5650-5690 Balance Repair manual

SAME DEUTZ-FAHR DEUTSCHLAND GmbH

WORKSHOP MANUAL

Combine 5650 H, 5660 HTS 5670 H / HTS 5680 H, 5690 HTS

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Service Training

The technical informations and data in this Service documentation were correct when the manual was printed. We are constantly seeking to improve our products and therefore reserve the right to introduce all changes and improvements that we consider appropriate. However, we undertake no obligation to apply such improvements to previously supplied machines and additional equipment. This document may not be copied - even in part - without our consent. We reserve all rights under German copyright law and accept no liability for possible mistakes. This document describes the full equipment level, including special accessories that are not part of the standard equipment version. No claims regarding the equipment of machines already delivered or to be delivered may be derived from this description. The price list applicable at the time of purchase is decisive. Products made by other manufacturers (GPS, printer, etc.) and the associated software are described without obligation and based on information provided by the manufacturer in each case. The safety regulations contained in the normal operating manual also apply here. Impressum: Manufacturer SAME DEUTZ-FAHR DEUTSCHLAND GmbH Deutz-Fahr-Straße 1 D-89415 Lauingen/Donau Germany Telefon/Phone +49 (0) 90 72 / 9 97 0 Fax +49 (0) 90 72 / 9 97 - 300 WWW: http://www.deutz-fahr.de

Copyright © 2006 by

SAME DEUTZ-FAHR DEUTSCHLAND GmbH Deutz-Fahr-Str. 1 D-89415 Lauingen/Donau

Contents Layout Order

DF-EZ (Technical Documentation) DF-EZ (Technical Documentation) DF-LC (Spare Parts Department)

All rights reserved. 1. Edition, 10.2006

Part No.: 307.1133.3.6 Printed in the Federal Republic of Germany

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Summary 5650H – 5690HTS

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i4 General

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Engine Assembly, Engine Parts, Engine Control, Engine Power Take-Off

....

A

Front axle, gearbox, Steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B Belt drive clutches, Greasing equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D Feed passage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E Cabin, Driver's stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H Air condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I Threshing mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K Cleaning aggregates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .L Grain elevator, Grain tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M Cutting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P Straw chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .U

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General Safety Instructions Before starting assembly, repair or maintenance work, make sure you read and follow these safety instructions. Please also transmit all safety instructions to all other people concerned. In this manual, we have marked all points relevant to your safety with the following symbol:

WARNING! This combine harvester is designed exclusively for normal use in agricultural work (intended use). Any use of the machine beyond the above description does not conform to the intended use. The manufacturer shall not accept any liability for any damage resulting from such use; the user shall bear all risks relating to such use. Conformity with the intended use includes adherence to the operating, servicing and maintenance conditions specified by the manufacturer. This combine harvester may only be operated, serviced and repaired by persons familiar with the machine and instructed in the dangers involved. The manufacturer shall not accept any liability for any damage resulting from modifications to the machine by persons not authorised by the manufacturer. General regulations on safety and accident prevention: 1. In addition to the instructions contained in this manual, you must strictly follow all relevant accident prevention regulations and other generally recognised rules of technical and occupational safety. The legal operating specifications laid down in the Operating Manual for driving the combine on the road and for working use also apply to this manual and must therefore also be observed. 2. Before starting the engine, make sure that no gear is engaged or, in the case of hydromatic systems, that the drive lever is in the '0' position, and that all protective devices are fitted and in the protection position. 3. Only start the engine from the driver's cab. The engine must not be started by short-circuiting the electrical connections of the starter motor, because otherwise the machine may start moving immediately. 4. Before driving off, check the zone immediately around the combine harvester. Make sure you have sufficient visibility. Sound the horn as a warning signal. 5. Do not leave the engine running in enclosed spaces. 6. On leaving the combine harvester, protect it from rolling free (parking brake, wheel chock). Switch off the engine and remove the key. If applicable, lock the cab door. 7. Before leaving the combine, fully lower all front attachments (cutting table etc.). 8. Take care when handling fuel – increased fire risk. Never refuel the combine close to naked flames or ignitable sparks. Do not smoke when refuelling. 9. Before refuelling, switch off the engine. Do not refuel in enclosed areas. Immediately wipe away any spilt fuel. 10. To prevent fire risk, keep the machine clean. 11. Take care when handling brake fluid and battery acid (toxic and liable to cause chemical burns).

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Safety instructions for maintenance and repair General: 1. As a general rule, the drive train must be disengaged and the engine stopped before carrying out any assembly, repair, maintenance and cleaning work or before remedying malfunctions. Remove the ignition key. 2. Fluids escaping at high pressure (fuel, hydraulic oil etc.) can pierce the skin and cause severe injury. In the event of injury, immediately call a doctor, because otherwise there is a grave risk of infection. 3. Care is required when handling fuel – increased fire risk. Never refuel the combine close to naked flames or ignitable sparks. Do not smoke when refuelling. 4. To prevent fire risk, keep the machine clean. Electrical system: 1. When working on the electrical system, always remove the cable from the negative pole of the battery. 2. Make sure that the battery is correctly connected. First connect the positive pole and then the negative. 3. Take care with battery gases, since they are highly explosive. Avoid generating sparks or naked flames close to batteries. 4. Only use OEM fuses of the specified ratings. If any of the fuses used are too highly rated, the electrical system may be destroyed. 5. Before starting any electric welding work on the combine harvester, disconnect the cables from the alternator and battery. 6. Take care when handling battery acid (toxic and corrosive). 7. Only operate the starter motor for a limited period, because otherwise the winding will overheat. Allow the starter to cool down. Brakes, brake fluid: 1. Check that the brakes are working correctly before each use. 2. The brake systems must be regularly submitted to a thorough test. 3. Settings and repairs to the brake system must only be carried out by qualified workshops or recognised brake services. 4. When driving on public roads, the individual wheel braking mode must be deactivated (interlock the pedals). 5. Regularly check the brake fluid level. Only use the specified brake fluid and change as specified. 6. Take care when handling brake fluid (toxic and liable to cause chemical burns). Do not spill brake fluid. 7. Dispose of brake fluid in accordance with the applicable regulations.

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Safety instructions for maintenance and repair Hydraulic system: 1. The hydraulic system is under high pressure. When searching for leaks, use a suitable aid (e.g. piece of cardboard) to protect against the risk of injury. 2. Before carrying out any work on the hydraulic system, depressurise the system and lower any front attachments. 3. When working on the hydraulic system, switch off the engine and remove the key. Prevent the combine harvester from rolling (handbrake, wheel chocks). 4. When connecting hydraulic equipment, make sure that the hydraulic hoses are correctly connected. If the hoses are connected to the wrong points, the switch functions will be inverted (e.g. raise/lower). Risk of accident. 5. Regularly inspect hydraulic hoses and replace if damaged or aged. The replacement hoses must conform to the technical specifications of the device manufacturer. 6. The hydraulic accumulator contains pressurised gas. Do not drop the accumulator or expose it to temperatures above 150°C Air conditioning system: 1. Avoid all contact with the liquid refrigerant of the air conditioning system. If refrigerant is sprayed into the eyes, call a doctor immediately. 2. All maintenance, installation and repair work must be carried out exclusively by qualified personnel. 3. No welding work may be performed on components of the refrigerant circuit or in its immediate vicinity. Risk of poisonous fumes. 4. Maximum ambient temperature for refrigerant: 80°C. 5. When draining the air conditioning system, dispose of the refrigerant in accordance with the applicable regulations. Tyres, screwed fixings: 1. When working on the wheels, make sure that the combine harvester is safely immobilised and prevented from rolling (wheel chocks). 2. When working under the jacked combine, allow no-one on the machine. 3. Make sure that the lifting device has sufficient load-bearing capacity. 4. Removing and refitting tyres requires sufficient knowledge and specified fitting tools. 5. Check the tyre pressures regularly. Excessive tyre pressure leads to a risk of bursting. 6. All fixing screws and nuts for the front and rear wheels and track adjusting components must be retightened in accordance with the manufacturer's specifications. 7. This retightening is also required after each track adjustment and wheel change.

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Safety instructions for maintenance and repair Engine: 1. Do not carry out maintenance work while the engine is running. Remove the ignition key. 2. When working on the engine, disconnect the battery (negative terminal). 3. Only refill the fuel tank when the engine is at standstill. Do not smoke while refuelling. 4. Take care whenever hot oil may be released – risk of burns. 5. Make sure that the oil and fuel used are of the specified quality, and only store them in approved containers. 6. Dispose of oils, fuels and filters in accordance with the relevant regulations. Miscellaneous: 1. Before throwing away used and apparently empty pressurised cans (paint sprays etc.), empty them fully in a well-ventilated area away from sparks and naked flame. 2. If any parts have to be replaced, only authentic original DEUTZ-FAHR spare parts may be used. The use of spare parts, accessories and auxiliary devices that do not originate from DEUTZ-FAHR and are not tested and approved by DEUTZ-FAHR can have a negative effect on the specified characteristics or reliability and thereby detract from active and/or passive driving and working safety (accident protection etc.). DEUTZ-FAHR cannot accept any liability for any damage caused by the use of non-DEUTZ-FAHR original parts, accessories and auxiliary devices. 3. Replace all protective devices and guards after maintenance and repair work. 4. Do not carry out any welding, drilling, sawing and grinding work on the cab frame or the safety frame. Replace any damaged parts. 5. When replacing the cab ventilation filter, dispose of the used filter in accordance with regulations. 6. Auxiliary heaters must never be operated in closed rooms or during refuelling. 7. When carrying out electric welding work on the combine harvester, disconnect the alternator cable and battery.

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Notes

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5650H – 5690HTS General information on repair and maintenance Table of Contents Combine Harvester Type

5650H 5680H 5660HTS 5690HTS

Conversion table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 – 03

X

X

Tightening torques, bolting classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04

X

X

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05

X

X

Sealing, Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06

X

X

Single-component adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07

X

X

Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .08 – 09

X

X

Operating fluids, filling levels and oil grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

X

X

Release list DEUTZ lube oil quality stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

X

X

Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 – 13

X

X

Tightening torques for adapter sleeve bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

X

X

Check tension of chain and belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 – 19

X

X

Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

X

X

Servicing and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

X

X

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

X

X

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Conversion Tables Conversion factor 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

mm in. ft cm2 sq.in. cm3 l cu.in. US gall Imp.gall g kg oz Ibs kp/cm2 Ibs/sq.in. bar kpm ft.lbs Nm daNm PS BHP kW

1,0 25,4 304,8 1,0 6,4516 1,0 1000 16,3870 3785,4 4546 1,0 1000 28,353 453,59 1,0 0,0703 1,0193 1,0 0,1383 0,1019 1,019 1,0 1,0139 1,36

mm mm mm cm2 cm2 cm3 cm3 cm3 cm3 cm3 g g g g kp/cm2 kp/cm2 kp/cm2 kpm kpm kpm kpm PS PS PS

0,03937 1,0 11,9999 0,155 1,0 0,001 1,0 0,016387 3,7854 4,546 0,001 1,0 0,028353 0,45359 14,21 1,0 14,485 7,233 1,0 0,7373 7,373 0,98632 1,0 1,3405

in. in. in. sq.in. sq.in. l l l l l kg kg kg kg Ibs/sq.in. Ibs/sq.in. Ibs/sq.in. ft.Ibs ft.lbs ft.Ibs ft.lbs BHP BHP BHP

0,00328 0,08333 1,0

ft ft ft

0,06102 61,024 1,0 23,1 277,41 0,03527 35,27 1,0 15,9983 0,981 0,06903 1,0 9,81 1,356 1,0 10,0 0,736 0,7462 1,0

cu.in. cu.in. cu.in. cu.in. cu.in. oz oz oz oz bar bar bar Nm Nm Nm Nm kW kW kW

0,00026477 0,26417 0,04329 1,0 1,20091 0,0022046 2,2046 0,0625 1,0

USgall USgall USgall USgall USgall Ibs Ibs Ibs Ibs

0,981 0,1356 0,1 1,0

daNm daNm daNm daNm

0,00021998 0,21998 0,03604 0,8327 1,0

Imp.gall Imp.gall Imp.gall Imp.gall Imp.gall

Conversion from mm to inches mm 0 1 2 3 4 5 6 7 8 9 10

2

0,0 0,0394 0,0787 0,1181 0,1575 0,1969 0,2362 0,2756 0,3150 0,3543 0,3937

0,1 0,00394 0,0433 0,0827 0,1220 0,1614 0,2008 0,2402 0,2795 0,3189 0,3583 0,3976

0,2 0,00787 0,0472 0,0866 0,1260 0,1654 0,2047 0,2441 0,2835 0,3228 0,3622 0,4016

0,3 0,0118 0,0512 0,0906 0,1299 0,1693 0,2087 0,2480 0,2874 0,3268 0,2661 0,4055

0,4 0,0157 0,0551 0,0945 0,1339 0,1732 0,2126 0,2520 0,2913 0,3307 0,3701 0,4094

0,5 0,0197 0,0591 0,0984 0,1378 0,1771 0,2165 0,2559 0,2953 0,3346 0,3740 0,4134

0,6 0,0236 0,0630 0,1024 0,1417 0,1811 0,2205 0,2598 0,2992 0,3386 0,3780 0,4173

0,7 0,0276 0,0669 0,1063 0,1457 0,1850 0,2244 0,2638 0,3031 0,3425 0,3819 0,4213

0,8 0,0315 0,0709 0,1102 0,1496 0,1890 0,2283 0,2677 0,3071 0,3465 0,3858 0,4252

0,9 0,0354 0,0748 0,1142 0,1535 0,1929 0,2323 0,2717 0,3110 0,3504 0,3898 0,4291

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Conversion Tables Conversion from degrees Celsius (°C) to degrees Fahrenheit (°F) °C

°F

°C

°F

°C

°F

°C

°F

°C

°F

°C

°F

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

32 33,8 35,6 37,4 39,2 41 42,8 44,6 46,4 48,2 50 51,8 53,6 55,4 57,2 59 60,8 62,6

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 –

64,4 66,2 68 69,8 71,6 73,4 75,2 77 78,8 80,6 82,4 84,2 86 87,8 89,6 91,4 93,2 –

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 –

95 96,8 98,6 100,4 102,2 104 105,8 107,6 109,4 111,2 113 114,8 116,6 118,4 120,2 122 123,8 –

52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 –

125,6 127,4 129,2 131 132,8 134,6 136,4 138,2 140 141,8 143,6 145,4 147,2 149 150,8 152,6 154,4 –

69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 –

156,2 158 159,8 161,6 163,4 165,2 167 168,8 170,6 172,4 174,2 176 177,8 179,6 181,4 183,2 185 –

86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 – – –

186,8 188,6 190,4 192,2 194 195,8 197,6 201,2 203 204,8 206,6 208,4 210,2 212 – – – –

Conversion from degrees Celsius (°C) to degrees Kelvin (K) °C

K

°C

K

°C

K

°C

K

°C

K

°C

K

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 –

291 292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 –

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 –

308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 –

52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 –

325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 –

69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 –

342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 –

86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 – – –

359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 – – –

Temp. °C = 5 (t °F – 32) 9

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Temp. °F = 5 (t °C + 32) 9

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5650H – 5690HTS Tightening value for bolts according to in-house standard H0385-1 Bolting class II Bolts and nuts are to be tightened by means of a torque wrench Shoulder stud with standard metric thread Friction factor µges. = 0,12

4

Bolting class II Tightening torques M A nenn Nm

Shoulder stud with metric fine thread Friction factor µges. = 0,12 Bolting class II Tightening torques M A nenn Nm

d mm

Strengh class

M4

8,8 10,9 12,9

2,5 3,5 4,5

M8 x1

8,8 10,9 12,9

22 34 38

M5

8,8 10,9 12,9

5,0 7,5 8,5

M10 x 1,

8,8 10,9 12,9

46 70 80

M6

8,8 10,9 12,9

8,5 13 13

M10 x 1,25

8,8 10,9 12,9

44 65 75

M7

8,8 10,9 12,9

14 20 24

M12 x 1,25

8,8 10,9 12,9

80 110 140

M8

8,8 10,9 12,9

20 30 36

M12 x 1,5

8,8 10,9 12,9

75 110 130

M10

8,8 10,9 12,9

42 60 70

M14 x 1,5

8,8 10,9 12,9

120 180 210

M12

8,8 10,9 12,9

70 110 120

M16 x 1,5

8,8 10,9 12,9

190 280 320

M14

8,8 10,9 12,9

110 170 200

M18 x 1,5

8,8 10,9 12,9

280 400 480

M16

8,8 10,9 12,9

180 260 300

M18 x 2

8,8 10,9 12,9

260 380 440

M18

8,8 10,9 12,9

260 360 420

M20 x 1,5

8,8 10,9 12,9

400 550 650

M20

8,8 10,9 12,9

360 500 600

M20 x 2

8,8 10,9 12,9

360 550 600

M22

8,8 10,9 12,9

480 700 800

M22 x 1,5

8,8 10,9 12,9

550 750 850

M24

8,8 10,9 12,9

600 850 1000

M22 x 2

8,8 10,9 12,9

500 700 850

M27

8,8 10,9 12,9

900 1300 1500

M24 x 1,5

8,8 10,9 12,9

700 1000 1200

M30

8,8 10,9 12,9

1200 1700 2000

M24 x 2

8,8 10,9 12,9

650 950 1100

M27 x 2

8,8 10,9 12,9

650 950 1100

M30 x 2

8,8 10,9 12,9

1400 1900 2300

d mm

Strengh class

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Lubricants Solid lubricants Material specification

Part No.

Operating temperature range in °C

Equivalent manufacturer's

DEUTZ S 1

0134 0198

–180° bis +1400°

Never Seize

DEUTZ S 2 DEUTZ S 5

0100 5149 0101 6126

–125° bis +1450° –130° bis +1130°

Molykote Paste G-n Rapid Molykote BR 2

0100 9454

–20° bis +140°

Emteka NU 15

Grease DEUTZ F 15

Cooling System Protection

5l Container

0101 1490

20l Container

0101 6416

210l Container

1221 1500

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Sealants Material specification

KHD Part-No.

Operating temperature range in °C

Equivalent manufacturer's designation

DEUTZ DW 25 DEUTZ DW 30 DEUTZ DW 40

0100 1306

– 190° to + 250° – 190° to + 700° – 190° to + 350°

DEUTZ DEUTZ DEUTZ DEUTZ DEUTZ

0100 0100 0100 0134 0100

9463 8379 8383 0088 1286

– 135° – 130° – 165° – 173° – 190°

to to to to to

+ 100° + 150° + 230° + 230° + 110°

0100 0131 0109 0101 0134 0100 0131 0100 0100 0100 0100 0109 0633

8329 9907 8072 6113 0167 1254 9912 9670 8802 8874 9679 1503 9192

– 190° – 155° – 155° – 155° – 155° – 155°

to to to to to to

+ 150° + 150° + 150° + 150° + 150° + 150°

– 155° – 155° – 155° – 155° – 155°

to to to to to

+ 200° + 150° + 150° + 120° + 150°

Thread tape Devametal NiCuFe 10.83/8-3W Reinz 4402 Ferrolastic Terostat 8585 Terolan 3531 Silastic Q3-3305 Silastic 732 RTV Curil Teroson-Fluid Sealing compound G Loctite Prod.-No. 601 Loctite Prod.-No. 586 Loctite Prod.-No. 221 Loctite Prod.-No. 270 Loctite Prod.-No. 582 Loctite Prod.-No. 747 (activator T) Loctite Prod.-No. 640 Loctite Prod.-No. 573 Loctite Prod.-No. 275 Loctite Prod.-No. 638 Loctite Prod.-No. 570 Sikaflex

DW DW DW DW DW

43 44 47 48 50

DEUTZ DW 53 DEUTZ DW 55 DEUTZ DW 56 DEUTZ DW 57 DEUTZ DW 59 DEUTZ DW 60 DEUTZ DW 61 DEUTZ DW 62 DEUTZ DW 63 DEUTZ DW 64 DEUTZ DW 65 DEUTZ DW 66 Sealing Compound

Adhesives

6

Material specification

KHD Part No.

Operating temperature range in °C

Equivalent manufacturer's designation

DEUTZ DEUTZ DEUTZ DEUTZ DEUTZ DEUTZ DEUTZ DEUTZ

0100 0292 0100 0100 0100 0131 0100 0100

– 30° to + 200°

Gupalon normal Epple adhesive 56 Loctite – IS – 414 Loctite – IS – 495 Loctite – IS – 416 Terostat 58 Terokal Gupalon express

KL 1 KL 1 KL 5 KL 5A KL 5B KL 8 KL 9 KL 14

1300 5947 8365 9331 9332 9914 4131 9506

– 60° – 60° – 60° – 30° – 30° – 30°

to to to to to to

+ 180° + 180° + 180° + 120° + 120° + 200°

307.1133.3.6 englisch (en) 10.2006

Service Training

Single-component adhesives Use of single-component adhesives For particularly important screwed connections and for snug-fit connections subject to high stress, a single-component adhesive is factory-applied, to guarantee increased protection against loosening and undoing. When the machine is repaired, the parts to be glued together must first be cleaned carefully with commercially available cleaning agents or purified gasoline. The threads or surfaces to be glued must be free of oil and grease and must be dry. Adhesive application: For threaded connections, it is sufficient to apply the adhesive to the outside thread. For tapped blind holes, the adhesive must always be applied to the internal thread, since otherwise the adhesive would be forced out by the air escaping as the part is screwed in. For snug-fit and joint connections with low play on one part, if there is relatively high play on both parts, apply the adhesive as a closed ring and mount with a gentle rotating movement. Hardening: The adhesive takes 6 – 24 hours to harden at a room temperature of 20 °C, which must be maintained constant for the entire hardening period. Since this is not always possible for outside assemblies, we recommend that the relevant site be locally heated by heaters. About 1– 4 hours at 60 °C will be sufficient to harden the adhesive. Do not move the parts. Accelerated hardening is also achieved by pretreatment with an activator. The use of activators reduces the strength of the adhesive, and so if necessary the strongest adhesive should be used. The following table provides a list of adhesives of different makes used in combine harvesters.

KHD Designation

KHD Part No.

Loctite Type

Omnifit Type

Conloc Type

Guidelines for use

DEUTZ DW 55

0100 1251

601

M 150

CL 202

for play of 0.02–0.03, makes threads harder to loosen, secures screws up to M16

DEUTZ DW 56

0109 8072

586 (AVX)

M 80 red

CL 103

for play of 0.02–0.02, makes threads harder to loosen, secures screws up to M20

DEUTZ DW 57

0100 1256

221

L 150 green

CL 051

Improved press-fit 0–0.03, easily loosened, screws up to M14

DEUTZ DW 59

0100 1252

270

M 250 violet

CL 301

for play of 0.02–03, very firm connection, only for large-size threads

DEUTZ DW 60

0100 1254

582 (CVX)

H 150 green

CL 303

for play of 0.03–0.5, extra-firm connection for temperatures up to 100°, only for large-size threads

DEUTZ DW 61

0109 8073

747 Activator (Activator T) RS US

CL Activator

for faster hardening

0114 5546

648

307.1133.3.6 englisch (en) 10.2006

high-strength connection for joints shafts hubs

7

Service Training

Maintenance and Inspection Schedule for Combine Harvesters for the first time after operating hours

after every operating hours

X

X

Maintenance and Inspection Schedule for DEUTZ-FAHR Combine Harvesters To be carried out by authorised DEUTZ-FAHR workshops only

1

X

Engine Maintenance and inspection according to engine operating instructions 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23 1.24

Check oil level (twice per day during running in phase) Engine oil change (at least once a year) Replace lube oil filter cartridge Check coolant level (antifreeze protection) Change coolant Retighten engine fastening bolts Check engine for leak tightness Check, adjust valve clearance (not earlier than

X

X X

X

X X

X

every two years X X

X

X

2 hours after engine shutdown) X

Check air intake and exhaust system for form fit and for leaks Check condition of hose sleeves of air ducts and coolant lines and check for leaks Check cooler, clean if necessary: Coolers for engine, charge air, fuel Drain condensate at the charge air cooler Check condition of oil drain hose and check for leaks Check alarm facilities (air filter, oil pressure, temperature, coolant level) Check sealing at cooler frame and sieve pan Clean engine compartment

X X

X

X

Change fuel filter cartridge Drain fuel tank sump Drain fuel pre-filter Replace fuel pre-filter, filter cartridge Clean air filter cartridge if indicated by warning light Replace air filter cartridge when cleaned five times or when contaminated by soot Replace air filter safety cartridge

X

Oil quality Deutz DQC III-05, ACEA E4-99/E6-04*

X X

X

X X

X

X

X

at least every two years X X

X X

X

X X X

X X

X X

X

X

X X X

X

X X X

*Deutz lube oil TLX-10W 40FE Alternatively it is possible to use oils in compliance with the DEUTZ lube oil quality classes DQC III-05, CEA E4-99/E6-04

2

Drives 2.1 2.2 2.3 2.4 2.5 2.6 2.7

3

3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12

Check hydraulic oil level Clean ventilating filter at oil reservoir Hydraulic oil change (oil change at least once a year) Check hydraulic system for leaks Check hydraulic functions Check hydrostatic steering system Check zero-point setting of hydrostatic ground drive control Replace disposible filter cartridge of hydrostatic ground drive (Hydromat) Check high pressure hoses at hydrostatic pump and motor for secure mounting Clean oil cooler when contaminated Clean or replace line filter of hydrostatic ground drive Check condition of hydraulic hoses

Gear oil API-GL 5 (MIL-L-2105 D) SAE 90 X

X

X X

X X

X X

X

X

X

X

X X

X

X

X

X X

X X X

X

X X

X

X

X Hydraulic oil HLP 46 DIN 51524 Part 2

X

X X X

X

X X

X

X X X

X X

X X

X

X

X

X

X

Check tension of V-belt and feeding chain Check, adjust friction clutch

X X X

X X

Check function of electrical reversing device Check rotating parts for signs of wrapping and remove crop residue Check feeding chain, tighten if necessary Check locking device for cutting mechanism Adapt cutting mechanism to ground with diagonal struts in the feed passage

X

X

X X X X

X

X

X

Threshing Mechanism, Cleaning System, Grain Tank 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8

8

Oil level checking Lower angular gear for grain tankoil change (at least once a year) Oil level checking Check V-belt and chain tension and retighten if required Check belt guides and adjust if required

X

Feed passage 4.1 4.2 4.3 4.4 4.5 4.6 4.7

5

Check gear shift and adjust if necessary Final drive oil change (at least once a year) Oil level checking Threshing drum reduction gear oil change (at least once a year)

X

Hydraulic system 3.1 3.2 3.3

4

Check for oil leakage

Shift gear oil change (at least once a year) Oil level checking

Check concave basic setting, threshing drum Check threshing drum speed variator Check basic setting of turbo separator Empty stone trap Check spray cloth at concave, above straw walkers Check straw walker shaft speed Check sieve pan drive and rubber bearings Check straw walkers, sieve securing bolts and seals

X X X

X

X X X

X X X X X

X X X X

X X

307.1133.3.6 englisch (en) 10.2006

Service Training

Maintenance and Inspection Schedule for Combine Harvesters for the first time after operating hours

after every operating hours

X

X

Maintenance and Inspection Schedule for DEUTZ-FAHR Combine Harvesters 5 Threshing Mechanism, Cleaning System, Grain Tank 5.9 5.10 5.11 5.12 5.13 5.14

Check grain pan sections for firm fit

Check fan variator Check grain elevator chain, tighten if necessary Check grain tank tube lock Check, adjust friction clutch Check grain tank and unloading system for leaks Remove accumulations of crop residuals: Concave, threshing drum, grain pan, under-walker return floor, 5.15 augers, hollow space above fan 5.16 Check inspection and service flaps for tightness and proper closed locks.

X X X X X X

X

X

X

X

X X X X

X

X

6 Wheels and Brakes 6.1 6.2 6.3 6.4 6.5

X X

6.6

Check service brake, free movement of brake pads Check brake fluid level Replace brake fluid Check parking brake, readjust if necessary Retighten screwed connections: Shift gear, final drive, chassis to axle Retighten wheel nuts to specified torqueDrive wheels 750 Nm Rear wheels310 Nm

6.7 6.8 6.9 6.10

Check screw connections on the adjustable steering axle to specifications, retighten 410 Nm Check toe-in of the rear wheels, adjust if necessary Check bearing play of the rear wheels, readjust Check tyre pressure

X X X X

X

X X every two years X X

X X X

X

X

X X X

X

X X X

X X

7 Lubrication (see Lubrication Schedule)

Thoroughly clean points of lubrication prior to greasing 7.1 7.2

Check for grease escape at points of lubrication (hose connection, condition of lubrication hoses) Check for grease escape at relief pressure valve with centralised lubrication system

X

X X

8 Electrical System 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12

Check lighting equipment Check adjustment of headlights Check electrical system Check wiring harness and plugs for pinches or damage Check battery fastening, terminals Check battery electrolyte level and density of acid Check warning devices Check electrical adjustment of concave and turbo separator, calibrate with Com. Control if necessary Check on-board computer, grain loss monitoring system Clean grain loss sensors when contaminated Calibrate electronic cutting mechanism control (EMR-D) with each change of front attachment Check Balance control, recalibrate if necessary

X X X

X X X X

X X X X X

X X X X

X X

X

X

X X

X

X

9 Cabin, Compressor Cooling System, Cabin Heating 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8

Check sealing of fresh air filters Clean fresh air filter and recirculating air filter (replace if required)

X

X

Check correct functioning of compressor cooling system Retighten V-belt for air conditioning compressor Check correct coolant filling level, check for leaks Clean evaporator, condenser when contaminated Replace fluid container when humidity indicator changes its colour Check cabin heating for proper functioning and for leaks

X X X

X

X

X

X

X

10 Cutting Mechanism, Trailer, Front Attachment for Rape 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10

Check tension of V-belt and chains Check friction clutches Check settings of intake auger Check proper functioning of reel hydraulics Check knife gear (head bearing) Check knife guide for wear Check sensing skids for free movement, remove contamination Retighten trailer wheel bolts, wheel nuts Check oil level of front attachment for rape Change hydraulic oil, replace return filter

X X X X X

X

X

X X X

X X

X X X

X

X X

X

Cutting Mechanism with Trailer, Front Attachments for Special Crops, Maize Header, Straw 11 Chopper, Chaff Spreader etc.

X

X

X X

All maintenance and inspection operations must comply with the individual operating instructions

12 Accident Prevention Regulations Inform operators about compliance with legal requirements 12.1 (see operating instructions) 12.2 Check protective and locking devices 12.3 Let fire extinguishers be checked for proper functioning Components made by other manufacturers may only be installed with the written 12.4 consent of SAME DEUTZ-FAHR

307.1133.5.6 englisch (en) 10.2006

X X

X every two years

9

Service Training

5650H, 5660HTS, 5680H, 5690HTS Operating fluids, filling levels1) and oil grades Designation

5650H 5660HTS

5680H 5690HTS

Level Change Inspection2) Interval3)

operating media Specifications

Fuel tank

ca.555 l

ca.555 l

daily

Diesel fuel, sulphur content below 0,5 %

DEUTZ-engine

20,0 l

20,0 l

10 h

incl. filter change

21,0 l

21,0 l

50 h then DEUTZ lube oil TLX-10W 40FE, every 250 h or oils according to Deutz quality class DQC III-05 4) (ACEA E4-99/E6-04)

Cooling System

55.0 l

55.0 l

daily

2000 h or every two years

Shift gear

17,0 l

17,0 l

250 h

50 h then Gear oil every 500 h API-GL 5 (MIL-L 2105 D) SAE 90

Final drive

10,0 l

10,0 l

250 h

50 h then Gear oil every 500 h API-GL 5 (MIL-L 2105 D) SAE 90

65 l

65 l

daily

50h then Hydraulic oil DIN 51524 part 2 every 500 h HLP 46 (ISO)

Front attachment for rape

6l

6l

50 h

50 h then Hydraulic oil DIN 51524 part 2 every 500 h HLP 46 (ISO)

Hydraulic brake system

0,3 l

0,3 l

100 h

every two years

Threshing drumReduction gear

1.0 l

1.0 l

250 h

50 then Gear oil API-GL 5 (MIL-L 2105 D) SAE 90 every 500 h

2,0 kg 3 207 cm

2,0 kg 3 207 cm

annualy

Lower angular gear at grain tank tube

0,75 l

0,75 l

250 h

Gear chaff spreader

0,4

0,4 l

Chains, joints

as required as required

Hydraulic System

4)

Air conditioning system Compressor

5)

Deutz Cooling System Protection Agent Ordering no. 01011490 (5l)

Brake fluid DOT 4 yellow / DOT 3 or SAE J 1703

Coolant R134a Refrigerant oil SP20 for R134a 50 then Gear oil API-GL 5 (MIL-L 2105 D) SAE 90 every 500 h 50 then Gear oil API-GL 5 (MIL-L 2105 D) SAE 90 every 500 h SAE EP multi-purpose grease NLGI2

1) The specified filling quantity is a recommended value. The corresponding control facilities shall be definitive. 2) Daily visual inspection for oil leaks 3) Oil change at least once a year. 4) In case of high ambient temperatures oils of higher viscosity can be used. 5) Works at the compressor cooling system must only be performed by a specialised work shop.

10

307.1133.3.6 englisch (en) 10.2006

Service Training

Release list DEUTZ lube oil quality stage DQC III-05 Manufacturer DEUTZ ADDINOL AGIP Akros ARAL AVIA BAYWA BP OIL International

Castrol

CEPSA CHEVRON DEA

ESSO FUCHS EUROPE MOBIL OIL

OMV AG Ravensberger Schmierölvertrieb Lube oil refinery Salzbergen Shell International

Texaco TOTAL

Lubricant type DEUTZ OIL TLX-10W40FE ADDINOL Super Truck MD 1048 ADDINOL Ultra Truck MD 0538 Agip Sigma Ultra TFE Autol Valve Ultra FE Akros Synth. Gold Aral MegaTurboral Aral SuperTurboral TURBOSYNTH HT-E BayWa Super Truck 1040 MC BayWa Turbo 4000 BP Vanellus E7 Plus BP Vanellus E7 Supreme BP Vanellus C8 Ultima Castrol Enduron Plus

SAE class 10W-40 10W-40 5W-30 10W-40 10W-40 10W-40 10W-40 5W-30 10W-40 10W-40 10W-40 10W-40 10W-40 5W-30 5W-40

Castrol Enduron

10W-40

Castrol Elexion EUROTRANS SHPD Chevron Delo 400 Synthtic DEA Cronos Synth DEA Cronos Premium LD DEA Cronos Premium FX Essolube XTS 501 Fuchs Titan Cargo MC Fuchs Titan Unic Plus MC Mobil Delvac 1 SHC

5W-30 10W-40 5W-40 5W-30 10W-40 10W-40 10W-40 10W-40 10W-40 5W-40

Mobil Delvac 1 Mobil Delvac XHP Extra OMV super Truck OMC truck FE plus Ravenol Performance Truck

5W-40 10W-40 5W-30 10W-40 10W-40

Availability Europe Europe, Asia Europe, Asia worldwide Germany Europe worldwide worldwide Germany South Germany South Germany Europe Europe Europe Europe, America, Australie, Afrique du Sud Europe, Amérique, Australia, South Africa USA Spain, Portugal North America Germany, Europe Germany, Europe Europe Europe worldwide worldwide Europe, SE Asia, Africa worldwide Europe, SE Asia Europe Europe Germany

Wintershall TFG

10W-40

Europe

Shell Myrina TX/Shell Rimula Ultra

5W-30

Europe, designation varies nationally

Shell Myrina TX/Shell Rimula Ul-tra

10W-40

Ursa Super TDX10W-40 Ursa Premium FE 5W-30 TOTAL RUBIA TIR 8600 EXPERTY

10W-40 5W-30 10W-40 10W-40

Europe, designation varies nationally Europe Europe worldwide worldwide

307.1133.5.6 englisch (en) 10.2006

11

Service Training

5650H – 5690HTS Speeds 5670

Combine Harvester

5680 5690 -12225

5650, 5660 5680, 5690 + 12226

1

Engine with threshing mechanism disengaged

1/min

2610 – 2655

2425

±15

2390

±15

1

Engine with threshing mechanism engaged

1/min

2590 – 2635

2415

±15

2385

±15

2

Straw stripper drum 1)

1/min

930

3

Threshing drum

1/min

400 – 1250

4

Grain tank discharge

1/min

560

5

Fan

1/min

400 – 900

6

Sieve box

1/min

285

7

Returns elevator – grain Returns elevator – maize

1/min 1/min

1110 ±30 795 ±20

8

Straw walkers – grain Straw walkers – rice

1/min 1/min

201 210

+5

206 213

±2 ±2

206 213

±2

+5/ –6

9

Feed passage shaft, top

1/min

425

+/ –2

430

±20

430

±20

10

Turbo Separator Grain Turbo Separator Maize

1/min 1/min

790 ±20 380 ±30

805 390

+30/ –20

805 390

+30/ –20

+25/–40

945 ±50

±40

+15

945

405 – 1265 530

+50/–30

+25/–40

±40

410 – 950 301

±50

405 – 1265 530

+50/–30

±5

±50

±40

410 – 950 301

1170 ±30 850 ±20

+25/–40

+50/–30

±5

1170 ±30 850 ±20

±30

±2

±30

1) As of year of manufacture 2007 the straw stripper drum is driven by the threshing drum.

12

307.1133.3.6 englisch (en) 10.2006

Service Training

A00005

A00006

307.1133.3.6 englisch (en) 10.2006

13

Service Training

5650H – 5690HTS Tightening values of adapter bearings Bearing point

Bearing

Tightening torque

Threshing drum/turbo separator

Grooved ball bearing

140 Nm

Straw stripper drum left side

Grooved ball bearing

140 Nm

Straw stripper drum right side

Ball joint bearing

180 Nm

Straw walker bearing

Grooved ball bearing

Pretensioning torque 50 Nm + Swivelling angle 180°

Shaft of sieve box drive

Swivel-joint roller bearing

100

Countershaft inside of feed passage

Swivel-joint roller bearing

56 Nm

14

+20

Nm

307.1133.3.6 englisch (en) 10.2006

Service Training

Notes

307.1133.3.6 englisch (en) 10.2006

15

Service Training

5650H – 5690HTS Check tension of chain and belt at left side

2

1

5

6

7

8

3

9

4

10

11

Check spring tension L Caption

Tensioning piece

Length

Comment

1

Block tightener reel drive chain

–

fixed

2

Block tightener angular gear drive chain

–

fixed

3

Idler pulley, turbo separator drive

L

4

Idler pulley, straw walker countershaft

L

5

Tensioning pulley knife gear drive

–

fixed

6

Tensioning wheel intake auger drive chain

–

fixed

7

Idler pulley, cutting table

L

8

Tensioning pulley impeller synchronous drive

L

9

Idler pulley, sieve box drive

L

10

Idler pulley, grain auger drive chain

L

11

Tensioning pulley returns elevator drive belt

–

fixed

L = Length according to adjustment gauge

Note: Refer to chapter C for checking and adjustment of the belt couplings

16

307.1133.3.6 englisch (en) 10.2006

Service Training

2 1 L 34940-1

35371

35036

2

1

3

6

5

L

35035

32983

5

4

32983

6

L L

L

35355

33815 K0036-2

7

8

9

11

L

30969 90009

10

307.1133.5.6 englisch (en) 10.2006

11

17

Service Training

5650H – 5690HTS Check tension of chain and belt at right side 18 13

12

14

16

19

17

15

24

23

22

20

21

34939-2

Check spring tension L Caption 12 13 14 15 16 17 18 19 20 21 22 23 24

Tension spring Length Dust extractor fan – Idler pulley, cooler drive L Fuel pump, generator V-belt – Air-conditioning compressor V-belt – Idler pulley, grain tank discharge drive L Block tightener grain tank filler auger drive chain – Tension device elevator chain – Idler pulley, threshing drum drive L Chain variator adjustment – Idler pulley, fan drive L Idler pulley, straw walker drive L Idler pulley, straw chopper drive L Chaff spreader: Check belt alignment, correct if necessary –

Comment

Visual inspection

L = Length according to adjustment gauge

18

307.1133.3.6 englisch (en) 10.2006

Service Training

12

14

L

35366

35455

12

13

00-2

14

15

17 L

30509

15

35367

16

31658

17

20 18 L 31656

18

34944

19

35362

20

L

L

L 35353

21

34945

22

34942

23

00-3

24 307.1133.3.6 englisch (en) 10.2006

19

Service Training

5650H – 5690HTS Maintenance and repair General instructions Observe the general accident prevention regulations with all repair and maintenance works. Make sure that the engine cannot be started by a second person while working at the combine harvester: Remove start key and battery master switch! Operating media must be disposed environmental fairly. Retighten highly stressed screwed connections subsequent to reassembly after a few operating hours, e.g. wheel nuts, bolts on axles. Perform a functional test and check the oil level after carrying out repair works at the hydraulic system. Check hydraulic system for leaks. Replace porous or damaged hydraulic or fuel hoses in due time. Check cable harnesses for pinched spots or damages. Observe fire protection requirements while carrying out welding works at the combine harvester. Thoroughly remove dust and crop residuals. Protect cable harnesses, hydraulic hoses and sealing elements against impact of heat. Remove connectors from electronic control units. Tighten the circlip to rotational direction of shaft while assembling circlip bearings. Mount adapter bearing according to factory specification. Causes for vibration must be remedied immediately. E.g. imbalance caused by foulings on beating arms of the threshing drum or by broken chopper knives, by v-belts with grinding marks or by imbalance of tensioning pulleys by dust deposit.

