11
X20:6 table height 11
X20:7 feeder rpm 11
X20:8 threshing signal 10
X20:9 fan signal 10
X20:10 vertical knife control right 19
X20:11 vertical knife control left 19
X20:12 reel rpm signal 11
X20:13 differential lock 9
X20:14 differential lock light 9
X20:15 not used 18
X20:16 Hydraulic oil temperature switch 5
X20:17
X20:18 11

X21:1 Sensors, +12V 11

X21:2 Start 3
X21:3 not used
X21:4 not used
X21:5 Reverse beeper 4
X21:6 Workinglight control rear 7
X21:7 Engine temperature, gauge 10
X21:8 4WD Y15,Y16 8
X21:9 CSP rmp signal 11
X21:10 Chopper spreader adj. 17
X21:11 Chopper spreader adj. 17
X21:12 Chopper spreader adj. 17
X21:13 Chopper spreader adj. 17
X21:14 Rotating beacon 7
X21:15 Rotating beacon 7
X21:16 Return amount 11
X21:17 Throttle 18
X21:18 gearbox lightener 12
X21:19 17
X21:20 CAN HI 10
X21:21 CAN LO 10

X22:1 gearbox /lock/lightener 12

X22:2 gearbox /lock/lightener 12

X23:1 fan rpm adjustment 13

X23:2 fan rpm adjustment 13
X23:3 threshing rpm adjustment 13
X23:4 threshing rpm adjustment 13
X23:5 Precongave adjustment 13
X23:6 Precongave adjustment 13
X23:7 front congave adjustment 13
X23:8 front congave adjustment 13
X23:9 reverce solenoid control 15
X23:10 reel forward/backward 17
X23:11 reel forward/backward 17
X23:12 reel speed + -
X23:13 reel speed + -
X23:14 not used 18

7-30
X23:15 Gear lock 12

X24:1 Brake light 8

X24:2 Horne
X24:3 Workinlight 7
X24:4 DHC 13
X24:5 Graintank cover 13
X24:6 Graintank cover 13
X24:7 Hand brake 5
X24:8 wash windscreen 9
X24:9 table stopoption/threshing machine pressure switch 14
X24:10 grain tank relay K13 control 12
X24:11 grain trank full 12
X24:12

X25:1 air filter 5

X25:2 oil pressure 5
X25:3 Straw walker, rpm 11
X25:4 Engine temperature, high signal 5
X25:5 grid heater light 5
X25:6 motor diagnostic light 5
X25:7 threshing pressure switch 14
X25:8 sieve loss 11
X25:9 Straw walker, loss 11
X25:10 unloading tube travel 5
X25:11 Indicator light for over 4 m height 5
X25:12 Radio, memory 3
X25:13 Main switch 3
X25:14 Main switch 3
X25:15 fuel sensor 10
X25:16 chopper switch off 14
X25:17 chopper switch on 14
X25:18 Hydraulic oil filter 5
X25:19 Table pressure switch 11
X25:20 Brake light 8
X25:21

X26:A thresh drum 11

X26:B grain elevator rpm 11
X26:C return elevator 1(bottom auger) rpm 11
X26:D straw walker rpm 11
X26:E feeder rpm 11
X26:F reel rpm 11
X26:G feeder engaged/disengaged 11
X26:H chopper engaged/disengaged 11
X26:J fan rpm 11
X26:K chopper rpm 11
X26:L sieve grain loss 11
X26:M straw walker grain loss 11
X26:N header height 11
X26:P grain tank full 11
X26:R 0V reference for analogue sensors 11
X26:S +5V reference for analogue sensors 11
X26:T return material amount 11
X26:U reel speed increase 11
X26:V CSP rpm 11
X26:W reel speed decrease 11
X26:X 0V for digital sensors 11
X26:Y grain tank full (Out -2) 11
X26:Z +12V power supply 11
X26:a external alarm out-2 11
X26:b forward speed 11
X26:c automatic/manual reel speed 11
X26:d Straw compartment blockage switch/CSP-drum alarm 11