20

307.1133.3.6 englisch (en) 10.2006

Service Training

Servicing and Maintenance General Instructions V-Belts Since new V-belts still stretch, their tension must be monitored more frequently during the first few operating hours. ● V-belts with fixed idler pulley are correctly tensioned if they can still be pressed down slightly. Belts that are too loose are subject to greater wear. ● The V-belt guide must be designed to prevent the disengaged belt rubbing against the belt pulley. The gap between the guide and the tensioned V-belt must be 8 mm. ● Never pull the V-belt over a pulley violently or with a tool. ● We recommend that dirty V-belts should be cleaned with a 1:10 solution of glycerine spirit solution (or similar). Do not use petrol, benzene, terpentine etc. ● Avoid mechanically stressing the V-belts. During winter storage, make sure that the pulleys are not attacked by rust.

A00160

Chains The drive chains must be regularly lubricated with transmission oil. After the harvest season, remove the drive chains, clean with diesel fuel, dip in warm chain grease and refit. ● Always mount chain locking links so that they cannot catch, e.g. with the closed side of the retaining spring facing the direction of drive. ● Always use new locking wire if chain locks have been openend. Variator drives Remove dust and dirt deposits between the pulley halves. The variator drives (reel, threshing drum and cleaning fan) must be adjusted after lubricating in order to ensure that the lubricating film spreads evenly over the friction surfaces.

A00161

Screwed fixings Check that all screwed fixings are secure, especially on the sieve box, and retighten if necessary. Check nuts secured with split pins. Fuel and oil tanks Refill the tanks after ending work, in order to prevent condensation, especially if the difference between working and non-working temperatures is high. Tyres Regularly check the tyre pressures and the tightness of the wheel nuts. 307.1133.3.6 englisch (en) 10.2006

A00162

21

Service Training

5650H – 5690HTS Special tools Nut wrench for mounting adapter bearings Application

22

Part No

Sieve box drive shaft bearing, countershaft inside of feed passage

0043 6070

Straw walker bearing d 40

0041 6050

Threshing drum bearing, straw stripper, turbo separator

0041 6055

Miscellaneous Tube headpiece for knocking loose the speed variator pulley on the shaft of the straw stripper drum Detaching device heavy Tubular key SW36/46 Torsion bar Key driver straight small Key driver straight great Key driver crooked Bolt M16x240 to spread apart the speed variator pulleys (threshing drum, reel)

0043 6021 0041 6010 0620 8673 0041 6031 0041 6100 0041 6101 1601 2260

Remark

0625 7346

Bolt M16x140 to draw out the adjusting device of the threshing drum variator

0041 6070

3 pole test adapter for position transmitter EMR-D, balance 55 pole test adapter for EMR-D control device Programming cable for Balance and Commander Control

1603 1484 1601 7182 1605 0267

307.1133.3.6 englisch (en) 10.2006

A Service Training

5650H – 5690HTS Engine Table of Contents Combine Harvester Type

5650H

5680H

5660HTS 5690HTS Index of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02

X

X

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03

X

X

Technical data DEUTZ engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04

X

X

Rating plate / serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05 – 06

X

X

Bolt tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07

X

X

Description of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08 – 09

X

X

EMR, electronic engine controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 – 15

X

X

Overview power supply EMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 – 17

X

X

Control unit EMR, gas control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 – 19

X

X

Plug assignments of the EMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 – 21

X

X

Sensor and transmitters overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 – 23

X

X

Fuel system, overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 – 25

X

X

Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

X

X

Clean/replace fuel pre-filter, filter element; bleeding of fuel system . . . . . . . . . . . . . . . . . . .27

X

X

Change fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

X

X

Change fuel oil leakage pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

X

X

Fuel injection valve, injection pipes assembly, disassembly . . . . . . . . . . . . . . . . . . . . . . . . .30 – 31

X

X

Testing and setting of injectors free from leak-off fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 – 33

X

X

Cooling circuit, overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 – 35

X

X

Draining / filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

X

X

Mounting of the coolant temperature transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

X

X

Replacement of thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

X

X

Mounting of coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

X

X

Maintenance and inspection Deutz engine, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

X

X

Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

X

X

Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

X

X

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

X

X

Operating media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

X

X

Release list DEUTZ lube oil quality stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

X

X

Engine oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

X

X

V-Belt generator tensioning/replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

X

X

Checking, adjusting valve clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

X

X

Adjustment instruction for valve clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

X

X

Determination of cylinder-head gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 – 53

X

X

Mounting of the cylinder-head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

X

X

Tightening of the cylinder head screws sequential order . . . . . . . . . . . . . . . . . . . . . . . . . . .55

X

X

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 – 57

X

X

Charge cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

X

X

Cooling fan drive, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

X

X

Exhauster drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 – 61

X

X

Rotating sieve pan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 – 63

X

X

Driven shaft of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 – 67

X

X

Mounting of hydraulic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

X

X

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A Service Training

5650H – 5690HTS Engine, driven shaft of engine Index of abbreviations ATL Exhaust-driven turbocharger Bh Running hours EMR Electronic engine controller

Further technical documentation for the engine of Deutz AG: Operating instructions engine 1012/1013 Workshop manual BFM 1012/1013 de, en, fr, es System description EMR de, en Manual SERDIA, LEVEL III Fault diagnosis, main focus on fuel injection system

A2

0297 0297 0297 0297 0297

7379 7438 7432 7482 7509

307.1133.3.6 englisch (en) 10.2006

A Service Training

5650H – 5690HTS Maintenance and Inspection DEUTZ Engine: General Safety Instructions Engine: 1. Do not maintain the engine while running. Remove the ignition key! 2. On principle always disconnect the battery (negative pole) while working at the engine! A00009

3. Only fill up fuel with the engine stopped – No smoking! 4. Caution while draining hot lube oil – danger of burning! 5. Observe the specified quality of oil and fuel and store both only in approved containers! 6. Provide for collection of leakage fuel and waste oil in accordance with anti-pollution regulations! 7. Dispose of properly oils, fuels and filters! 8. After maintenance and repair works: Check whether all safety devices have been remounted and all tools have been removed from the engine! 9. Only carry out cleaning jobs with the engine stopped! 10. Battery gases are explosive! Avoid sparking and open fire near the batteries! Do not spill acid on skin or clothes! Wear safety goggles! Do not put tools on the batteries! 11. Also observe the additional safety instructions in this chapter!

307.1133.3.6 englisch (en) 10.2006

A3

A Service Training

5650H – 5690HTS Technical Data DEUTZ Engine Type BFM 1013 E Four-Stroke Diesel Engine with Direct Injection

BF6M 1013 E Number of cylinders / configuration

6 in tandem

Bore [mm]

108

Stroke [mm]

130

Total cylinder capacity [ltr.]

7,1

Method of operation / method of combustion

Four-stroke diesel with direct injection and exhaust-driven supercharger.

Firing order

1-5-3-6-2-4

Rotational direction

when facing flywheel: left

Rated speed [rpm]

see engine name plate

Power [kW]

see engine name plate

Valve clearance inlet / exhaust [mm] Commencement of delivery Injector opening pressure [bar] Min. oil pressure [bar], at lower idle speed and

0,3+0,1 / 0,5+0,1 see engine name plate 275+8 0,8

warmed-up engine (120 °C operating temperature) Method of cooling

Liquid cooled with integrated lube oil cooler

Coolant quantity [approx. ltr.] Engine and cooling system

55

Thermostat starts opening at [°C]

83

Thermostat fully open from [°C]

95

A4

307.1133.3.6 englisch (en) 10.2006

A Service Training

A

5650H – 5690HTS Rating Plate, Engine Serial Number Engine Data

B

The type (A), the engine serial number (B) and the performance data are stamped on the rating plate. When ordering spare parts, it is essential to quote the type and the engine serial number.

26 332_3

The rating plate (C) is affixed to the crankcase.

26 231_1

The engine serial number is stamped on the crankcase itself (arrow) as well as on the rating plate.

26 232_1

The cylinders are numbered consecutively, beginning at flywheel end.

26 233_0

307.1133.3.6 englisch (en) 10.2006

A5

A Service Training

5650H – 5690HTS Technical data DEUTZ engine Rating Plate

2013-0008

Pos.

Description

Remark

1

Type of engine

e.g. BF6M 1013 EC

2

Code

with engines according to specifications of commission 88/195/EWG

3

engine number

–

4

kW (G)

"overall power” (G-power), cooling fan is not running.

5

kW (S)

"nominal power” (S-power), cooling fan is running at full speed.

6

1/min

Nominal speed of the engine.

7

Commencement of delivery and

Commencement of delivery in degrees.

type of camshaft 8

kW (W)

Letter stands for type of camshaft "Active vent” (fan/blower) as a part of the specified power.

9,10

For free disposal.

11

Statement of standard and/or regulation

12

kW (G) red.

Reduced "overall power”, conditions on site pos. 14, 15.

13

kW (S) red.

Reduced "nominal power”, conditions on site pos. 14, 15.

14

Air temperature in °C

For environmental conditons on site.

15

Altitude above sealevel in m

For environmental conditons on site.

16

Injection pump code

Code for cylinder related statement about the toolfitting dimension of the pump determined at manufacturing (beginning from above with cylinder #1)

A6

307.1133.3.6 englisch (en) 10.2006

A Service Training

5650H – 5690HTS Technical data DEUTZ engine Bolt Tightening Torques (for further statements see workshop manual BFM 1012/1013) Flywheel If traceable use bolts 5 times max.

Initial tightening value: Bolts 30 – 45 mm long

20-30 Nm

Bolts 50 – 85 mm long

30-40 Nm

1. retightening angle Bolts 30 – 85 mm long

60°

2. retightening angle Bolts 30 mm long Bolts 35 – 85 mm long Cover for wheelhouses V-belt pulley

30° 60° 21±2 Nm

Initial tightening value:

40-50 Nm

1. retightening angle If traceable use bolts 5 times max.

Bolts 60 mm long

60°

Bolts 80 mm long

60°

2. retightening angle Bolts 60 mm long

30°

Bolts 80 mm long

60°

Note: Use Torx socket wrench E20 Front covers

21±2 Nm

Vibration damper with clutch flange (bolts fixed with glue) Cylinder head bolts (Observe sequential order)

70 Nm Initial tightening value: 1. step

50 Nm

2. step

130 Nm

Retightening Rocker arm support

90° 21 Nm

Rocker arm locknut

20±2 Nm

Crank case vent

8,5±1 Nm

Cylinder head cover

9±1 Nm

Connection nut fuel injection valve

40-50 Nm

Grip holder for fuel injection valve Injection pipe

16 + 5 Nm Initial tightening Retightening

Pressure control valve

5 Nm 25 + 3,5 Nm 30 Nm

Charging air pipe at cylinder head

11±1 Nm

Coolant tube at cylinder head

21±2 Nm

Coolant pump

21±2 Nm

Exhaust manifold

25±2 Nm

Exhaust-driven supercharger

- Bolts M8 - Bolts M10

21±2 Nm 40,5±4 Nm

Pressure oil pipe at turbocharger

21±2 Nm

Pressure oil pipe at crank case

39±3 Nm

Oil return pipe

21±2 Nm

Lube oil cooler

21±2 Nm

Connection piece at fuel filter casing

50±5 Nm

Oil pan - sheet metal oil pan

21±2 Nm

Connection case at flywheel Starter Shut-off solenoid Positioning element (observe sequential order) Oil pressure switch, oil pressure transducer

307.1133.3.6 englisch (en) 10.2006

M12

99±10 Nm

M16

243±25 Nm 70 Nm 21 Nm 17±1,5 Nm 18±2 Nm

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A Service Training

5650H – 5690HTS Description engine BFM 1013 E Overview 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 A

A8

Oil filling tube Coolant pump Fuel pump Vibration damper (2 pieces) Exchangeable fuel filter not applicable Exchangeable oil filter Oil sump Oil-level dip-stick Lube oil cooler Attachment facility for hydraulic pump resp. compressor Fuel oil leakage pipe with pressure control valve Cylinder head Transport device Crank case venting valve Speed controller SAE housing Flywheel Starter Exhaust-driven supercharger not applicable Exhaust manifold Intake Coolant inlet

307.1133.3.6 englisch (en) 10.2006

A Service Training

3

5

4 26336-3

26337-0

307.1133.3.6 englisch (en) 10.2006

A9

A Service Training

5650H – 5690HTS EMR Electronic engine controller System description

Use of EMR The electronic engine controller (EMR) serves as speed controller of DEUTZ Diesel engines of product line 1012/1013 (1015) for use in agricultural and construction machines as well as in aggregates. It has been designed for heavy operation even under difficult environmental conditions and has been approved the corresponding protection classes. The controller includes all functions of the mechanical controller (all speed control, torque limitation, LDA function) and provides moreover further functions.

System overview The EMR mainly consists of the sensors, the control unit and the manipulating element (actuator). All eqipment pertaining to the engine as well as pertaining to the vehicle/system are connected to the EMR control unit by means of separate prefabricated cable harnesses. The cabling pertaining to the vehicle is carried out by the manufacturer of the vehicle/system.

Equipment pertaining to the engine charging air pressure sensor

adjusting rod position transmitter/ actuator

temperature sensor coolant

speed sensor camshaft

EMR control unit

Equipment pertaining to the vehicle power supply

gas control unit Gasverstellmodul +switch S5S5 +Schalter switch motorspeed: Schalter Motordrehzahl: - -lower idleLeerlauf speed unterer - -increased idle speed erhöhter Leerlauf - -nominal speed Nenndrehzahl

Droop switchover K11

key switch start/stop indicator lamp malfunction EMR

Fuel temperature EMR 2

A 10

oil pressure lifting magnet sensor (optional) (optional)

diagnosis plug-socket

307.1133.3.6 englisch (en) 10.2006

A Service Training

5650H – 5690HTS EMR Electronic engine controller System description

The sensors mounted on the engine supply the electronics in the control unit with all relevant physical dimensions. According to these informations about the actual engine condition and according to the setpoints (gas control unit) the EMR excites a turning magnet actuating the adjusting rod of the injection pumps and thereby metering the fuel amount. The exact position of the adjusting rod is fed back and corrected if necessary by means of the adjusting rod position transmitter located in a housing together with the turning magnet, the "manipulating element”. The EMR is equipped with safety facilities and safety measures both in hard- and software, in order to ensure emergency operating functions (limp home). The EMR is cut off from the power supply by means of the ignition switch in order to shut down the engine. A sufficiently strong spring inside of the manipulating element is pushing the adjusting rod into its neutral position when the power is disconnected. As an option it is possible to additionally excite a lifting magnet for shut-down of the engine. At first the EMR is programmed non-specifically with respect to the engine. On the test cell the engine is tested, adjusted and programmed together with the EMR. After this programming, the EMR is assigned to this specific engine and contains a engine specific data record. For the various cases of application, e.g. with regard to a defined scope of functions, the EMR is being customized ex works by means of the band end programming via the ISO 9141 interface.

System functions The EMR provides a broad choice of functions, which can be activated through an application dependant configuration and by means of assigning the inputs and outputs. It enables a signal exchange between the engine (via the engine plug) as well as between the vehicle (via the vehicle plug) and the EMR. The signals may be analog, digital or pulse width modulated (PWM) signals. Which of the functions will be used depends on the operating conditions of the engine. Accordingly there are different variants of the functions and of the pin assignment of the plugs. The functions of the EMR refer to the speed control, fuel metering (injection), monitoring, vehicle and device functions as well as to communication and diagnosis interfaces.

Droop In contrast to a mechanic controller, it is a special feature of an electronic controller to be able to adjust the droop percentage to 0% and to switch over between two fixed droop percentages. The maximum value is at 80%. For emulation of the droop behaviour of the mechanic controller a speed dependant droop function is provided (characteristic with 8 speed bases).

307.1133.3.6 englisch (en) 10.2006

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A Service Training

5650H – 5690HTS EMR Electronic engine controller System description

The EMR offers a basic configuration, upon which all variants optionally are based:

sensor inputs for: displacement of adjusting rod speed coolant temperature charging air pressure oil pressure Fuel temperature EMR 2

setpoint

microprocessor

pedal position transmitter manual gas switch for changeover gas control unit

interfaces

underlined = basic configuration program memory

power supply diagnosis interfaces CAN bus

display functions

actuator functions actuating magnet lifting magnet

parameters characteristic characteristic diagram

speed torque warning signals error lamp

Key start/stop The EMR must be switched off by means of the ignition key in order to shut down the engine. With this shutdown the adjusting rod is moved to the stop position by the spring-loaded actuator. As soon as the start speed signal is detected by the control unit, the adjusting rod is released for the start-up.

Repair It is only possible to replace all components (no repair) which are all available individually. As the control unit needs to be programmed with a engine specific data record, the following information is necessary: ● ●

number of engine complete part number

Caution: Prior to carry out electric welding works the plug-in connections at the control unit need to be disconnected in order to avoid damage of the control units!

A 12

307.1133.3.6 englisch (en) 10.2006

A Service Training

5650H – 5690HTS EMR Electronic engine controller Diagnosis

Diagnosis Self-diagnosis with error lamp The EMR provides a multitude of protective functions for the engine – depending on the available points of measurement resp. sensors. According to the severity of the detected error the engine can either keep on running (eventually with restrictions, error lamp is permanently lit) or it will be shut off (error lamp is flashing). Lighting of the error lamp indicates either a wiring fault (short circuit, cable break) or a malfunction with the displays or the corresponding sensors. As further error sources falling below or exceeding of measuring value limits may come into question (see table hereafter). All detected errors in the electronic system will be indicated in the control unit and by means of the error lamp. As soon as the error is not pending any more, the error lamp is extinguished; only if the electronic system has been changing over to emergency run (speed), the engine needs to be shut off shortly by means of the ignition key in order to terminate flashing of the error lamp. Even recovered resp. non-current errors will be memorized in the control unit and can be read out or erased by means of the diagnosis software SERDIA, see following chapter.

Diagnosis options with software SERDIA The error messages stored in the control unit can be read out resp. evaluated by means of the diagnosis software SERDIA. Hereby information is displayed about: -

Error location (e.g. "pedal value transmitter”,* "coolant temperature sensor”). Type of error (e.g. "lower limit exceeded”, "sporadic error”) Environmental data (e.g. speed at the moment of error occurrence) Number of error locations Frequency Error status ("1” for active, "0” for passive).

Error messages of non-current/recovered errors can be erased with SERDIA. SERDIA (service diagnosis) is a software program which makes it possible for the user to monitor measuring values by means of a PC while the Diesel engine is running and hence be able to recognize an incorrect operational behaviour. Then upon standstill of the engine it is possible to selectively preset specific parameters from the PC via the control unit (parameterization), in order to change the operational behaviour. For this, the PC must be connected with the diagnosis interface via an interface. Communication with the control unit is done via a special EMR protocol. For handling of SERDIA see separate operating instructions.

* With the combine harvester, the pedal value transmitter corresponds to the gas control unit. 307.1133.3.6 englisch (en) 10.2006

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A Service Training

5650H – 5690HTS EMR Electronic engine controller Diagnosis error lamp

error messages (only readable with SERDIA) type of error error location (x= type of error) extinguish subse- (3) reduced power Coolant temperature monitoring (834x) quent to oil pressure monitoring (836x) continuous light (normal (5) shut down limit speed monitoring (8305) operation) fallen below/exceeded continuous light (0) cable break or short circuit existing

(2) measuring point defective

(3) reduced power

continuous light (engine off) flashing (reduced power)

(5) shut down limit fallen below/exceeded (5) shut down limit fallen below/exceeded

(0) cable break or short circuit existing

(2) measuring point defective

(5) shut down limit fallen below/exceeded

(engine cannot be started) flashing

(0) cable break or short circuit existing

flashing or continuous light off

A 14

coolant temperature too high for short time, oil pressure too low for short time recovery limit of overspeed was fallen below again plug-in connection interrupted

speed control unit

o.k.↓

(M9) coolant temperature sensor (8140)

plug contacts polluted or corroded o.k.↓ sensor defective o.k↓. wire interrupted

(M24) boost pressure sensor (8150) (M21) oil pressure sensor (8160) (M13) speed 1, camshaft (8170) (M11) speed 2, terminal w (8180) (internal) temperature of electronics (8190) PWM signal monitoring for PWM input 1 (F18) (8002) PWM signal monitoring for PWM input 2 (F21) (8012) coolant temperature monitoring (834x) oil pressure monitoring (836x)

speed monitoring (8305) Coolant temperature monitoring (834x) oil pressure monitoring (836x)

(M13) speed 1, camshaft (8170) (only, if speed transducer 2 is not existing or defective)

(M17) position sensor (8112)

speed monitoring (8305) Coolant temperature monitoring (834x) oil pressure monitoring (836x) failure actuating magnet (8405) EEPROM data (8210) displacement measuring system calibration data (8220) output engine shutdown (8010) output excitation actuating magnet (8020) -

0) cable break or short circuit existing

(M13) speed 1, camshaft (8170) (only, if speed transducer 2 is not available)

(5) shut down limit fallen below/exceeded

failure actuating magnet (8405)

remedy n.o.k.

engine speed switch

(M11) speed 2, terminal w (8180) (only, if speed transducer 1 is defective)

flashing (engine off)

possible causes

→

restore plug-in connection

→

clean plug, replace if necessary

→

replace sensor

→

check cable harness, replace

→

check data in SERDIA menu "configuration”, change if necessary

→

restore plug-in connection

→

clean plug, replace if necessary

→

replace the sensor

→

check cable harness, replace if necessary

problems with evaluation of external PWM signal

temperature alert limit exceeded for too long oil pressure alert limit was fallen below for too long. Configuration incorrect. overspeed was exceeded. temperature alert limit exceeded for short-time. oil pressure alert limit was fallen below for short-time. plug-in connection interrupted o.k.↓ plug contacts polluted or corroded o.k.↓ sensor defective o.k.↓ wire interrupted

plug-in connection interrupted → o.k.↓ plug contacts polluted → or corroded o.k.↓ actuator defective → o.k.↓ wire interrupted → limits were fallen below resp. → exceeded for too long. Incorrect configuration (e.g. push operation off). actuator defective → data loss, software defective →

failure failure failure in central electronic system, program in EMR was not executed

actuator defective

restore plug-in connection clean plug, replace if necessary replace actuator check cable harness, replace if necessary check data in SERDIA menu configuration”, change if necessary replace actuator replace control unit

→

replace control unit

→

replace actuator

307.1133.3.6 englisch (en) 10.2006

A Service Training

5650H – 5690HTS Engine - Sensors

Sensor Charge Air Pressure Oil Pressure

Temperature Sensor Coolant Temperature Switch/Sensor

307.1133.3.6 englisch (en) 10.2006

Connector X 107 at Engine

Connector X 107 at Engine

A 15

A Service Training

F19

50a

30

75

K0

15

F39

G3

F34 D+

W

te Nulls

B46

H34

0 1 2 S5

A H S

A30 B7

S40

Commander Control 2000

15a

A13

B48

30

15 F7

F42

K11 K12

K48

K22

15b

A1

M1

EEC

A2

1

2

3

4

5

56-104--1

A 16

307.1133.3.6 englisch (en) 10.2006

A Service Training

5650H – 5690HTS Overview power supply EMR, engine monitoring in addition to EMR (EEC) Start system

A1 A2 A13 A30 B7 B40 B45 B46 B48 F.. G3 H34 K0 K11 K22 K48 M1 S2 S5 S40

Control unit EEC (electronic controller Diesel engine) Gas control unit for control unit EEC (A1) Logic unit Commander Control 2000 Buzzer Combined instrument gauge Sensor multifunction handle neutral (start interlock) Sensor multifunction handle reverse (reverse gear horn) Reverse gear horn Fuses Generator Failure lamp engine 70 A relay for terminal 15 Relay release threshing mechanism on, terminal 15b, droop switchover Relay starter Relay power supply EEC Starter Ignition start switch Switch engine speed Working master switch

1 2 3 4 5

Low-pressure switch air filter Temperature switch coolant Temperature switch engine oil Oil pressure switch Coolant level switch

307.1133.3.6 englisch (en) 10.2006

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A Service Training

5650H – 5690HTS Control unit EMR Gas control unit 1 2 3 4 5 6 7 8 9 10

A1 control unit EMR Connector on the engine side Connector on the vehicle side A2 Gas control unit Diagnosis plug-socket LED UB, power supply LED VCC, supply from EMR LED TH/2, half throttle LED TH/1, full throttle LED SDW, threshing mechanism on = 15b, (LED on = threshing operation)

Note: Upon full throttle and switched-on threshing mechanism all LEDs are lit. Subsequent to a replacement of the gas control unit a calibration of the setpoint generator must be carried out (see SERDIA manual, parameterization page 10).

A2 pin assignment Pin 1 2 3

A 18

Designation Input half throttle from S5 Input full throttle from S5 Pot. throttle ground

Cable colour gr/rt gr/bl br

4

Pot. throttle slider

ws/bl

5 6 7 8 9 10 11 12 13 14 15 16

Pot. throttle supply Input droop changeover from K11 Output droop changeover to A1 Ground droop changeover Supply 12V from control cabinet X8 Supply A1

ws/rt sw/gn ws/gn br sw sw

Supply for diagnosis connector Ground for diagnosis connector Ground for A1 Ground for A1 Ground for diagnosis connector

sw br br br br

Measuring value 0V/12V 0V/12V 1,2V idle throttle 2,8V half throttle 4,1V full throttle 5V 0V/12V digit 12V 12V 12V

307.1133.3.6 englisch (en) 10.2006

A Service Training

X8

MED_ACAD*11/24/10 11:01 AM Rev:12.23

SOLARI 1.she

1

Engine

Vehicle

A1

2

A2 3

7

16

9 1

8

6

4

56-116

4

56-055

8

9

5

10

4

307.1133.3.6 englisch (en) 10.2006

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A Service Training

5650H – 5690HTS Plug assignments of the EMR 1 control unit

25

13

25

1

14

13

14

Pin-No. Designation

Description

1

Pin-No. Designation

Description

1

Reserve

Reserve

1 x U Batt -

Negative pole at battery (clamp 31)

2

Output: digital 3

Digital output for solenoid

2 x GND

Reference potential for signal

3

Output: DIGITAL/PWM 3

PWM or digital output

3

4

NC

Not occupied

PWM or digital output, various functions

5

NC

Not occupied

4 x Output: Digital 1

Fault lamp

5

Output: digital / PWM 1

PWM or digital output, various functions

6

Reserve

Reserve

7

NC

Not occupied

8

NC

Not occupied

9

NC

Not occupied

6

NC

Not occupied

7

NC

Not occupied

8

GND

Reference potential for analog signal at pin 9

9

Input: Analog 3

Analog input for coolant temperature transmitter (NTC)

Output: digital / PWM2

10

GND

Reference potential for signal at pin 11

10

11

Input: Drehzahl 2

Digital input second engine speed (crankshaft)

11 x K-Line 12 x CAN high

Interface for CAN-Bus

12

GND

Reference potential for signal at pin 13

13 x CAN low

Interface for CAN-Bus

13

Input: Drehzahl 1

Digital input first engine speed (camshaft)

14 x U Batt +

Positive pole for battery (clamp 15)

L-Line

Serial ISO 9141 interface Serial ISO 9141 interface

15

Output: digital 2

Digital output, various functions.

16

Output: digital / PWM/ Frequency

Frequency ., PWM or Digital output various functions

14

STG -

PWM ouitput, signal for control coil

15

STG +

PWM ouitput, signal for control coil

16

Screen

Shielding for position encoder (for lines 17,18,19)

17 x Ground

Reference potential for signal at pins 18, 19 and 21.

17

RF -

General connection for reference and measuring coil

18

PWM or digital input, various functions

18

RF REF

Analog input, reference signal of the reference coil

19

RF MESS

Analog input, measuring signal of the measuring coil

20

GND

Reference potential for signal at pin 24

21

Input: Analog 4

22

Input: Digital / PWM 1

19

Input: digital

Digital input, various functions

20

Input: digital / Analog

Digital or analog input, various functions

21 x Input: digital / PWM 2

PWM oder digital input, various functions

Analog input 2 sensor signal charge air

22

+5V REF

+5 V Reference voltage for signal at pin 21 (max. 15 mA)

Screening (e.g. for lines 9 hand throttle or PWG)

23 x GND

23

GND

Reference potential for signal at pin 24

Reference potential for signal at pin 24

24

Input: Analog 2

Analog input sensor signal charge air

24 x Input: Analog 1

25

+5V LDA

+5 V Reference voltage for signal at pin 24 (max. 15 mA)

Analog input pedal value sensor, (PWG)

25 x +5V REF

+5 V Reference voltage for signal at Pin 24

Screen

x) Pin used for combines

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A Service Training

5650H – 5690HTS Plug assignments of the EMR 2 control unit

25

13

25

1

14

13

14

Pin No. Designation 1

Reserve Reserve

2

Output: digital 3

Description

Digital output for solenoid 1)

1

Pin-No Designation 1 x U Batt -

Description Negative pole at battery (clamp 31)

2 x GND

Reference potential for signal

3

PWM or digital output, various functions

Output: digital 2

3

Output: digital 4

For heating flange (optional)/ glow plug (optional)

4

Input (optional) Temp 1

Fuel temperature 2)

4 x Input / output: DigInOut

Fault lamp and diagnostic button

5

Input (optional) Temp 2

Charge air temperature

5

Output: PWM 1/Dig 1

6

Input (optional) DigIn 5

Coolant level / oil level

PWM or digital output, various functions

7

Output: PWM2/digital 6

6

Multi-function input: Digin 3

Genset applications/gear shift/motor brake

8

GND

Reference potential for analog signal at pin 9

7

Input: digital 10/velocity

Speed signal (tacho input)

9

Input: analog 7

Analog input for Coolant temperature sensor (NTC)

8

NC

Not occupied

10

GND

Reference potential for signal at pin 11

11

Multi-function input: speed 2/DigIn 2

Digital input second engine speed (crankshaft) (optional) and speed signal (optional)

12

GND

Reference potential for signal at pin 13

13

Input: speed 1

Digital input first engine speed (camshaft)

14

STG -

PWM output, signal for actuator coil

15

STG +

PWM output, signal for actuator coil

16

Screen

Screening regulating rod travel sensor (for lines 17, 18, 19)

17

RF -

General connection for

18

RF REF

Analog input, reference signal

19

RF MESS

9 NC 10 x L-line 11 x K-line

Interface for CAN-Bus

15

Output: digital 5

Digital output, various functions

16

Output: digital 7/Frequency

Frequency, PWM or digital output, various functions

20

GND

Reference potential for signal at pin 21

21

Input: analog 4/digital 9

Analog input 4 (sensor signal oil pressure sensor) or digital input 9

22

+5 V REF

+5 V Reference voltage for signal at pin 21 (max. 15 mA)

23

GND

Reference potential for signal at pin 24

24

Input: analog 2/digital 7

Analog input 2 (sensor signal charge air) or digital input 7

25

+5 V LDA

+5 V Reference potential for signal at pin 24 (max. 15 mA)

1) For continuous power: < 4 A 2) Corresponds to special function”fuel temperature compensation at the EMR (0211 2571)

307.1133.3.6 englisch (en) 10.2006

Interface for CAN-Bus

Positive pole for battery (clamp 15)

17 x Ground

Reference potential for signal at pins 18, 19 and 21.

18

Input: digital 1 / PWM 1

PWM 1 or digital input 1, various functions

19

Multi-function input: DigIn 4 Performance curve switching/genset applications

20

Multi-function input: digital 8 / analog 3

Analog input, measuring signal of the measuring coil

Serial ISO 9141 interface Serial ISO 9141 interface

12 x CAN high 13 x CAN low 14 x U Batt +

reference and measuring coil

of the reference coil

Not occupied

Hand hand throttle/genset applications, Digital (8) or analog input (3)

21 x Input: digital 2 / PWM 2

PWM 2 or digital input 2, various functions

22

Screening (e.g. for lines 9 hand throttle or PWG)

Screen

23 x GND

Reference potential for signal at pin 24

24 x Input: analog 1 / digital 6 Analog input 1 (pedal value sensor, PWG) digital input 6 25 x +5V REF +5 V Reference voltage for signal at Pin 24 x) Pin used for combines

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A Service Training

5650H – 5690HTS Sensors and transmitters engine BFM 1013 Overview 1 1.1 2 2.1 3 4 5 6 7 8 9

Transmitter/switch coolant temperature display Insulating hose EMR sensor boost pressure EMR sensor boost air pressure as of 2005 EMR sensor coolant temperature EMR actuator (adjusting rod of the injection pumps) Oil pressure switch (warning light combined instrument gauge) EMR sensor speed EMR sensor oil pressure Transmitter/switch oil temperature display EMR sensor fuel temperature with EMR 2

1

2.1 56-117

2

1.1 4

3

2 19,39

20,9

6

7

8 18,57

19,63

5 9 19,41 A 22

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1 2

3 4

5

26337-2

2.1

9 6

8

7 26336-2 307.1133.3.6 englisch (en) 10.2006

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2

1

3

34926

4

5 6 7

11

10

8 9

14

12 13

17

18 15 19 16 A007

A 24

56-069

307.1133.3.6 englisch (en) 10.2006

A Service Training

5650H – 5690HTS Fuel system, overview

1

Injection pipe

2

Shut-off solenoid (until year of manufacture 2002)

3

Fuel oil leakage pipe from fuel injection valves (until year of manufacture 2002)

4

Pressure control valve 5 bar

5

Plug-in injection pump

6

Line to plug-in injection pumps

7

Line to fuel filter

8

Fuel pump

9

Fuel filter

10

Fuel suction line to fuel pump

11

Return line to fuel cooler

12

Fuel Cooler

13

Fuel suction line to pump

14

Tank stopcock

15

Vent pump

16

Fuel tank

17

Fuel pre-filter

18

Drain plug at pre-filter

19

Drain plug at fuel tank sump

Check for proper connection of fuel lines at the pre-filter: — Line from bleed pump (16) to connection EIN / IN — Line to engine at connection AUS / OUT

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A Service Training

5650H – 5690HTS Fuel pump

The fuel pump is a rotor pump which is driven by the wedge rib belt. The pump disposes of a double valve (pos. 1 Popen: 6 ± 0,5 bar, pos. 2 Popen: 0,5 bar). As of year of manufacture 2006 fuel pressure pumps with a relief pressure valve of 7 bar are being used The relief pressure valve (1) is of the piston valve type and opens at 6 ± 0,5 bar and 7 bar resp. Furthermore the maximum system pressure is limited to 10 ± 0,5 bar with this valve. The bypass valve (2) is a ball valve. After draining of the fuel lines it is hereby possible to prefill the fuel system by means of the hand feed pump. In this way a too long start process will be avoided (starter protection). Note: Do not reduce the pipe diameter and the connection to the fuel pump (see installation manual), as otherwise loss of nominal engine power may occur.

2013 - 0043

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5670-90 englisch (en) 02.2001

A Service Training

5650H – 5690HTS Clean/replace fuel pre-filter, filter element; bleeding of fuel system

1

Changing interval filter element: 1000 op. hrs

2 Clean/replace filter element (8)

3 34923

5

6

7

4

8

–

Close tank stopcock (1).

–

Open the venting screw (7).

–

Loosen the drain plug (3) and drain the fuel.

–

Unscrew tightening screw (6), remove filter housing (5).

–

Replace filter cartridge (8) and if necessary the sealings (4).

–

Replace filter housing (5).and secure with screws (6).

–

Tighten drain plug (3).

–

Open tank stopcock (1).

–

Open the venting screw (7) until fuel flows out.

–

Actuate vent pump (2) until fuel flows hereable without air into the tank.

3 25 801_0

Venting the fuel system. –

Open the venting screw (7).

–

Open tank stopcock (1).

–

Actuate vent pump (2) until fuel flows out from the venting screw (7).

–

Close the venting screw (7).

–

Actuate vent pump (2) repeatedly.

–

Start the engine. Note: If the engine does not start up despite repeated attempts: - Vent the system again by means of the vent pump. - Possibly loosen the pressure control valve (9) and actuate vent pump until fuel emerges from the pressure control valve. Retighten pressure control valve and start the engine.

30 084_0

–

5670-90 englisch (en) 02.2001

Check system for leakage after start-up of the engine.

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A Service Training

5650H – 5690HTS Change fuel filter –

Close tank stopcock.

–

Loosen and unsrew fuel filter cartridge (1).

–

Collect leaking fuel

–

Remove possible dirt from the sealing surface of the filter support.

– –

Slightly lubricate the rubber seal of the new fuel filter cartridge resp. moisten with fuel oil. Fill filter cartridge with fuel.

–

Screw on cartridge by hand until the seal properly fits.

–

Tighten fuel filter cartridge with another half turn.

–

Open tank stopcock.

–

Actuate vent pump repeatedly.

–

Check filter for leakage.

1 26336-2

25880/0

25881/0

25882/0

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A Service Training

5650H – 5690HTS Change fuel oil leakage pipe

Changing interval: 1000 operating hours, at least every second year. Mounting tool: Hose clamp pliers TN8020 –

Close tank stopcock.

–

Take down the rocker assembly cover hood.

–

Loosen hose clamps (6) by means of hose clamp pliers TN 8020.

–

Disconnect rubber hoses (3) and hose clamps (6) from the fuel injection valves.

–

Loosen the pressure control valve (9).

–

Take down the hose clamps (6), rubber hoses (1), (3), (4) and the adapters (2) and the collar with socket pin / threaded pin (5) and dispose of in accordance with antipollution regulations.

30034_1

Observe at assembly that the hose clamp lock is pointing to the fuel injection valves and the hose clamp cannot fall into the engine compartment. –

Attaching new oil leakage pipe: Slide rubber hoses (3) (coat inside with sliding grease) together with hose clamps (6) steadily onto the fuel injection valves to the connection fitting stop at the fuel control valve and close by means of hose clamp pliers TN 8020.

30901_0

–

Assembly of pressure control valve (9): Tighten new collar piece with socket pin / threaded pin (5).

–

Remount the rocker assembly cover hood.

–

Open tank stopcock.

–

Actuate vent pump repeatedly.

–

Check for leakage after commissioning.

30 084_0

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5650H – 5690HTS Fuel injection valve, injection pipes Assembly, disassembly

Slide the new seal onto the fuel injection valve by using some grease and insert injection valve. Note: The leakage oil line connection must point to the exhaust side.

28-4-44

Put on the grip holder. Screw in bolt slightly.

38-4-192

Attach new injection pipe with rubber seal. Screw on connection nut slightly by hand. Note: At assembly of the fuel injection pipes the sealing cones must match exactly. Subsequent bending is not permissible. The fuel injection pipes may not be used twice.

38-4-193

Tighten the bolt of the gripholders with a tightening torque of 16 + 5 Nm.

38-4-194

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307.1133.3.6 englisch (en) 10.2006

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5650H – 5690HTS Fuel injection valve, injection pipes Assembly, disassembly Tighten the connection nuts of the fuel injection pipe at the injection pump and the injection valve with a pretightening torque of approx. 5 Nm. Tighten the connection nuts subsequently with a tightening torque of 25 ± 3,5 Nm.

38-4-145

Attach oil leakage pipe and introduce through rubber seals. Note: It is mandatory to replace used oil leakage pipes.

38-4-146

Attach pressure control valve with new copper seals and oil leakage pipe. Tighten pressure control valve with a tightening torque of 30 Nm.