7-31
X26:e vertical return elevator 2 auger rpm 11

X27:1
X27:2 Sisu display,+12V 10
X27:3 Sisu display,gnd 10
X27:4 Sisu display,Can H 10
X27:5 Sisu display,Can L 10

X28:1 Horn switch 4

X28:2 Switch for head lights, high 4
X28:3 Switch for head lights, low 4
X28:4 Parking lights switch 4
X28:5 Current to light switches 4
X28:6 4
X28:7 Blinker switch 4
X28:8 Blinker switch,right 4
X28:9 Blinker switch, left 4

X29:1 Fan rpm 10

X29:2 Threshing cylinder rpm 10
X29:3 ground 10
X29:4 + 12V 10

X30:1 speed 10
X30:2 speed 10
X30:3 Ground 10
X30:4 + 12V 10

X31:1 Indicator lights panel, supply 5

X31:2 Indicator lights panel, ground 5,4,9

X32:1 Unloading pipe moving 5

X32:2 4-WD 9
X32:3 Chopper on 5
X32:4 Grain elevator indication light K37 5
X32:5 Return bottom auger indication light 5
X32:6 Chopper off 5
X32:7 Return vertical auger indication light K36 5
X32:8 Straw compartment blockage 5
X32:9 Grain tank full 5
X32:10 Grain tank 1/2 5
X32:11 Table down 5
X32:12 5

X33:1 Charging indicator light 5

X33:2 Oil pressure 5
X33:3 Heater light 5
X33:4 Diagnostic indicator light 5
X33:5 Engine temperature 5
X33:6 Air intake clogged 5
X33:7 Hand brake 5
X33:8 Indicator light for head lights high 4
X33:9 Blinker indicator light 4
X33:10 Hydraulic system clogged 5
X33:11 Temperature in hydraulic system 5
X33:12 Indicator light for over 4 m height 5

X34:1
X34:2 Blinker, right 4
X34:3 Blinker, left 4
X34:4
X34:5 Ground 8
X34:6 Parking light 8
X34:7

7-32
X34:8
X34:9

X35:1 Grain tank 1/1 12

X35:2 Grain tank 1/2 12
X35:3 Grain tank light 8
X35:4 Graintank cover 13
X35:5 Graintank cover 13
X35:6 Grain tank limiter switch ground 12
X35:7 Grain tank light, ground 8

X36:1 Workinglight 7
X36:2
X36:3 Parking light 8
X36:4 Blinker, right 4
X36:5 gnd 4,7,8

X37:1 Head beam, low 4

X37:2 Head beam, high 4
X37:3 Ground 4

X38:1 Head beam, low 4

X38:2 Head beam, high 4
X38:3 Ground 4

X39:1 Workinglight 7
X39:2 Windscreen wash +12V 9
X39:3 Parking light 8
X39:4 Blinker, left 4
X39:5 gnd 4,7,8,9

X40:1 windscreen wash + 9

X40:2 windscreen wash - 9

X41:1
x41:3
X41:6

X42:1 DHC activating limit supply 13

X42:2 DHC activating limit signal 17
X42:3 DHC lower limit signal 17
X42:4 DHC lower limit supply 17

X43:1 Threshing cylinder rpm M11 13

X43:2 Threshing cylinder rpm M11 13

X44:1 threshing rpm - 10

X44:2 threshing rpm + 10
X44:3 threshing rpm signal 10

X45:1 Threshing cylinder rpm adj. 13

X45:2 Threshing cylinder rpm adj. 13
X45:3 S59,S60 supply 13
X45:4 Fan rpm adj. 13
X45:5 fan rpm adjustment 13
X45:6 ground S59,S60 13
X45:7