38-4-164

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5650H – 5690HTS Testing and setting of injectors free from leak-off fuel 1. Testing the injector The volume of leak-off fuel cannot drain and is collected above the nozzle needle in the spring compartment of the injector. Now, the hand lever of the nozzle tester can no more be operated. To have the pressure in the spring compartment relieved, prior to every test, the tensioning nut must be unscrewed and then be tightened again as specified. 1.1 Unscrew tensioning nut by approx. 180° and tighten it again. Tightening instruction: 40 - 50 Nm Special tool for taking the injector depending on engine type 6 1.2

Mount injector to nozzle tester. Attention! Do not touch the nozzle jet. The fuel deeply enters the flesh and can cause blood-poisoning.5

1.3

Slowly press down lever of the nozzle tester with connected pressure gauge.The pressure at which the pointer stops or suddenly drops is the opening pressure. Opening pressure: 275 + 8 bar

Reference: After having operated the hand lever of the nozzle tester for three to four times, the pressure in the spring compartment is established again. The tensioning nut must be newly unscrewed and tightened again according to the tightening instructions and the test be repeated.5 1.4

If the measured values of 3 tests are identical, they can be considered valid.

Chattering and spray pattern test Disconnect pressure gauge of the tester. The chattering test permits to check the unhindered movement of the nozzle needle in the nozzle body via the developing noise. New injectors have a different chattering behaviour than used ones. Due to wear in the needle seat area, it deteriorates. If the injector does not chatter despite having been cleaned, it must be replaced by a new one. A used injector must clearly chatter upon rapid lever operation and inject with a good atomisation. The spray pattern can considerably differ from that of a new injector.

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A Service Training 2. Setting the injector 2.1

If the opening pressure must be corrected,dismantle injector from nozzle tester. Unscrew tensioning nut, dismantle all parts. Special tools for taking the injector depending of engine type.

2.2

Sequence of dismantling and mounting of parts 1. Tensioning nut 2. Injector comprising nozzle body with nozzle needle 3. Adapter 4. Pressure bolt 5. Pressure spring 6. Spacer disk

2.3

Set the opening pressure by selecting the suitable spacer disk. Thicker spacer disk results in higher opening pressure. Mount injector. Tighten tensioning nut. Tightening instruction: 40 - 50 Nm Test injector again on the nozzle tester.

3. Check for tightness 3.1

Dry injector – blow dry with air. Slowly press down hand lever of the nozzle tester, until approx. 20 bar below the previously read opening pressure are reached.

3.2

Injector is tight, when no drop falls down within 10 seconds.

3.3

If a drop should fall, the injector must be decomposed and the leakage be eliminated by cleaning. If this should not be successful, the injector must be renewed. Reworking is not admissible.

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5650H – 5690HTS Cooling circuit, overview

2

1.2

1.1

1

6

5

4

8

9

7

4

11

12

3

7

18,7

5 A 34

3

10 56-107

307.1133.3.6 englisch (en) 10.2006

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5650H – 5690HTS Cooling circuit, overview

1

Expansion tank

1.1 Sight glass 1.2 Relief valve in the cap opens at 95 kPa 2

Vent hose from cylinder head

3

Inlet from radiator to coolant pump

4

Return line from thermostat housing to radiator

5

Balance line from expansion tank to suction side of the coolant pump

6

Vent hose from radiator

7

Radiator

8

Coolant pump

9

Heat exchanger coolant/engine oil

10

Drain cock

11

Thermostat housing

12

Connection vent hose (2) at cylinder head

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5650H – 5690HTS Draining / Filling of Cooling System Draining: Open the cap only after cool down of the cooling system. Be careful when draining hot coolant: Danger of scalding! Collect drained coolant and dispose of in accordance with anti-pollution regulations!

1 18,7

–

Place drip tray under drain plug.

–

Open the cap (2) at the expansion tank.

–

Attach hose to drain cock.

–

Drain coolant via drain cock (1).

–

Drain coolant which remains in the engine at the drain plug (6) of the heat exchanger.

2 3

Filling: –

Close drain cock (1).

–

Fill up coolant at cap opening (2) until the sight glass (3) is covered.

–

Attach the cap (2).

–

Start the engine and warm up until the thermostat opens.

–

Turn off the engine.

–

Check coolant level when the engine is cold and refill if necessary.

–

Venting is done automatically through the vent hoses.

19,1

5

Note: Open the heating valve entirely if the heating circuit for the cabin is connected.

6 (5) Connection for heating hose to the cabin (header). 56-113

4

(4) Connection for heating hose from the cabin.

56-112

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A Service Training

5650H – 5690HTS Mounting of the coolant temperature transmitter

2

–

Tighten coolant temperature transmitter (1) with new seal with a tightening torque of 18 ± 2 Nm.

–

Slide insulating hose (2) over the transmitter (1).

1 39-40

Assembly of coolant level sensor 3 4 5

3

Coolant level sensor Floater Marking

The marking (5) at the hexagonal bolt must point upward after screwing in. When the float lever (4) is level the switching contact closes causing a warning message at the commander control when ground speed 56-119

exceeds 2 km/h.

4 3

5

56-120

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5650H – 5690HTS Replacement of thermostat Mounting tool: 170 090 –

Dismantle the thermostat housing (1).

–

Push down thermostat and remove from thermostat housing.

–

Visually inspect all parts, replace if necessary.

–

Push down thermostat and screw into the thermostat housing.

1

54

10-3.130

10-3.131

Note: The retainer must engage in the thermostat housing. –

Remove the seal ring for the thermostat housing if necessary.

10-3.132

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5650H – 5690HTS Mounting of coolant pump

–

Force on new o-ring seals on plug-in piece.

Note: Coat o-ring seals with mounting agent AP25N.

–

Push plug-in piece into the coolant pump.

–

Insert new o-ring seal in connecting piece.

10-4.184-1

Note: Coat o-ring seal with mounting agent AP25N.

38-4-112-1

–

Attach the assembled coolant pump with a new seal.

–

Tighten the bolts mutually with a tightening torque of 21 ± 2 Nm.

38-4-244

38-4-245

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5650H – 5690HTS Maintenance and Inspection DEUTZ Engine General Engine running-in time The engine is immediately ready-to-operate. Please observe that a new engine requires a running-in time of approx. 300-500 running hours. The oil consumption of new engines can be higher than normal until the engine running-in procedure has been completed. Therefore check the oil level daily during running-in time. All DEUTZ Diesel engines are precision products, so that special running-in regulations for executing the running-in procedure ”smoothly” in order to avoid seizing damage are not necessary. Actually, smooth running-in of new engines, as known from other engine fields of application, may even have a negative influence on the running-in process. Therefore you can and you should utilize the full performance of your DEUTZ engines also in new condition. There is no seizing damage danger if the basic rule is observed, that full load is only permitted after warming up the engine. Only if cylinders and/or piston rings have been replaced on the occasion of repair, the engine should be operated carefully for the first 10 running hours.

Commissioning Check engine oil level prior to commissioning.

10-3.130

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5650H – 5690HTS Maintenance Schedule Engine 1013 Job

Check oil level

once at/after (op. hrs)

regularly every (op. hrs)

upon delivery

daily1)

Clean engine compartment

daily

Visual inspection of engine for leaks

upon delivery

5 / 50-150

Check battery and battery cable connections

upon delivery

100

Check cooling system Change engine oil 2) 3)

125/250/500/1000/2000 50

250 at least annualy

Change oil filter cartridge

50

250

Clean air filter cartridge

only when indicator light is on

Change air filter cartridge

after cleaning 5 times resp.

at least annually

after choking with rust Change safety cartridge of air filter Fuel filter cartridge, replace pre-filter element Drain fuel pre-filter Check fuel oil leakage pipes Replace fuel oil leakage pipes (only complete replacement) Fuel tank: Draining of sump Check valve clearances, readjust if necessary Retighten engine mount bolts

when replacing air filter cartridge 50

1000

upon delivery

if required

50-150

---

---

10004)

upon delivery

at least annually

50

500

50-150

500

Vibration damper, check condition Check V-belt tensions, retension if necessary at:

at least every 2 years

500 upon delivery / 50-150

250

upon delivery / 50-150

annually

generator, coolant pump, fan, suction blower Alarm system, check/clean Attachments

50-150

Coolant, check concentration of additives Check coolant level

upon delivery

Change coolant Check hose connections / hose clamps Drain condensate at the charge air cooler

--500 daily 2000/or every 2 years

upon delivery / 50

250

upon delivery

annually

Check hose sleeves between air filter and turbocharger

upon delivery / 50

250

Check sealing brush at sieve pan, replace if necessary

upon delivery / 50

250

upon delivery

250

upon delivery / 50

annually

Check condition of oil drain hose, fuel hoses Check cable harnesses, connectors for damage and proper laying

1) During the running-in period twice a day. 2) For approved engine oils see Deutz engine oils approval list (page 46) 3) These intervals only apply for a Diesel fuel with maximum 0,5% by weight of sulfur and for central-european or comparable climate conditions. In the case of aggravating conditions for oil stress, e.g. • intensified climate conditions (temperatures exceeding permanently 30 °C) • usage of fuels containing more than 0,5% of sulfur the oil change intervals shown in the table must be halved for each aggravating condition. 4) Replace however every 2 years. 307.1133.3.6 englisch (en) 10.2006

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Notes

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Air filter Cleaning of dry-type air filter Indication at combined instrument gauge. Lighting of indicator light (1), flashing of central warning light (2) and sounding of an alarm signal. The low-pressure switch (3) initiating the alarm is mounted in the filter housing (4).

2

1

Never wipe the air filter cover or the filter cartridge by using oily rags. 31663

Replacement of fine filter cartridge

11 10

–

3

Verify that the gasket between the fine filter cartridge and the filter housing is clean and undamaged.

4

5 6 11

34927

7

When equipped with exhaust ejector (10) unscrew butterfly nut (5) and remove cover (6).

–

Remove dirty fine filter cartridge (8), either clean or replace by new one. If the indication (2) is alerting again after maintenance of the fine filter cartridge, the safety cartridge (7) must be replaced, too.

Replacement of the safety cartridge It is not possible to clean the safety cartridge (7); after repeatedly cleaning of fine filter cartridge for 5 times it must be replaced at the latest. Do not start the engine without the cartridge in it.

9

8 31696 Checking the lines: – Check hose sleeves and lines between air filter and turbosupercharger for proper fit and possible damage. – Check hose sleeves and lines between charging air cooler and engine for proper fit and possible damage. – Check hose sleeves and line (11) of the exhaust ejector for proper fit and possible damage.

307.1133.3.6 englisch (en) 10.2006

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5650H – 5690HTS Coolant

Remark The cooling circuit of the engines is filled ex works with instant mixture 40/60 providing frost protection down to –28 °C. Water quality for coolant The values given below must not be exceeded. A test kit (order number 1213 0382) can be obtained from DEUTZ Service to check the quality of the water available. Coolant preparation Water quality min. max. ph-value at 20 °C

6,5

Chloride ion content [mg/dm3]

100

Sulfate ion content [mg/dm3]

100

Total hardness [°dKH]

3

The preparation and monitoring of the coolant in liquidcooled engines is especially important because corrosion, cavitation and freezing can lead to engine damage. The coolant is prepared by admixing a cooling system protective agent with the cooling water.

8,5

12

The cooling system must be monitored continuously. The water level and the cooling system protective agent concentration should both be checked. The cooling system protective agent concentration can be checked with a tester commercially available (e.g. gefo glycomat ®).

Cooling system protective agent Cooling system protective agents must be disposed of in accordance with anti-pollution regulations. The cooling system protective agent (nitrite-, amine- and phosphate-free; obtainable under order no. 0101 1490 in 5-liter containers) provides effective protection aigainst corrosion, cavitation and freezing. The concentration of the cooling system protective agent in the coolant should not fall below/exceed the following limits in order to obtain a sufficient corrosion protection: Cooling system protective agent max. 45% by vol. min. 35% by vol.

Water 55% 65%

Other cooling system protective agents, e.g. chemical corrosion inhibitors, can, in exceptional cases, be used in the coolant; in consultation with DEUTZ service.

When nitrite-based cooling system agents are mixed with with amine-based agents, harmful nitrosamines are formed.

Cooling system protective agents must be disposed of in accordance with anti-pollution regulations.

Cooling System Protection Protective Agent [% by vol.]

Protection against freezing to [°C]

35

-22

40

-28

45

-35

50

-45

A 44

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5650H – 5690HTS Operating Media Lube Oil Quality grade The lube oil quality grade is defined by specifications. The following classifications are being used: DEUTZ Lubrification oil quality class

DQC I-02 DQC II-05 DQC III-05 DQC IV-05

ACEA-Classification

E2-96

or API-Classification

CF/CF-4

or worldwide specification

–

E3-96/ E5-02 E7-04 CG-4/ CH-4/CI-4 DHD-1

E4-99/ E6-04

E4-99/ E6-04

–

–

–

–

Lubricating oils in compliance with the Deutz quality class DQC III-05 or oils listed on the approval list overleaf shall be used for the combine harvester engines Viscosity The lube oil viscosity of the SAE grade is selected according to the viscosity diagram opposite. The ambient temperature is decisive for the correct choice. Should the temperatures temporarily fall below the limits of the SAE grade selected, this will merely effect the cold start performance, but will not cause any engine damage. The application limits should not be exceeded over lengthy periods of time in order to keep wear down to a minimum. For all-year application we recommend to use multigrade oils.

Fuel Viscosity classes in relation to the ambient temperature

Quality grade Use commercial brands of diesel fuel with a sulfur content less than 0,5%. If the sulfur content is higher than 0,5%, oil change intervals should be reduced, see maintenance schedule. Diesel fuels are approved and can be used according to the following specification: Fuel EN 590 ASTM Designation: D 975 Grade-No 1-D and Grade Low Sulfur No. 1-D ASTM Designation: D 975 Grade-No 2-D and Grade Low Sulfur No. 2-D JIS K 2204 Grade 1 Fuel and Grade 2 Fuel NATO F-54, is equivalent to EN 590 The exhaust emission levels possibliy determined during certification always refer to the reference fuel specified by the supervising authorities for such certification.

Figure legend: I II A B

Summer diesel fuel Winter diesel fuel Ambient temperature Percentage of kerosene added

!

Winter-grade fuel At low temperature, waxing may occur and clog the fuel system, causing operational trouble. In case of sub-zero ambient temperatures it is recommended to use winter-grade diesel fuel (down to –15 °C). A26441-1

Mix in tank only! Fill in the appropriate amount of kerosene first, then add the diesel fuel.

307.1133.3.6 englisch (en) 10.2006

• At temperatures below –15 °C or –20 °, kerosene should be added to the diesel fuel. The relevant percentages are given in the diagram opposite. If summer-grade diesel fuel has to be used at temperatures below 0 °C, up to 60% kerosene may be added (see diagram opposite). In most cases, adequate resistance to cold is also attained by adding a flow improver (fuel additive). Ask your service representative for further information. A 45

A Service Training

Release list DEUTZ lube oil quality stage DQC III-05 Manufacturer DEUTZ ADDINOL AGIP Akros ARAL AVIA BAYWA BP OIL International

Castrol

CEPSA CHEVRON DEA

ESSO FUCHS EUROPE MOBIL OIL

OMV AG Ravensberger Schmierölvertrieb Lube oil refinery Salzbergen Shell International

Texaco TOTAL

A 46

Lubricant type DEUTZ OIL TLX-10W40FE ADDINOL Super Truck MD 1048 ADDINOL Ultra Truck MD 0538 Agip Sigma Ultra TFE Autol Valve Ultra FE Akros Synth. Gold Aral MegaTurboral Aral SuperTurboral TURBOSYNTH HT-E BayWa Super Truck 1040 MC BayWa Turbo 4000 BP Vanellus E7 Plus BP Vanellus E7 Supreme BP Vanellus C8 Ultima Castrol Enduron Plus

SAE class 10W-40 10W-40 5W-30 10W-40 10W-40 10W-40 10W-40 5W-30 10W-40 10W-40 10W-40 10W-40 10W-40 5W-30 5W-40

Castrol Enduron

10W-40

Castrol Elexion EUROTRANS SHPD Chevron Delo 400 Synthtic DEA Cronos Synth DEA Cronos Premium LD DEA Cronos Premium FX Essolube XTS 501 Fuchs Titan Cargo MC Fuchs Titan Unic Plus MC Mobil Delvac 1 SHC

5W-30 10W-40 5W-40 5W-30 10W-40 10W-40 10W-40 10W-40 10W-40 5W-40

Mobil Delvac 1 Mobil Delvac XHP Extra OMV super Truck OMC truck FE plus Ravenol Performance Truck

5W-40 10W-40 5W-30 10W-40 10W-40

Availability Europe Europe, Asia Europe, Asia worldwide Germany Europe worldwide worldwide Germany South Germany South Germany Europe Europe Europe Europe, America, Australie, Afrique du Sud Europe, Amérique, Australia, South Africa USA Spain, Portugal North America Germany, Europe Germany, Europe Europe Europe worldwide worldwide Europe, SE Asia, Africa worldwide Europe, SE Asia Europe Europe Germany

Wintershall TFG

10W-40

Europe

Shell Myrina TX/Shell Rimula Ultra

5W-30

Europe, designation varies nationally

Shell Myrina TX/Shell Rimula Ultra

10W-40

Ursa Super TDX10W-40 Ursa Premium FE 5W-30 TOTAL RUBIA TIR 8600 EXPERTY

10W-40 5W-30 10W-40 10W-40

Europe, designation varies nationally Europe Europe worldwide worldwide

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Notes

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5650H – 5690HTS Maintenance and Inspection DEUTZ Engine: Engine Oil Change Be careful when draining hot oil: Danger of scalding! Do not let used oil run into the soil but collect it in a container ready for proper disposal!

A00023

Ensure that the combine harvester is on a level surface. Allow the engine to warm up – lube oil temperature approx. 80 °C. Switch off the engine

A00024

Unscrew oil drain plug (1). Drain oil. Fit oil drain plug with new seal ring and tighten firmly. Replace oil filter cartridge at each oil change. Fill up with lube oil. – For grade/viscosity see section ”operating media”. – Quantity: First-filling quantity approx. 21 l

1 33975

Start the engine and operate at low idle speed. Observe oil pressure indicator light. Switch off the engine. Check oil level with the machine placed on a level surface. If necessary, fill up oil to the max marking.

A00026

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A Service Training

5650H – 5690HTS V-Belt generator Tensioning/Replacement Tensioning: –

Loosen screws (1), (2) and (3).

–

Push generator (5) to direction of arrow (A) until correct v-belt tension is attained.

Replacement: –

Loosen screws (1) and (2).

–

Push generator (5) to direction of arrow (B) until v-belt is strainfree.

–

Remove v-belt and apply new v-belt and tension (see above).

–

Retighten screws (1), (2) and (3).

91 107

V-Belt coolant pump/fuel pump Tensioning: –

Loosen screws (1) and (2).

–

Push fuel pump (3) to direction of arrow until correct vbelt tension is attained.

–

Retighten screws (1) and (2).

A-008

Replacement: – Loosen screws (1) and (2). – Push fuel pump (3) to direction of arrow. –

Slackening/tensioning of v-belt for cooling compressor and ventilating wheel: – Disassemble half-flange (7) from driven shaft of engine.

– –

Remove v-belt and apply new v-belt. Push fuel pump (3) against direction of arrow until correct v-belt tension is attained. Retighten screws (1) and (2). Reattach half-flange (7).

A-009

– –

7 A00175-2

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5650H – 5690HTS Checking valve clearances, adjusting valve clearances if necessary –

Loosen venting valve and slew to the side.

–

Remove cylinder-head cover.

–

Position of crankshaft as per schematic.

–

Before adjusting valve clearance, allow engine to cool down for at least 30 minutes: The oil temperature should be below 80 °C.

–

Check valve clearance 1 between rocker arm tappet contact face 2 and valve stem 3 with feeler gauge 6 (there should only be a slight resistance when feeler blade is inserted).

–

Permissible valve clearances: Inlet IN = 0,3+0,1 mm Outlet EX = 0,5+0,1 mm

–

If necessary, adjust valve clearances as follows:

19 961_2

- Loosen counter nut 4. - Adjust set screw 5 by means of screw driver 7 in such a manner that the correct valve clearance 1 is attained after tightening of counter nut 4. Tightening torque of counter nut 20 ± 2 Nm. –

Check the valve clearances at each of the cylinders and adjust if necessary.

–

Remount the cylinder-head cover (use new seal if necessary).

–

Slew venting valve back into position and attach.

Note: Increase the valve clearance by 0,1 mm upon each replacement of the cylinder-head gasket. Adjust the standard valve clearance after 50 – 150 operating hours.

26262_1

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5650H – 5690HTS Valve clearance adjustment schematic

–

Crankshaft position 1: Turn crankshaft until both valves of cylinder no. 1 overlap (exhaust valve not closed yet, inlet valve starts opening). Execute valve clearance adjustment according to adjustment schematic, black marking. Check the proper adjustment by means of marking each respective rocker-arm with chalk.

–

Crankshaft position 2: Turn the crankshaft one complete revolution (360°). Execute valve clearance adjustment according to adjustment schematic, black marking.

26263_2_1

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5650H – 5690HTS Determination of cylinder-head gasket

The thickness of the cylinder-head gasket is responsible for the proper free gap of the piston ring. The gap of the piston ring (0,9 – 1,1 mm) has a decisive influence on the combustion and therefore on: - the performance - the fuel consumption - the exhaust emission The free gap of the piston ring must be adjusted after determining the piston projection dimension by means of the thickness of the cylinder-head gasket. 38-4-238

Measuring the piston projection A dial gauge with an appliance is required in order to measure the piston projection. The appliance consists of:

1

–

Dial gauge

–

Bridge 100750

–

2 Distance plates (1)

-

Put the distance plates on the sealing surface of the crankcase and set dial gauge to "0”.

38-4-188

The piston to be measured must be standing in the T.D.C.

95 90

–

Place the dial gauge on the piston at the measuring points and determine the biggest piston projection.

Note: All pistons must be measured. –

Observe measuring points: BFM 1013 95 mm

Axe de Piston Eje de bul de piston

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5650H – 5690HTS Determination of cylinder-head gasket

–

Compare highest value with the table and determine the corresponding cylinder-head gasket.

BFM 1013 Piston projection

10-4.152

0,28 - < 0,54 mm 0,54 - < 0,64 mm 0,64 – 0,75 mm

Marking of cylinder-head gasket 1 hole 2 holes 3 holes

28-4.36

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5650H – 5690HTS Mounting of the cylinder head

Before mounting the cylinder head onto the crankcase the sealing surfaces for the cylinder-head gasket need to be clean and oil-free. Take care of close-tolerance sleeves. Slightly lubricate the cylinder head screws. It is mandatory to observe the specified tightening order of the screws in opposite diagram. Tightening specification 1013: 1. step: 50 Nm 2. step: 130 Nm 3. step 90°

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5650H – 5690HTS Tightening of the cylinder head screws Sequential order

Manifold side

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5650H – 5690HTS Special Tools V-belt tension gauge Order no. 91107

All special tools can be ordered from: WILBÄR PO-box 14 05 80 D – 42826 Remscheid

91 107

Adapter for compression gauge Order no. 100 110

100 110

Extractor for fuel injection valve, to be used with 150800 Order no. 110 030

110 030

Extractor for fuel injection valve, to be used with drawing device Order no. 150 800

150 800

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A Service Training Mounting tool for coolant thermostat Order no. 170 090

170 090

Pliers for hose-clamps Order no. 8011

8011

Torx tool set Order no. 8189

8189

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1

19,59

5650H – 5690HTS Charge cooling

1 2 3 4 5 6 7 8

Pipe from charging air cooler to cylinder head Inlet from charging air cooler to cylinder head Inlet side turbosupercharger from air filter Outlet to charging air cooler Charging air cooler Outlet from charging air cooler to cylinder head Inlet charging air cooler from turbosupercharger Drain plug for condensate

2

3 4

19,55

6 5 7 2004514-2

8

5

A-010

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5650H – 5690HTS Cooling fan drive, radiator

1 2

3

1

Hydraulic oil cooler

2

Condenser for cooling system

3

Fuel Cooler

4

V-belt pulley on driven shaft of engine

5

Tensioning pulley

5.1 Tension spring with adjusting plate (5.2)

35510

11

12

6

Charging air cooler

7

Cooler for engine coolant

8

Ventilating wheel

9

V-belt pulley

10

V-belt exhauster drive

11

Sieve pan covering

12

Locking device of sieve pan covering

19,13

6 7

5.2 5.1 4

5 8 9 10

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5650H – 5690HTS Exhauster drive

1

Charging air cooler

2

Radiator

3

V-belt pulleys

4

V-belt exhauster drive

5

Exhauster drive

6

Flexible suction tube to cooling air duct

7

Counter support for exhauster (for tensioning of the v-belt loosen nut and push exhauster housing downwards)

8

Rotating sieve pan

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1,2

8 3

4

7

5

4 6 5

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13_mot.tif

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5650H – 5690HTS Rotating sieve pan drive

1

Rotating sieve pan

2

Driving belt

2.1 Guide pulley 3

Tensioning pulley, spring-loaded

4

Driven shaft of engine

5

Sealing brush: Mount with initial tension. The bristles line up at the sealing surface when the mounting position is correct.

6

Bedding of sieve pan and air intake louver

7

Connecting branch exhauster hose

8

Air intake louver in sieve pan (locked witch headless screw (11) on bearing shaft)

9

Fume hood

10

Stripping brush

11

Headless screw

Do not start the engine when the sieve pan is in swung out position, as otherwise the V-belt (2) will be damaged. Check whether the V-belt properly lies in the guide pulley (2.1) subsequent to swinging in the sieve pan.

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1

2

2.1

4

4

2 3 3

19,59

2004514-2

9 5

1 1

6 8

10 11 9

9 2004514-1

16053690

7

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5670 Driven shaft of engine 1

Vibration damper: Check for cracks in the rubber coating.

2

Screws

3 4

Set collar (threaded pin unsrewed from the groove) Gap 1+1 mm to seal ring

5

Grease outlet

6

Screw

7

Screw

8

Nut

Screws (2, 6, 7) and nut (8) locked with screw retention agent. Apply grease before mounting.

5650H – 5690HTS Driven shaft of engine 1

Vibration damper

2

Screws M10x110, 10.9

Assembly dimension [mm] of V-belt pulleys

2.1 Distance ring 3

V-belt pulley cooling compressor drive

4

V-belt pulley cooling fan drive

5 6

Set collar (threaded pin unscrewed from the groove) Gap 1+1 mm to seal ring

7

Bearing cover: Remove before mounting

8

Bearing housing: Center while mounting

9

Grease outlet

Type

A

B

C

5650/60

36

174

227

5680/90

136

201

378

Lock screws with screw retention agent Loctite 243 Apply grease before mounting.

5650H – 5690HTS Observe proper sequential order when mounting: –

Flange driven shaft to engine.

–

Align bearing housing (8) to bearing shell.

–

Mount bearing cover (7).

–

Place set collars (5) left and right with a clearance of 1 mm to the seal ring. Fasten the v-belt pulleys by wedges before attaching them to the engine.

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5670 6

8

7

A00158-1

5650H – 5690HTS Mta =

Mta =

70 Nm

Mta =

Mta =

25 Nm

250 Nm

50 Nm

2,1 3

4

5

6

7

6

2

+1

22310 CC/C3

A B C 1

Mta =

210 Nm

9

8 56-110

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A00174-1

6

7 3 4

5

2 A00175

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5650H – 5690HTS Driven shaft of engine Bedding

Aligning of driven shaft of engine (required upon replacement of the engine or the engine supporting frame) 1

Remove stop prior to alignment and weld again subsequently (bearing housing must rest against stop).

2

Compensating cams

3

Mount 3 aligning sleeves instead of the flexible disk and bolt firmly.

4

Mount with strong washer

5

Mount bearing and align shaft laterally and vertically (without belt pulley)

5.1 Turn the engine and check once more, reassemble the flexible disk. 6

Half-flange (not 5670) – Dismantle in order to replace the v-belt.

7

Fill locating bearing with EP long-time grease prior to mounting.

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5650H – 5690HTS Mounting of hydraulic pumps –

Apply new o-ring seal (1).

–

Place new gasket (2) with mounting flange on hydraulic pump.

–

Mount gearwheel (3).

1

2

28-3.51

3 Note: Observe whether the feather key is existing.

28-3.52

–

Tighten self-locking nut with a tightening torque of 80 Nm.

Note: Always use new self-locking nut.

28-3.53

Attaching the hydraulic pumps: In the case of balance hydraulics 2 washers of 2 mm thickness must be applied at the tie rod head.

4

For standard hydraulics: 2x tie rod (4), M10x275 10.9 For balance hydraulics: 2x tie rod (4), M10x285 10.9 Tightening torque: 50 + 10 Nm. 56-076

A 68

–

Clean tie rod threads and screw in with sealing compound (sealing of thread hole in the flange to the engine). 307.1133.3.6 englisch (en) 10.2006

B Service Training

5650H – 5690HTS Drive axle, Gearbox, Steering Axle Table of Contents Combine Harvester Type

5650H 5680H 5660HTS 5690HTS

Maintenance and inspection Safety instructions, tyres, screwed fixings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02

X

X

Safety instructions, brakes, brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02

X

X

Drive axle / Steering Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03

X

X

Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04

X

X

Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05

X

X

Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 – 12

X

X

Tyres and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

X

X

Drive axle / steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 – 15

X

X

Balance Drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 – 17

X

X

Shift Gear SBK 419, gear change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 – 21

5670

Shift Gear, gear change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 – 25

X

X

Shift Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 – 27

X

X

Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 – 29

X

X

Steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 – 31

X

X

307.1133.3.6 englisch (en) 10.2006

B1

B Service Training

5650H – 5690HTS Maintenance and inspection General Safety instructions Tyres, screwed fixings: 1.

When working on the wheels, make sure that the combine harvester is safely parked and secured against rolling (wheel chocks).

2.

When working underneath the jacked combine harvester, make sure that nobody is allowed on the combine.

3.

Make sure that the jack or lifting device has sufficient load-bearing capacity.

4.

Tyre removal and fitting require specialised knowledge and regulatory fitting tools.

5.

Check the tyre pressures at regular intervals. If the pressure is too high, the tyre(s) may burst.

6.

Tighten all fixing screws and nuts of the front and rear wheels and the track adjusting components in conformity with the manufacturer's specifications.

B-8

Brakes, brake fluid:

B2

1.

Always check the brakes before setting out.

2.

The brake systems must be thoroughly tested at regular intervals.

3.

Brake system settings and repairs may only be carried out by specialised workshops or recognised brake services.

4.

When driving on public roads, the independent wheel braking system must be disabled (engage the pedal interlock).

5.

Check the brake fluid level at regular intervals. Only use authorised brake fluid and replace it as specified.

6.

Take care when handling brake fluid (toxic and corrosive). Do not spill or pour brake fluid into the environment.

7.

Dispose of brake fluid in conformity with environmental regulations.

8.

During all repairs to the brakes, make sure that no impurities enter the system.

9.

After all servicing, maintenance or repairs of the brake system, carry out a final test of leakproofing, operation and efficiency.

307.1133.3.6 englisch (en) 10.2006

B Service Training

5650H – 5690HTS Maintenance and inspection Drive axle Maintenance / inspection

Service interval

Oil change Manual gearbox

After 50 operating hours, and then every 500 operating hours but at least once a year

Oil change Side gears

After 50 operating hours, and then every 500 operating hours but at least once a year

Check oil level Manual gearbox / side gears

On handover, every 250 operating hours,

Check the gearshift and reset if necessary

On handover, after 50 operating hours, and then every 500 operating hours

Capacities and oil grades´ For filling quantities and oil qualities see section "General"

Drive axle / steering axle Maintenance / Inspection

Service interval

Inspect brake system

On handover, after 50 operating hours, and then every 500 operating hours, but at least once a year

Check brake fluid level,

On handover, and then every 50 operating hours, every 250 operating hours

Change brake fluid

At least every 2 years

Check parking brake, readjust if necessary

On handover, after 50 operating hours, every 250 operating hours

Retighten screw fixings

After 20 operating hours, after 50 operating hours, and then every 500 operating hours

Retighten wheel nuts as specified

On handover, after 5, 20, 50 operating hours, and then every after 250 operating hours

Check toe-in of the guide wheels

On handover, and then every after 500 operating hours

Check or set the wheel bearing play of the steered wheels

On handover, after 20 operating hours, and then every 250 operating hours

Check tyre pressure

On handover, daily

Visual inspection for oil leaks at gears and Brake system

307.1133.3.6 englisch (en) 10.2006

daily

B3

B Service Training

5650H – 5690HTS Maintenance and inspection Manual gearbox

1

Checking the oil level The oil inspection screw (1) is located on top of the manual gearbox. Check the oil using the dipstick attached to the screw. 35485

Changing oil The gearbox must be warmed up to operating temperature to change the oil. – Unscrew the oil drain plug (2). – After draining the oil, screw the oil drain plug (2) back into place. – Pour fresh oil into (1), up to the marking on the oil dipstick.

☞ 2

35486

3

For the oil change intervals please refer to the lubrication plan, but in all cases the oil must be changed at least after the harvest season in the course of the winter storage preparations.

Final drives Checking the oil level Check the oil level at the screw plug (3). Bleed the side gears using the venting valve (5). Keep the valve clean at all times.

4

33802

Oil change The gearbox must be warmed up to operating temperature to change the oil. – Unscrew the oil drain plug (4). – After draining the oil, screw the oil drain plug (4) back into place.

5

– Pour fresh oil into (5), up to the bottom edge of the threaded hole at (3). – Screw in the oil inspection screw (3).

☞ 33820

B4

For the oil change intervals please refer to the lubrication plan, but in all cases the oil must be changed at least after the harvest season in the course of the winter storage preparations.

307.1133.3.6 englisch (en) 10.2006

B Service Training

5650H – 5690HTS Maintenance and inspection

1

Final drive Balance

2

The gear case is vented through the venting valve (1). Oil level checking – Place the machine in neutral position (the front gear cover must be perpendicular – 90° to the ground). – Oil level shall be checked at the control screw (2).

3 35626

Oil change – Remove control screw (2). – Remove oil drain plug (3), drain oil. – Reinstall oil drain plug (3). – Replenish new oil through the opening of the control screw (2) until oil level has reached the opening. – Screw in control screw (2). – Check oil drain plug (3) and control screw (2) for leakage.

307.1133.3.6 englisch (en) 10.2006

B5

B Service Training

5650H – 5690HTS Maintenance and inspection Brake system General The combine harvesters are fitted with hydraulic disc brakes. (double calliper disc brakes as from Type: 4040).

Checking the brake fluid / brake pads Important! B-1

For reasons of traffic safety, it is indispensable that the brake systems are thoroughly inspected at regular intervals. This work must be performed in a specialised workshop. Checking the brake fluid: Check the level on the reservoir (B). Wipe the screw cap clean of any dirt deposits before opening. Replacing the brake pads: ● ●

When the brake pad has worn down to a thickness of 2 mm If the brake pads are unevenly worn.

Always replace the brake pads on all callipers of an axle at the same time. Only use brake pad sets approved by the vehicle manufacturer or brake manufacturer.

B-7

B6

307.1133.3.6 englisch (en) 10.2006

B Service Training

5650H – 5690HTS Maintenance and inspection: Brake system Changing the brake pads on the fixed calliper General: When changing the brake pads, clean the guide surfaces or the seat in the housing slot. Do not use solvents containing mineral oils or any metal, sharp-edged tools. Check that the protective boots and clamping rings fit perfectly. Damaged, hard or brittle boots must be replaced. Siphon off the brake fluid to prevent the reservoir from overflowing when the pistons are retracted. The bleeder valve of the relevant disc brake can also be opened, so that the brake fluid displaced by the piston can be discharged via a bleed hose into a collecting container. When the pistons are returned to their starting position, the bleeder valve must be reclosed before releasing the piston retracting tool. Remove the rust scale from the outer edge of the brake disc. Determine the brake disc wear with the aid of a disc brake gauge. B-6

1

Fixed calliper

2

Repair set

3

Brake pad assembly

4

Fit bolt

5

Hexagon-head bolt

6

Bleeder valve

307.1133.3.6 englisch (en) 10.2006

B7

B Service Training

5650H – 5690HTS Maintenance and inspection: Brake system Changing the brake pads on the fixed calliper After removing the brake pads: Insert a 20° piston gauge in the housing slot and check that the piston face recess angle matches the slant of the piston gauge.

B-13

Using piston-rotating pliers, rotate the piston to the correct position against the gauge.

1

Direction of rotation of the disc brake during forward travel

2b Lower contact surface in the calliper slot 3

Piston gauge with 20 measuring edge

4

Piston face recess angle

5

Hole for applying the piston-rotating pliers

Insert new brake pads in the pad slot. Fix the brake pads with new spreader springs and pad retainer pins.

B-17

Note: On installing the retainer pins, make sure that the outer bearing surface of the clamping sleeve completely disappears into the hole. Do not hammer the rivet-head in front of the clamping sleeve. Finishing operations: Operate the brake pedals several times so that the brake pads come into contact with the disc. Check the brake fluid level in the reservoir and top up if necessary. Test the leakproofing, operation and effectiveness of the overall brake system. Special tool:

For mounting the retaining pins

Brake pin punch: C4 Sliding shank sleeve: Make as per drawing B-14

Works photos Fa. Alfred Teves GmbH 6000 Frankfurt/Main 90

B-15

B8

307.1133.3.6 englisch (en) 10.2006

B Service Training

5650H – 5690HTS Maintenance and inspection: Brake system

1

Changing the brake pads Special tools 1 Brake pad remover Part No. 03.9314–1400.2/011)

B-22

2 Piston retracting tool Part No. 03.9314–4950.3/01

2

B-18

3

Piston-rotating pliers for setting the 20° piston face recess angle Part No. 03.9314–5700.3/01

20° piston gauge for checking the setting of the 20° piston face recess angle for piston-Ø 42 – 48 mm Part No. 03.9314–0900.1/02 for piston-Ø 52–57 mm Part No. 03.9314–0600.1/02 for combine harvester types 4030, 4035, 4040, 4045H

3

B-20

4

4

5 Gauge for measuring brake pad wear Part No. 03.9314–6170.3/01

B-21

5

Works photos Firma Alfred Teves GmbH 307.1133.3.6 englisch (en) 10.2006

B-19

B9

B Service Training

5650H – 5690HTS Maintenance and inspection: Brake system Checking the brake discs Brake wear must be checked with a brake pad gauge. Wear is measured with the brakes installed. After removing the brake pads and retracting the piston, measure the piston through the pad slots. Only max. 0.5 mm may be reworked on each friction surface side. B-25

Always change both brake discs on an axle at the same time.

Reworking dimensions

5650H– 5690HTS

Disc thickness original

Minimum thickness reworked

22 mm

21 mm

Condition: a)

Brake disc can be reworked if necessary.

b)

Severe scoring and ridging of the outer circumference. The possibility of reworking depends on the depth of wear. The wear depth must not exceed the maximum reworking dimension.

c)

Wedge-shaped wear of the brake disc. The brake disc must be replaced, because fracture of the housing between the sealing ring groove and the boot seat on the calliper is likely (Figure B-24).

B-.23

B-24

B 10

307.1133.3.6 englisch (en) 10.2006

B Service Training

5650H – 5690HTS Maintenance and inspection: Brake system Procedure for bleeding the brakes and changing brake fluid General: If devices, fittings, hoses or pipes are repaired or replaced in the brake system, the brake fluid must be topped up and the entire system must be bled. A filling and bleeding tool must be used. When bleeding the brakes or changing the brake fluid, the system must be bled and/or brake fluid must be drained at each bleeder valve in the system. Procedure Bleeding (topping up) using a workshop brake bleeder Wipe any dirt from the screwed joint of the brake fluid reservoir, bleeder nipple and surrounding parts. Connect the brake bleeder – prepared according to the relevant manufacturer's specifications for a system pressure of 2 bar - to the screwed joint of the brake fluid reservoir and open the shut-off valve on the filler hose. The system is now pressurised. Connect transparent hoses (approx. 1.3 m long) to the bleeder valves. Place the free hose ends in containers at approximately the same height as the relevant bleeder valve. Keep the bleeder valves open until the brake fluid is discharged without bubbles. During the bleeding process, operate the pedals several time to release air from the primary chamber of the master cylinder. After bleeding the system or changing the brake fluid, the dust caps must be replaced on the bleeder valves. Bleeding without brake bleeder Fill the system, so that the fluid level in the reservoir is at the maximum mark. Connect a transparent hose (approx. 1.3 m long) to the bleeder valve. Place the free hose end in a container at roughly the same height as the bleeder valve. Open the bleeder valve. Slowly and smoothly press the pedal down as far as it will go and then allow it to return slowly and fully to the rest position. Repeat the procedure until the brake fluid pours out continuously without bubbles. Close the bleeder valves after pressing the pedal. Note: Due to the built-in pilot pressure valves in the master cylinder, the bleeder valves do not have to be closed after each pedal activation. If the brake pedal travel is too long or the brake pressure is too "soft" after bleeding the system, the bleeding process must be repeated after activating the brakes vigorously several times.

307.1133.3.6 englisch (en) 10.2006

B 11

B Service Training

5650H – 5690HTS Maintenance and inspection: Brake system Handbrake: repair The handbrake is mounted on the right-hand side of the gearbox. Dismantle the brake as shown in Figure B-26. Check individual parts for wear and replace if necessary. Setting: When the handbrake is applied, the brake lever must engage with the first third of the ratchet segment. To adjust, use the yokes on the link-rods or pull-cable: see Operating Instructions.

B 12

1

Brake lever

4

O ring

5

Brake plate

6

Shaft

8

Brake shoe with brake pad

19

Thrust washer

17

Flange

18

Brake drum

307.1133.3.6 englisch (en) 10.2006

B Service Training

5650H – 5690HTS Tyres and wheels Wheel offset = E In case of wheels for single mounting the tread is determined by the wheel offset of the rims and by the clearance between outside edges of wheel hubs. The wheel offset must therefore be determined by the vehicle design. In case of a wheel offset of zero the tread is equal to the clearance between outside edges of wheel hubs

Generally common configuration: Positive offset E

Offset

1

Rim centre line

2

Inner attachment face

3

Pitch circle

4

Hub bore

B-40

Special design: Negative offset E

Offset

1

Rim centre line

2

Inner attachment face

3

Pitch circle

4

Hub bore

B-37

307.1133.3.6 englisch (en) 10.2006

B 13

B Service Training

M20x1.5 300 Nm

740 Nm M24

3

750 Nm

210 Nm

1 A

2

4

4.1

4

3

A 5 210 Nm

5

B-38

B 14

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B Service Training

5650H – 5690HTS Drive axle 1

End play of the side shafts, max. 3 mm

2

Parking brake

3

Brake calliper

4

Profilmuffe

4.1 Bolt M10x85 5

Fitting bolt M14 x M1,5, 10.9 secured with Loctite 243

Hydrostatic motor

HMF 105: 5650 - 5660 HMF 135:

5650 - 5660 Balance 5680 - 5690

A cover plate is mounted onto the lining groove at the upper brake callipers in order to prevent penetration of dust and chaff.

Fire hazard! Daily remove deposits of crop residuals from the brake callipers.

307.1133.3.6 englisch (en) 10.2006

B 15

B Service Training

5650H – 5690HTS Balance Drive axle 1

Axle

2

Final drive

3

Drive plate

4

Bolt M20, 10.9 secured with Loctite 243

5

Washer Disc

6

Thrust ring

7

Spacer discs

8

Retaining plate

9

Bearing sleeve, cemented in place with Loctite 648

10 Spacing sleeve between profile sleeves 11 Grease pipe for outer profile sleeves 12 Bolt M10x85, 10.9 13 Connecting rod 14 Lifting cylinder 15 Spacer discs as required 16 Intermediate Shaft 17 Grease pipe for outer bearing sleeve 18 Grease pipe for inner bearing sleeve

Assembly / dismantling Removing the tilt cylinders Jack the combine and mount it on supports (tilt cylinders must be fully extended). Disconnect the hydraulic connections. Detach the front tilt cylinder by removing bolt and pull the rear tilt cylinder off bolt (after removing the locking screw). Note: – Tighten connecting rod (13) in unloaded condition of the driving axle (supported) with 20 Nm and secure with lock washer. – Axial play of intermediate shafts (16): max 3 mm – Cement in place bearing sleeves (9) with Loctite 648: Clean axle tube and bearing sleeves and apply Loctite on contact surfaces. – Draw in outer bearing sleeves with butt joint at the bottom, inner bearing sleeves with butt joint on top. Observe that the lubrication hole of axle tube and bearing sleeve is aligned. Remove Loctite from lubrication hole, fill grease pipes (17, 18) with grease. – Adjust axial play of the final drives in the axle tube to 0.2 - 0.7 mm by means of spacer discs (7). – Grease axle tube after assembly of the final drives until grease comes out. – Clean and degrease contact surface between drive plate (3) and final drive (2).

Note: – For dismounting and mounting of the shift gear the retaining plates (8) must be removed and the final drives need to be pulled outward a little in order to release the profile sleeves.

B 16

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B Service Training

3 4

300 Nm

5, 7, 8

2

17

1 9 B-50

16 18

1

8

5

7

9

10

12

4

11

5

210 Nm

6 2

15

14

9

3

13 20 Nm

B-49

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B 17

B Service Training

5670 Shift Gear SBK 419 (1604 0899) 1

Drive Shaft

2

Countershaft

3

Slotted nut, caulked on the drive shaft

4

Shifter collar, 1st and 2nd gear

5

Shifter collar, 3rd and 4th gear

6

Hand Brake

7

Differential Gear

8

Output Shaft with Brake Disc

9

Disc

Mounting instruction: – Cover and flanges are sealed up to the gear box housing by means of sealing compound. – Insert bolts in through borings in the housing by means of sealing compound.

B 18

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307.1133.3.6 englisch (en) 10.2006

1

200-250 Nm 3

46-54 Nm

8

46-54 Nm

9

0-0,6

4

5

7

2

64 Nm

6

25-28 Nm

25-28 Nm

80-94 Nm

8

46-54 Nm

B

Service Training

B005

B 19

B Service Training 1 13

2

13

200-250 Nm

3

4

7

7

B006

30-35 Nm

B–B

3 35-41 Nm

5

54-69 Nm 69-83 Nm

10 4 10

6

7

8

9 B007

B 20

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B Service Training

5670 Shift Gear SBK 419 (1604 0899), gear change 1

Housing cover

2

Shifter rail for shift finger

3

Shift finger

4

Shift lock

5

Guide pin for shift lock

6

Ball, pressure spring for locking of the shifter rails

7

Shifter rails for shift-forks

8

Shift-fork, 1st and 2nd gear

9

Shift-fork, 3rd and 4th gear

10

Threaded pin with counter nut, secured with Loctite 262

Adjustment of the shift-forks (8, 9): – Shift-forks (7) are in neutral position, see cross-section B-B. – When threaded pins (10) are loosened, adjust shift-forks such that the clearance A, B between shifter collars and gear wheels is equal (difference between measurement A and B max. 0,5 mm, see previous page). – Equally tighten threaded pins alternately to 30-35 Nm. By doing this, the shift-fork must not move anymore along the shifter rail (7).

.

– Secure threaded pins with counter nuts, 35-41 Nm. While securing the nut, the threaded pin must not be twisted anymore. – Shift into the gears and check whether the shifter collars (8, 9) are tensed axially (correct the adjustment of the shiftforks if necessary)

307.1133.3.6 englisch (en) 10.2006

B 21

B Service Training

5680, 5690 Shift Gear (1604 0895) 1

Drive Shaft

2

Countershaft

3

Shifter collar, 1st and 2nd gear

4

Shifter collar, 3rd and 4th gear

5

Hand Brake

6

Output Shaft with Brake Disc

7

Differential lock, actuation not coupled

8

Differential Gear

9

Shim ring for adjustment of the axial bearing play 0,3 – 0,8 mm

Mounting instruction: – Cover and flanges are sealed up to the gear box housing by means of sealing compound. – Insert bolts in through borings in the housing by means of sealing compound.

B 22

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6

90-106 Nm

46-54 Nm

1

2

46-54 Nm

80-94 Nm

9

0,3-0,8

3

8

4

80-94 Nm

46-54 Nm

24-28 Nm

5

116 Nm

80-94 Nm

25-28 Nm

80-94 Nm

25-28 Nm

7

6

90-106 Nm

B

Service Training

B001

B 23

B Service Training 1 9

4

3

9

2 5

10

11

B002

4 1

C–C

A–A

55-65 Nm

6

30-40 Nm

4 B004

12 7

E–E

30-40 Nm 55-65 Nm

8 9

F–F 9 10

11

10, 11

B010

F–F

B003

9 B 24

8

B011

9

307.1133.3.6 englisch (en) 10.2006

B Service Training

5650H – 5690HTS Shift Gear (1604 0895), gear change 1

Gear Shift Cover

2

Housing cover

3

Shaft for shift finger

4

Shift finger

5

Dowel Pin, two pieces

6

Threaded plug, tap depth in housing cover: 0,5 mm

7

Ball, pressure spring for locking of the shifter rails

8

Balls for shift lock

9

Shifter rails for shift-forks

10

Shift-fork, 1st and 2nd gear

11

Shift-fork, 3rd and 4th gear

12

Threaded pin with counter nut, secured with Loctite 262

Adjustment of the shift-forks (10, 11): – Shift-forks (9) are in neutral position, see cross-section A - A. – When threaded pins (12) are loosened, adjust shift-forks such that the clearance A, B between shifter collars and gear wheels is equal (difference between measurement A and B max. 0.5 mm, see previous page). – Equally tighten threaded pins alternately to 30-40 Nm. By doing this, the shift-fork must not move anymore along the shifter rail (9). – Secure threaded pins with counter nuts, 55-65 Nm. While securing the nut, the threaded pin must not be twisted any more. – Shift into the gears and check whether the shifter collars (10, 11) are tensed axially (correct the adjustment of the shiftforks if necessary)

307.1133.3.6 englisch (en) 10.2006

B 25

B Service Training

5650H – 5690HTS Gear Shift

1

Gearshift Lever

2

Gear shift bracket (Selection of gear shift gate)

3

Star wheel with guide finger (engaging of gears)

4

Steering rod star wheel bellcrank

5

Bellcrank gears

6

Shifting Gate

7

Feed rods gear shift gate

8

Feed rods Gears

9

Bellcrank for shift gate at gear box

10

Gear Shift Head

11

Shifter rail in gear cover

X

Gear shift bracket fulcrum (2) - Selection of shift gate

Y

Star wheel fulcrum (3) - Engaging of gears

Position of shift gates A 5670

B

3 and 4

1 and 2

5650, 5660 1 and 2

3 and 4

5680, 5690

The depicted feed rod linkage (7) at the bellcrank (9) corresponds to 5650/60, 5680/90. In case of 5670 the feed rod (7) is located in front of the fulcrum of the bellcrank (9).

B 26

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B Service Training

2

1

4

3

1

2

y

3

3

2

1

4

4 6

5

x

5 7 8

7

8

7

8

11

10 A B

7

9 8 1,3

2,4 307.1133.3.6 englisch (en) 10.2006

56-116

B 27

B Service Training

3

5

4 6

7

8 2 6

6 1

2 3

X

4 1

6

B 28

5

307.1133.3.6 englisch (en) 10.2006

B Service Training

5650H – 5690HTS Final Drive (1604 0897) 1

Drive Shaft, Initial tension of the bearing 0 – 0,05 mm

2

Intermediate Shaft, initial tension of the bearing 0,03 – 0,05 mm

3

Gear Wheel Shaft

4

Shrunk-on intermediate ring

5

Slotted nut, caulked on the gear wheel shaft, tightening torques 450 Nm

6

Shim Rings

7

Thrust Washer

8

Shaft Seal Ring

Mounting instruction: Lubricate shaft seal ring (8) and taper roller bearing. Pretension the taper roller bearing of the gear wheel shaft (3) with dismantled spur gear such that the moment of friction amounts to 15 - 17 Nm. Turn the gear wheel shaft back and forth several times on this occasion. Determine the thickness of the required shim rings (6) between thrust washer (7) and shaft shoulder. Mount gear wheel shaft with shim rings and securely tighten slotted nut (5). Check moment of friction again, correct thickness of shim rings if necessary. Mount gear wheel shaft with spur gear, tighten slotted nut (5) with 450 Nm and stake into the grooves of the gear wheel shaft. Fill shaft seal ring (8) between the sealing lips with grease.

X Detail Final Drive (1604 1806) for Balance Axle 1

Drive Shaft

2

Shaft Seal Ring

3

Retaining Ring

4

Shim Rings

5

Washer Disc

6

Gear Box Housing with Bearing Tube

For oil level check move Balance axle into neutral position (housing cover of final drive is in vertical position).

307.1133.3.6 englisch (en) 10.2006

B 29

B Service Training

5650H – 5690HTS Steering Axle 1

Steering Axle Support

2

Hinged Stop

3

Steering knuckle

4

Steering tie rod

5

Steering cylinder

6

Ball joints, tightening torque of castle nut M20x1.5: 230 Nm

7

Stop Screw

8

Steering Stop Limit

9

Hub of the Wheel

10

Seal Washer

11

Supporting Disc

12

Castle nut, secured with cotter pin

13

Washer Disc

14

Thrust Washer

15

Cover disc with spring dowel (anti-rotation pin)

16

Washer disc, shim ring

Adjustments at the steering axle: 1. Toe-in approx. 3 mm, measured at beads of rim at hub centre level. 2. Piston rods of steering cylinders (5) must hit the limit positions simultaneously. 3. Adjustment of stop screw (7) at steering stub axle: Set the stop screw in the steering cylinder limit positions until the steering stop limit (8) is reached. 4. Axial play of steering knuckles (3) inside of axle casing: 0,2 – 0,4 mm 5. Axial play of wheel bearings max. 0.1 mm

Mounting instruction: – Observe mounting position of thrust washer and washer disc (14, 13): Chamfer (a) of thrust washer (14) and lubrication groove (b) of washer disc (13) must face each other (ground faces). – Fill hub of the wheel (9) and bearing with grease. – If the steering axle is pivoted in the lower borehole (1.1) of the steering axle support, the hinged stop (2) must be mounted at the steering axle support.

B 30

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B Service Training

1 1,1

6

4

6

2

6

6 3

3

7

8

5

5

8

7

15

9

16

3

8 14 10 12

11 13 b

307.1133.3.6 englisch (en) 10.2006

a

B 31

B Service Training

Notes

B 32

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C Service Training

5650H – 5690HTS Belt drive clutches, Lubrication System Table of Contents Combine Harvester Type

5650H 5680H 5660HTS 5690HTS

Electric actuation of belt couplings, Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 – 03

X

X

Integrated clutch control power unit (CCP2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04 – 05

X

X

Straw chopper clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 – 07

X

X

Grain tank discharging clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 – 07

X

X

Threshing mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .08 – 09

X

X

Feed passage clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .08 – 09

X

X

Installation Diagram Lubrication distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 – 11

X

X

Installation Diagram Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 – 13

X

X

307.1133.3.6 englisch (en) 10.2006

C1

C Service Training B40 15

S22

S23

15

30

31

F34 F39

30506-1

H35

X505

X515

S40

A30 X510

X507 2

1

A8

26

13

14

1

H1b H2b H3b H4b

F2

F1

35402

X5 X1 H1a

X505 X508 X509

4

3

X508

X2 H2a

4 F3

F4

R1 R2

X4 H4a

X3 H3a

G3

D+

X1 X3 X4

+12V X6 GND-

R3 R4

C0105

K50 K71

G W

X16

M5 X142 X143

B39

M4

M6

B38 B19

C2

M7

307.1133.3.6 englisch (en) 10.2006

C Service Training

5650H – 5690HTS Electric actuation of the belt couplings Overview A8

Clutch Control Power Unit

A30

Commander Control

B19

Speed sensor chopper

B38

Sensor for chopper flap position

B39

Sensor grain tank tube

B40

Central Indicator

F…

Fuses

G3

Generator

H35

Indicator light chopper flap

K50, K71

Relay swivel grain tank tube

M4

Servomotor threshing mechanism clutch

M5

Servomotor for feed passage clutch

M6

Servo motor grain tank clutch

M7

Servomotor chopper clutch

S22

Foot switch cutting mechanism stop

S23

Foot switch grain tank clutch

S40

Working master switch

X....

Connector

Note: The cutting table clutch is also referred to as the feed passage clutch. The long straw discharge flap is also termed the straw chopper flap or (straw) distributor flap. Prerequisites for proper function of the belt couplings: – Engine is running with low idle speed (charge control light off) – Working master switch S40 on – Grain tank clutch can only be activated after swivelling of the grain tank tube. Sensor B39 must be functioning.

Engaging belt couplings at engine stop: – Press key

on Commander Control 2000 while turning Starting key in position I.

– Working master switch must be ON.

307.1133.3.6 englisch (en) 10.2006

C3

C Service Training

34939-4

MED_ACAD*11/24/10 11:01 AM Rev:12.23

SOLARI 1.she

56-000

2

1

A8

26

13

14

1

H1b H2b H3b H4b

F2

F1

X5 X1 H1a

4

3 4 F3

X2 H2a +12V X6 GND-

F4

X3 H3a

30 31

R1 R2

X4 H4a

R3 R4

C0105

C4

307.1133.3.6 englisch (en) 10.2006

C Service Training

5650H – 5690HTS Electric actuation of the belt couplings Integrated clutch control power unit (CCP2) 1–4

Load relay 1

Threshing mechanism

2

Feed passage

3

Grain tank discharging

4

Straw chopper

F1 – F4

Fuses 30 A

F1 – F5

Fuse 60 A

X1 – X6

Plug-in connectors

H1b – H4b

LEDs, control input

H1a – H4a

LEDs, load output

R1 – R4

Potentiometers

Description: Indicators (LEDs): Red: disengage Green: engage H1b – H4b:

LEDs for indicating the switch status at the control input (signals from the control unit) for belt clutches 1 – 4

H1a – H4a:

LEDs for indicating the switch status at the load output (connectors X1 – X4) for belt clutches 1 – 4

Setting the load switching point: R1 – R4:

Potentiometer for adjustment of the cut-off current of the servo motors (spring-loading of the relevant belt clutch) – Turn clockwise: – increase load current (spring-loading) – Turn counter-clockwise: – reduce load current (spring-loading) 1 turn = approx. 2.8 A change in load current

Note: – Use a screwdriver with 1.2 mm blade – The potentiometers do not have a mechanical end-stop. Observe the proper polarity while connecting the power supply Control unit

Pin

A8 A8 A8 A8 A8 A8 A8 A8

X5 X5 X5 X5 X5 X5 X5 X5

Pin No. Function 6 2 9 8 19 18 22 21

Cutting mechanism on Cutting mechanism off Threshing mechanism on Threshing mechanism off Chopper on Chopper off Grain tank discharge on Grain tank discharge off Foot switch grain tank Foot switch cutting mechanism stop Sensor grain tank tube Sensor chopper flap

307.1133.3.6 englisch (en) 10.2006

Cable colour

Pin

Pin No.

black-brown white grey blue-yellow violet yellow green-pink green-blue violet-yellow orange-green white-blue green-black

X 507 X 507 X 507 X 507 X 507 X 507 X 507 X 507 X 515 X 515 X 509 X 508

1 2 3 4 5 6 7 8 2 1 5 11

Com. Control

Pin

A 30 A 30 A 30 A 30 A 30 A 30 A 30 A 30 A 30 A 30 A 30 A 30

1 2 3 4 5 6 7 8 52 20 53 34

C5

C Service Training

5650H – 5690HTS Belt drive clutches Straw chopper clutch Basic setting: Spring-loading when engaged (dimension A): 110 mm The spring-loading is set on the potentiometer of the relevant load relay in the switch box. Servomotor stroke (dimension B): 60 mm The stroke is adjusted with setscrew (C). Reference dimension D must be at least 115 mm in the engaged state. If dimension D is less than 115 mm, adjust the transmission shaft and check the servomotor stroke.

Grain tank discharging clutch Basic setting: Spring-loading when engaged (dimension A): 135 mm The spring-loading is set on the potentiometer of the relevant load relay in the switch box. Servomotor stroke (dimension B): 60 mm The stroke is adjusted with setscrew (C).

C6

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C0110

C0111

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C7

C Service Training

C0112

C0113

C8

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C Service Training

5650H – 5690HTS Belt drive clutches Threshing mechanism Basic setting: Spring-loading engaged (dimension A): 140 mm The spring-loading is set on the potentiometer of the relevant load relay in the switch box Servomotor stroke (dimension B): 72 mm The stroke is adjusted with setscrew (C).

Feed passage clutch Basic setting: Spring-loading when engaged (dimension A): 145 mm The spring-loading is set on the potentiometer of the relevant load relay in the switch box Servomotor stroke (dimension B): 60 mm The stroke is set by adjusting the spring assembly on the threaded rod (G).

307.1133.3.6 englisch (en) 10.2006

C9

C Service Training

Lubrication distributor left side Installation Diagram

1

Bent pipe discharge pipe

2

Slewing rim bent tube

3

Slewing rim bent tube

4

Angular gear grain tank discharge

5

Turbo separator

6

Impeller

7

Threshing drum

8

Shaft of sieve pitman arm

9

Bearing feed passage

11 Bearing feed passage shaft

C 10

☞

For more information about lubrication distributor blocks refer to section "lubrication distributor right side”.

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C Service Training

Lubrication distributor right side

10h

1. Bearing feed passage 2. Bearing feed passage shaft

35618

3. Elevator head 4. Threshing drum 5. Impeller 6. Turbo separator 7. Engine bearing 8. Shaft of sieve pitman arm

Installation diagrams of lubrication distributor blocks

Instructions for trouble shooting ATTENTION! It is not admissible to obturate individual lines from the distributor block to the point of lubrication (e.g. a ruptured hose line) as thereby the remaining points of lubrication of the corresponding distributor block will be also blocked.

In the installation diagrams, the allocation and assignment of the points of lubrication to the corresponding distributor block is shown.

☞

If lines are replaced, they must be connected according to the installation diagram as the amount of grease for each point of lubrication is metered individually by the corresponding distributor block valve!

307.1133.3.6 englisch (en) 10.2006

-

If the distributor block cannot be lubricated, identify the clogging point of lubrication and clear.

-

Call on a specialised workshop if necessary.

C 11

C Service Training

Lubrication distributor Balance

1+2

Journal bearing

3+4

Journal bearing

5+6

Hydraulic cylinder rear

7+8

Hydraulic cylinder front

35618

☞

For more information about lubrication divider blocks refer to section "lubrication distributor right side”.

Installation Diagram Central lubrication system Block No

Designation

1

Pump unit of centralised lubrication system

2

Distributor block right

3

Distributor block

4

Distributor block

5

Distributor block

6

Distributor block

7

Distributor block above front axle

Instructions for trouble shooting ATTENTION! It is not admissible to obturate individual lines from the distributor block to the point of lubrication (e.g. a ruptured hose line) as thereby the remaining points of lubrication of the corresponding distributor block will be also blocked.

(only with Balance) 8 10

C 12

Distributor block left Distributor block feed passage

-

If the distributer block cannot be lubricated, identify the clogging point of lubrication and clear.

-

Call on a specialised workshop if necessary.

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307.1133.3.6 englisch (en) 10.2006

Tensioning pulley Chaff spreader Chaff spreader Chaff spreader Rear axle Rear axle

Chopper

Right side

2

5

VPKM-4-520 Lubrication aid

Chopper Chopper Tensioning pulley Tensioning pulley Sieve pitman arm Sieve pitman arm Sieve pitman arm Rear axle

1

6

VPBM-4-209 Lubrication aid

3

Feeder front right

Pivoting cutting mechanism

Feed passage

Sieve pitman arm Sieve pitman arm Sieve pitman arm Tensioning pulley

Left side

Angular gear Tensioning pulley for fan Tensioning pulley for fan Tensioning pulley Tensioning pulley Tensioning pulley

8

7

Tensioning pulley Tensioning pulley Tensioning pulley Tensioning pulley

Speed setting

Pivoting cutting mechanism Tensioning pulley Feeder front left

Revolvingg turret Tensioning pulley Tensioning pulley Tensioning pulley Chopper

VPKM-5-404 Lubrication aid

4

C

Service Training

C 13

C Service Training

Notes

C 14

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D Service Training

5650H – 5690HTS Hydraulic Table of contents Combine Harvester Types

5650H 5680H 5660HTS 5690HTS

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03

X

X

Circuit symbols in the hydraulic circuit diagram conforming to ISO 1219 . . . . . . . . . . . . . . .04 – 09

X

X

Circuit diagram working hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 – 11

X

X

Circuit diagram working hydraulics in case of Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 – 13

X

X

Layout plan working hydraulics in case of Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 – 15

X

X

Control valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 – 17

X

X

Subplate for control valve block: Flow control valve with integral pressure-limiting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 – 19

X

X

Control valve, single-acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 – 21

X

X

Control valve, double acting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 – 23

X

X

Pressure accumulator switching valve with pressure sensor . . . . . . . . . . . . . . . . . . . . . . . .24 – 25

X

X

EMR-D control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 – 29

X

X

Balance Hydraulic circuit diagram of the Balance self-levelling system . . . . . . . . . . . . . . . . . . . .30 – 31 Pilot control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 – 33 "Balance" control valve block with integral non-return valve . . . . . . . . . . . . . . . . . . . . .34 – 35 Tilt control cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 – 37 Cutting table automatic lateral float (field tracker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 – 39 Hydraulic cutting angle adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 – 39

X X X X X X

X X X X X X

Working hydraulic Actuating cylinders – cutting table (feed passage) . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 – 41 Actuating cylinders – Steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 – 43 Hydraulic cylinders – repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 – 47

X X X

X X X

Hydraulic steering . . . . . . . . . . . . . . . . . . . . . Danfoss Lenkorbitrol Type OSPC 160 ON Inspecting the steering system . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . .

X X X X

X X X X

X X

X X

X X X x X x X

X X X X X X X

. . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 – 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 – 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 – 54

Hydrostatic ground drive General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Basic construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 – 57 Fitting the hydrostatic pump to the engine BoWex coupling between hydrostatic pump and engine . . . . . . . . . . . . . . . . . . . . . . . .58 – 59 Drive control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 – 61 Swashplate pump HPV 105/135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 – 65 Swashplate pump HPV 135 measuring and testing . . . . . . . . . . . . . . . . . . . . . . . . . . .66 – 67 Hydrostatic motor type HMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 – 71 New refilling and bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 – 73 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 – 77

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D Service Training

5650H – 5690HTS Hydraulic Table of contents Combine Harvester Types

5650H 5680H 5660HTS 5690HTS

Drive hydraulics Steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 – 79 Hydraulic block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 – 81 Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 – 81 Double valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 – 83 Hydraulic switching valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 – 83 Pressure maintaining valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 – 83 Operating principle of the radial piston motors, traction control . . . . . . . . . . . . . . . . . . .84 – 85 Installation position of sensors and valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 – 87 Setting - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Troubleshooting - Traction control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

D2

X X X X X X X X X X

X X X X X X X X X X

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D Service Training

Hydraulic system General Safety instructions 1. 2. 3.

4. 5.

The hydraulic system is under high pressure. When searching for leaks always use suitable aids (e.g. piece of cardboard) to shield against injury. Hydraulic oil forced out under pressure can cut the skin and cause severe injury. In such cases, call a doctor immediately, since otherwise serious infection may result. Before working on the hydraulic system, depressurise the system and lower all front attachments. When working on the hydraulic system, always switch off the engine and remove the ignition key. Also, secure the combine harvester against unintentional movement (handbrake, wheel chocks).

Maintenance 1. 2. 3. 4.

5. 6.

When connecting hydraulic equipment, make sure that the hydraulic hoses are connected as specified. If the hoses are connected incorrectly, the functions may be inverted (e.g. raising/lowering). The hydraulic accumulator contains compressed gas. Do not drop the accumulator or expose it to temperatures above 150 °C. Check the hydraulic hoses at regular intervals and replace them if damaged or worn. The replacement hoses must comply with the technical requirements of the combine harvester manufacturer. Hydraulic oils and filters must be correctly disposed of in accordance with environmental regulations. Before opening hydraulic equipment, thoroughly clean the surrounding area. Maintain scrupulous cleanness while working.

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D3

D Service Training

Hydraulic system General Circuit symbols in the hydraulic circuit diagram conforming to ISO 1219 Basic symbols Designation

Meaning

Lines

Working line

Energy conversion Symbol

Designation

Meaning

Constant Hydraulic pump displacement with almost constant pump displacement per revolution or per double stroke

Control line Leak line Double line

Shaft, lever, rod

with 1 delivery direction

Circle

Differentiated by size of symbol: Pump, compressor, motor

with 2 delivery directions Constant Hydraulic motor displacement with almost constant motor displacement per revolution

Measuring device Check valve, rotary connection

with 1 direction of flow

Joint, contact roller

with 2 directions of flow

Square, Rectangle

Example: valves, cylinders, actuators

Square on tip

Filter, lubricator, heat exchanger

Various symbols

Spring

Symbol

Variable Hydraulic motor displacement with variable motor displacement per revolution with 1 direction of flow

Restrictor with 2 directions of flow Measuring orifice Function symbols Designation

Meaning

Function symbols Delta

Direction of flow with indication of pressure medium hydraulic pneumatic

Arrow

Direction of flow Rotatability

Oblique arrow

An oblique arrow drawn through the complete symbol the device is variable

Thin dotted border

Frame around parts belonging to a single block or subassembly

D4

Symbol

Pump motors

Hydraulic devices that can operate as both pump and motor

Constant Hydraulic device with displacement almost constant pump displacement per revolution, acting as a pump in 1 direction of flow and as a motor in the opposite direction acting as both pump and motor in 1 direction of flow acting as both pump jand motor in 2 directions of flow

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Hydraulic system General Circuit symbols in the hydraulic circuit diagram conforming to ISO 1219 Cylinders

Pressure valves

Designation

Meaning

Singleacting cylinders

The force applied by the pressure medium moves the piston in only 1 direction

Symbol

Designation

Return movement by built-in return spring The force applied by the pressure medium moves the piston in 2 directions with single piston rod with double piston rod Differential cylinders

Double-acting cylinder with single piston rod, if particular emphasis should be placed on hedifferential effect with supply through the piston rod

Telescopic cylinders

Cylinder with a number of telescoping pistons adding their strokes together

singleacting

Return movement only by external force

doubleacting

Forward and return movement by hydraulic liquid or compressed air

Symbol

Valves that mainly influence pressure. With 2 end-positions and infinitely variable intermediate position. Represented with only one box (neutral position)

Return movement by external force

Doubleacting cylinders

Meaning

with 2 controlled connections and closed neutral position PressureValve for limiting limiting valve the inlet pressure by opening the outlet against return force (spring) Pressurelimiting valve, remote controlled

Valve with a remote control influencing the return force The remote control cancels the return force (opposite direction) The remote control amplifies the return force (same direction)

Cylinder with Double-acting cylinder, end-damping e.g. with non-variable damping at the piston end Double-acting cylinder, e.g. with non-variable damping at both ends

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D Service Training

Hydraulic system General Circuit symbols in the hydraulic circuit diagram conforming to ISO 1219 Flow control valves Designation

Meaning

Check valves Symbol

Designation

Valves that mainly influence the flow rate

Orifice valve

2-way flow control valve

Flow valve with constant restriction built into a line. Flow and pressure drop are determined by viscosity.

2-way adjustable flow control valve

Flow valve that maintains a constant outlet flow by closing automatically; the desired outlet flow setting can be adjusted.

3-way flow control valve

Flow valve that maintains the outlet flow constant by automatically opening a drain (bypass valve)

3-way adjustable flow control valve

Non-return valve

Flow valve with constant short restriction. Flow and pressure drop are mainly determined by viscosity. Flow valve that maintains a constant outlet flow by closing automatically

Flow valve that maintains the outlet flow constant by automatically opening a drain; the desired drain flow setting can be adjusted.

Symbol

Valves that block the flow in one direction and allow flow in the opposite direction. The pressure on the outflow side loads the checking component, thereby reinforcing the closing of the valve.

Flow control valves with constant restriction Restrictor valve

Meaning

Check valve that closes due to a force acting on the checking part. Blocks the flow when the outlet pressure is higher than the inlet pressure. With counter-pressure, e.g. spring; blocks the flow when the outlet pressure is greater than or equal to the inlet pressure.

Remotecontrolled non-return valve

Non-return valve with actuator, e.g. hydraulic, to cancel the blocking or passing action. Blocks the flow if the outlet pressure is greater than the inlet pressure, but the blocking action can be deactivated by the remote control. Allows flow when the outlet pressure is greater than or equal to the inlet pressure, but the flow can be deactivated by the remote control.

Switch positions Circulating position

Supply is connected to return, and the load ports are closed.

Floating position

All ports are connected.

Blocking position

All ports are closed.

D6

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Hydraulic system General Circuit symbols in the hydraulic circuit diagram conforming to ISO 1219 Directional control valves are essentially characterised by: Designation

Meaning Valves with several defined switch positions, each represented by 1 box. The ports (supply and outlet connections) are drawn in the neutral position box, or, if neutral is unavailable, in the outlet position. The other positions are obtained by shifting the boxes until the ports are lined up with the internal lines (channels) of the relevant box.

Symbol

Actuators Designation Actuators with operatorsupplied control force

Forward position

Reverse position

Connections are switched o generate a flow that causes the connected devices to perform their specified functions. Each connection points is connected to its opposite connection point (the flow arrows are parallel). The connection points are connected to their diagonally opposite connections (flow arrows cross over diagonally).

307.1133.3.6 englisch (en) 10.2006

by pushbutton

Mechanically by momentaryoperated contact switch actuators by spring by contact roller by contact roller with no-load return e.g. device is operated mechanically by contact roller with automatic no-load return

Channel shut-offs are indicated by transverse dashes inside the boxes.

Flow positions

General

by pedal

Connections between channels inside a valve are indicated by a dot.

The designation "-way valve" is preceded by the number of controlled ports and switching positions, e.g. a directional control valve with 3 controlled connections and 2 positions is termed a "3/2-way valve" (a three-two-way valve).

Symbol

by lever

Inside the boxes, the lines represent the channels and the arrows the directions of flow.

Abbreviated designation

Meaning

Electrically operated actuators

by solenoid with 1 effective winding by solenoid with several windings acting in the same direction, e.g. 2 windings with 2 opposed windings by electric motor

Directly operated actuators

M

by applied pressure

Filters Designation

Meaning

Filter

Device for separating dirt particles

Symbol

D7

D Service Training

Hydraulic system General Circuit symbols in the hydraulic circuit diagram conforming to ISO 1219 Coolers

Pipes/Lines

Designation

Meaning

Cooler

Device for cooling the hydraulic fluid or air. The arrows pointing outwards indicate that heat is discharged, but the coolant circuit is not shown.

Symbol

Meaning

Hydraulic accumulator

Device for storing hydraulic energy. The fluid is pressurised by a spring, weight or gas (e.g. air, nitrogen etc.). The energy is then transmitted by the flow of this pressurised fluid.

Symbol

Meaning

Containers

Ventilated, with pipes above the level of the liquid

Symbol

Control line

Line for transmitting the control energy, including settings and adjustments

Leakage line

Line for draining any leaking liquid or for venting

Flexible line

Line that can flex during operation, e.g. rubber hose, corrugated tube, spiral tube, mainly connected to moving parts

Connection between lines

Fixed connection, e.g. welded, soldered or screwed.

Pressurised connections Designation

Meaning

Pressurised connections

Ventilated, with supply to pump

Pressure coupling on devices and pipes to tap energy or for measurements

Pressurised

with stopper

Ventilated, with pipes below the level of the liquid

Meaning

Electric motor

with quasi-constant speed (for further details, see DIN 40715).

Combustion motor

Symbol

with connecting line

Energy sources Designation

Symbol

Electric line

Containers/Tanks Designation

Meaning

Working line, Line for transferring return line energy and supply (feed) line

Accumulators Designation

Designation

Symbol Quick-release coupling M

Designation

Meaning

Quickrelease coupling

Line connector that can be joined and separated without tools

Symbol

Coupled Decoupled, with mechanically opened check valves Decoupled, line open Decoupled, line closed by check valve

D8

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Hydraulic system General

Pressure regulating

Pressure-limiting valve Pressure-reducing valve

Pressure switching

Pressure valves

Pressure control

Circuit symbols in the hydraulic circuit diagram conforming to ISO 1219

Connecting valve

with fixed switching positions without fixed switching positions pressuredependent pressureindependent

Flow control valves

3/2-way valve 4/2-way valve 4/3-way valve 5/3-way valve

Shut-off valves

Check valves

Flow control

Directional control valves

VALVE FUNCTIONS

2/2-way valve

307.1133.3.6 englisch (en) 10.2006

Plunger valve Servovalve

Restrictor

Orifice

2-way flow control valve 3-way flow control valve

Non-return valve Releasable non-return valve

Shut-off valve

D9

D Service Training

5650H – 5690HTS Circuit diagram working hydraulics

Circuit logic – working hydraulics: Adjustment function

Magnet

Cutting table

Raise Lower

Reel, vertical adjustment

M1 M2 M3 M4 M5 M6 M9 M10 M11 M12 M14 M15 M16 M17 ● ●

Raise Lower

Grain tank discharge tube

● ●

Slew outboard

●

Slew inboard Reel, horizontal adjustment

Forward Back

Grain tank extension

● ● ● ●

Extend

●

Retract Cutting angle

Forward Back

Cutting table tilting

Left down Right down

1

Hydraulic pumps

1.1

Geared pump for lifting - lowering cutting mechanism (14 ccm/rev)

1.2

Geared pump for control block small consumers (4 ccm/rev)

1.3

Geared pump for steering gear (8 ccm/rev)

2

Pressure-control valve for cutting mechanism, 180 bar

3

Control valve for cutting mechanism

4

Sequence valve for accumulator, with pressure sensor

5

Two accumulators, filling pressure 45 bar and 70 bar

6

Control block for small consumers

7

Steering hydraulics

8

Oil cooler for work hydraulics (not with 5650 or 5660 standard)

D 10

● ● ● ●

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7

1.1 1.2 1.3

6

8

2 4 5 3 A00242-1

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D Service Training

5650H – 5690HTS Circuit diagram for work hydraulics in case of Balance

1

Hydraulic pumps:

1.1 1.2

Lift/lower cutting table (14 cm3/rev) Small consumers (8 cm3/rev)

1.3

Steering (8 cm3/rev)

2

Pressure relief valve 200 bar

3

Flow divider

4

Control block

4.1

Reel vertical

4.2

Grain tank tube

4.3

Reel horizontal

4.4

Grain tank extension

4.5

Cutting angle adjustment

5

Control block for automatic pitch compensation of cutting table

5.1

Control valve, lateral tilt of cutting table (proportional valve)

5.2

Pressure control valve

6

Pressure relief valve 150 bar for banking cylinder of cutting table

7

Control valve for cutting table

7.1

Sequence valve for accumulator, with pressure sensor

7.2

Two accumulators, filling pressure 45 bar and 70 bar

8

Pressure relief valve 180 bar for control valve of cutting table

9

Oil cooler

10

Oil reservoir with return filter

A

Hydraulic system of Balance

B

Steering

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D

1.2

1.3

1.1

7.1

7.2

7

2

8

10

3

4

9

4.1

4.2

4.3

5

4.4

6

5.2

4.5

5.1

6

Service Training

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D56-1

D 14

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5650H – 5690HTS Layout plan Working hydraulic in case of Balance

1

Hydraulic pumps:

1.1 Lift/lower cutting table (14 cm3/rev) 1.2 Small consumers (8 cm3/rev) 1.3 Steering (8 cm3/rev) 2

Pressure relief valve 200 bar

3

Flow divider

4

Control block

5

Control block for automatic pitch compensation of cutting table

5.1 Control valve, lateral tilt of cutting table (proportional valve) 5.2 Pressure control valve 5.3 Baseplate with pressure-control valve 170 + 5 bar 5.4 End plate 5.5 Orifice 2,5 mm in the pipe for oil under pressure 5.6 Changeover valve 6

Pressure relief valve 150 bar for banking cylinder of cutting table

7

Control valve for cutting table

8

Pressure relief valve 180 bar for control valve of cutting table

9

Oil cooler

10 Oil reservoir: The feed line of the oil cooler is connected to connection N of the control valve (7) for cutting table.

A

Hydraulic system of Balance

B

Steering

C

Banking cylinder of cutting table

Tightening torque values for nuts and adjustable bolts a = b = c =

25+8 Nm 25+8 Nm 13,5+4,5 Nm

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5650H – 5690HTS Working hydraulics Control valve block Note: Common oil tank for working hydraulics and ground drive hydraulics. Tank capacity/filling volume: Capacity of overall working/ground drive hydraulic system:

approx. 70 ... 75 litres (depending on variant)

Depending on the equipment variant, some models may not have the control valves for the grain tank extension, field tracker and/or cutting angle adjustment. Warning: The control valves must not be confused with one another. The control valves are identified by the Bosch Type Number on the nameplate on the back of the valve. Bosch Type No.