X46:1 Avoid starting 3

X46:2 Avoid starting 3
X46:3 Full throttle 18
X46:4 Throttle ref 18

7-33
X46:5 Half throttle 18
X46:6 Engine running, switch feed 14
X46:7 Unloading on 14
X46:8 Unloading off 14
X46:9 Table off/reset 14
X46:10 Table on 14
X46:11 Threshing mach. off/reset 14
X46:12 Threshing mach. on 14
X46:13 backlights light,through ignition switch,reverce beeper 4
X46:14 AHC potentiometer 16,20
X46:15 AHC led 16,20
X46:16 AHC potentiometer feed 16,20
X46:17 AHC potentiometer 16,20
X46:18 AHC potentiometer ground 16,20
X46:19 AHC led 16,20
X46:20
X46:21
X46:22
X46:23 AHC back light 16,20
X46:24 ground, arm 4,16,20
X46:25
X46:26 Reverse beeper 4
X46:27
X46:28 Seat limiter switch 14
X46:29 Seat compressor +12V 6
X46:30 Seat compressor ground 6
X46:31 AHC PWM 16
X46:32 DHC on 17
X46:33 AHC on/off 16,20
X46:34 symbol lights feed,H47,H48 13
X46:35
X46:36 LH Auto/Man 11
X46:37

X47:1 Seat compressor ground 6

X47:2 Seat compressor +12V 6

X48:1 Seat limit switch supply 14

X48:2 Seat limit switch signal 14

X49:1 Table switch feed 14

X49:2 Table off/reset 14
X49:3 Table on 14

X50:1 Threshing mach. switch feed 14

X50:2 Threshing mach. off/reset 14
X50:3 Threshing mach. on 14

X51:1 AHC potentiometer 16,20

X51:2 AHC led 16,20
X51:3 AHC potentiometer feed 16,20
X51:4 AHC potentiometer 16,20
X51:5 AHC potentiometer ground 16,20
X51:6 AHC led 16,20

X52:1 Table height -(AHC) 16,20

X52:2 Table height +5V(AHC) 16,20
X52:3 Table height signal (AHC/LH) 16,20

X53:1 Table height +5V (LH) 11

X53:2 Table height signal (LH) 11

X54:1 Feeder elevator rpm - 11

X54:2 Feeder elevator rpm +12V 11

7-34
X54:3 Feeder elevator rpm signal 11

X55:1 Differential lock gnd 9

X55:2 Differential lock limit switch 9
X55:3 Differential lock control 9

X56:1 Table down 16,20

X56:2 Table up 16,20
X56:3 Freeflow valve 16,20
X56:4 Pick-up reelvalve down 16,20
X56:5 Pick-up reelvalve up 16,20
X56:6 Unloading pipe valve out 16,20
X56:7 Unloading pipe valve in 16,20
X56:8 Unloading pipe valve ,gnd road switch 16,20
X56:9 Table is on the ground signal, pressure switch 5
X56:10 Table is on the ground supply pressure switch 5
X56:11 Tabletiltvalve right 16,20
X56:12 Tabletiltvalve left 16,20
X56:13 Reverse valve 15
X56:14 Pickupreelvalve front 16,20
X56:15 Pickupreelvalve back 16,20
X56:16 Pressuresensor, tablelifthydraulics (AHC) 16,20
X56:17 Sensors +12V 16,20
X56:18 GND 16,20

X57:A1
X57:A2
X57:A3
X57:A4
X57:A5
X57:A6
X57:A7
X57:A8
X57:B1
X57:B2
X57:B3
X57:B4
X57:B5
X57:B6
X57:B7
X57:B8
X57:C1
X57:C2
X57:C3
X57:C4
X57:C5
X57:C6
X57:C7
X57:C8

X58:1 Joystick, table ground 16,20

X58:2 Joystick, table down 16,20
X58:3 Joystick, table up 16,20
X58:4 Joystick,t PU-reel forward/backward, ground 16,20
X58:5 Joystick, (PU-reel forward) 16,20
X58:6 Joystick, (PU-reel backward) 16,20
X58:7 Joystick, shift 16,20
X58:8 Joystick, shift 16,20
X58:9 Joystick, unload. pipe ground 16,20
X58:10 Joystick, unload. pipe in 16,20
X58:11 Joystick, unload. pipe out 16,20
X58:12 Joystick, Pick-Up-reel, ground 16,20
X58:13 Joystick, Pick-Up-reel, down 16,20
X58:14 Joystick, Pick-Up-reel, up 16,20