Function

1 525 503 524

Connection subplate (flow control valve) with pressure-limiting valve Control valve single-acting, reel vertical adjustment

0 521 608 851 Control valve, double-acting, slew grain tank discharge tube inboard/outboard 0 521 608 852 Control valve, double-acting, reel horizontal adjustment 0 521 608 854 Control valve, double-acting, extend/retract grain tank extension 0 521 608 848 Control valve, double-acting, cutting table adjustment 0 521 608 854 0 521 608 825 0 521 608 853

Control valve (proportional valve), double-acting, field tracker control (located in a separate valve block in case of balance)

Adhere to the sequence a → b → c and the specified tightening torque of the tie rods. ● Otherwise the control spools may stick. Solenoid coils: UNenn 12 V, Umax 14 V, Umin 11.5 V 0 521 608 851 ... 0 521 608 854) Solenoid coils: Field tracker 0 ... 12 V (0 521 608 853) proportional magnet Repair work on the solenoid valves is limited to sealing and cleaning. The individual control spools cannot be replaced. ● Replace the complete control valve. Note: The control valve functions (lower/retract) can only be activated with the engine running (pressurised oil supply required to open the check valves). 1 2 3 4 5 6 7 8 9 10 11

Control valve block Manual operation right and left Changeover valve (in each control unit) Factory punch-marks for control spool relief Restrictor plate (only mounted in the subplate) EMR-D control valve Pressure-limiting valve 3x hydraulic pump Bleed valve, filler orifice Return filter Hydraulic oil tank for working / ground drive hydraulic system

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bl/rt br br/ge ge/rt gn gn/ge gn/rt or rt sw ws

= = = = = = = = = = =

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5650H – 5690HTS Working hydraulics Subplate for control valve block: Flow control valve with integral pressure-limiting valve Function: The subplate is the basic element of the load-dependent control system of the control valve block. Neutral circulation If no control valve is activated, the load-dependent control port (4) is connected via the end-plate to the return (R) (i.e. unpressurised). If the pressure at port (P) exceeds the spring pressure [∆P = 3 bar (3)], the pressure-balancing piston (1) opens to the neutral circuit (R) in proportion to the pump delivery rate. Activation of a control valve When a control valve is activated (causing the control spool to connect the load-dependent control port to the P channel), the pressure (P) applied via the control port (4) acts in support of the spring pressure [∆P = 3 bar (3)], thereby causing the pressure-balancing piston (1) to close the neutral circuit. The pressure (P) increases up to the load pressure, so that the oil can flow to the load (A/B). In the event of overload or if the maximum operating pressure is attained (via the load-dependent control port 4), the pressure limiting valve (170 + 5 bar) is opened. The pressure-balancing piston (1) therefore acts as the main stage of the pressure limiting valve (2). Pressure limiting valve setting: 170

+5

bar

Warning: The pressure limiting valve must only be inspected and set with a test pressure gauge connected to the appropriate measuring port. A

Port

B

Port

P

Pump (Supply)

R

Return

1

Pressure balancing piston

2

Pressure limiting valve

3

∆P 3 bar spring

4

Load-dependent control port

LS Load-dependent control system

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5650H – 5690HTS Working hydraulics Control valve, single-acting ●

Reel, vertical adjustment

Function: Neutral circulation For neutral circulating flow, the control spool is in neutral position 0. The load-dependent control port (4) is connected to the return (R) in the end-plate via the change-over valve (3). The oil supply pressure (P) is blocked by the control spool (1). The check valve (2) is closed. Position 1: Raise On energising the solenoid coil (1.1), the control spool (1) is pushed to the left and therefore brought into position 1. The pressurised oil (P) is now connected to the load-dependent control port (4) (control port (4) closes the neutral circuit in the subplate) and to channel B. On reaching the load pressure (B), the check valve (2) opens. The pressurised oil (P) can now flow to the load port (B). Position 2: Lower On energising solenoid coil (1.2), the control spool (1) is pushed to the right and therefore brought into position 2. The pressurised oil (P) is now in channel A and forces the floating piston (5) to the left, thereby mechanically opening the check valve (2). The return oil flow is now channelled from port (B) to the return (R). Note: ● In all single-acting control valves, except for the control valve for raising/lowering the cutting table (Powerliner), the 2nd opening stage of the check valve (2) is blocked by copper washers (2.3). Please take this into account when assembling/dismantling. ● The control spool (1) can only be removed in the direction shown by the arrow.

A

Port

B

Port

P

Pump (supply)

R

Return

1

Control spool

1.1

Solenoid coil

1.2

Solenoid coil

2

Check valve

2.3

Copper washers

3

Change-over valve

4

Load-dependent control port

5

Floating piston

LS

load-dependent control system

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5650H – 5690HTS Working hydraulics Control valve, double-acting ● ● ● ● ●

Grain tank discharge tube, slew inboard/outboard Reel, horizontal adjustment Grain tank extension, extend/retract (if fitted) Cutting table tilt (field tracker) (if fitted) Cutting angle adjustment (if fitted)

Function: Neutral circulation For neutral circulating flow, the control spool is in neutral position 0. The load-dependent control port (4) is connected via the change-over valve (3) to the return (R) in the end-plate. The oil supply pressure (P) is blocked by the control spool (1). The check valves (2.1) and (2.2) are closed. Position 1: (Oil pressure supply to A) On energising the solenoid coil (1.1), the control spool (1) is pushed to the left and therefore brought into position 1. The pressurised oil supply (P) is now connected to the load-dependent control port (4) (control port (4) closes the neutral circuit in the subplate) and to channel (B). On reaching the load pressure (A), the check valve (2.1) opens, and at the same time check valve (2.2) is mechanically opened by the floating piston (5). The pressurised oil (P) can now flow to the load port (A), and the return oil can flow from port (B) back to the return (R). Position 2: (Oil pressure supply to B) On energising solenoid coil (1.2), the control spool (1) is pushed to the right and therefore brought into position 2. The pressurised oil supply (P) is now connected to the load-dependent control port (4) (control port (4) closes the neutral circuit in the subplate) and to channel (B). On reaching the load pressure (B), the check valve (2.2) opens, and at the same time check valve (2.1) is mechanically opened by the floating piston (5). The pressurised oil (P) can now flow to the load port (B), and the return oil can flow from port (A) back to the return (R). Note: ● In all double-acting control valves, the 2nd opening stage of the check valves (2.1), (2.2) is blocked by copper washers (2.3). Please take this into account when assembling/dismantling. ● The control spool (1) can only be removed in the direction shown by the arrow.

A

Port

B

Port

P

Pump (supply)

R

Return

1

Control spool

1.1

Solenoid coil

1.2

Solenoid coil

2.1

Check valve

2.2

Check valve

2.3

Copper washers

3

Change-over valve

4

Load-dependent control port

5

Floating piston

LS

load-dependent control system

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5650H – 5690HTS Working hydraulics Pressure accumulator switching valve with pressure sensor The pressure accumulator and the switching valve with pressure sensor are mounted on the front right-hand side of the front axle. Function of the switching valve: connecting/disconnecting the pressure accumulators (3) In switch position 0, the solenoid coil (1.1) is not activated. Only a very limited amount of oil can flow to the pressure accumulators (3) through the restrictor port (1.2) of the control spool (1) (pressure accumulator cut-off function). On activating the solenoid coil (1.1), the control spool (1) moves leftwards into switch position 1 and provides a connection from A to B via the control edge (1.3) of the spool. In other words, the pressure accumulators (3) are now connected to the cutting table cylinders (4). Switching logic of the pressure accumulator switching valve The pressure accumulators are always active (connected to the cylinders) except in the following modes: 1. Raise/lower cutting table with manual control: The pressure accumulators are cut off for approx. 3 seconds from the start of the control signal. 2. Clearance adjustment mode When the ground contact sensors (skids) of the cutting table are activated, the pressure accumulators are cut off. Specification: Pressure: Volume:

P = 45 bar + P = 70 bar V = 0.5 Liter V = 0.5 Liter

Pressure sensor: The pressure sensor (2) detects the pressure in the cutting table cylinders and sends the corresponding signal to the electronic control box of the EMR-D control for further processing. Specification: Supply voltage: Signal: Pressure:

9.5 V 2.4 ... 7.1 V 0 ... 160 bar

1

Control spool

1.1

Solenoid coil

1.2

Restrictor port

1.3

Control edge

2

Pressure sensor

3

Pressure accumulator

4

Cutting table cylinders

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5650H – 5690HTS Working hydraulics EMR-D control valve Neutral position Neutral circulation from (P) (pump) to (N) (oil tank) is enabled as follows in the flow control valve (1): after overcoming the spring load (∆P ≈ 3 bar, spring chamber connected to (R) by means of the control spool), the control spool (2) of the flow control valve (1) moves to the right until the corresponding volume of oil can flow to (N) (oil tank). A minimum oil flow of approx. 4 l/min is guaranteed by the control edges (1.1) of the control valve (1) under all conditions. The check valve (6) protects the load on port (A) (cutting table cylinder). Peak pressures are absorbed by means of the shock valve (4) (200 bar) and channelled to the return (R). The proportional solenoids (7), (8) of the EMR-D control valve are electrically energised by pulse-width frequency signals from the electronic control box. These signals are controlled as a function of the actual/setpoint values. Warning: ● Never transmit 12 V continuous voltage to the solenoid coils, because otherwise they would be destroyed. A maximum of 7 V continuous voltage is permitted. ● The solenoid coils (7), (8) must not be confused or interchanged. In the event of electronic failure, the EMR-D control valve can also be operated manually by pressing in the solenoid coils from the front.

A

Working cylinder

N

Neutral circulation

P

Pump

R

Return

1

Flow control valve (pressure balancing valve)

2

Control spool (proportional valve)

3

Adjusting restrictor, lowering

4

Pressure limiting valve (200 bar, cylinder safety valve)

5

Lowering valve with load compensation

6

Check valve

7

Proportional solenoid – lower

8

Proportional solenoid – raise

Neutral circulation or return Control oil flow Lowering or raising oil flow Flow direction Residual oil flow

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5650H – 5690HTS Working hydraulics EMR-D control valve Raise cutting table In the "raise" position, the proportional solenoid (8) moves the control spool (2) to the left, thereby cutting off the flow of ("unpressurised") oil from the spring chamber of the flow control valve (1) to the return (R) of control spool (2), so that the combined action of (P) and ∆P (3 bar spring pressure) forces the control spool of the flow control valve (1) to the left, thereby cutting off the neutral circulation. A minimum flow of approx. 4 l/min. is permanently guaranteed to (N) via the recessed control edges (1.1). The pressure (P) continues to rise until the load pressure (A) is reached and the check valve (6) is opened. Due to the control port (2.1) in the control spool (2), the load pressure is also applied in the spring chamber of the flow control valve (1). As soon as the pressure (P) attains the load pressure plus ∆P (3 bar spring pressure), the spool of the flow control valve slides to the right and releases the corresponding oil flow to the neutral circuit (N). The "raise" oil flow varies according to the opening cross-section at the control edge (2.3) of the control spool (2), i.e. it is proportional to the control current at the solenoid coil (8).

Lower cutting table The proportional solenoid (7) drives the control spool (2) to the lowering position. A control oil flow is channelled via the spring chamber of the flow control valve (1) to the lowering valve (5), thereby opening the check valve (6) mechanically by means of a pin. The lowering oil flow is channelled from port (A) to the return (R) via the open control edge (2.2) of the control spool (2). Variations in the load at (A) are compensated by the lowering valve (5) in combination with the check valve (6). The lowering speed is determined by the adjusting restrictor (3) and by the travel of the control spool (2). Warning: The adjusting restrictor (3) is factory-set and must not be adjusted.

A N P R

Working cylinder Neutral circulation Pump Return

1 2 3 4 5 6 7 8

Flow control valve (pressure balancing valve) Control spool (proportional valve) Adjusting restrictor, lowering Pressure limiting valve (200 bar, cylinder safety valve) Lowering valve with load compensation Check valve Proportional solenoid – lower Proportional solenoid – raise

Neutral circulation or return Control oil flow Lowering or raising oil flow Flow direction Residual oil flow

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5650H – 5690HTS Working hydraulics Balance Hydraulic circuit diagram of the Balance self-levelling system 1

Oil tank for working hydraulics and ground drive hydraulics

2

Hydraulic pump: capacity 19 cm3 / Udr.

The hydraulic pump for self-levelling control is flanged to the feed pump of the hydrostatic ground drive. 3

Pilot control unit: Neutral circuit check valve M0 with pressure limiting valve (175 bar)

4

Control valve block "Balance” left

5

Control valve block „Balance“ right

6

Check valve – pipe break safety device (built into hydraulic cylinder)

7

External flow control valves + SR2. Observe the mounting position

A1.1 - A2.2 Cylinder connections at control valve block

→ Arrow points in forward direction.

Circuit logic for self-levelling control: Adjustment function

M0

M1

Extend left and right actuators Raise front of machine

●

●

Retract left and right actuators Lower front of machine

●

Extend left / Retract right actuator Tilt machine from mid-position to right

●

Extend right / Retract left actuator Tilt machine from mid-position to left

●

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M2

M3

M4

M5

M6

●

●

●

●

● ●

●

● ●

●

●

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M1

A1.1

6

A2.2

A1.2

A1.2 ERV

RV2

M3

M6

M4

M1

A1.1

A2.2

ERV

RV2

5

M2

A2.1

A2.1

M2

M1 M2

M5

4

RV1

RV1

–SR1

-SR1

P

P

T

T

7 +SR2

+SR2

max. 29 l/min

T

max. 29 l/min

T

2

P

M P1

P

M0

175 bar

T T

T1

3

1

1

7

2

A1.2 5 A2.2 6

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5650H – 5690HTS Working hydraulics Electromagnetic control valves Balance pilot control Description 1

Valve block – pilot control

2

Pilot control valve (M0)

2.1 Solenoid coil 2.2 Pilot control cone (tapered plug) 2.3 Opening spring 2.4 Pilot control port 2.5 Valve piston 2.6 Non-return valve 2.7 Armature 2.8 Valve seat 3

Pressure limiting valve 175 bar

3.1 Pressure adjusting device 3.2 Valve body 3.3 Compression spring 3.4 Spring cup with hydrodynamic stroke assist system 3.5 Closing plug with damping piston 3.6 Valve seat 4

O-ring seal

5

G1/8" measuring port for pressure measurement

Neutral In neutral circulating mode, the solenoid coil (2.1) is deenergised. The pilot control plug (2.2) is lifted by spring pressure (2.3), thereby hydraulically opening the valve piston (2.5) so that the oil can flow from P to T. Working position If voltage (12 V) is applied to the solenoid coil (2.1), the pilot control plug (2.2) closes against spring pressure (2.3), so that the valve piston (2.5) remains closed. Pressure (P) builds up until the pressure limiting valve (3) has reached the preset opening pressure (175 bar, set with 3.1). Dismantling / Assembling The valve bodies (2.2 ... 2.8), (3.1 ... 3.6) cannot be dismantled (adhesive-bonded and brazed). Warning: When dismantling the pressure limiting valve (3) or pilot control valve (2), the O-ring (4) will inevitably be damaged. Fit a new O-ring when reassembling. Magnetspule (2.1) has an integral anti-surge diode. UNenn: 12 V R: 8Ω P: 18 W

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2

M3 / M6

5

M1 / M4

2

25+5 Nm

3 7

2

25+5 Nm

5

30 Nm

4

25+5 Nm

5

RV2

3

A1.1

T A2.1

P

6 –SR1

1

40 Nm

7

30 Nm

RV1

9

A1.2 A2.2

10 M1

40 Nm

10 M2

30 Nm

8 ERV

M1

A1.1

A2.2

A1.2

M4

A1.2 ERV

M6

M1

A1.1

A2.2

ERV

RV2

M2

A2.1

A2.1

M2

RV2

M3

M1 M2

M5

RV1

RV1

—SR1

-SR1

P

11

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P

T

T

11

+SR2

+SR2

max. 29 l/min

max. 29 l/min

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5650H – 5690HTS Working hydraulics Electromagnetic control valves Balance "Balance" control valve block with integral non-return valve Description 1

Balance valve block

2

Solenoid coils

3

2/2-way valves (M1, M2, M4, M5)

4

3/2-way valves (M3, M6)

5

O-ring seal

6

Flow control valve (–SR1, +SR2)

7

Non-return valve (RV1, RV2)

8

Hydraulically releasable non-return valve (ERV)

9

Machined hole (no function)

10 Measurement port M1, M2, (M14 x 1,5) 11 Flow control valve + SR2 externally in return line

Observe the mounting position

Functional description Extend cylinder (lift) When solenoid M1 (M4) is activated, compressed oil is flowing to the cylinder connection via check valve RV2 A1.1 and A1.2. resp. The pressure increase causes the hydraulically releasable non-return valve (8) to open, thereby opening the return to the tank. After reaching the load pressure, the oil flow to the tilt actuating cylinder is maintained constant by the flow control valve (–SR1).

Retract (lower) If voltage (12 V) is applied to M2 (M5) and M3 (M6), solenoid valve M2 (M5) opens, thereby channelling the oil flow to the return via the flow control valve (+SR2). At the same time, pressurised oil (P) is channelled from solenoid valve M3 (M6) through the piston (4.2) to port A2. In the course of this the external flow control valve (+SR2) is maintaining the return oil flow on a constant level.. Dismantling / Assembly The valve bodies themselves (3.4), (4.1) cannot be dismantled (adhesive-bonded and brazed). Warning: When dismantling the solenoid valves M1 – M6, the O-ring seal (5) will inevitably be damaged. Fit a new O-ring when reassembling. The flow control valves (–SR1, +SR2) are not fitted in the same direction (see figure). Please take this into account when assembling/reassembling.

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5650H – 5690HTS Working hydraulics Balance Balance tilt control cylinder Pipe break safety valve 1

Piston rod

2

Pipe break safety valve

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B

3

2

S62

b a

Ø 1,0 mm

A 1

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5650H – 5690HTS Working hydraulics Cutting table automatic pitch compensation (field tracker) 2

Pressure retaining valve (35 bar)

3

Shock valves 150 bar

Make sure that the basic setting of the cutting table pitch compensation control is correct, i.e. the maximum tilt angle for lateral tilting must be the same on both left and right-hand sides. The two piston rods must therefore reach their respective end-stops simultaneously in both directions. The max. tilt angle is set on the adjusting thread of the actuating cylinders (by turning the swivel-heads). Basic setting of the cylinder in the retracted position. Dimension B 514 mm

Balance Hydraulic cutting angle adjustment Description ●

Basic setting of the cutting angle adjustment cylinder in the retracted position:

A

515 mm, stroke approx. 200 mm The swivel frame must not rest on the feed passage connection.

Note: A restrictor valve is mounted at port (1) (ensure correct installation position). Make sure that the piston rod (a) is screwed to a minimum screw-in depth of 24 mm into the rod eye (b) (swivelhead).

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5650H – 5690HTS Working hydraulics Hydraulic cylinders Actuating cylinders – cutting table (feed passage) Repair Clamp the cylinder tube firmly in the vice. Insert a screwdriver through the oil port opening. Press the screwdriver into the spring end of the snap ring (1) and strip the snap ring (1) from the piston by turning the piston. The piston can now be gently pulled out of the hydraulic cylinder. Push the scraper ring (2) and grooved ring (3) out of the cylinder with the screwdriver. When repairing hydraulic cylinders, make sure all parts are kept perfectly clean. When reassembling, always fit new seals. Use the repair set. 1

Snap ring

2

Scraper ring

3

Grooved ring

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3

1

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5

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5650H – 5690HTS Working hydraulics Hydraulic cylinders Actuating cylinders – Steering axle Repair Clamp the guide bushing (1) in the vice. Lift the locking wire (2) in the bore off the pressure cylinder. Push the locking wire (2) out of the bore by turning the piston rod guide (1) counter-clockwise. The piston rod guide (1) can now be pulled out of the hydraulic cylinder complete with the piston rod and piston. The scraper ring (4) and sealing rings (5) can be replaced after unscrewing the cap nut (3). 1

Guide bushing

2

Locking wire

3

Cap nut

4

Scraper ring

5

Sealing ring

A Version: Hengstler B Version: Pacoma

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5650H – 5690HTS Working hydraulics Hydraulic cylinders – repair A Reel vertical (4.2 – 7.2 m cutting table width) 1

Scraper ring

2

Sealing ring

3

Locking wire

4

O-Ring

5

Piston seal

B Reel horizontal left 1

Scraper ring

2

Grooved ring

3

Locking wire

4

O-Ring Piston seal

5

Leakage oil compensation

C Grain tank discharge tube 1

Scraper ring

2

Sealing ring

3

Locking wire

4

O-Ring Piston seal

D Grain tank discharge tube-locking 1

Snap ring

2

Grooved ring

3

Scraper ring

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2

3

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2

3

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5

4

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C

1

2

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4

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A

S70

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5650H – 5690HTS Working hydraulics Hydraulic cylinders – repair Reel cylinder vertical single-acting Reel cylinders horizontal (synchronised cylinders) double-acting 1

Port P or R

2

Bleeder

A1 – A2 Reel horizontal A1 – B

Reel vertical

Hydraulic actuator for grain tank extension A

0.6 mm baffle plate. Dismantle to bleed.

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5650H – 5690HTS Working hydraulics Hydraulic steering Description The fully hydraulic steering system is a steering system in which the steering movement is transmitted hydraulically. There is no mechanical link between the steering wheel and the steered wheels. Version ON = Opencenter Non-reaction – In the Opencenter Lenkorbitrol, there is an open connection between pump and tank when the Lenkorbitrol is in the neutral position. – In the Non-reaction Lenkorbitrol, external forces acting on the wheels are prevented from having any turning effect on the steering wheel when the Lenkorbitrol is in neutral position. Function In neutral position, oil flows freely through the Lenkorbitrol from P to T. When the steering wheel is turned in one direction, this movement causes the valve spools (5, 6) to rotate relative to each other. When turned through 1.5°, the channels to the chambers start to open. At 4°, the neutral position channels are fully closed. At 6°, the channels to the chambers are fully open. The rotation of the spools (5, 6) relative to each other is limited to ± 8°. The supply of pressurised oil to the rotor assembly (8, 9) has the following effects: – The rotor (9) starts to revolve. – A volumetric oil flow proportional to the revolution of the rotor is supplied to the steering cylinders, causing the steered wheels to turn. – Internal mechanical feedback from the rotor to the outer spool, so that the channels in the valve close when the rotor has turned through the same angle as the steering wheel. Emergency steering (manual) In the event of failure of the oil pressure from the pump, when the steering wheel is turned the inner spool drives the outer spool by means of the transverse bolt, thereby causing the universally jointed shaft (7) to turn the rotor (9) in the rotor ring (8). The rotor assembly therefore acts as a hand pump and pumps oil into the steering cylinder. The open non-return valve (ball valve) (4) between T and P draws oil from the rotor assembly return line. In this case, the steering system is stiffer and requires greater effort but remains fully controllable.

1

Steering column

2

Neutral position springs

3

Housing

4

Non-return valve (short-circuit valve)

5

Inner spool

6

Outer spool

7

Universally jointed shaft

8

Toothed ring (rotor ring)

9

Gear wheel (rotor)

10

Shock valves

11

Refill valves

12

Non-return valve (TÜV valve)

13

Pressure limiting valve

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A00225

A00227

A00224

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A00210

A00227

A00220

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A00222

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5650H – 5690HTS Working hydraulics Hydraulic steering Danfoss Lenkorbitrol Type OSPC 160 ON 1

Shock valves (205 bar)

2

Pressure limiting valve (150 bar)

3

Housing

4

Non-return valve (short-circuit valve)

5

Inner spool

6

Outer spool

7

Universally jointed shaft

8

Toothed ring (rotor ring)

9

Gear wheel (rotor)

10

Refill valve

11

Non-return valve (TÜV valve)

12

O-rings

13

Axial needle bearing

14

Ring

15

Neutral position springs

16

Distributor plate

17

Cover

18

Washers

19

Screws (tighten in diagonally opposite sequence)

20

Nameplate

21

Pressure setting screw

Repairs / General overhaul of the Lenkorbitrol For safety reasons, we recommend that you have the Lenkorbitrol repaired/overhauled only by an authorised Danfoss service workshop. Assembly instructions A special tool is required to assemble the Lenkorbitrol (sealing ring mounting tool – available from Danfoss dealers). Pressure measurement Only check the pressure when the system has warmed up to operating temperature (oil temperature approx. 60°). – Connect an oil pressure gauge (200 bar) to the measuring port (pressure line between the pump and the Lenkorbitrol). – Start the diesel engine. – Turn the steering wheel as far as it will go and hold it in the end-position. Read the pressure on the pressure gauge. Pressure limiting valve setting (OSPC 160 ON): 150 bar + measured circulating oil pressure, i.e. if the neutral circulating pressure (steering system in neutral position) is e.g. 6 bar, the pressure limiting valve must be set to 150 + 6 = 156 bar. Shock valve setting: 205 bar A shock valve pressure test is only possible on a test bench after dismantling the Lenkorbitrol. Note: Before dismantling the shock valves, note the insertion depth of the pressure setting screw and make sure that it is screwed to the correct depth after reassembling.

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5650H – 5690HTS Working hydraulics Hydraulic steering Inspecting the steering system Checking the internal leakage of the steering cylinder: For this inspection, fully retract the piston rod and unscrew the hose on the right-hand side of the cylinder. Start the diesel engine (running at nominal revs) and apply the full working pressure to the left-hand port. No oil may flow out of the open right-hand port. Repeat the test on the other side. Locating internal oil leakage in the steering system: Remove one connecting hose from the steering cylinder. Plug the hose connector and steering cylinder port with stoppers and try to turn the steering wheel. If the steering wheel is impossible to turn, the leak is in the steering cylinder; otherwise, the leak is in the Lenkorbitrol. – Turn the steering wheel with a torque of 25 Nm towards the end-stop. If the steering wheel can continue to be turned at a rate of more than 4 revolutions per minute (in both directions): a) the shock valve is leaky, b) the rotor or control spool is worn. – Connect a pressure gauge to the test port and measure the pressure. If the pressure is too low: a) correct the pressure setting. b) inspect the pressure limiting valve (possible leak). – Check the pump using the flow meter. – Check that the piston rod is straight. – Check that the steering knuckle moves smoothly and easily. – Check the steering column: The steering column must have approx. 1 mm clearance from the base of the inner spool of the Danfoss Lenkorbitrol. (Adjust the clearance with spacer washers between the retaining ring and the steering column). Steering column height clearance = 0.1 – 0.3 mm – After turning, the steering wheel must return automatically to the 0 position (check with the diesel engine off). Warning! Bleed the hydraulic steering system after any assembly operation.

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5650H – 5690HTS Working hydraulics Hydraulic steering type OSPC 160 ON Troubleshooting Fault

Possible cause

Remedy

The steering wheel is hard to turn.

1. No or insufficient oil pressure. a) Pump not running. b) Pump faulty. c) Pump rotating the wrong way.

1.

d) Pump worn.

Constant steering corrections are required with the steering wheel (cornering).

The steering wheel does not return to the neutral position.

The steering wheel continues turning after it is turned.

Steering wheel play.

307.1133.3.6 englisch (en) 10.2006

a) Start pump. b) Repair or replace pump. c) Correct the pump direction or change pump. d) Replace pump.

2. The pressure limiting valve sticks in the open position, or the set pressure is too low.

2. Repair or clean the pressure limiting valve. Adjust the valve to the correct pressure.

3. Excessive friction of the mechanical parts of the steering system.

3. Lubricate the bearings and links of the steering system, and repair if necessary. Check the steering column assembly.

1. Leaf springs lacking tensional force or broken.

1. Change the leaf springs.

2. Spring in double shock valve broken.

2. Replace the shock valve.

3. Gear set worn.

3. Replace the gear set.

4. Cylinder cracked or piston seals worn.

4. Replace the defective parts.

1. Steering column and steering unit not centred.

1. Centre the steering column in alignment with the steering unit.

2. Insufficient or no clearance between the steering column and the drive shaft of the steering unit.

2. Adjust the clearance. If necessary, shorten the multiple-spline shaft.

3. Seizing between the inner and outer spool.

3. Contact your nearest Danfoss service agent.

1. Leaf springs lacking tensional force or broken.

1. Replace the leaf springs.

2. Inner and outer spools seizing, possibly due to dirt.

2. Clean the steering unit or contact your nearest Danfoss service agent.

1. Yoke of universally jointed shaft worn or broken.

1. Replace the universally jointed shaft.

2. Leaf springs lacking tensional force or broken.

2. Replace the leaf springs.

3. Splines of steering column worn.

3. Replace the steering column.

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5650H – 5690HTS Working hydraulics Hydraulic steering type OSPC 160 ON Troubleshooting Fault

Possible cause

Remedy

Steered wheels vibrate. (coarse tyre tread causes vibrations).

1. Air in the steering cylinder.

1. Bleed the cylinder. Identify and remedy the cause of the air build-up.

2. Piston seal of the steering cylinder faulty.

2. Replace or repair the cylinder.

3. Gear set worn.

3. Replace the gear set.

4. Spacer missing above the universally jointed shaft.

4. Fit the spacer.

The steering wheel can be turned slowly in one direction, and possibly both directions, without turning the steered wheels.

1. One refill valve, or possibly both, leaky or missing.

1. Replace the defective valves.

2. One shock valve, or possibly both, leaky or missing.

2. Clean/replace defective valves or fit missing valves.

The steering responds too slowly and is too hard to turn when you try to steer rapidly.

1. Steering unit is not receiving enough oil; pump defective or running too slowly.

1. Replace pump or increase its speed.

2. Pressure limiting valve "sticking" due to dirt.

2. Clean the valve and adjust to the correct pressure.

"Kick-back" from the system to the steering wheel.

1. Fault in system.

1. Contact Danfoss service.

Jolts from the wheels.

1. Incorrect setting of universally jointed shaft and gear set.

1. Correct the setting or contact Danfoss service.

Steering wheel jerks forcefully to both sides. When the steering wheel is turned, the steered wheels turn the wrong way.

1. Mismatched connection between the steering unit and the steering cylinder.

1. Replace the hoses.

Insufficient steering force (possibly on one side only).

1. Pump pressure too low.

1. Correct the pump pressure.

2. Steering cylinder too small.

2. Fit a larger cylinder.

3. Area of the piston rod in the differential cylinder too large in relation to the piston diameter.

3. Install a cylinder with a thinner piston rod, or fit 2 differential cylinders.

1. Seal faulty.

1. Replace seal, or contact Danfoss service.

2. Screws loose.

2. Tighten screws. Torque 3 – 5 daNm.

3. Washers or O-rings faulty.

3. Replace washers or O-ring.

Leakage at the drive shaft or endcover, gear set, housing or top part.

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5650H – 5690HTS Hydrostatic ground drive General –

Only shift the gears while the vehicle is stationary and the drive lever is in neutral.

–

Only apply load to the ground drive hydraulic system after the engine is revved to a speed of at least 1000 rpm (manoeuvring).

–

Regularly clean the oil cooler.

–

Keep all parts scrupulously clean after topping up or changing the oil, changing the filter or carrying out repairs.

–

After changing the filter, run the engine briefly at low idling speed with the drive lever in neutral in order to expel air from the supply circuit.

–

In the event of any damage to the hydrostatic pump or hydrostatic motor, check the pipes and hoses for dirt due to metal abrasion. In case of doubt, always purge the cooling circuit, high-pressure hoses and return line thoroughly before installing a new or repaired system (remove the oil cooler if necessary).

–

When replacing the hydrostatic motor, drain the oil from the gearbox and refill.

–

Strictly follow the safety instructions!

Combine harvesters equipped with hydrostatic units Combine Harvester Type

Hydrostatic pump

Hydrostatic motor

5650, 5660 HTS

HPV 105-02

HMF 105-02

5650, 5660 HTS - Balance

HPV 135-02

HMF 135-02

HPV 135-02

HMF 135-02

5680, 5690 HTS Standard and Balance

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5650H – 5690HTS Hydrostatic ground drive Basic construction: – –

Wiring diagram Circuit diagram

1

Hydrostatic pump (swashplate pump)

2

Bypass valve integrated in the change-over filter

3

Feed pump

4

Block-type oil cooler in the air duct

5

Replaceable filter

6

High-pressure valve

7

High-pressure valve

8

Axial piston pump

9

Supply pressure valve opening pressure:

10 Cold-starting valve 11 Hydrostatic motor 12 Servo adjustment 13 Drive lever with Bowden cable 14 Oil tank 15 Purge line 16 High-pressure circuit 17 Switch-over valve 18 Purge valve 19 Return filter

Observe mounting position

Function description of the hydrostatic system The swashplate pump (1) is directly driven by the diesel engine. In the neutral position (zero position), the swashplate has no axial movement, and therefore no oil is delivered. The internal gear pump (feed pump) (3), which is flanged as a complete unit to the swashplate pump, draws oil from the pump housing and delivers it to the axial piston pump (8) via the oil cooler (4), replaceable filter (5) and the supply valves integrated in the high-pressure valves (6 and 7). The cold-starting valve (10) protects the oil cooler (4) and is activated in response to a high resistance to flow (e.g. starting at low outside temperatures). All the oil that is not needed to cover leakage and hydraulic pump adjustments (servo adjustment) is returned via the supply pressure valve (9), which at the same time maintains the supply pressure and therefore the high-pressure circuit on the return side. Depending on the swivel direction of the swashplate pump (8), i.e. "forwards" or "reverse", the oil is supplied to the appropriate port of the hydraulic motor (11), thereby building up high pressure, which simultaneously closes the supply valve integrated in the relevant high-pressure valve (6 or 7) on the low-pressure side. If the high pressure at the combined supply and high pressure valve (6 or 7) exceeds 420 bar, the oil overflows to the low pressure side via the connecting channel and the opposite supply valve (6 or 7). The switchover valve (17) built into the hydrostatic motor (11) connects the low-pressure side to the purge valve (18), which is set to 10 bar. A metered amount of oil is conducted to the crank case via the purge valve for cooling and purging purpose and fed back to the oil reservoir via the scavenging conduit (15) and the return filter (19).

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4

13

14

kor22/18-l

11 1

5

19

16 15

15 HY003-1

4

14

L2

19

F

L1

5

2

10

1

A

10 2

15

X

9

11 P

B

18

420

16

10

U

17

3

6

8

Ma

M 420

A L

10

7 Ms

S U L

12 B

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HPV7-2

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2

3

2.1 1

210

49

4

1

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5650H – 5690HTS Hydrostatic ground drive Fitting the hydrostatic pump to the engine BoWex coupling between hydrostatic pump and engine 1.

Flange for mounting of hydrostatic pump

2.

Clutch disc

2.1

Bolt M10 x 35, cemented in place

3.

Clamping hub with retaining ring

4.

Diesel engine flywheel

Mounting instruction: The clamping hub (3) must not press axially on the engine flywheel.

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5650H – 5690HTS Hydrostatic ground drive Drive control 1

Adjusting nut

2

Holder

3

Drive lever

4

Rack mechanism

5

Ball joint

6

Neutral detent

Testing or adjusting the neutral position of the drive control system (testing is necessary if the combine rolls slowly forward or back when in neutral on a flat surface, or if grinding noises can be heard when selecting a gear). –

Jack up the left-hand side of the combine harvester, and secure with chocks against rolling.

–

Release the handbrake.

–

With the engine idling slowly and in 1st gear, activate the forward control on the drive lever and return to neutral.

–

Set the drive lever to reverse and back to neutral. In each case, the drive wheel must remain stationary when the drive lever is set to the neutral position. If not, adjust the Bowden cable in the holder (2) using the nut (1). Then repeat the test procedure.

If neutral cannot be set, check the Bowden cable or activating mechanism for excessive free travel: –

Backlash in the connection between the drive lever (3) and the rack mechanism (4).

–

Backlash in the rack mechanism (4)

–

Play in the ball joint (5)

–

Excessive play in the neutral detent (6) of the drive lever.

Rack mechanism 1

Engaging fork

2

Rack

3

Guide sleeve

Take care to reassemble correctly when replacing the Bowden cable or repairing the rack mechanism. In the illustrated position of the drive lever engaging fork (1), the rack (2) must be flush with the guide sleeve (3) – see "X".

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5650H – 5690HTS Hydrostatic ground drive Swashplate pump HPV 105/135 Basic construction: 1

Cam adjustment

2

Replaceable filter

3

Pressure limiting valve (cold-starting valve)

4

Gear pump (feed pump)

5

Pressure limiting valve (Boost pressure)

6

Pressure limiting valves (combined supply valves and high-pressure limiting valves)

7

Pressure outlet, gear pump (A)

8

Shaft

9

Cradle (hydrostatic swashplate bearing)

10 Working piston (quantity: 9) 11 Cylinder block 12 Control head 13 Intake strainer for feed pump

Tightening torques for valves Valve

HPV 105

HPV 135

Cold start valve 3

30 Nm

40 Nm

Boost pressure valve 5

30 Nm

40 Nm

High pressure valves 6

140 Nm

170 Nm

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1 2

HPV1-1

3

5

6

6 HPV4

4 7 1

4

8

9

10 11

12

13 HPV3

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5650H – 5690HTS Hydrostatic ground drive Swashplate pump HPV 105, HPV 135 Cam-type adjustment Construction Operation Inspection 1

Adjustment

2

Cam

3

Operating lever

4

Stop screws

5

Nozzles

6

Pilot housing (hollow screw)

7

Marking

8

Pilot

9

Feed pump

10

Adjusting piston

11

Adjusting piston

12

Compression spring (mechanical neutral position)

13

Retaining plate

14

Cradle

Drive direction: right, (view X) Compressed oil discharge at P by turning the adjusting lever from 0 in direction I. Compressed oil discharge at S by turning the adjusting lever from 0 in direction II. a. Mechanical neutral position centring The swashplate is centred in its neutral position by means of the two return springs (12) on the adjusting pistons (10, 11). This setting is factory-set during pump assembly and cannot be changed from outside. b. Setting the maximum pump delivery rate The maximum pump delivery rate is factory-set on the test bench using the grub screws (4) and must not be reset. c. Inspecting and setting the hydraulic neutral position Set the adjusting lever (cam) to the neutral position, i.e. the marking (7) on the cam must be roughly parallel to the pilot housing (6). The hydraulic neutral position can be corrected by turning the pilot housing (hollow screw) (6). Warning: These settings have already been verified on the test bench and should not be adjusted.

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1 1

8 9 4 10

11

12

12

14

2

13

5

6 6

7

X

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2

1 3

3

4

F

A

3

L2

L1

4

10 10 2

X

2 1 P

B

Ma 420

3

M 420

10

A

Ms

S

U

L

U L

B

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5650H – 5690HTS Hydrostatic ground drive Swashplate pump HPV 105, HPV 135 Measuring and testing – Overview of connections and measuring points – Circuit diagram P, S

High-pressure port

A

Pressure port, feed pump

B

Intake port, feed pump

F

Control pressure supply, Pressure supply, filter inlet

X

Measuring port, supply pressure, M14x1,5

Ms, Mp

Measuring ports, high pressure, M14x1,5

L, U

Leakage oil connections Oil drain, optional leakage oil and purge oil return from hydrostatic motor

L1, L2

Bleed connections

Pos Part 1

Setting: 2

19 bar

20 bar

25 bar

25 bar

420 bar

420 bar

Combined supply/high-pressure limiting valves Setting:

4

HPV 135

Cold-starting pressure limiting valve Setting:

3

HPV 105

Supply pressure limiting valve

Change filter

–

–

→ Arrow points in forward direction.

General instructions for pressure measurement: –

Check hydraulic oil level.

–

Warming up hydostatic system, oil temperatures approx. 60 °C.

–

Even under load the boost pressure must not fall below 10 bar.

–

In case of uncertainty whether a too low boost pressure is caused by the pump or by the hydro motor, obturate the high pressure connections at the pump and measure again.

–

High pressure measurements must only be performed for a short time; danger of valve overheating.

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5650H – 5690HTS Hydrostatic motor, type HMF Hydrostatic motor HMF 105, HMF 135 HMF-type hydrostatic motors are swashplate axial-piston motors. 1

Drive shaft

2

Bearing

3

Working piston with sho

4

Cylinder block

5

High-pressure ports

6

Discharge

6.1 Purge valve (10 bar) 6.2 Switchover valve 7

Leakage oil / purge oil, max. housing pressure: 1.5 bar

8

Control head

9

Swashplate

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HMF

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B

4 5 10

A

U

L

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5650H – 5690HTS Hydrostatic ground drive Hydrostatic motor HMF – – –

Circuit diagram Radial shaft seal Discharge device

1

Retaining ring

2

Radial shaft seal

3

Shaft seal holder

4

Switchover valve

4.1 Plug screw M 22 x 1.5 – V80 4.2 O-ring 23.52 x 1.8 – V80 4.3 Compression spring 4.4 Washer 4.5 Valve piston 4.6 Valve sleeve 5

Purge valve 10 bar

5.1 Plug screw 5.2 Spacing washer 5.3 Compression spring 5.4 Ball 5.5 Valve sleeve (adhesive-mounted) 5.6 O-ring 11 x 2 – V80 6

Purge oil / leakage oil port

Dismantling/Assembly of radial sealing ring (2) – –

Release the retaining ring (1) Force out the shaft sealing ring holder (3), including the shaft sealing ring (2) by blowing compressed air through the leakage oil port (6). Note: Fix the washer and screw to the shaft end, in order to prevent the cover (3) being blown off.

The discharge system is used for purging the circuit and the housing. Discharge flow rate: 12 l/min. Purge valve opening pressure: 10 bar Note: The valve sleeve (4.6) of the switchover valve (4) is secured with adhesive. Assemble/dismantle accordingly (dismantling: heat to approx. 200 °C).

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5650H – 5690HTS Hydrostatic ground drive New refilling and bleeding 1

Drain screw

2

Plug screw

3

Measuring port – supply pressure

4

Measuring port – high pressure

1.

Fill the system from the oil tank

2.

Remove the drain screw (1) from the hydrostatic motor. If oil escapes from the drain hole when filling the system, refit the drain screw. Note: If the high-pressure circuit is opened, check that the high-pressure hoses are filled with oil. Keep all parts scrupulously clean.

3.

Unscrew the plug screw (2) to allow air to escape. When oil starts escaping at the plug screw, retighten the plug screw. Now fill the oil tank up to the "MAX" mark.

4.

Screw a transparent hose to the measuring point (3), and place the other end of the hose in the tank. – Turn the pump with the starter motor until oil is discharged without air bubbles (drive lever in neutral position). – un the engine at low idling speed (approx. 2 to 3 minutes), and monitor the transparent hose to the oil tank to make sure that the return oil is free of bubbles. Caution: The drive lever must be in neutral position. Check the oil level in the oil tank. – Repeat this procedure several times. – Remove the transparent hose. – Plug the measuring point (3). – Check the oil level in the oil tank and top up if necessary.

5.

Fit a transparent hose to the high-pressure measuring port (4), and place the other end of the hose in the tank. – Set the manual gearbox to idling mode (neutral). – Start the engine and run at low idling speed. – Move the drive lever gently forward and back until bubble-free oil is discharged from the transparent hose. Repeat this procedure several times. Monitor the oil level constantly, and top up if necessary.

Additionally: for machines with steering axle drive (all-wheel drive) Secure the vehicle, i.e. apply the handbrake and block the drive axle wheels with safety chocks. – Jack up the steering axle, so that the wheels can turn freely. – Select 1st gear. – Repeat the bleeding procedure described in Step 5 (high pressure).

Tools required for bleeding: Screw nipple x GE 8 SM M14x1.5 0110 1368 Cap nut M8 S 0111 6660 Cutting ring M8 L 0111 6635 Steel pipe 8x1 St 35.4 NBK – Zn approx. 50 mm long Hose clip S 12 – 8 Zy Plastic hose, transparent, approx. 1500 mm long

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2

3

4

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Mp

Ms

4

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5650H – 5690HTS Hydrostatic ground drive Troubleshooting 1. Loud cavitation noises on starting up the system The flow delivered by the feed pump is not sufficient to replace the leakage. The supply pressure collapses. Check the supply pressure with the system under load. Lines between pump and hydrostatic motor leaky

yes

Seal the lines, top up with oil, bleed system

yes

Replace the feed pump, clean the filter

yes

Replace the cold-starting valve

yes

Repair or replace the hydrostatic motor –

no Delivery capacity of pump too low no Cold-starting valve set too low no Excessive oil leakage in hydrostatic motor

Linde Repair Manual no Excessive oil leakage in pump

yes

If leakage identified, replace or repair the pump.

2. Insufficient system traction with normal supply pressure and without cavitation noise Slipping (internal connection) from the high-pressure side to the low-pressure side High-pressure valve is leaky at the cutting edge and valve seat

yes

Tighten high-pressure valve as specified

yes

Replace high-pressure valve

yes

Replace pump and hydrostatic motor

no High-pressure valve is set too low no Running surfaces of cylinder block and control head worn

General You can determine whether the control head of the pump or hydrostatic motor is worn (scored) by dismantling the feed pump from the main pump and checking the filter behind it for metal shavings.

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5650H – 5690HTS Hydrostatic ground drive Troubleshooting 3. System seized Motor piston seized

yes

Replace motor

yes

Adjust the linkage or Bowden cable to the pump so that the end-stop of the drive lever matches the end-stop in the pump

4. Machine fails to reach top speed Linkage or Bowden cable incorrectly set Check whether the adjusting lever on the pump is moved to its end position by link-rods or Bowden cable.

5. Machine does not move forward or back when the drive lever is actuated Not enough oil in tank

yes

Top up with oil

yes

Repair or replace

yes

Replace Centaflex coupling

yes

Check the supply circuit (feed pump, supply pressure valve, cold-starting valve)

yes

Clean nozzles Linde Repair Manual

no Linkage or Bowden cable sticking no Centaflex coupling between engine and pump worn. no No supply pressure no Nozzles of servo adjusting system dirty

Testing Remove the pump cover and adjusting lever

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5650H – 5690HTS Hydrostatic ground drive Troubleshooting 6. Excessive oil temperature – Max. 95 °C Oil cooler fouled

yes

Clean oil cooler. Seal the leak in the air shaft or cyclone (prevent dirt ingress)

yes

Make sure of correct air supply

yes

Replace temperature sensor

yes

Select a lower gear

yes

Replace cooler and pipes

yes

Replace cold-starting valve

yes

Replace high-pressure valve

yes

Replace pump and motor

yes

Set the linkage or Bowden cable so that the drive lever and pump adjusting lever reach the neutral position (0 position) simultaneously

no Insufficient cooling supply no Temperature sensor defective no Selected gear too high for working at high load no Cooler back-pressure too high. Cooler and pipes crushed. no Cold-starting valve set too low no High-pressure valve set too low no Excessive leakage oil from hydrostatic motor and pump

7. Neutral position unattainable Linkage or Bowden cable incorrectly set.

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5650H – 5690HTS Hydrostatic ground drive Troubleshooting 8. No supply pressure Not enough oil in tank

yes

Top up with oil

yes

Replace the feed pump

yes

Replace the cold-starting valve

yes

Replace the supply pressure valve

yes

Repair or replace the hydrostatic motor

yes

If leakage is detected, repair or replace the pump

yes

Repair or replace

yes

Replace high-pressure valve

yes

Clean nozzle

yes

Repair or replace pump

no Feed pump capacity too low no Cold-starting valve set too low no Feed pump set too low no Excessive leakage in hydrostatic motor no Excessive leakage from pump to outside

9. Machine only runs in one direction Linkage or Bowden cable seized no Check high-pressure valve (seized, fouled or faulty) no Nozzle of servo adjusting system clogged no Piston of servo adjusting system damaged or leaky

10. In one direction, the speed fluctuates irregularly or traction is reduced

A spring in the switchover valve of the hydrostatic motor is broken, or the valve piston does not close fully

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yes

Repair the switchover valve

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5650H – 5690HTS Drive Hydraulics Steering axle drive 1. Description / Function The hydrostatic drive for the steering axle supports the ground drive under difficult working conditions. 2 slow-running wheel hub motors of the radial piston type are built into the steering axle to transmit the drive torque. These motors are switched into the hydrostatic oil circuit by an electrohydraulic valve. An electronic traction control system (ASR) prevents single-sided wheel spin when the traction conditions are different on the two sides ("differential lock" effect). 2. Operation The steering axle drive is engaged by the electric switch for 4-wheel drive in the driver's cab. The integral warning lamp in the switch comes on to indicate that 4-wheel drive is activated. Warning: – The steering axle drive can only be engaged when the machine is stationary (hydrostatic drive lever in neutral position). – The steering axle drive can only be disengaged when the machine is stationary, since otherwise the vehicle would suddenly accelerate. – The steering axle drive cannot be activated in 4th gear. – On very steep downhill slopes with low load on the steering axle drive, the vehicle may accelerate due to loss of traction on the driven steering axle. Under these conditions, it is advisable to switch off the all-wheel drive. The driver is informed that the steering axle drive is engaged by the green warning lamp with the 4-wheel drive symbol.

Traction control If one of the drive wheels on the steering axle starts to spin, the traction control can be activated by pressing the foot-switch. The red warning lamp confirms to the driver that traction control is activated. When cornering with a steering angle of more than 10°, the ASR control function is automatically suspended until the steering angle is again less than 10 °C.

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5650H – 5690HTS Drive Hydraulics Steering axle drive – Operation

1

Operating instructions Activating 4-wheel drive 1.

Start the engine, or stop the combine harvester and leave the engine running.

2.

Make sure that the Commander Stick is in neutral position.

3.

Select the desired gear (not 4th).

4.

Press the "4-wheel drive" push-button.

5.

The "4-wheel drive" indicator lamp comes on.

2

3

If you select 4th gear in this mode, the steering axle drive will be switched off, and will be immediately switched on again when you select another gear.

1

2

3

4

4

5 31395-1

ASR Traction Control 1.

4-wheel drive is on. The "4-wheel drive on" indicator lamp is lit.

2.

The steering angle to the left or right is no more than 10°.

3.

Press the ASR foot-switch.

4.

The "ASR on" indicator lamp comes on.

1

ASR traction control only remains activated while the foot-switch is depressed.

2 10°

3

4

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5650H – 5690HTS Drive Hydraulics Steering axle drive – Hydraulic block diagram 1

High-torque radial piston motors

2

Pressure maintaining valve (1.5 bar)

3

Leakage oil return

4

Double valve (ASR)

5

Oil reservoir

6

Forwards high pressure

7

Hydrostatic pump.

8

Switching valve, steering axle drive

9

Arrow shows direction of travel

10 High pressure when driving forwards 11 Hydrostatic motor. Type: HMF 12 Forwards high pressure

Steering axle drive – Hydraulic circuit diagram 1

High-torque radial piston motors

2

Pressure maintaining valve (1.5 bar)

3

Leakage oil return

4

Double valve (ASR)

5

Oil reservoir

6

Forwards high pressure

7

Hydrostatic pump.

8

Switching valve, steering axle drive

9

Arrow shows direction of travel

10 High pressure when driving forwards 11 Hydrostatic motor. Type: HMF 12 Forwards high pressure

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5650H – 5690HTS Drive Hydraulics Steering wheel drive, double valve (ASR Traction Control)

Steering wheel drive, hydraulic switching valve (without pilot control valve) 1 Tightening torque 65

+/− 6,5

Nm

2 Tightening torque 65

+/− 6,5

Nm

3 Tightening torque 25

+/− 2

Nm

4 Tightening torque 30

+/− 3

Nm

5 Tightening torque 10

+/− 1

Nm

Steering wheel drive, pressure maintaining valve (1.5 bar) 1 Tightening torque 60

+/− 6

Nm

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5650H – 5690HTS Drive Hydraulics Steering axle drive Operating principle of the radial piston motors Movement stages of the piston in relation to the cams: – Piston position 1 The oil is channelled under pressure to the distributor, passes through the distributor and presses against the piston. This stage is the start of the oil supply stroke. The pressure of the piston causes the roller to roll along the cam, thereby turning the cylinder block. – Piston position 2 The oil supply is opened to its maximum and now starts closing again as the piston continues its travel. – Piston position 3 When the piston reaches the bottom of the cam, oil supply is stopped. There is no further driving force. This point is the bottom dead centre. Another piston must drive, so that the next cam brings the first piston back. – Piston position 4 The dead centre is overcome by the drive from another piston. The oil can return to the tank. This stage is the start of the oil return stroke. – Piston position 5 The oil return reaches its maximum, and then the outlet port gradually starts reclosing. When the piston reaches the top point of the cam (top dead centre), a new working cycle can start. The direction of rotation of the motor depends on the setting of the distributor. If the direction of oil flow is reversed, the direction of rotation is automatically changed.

1

Piston position 1

2

Piston position 2

3

Piston position 3

4

Piston position 4

5

Piston position 5

Steering wheel drive Traction control (ASR) The traction control system operates on the principle of rotary speed compensation, i.e. the speeds of the individual wheels are measured and compared in the central electronic control unit. If a faster speed (wheelslip, spinning) is measured on one or both wheels of the steering axle, a corresponding control signal is sent to the control valve to reduce the oil flow to this wheel or wheels.

1

Double valve (proportional control valve)

2

Wheel drive

3

Speed (rotary speed tolerance range1)

4

Wheelslip

1)

Permissible speed difference without requiring control adjustment

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5650H – 5690HTS Drive Hydraulics Steering axle drive Installation position of sensors and valves Switching valve (Fig. 31329) The steering axle drive is engaged by the solenoid valve mounted on the left-hand side of the machine.

31329

Inductive sensor for hydrostatic pump The inductive pickup (1) at the hand throttle prevents engaging of the steering drive axle while driving. To activate the steering axle drive, the commander stick must be in neutral position.

0 V R

1+

0,

5

1 ,5

0

Nulls

tellu

ng

1+

56-072de

4th gear switch The switch (2) on the shift linkage prevents the steering axle drive from being activated. When 4th gear is engaged, the steering axle drive is switched off.

2

D-65

Pressure maintaining valve, 1.5 bar The pressure maintaining valve (3) under the hydraulic fluid tank maintains the pressure (1.5 bar) in the leakage collecting line of the radial piston motors.

3

31332

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5650H – 5690HTS Drive Hydraulics Steering axle drive Installation position of sensors and valves Speed sensor for wheel hub motors (Fig. 31333 / Fig. 31334) Traction control (ASR) The two sensors on the rear wheels, Fig. 31333 (1) and the wheel sensor on the front right wheel, Fig. 31334 (1), record the number of wheel revolutions. The ASR electronic control unit calculates the distances each wheel has travelled, taking into account the tyre size, and compares these distances.

31333

Front axle speed sensor (Fig. 31334)

31334

Double valve (Fig. 31335) If the values deviate from one another, the electronic control unit actuates the double valve (1) under the steering drive axle in order to adjust the volumetric flow in the two radial piston motors accordingly, thereby preventing the rear wheels from spinning.

31335

Steering angle sensor (Fig. 31382) The steering angle sensor (1), mounted on the right of the driven steering axle, monitors the steering angle. When cornering with a steering angle of more than 10° to the left or right, the ASR traction control function is suspended until the steering angle is again reduced to less than 10°. The "ASR on" warning lamp goes out while the ASR control function is suspended.

31382

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5650H – 5690HTS Drive Hydraulics Steering axle drive Setting – Inspection 1. – Before inspecting, make sure that the hydrostatic system, including the steering axle drive (wheel motors) is properly bled. – Jack up the combine harvester (all 4 wheels). – Set the steered wheels to the "straight ahead" position. 2. – Test the supply pressure of the BPV hydrostatic pump. The pressure at nominal speed is 21 bar (system at operating temperature). When the ASR traction control is activated, the pressure must not drop below 19 bar. 3. – Inspecting the wheel speed sensors and steering angle sensor – Ignition on (engine off). – Engage the steering axle drive (green lamp comes on in the instrument panel). – Rotate the front wheel: Sensor flashes – ready for operation Sensor constantly lit – gap too small Sensor unlit – gap too wide Follow the same procedure for inspecting the rear wheels. – Air gap of wheel sensors and steering angle sensor: 1

+0,5/−0,3

mm

– Test the steering angle sensor: Sensor constantly lit – ready for operation. Caution: observe gap setting! Sensor unlit – sensor gap too wide or steering angle > 10° – Steering angle coverage: +10° / –10° – Check the gap of the inductive sensor on the hydrostatic pump: Gap size: 4 +/−2 mm (hydrostatic drive lever in neutral position). – Check the switching function of the electrical 4th gear switch: Engage 4th gear – switch open (normally closed) – no pass 4th gear not engaged – switch closed – pass After successful inspection / setting, the machine can be let down again.

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5650H – 5690HTS Drive Hydraulics Troubleshooting – Traction control (ASR) Problem

Possible cause

Remedy

One or both steered drive wheels spinning very excessively

– Double valve sticking/blocked

– Replace the valve if the blockage cannot be cleared – Check the electrical connections

– Electrical connections of double valve broken

One or both steered drive wheels tending to brake

– Speed sensor defective or wiring broken

– Replace the sensor – Check the wiring

Traction control (ASR) not working

– Electrical supply – Steering angle sensor faulty or air gap too wide – Fuse in central electronic control box defective – Programming error in central electronic control bo

– Check the supply voltage – Check the wiring

– Supply pressure too low

– Measure the supply pressure (> 19 bar) – Check/replace double valve – Check the supply voltage

Traction control (ASR) working with considerable delay

Wheels "chatter" when driving in one direction

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– Double valve blocked – Supply voltage too low or too high – Control spool of double valve sticking – Restrictor hole fouled

– Check/replace fuse – Replace electronic control box

– Dismantle the valve – Clean the restrictor hole – Test the control spool

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5650H – 5690HTS Feed passage Table of Contents Combine Harvester Type

5650H 5680H 5660HTS 5690HTS

Feed passage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 – 03

X

X

Feed passage, Feed passage slip clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04 – 05

X

X

Feed passage, Stabilising shaft for intake chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 – 07

X

X

Feed passage clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .08 – 09

X

X

Anti-wrapping device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 – 11

X

X

Anti-wrapping device between the chain sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 – 11

X

X

Reversing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 – 13

X

X

Feed passage floating frame, tilt adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 – 15

X

X

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5650H – 5690HTS Feed passage

The cutting table can be positioned parallel to the ground by tensioning or loosening the diagonal struts (1) with the nuts (2). Before retightening a diagonal strut, loosen the screws (3) on the left and right and loosen the opposite diagonal strut. 1

Diagonal struts

2

Nuts

3

Screws

4

Floating bearing

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3

E0002

E0003

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5650H – 5690HTS Feed passage

1

M10 screws

2

Spacer washer

3

Lubricate the sliding surface of the bearing housing and the bearing half shell on the left and on the right side.

5650H – 5690HTS Feed passage Feed passage slip clutch

Before each harvest season, air the slip clutch and make it slide through its complete adjustment range. 1 2 3

Metal surfaces must be degreased and coated with anti-corrosion agent "i RC 123 V" (Fuchs), part No. 0 9097 123 400 40, before assembly (drying time: approx. 4 hours at 20 °C). Greased with Molykote BR2 0 9097 127 544 50 Slipping torque 450 Nm

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5650H – 5690HTS Feed passage Feed passage

1 2 3 4 5

Tightening torque: 400 Nm (M24x1.5) Upper end-stop for rocker arm Lower end-stop for rocker arm (for maize threshing: turn 180°) Tightening torque for grooved nut: 56 Nm Intake chain tensioner

5650H – 5690HTS Feed passage

Stabilising shaft (2) for intake chain For threshing maize or sunflowers, lock the stabilising shaft (2) in the upper position or remove it. 1

Limit tube

2

Stabilising shaft

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E0004

E0005

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5650H – 5690HTS Feed passage Feed passage clutch 1

Reference dimension for the servomotor stroke (60 mm) during the clutch engaging process.

2

Spring-loading dimension for the engaged clutch (set by means of the load relay potentiometer: see Chapter C ).

3

The servomotor stroke is set by adjusting the position of the spring assembly on the threaded rod (3).

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5650H – 5690HTS Feed passage Anti-wrapping device Item

Designation

Quantity

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Anti-wrapping device left Anti-wrapping device right U-piece Screw M10x80 Screw M10x85 Stud bolt M10x90 Screw M10x100 Spring washer A10 Mushroom head screw M8x30 Washer 8.4x18x2 Spring washer A8 Nut M8 Washer 10.5x30x3 Lock nut M10

1 1 2 6 6 1 1 10 4 4 4 4 4 2

5650H – 5690HTS Anti-wrapping device between the chain sprockets (Extra attachment for linseed threshing) 1

Plastic slider

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E0020

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5650H – 5690HTS Feed passage Reversing device

1

Plate

2

Relay for magnet-operated switch

3

Insulators

X

Connector for thermal protection switch (see wiring diagram)

1

Plate

2

Self-tapping screws M10x35

Detail Z1: 5.5 mm clearance between the ring gear and the armature spindle. This clearance is set by adjusting the plate (1) in the oblong hole. Detail Z2: 3 mm axial clearance between the ring gear and the pinion. This clearance is set by adjusting the position of the flywheel on the transmission shaft.

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E0023

E0024

E0025

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E0026

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5650H – 5690HTS Feed passage Floating frame Tilt adapter for cutting table (without hydraulic cutting angle adjustment) The cutting angle of the cutting table must be adapted to the tyre size by adjusting the turnbuckles (1). 1

Turnbuckles

2

Sealing plate

5650H – 5690HTS Feed passage Floating frame Tilt adapter for cutting table with hydraulic cutting angle adjustment When the piston rods of the hydraulic cylinders are fully retracted, the tilt adapter must not strike the feed passage. If necessary, adjust the piston rods in the rod-end swivel joints. The piston rod (1) must be screwed at least 24 mm into the swivel joint (2). The reference dimension between the piston rod and the lock nut is max. 26 mm.

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E0028

E0029

E0030-1

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Notes

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5650H - 5690HTS Cabin, Driver's stand Table of Contents Combine Harvester Type

5650H 5680H 5660HTS 5690HTS

Driver’s Stand, Control consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 – 03

X

X

Commander Control 2000, EMR-D control panel . . . . . . . . . . . . . . . . . . . . . . . . . . .04 – 05

X

X

Driver’s Stand, Commander Stick, Control consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . .06

X

X

Driver’s Stand, Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .07

X

X

Cabin, Foot-operated controls, Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .08

X

X

Cabin, Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .09

X

X

Cabin, Operating Controls, Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 – 11

X

X

Cabin Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

X

X

Cabin, Operating Controls, Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

X

X

Cabin, Rear-view mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

X

X

On-board computer (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 - 17

X

X

Cabin suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 - 19

X

X

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1

1.1

1.2

3

2

4

5

1.3

6 33892

14

15

16

17

18

19

20 13 12 11

21

10 9

22

8

7 30

29

28

27

26

25

24

23 33899

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5650H - 5690HTS Driver's stand Control consoles

1

25

Instrument panel

Indicator lights, spreader plates left

1.1 Central instrument cluster

25.1 Indicator light, spreader plates half-left

1.2 Hydraulic temperature display

25.2 Indicator light, spreader plates full left

1.3 Coolant temperature gauge

26

Indicator light, differential lock, on/off

2

Shift lever

27

Switch, 4-wheel drive on/off

3

Commander Control 2000

28

Indicator light, automatic fan inclination control on/off

4

EMR-D control panel

29

Fault indicator light, engine management (EMR)

5

Control console

30

Engine speed switch with three positions:

6

Commander Stick

• lower idling

7

Starter switch

• increased idling speed

8

Hazard warning lights on/off switch

• nominal engine speed

9

Indicator light, straw chopper on/off

10

Indicator light, one-point lubrication system

11

Automatic cutting angle control

12

Grain tank extension extend/retract

13

Grain tank lamp on/off switch

14

Indicator light, 4-wheel drive on/off

15

Rocker switch, reversing system on

16

Rocker switch, side cutting table on/off

17

Width segment switch (TCS only)

18

Switch, spreader plate adjustment left/right

18.1 Key: spreader plates to right 18.2 Key: spreader plates to left 19

Indicator lights, spreader plates right

19.1 Indicator light, spreader plates half-right 19.2 Indicator light, spreader plates full right 20

Operating hour counter

21

Socket, 12 Volt

22

Cigar lighter

23

Switch, straw guide plate, short/long straw

24

Work master switch

25.1

18.1 19.1

19.2

25.2

18.2

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2

1

3

4

5

9

8

6

7

33898

1.4

1.3

1.2

1.1

1 6 5 2

4

G4

3

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5650H - 5690HTS

Commander Control 2000 General The Commander Control is operated by a membrane keypad with 14 keys.

1 2 3 4 5 6 7 8 9

Screen Swing grain tank discharge pipe inboard/outboard Threshing section on/off Cutting table on/off Adjust concave clearances Adjust speeds alarm Fan speed adjustment/Setup menu* Threshing drum speed adjustment/Diagnosis menu* Pick-up reel speed adjustment/Calibration menu* * Press + and – keys at the same time

For detailed information and instructions on the function and operation, see section H.

5650H – 5690HTS EMR-D control panel

1 1.1 1.2 1.3 1.4 2 3 4 5 6

Mode selector switch Transport mode, calibration Cutting height preselection mode Ground pressure mode Cutting height control mode Overstroke button Ground pressure preselection Cutting height preselection Diagnosis indicator (red LED) Status indicator (green LED)

For detailed information and instructions on the function and operation, see section H.

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5650H - 5690HTS Driver's stand Commander Stick Control Consoles

2 1

1

Shift lever Gearshift positions

1

2

3

4

33900

2

33901-1 All gears must only be shifted during standstill!

3

4

7 5

6

8

2

Commander Stick

3

Cutting angle adjustment forward/back

4

Pick up reel, raise/lower

5

Front attachment, tilt right down/left down

6

Front attachment, raise/lower

7

Pick-up reel forward/back

8

EMR-D automatic mode button

32504/1 9

10

12

11

17

9

15

16

14

13

33895

Air conditioner control panel

10

Rotary control knob for heater

11

Blower control knob

12

Cab cooling system control knob

13

Cab cooling system on/off switch

14

Fault indicator light, cab cooling

15

Unused

16

Digital clock

17

Loudspeaker

18

Warning beacon

19

Windscreen wiper

20

Control panel

21

Work lights:

• Off • 4 front work lights • All work lights

19

18

G6

22

Headlights top/bottom

23

Headlights:

• Off • Parking lights

20

23

22

• Driving lights

21 33894

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2 1

3

5650H - 5690HTS Driver's stand Steering wheel

1

Spindle-shaped button for steering wheel adjuster

2

Drop-arm switch comprising the following switch functions:

Position 33708

3 2 2 1

4 5 6

33748

Function

1

Press

Horn

2

Push forward

Indicator, right

3

Raise

Main beam (only at engine running)

4

Pull back

Indicator, left

5

Down

Dipped beam (only at engine running)

6

Fully down

Headlight flasher

3

Grain loss monitor

4

Ignition switch with following switching functions:

4 0

I

0 I

II

Zero position Operating position (the warning lights for the battery charge and oil pressure are lit if the engine is off). Start

II • The servomotors of the belt clutches may move on switching on the ignition and starting the engine. The clutches will be driven to the disengaged position. 33946

• After switching off the engine, always remove the key from the ignition on leaving the cab.

☞

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The engine can and may only be started when the Commander Stick is in the Neutral position.

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5650H - 5690HTS Cabin Foot-operated controls

1

Parking brake (Handbrake)

2

3

1

Cover for switch (3)

2

Cutting table emergency stop, red

3

Grain tank discharge, yellow

4

Pedal for braking the right wheel

5

Interlock plate

6

Pedal for braking the left wheel

7

Locking button

8

Handbrake lever

33910

4

5

6

32567

8 7

33911

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2

1

3

4

5650H - 5690HTS Cabin Operating Controls

1

Lamp for interior lighting

2

Switch for interior lighting

3

Spotlight

4

Spotlight switch

5

Flap for access to air conditioning system evaporator

6

Recirculating air filters

7

Fresh air filters

33902

5

33948

6 33903

7

33925

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5650H - 5690HTS Cabin Operating Controls Seats

1

1

Drawer

2

Pocket

3

Crank handle

2 33909

7

8

- Height adjust of seat (seat unloaded) - Weight adaption mechanism (seat unloaded)

3

4

Weight display

5

Seat forward/back

6

Backrest inclination adjustment

7

Armrest angle adjustment

8

Foldable armrest

9

Passenger seat

6 4

5

33907

9

33908

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9

1 8

2

2

2 7 10

3 6

4 1

2

5 Aero Fit seat (air sprung) (optional)

4

5

32863-1 5

Combined weight/height adjuster (infinitely variable) Weight setting:

Never adjust the seat while driving.

Raise or push the handle slightly until the green marking on the weight and height display is visible.

1

Headrest, height adjustable and removable

Height setting:

2

Lumbar support

Fully raise or press the handle until the desired position is obtained (the green marking must be visible).

3

Backrest inclination = backrest adjustment

4

Weight and height display

The weight and height adjuster can only be operated when the ignition is on. The adjuster should not be operated continuously for longer than 1 minute. 6

Longitudinal adjustment

7

Safety belt fixing

8

Armrest, folding

9

Height adjustment, armrest

10 Armrest inclination

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5650H - 5690HTS Cabin Operating Controls

1 1

Defroster/demister nozzles

2

Fresh air nozzles

3

Fresh air nozzles

4

Inspection window

5

Beverage holder

33904

2 3

33905

5

4

33906

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A 1

5650H - 5690HTS Cabin Operating Controls Emergency exit 1

Lever: - Opening of knockout window

33912 - Emergency exit. For this purpose lift lever and

B

1

unhinge from interlock (2), push open window.

2

Interlock

3

Door handle

4

Knob (opening of driver’s cabin door from outside)

2 33913

3 33914

4

33915

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2

1

5650H - 5690HTS Cabin Rear-view mirrors

1 1

Hexagon bolts: - Basic adjustment

2

Tighten the screws - only sufficiently to hold the mirrors in position, but

2

allowing them to fold in without damage if they hit

33887

an obstacle

2

2

35607 Electrical adjustment of the right rear-view mirror

3

3

Switch

Press the edges of the knob to adjust the mirrors to the desired position. up down right left 35608 The mirrors must be adjusted to the seat position and driver's height.

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Notes

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1

2

3

4 7

6

5

30672

10

9

8 30768

G 16

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5650H - 5690HTS On-board computer (optional) System description The hectaremeter comprises the following units: 1. Control instrument:

For display and operation

2. Wheel sensor:

Transmits one impulse per wheel revolution to the control instrument to enable the various functions to be controlled and calculated.

3. Solenoid switch:

Starts and stops the hectaremeter. If the hectaremeter is stopped, the letter "r" ("raised") is displayed on the left-hand side of the display next to the speed indicator.

The solenoid switch is located on the right-hand side of the feed channel bearing. The hectaremeter is started or stopped by raising or lowering the cutting table. The switching threshold is set to a cutting table height of about 40 – 50 cm above the ground. The operation of this solenoid switch can be monitored by switching over from hectaremeter to speed indicator.

Description of the function keys 1

Working time (hours and minutes)

2

Hectaremeter (partial count)

3

Hectaremeter (total count)

4

Speed (km/h)

5

Working width input

6

Wheel circumference input

7

Zero reset for all functions:

working time, partial area and total area This key is also used to enter the figure 0.

Description of system connections 8

Connection to 12 V power supply

9

Connection for wheel sensor

10

Connection for solenoid switch

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2

1

1, (2)

3

4

5

6

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5650H - 5690HTS Cabin suspension 1

front rubber suspension, marking 510 – 5 – N – S

2

rear rubber suspension, marking 510 – 3 – N – S, colour coding green - white

3

Marking at rubber suspension

4

Distance plate

5

Disc

6

Bolt M12x80

Observe upon assembly: Do not interchange front and rear rubber suspensions, observe marking. Observe mounting position of rubber suspensions.

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Notes

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5650H – 5690HTS Electrical System Table of contents Combine Harvester Types

5650H 5680H 5660HTS 5690HTS

General, Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03

X

X

Index of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04

X

X

Cable colours and colour coding for connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05

X

X

Electrical system, wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 – 09

X

X

System overview of electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 – 11

X

X

Control console, overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 – 13

X

X

Operating elements in cabin roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 – 13

X

X

Control console, switches and lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 – 15

X

X

Control elements Commander Control 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 – 15

X

X

Overview wiring diagram electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 – 17

X

X

Fuse assignment in control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 – 19

X

X

Relay assignment in control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 – 21

X

X

Funktion Diode arrays D1, D2, D3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 – 23

X

X

Cable harnesses, connector assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 – 27

X

X

Multiple contact strips in control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 – 43

X

X

Multiple contact strips under the control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 – 45

X

X

Connector plug configuration foot switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 – 45

X

X

Distributing connector engine frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 – 49

X

X

Pin configuration actuator connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

X

X

Schematic diagram CAN bus Commander Control 2000 with combined instrument gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 – 53

X

X

Schematic diagram CAN bus Commander Control 2000 with TERIS/TCS . . . . . . . . . . .54 – 55

X

X

Schematic diagram electrical deflector adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 – 57

X

X

Schematic diagram electrical straw guide plate adjustment . . . . . . . . . . . . . . . . . . . . . .58 – 59

X

X

Schematic diagram electrical sieve adjustment control . . . . . . . . . . . . . . . . . . . . . . . . .60 – 61

X

X

Wiring diagram CAN bus system with combined instrument gauge . . . . . . . . . . . . . . . .62 – 63

X

X

Wiring diagram CAN bus system with Commander Control und TERIS/TCS . . . . . . . . .64 – 65

X

X

Function and programming of CAN modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 – 73

X

X

Connector pin assignment at job computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 – 79

X

X

Connector pin assignment CAN modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 – 81

X

X

Combined instrument gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 – 83

X

X

Combined instrument gauge and Commander Control 2000, overview monitoring and control functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 –85

X

X

Diagram inputs/outputs Commander Control 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 – 87

X

X

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5650H – 5690HTS Electrical System Table of contents Combine Harvester Types

5650H 5680H 5660HTS 5690HTS

Connector pin assignment A30, Commander Control 2000 . . . . . . . . . . . . . . . . . . . . . .88 – 89

X

X

Functional monitoring by the Commander Control 2000 . . . . . . . . . . . . . . . . . . . . . . . .90 – 91

X

X

Switches and sensors for monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 – 95

X

X

Functional description inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 – 97

X

X

Sensors, overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 – 101

X

X

Multifunction lever, gear rack device/sensor adjustment . . . . . . . . . . . . . . . . . . . . . . . .102 – 103

X

X

Multifunction lever, connector pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 – 105

X

X

A13 logic module, connector pin assignment, function . . . . . . . . . . . . . . . . . . . . . . . . . .106 – 107

X

X

Control unit EEC, gas control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 – 109

X

X

Electronic cutting table control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 – 119

X

X

Control unit EMR-D, connector pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

X

X

Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

X

X

Throughput Monitor (Grain Loss Monitor) / On-board Computer . . . . . . . . . . . . . . . . . .146

X

X

Appendix A: Wiring diagrams Appendix B: Commander Control 2000, Operating Instructions Appendix C: Commander Control 2000, Setup and Diagnosis

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5650H – 5690HTS Electrical System General Safety instructions 1.

When working on the electrical system, always disconnect the cable from the negative terminal of the battery.

2.

Always observe the correct connection procedure – first connect the positive terminal, then the negative.

3.

Beware of battery gases – they are highly explosive! Avoid generating any sparks or naked flame near the battery!

4.

Only use original fuses. The electrical system will be destroyed if fuses with too high ratings are used!

5.

Disconnect the cable from the generator and battery when carrying out electric welding work on the combine harvester!

6.

Take care when handling battery acid (toxic and corrosive)!

7.

Only operate the starter for a limited time, since otherwise the winding will overheat. Allow the starter engine to cool!

8.

Do not place any tools on the battery!

A0009

Remark The electrical system is described with full equipment, which means that the combine harvester maintained by you may not be equipped with particular components (e.g. printer, PC keyboard, etc.), depending on the respective equipment.

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5650H – 5690HTS Index of Abbreviations AHS

Working master switch

CCP

Clutch Control Power Unit (shift gear control device)

EEC

Engine control unit (electronic engine control)

EMR-D Electronic control of cutting mechanism GPS

Global Positioning System

KT

Grain tank

KTS

Grain tank unloading auger

MF

Multifunction control lever (Commander Stick)

MV

Solenoid valve

MW

Cutting mechanism

TS

Turbo-separator

TCS

Terminal Control System (job computer)

SMPS

Constant voltage power supply 5V/12V

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5650H – 5690HTS Cable colours and colour coding for connectors

Basic colours applied for cables:

Colour codes for connectors

Abbreviation

Colour

Abbreviation Colour

bl

blue

DBL

dark blue

br

brown

DBR

dark brown

ge

yellow

DGR

dark grey

gn

green

DGN

dark green

gr

grey

DRT

dark red

nat

nature

ELB

ivory

or

orange

GEL

yellow

pk

pink

HBL

light blue

rs

pink

HBR

light brown

rt

red

HGN

light green

sw

black

HGR

light grey

tr

transparent

HRT

light red

vi

violet

NAT

nature

ws

white

OR SW WS

orange black white

Fundamentally, the basic colour is always indicated first, followed by the indication colours. Therefore, rt/ws/bl is a cable with red as basic colour and white/blue as indication colours. Markings in the circuit diagram A30.5 pin number device number

X512.14 pin number connector X512

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5650H – 5690HTS Electrical System Wiring diagram Layout of the wiring diagrams The wiring diagrams are clearly broken down and their structure is easy to understand at a glance. The positive lines are shown at the top edge: 30 = Permanent positive 15 = Switched positive The negative lines are shown at the bottom: 31 = Vehicle earth These three lines extend along the full length of the wiring diagram and are marked with 30, 15 and 31. The individual circuits are all located between positive and negative and can therefore be clearly and comprehensibly represented in "current paths" next to one another. Each circuit contains: ● ● ●

Wire colour and cross-section, Colour and number of the plug-in connector, Serial number and current rating of the fuse.

The "inner life" of the individual components is also shown for better comprehension. Please note that, in conformity with the DIN standard, all switches and relays have been drawn in the rest position, i.e. without the effect of voltage, pressure or temperature etc.. You therefore have to imagine the working position when voltage, pressure or temperature is applied. All components are identified by a circle containing a number (item number). You can then find the corresponding part name in the parts list. In the course of the wiring diagram, the same components may have different numbers when used in different sections. Cable cross-sections used in the combine harvester: Starter motor cable Main cables Load cables:

50 mm2 / 70 mm2 4 mm2 / 6 mm2 4 mm2 / 2.5 mm2 / 1.5 mm2 / 1 mm2 / 0.75 mm2.

Basic cable colours used: Colour:

Abbreviation:

Use:

red black brown grey white yellow blue green mauve orange natural

rd bk br gr wt yl bu gn mv or nat

B + /30 15 31 58 56a 56b monitoring

As a rule, the basic colour is specified first, followed by the identification colours. Therefore "rd/wt/bu" designates a cable with the basic colour red and with white/blue as identification colours.

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Electrical System Wiring diagram Terminal Designations Terminal

Designation

30 31 31b 30a 31a 50 50a 15 19 17 61 D+ D– DF 54 54f 56 56a 56b 58 58L 58R 53a 53 31b 52 54g 49 49a C C2 L R LB RB 54f 86 85 88 88a 87 87a 87 87a 88a

Battery + (unswitched positive) Battery – (earth) Switched negative to earth Battery switchover relay, battery II input Battery switchover relay, battery II return Starter motor control (direct) Starter motor control (indirect) Switched positive Preheating (upstream resistor input) Preheating when starting (bridging over the resistor) Battery charge warning lamp (D+) Dynamo + Dynamo – Dynamo field Brake light Output from brake light switch to dual circuit flasher switch Supply cable to headlight dipper switch Main beam, main beam indicator Dipped beam Parking light, sidelights, contour lights and instrument panel lamps Rear light, left, number plate light Rear light, right, number plate light Windscreen wiper + Windscreen wiper actuation (switched positive) Switched negative for final switch-off Tyre monitor or other signal from the trailer Magnetventil für Dauerbremse im Anhänger Flasher + (input) Flasher pulse (output) Flasher warning light for tractor vehicle Flasher warning light for trailer Turn signal lights, left Turn signal lights, right Dual-circuit flasher switch, left Dual-circuit flasher switch, right Input from brake light switch (dual circuit system) Relay coil (+) Relay coil (–) Relay input contact for make relay Relay output contact for make relay Relay input contact for break relay Relay output contact for break relay Relay input contact for change-over relay Relay output contact for break side Relay output contact for make side

The terminal designations are not cable designations and are therefore not marked on the cables.