7-35
X58:15 Joystick, Pick-Up-reel speed adj. Ground 16,20
X58:16 Joystick, Pick-Up-reel speed,down 16,20
X58:17 Joystick, Pick-Up-reel speed, up 16,20
X58:18
X58:19
X58:20
X58:21
X58:22
X58:23
X58:24

X59:1 front congave sensor - 10

X59:2 front congave sensor + 10
X59:3 front congave sensor signaali 10

X60:1 congave adjustment M13 13

X60:2 congave adjustment M13 13

X61:1 congave sensor - 10

X61:2 congave sensor + 10
X61:3 congave sensor signal 10

X62:1 Precongave adjustment M14 13

X62:2 Precongave adjustment M14 13

X63:1 Fan rpm,- 10

X63:2 Fan rpm,+ 10
X63:3 Fan rpm,s 10

X64:1 fan rpm adjustment M12 13

X64:2 fan rpm adjustment M12 13

X65:1 drive speed - 10

X65:2 drive speed + 10
X65:3 drive speed signal 10

X66:1 Reel speed motor M17 16

X66:2 Reel speed motor M17 16

X67:1 not used Reel forward/back motor left M21

X67:2 not used Reel forward/back motor left M21

X68:1 not used Reel forward/back motor right M22

X68:2 not used Reel forward/back motor right M22

X69:1 Graintank cover 13

X69:2 Graintank cover 13

X70:1 grain tank 3/4 signal 12

X70:2 grain tank 3/4 ground 12

X71:1 grain tank full signal 12

X71:2 grain tank full ground 12

X72:1 grain tank light+ 8

X72:2 grain tank light- 8

X73:1 Graintank cover 13

X73:2 Graintank cover 13

X74:1
X74:2

7-36
X75:1 Sensors, +12V 16,20
X75:2 Sensors, gnd 16,20
X75:3
X75:4 Potentiometer, skid right (AHC) 16,20
X75:5 Potentiometer, skid left (AHC) 16,20
X75:6 Pickup reel rpm 16,20
X75:7
X75:8
X75:9

X76:1 Pickup reel rpm 16,20

X76:2 Pickup reel reverse 16,20
X76:3 GND 16,20
X76:4
X76:5

X77:1
X77:2

AHC
X78:1 Ground
X78:2 input unloading auger out
X78:3 input, pick-up reel valve down
X78:4 Led, AHC-contourheight
X78:5 input, voltage +12V(emergency off)
X78:6 Potentiometer, skid right (AHC)
X78:7 Potentiometer, feeder height
X78:8 Potentiometer, presetheight (AHC)
X78:11 UB out +5V potentiometers
X78:13 input, AHC working
X78:14 input, cutting table down
X78:15 input, pick-up reel front
X78:16 input, Ahc slow moving
X78:19 Signal ground
X78:20 input unloading auger in
X78:21 input, pickup reel up
X78:22 Led, AHC-preset height
X78:23 Standby input
X78:25 Potentiometer, skid left (AHC)
X78:26 Pressure sensor, table lift hydraulics (AHC)
X78:27 Potentiometer, contourheight (AHC)
X78:31 REF-GNDA signal earth analog
X78:33 input, cutting table up
X78:34 input, pick-up reel back
X78:35 input, change switch
X78:38 Operating voltage load
X78:39 Operating voltage load
X78:40 Operating voltage of
X78:42 Coil, freeflow valve
X78:43 Coil, unloading auger valve in
X78:44 Coil, unloading auger valve out
X78:45 Coil, pickup reel valve up
X78:46 Coil, pickup reel valve down
X78:48 Coil, pickup reel valve front
X78:49 Coil, pickup reel valve back
X78:52 Coil, cutting table valve up
X78:53 Coil, cutting table valve down
X78:54 Coil, table tilt valve right
X78:55 Coil, table tilt valve left

X79:1 Upper sieve adj. 8

X79:2 Upper sieve adj. 8
X79:3 Sieve adj.sensor ground 8
X79:4 Sieve adj.sensor signal 8

7-37
X79:5 Sieve adj. sensor feed 8
X79:6
X79:7 Fond light for sieve adj. 8
X79:8 Sieve adj. +12V 8
X79:9 Sieve adj. ground 8

X80:1 Lower sieve adj. 8

X80:2 Lower sieve adj. 8
X80:3 Sieve adj.sensor ground 8
X80:4 Sieve adj.sensor signal 8
X80:5 Sieve adj. sensor feed 8
X80:6
X80:7
X80:8
X80:9
Rear central
X101:1 AC compressor 9
X101:2 D+ alternator 3
X101:3 air filter 5
X101:4 Oil pressure 5
X101:5 Engine temperature, gauge 10
X101:6 Engine temperature, switch 5
X101:7 ignition +15 18
X101:8 Throttle ref 18
X101:9 Throttle gnd 18
X101:10 Throttle signal 18
X101:11 grid heater light 5
X101:12 motor diagnostic light 5
X101:13 diesel running information 12
X101:14
X101:15

X102:1 parking light right,trailer 8

X102:2 parking light left,trailer 8
X102:3 blinker right 4
X102:4 blinker left 4
X102:5 brake light 8
X102:6 sensors gnd 11
X102:7 sensors +12V 11
X102:8 rotating beacon rear 7
X102:9 reverse beeper 4

X103:1 Chopper valve 15

X103:2 15
X103:3 Threshing mach. pressure switch 14
X103:4 Chopper pressure switch 14
X103:5 Unloading pipe, limit switches 5
X103:6 Unloading pipe, limit switch 5
X103:7 Grain elevator rpm 11,13
X103:8 Grainelevator rpm 11,13
X103:9 Returns vertical auger rpm 11,13
X103:10 Returns upper rpm 11,13
X103:11 Returns lower rpm 11,13
X103:12 Returns lower rpm 11,13
X103:13 Main switch 3
X103:14 Main switch 3
X103:15 Hydraulic oil filtter 5
X103:16 Strawalkers rpm 11
X103:17 Return amount 11
X103:18 Chopper on limit switch 14

X104:1 Start, control 3

X104:2 Radio memory 3

7-38
X104:3 working light,control rear 7
X104:4 Main switch 3
X104:5 Main switch 3
X104:6 Chopper rpm 11
X104:7 Fuel sensor 10
X104:8 Clogged straw compartment 5
X104:9 Chopper on level switch 14
X104:10 Chopper off 14
X104:11 CSP drum rpm sensor 13,11
X104:12 CSP drum rpm sensor 13,11
X104:13 sieve grain loss 11
X104:14 Walker loss 11
X104:15 Table pressure switch 11
X104:16 Sensors +12V 11
X104:17 Sensors GND 11
X104:18 Chopper spreader 17
X104:19 Chopper spreader 17
X104:20 Chopper spreader 17
X104:21 Chopper spreader 17

X105:1 CAN H(optio)

X105:2 CAN L (optio)

X106:1 IGN 18
X106:2 Threshing mach. on 15
X106:3 Table on 15
X106:4 Unloading on 15
X106:5 Bottom auger, limit switch 5
X106:6 CAN LO 10
X106:7 CAN HI 10
X106:8 4WD, Y15,Y16 9
X106:9 gearbox lightener 12

X107:1
X107:2 CANL 10
X107:3
X107:4
X107:5
X107:6
X107:7 CANH 10
X107:8
X107:9

X108:1 Diesel +12V 18

X108:2 Diesel +12V 18
X108:3
X108:4
X108:5 +12V electric socket motor/fueltank 6
X108:6 Urea Main relay 18
X108:7 Urea Main relay 18
X108:8 Diesel +12V 18
X108:9 Diesel +12V 18
X108:10 Diesel +12V 18
X108:11 Start solenoid 3
X108:12 Start solenoid 3
X108:13 Dosing module +12V 18
X108:14 Main switch control 18
X108:15 Can LO 10
X108:16 Can HI 10
X108:17 Nox sensor +12V 18
X108:18 Waste gate +12V 18