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Electrical System Wiring diagram Key to Wiring Diagram

Permanent positive from the battery, always energised Switched positive behind the battery, switched by the ignition switch From the alternator only energised when the engine is running Fuse specifying the fuse strip (GN = green) and number (3, input), C: output to load, current rating (7.5 A)

Cable colour Connector with receptacle assignments and connector colour Component positioning Description and designation in the key Cross-reference To the section (module/group) to which the cable leads

Terminal designation on the component Switch symbol here diode Vehicle earth Section designation (group) for delimiting the section in the wiring diagram

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Electrical System Terminal designations of the 8-pin connectors Coloured connectors with anti-torsion protection are used. The position of the terminals is shown in the sketch below. The simplified diagram shows which pins the cable cores are connected to at the inlet and outlet of the connector.

Example: If a cable core enters the connector at pin 8, the cable core on the other side leaves from pin 5.

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5650H – 5690HTS System Overview of Electrical System The electrical system consists of the following main components:

1

Connector X140 – X147, AMP connector grain loss sensory system

2

A1, A2 electronic engine controller EEC

3

Control cabinet

4

A4 control unit EMR-D

5

A30 Commander Control 2000

6

A24 control unit balance II

7

A31 or A22, LH 1000 area meter or printer (with TERIS/TCS)

8

Control unit air condition/heating/ventilation

9

A32 grain loss monitor LH 865 or display unit A21 (with TERIS/TCS)

9.1

Distribution box grain loss sensory system

10

B40 or A17, combined instrument gauge or terminal (with TERIS/TCS)

11

Control console

12

A19 control unit balance II

13

G1 battery, S1 battery main switch

14

K101 hazard flasher relay

15

A8 powershift device for actuators of belt couplings

16

A10 control unit all-wheel drive (optional)

17

Fuses

18

Relays

18.1 Diode array D1, D2, D3 19

A3 control unit EMR-D

20

A11 job computer (TERIS/TCS)

21

A12 control unit autocontrol

22

A13 logic module: starter blocking/reversing horn/all-wheel drive/differential lock

23

A25 CAN module deflector adjustment

24

A26 CAN module straw guide plate adjustment

25

A16 inclinometer (fan control TERIS/TCS)

26

A27 CAN module sieve adjustment

27

A14 constant voltage power supply 5V, 12V (only TERIS/TCS) for:

Observe the proper mounting position!

– Job computer – Inclinometer – Field data printer – PC keyboard 28 Insulated ground connector strip for potentiometer ground of servo motors for chopper deflectors, chopper flap and sieve adjustment.

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1

3

2

4

5

6

8

7

9 10

11

34939-2

13

9.1

12 28

14

MED_ACAD*11/24/10 11:01 AM Rev:12.23

15

16

23

24

25

26

27

SOLARI 1.she

18.1

22 21

20

19

H001

17

H002

18

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1

3

2

4

5

1.2 1.1

1.3

6 33892

8

2

3

4

5

7

6 33923 H 12

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5650H – 5690HTS Control console, overview Standard design 1 1.1 1.2 1.3 2 3 4 5 6

Instrument panel Combined Instrument Gauge Indication hydraulic system temperature Indication coolant temperature Gear-shift lever Commander Control 2000 EMR-D operating device Control console Commander stick

TERIS/TCS design 7 8

TERIS/TCS terminal (optional) Keyboard (only TCS)

Operating elements in cabin roof Control panel air condition

8

10

9

13

14

12

15

11

8

Control button for heating (type 5680/5690 only)

9

Rotary switch for ventilation

10

Control button for cooling system

11

Switch cooling system on/off

12

Indicator light cooling system malfunction

13

Empty field

14

digital clock

15

Loudspeaker

33895

Control panel lighting

17

16

18

16

Revolving lights

17

Windscreen wipers

18

Control panel

19

Work light:

• off • 4 front projectors • all projectors

21

20

307.1133.3.6 englisch (en) 10.2006

19

20

Projectors on top/ at the bottom

21

Projector:

• off • parking light

33894

• dipped beam

H 13

H Service Training

5650H – 5690HTS Control console, switches and lamps 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

25

Ignition start switch Switch hazard warning signal flasher on/off Indicator light straw guide plate in position chopper operation Indicator light central lubrication system Indicator light Automatic cutting angle control Retract/extend grain tank extension Switch grain tank illumination on/off Indicator light all-wheel drive on/off Rocker button reversing on Switch side cutter bar on/off Partial width activation (only TCS/TERIS) Switch deflector adjustment left – right Indicator lights deflector position Operating-hours counter Plug-socket 12 Volt Cigarette lighter Switch straw guide plate, chopping or long straw shedding Working master switch not applicable Indicator light slip control active Switch all-wheel drive on/off Indicator light automatic slope blower control on/off (only TCS/TERIS) Indicator light engine controller (EEC) malfunction (only 5680/90) Switch engine speed (only 5680/90) with three positions: • lower idle speed • increased idle speed • nominal speed Buzzer

Control elements Commander Control 2000 The Commander Control 2000 is operated by means of a touch key board with 14 keys. 1 2 3 4 5 6

7 8 9

Display Retract/extend grain tank tube Threshing mechanism on/off (chopper) Cutting mechanism on/off Menu key for adjustment of concave clearance and TS clearance resp. concave quick opening Menu key for adjustment of speed warning thresholds Special function of menu key: Hold key pressed down while turning start switch into pos. I. When buzzer resounds, belt couplings can be activated while the engine is stopped. Working master switch (18) must be switched on. Adjustment of blower speed setup menu* Adjustment of threshing drum speed diagnosis menu* Adjustment of reel speed resp. activation of automatic speed control* calibration menu*

* Plus and minus key pressed simultaneously (see instructions)

H 14

307.1133.3.6 englisch (en) 10.2006

H Service Training

8

9

10

11

12

13

14 7 6 15

5 4 3

16

2 25 1 24

23

22

21

13

20

18

17 33898

2

1

3

4

5

9

8

7

6

33898

307.1133.3.6 englisch (en) 10.2006

H 15

H Service Training

P

0

I

II III

H 16

307.1133.3.6 englisch (en) 10.2006

H Service Training

5650H – 5690HTS Overview wiring diagram electrical system A1 A2 A3 A8 A13 A19 A23 A30 B7 B40 B45 B46 B48 F.. G3 K0 K11 K12 K13 K22 K48 K34 K51 K55 K98 M1 M19 S2 S5 S40 S42 S43 S44 S49 S55 S66 S67 Y11, Y12

Control unit EEC (electronic controller Diesel engine) Gas control unit for control unit EEC (A1) Control unit EMR-D Clutch control power unit couplings CCP II Logic module Control unit Balance II Distribution box grain loss sensory system (supply from F44 with TERIS/TCS) Commander Control 2000 Buzzer Combined instrument gauge sensor multifunction handle neutral (start interlock) sensor multifunction handle reverse (reversing horn) Reverse gear horn Fuses Generator 70 Relay for terminal 15 Relay release threshing mechanism on, terminal 15b Relay release EMR automatic system Relay multifunction handle release reel (relay was dropped as of year of construction 2001) Relay starter Relay power supply EEC Relay multifunction handle release channel Relay rape ripping knife Relay multifunction handle release EMR Relay reversing motor (attached at feed passage) Starter Reversing motor Ignition start switch Switch engine speed Working master switch Switch rape ripping knife Switch reversing device Switch grain tank interior light Switch deflector adjustment, chopper Hand break switch Switch straw guide plate adjustment Switch grain tank extension lift/lower Solenoid valves cutting angle

Relay sets: K8, K29 Extend/retract grain tank extension K7, K28, K49, K70 Relay reel hydraulics K50, K71 Swing out/swing in grain tank tube K59, K80 Relay cutting angle up/down

Must not be inserted with balance model!

Speed adjustment KX, KY: K14, K35 Relay set reel variator K15, K36 Relay set blower variator K56, K77 Relay set threshing drum variator Concave clearances KV, KW: K18, K39 Relay set concave front K19, K40 Relay set turbo separator up/down K60, K81 Relay set concave rear

307.1133.3.6 englisch (en) 10.2006

H 17

H Service Training

5650H – 5690HTS Fuse assignment in control cabinet Left row

Middle row

Right row

L

M

R

revolving lights right

grain tank tube

flasher system

cooling system, heating blower control cooling syst., heating treshing drum variator

controls AHS term. 15 a

controls threshing on term. 15b

cabin roof

H 18

307.1133.3.6 englisch (en) 10.2006

H Service Training

MED_ACAD*11/24/10 11:01 AM Rev:12.23

SOLARI 1.she

L

M

R

56-000

307.1133.3.6 englisch (en) 10.2006

H 19

H Service Training

MED_ACAD*11/24/10 11:01 AM Rev:12.23

SOLARI 1.she

D1-D3

K64 K0

K1 K73 K74 K10 K11 K83

K20

56-000

H 20

307.1133.3.6 englisch (en) 10.2006

H Service Training

5650H – 5690HTS Relay assignment in control cabinet

S55

display steering column

Multifunction handle release reel

chopper flap

307.1133.3.6 englisch (en) 10.2006

H 21

H Service Training

D+ K44, Kl.2 K45, Kl.2 K65, Kl.2 K66, Kl.2 K2, Kl.2 K25, Kl.2

D1 87 30 86

87a

K64, Kl.2

85 K43, Kl.2

3

1

K67

D2 87

4

5

2

30 K75, Kl.2

86

87a

85

D3 87 30 Comm.Control PIN 48 X509.1

86 P

87a

X503.4

85

S55

K76, Kl.2

2

1

Handbremschalter hand brake switch

H57

86 87a 30

87 85

56-073

H 22

307.1133.3.6 englisch (en) 10.2006

H Service Training

5650H – 5690HTS Function diode arrays D1, D2, D3 D1 D2 D3

Connection to ground of the relays for lighting via relay K67 (ground at D+) Connection to ground of relay K75 (power supply Balance) via relay K67 Connection to ground via hand brake switch S55 for: – Relay K76 (Balance) – Hand brake switch monitoring of Commander Control – Indicator light hand brake H57 with TERIS/TCS K67 Ground at D+ S55 Switch hand brake

Function: Prevention of return current between the relays which are connected in series with K67 or with the hand brake switch. Current load max. 1A per diode.

1 2

View on male connectors, position of terminals. Backside view, marking with yellow label.

307.1133.3.6 englisch (en) 10.2006

H 23

H Service Training

5650H – 5690HTS Cable harnesses, plug-in connections between – cabin and control cabinet – control cabinet and tail 1 1.1

Control console Connector inside of control console: - X170, X171 for combined instrument gauge - connector for terminal TERIS/TCS - X308 for keyboard - X514 programming plug for Commander Control 2000

2 2.1

Multifunction handle sensors for start interlock and reverse gear horn

3

Electric system steering column

4

Foot switch cutting mechanism stop

5

Foot switch grain tank clutch

6

Foot switch all-wheel slip control

7

Switch hand brake

8

Driver’s cabin

8.1 9

Distributing connector in cabin roof right Control cabinet

9.1

Multiple contact strip, 8-pole connector below in control cabinet

9.2

Multiple contact strip, 21-pole connector in control cabinet

10

Distribution box grain loss sensory system

11

Electronic control system engine controller

12

Distributing connector engine frame

13

Ground - collecting terminal

H 24

307.1133.3.6 englisch (en) 10.2006

H Service Training

5

8.1

3

4

X135 X136

2

X134 X115 X182

1.1 1 8 6 2.1 7 X1 X1 90 91 92

ge

X515 X190 X191 X192

X5

15

X1

hebl hegn hert

9 E 40

21

20

1

9.2

9.1 D

X513

X512

X510

X509

X508

X507

X511

X506

X505

X504

X503

B A C

X502

X501

11

EEC

10 F

H

X146 X145 X144 X147 X143 X142

12 G

13

X141 X140

56-018

307.1133.3.6 englisch (en) 10.2006

H 25

H Service Training

X135 X136

X134 X115 X182

1

X515 X190 X191 X192

X5

X1 X1 90 91 92

15

X1

ge hebl hegn hert

E 40

21

20

1

D

X513

X512

X510

X509

X508

X507

X511

X506

X505

X504

X503

B A C

X502

X501

EEC

F

H

X146 X145 X144 X147 X143 X142

G

X141 X140

56-018

H 26

307.1133.3.6 englisch (en) 10.2006

H Service Training

5650H – 5690HTS Cable harnesses, plug-in connections between – cabin and control cabinet – control cabinet and tail 21-pole connector in control cabinet

A

X504 X505 X506 X512

Connector in control console switches, indicator lights in control console control unit cutting mechanism control X190 X191 X192 X515

multifunction handle sensor start interlock sensor reverse gear horn foot switch grain tank clutch foot switch cutting mechanism stop footswitch all-wheel hand brake switch

B

X507 X508 X509 X510 X511

Commander-Control X514 programming plug X170 ZI I ws X171 ZI II sw monitor TERIS/TCS X308 keyboard

C

X503

steering column Connectors in cabin roof

X501

D

X502 X513

X115 dark brown sensor brightness, power supply data printer X182 dark green LH 1000 switch illumination control unit balance data line for printer

8-pole connectors below at control cabinet X34 yellow

E

X134 yellow, term. 30 cabin roof, air condition X135 light green, working lights

X14 light red

X136 ivory, dipped beam projector at the top ground cabin roof, interior light, revolving light

Connectors in engine compartment AMP connectors 5-pole for supply distribution box grain loss sensory system

F

G

X140-X147

H

307.1133.3.6 englisch (en) 10.2006

Power supply for consumers and sensors at engine and combine harvester tail

Junction box grain loss sensor

H 27

H Service Training

5650H – 5690HTS Multiple contact strips in control cabinet Upper multiple contact strip (A), 21-pole connector

A

front Note: Push the unlock pin (2) in order to separate the connector housing. Pull the brown interlocking strip (1) out of the connector housing and unlock the snap-in pin of the contacts in order to remove the plug contacts.

Connector 21-pole, view from cable side connector housing (fixed in control cabinet)

A1

Connector 21-pole, view from cable side female connector housing (plugged in from below)

A2

2 H 28

307.1133.3.6 englisch (en) 10.2006

H Service Training

MED_ACAD*11/24/10 11:01 AM Rev:12.23

SOLARI 1.she

A1

A

A2

56-003

A1

1

1 A2

2 1,19

307.1133.3.6 englisch (en) 10.2006

H 29

H Service Training

5650H – 5690HTS Pin Assignment Connector X501 - X505

A1

56-020

H20

H 30

307.1133.3.6 englisch (en) 10.2006

H Service Training

5650H – 5690HTS Pin Assignment Connector X506 - X509

A1

H20

307.1133.3.6 englisch (en) 10.2006

H 31

H Service Training

5650H – 5690HTS Pin Assignment Connector X510 - X513

A1

56-020

H20

Note: At Connector X513 the colours of the lines change from A1 to A2.

H 32

307.1133.3.6 englisch (en) 10.2006

H Service Training

Notes

307.1133.3.6 englisch (en) 10.2006

H 33

H Service Training

MED_ACAD*11/24/10 11:01 AM Rev:12.23

SOLARI 1.she

1 20 B C

21

40 56-003

Only 5650 - 5690 with combined instrument gauge: Resistor 68 Ohm at connector X1, pin 8 (input temperature transducer engine oil).

H 34

307.1133.3.6 englisch (en) 10.2006

H Service Training

colour

32

33

34

30

31

function allocation

35

X20

GE

SW

NAT

GE

X40

SW

X19

NAT

20

X39

ELB

19

X18

X17

X13

X12

X16

X11

X14

X25

HBL HRT DBR

DRT DGN

OR

HBR HGN

38

39 40

36

37

C

B connector connector no. design 1 X1

HRT HGN HBR

18

X38

29

HBL

17

X37

28

OR

16

X36

27

HGN DBL

15

X34

26

14

X33

25

24

13

X32

SW

12

X35

GE

11

X31

HGN

X30

X28

OR

X29

X27

HBL DRT HGR NAT DGR ELB

NAT DGR

23

10

X10

9

X9

8

X8

X7

X6

7

X15

X23

22

6

X26

X4 SW

5

X24

X3 DGN

HGR DBL

21

4

X2

C

3

GE

WS

X22

front

X1

B

2

X21

1

X5

5650H – 5690HTS Lower multistrip connector, rear (B) and front (C), pneutron connector

connector connector no. design 21 X21

colour HGR

function allocation Speed sensor elevator; rear outline marker lamp; switch straw chamber; lighting sieve pan, - tail Grain loss sensors; wheel sensor LH 1000; CAN bus

WS

Engine: Terminal W, D+; Starter; sensors motor monitoring Engine: Temperature transmitter hydraulic oil, switch cooling fan, air filter

22

X22

DBL

Drum variator, sensor straw walker speed, grain tank tube; switch air filter; cooling compressor; rear working light Flasher lamps; sensor, chopper flap, chopper speed, fuel tank; reverse gear horn; sensors returns elevator Servo-motor chopper flap; key switch lower sieve open - close

23

X23

NAT

not allocated

24

X24

DGR

not allocated

25

X26

OR

2

X2

GE

3

X3

DGN

4

X4

SW

5

X5

HBL

6

X6

DRT

EMR: Solenoid valve accumulator; pressure sensor; transmitter feed passage

26

X15

HGN

7

X7

HGR

Cutting mechanism: reel variator; potentiometer for touching skids

27

X27

GE

Cutting mechanism: Speed sensor reel; solenoid valve colza cutter left

8

X8

NAT

Engine control EEC; CAN -BUS SAEJ1939

28

X28

SW

Electric system balance: Connection to EMR

9

X9

DGR

Solenoid valves working hydraulics

29

X29

HBL

Electric system balance

10

X10

ELB

Solenoid valves working hydraulics

30

X30

HRT

Electric system balance

11

X25

HGN

EMR: Regulating valve cutting mechanism, solenoid valve Autocontrol

31

X31

DBR

Electric system balance

12

X11

DBL

Grain tank: Interior light, sensors, working light

32

X35

ELB

Servo-motors concave open - close

13

X12

OR

Front lighting: flasher light, position lights

33

X32

NAT

Cabin: bugle, flasher-, position lights, projectors, brake light switch

14

X17

HBL

Speed sensors: Threshing drum, blower, sieve pan, ground sensors feed passage

34

X33

SW

Central lubrication; auxiliary heating

15

X14

HRT

Cabin roof - lighting

35

X34

GE

Cabin roof: Cooling system, wind screen wipers, working lights

16

X16

HGN

Belt clutches

36

X36

DRT

Turbo separator: Servo-motor, speed sensor

17

X13

HBR

Adjustment rear-view mirror

37

X37

DGN

18

X18

SW

not allocated

38

X38

OR

Feed passage: sensor LH 1000, speed sensor, relay K98; servo-motor wind variator; inductive sensor gear-shift mechanism Allwheel – electric system

19

X19

NAT

not allocated

39

X39

HBR

Allwheel – steering angle sensor

20

X20

GE

not allocated

40

X40

HGN

Allwheel – speed sensor, -solenoid valve

307.1133.3.6 englisch (en) 10.2006

Servo-motor straw spreader; key switch upper sieve open - close Servo-motor upper-, lower sieve

H 35

H Service Training

5650H – 5690HTS Lower rear multiple contact strip (B)

pin configuration connector 1 to 10 Inside of control cabinet

push-button

push-button

left rear and trailer

br ,

bl

switch coolant level _

switch coolant level +

5670: cylinderhead temperature

H 36

307.1133.3.6 englisch (en) 10.2006

H Service Training

pin configuration connector 1 to 10 Outside of control cabinet

5650H – 5690HTS Lower rear multiple contact strip (B)

extend/retract grain tank tube

push-button

push-button

reverse gear horn left rear and trailer

sw

br switch coolant level _

switch coolant level +

5670: cylinderhead temperature

307.1133.3.6 englisch (en) 10.2006

H 37

H Service Training

5650H – 5690HTS Lower rear multiple contact strip (B)

H 38

pin configuration connector 11 to 20 Inside of control cabinet

307.1133.3.6 englisch (en) 10.2006

H Service Training

pin configuration connector 11 to 20 Outside of control cabinet

307.1133.3.6 englisch (en) 10.2006

5650H – 5690HTS Lower rear multiple contact strip (B)

H 39

H Service Training

5650H – 5690HTS Lower front multiple contact strip (C)

H 40

pin configuration connector 21 to 30 Inside of control cabinet

push-button switch

push-button switch

push-button switch

push-button switch

307.1133.3.6 englisch (en) 10.2006

H Service Training

pin configuration connector 21 to 30 Outside of control cabinet

push-button switch

5650H – 5690HTS Lower front multiple contact strip (C)

push-button switch

supply push-button switch

push-button switch

307.1133.3.6 englisch (en) 10.2006

H 41

H Service Training

5650H – 5690HTS Lower front multiple contact strip (C)

pin configuration connector 31 to 40 Inside of control cabinet

gn-ge 1,0

to push-button switch

H 42

307.1133.3.6 englisch (en) 10.2006

H Service Training

pin configuration connector 31 to 40 Outside of control cabinet

5650H – 5690HTS Lower front multiple contact strip (C)

sw-ge 2,5

to push-button switch

307.1133.3.6 englisch (en) 10.2006

H 43

H Service Training

5650H – 5690HTS Multiple contact strip under the control console Connector plug configuration X190, X191, X192

multi-function handle

reverse gear sensor

neutral position sensor

– Control cabinet –

56-029

Connector plug configuration X515 Foot switch pin configuration X515, from switches

GE X515

bl

1 sw/rt

2

switch S55 hand brake

foot switch S28 foot switch S23 all-wheel anti-slip control grain tank clutch

5 br

6

sw

3

vio/ge

4

or/gn

foot switch S22 cutting mechanism stop

8

7

ground

ground

pin configuration X515, to control cabinet or/gn

2

bl

4

sw/rt

GE

1

X515

foot switch S22 cutting mechanism stop

foot switch S23 grain tank clutch

switch S55 foot switch S28 all-wheel anti-slip control hand brake

5

6

3

br

ground

vio/ge

3

8

br

ground

56-070 H 44

307.1133.3.6 englisch (en) 10.2006

H Service Training

MED_ACAD*11/24/10 11:01 AM Rev:12.23

SOLARI 1.she

X192 HRT X191 HGN X190 HBL X515 GE

H003

307.1133.3.6 englisch (en) 10.2006

H 45

H Service Training

34939-2

C

MED_ACAD*11/24/10 11:01 AM Rev:12.23

SOLARI 1.she

56-114

A B

56-018-1

H 46

56-062

307.1133.3.6 englisch (en) 10.2006

H Service Training

5650H – 5690HTS Distributing connector engine frame A Pneutron connector Connector no. Connector id. 1

X140

Colour WS

function allocation Rear flasher light, tail- /brake lights Returns elevator

2

X141

GE

Flasher, tail / brake lights trailer

3

X142

SW

Cooling system, Straw chamber warning flap,

4

X143

HRT

sensors grain tank tube / straw guide plate,

5

X147

HBR

push-button switch sieve operation

6

X144

HGN

sieve actuators

7

X145

OR

potentiometer / deflector drive, chopper

8

X146

HBL

potentiometer / straw guide plate drive

Speed sensor chopper, Lighting hydraulic oil temperature sensor, Lighting sieve pan

B AMP grain loss sensory system connector PIN

colour

5

rt

grain loss sensor sieve pan

function allocation

Cable harness junction box gn/ge

4

ge

wheel sensor for LH 865 and LH 1000

sw 4

3

bl

grain loss sensor straw walker

sw 3

2

ws

power supply grain loss sensory system

sw 2

1

br

ground grain loss sensors

sw 1

returns sensor with TERIS/TCS

C trailer plug socket PIN

colour

function allocation

1/L

sw/ws

flasher light left

2/54g

–

not used

3/31

br

ground

4/R

sw/gn

5/58R

gr/rt

tail light right

6/54

sw/rt

brake lights left/right

7/58L

gr/sw

tail light left

307.1133.3.6 englisch (en) 10.2006

flasher light right

H 47

H Service Training

5650H – 5690HTS multiple contact strip at engine frame engine cable harness side (coming from control cabinet)

left rear

H 48

push-button switch

push-button switch

push-button switch

push-button switch

right rear

307.1133.3.6 englisch (en) 10.2006

H Service Training

5650H – 5690HTS multiple contact strip at engineframe hood cable harness side

push-button

push-button

push-button

push-button

right rear

307.1133.3.6 englisch (en) 10.2006

left rear

H 49

H Service Training

5650H – 5690HTS pin configuration actuator connectors

t

H 50

1

307.1133.3.6 englisch (en) 10.2006

H Service Training

Notes

307.1133.3.6 englisch (en) 10.2006

H 51

H Service Training

1

2

56-030

H 52

307.1133.3.6 englisch (en) 10.2006

H Service Training

5650H – 5690HTS Schematic diagram CAN bus Commander Control 2000 with combined instrument gauge

A25

CAN module deflector adjustment

A26

CAN module straw guide plate adjustment

A30

Commander Control 2000

B40

combined instrument gauge

K16

relay chopping

K17

relay deflectors left

K37

relay long straw

K38

relay deflectors right

M12 deflector servo-motor M13 straw guide plate servo-motor 1

120Ω load resistor: terminal connector (pin 7, 8) in control console

2

120Ω load resistor: connector X22 (pin 5, 6) at outside of control cabinet

The Commander Control 2000 is responsible for the following functions: – Operation – Monitoring (speeds) – Display (Commander Control 2000 and combined instrument gauge) The display functions of the combined instrument gauge are controlled by the Commander Control 2000.

307.1133.3.6 englisch (en) 10.2006

H 53

H Service Training

5650H – 5690HTS Schematic diagram CAN bus Commander Control 2000 with TERIS/TCS

A11

TCS job computer

A14

stabilized power supply unit (SMPS)

A15

keyboard

A16

inclinometer (fan control TERIS/TCS)

A17

terminal with load resistor 120 Ohm

A21

display unit steering column

A22

printer

A25

CAN module deflectors

A26

CAN module straw guide plate

A27

CAN module sieve adjustment

A30

Commander Control 2000

X22

load resistor 120Ω in connector X22, outside of control cabinet

Observe proper mounting position!

connector pin assignment inclinometer A16 connection

cable colour to SMPS

cable colour at inclinometer

PIN

from A14.6

rt/sw

br

1

to job computer connector B.17 from A 14.2

signification inclinometer power supply 5V

bl

bl

2

inclinometer signal

br/ws

sw

3

inclinometer ground

connector pin assignment SMPS A14 (stabilized power supply unit) colour

PIN

signification

br/ws

1

ground stabilized for printer

br/ws

2

ground stabilized for PC-keyboard and inclinometer

br/ws

3

ground stabilized for job computer connector A.12

br

4

ground SMPS

rt/gr

5

5 V stabilized printer

rt/sw

6

power supply 5V for PC-keyboard and inclinometer

rt/ws

7

12 V stabilized job computer connector A.11

sw

8

power supply SMPS

pin configuration A14

fuse 10 AP

H 54

8

7

6

5

4

3

2

1

LEDs for output Stabilised voltage 1 x 12 V, 2 x 5 V

LED for supply 12 V

307.1133.3.6 englisch (en) 10.2006

H Service Training

A25

56-031

307.1133.3.6 englisch (en) 10.2006

H 55

H Service Training

switch operation deflectors left

CAN module deflectors A25 relay K17 deflectors left

M12

light deflectors left outside

light deflectors left centre

actuator deflectors with potentiometer light deflectors right centre

relay K38 deflectors right

light deflectors right outside

switch operation deflectors right

56-033

H 56

307.1133.3.6 englisch (en) 10.2006

H Service Training

5650H – 5690HTS Schematic diagram electrical deflector adjustment chopper

A25

CAN module deflector adjustment

A30

Commander Control 2000

K17

relay deflectors left

K38

relay deflectors right

M12 actuator deflectors with potentiometer

pin configuration: DI DO AI AO

digital IN digital OUT analog IN analog OUT

designation: D O / 1 ( 11 ) pin no. channel digital OUT

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5650H – 5690HTS Schematic diagram electrical straw guide plate adjustment

A26

CAN module straw guide plate

A30

Commander Control 2000

K16

relay chopping

K37

relay long straw

M13

actuator

pin configuration: DI DO AI AO

digital IN digital OUT analog IN analog OUT

designation: D O / 1 ( 11 ) pin no. channel digital OUT

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operation of deflector switch (S66) in position "chopping”

CAN Module deflector

relay K16 chopping

actuator M13 deflector with potentiometer

operation of deflector switch (S66) in position "long straw deposit”

relay K37 long straw

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keyswitch upper sieve open S70

S70

CAN module CAN-Modul sieve adjustment Siebverstellung

relay upper sieve open K41

K41

A27 A27 keyswitch upper sieve close S69

S69

keyswitch lower sieve open S72

S72

keyswitch lower sieve close S71 S71

actuator upper sieve with potentiometer M17 M17

relay upper sieve close K20

K20

relay lower sieve open K83

K83

actuator lower sieve with potentiometer M18

M18

relay lower sieve close K62 K62

56-032

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5650H – 5690HTS Schematic diagram electrical sieve adjustment control

A27

CAN module sieve adjustment

A30

Commander Control 2000

K20

relay upper sieve close

K41

relay upper sieve open

K62

relay lower sieve close

K83

relay lower sieve open

M17 actuator upper sieve with potentiometer M18 actuator lower sieve with potentiometer S69

key switch upper sieve close (behind at the toolbox)

S70

key switch upper sieve open (behind at the toolbox)

S71

key switch lower sieve close (behind at the toolbox)

S72

key switch lower sieve open (behind at the toolbox)

pin configuration: DI DO AI AO

digital IN digital OUT analog IN analog OUT

designation: D O / 1 ( 11 ) pin no. channel digital OUT

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5650H – 5690HTS Wiring diagram CAN bus system Com. Contr. with combined instrument gauge

A25

CAN module deflector adjustment

UNIT 19

A26

CAN module straw guide plate adjustment

UNIT 19

A27

CAN module sieve adjustment

UNIT 19

A30

Commander Control 2000

UNIT 18

1

Terminating resistor 120 Ω at terminal connector in the control console

2

Terminating resistor 120 Ω at connector X22 control cabinet outside

Resistance CAN bus line with 2 terminating resistors 120 Ohm CAN bus participant Without A30, without CAN-Module

Measuring value 60 Ohm

With A30, without CAN modules

44 Ohm

With A30 and 1 CAN module

35 Ohm

With A30 and 2 CAN modules

29 Ohm

Internal resistance of CAN bus participants Com. Control A30, pin 94 - 95 163 Ohm CAN module, pin 4 - 12

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163 Ohm

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95

94

1

2

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H

95

94

Service Training

1

56-027

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5650H – 5690HTS Wiring diagram CAN bus system with Commander Control 2000 and TERIS/TCS A11

job computer

UNIT 8-13

A17

terminal

UNIT 0-3

A21

throughput display steering column

UNIT 26

A25

CAN module deflector adjustment

UNIT 19

A26

CAN module straw guide plate adjustment

UNIT 19

A27

CAN module sieve adjustment

UNIT 19

A30

Commander Control 2000

UNIT 18

1

Terminating resistor 120 Ω at connector X22 control cabinet outside

Resistance CAN bus line with 1 terminating resistor 120 Ohm CAN bus participant

Measuring value

Without A17, without A30, without CAN modules

120 Ohm

With A17, without A30, without CAN modules

60 Ohm

With A17, A30, without CAN modules

44 Ohm

With A17, A30 and 1 CAN module

35 Ohm

With A17, A30 and 2 CAN modules

29 Ohm

With A17, A30 and 3 CAN modules

24 Ohm

Internal resitance of CAN-Bus partcipans Terminal A17, pin 7 - 8

120 Ohm

Com. Control A30, pin 94 - 95

163 Ohm

CAN module, pin 4 - 12

163 Ohm

The internal resistance of job computer A11 and display unit A21 is in the kOhm range.

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5650H – 5690HTS Function and programming of CAN modules The CAN modules (part number: 16057402) for controlling of the deflectors, the straw guide plate and the sieves serve for supporting of the Commander Control 2000. The modules are working in remote control mode, i.e. they cannot perform any controlling actions without the master computer, which in this case means without the Commander Control 2000. The Software of the modules is only able to execute commands which are transmitted via CAN bus.

Example The illustration opposite shows a flow chart as an example. The Commander Control 2000 (A30) is supposed to further open the upper sieve (open 5 mm). The actuator is connected to CAN module A27. For this purpose the following command sequence is necessary: 1. 2. 3. 4.

A30: A27: A30: A27:

"A27, "A30, "A27, "A30,

switch on connection DO/1 (relay upper sieve open)”. connection DO/1 (relay upper sieve open) is switched on”. send voltage from connection AI/1 (potentiometer upper sieve)”. voltage at connection AI/1 (potentiometer upper sieve) amounts to 3,6V”.

A30 now performs the control and compares the actual voltage of A27.AI/1 with the nominal voltage. For this purpose several requests for voltage measuring are sent to A27, and A27 continually communicates the actual voltage to A30. If actual voltage and nominal voltage are identical the report is as follows: 5. 6.

A30: "A27, disconnect connection DO/1 (relay upper sieve open)”. A27: "A30, connection DO/1 (relay upper sieve open) is disconnected”.

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Upper sieve open 5mm

A30: A27, activate DO/1! (relay upper sieve open)

A27: A30, DO/1 (relay upper sieve open) is activated.

A30: A27, send voltage AI/1!

A27: A30, voltage AI/1 = ... V

A30 U AI/1 = Usetp ?

no

yes A30: A27, deactivate DO/1! (relay upper sieve open)

A27: A30, DO/1 (relay upper sieve open) is deactivated.

Upper sieve is open 5mm

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5650H – 5690HTS Function and programming of CAN modules

All modules are physically identical and mutually exchangeable. All modules are equipped with the same software The only difference is the CAN bus address the modules and thus also the functions can be accessed with. This operational address is assigned from Commander Control 2000 by setup. For this purpose the Commander Control 2000 transmits the future operational address with a special message to the programming address of the module. The programming address is identical with all modules, for this reason observe that only one module is connected during this process. The operational address can be reassigned anytime via the Commander Control 2000, it is therefore possible to mutually exchange the modules of a machine.

Programming procedure (upon upgrading or exchange of a module): 1. 2. 3.

4. 5.

only 5670: Switch off Diesel engine Switch off ignition Unplug the modules which are not to be programmed, only one remaining module is allowed to be connected to the CAN bus (the slot position however does not matter for programming, as only the CAN bus and the power supply are used) Switch on ignition (Do not start Diesel engine!!) Press the right push button and the right push button at Commander Control 2000 simultaneously, the program enters the "setup”

By means of these push buttons:

By means of these push buttons:

Both push buttons pressed simultaneously:

--> Select page

--> Select line

--> Call setup

--> Quit menu

By means of the push buttons: --> Confirm selection

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5650H – 5690HTS Function and programming of CAN modules The LC display now shows the following screen: number of pages in this menu

current page

Setup

1/3

Language:: english Language

Front tires: R adial 650/75R32 Turbo separator: yes LCD View angle;

5

screen 2 --> Switch over to page 3 by means of one of the left push buttons or :

Setup

3/3

El.sieve adj.:

yes

El.straw guid:

yes

El.spre a. dp .l p.l:.: El.spre ad

no

Eng.sp. factor:

3.32

Selected line

screen 3 --> Change to the corresponding line by means of one of the centre push buttons or and confirm by means of one of the right push buttons or :

Setup

3/3

El.sieve adj.: New address Et lraw .sieve adj.: El.s guid:

yes

El.spread.pl.: Eng.sp. factor:

yes no yesno 3.32

screen 4

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5650H – 5690HTS Function and programming of CAN modules For programming change over to "yes” by means of one of the centre push buttons or and confirm by means of one of the right push buttons or bestätigen:

Setup

3/3

El.sieve adj.: New address Et lraw .sieve adj.: El.s guid:

yes

El.spread.pl.: Search module Eng. sp. factor:

yes no yesno 3.32

screen 5 --> If no module could be found the highlighted bar remains on "no” as shown in screen 4. If the module logs in correctly to the CAN bus the highlighted bar changes to "yes”:

Setup

3/3

El.sieve adj.: New address Et lraw .sieve adj.: El.s guid:

yes

El.spread.pl.: Search module Eng. sp. factor:

yes no yesno 3.32

screen 6 --> Confirm with one of the right push buttons or . The operational address is transmitted from the Commander Control to the module and stored into a nonvolatile memory (EEPROM) of the module:

Setup

3/3

El.sieve adj.: New address Et lraw .sieve adj.: El.s guid:

yes

El.spread.pl.:

yes no yesno

Send Adresse Eng. sp. factor:

3.32

screen 7

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5650H – 5690HTS Function and programming of CAN modules The setup can be quit by means of simultaneously pressing the left push buttons and . --> Switch off ignition --> Reconnect all devices The module is now logged on to the Commander Control and all the related functions and diagnostic pages are ready to operate:

CAN diagnosis

1/4

El. adjustment: Top sieve Potentiomet. Cal. min Cal. max Actual value Extend button R etract button R el.:Extend " R el.:Retract screen 8 In case of a module failure a corresponding error message will be displayed by the Commander Control 2000:

Error Sieve adjusting is not addressable

screen 9

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5650H – 5690HTS Function and programming of CAN modules Deactivation of a function with CAN module If for some reason one of the modules cannot be accessed any more and no spare parts are available (or the machine must be downgraded), the affected module must be logged out from the Commander Control. As a result, unsubstantial error messages will be avoided. Logging out of a CAN module: --> Switch on ignition --> Press the right push button and the right push button at the Commander Control 2000 simultaneously, the program enters the "setup”

Setup

1/3

Language: english Front tires: R adial 650/75R32 Turbo separator: yes LCD View angle;

5

screen 10 --> Switch over to page 3 with one of the left push buttons or :

Setup

3/3

El.sieve adj.:

yes

El.straw guid:

yes

El.spreaadd..ppll..::

no

Eng.sp. factor:

3.32

screen 11

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5650H – 5690HTS Function and programming of CAN modules Change to the corresponding line by means of one of the centre push buttons or and confirm with one of the right push buttons or :

Setup

3/3

El.sieve adj.: New address Et lraw .sieve adj.: El.s guid:

yes

El.spread.pl.: Eng.sp. factor:

yes no yesno 3.32

screen 12 --> Confirm by means of one of the right push buttons or in order to log out. Now the corresponding module is not known any more by the Commander Control 2000 and the functions and diagnostic pages are not ready any more, error monitoring is not activated any more for this module.

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A

56-001

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5650H – 5690HTS Connector pin assignment at job computer signal

Connector Asignification

colour

signification

colour

signal

spreader drum speed*

gr-rt

inductive

12

ground stabilized

br-ws

0V

11

ignition stabilized

rt-ws

12V

5

CAN-GND

sw

0V

4

CAN-H

bl

data

3

GPS/printer TxD

gr

data

2

yield logger TxD

gn

data

1

screen power supply

ws

12V

Pin No. 18

35 17 34 16 12V/4V

br-ws

elevator speed

33 15 32 14 31 13 30

0V

br-ws

ground stabilized

29 28 10 27 9 26 8 25 7 24 6 23

data data data 0V

rt ro ge

CAN-L GPS/printer RxD yield logger RxD

br

screen ground

22 21 20 19

* only for 8XL

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5650H – 5690HTS Connector pin assignment at job computer Connector B signal

colour

signification

signification

colour

signal

17

fan inclinometer

bl

0V...5V

16

engine oil temperature

sw-vi

0V...12V

15

ground drive hydr. temp. bl-vi

0V...12V

14

fuel tank level

vi-ws

0V...12V

9

turbo separator speed

ws-vi

12V/4V

8

conveyor auger speed* bl

12V/4V

6

sieve pan speed

ws-rt

12V/4V

5

partial width +

gn-vi

12V/0V

4

returns load

vi-sw

impulses

3

straw walker loss sensor bl

Pin No. 18 35

2,4-7,1V 0V.12V 2V...6V

sw-bl angle sensor feed passage bl-gn gn-ge

coolant temp. transmitter cutting angle transmitter

34 33 32 31 13 30 12 29 11 28 10 27 26 25 7 24

12V/0V

gn-ge

partial width -

23 22

impulses

rt

sieve pan loss sensor

21 impulses

20 2 19 1 * only for 8XL

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B

56-001

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C

56-001

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5650H – 5690HTS Connector pin assignment at job computer signal

colour

signification

Connector C Pin No.

signification

colour

signal

18

signal MW skid centre or

2,4.7,1V

17

processing hydraulics temp.

bl-vi

35 0V.12V

gn-vi cutting mechanism hydr. temp.*

34

0V..12V

(Sensor not mounted) 16

33 15 32 14

impeller speed**

ws-rt

12V/4V

feed passage speed

ws-ge

inductive

31 13 30 12 29 11 28 10 27 9 12V/0V

rt-ws

indicator light fan control

26 8 25 7 24 6 23 5 22 4 21 3 20 2 19 1

* only for 8XL ** only with synchronous drive of impeller

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2

1 2 3 4 5 6 7 8

CAN-Modul

1

9 10 11 12 13 14 15 16

A25

CAN module deflector adjustment

A26

CAN module straw guide plate adjustment

A27

CAN module sieve adjustment relay lower sieve close (K62) relay upper sieve close (K20)

key switch upper sieve open key switch upper sieve close

key switch lower sieve open key switch lower sieve close

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5650H – 5690HTS Connector pin assignment CAN modules 1

CAN module

2

Connector

Technical data CAN modules: Power supply:

10...16V (computer works down to approx. 7Volt), approx. 90mA/13,8V (without loads). Reverse battery protection, transient protection, optional 24-V operation.