X109:1 Main switch, indicator lamp 3

7-39
X109:2 Table pressure switch 11
X109:3 Sensors + 11
X109:4 Sensors GND 11
X109:5 Workinlight, Unloading E17 7
X109:6 Unloading on 15
X109:7 Threshing mach. on 15
X109:8 Table on 15
X109:9 gearbox lightener 12
X109:10 Chopper on 14
X109:11 Chopper on 14
X109:12 Main switch, control +12V 3
X109:13
X109:14
X109:15

X110:1 Working light E19 7

X110:2 Working light stairs/left side 7
X110:3 working light sieve/covers 7
X110:4 +12V electric socket motor/fueltank 6
X110:5 sieve grain loss left 11
X110:6 sieve grain loss right 11
X110:7 Walker loss monitor signal,right 11
X110:8 Walker loss monitor signal left 11
X110:9 CSP drum rpm sensor 11,13
X110:10 CSP drum rpm sensor 13,11
X110:11 Chopper rpm 11
X110:12 Fuel sensor 10
X110:13 Clogged straw compartment 5
X110:14 4WD Y15,Y16 9
X110:15 Chopper off 14
X110:16 Bottom auger, limit switch 5
X110:17 not used Chopper on 14
X110:18 Chopper on 14

X111:1 4WD 9
X111:2 4WD 9
X111:3 4WD,GND 9
X111:4 4WD,GND 9

X112:1 Chopper spreader left 17

X112:2 Chopper spreader left 17
X112:3 Chopper spreader right 17
X112:4 Chopper spreader right 17

X113:1
X113:2 Unloading pipe out, limiter switch 5
X113:3
X113:4 Unloading pipe out, limiter switch 5

X114:1 Sensor - 11
X114:2 Sensor +12V 11
X114:3 Strawalkers rpm 11

X115:1 Sensor - 11
X115:2 Sensor +12V 13/11
X115:3 Grain elevator rpm 13/11

X116:1 Sensor - 11,

X116:2 Sensor +12V 13/11
X116:3 Return bottom rpm 13/11

X117:1 Sensor - 11
X117:2 Sensor +12V 11,13

7-40
X117:3 Returns vertical rpm 11,13

X118:1 Sensor - 11
X118:2 Sensor +12V 11
X118:3 Return material amount 11

X119:1
X119:2 Unloading pipe in, limit switch 5
X119:3
X119:4 Unloading pipe in, limit switch 5

X120:1 18
X120:2 18
X120:3 Water detector ,gnd 18
X120:4 GND 18
X120:5 Engine CAN HI 18
X120:6 Engine CAN Low 18

X121:a Water detector ,+ 18

X121:b Water detector,signal 18
X121:c Water detector gnd 18

X122:1 Diesel, +12V (EEM 4) 18

X122:2 Urea supply module heater GND 18
X122:3 Diesel, GND (EEM 4) 18
X122:4
X122:5 Diesel, GND (EEM 4) 18
X122:6 DO, Diesel fault 18
X122:7 DEF pressure sensor , signal 18
X122:8 DEF tanksensor, temperature 18
X122:9 Downstream gas temp sensor 18
X122:10 Upstream/downstream gas temp sensor 18
X122:11
X122:12
X122:13 Din, Diesel airfilter 18
X122:14
X122:15
X122:16
X122:17
X122:18 Environmental temperature 18
X122:19
X122:20
X122:21
X122:22
X122:23 Urea dosing valve 18
X122:24
X122:25 Diesel, +12V (EEM 4) 18
X122:26 Diesel, +12V (EEM 4) 18
X122:27 Main switch control K107:86 18
X122:28 Diesel, GND (EEM 4) 18
X122:29 Diesel, GND (EEM 4) 18
X122:30
X122:31 Upstream gas temp sensor, 18
X122:32 DEF tank sensor, Level 18
X122:33 DEF tank sensor, GND 18
X122:36 Water detector signal 18
X122:39 DEF pressure sensor , gnd 18
X122:40 Environmental temperature 18
X122:41
X122:42
X122:43 Water detector,signal 18
X122:44 DO, Diesel fault 18
X122:46 Vehicle Can high 18

7-41
X122:47 Vehicle Can low 18
X122:48
X122:49 Diesel, +12V (EEM 4) 18
X122:50 Main relay , 86 18
X122:51
X122:52 Diesel, GND (EEM 4) 18
X122:53
X122:54
X122:55
X122:56
X122:57
X122:58
X122:59
X122:60
X122:61
X122:62
X122:66 Throttle, +5V 18
X122:68 Urea pressure sensor +5V 18
X122:69 IGN control 18
X122:70
X122:71 Engine CAN High 18
X122:72
X122:73 Diesel, +12V (EEM 4) 18
X122:74
X122:75 Diesel, GND (EEM 4) 18
X122:76 Diesel, GND (EEM 4) 18
X122:77 diesel running information 18
X122:78
X122:79 Throttle, signal 18
X122:80 Throttle, GND 18
X122:81
X122:82
X122:84 DEF pump motor, signal 18
X122:85 Urea reverting Valve 18
X122:86 grid heater indicator light 5
X122:87
X122:88
X122:89 Urea pump motor, - 18
X122:90
X122:91
X122:92
X122:93 Main relay , 85 18
X122:94
X122:95 ENGine CAN Low 18
X122:96 Urea dosing valve 18

X123:1 Clogged air intake 18

X123:2 Ground 18

X124:1 Environmental temperature 18

X124:2 Environmental temperature 18

X125:1 DEF tank sensor, GND 18

X125:2 DEF tanksensor, temperature 18
X125:3 DEF tank sensor, Level 18

DNOx supply module

X126:1
X126:2 DEF pressure sensor +5V 18
X126:3 DEF pressure sensor , signal 18
X126:4 DEF pressure sensor , gnd 18
X126:5 Supply module heater 18
X126:6 Supply module heater GND 18
X126:7

7-42
X126:8 DEF pump motor, - 18
X126:9 DEF' pump motor + 18
X126:10 DEF pump motor, signal 18
X126:11 DEF reverting Valve 18
X126:12 DEF reverting Valve 18

X127:1 Upstream NOX sensor, +15 18

X127:2 Upstream NOX sensor, GND 18
X127:3 Upstream NOX sensor, CAN Low 18
X127:4 Upstream NOX sensor, CAN High 18
X127:5 Upstream NOX sensor, GND 18

X128:1 Urea dosing valve 18

X128:2 Urea dosing valve 18

X129:1 Upstream gas temp sensor, 18

X129:2 Upstream gas temp sensor, 18

X130:1 Downstream gas temp sensor, 18

X130:2 Downstream gas temp sensor, 18

X131:1 Downstream NOX sensor,+15 18

X131:2 Downstream NOX sensor,GND 18
X131:3 Downstream NOX sensor, CAN Low 18
X131:4 Downstream NOX sensor, CAN High 18
X131:5

X132:1 Sensor - 11
X132:2 Sensor +12V 11
X132:3 Sieve loss, left 11

X133:1 Sensor - 11
X133:2 Sensor +12V 11
X133:3 Sieve loss, right 11

X134:1 Blinker left 4

X134:2
X134:3 Ground trailer 4
X134:4 Blinker, right trailer 4
X134:5 Rear parking light, right trailer 8
X134:6 Brake light trailer trailer 8
X134:7 Rear parking light, left trailer 8

X135:1 strawalker sensor - 11

X135:2 strawalker sensor + 11
X135:3 strawalker sensor signal left 11

X136:1 license plate light + 8

X136:2 license plate light - 8

X137:1 Blinker, left 4

X137:2 Rear parking light, left 8
X137:3 Brake light 8
X137:4 Ground 4,8
X137:5

X138:1 Chopper spreader left 17

X138:2 Chopper spreader left 17
X138:3 Chopper spreader right 17
X138:4 Chopper spreader right 17

X139:1 Chopper rpm sensor - 11

X139:2 Chopper rpm sensor + 11

7-43
X139:3 Chopper rpm sensor signal 11

X140:1 Chopper off 14

X140:2
X140:3 Chopper off 14
X140:4

X141:1 Chopper on 14
X141:2 Chopper on(LH) indicator panel 14
X141:3 Chopper on gnd 14
X141:4 Chopper on(LH) gnd 14

X142:1 Blinker, right 4

X142:2 Rear light, right 8
X142:3 Brake light 8
X142:4 Ground 4
X142:5

X143:1 Walker loss monitor - 11

X143:2 Walker loss monitor + 11
X143:3 Walker loss monitor signal 11

X144:1 CSP drum rpm sensor - 11

X144:2 CSP drum rpm sensor + (red) 13,11
X144:3 CSP drum rpm sensor signal (yellow) 13,11

x145:1
x145:2

Connectors, Rear plate

X1:1

X1/2_1:1
X1/2_1:2 Dosing module +12V 18
X1/2_1:3 Chopper spreader +12V 17
X1/2_1:4
X1/2_1:5 GND 17
X1/2_1:6 Chopper spreader GND 17
X1/2_1:7
X1/2_1:8
X1/2_1:9 Chopper spreader 17
X1/2_1:10
X1/2_1:11 Chopper spreader 17
X1/2_1:12 Chopper spreader 17
X1/2_1:13
X1/2_1:14 Main relay , 86 18
X1/2_1:15 Chopper spreader +12V 17
X1/2_1:16 Main relay , 85 18
X1/2_1:17 GND 17
X1/2_1:18 Chopper spreader GND 17
X1/2_1:19 Nox sensors, +12V 18
X1/2_1:20 Waste gate +12V 18
X1/2_1:21 Chopper spreader 17

X1/2_2:1 Waste gate +12V 18

X1/2_2:2
X1/2_2:3 Start 3
X1/2_2:4 Diesel +12V 18
X1/2_2:5 Start 3
X1/2_2:6 CAN H 10
X1/2_2:7 Diesel +12V 18
X1/2_2:8
X1/2_2:9 CAN L 10
X1/2_2:10 Nox sensors, +12V 18

7-44
X1/2_2:11 Main switch control K107:86 18
X1/2_2:12
X1/2_2:13 +12V electric socket motor/fueltank 6
X1/2_2:14 +12V electric socket motor/fueltank 6
X1/2_2:15

X2:1 +30

X3:1 +BATT

X3/4_1:1
X3/4_1:2
X3/4_1:3 Waste gate +12V 18
X3/4_1:4 Dosing module +12V 18
X3/4_1:5
X3/4_1:6 Nox sensors, +12V 18
X3/4_1:7 Dosing module +12V 18
X3/4_1:8
X3/4_1:9
X3/4_1:10 Radio memory, main switch control 3
X3/4_1:11
X3/4_1:12 K107, 85 18
X3/4_1:13
X3/4_1:14
X3/4_1:15

X3/4_2:1 Worklights, stairs,left side,unloading 7

X3/4_2:2 Worklights, stairs,left side,unloading 7
X3/4_2:3 Workinglight rear straw room option 7
X3/4_2:4 Start control, K86 3
X3/4_2:5 working light,control rear 7
X3/4_2:6 working light,control rear 7
X3/4_2:7 Working light, 7
X3/4_2:8 Chopper spreader +12V 17
X3/4_2:9 Chopper spreader +12V 17

X3/4_3:1
X3/4_3:2
X3/4_3:3
X3/4_3:4
X3/4_3:5
X3/4_3:6

X5:1 Chopper spreader 17

X5:2 Chopper spreader GND 17
X5:3 Chopper spreader +12V 17
X5:4
X5:5
X5:6
X5:7
X5:8 Chopper spreader 17
X5:9 Chopper spreader 17
X5:10 Chopper spreader 17
X5:11 Chopper spreader 17
X5:12
X5:13
X5:14 Chopper spreader 17
X5:15

7-45
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