Sensor supply:

8 Volt, 100mA

Internal diagnosis:

BV sensor supply can be read back

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5650H – 5690HTS Combined instrument gauge 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Straw chopper – speed Grain tank unloading tube Straw chamber (straw walker) Returns elevator Grain tank – level display Air filter – engine Cylinder head temperature – engine, resp. engine oil temperature Central warning light Parking brake Cooling fan – belt engine 5670 Oil pressure – engine Main beam Charge control Direction-indicator – transport trailer direction-indicator – combine harvester Fuel tank level – Diesel Oil temperature – engine (continually) Ground speed

When switching on the ignition lock to pos. I all indicator lights (position 1-11 and 13) are lit for approx. 3 sec., simultaneously the acoustic warning signal (buzzer) is sounding. During the operation a failure is indicated by activating the individual lights in the combined instrument gauge, simultaneously the buzzer is sounding in conjunction with flashing of the central warning light (pos. 8). Additionally, a warning message will appear in the Commander Control display. Except for the temperature switches for cylinder head and engine oil, all transmitters (sensors) are equipped with normally closed contacts to ground. In this way also a damage in the wire system (cable connections) will be indicated as a failure.

Connection diagram – connector pin assignment Connector X171 (sw)

Connector X170 (ws) pin

cable colour function

pin

cable colour function

1

ws

1

vi/ws

Fuel tank level – Diesel (16)

Main beam (12)

2

bl

Charge control (13)

2

sw/vi

Oil temperature – engine (17)

3

bl/ws

Direction-indicator

3

gn/sw

Straw chopper – speed (1)

transport trailer (14)

4

ws/bl

Control grain tank unloading tube (2)

4

bl

Direction-indicator

5

ge/rt

Straw chamber (3)

combine harvester (15)

6

bl/gr

Returns elevator (4)

5

sw

Plus 12V

7

or

Grain tank level display (5)

6

ws/rt

Ground speed

8

gn

Air filter – engine (6)

7

sw/ge

Central warning light (8)

9

bl/sw

Cylinder head temperature – engine (7)

8

sw/rt

Parking brake (9)

10

br

Ground

9

bl/rt

Cooling fan – engine (10)

11

br/rt

Terminal G

10

–

not used

12

gr

Lighting combined instrument gauge

11

bl/ge

Oil pressure – engine (11)

12

–

not used

*

equipped with TERIS/TCS a cable * When jumper must be connected from pin 10 to pin 11 at the connector X171 (connector II, black) of the combined instrument gauge.

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Transmitters – sensors

Combined instrument gauge

Commander Control 2000

engine oil temperature

Limit transmitters (switches)

position straw guide plate

buzzer fuel tank level

straw chamber – straw walker

AHS Page Working master switch B40

B7 individual light

central warning light

A30

returns elevator left/right grain tank level engine fan v-belt engine air filter engine cylinder headtemperature, oil temp. engine oil pressure terminal D+, W

ground speed

parking brake grain tank tube coolant level

Threshing drum Fan Reel

56-068

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5650H – 5690HTS Combined instrument gauge and Commander Control 2000 Overview monitoring and operation functions A8

Clutch control power unit CCP II for clutches

A30

Commander Control 2000

AHS Working master switch S40 B7

Buzzer

B40

Combined instrument gauge

K98

Relay reversing motor

M19 Reversing motor S43

Switch reversing device

relay sets: K50, K71 Grain tank tube swing out/swing in Speed adjustment: K14, K35 Relay set reel variator K15, K36 Relay set fan variator K56, K77 Relay set threshing drum variator Concave clearances: K18, K39 Relay set concave front K19, K40 Relay set turbo separator up/down K60, K81 Relay set concave rear

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5650H – 5690HTS Diagram inputs/outputs Commander Control 2000

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inductive sensors speed acquisition: reel, threashing drum, blower

inductive sensor (speed monitoring): straw walker, returns, filter auger, chopper

switch (condition monitoring): cylinder head- /coolant temperature, -level, engine oil excess temperature, engine oil pressure, cooling fan, air filter, hand brake, straw chamber, returns

H

Service Training

56-044

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5650H – 5690HTS Connector pin assignment A30, Commander Control 2000

34

45

51

56

46

52

63

67

72

64

68

466204

60 57

61

466203

40 35

41

466205

27

16

26 17

10 1

11

Connector view seen from cable side

93

100

86

94

466206

80

85

73

81

IFM sensor filter auger speed

56-065-1

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5650H – 5690HTS Connector pin assignment A30, Commander Control 2000

34

45

51

56

46

52

63

67 64

68

93

100

466204

72

60 57

61

80

85

466203

40 35

41

466205

27

16

26 17

10 1

11

Connector view seen from cable side

94

86

73

81

466206

Coolant level

Revolving light upon grain tank full

supply potentiometerservo motor turbo separator up/down

56-065-2

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1

2

3

A

5

4

B

6

LED

C

LED

D E

F

56-053

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5650H – 5690HTS Function monitoring with the Commander Control 2000 The Commander Control 2000 (4) monitors and acquires speeds and operating conditions of the combine harvester by means of switches and sensors. Speed monitoring: Evaluation of switching frequencies which are induced by a turning shaft inside of inductive sensor (B). Operating conditions: Monitoring is done with closed circuit systems. Upon normal operation the circuit between Commander Control 2000 and switch/sensor is closed. Upon interruption of this circuit either when the sensor has responded or wire break is existing or a switch/sensor is defective, the Commander Control 2000 indicates a warning message: Display (5), combined instrument gauge (1) or buzzer (3). Exception: The temperature switch (E) for cylinderhead resp. for coolant and engine oil: Switch contacts close against ground when exceeding the limit temperaturight

Function of terminal D+ und W of the generator: terminal D+:

- Function monitoring of generator (charge control). - Release of the belt clutches in connection with the working master switch (upon voltage drop at terminal D+ all belt clutches will be disengaged).

terminal W:

- Monitoring, acquisition of engine speed. - Release of the threshing mechanism clutch if engine speed is less than approx. 1500 min-1.

Legend: 1

Combined instrument gauge or monitor TERIS/TCS

2

Generator

3

Buzzer

4

Commander Control 2000

5

Display

6

Pulse transmitter (mounted on shaft)

A

Inductive transmitter shift gear

B

Inductive sensor as speed sensor

C

Inductive sensor as monitoring switch

D

Mechanical monitoring switch

E

Temperature switch at engine

F

Capacitive transmitter for grain tank level

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5650H – 5690HTS Switches and sensors for monitoring A

Inductive transmitter in the gear box cover for acquisition of the ground speed. Control dimension upon mounting: air gap 1±0,5 mm between sensor and toothed wheel. Internal impedance of the sensor: R = 1,05 kΩ ±100Ω Insulation against housing > 500kΩ In the case of TERIS/TCS the cutting mechanism drive is monitored with an inductive transmitter at the gear rim of the reversing device.

B

Inductive sensor for monitoring and acquisition of speeds. Control dimension upon mounting: air gap 4 mm between pulse transmitter (6) and head of sensor. The LED is lit, when the pulse transmitter (6) covers the sensor head.

Speed sensors: - Straw walker - Elevator head - Returns elevator - Chopper - Threshing drum - Blower - Reel drive - sieve pan oscillating arm - turbo separator

C

speed monitoring by means of Commander Control 2000

speed display and control of speed adjustment by means of Commander Control 2000 only with TERIS/TCS

Inductive sensor as monitoring switch Control dimension upon mounting: air gap min. 4 mm between head of sensor and lever, grain tank tube etc. Sensor grain tank tube:

LED is lit when grain tank tube is swung in. - As long as the grain tank tube is not completely swung in, the indicator light no. 2 in the combined instrument gauge is lighting. - The grain tank clutch is automatically disengaged when the grain tank tube is swung in (indicator light no. 2 is extinguishing). Upon defective sensor or wire break the grain tank clutch function is blocked.

Sensor grain tank top:

LED is lit when the grain tank extension is lowered and the grain tank cover is closed. - Warning message in display if: - grain tank top open - Threshing mechanism and working master switch off - Ground speed > 2 km/h

Sensor straw guide plate: LED is lit when the straw guide plate is adjusted to long straw. In chop position the sensor is activating the following functions: - Indicator light (3) at the control console is lit (see fig. control console). - Actuation of the chopper clutch upon engaging and disengaging of the threshing mechanism. - Speed monitoring for the chopper.

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1

2

3

A

5

4

B

6

LED

C

LED

D E

F

56-053

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1

2

3

A

5

4

B

6

LED

C

LED

D E

F

56-053

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5650H – 5690HTS Switches and sensors for monitoring D

Mechanical monitoring switches

Monitored function

type of switch*

Straw chamber straw walker 2 x Cover returns elevator 2 x Hand brake cooling fan belt (engine BF6L.913 C) Oil pressure switch engine Low-pressure switch air filter

normally normally normally normally normally normally

closed opened opened closed opened closed

* Switching status of the switch when operated away from its neutral position. Normally closed: switch contacts are opening upon operation Normally opened: switch contacts are closing upon operation

E

Temperature switch for cylinder head/coolant and engine oil (5650 - 5690) Switch contacts are closing when temperature limits are exceeded (exception from closed circuit concept).

F

Capacitive transmitter for grain tank level The capacitive transmitter is opening against ground (pin 2 to 3), when it is covered by the cone of grains. Simultaneously the red LED on top of the transmitter is extinguishing and the Commander Control 2000 is initiating the alarm message. One or two transmitters may be mounted in the grain tank. Design with one transmitter:

When the grain tank is full indicator light no. 5 in the combined instrument gauge is lit, the buzzer and the revolving lights are activated.

Design with two transmitters:

1. transmitter: Warns if grain tank is 3/4 full, indicator light no. 5 is flashing, revolving lights are operated in interval. 2. transmitter: Warns if grain tank is completely full, indicator light no. 5 is lit, buzzer and revolving lights are activated.

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5650H – 5690HTS Functional description inductive sensor The inductive sensor (1) is an electronic switch which changes its switching status when the distance Ds (switching distance) between a metal body (2) and the sensor head exceeds or falls below approx. 8mm. In this way the position of levers or flaps or speeds can be monitored. Depending on the electrical pin assignment the inductive sensor is working as a normally opened or as a normally closed contact against ground. Normally opened:

when the sensor clearance falls below 8mm the sensor current rises to approx. 10mA; LED (3) is lit. (with a clearance >8mm the sensor current decreases to 0,5mA, LED (3) is extinguished)

Normally closed:

when the sensor clearance falls below 8mm the sensor current decreases to approx. 0,5mA; LED (3) is extinguished.

The LED (3) is always lit when the switching status is closed, independant from the the pin assignment. At the combine harvester all inductive sensors are connected as normally opened contacts. A minimum distance Dmin of at least 4 mm must be observed between the sensor head and the monitored functional element in order to prevent possible damage. The inductive sensor must not be connected to a 12V power supply without protection resistance (approx. 70 Ohm) as otherwise it will be destroyed. Maximum current load 400mA.

1 2 3 4

H 96

Inductive sensor Metal body LED AMP-connector 282 104-1

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1 Ds 8mm

2

Dmin > 4mm

3

4

+

+

S

SW

W

WS

–

–

NPN NPN

NPN NPN

switching against minus minusschaltend

switching against minus minusschaltend

normally opened function

normally closed function

Schliesserfunktion

Oeffnerfunktion

56-054

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5650H – 5690HTS Sensors, overview Sensors right side of the machine 1

Low-pressure switch air filter

2

Grain sensor straw walker (left and right)

3

Switch straw chamber warning flaps

4

Potentiometer in servo motor for deflectors

5

Speed sensor chopper

6

Sensor for straw guide plate position

7

Potentiometer in servo motor for straw guide plate

8

Grain sensor sieve pan

9

Wheel sensor for grain loss monitor and job computer LH 1000 (not applicable with TERIS/TCS)

10

Switch returns elevator cover

11

Speed sensor returns elevator

12

Throughput sensor returns elevator (only with TERIS/TCS)

13

Potentiometer in the servo motors upper-/lower sieve open/close (only TERIS/TCS)

14

Sensor sieve pan oscillating arm (only TERIS/TCS)

15

Speed sensor turbo separator (only TERIS/TCS)

16

Sensor ground speed in gear box

17

Angle transmitter balance axis

18

Pressure sensor for cutting mechanism control

19

Speed sensor intermediate shaft in feed passage (only TERIS/TCS)

20

Angle transmitter cutting angle of cutting mechanism (only with balance)

21

Position sensor feed passage for LH-1000 job computer (not applicable with TERIS/TCS)

22

Position transmitter feed passage for cutting mechanism control

23

Potentiometer in servo motor concave clearance rear

24

Brake light switch

25

Switch hand brake

26

Sensors for start interlock and reverse gear horn multifunction handle

27

Brightness sensor for grain loss monitor

28

Speed sensor grains elevator

29

Throughput sensor in elevator head (only with TCS)

30

Humidity sensor in grain tank filling tube (only with TCS)

31

Potentiometer in servo motor turbo separator up/down

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3

31

1

2

29,30

28

27

26 25 24 23 22 21

4

5

6

7

8

9

10

11 12

13

14 15 16 17 18 19 20

34939-3

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15

13

14

12

11

10

9

1

2

3

4

5

6

7

8

34940-1

13, 14, 15

21 16 19 17,18 20 17

56-017

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5650H – 5690HTS Sensors, overview Sensors left side of the machine 1

Potentiometer for touching skid

2

Speed sensor reel

3

Potentiometer in servo motor concave clearance front

4

Angle transmitter balance axis

5

Speed sensor threshing drum

6

Speed sensor blower

7

Switch returns elevator cover

8

Throughput sensor returns elevator (only with TERIS/TCS)

9

Speed sensor straw walker

10

Level transmitter fuel tank

11

Temperature sensor hydraulic oil (in hydraulic pump)

12

Sensor grain tank tube

13

Sensor grain tank top

14

Level transmitter grain tank completely full

15

Level transmitter grain tank 3/4 full

Sensors at the engine (sensors for EEC see chapter A) 16

Transmitter/switch cylinder head temperature - 5670: transmitter mounted in 1. cylinder head, switch mounted in 2. cylinder head. - 5650 - 5690: transmitter and switch one component.

17

Transmitter/switch engine oil temperature (with 5670 only temperature transmitter)

18

Oil pressure switch at the 5670

19

Oil pressure switch

20

Switch at tensioning pulley cooling fan belt (only engine BF6L 913C)

21

Coolant level sensor

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5650H – 5690HTS Multifunction lever Gear rack device / sensor adjustment 1

Wedge action socket

2

LED, lighting when in reverse motion

3

B46 inductive sensor for reverse gear horn

4

B45 inductive sensor for start interlock neutral position sensor (release all-wheel drive)

5

LED (functional check, not lighting in neutral position)

6

Gear rack device

7

Control disk

8

Bowden pull wire

V

= forward motion

R

= reverse motion

Adjustments at gear rack device and Bowden pull wire 1 - Mechanical zero position 2 - Electrical zero position 3 - Zero position at the hydraulic pump (see chapter D) These three adjustments must be consistent!

mounting advice: - Move the multifunction lever out of zero position to reverse motion position. - Screw in the inductive sensors via the wedge action sockets into the gear rack device until reaching the mechanical stop at the connecting member. - Turn back one whole revolution (thread M12x1) and secure with flat nut. - Move multifunction lever into forward as well as reverse motion. Minimum distance of active sensor surface to control disk: 1 + 0,5 mm. In neutral position of the multifunction lever the LEDs (2) and (5) must not be lit!

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0 V R

7

8 1+

0,

5

1

1

5 2 4

5

1

Ze N ulrlo stepllos unigtio n

3

, +0

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6

H 103

H

– to control cabinet –

– to control cabinet –

Service Training

56-067

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5650H – 5690HTS Multifunction lever Connector pin assignment B45 Neutral position sensor B46 Reverse motion sensor X190 - X192 Pneutron connector under control console X506, X512 21-pole connector in control cabinet

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H 105

A10

H 106

0VP

WS

K22

WS

VOY

S41

M/A

S28

24VP

WS

12VP

B47

B46

B45

A B B

86

1

SW

85 2

5 C

S40 S2

NC

output starter

output starter

reversing horn

A

8

7

6

C

5

output allwheel drive

output all-wheel drive on

output all-wheel drive M/A

input working master switch terminal 15a

input all-wheel drive

input differential lock

input sensor for 4th gear

input reverse motion sensor

input neutral position sensor

GND

terminal 15 12V

logic module start interlock reversing horn all-wheel

4

3

2

1

16

15

14

13

12

11

10

9

A13

H

Service Training

30 15 D+ 15a 15b

logic module start interlock reversing horn all-wheel

F19

50a

B48

SW

F22

SW

3 30

87

4

87a

starter

control unit all-wheel drive

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5650H – 5690HTS A13 logic module, connector pin assignment, function A13

Logic module

A10

Control unit all-wheel

B45

Sensor neutral at hand throttle

B46

Sensor reverse at hand throttle

B47

Sensor 4th gear

B48

Reverse gear horn

F..

Fuses

K22

Start relay

H39

Indicator light all-wheel on

S2

Start switch

S28

Foot switch slip control (diff. lock)

S40

Working master switch

S41

Switch all-wheel on

Pin

Designation

Cable colour

Measuring value

1

Input from A10 M/A

bl

11V/0V

2

Input 12V for control unit A10

rt

12V

3

---

4

Output A10 12VPA

bl/ws

2V/12V

5

Output relay K22, starter

sw/vi

0V/12V

sw/vi

0V/12V

6

---

7

NC, input start switch S2

8

Output reverse gear horn B48

vi

1,5V/12V

9

Terminal 15

sw

12V

10

Ground GND

br

0V

11

Sensor neutral B 45

sw

11V/4V

12

Sensor reverse B46

ws

11V/4V

13

Sensor 4th gear B47

vi/gr

11V/4V

14

Input switch S28, diff. lock

15 16

bl

11V/0V

Input switch S41, all-wheel on

sw/ws

10V/0V

Input working master switch S40, terminal 15a

sw/gn

12V

When foot switch S28 is actuated the logic module is connecting pin 1 to ground.

Function of logic module: 1.

Start interlock: Release of relay K22 upon neutral position of the multifunction lever by means of sensor B45

2.

Activation of the reverse gear horn B48 by means of sensor B46 upon position ‘reverse’ of the multifunction lever

3a

Release of activating the all-wheel drive by means of switch S41 if: - Working master switch S40 is on (terminal 15a) - Multifunction lever is in neutral position, B45 - the 4. gear is not engaged, B47

3b

Activation of slip control (differential lock) upon activated foot switch S28 and activated all-wheel drive S41.

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5650H – 5690HTS Control unit EEC Gas control unit 1

A1 control unit EEC

2

Connector at engine side

3

Connector at vehicle side

4

Gas control unit

5

Diagnosis plug-socket

6

LED UB, power supply voltage

7

LED VCC, power supply from EEC

8

LED TH/2, half throttle

9

LED TH/1, full throttle

10

LED SDW, threshing mechanism on = 15b, (LED on = threshing operation)

Notice: With full throttle and switched-on threshing mechanism all LEDs are lit.

A2 pin assignment Pin 1 2 3

Designation Input half throttle from S5 Input full throttle from S5 Pot. throttle ground

Cable colour gr/rt gr/bl br

4

Pot. throttle slider

ws/bl

5 6 7 8 9 10 11 12 13 14 15 16

Pot. throttle supply Input droop changeover from K11 Output droop changeover to A1 Ground droop changeover Supply 12V from control cabinet X8 Supply A1

ws/rt sw/gn ws/gn br sw sw

H 108

Supply for diagnosis connector Ground for diagnosis connector Ground for A1 Ground for A1 Ground for diagnosis connector

sw br br br br

Measuring value 0V/12V 0V/12V 1,2V idle throttle 2,8V half throttle 4,1V full throttle 5V 0V/12V digit 12V 12V 12V

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X8

MED_ACAD*11/24/10 11:01 AM Rev:12.23

SOLARI 1.she

1

Motor

Fahrzeug

2

3

7

16

9 1

8

6

4

56-116

4

56-055

8

9

5

10

4

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Notes

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5650H – 5690HTS Electronic cutting table control EMR-D Self-levelling control / AutoControl Function The EMR-D self-levelling control / AutoControl system is used for automatic control of the cutting table levelling system on the combine harvester. The electronic control unit EMR-D processes the actualvalue signals (position sensor, pressure sensor, tracker bar sensor), compares them with the predefined settings (operating control) and transmits the appropriate control signals to the control valves (for a more detailed description, please refer to the Operating Instructions). Components of the EMR-D Self-levelling control / AutoControl: – Electronic EMR-D control unit (in the control box) – EMR-D control valve (on left as seen in direction of travel, mounted on the grain tank next to the grain tank discharge tube) – Electronic tilt control unit, AutoControl (in the control box) – Tilt control valve (on left as seen in direction of travel, built into the control valve block, next to the grain tank tube) – Control panel (control box) – Control functions in the Commander Stick – Position sensor (mounted on the centre of rotation of the feed passage, to the right as seen in the direction of travel) – Pressure sensor with activating valve and pressure accumulator (mounted on the drive axle) – Tracker rod sensors (up to 3) (4 kΩ potentiometer on the front attachment) – Floating frame with hydraulic cylinders for tilt control (AutoControl) Note: Tilt control is also termed "lateral flotation" or "field tracking".

Switching logic Operating standby / "Diagnostic" standby (precondition for adjustment) 1. First calibration completed 2. Front attachment and electrical connector connected 3. Ignition switch to position (1) 4. Engine running 5. Working master switch 6. Threshing mechanism engaged 7. Desired operating mode selected 8. Automatic button in commander stick pressed

A00253

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5650H – 5690HTS Electronic cutting table control EMR-D Self-levelling control / AutoControl Layout of controls Layout of the control panel for EMR-D self-levelling (basic variant) and AutoControl (variant with tilt control): Item No.Self-levelling / Autocontrol version (1)

Mode selector switch

(2)

Overstroke button (Important: only press briefly until reaching the cylinder end-stop).

(3)

Contact pressure preselection

(4)

Cutting height preselection

(5)

Diagnostic indicator light – red LED

(6)

Status indicator light (comes on in automatic mode) – green LED

Layout of controls of the Commander Stick Item No. Topliner (10)

Raise front attachment → normal → fast mode

(11)

Lower front attachment → normal → fast mode

(12)

Raise reel

(13)

Lower reel

(14)

Tilt front attachment, right side down

(15)

Tilt front attachment, left side down

(16)

Automatic mode

(17)

Reel back

(18)

Reel forward

Extra equipment: (19)

Cutting angle adjustment: up

(20)

Cutting angle adjustment: down

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1.3

1.4

1.2

1

1.1

6 5

2

3

4

33918

19 12 13

10 11

18

20 17

14 15

16

17

16

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WS/GR

WS/GE

GR/BR

GE

6

GR/PK

1

19

PK

6

VI

2

GN

8

BR

WS

4

14 15

RT/BL

5

GR

3

BL

7

SW

RT

hebl hegn

BN/GN

AUTO

1

8

2

4

8

20

WS/BL

13 18

WS/RT

12

WS/SW

11

10

hebl

hegn

5 7

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5650H – 5690HTS Electronic cutting table control EMR-D Self-levelling control / AutoControl Calibration Calibrating the EMR-D Self-levelling control / AutoControl Reason: To adapt the EMR-D to the relevant front attachment for optimal levelling and guidance of the front attachment. When? – When using for the first time – When changing tyres or changing front attachment – When fitting an extra hydraulic cylinder – If the combine sinks deeply on soft ground Conditions: The front attachment and combine must be standing on flat ground; the skids and tracker bars must be resting on the ground.

Second calibration stage (2) Determines and stores the weight of the front attachment. Required: after performing the first calibration stage, if the weight of the front attachment has been changed. Procedure: Steps 1. – 5. ● The front attachment must hover just above the ground (50 ... 100 mm). Press the "Lower front attachment" and "Raise front attachment" push-buttons simultaneously and hold them down for at least 7 seconds. ● The status indicator light flashes 8 times to confirm calibration.

Comment In the Balance version, the drive axle must be in neutral position (mid-position).

The second calibration stage (2) is complete.

First calibration stage (1)

Determines and stores the weight of the front attachment at maximum raised height.

Determines and stores the position of the feed passage when the front attachment is rested on the ground, and registers the sensor values at the skids.

Required: after carrying out the second calibration stage.

Conditions: The front attachment and combine must be standing on flat ground; the skids and tracker bars must be resting on the ground. Procedure: 1. Switch the ignition lock to position "I". 2. Start the engine. 3. Switch on the main switch for the hydraulic functions (threshing section master switch). 4. Switch the mode selector switch to the transport position (calibration). 5. Raise or lower the front attachment at least 100 mm, and then lower to ground. ●

●

The front attachment must rest on the ground. Press the "Lower front attachment" and "Automatic" push-buttons simultaneously and hold them down for at least 7 seconds. The status indicator light flashes 5 times to confirm calibration.

Third calibration stage (3)

Procedure: Steps 1. – 5. ● The front attachment must be raised to just under its maximum raised height (the cylinder end stop must not be reached). Press the "Automatic" push-button and hold it down for at least 7 seconds. ● The status light flashes 12 times to confirm calibration. The third calibration step (3) is complete. To repeat a calibration step, switch off the engine and restart the calibration process from the beginning. –

Note:: The field tracker remains active while the ground clearance and contact pressure are adjusted, even if the automatic function is not active. (signal change ≥ ∆ 2 Volt required to switch off).

The first calibration stage (1) is complete.

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5650H – 5690HTS Electronic cutting table control EMR-D Self-levelling control / AutoControl Fault diagnostics The EMR-D control unit constantly monitors the system for faults. Faults are classified in three classes. The EMR-D electronic cutting table control responds differently according to the error class. Reaction to faults: Major faults: – The EMR-D control action is stopped and locked in position. – The relay is switched off (output stage protection). – Driver warning: the red diagnostics indicator (5) emits the fault code. Error output is terminated when the control system is restarted. – To restart the control system: remedy the fault and restart with the ignition key. – The front attachment can now only be raised or lowered by manually operating the control valves. Medium-severity faults: – The EMR-D control action is stopped and locked in position. – Work can continue in any unaffected operating mode. – EMR-D functions in the "TRANSPORT" position. – Driver warning: the diagnostics indicator (5) emits the fault code. – To restart the control system: ⇒ Remedy the fault and release EMR-D by pressing the "Raise / Lower front attachment" buttons. The red LED (5) only goes out after pressing the operating buttons if the fault has been remedied. If a fault code has been started it will be finished. Minor faults: – The EMR-D control action continues. – Driver warning: the red diagnostics indicator (5) emits the fault code. The diagnostics indicator light goes out after the push-buttons have been pressed, provided that the fault has been remedied. If a fault code has been started it will be finished.

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5650H – 5690HTS Electronic cutting table control EMR-D Self-levelling control / AutoControl Fault diagnostics Fault code list for EMR-D With the aid of the fault code list, faults can be located and identified. The next few pages specify the fault codes and associated fault descriptions. The fault codes are divided into major faults, medium-severity faults and minor faults. The error message for a fault is divided into two sequences of flashes. The first flash sequence specifies the fault class and represents the first digit (tens) of the 2-digit fault code. First flash sequence: ⇒ 10

⇒ Major fault

Two flashes (✷✷)

⇒ 20

⇒ Medium-severity fault

Three flashes (✷✷✷)

⇒ 30

⇒ Minor fault

One flash

(✷)

The second sequence of flashes follows after a short pause and subdivides the class or severity of the fault. It corresponds to the second digit (ones) of the 2-digit fault code. The fault code is obtained by counting the number of flashes in the first flash sequence and entering this number in the tens position, and then counting the number of flashes in the second sequence and entering it in the ones position. The relevant fault description for this fault code can then be found by looking up the code in the fault code list. The diagnostics indicator light repeats the error message until the fault is remedied. Examples: Fault 22 If the signal line to the "cutting height" setting potentiometer is broken, the indicator light will show e.g. Fault 22. Two flashes - short pause - two flashes - long pause - ⇒ REPEAT ✷✷- -✷✷ - - - - - -✷✷- -✷✷ - - - - - -✷✷- -✷✷ - - - - - -

⇒ Fault 22

Examples: Fault 35 (Low battery voltage): Three flashes - short pause - five flashes - long pause - ⇒ REPEAT ✷✷✷- -✷✷✷✷✷- - - - - -✷✷✷- -✷✷✷✷✷- - - - - -

⇒ Fault 35

Simultaneous faults If a number of faults occur at the same time, the other fault codes are displayed after the long pause. After all faults have been indicated, the diagnostics indicator repeats all fault codes from the start. Examples: Fault codes 22 and 35 Two flashes - short pause - two flashes - long pause - three flashes - short pause - five flashes long pause - ⇒ REPEAT ✷✷- -✷✷ - - - - - -✷✷✷- -✷✷✷✷✷- - - - - -✷✷- -✷✷ - - - - - -✷✷✷- -✷✷✷✷✷ - - - - - - ⇒ Fault 22 and Fault 35 By switching the ignition off and on again, the error message is always restarted from the start of the first fault code and is then repeated.

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5650H – 5690HTS Electronic cutting table control EMR-D Self-levelling control / AutoControl Fault diagnostics List of fault codes for EMR-D ✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳

Fault Code

Brief Description

Major faults

✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳

Pin No.

Fault Description

11

RAISE output stage

37

The output stage for the "Raise front attachment" solenoid valve is defective, or the line from the raise/lower solenoid valve to pin 35 of the EMR-D control unit is broken.

12

LOWER output stage

19

The output stage for the "Lower front attachment" solenoid valve is defective, or the line from the raise/lower solenoid valve to pin 35 of the EMR-D control unit is broken.

13

Short-circuit

35

The current measured across pin 35 is too high. ⇒ Short-circuit between pins 19 and 35 or between pins 37 and 35 (solenoid coil short-circuit possible).

14

Cable break

35

No current is measured across pin 35, even though the solenoid coils are energised. ⇒ Possible cable break in the supply lines to the solenoid coils (pin 19, 37 or 35). ⇒ Possible defect in the solenoid coils. ⇒ Possible absence of battery voltage at pin 29 (defective fuse). ⇒ Defective control box.

15

Commander Stick Raise/Lower/Fast

9

Push-button signal is incorrect. Malfunction of the RAISE, LOWER or FAST push-button.

16

Power supply

2 20

The operating voltage supply is incorrect. Fault in 9.5 V supply or earth.

17

Battery

29

Battery voltage exceeds 18 Volt.

18

Mode selector switch

21

Selector lever signal is incorrect. Cable break or signal not connected.

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5650H – 5690HTS Electronic cutting table control EMR-D Self-levelling control / AutoControl Fault diagnostics List of fault codes for EMR-D ✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳

Medium-severity faults

✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳

Fault Code

Brief Description

Pin No.

21

Position sensor

6

Position ⇒ ⇒ ⇒

22

Cutting height setting potentiometer

22

Signal of the setting potentiometers incorrect. ⇒ Cable break or potentiometer not connected.

23

Pressure sensor

8

Contact pressure signal incorrect. (only responds if pressure control is preselected with the preselection switch).

24

Contact pressure setting potentiometer

5

Signal of the setting potentiometer incorrect. (only responds if pressure control is preselected with the preselection switch).

25

"FAST" push-button

14

The "FAST" push-button is activated even though the "RAISE" or "LOWER" button is inactive.

✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳

Fault Code

Brief Description

Pin No.

Fault Description signal incorrect. Cable break or sensor not connected. Short-circuit or short-circuit to chassis earth. Incorrect calibration of the position sensor.

Minor faults

✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳✳

Fault Description

31

Tracker bar sensor, right

26

The signal from the right-hand sensor is incorrect. ⇒ Cable break or sensor not connected. ⇒ Possible short-circuit or short-circuit to chassis earth. (This diagnosis is only carried out when tracker bar feedback control is active, i.e. only when the belt clutch for the threshing or pressing mechanism is engaged and "clearance control" mode is selected).

32

Tracker bar sensor, left

7

The signal from the left-hand sensor is incorrect. ⇒ Cable break or sensor not connected. ⇒ Possible short-circuit or short-circuit to chassis earth.

33

Commander Stick tilt (right/left) and automatic

27

Push-button signal incorrect, or malfunction of the "TILT, RIGHT", "TILT, LEFT" or "AUTOMATIC" operating function.

35

Battery

29

Low battery voltage (less than 12 Volt).

36

Valve defect or no oil pressure

307.1133.3.6 englisch (en) 10.2006

Despite activated RAISE current at pin 37 of the EMR-D box, the front attachment is not raised even though the engine is running. No pressurised oil supply available, or the valve is sticking.

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H Service Training

5650H – 5690HTS Control unit EMR-D (Bosch), connector pin assignment A3 Illustration seen from the cable side pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44-45 46 47-50 51 52-55

signification angle transmitter feed passage ground power supply EMR-D control unit MF handle lift/lower fast Release EMR-D automatic Setpoint pression on the support Angle transmitter feed passage signal Cutting mechanism skid left signal Pressure transmitter signal MF handle vers. lift/lower not used longitudinal slope from Balance Status indication (LED green) MF handle automatic Cutting mechanism coding >7,2 m Lateral tilt left input, pin 5 not used MF handle lift Solenoid valve reservoir Solenoid valve lower Control unit ground Control unit operation mode Setpoint cutting height Cutting mechanism skid centre signal Ignition terminal 15 not used cutting mechanism skid right signal MF handle vers. autom. lateral tilt Ground terminal 31 Power supply terminal 30 Overstroke key Diagnosis indication (LED red) MF handle left turn MF handle right turn Lateral tilt right input pin 4 MVs ground lift/lower MF handle lower Solenoid valve lift Pressure transmitter ground Pressure-/angle transmitter/skids vers. not used Cutting mechanism skids ground not used Coding cutting mechanism > 7,2 m not used Lateral tilt/MV reservoir ground not used Lateral tilt power supply, pin 2 not used

colour sw-vi rt br-gn bl-gn br sw-bl gn ws-ge sw

signal 0V 9,5V 0V/2,7V 11V/0V 0V...9,5V 2,4V...7,1V 2,4V...7,1V 2,4V...7,1V 5V

gr-sw rt-bl rs br rt-sw

Frequenz 392,5 Hz...2000 Hz 0V/5V 0V/6,3V 5V/0V with cutting mechanism >7,2 m jumper to PIN 43 inserted PWM 10V/0V, 125Hz

rt gr-ws br-sw bl ws or or sw

0V/3,5V 0V/12V, 2A PWM 0V/12V, 1...3,2 A, 1kHz/80Hz 0V 6,4V/ 5,7V/ 3,3V/ 4,9V 0V...9,5V 2,4V...7,1V 12V

ge rt-bl br rt gr sw-ws ws-gr ge-br sw-ge br bl ws ws-bl gr

2,4V...7,1V 11V 0V 12V 11V/0V 0V/5V 0V/6,3V 0V/6,3V PWM 10V/0V, 125Hz 0V 0V/3,5V PWM 0V/12V, 1...3,2 A, 1kHz/80Hz 0V 9,5V 1 EMR-D control unit (Bosch), A3 2 Lateral tilt control unit for EMR-D, A12 0V 3 Connector view EMR-D control unit seen from cable side 4 Connector view lateral tilt control unit from 0V cable side 5 Connector pin assignment EMR-D control unit 0V A4 6 Jumper for coding MW > 7,2m 12V 7 Ferrite ring for electromagnetic shielding of control unit A3 and A12

br br br sw

Connector pin assignment for lateral tilt control unit EMR-D (Bosch) A12 pin 1 2 3 4 5 6

H 120

signification MV right turn Lateral tilt power supply MV left turn Lateral tilt right input Lateral tilt left input Lateral tilt ground

colour sw-gn sw rt-gn sw-ge rt-sw br

signal PWM, 12V PWM, PWM, PWM, 0V

12/0V, 1,2...2,2A, 125Hz 12/0V, 1,2...2,2A, 125Hz 10V/0V, 125Hz 10V/0V, 125Hz

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3

2

1

4

5 4

7

6

1

3

1

2

4

3

6

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

10 11 12 13 14 15 16 17 18 19 5

6

7

8

9

7

38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

Pin Nr.

2

5 A3 20

H33

H32

S13 2

21 31

S12

12 Cutting height

R2 R1

Contact pressure

22 5 30 H017-1

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Electronic cutting table control Topliner 4060 – 4090H as from chassis No.: ...7296 EMR-D Self-levelling / AutoControl Measuring diagram For testing, use measuring adapter 16017182

Earth

Earth

Control panel

Status indicator

red

0 V or 5 V

green

0 V or 5 V

Setpoint, stubble height Setpoint, contact pressure

valve

solenoid

Lower

valve

open Threshing section open Straw chopper closed Power press

0 V or 12 V

open Threshing section open Powerpress closed Straw chopper

Right

Supply

Tilt prop.

Solenoid energisation

valve

solenoid

Tilt

Left

EMR-D control unit

solenoid

Cutting table Accumulator

0 V or 12 V

Rise

Activation Tilt

Valves

For version without tilt control, Nos. 7, 16 and 18 do not apply.

Overtravel push-button

(Earth)

All unmarked lines 1.0 mm 2 Ends marked with contact No.

Supply Selector lever 1 = Stubble height with 1 = tracking control 2 = Contact pressure 3 = Stubble height without 3 = tracking control 4 = Transport Diagnostics indicator

Earth Stationary state detection

S1 = open: S1 = closed: bl/br

Tracker control inactive Tracker control active 11 V or 0 V

Energisation via threshing section/powerpress relay R 28 Activation via relay K 12

1

Connector, rear view

2

7

15

5

6

3

4

ws

rt

sw

bl

br

white

red

black

blue

brown

A00262

H 122

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5650H – 5690HTS Electronic cutting table control EMR-D Self-levelling / AutoControl 13-pin

EMR-D control unit

Tracking sensor, middle

Self-levelling

Supply Signal Earth

variant without tilt control, with one tracking sensor

Supply Signal Earth

Tracking sensor L

Supply Signal Earth Supply Signal Earth

9

Tracking sensor R

Supply Signal Earth

7 8

Tracking sensor middle

10 11 12

5

9

13-pol.

Position measurement

yellow

Sensors

Measuring diagram (continued)

The sensor voltage increases with increasing ground clearance and must be less than 6.8 V. Supply Signal Earth

Cutting table / PU operation

Fast mode, Up

0 V / 2,7 V

Raise

0 V / 3,5 V

Lower

0 V / 3,5 V

Fast mode, Down

5V 11 V Automatic mode

0 V / 6,3 V

Turn anticlockwise

0 V / 6,3 V

Turn clockwise

0 V / 6,3 V

12 b

Multifunction lever

12 a

Pressure measurement

Battery terminal 30 (not via ignition lock)

Supply

Battery (line to earth) Ignition terminal 15

8 4

9

13

12a

14

12b

11

8

15

ge

dubl

hebl

sw

hegn

ws

sw

ws

white

black

white

7 6 3 2

yellow

5 1

8 4

7 6 3 2

5 1

dark blue

307.1133.3.6 englisch (en) 10.2006

8 4

7 6 3 2

5 1

pale blue

8 4

7 6 3 2

black

5 1

8 4

7 6 3 2

5 1

pale green

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5650H – 5690HTS Electronic cutting table control EMR-D Self-levelling / AutoControl

1

2

4

Feed passage position sensor Basic setting: – The turning slot of the position sensor shaft (3) must run in line (parallel) with the clamp lever (2). The adjusting mark on the position sensor shaft (3) must point in the direction of the connector (4) – rough setting. – Basic length of the coupling rod ≈ 173 mm (see drawing) – fine setting.

173

3

Checking the basic setting: Required conditions: the combine must be standing on a flat surface, with front attachment mounted. When the front attachment is lowered, the signal voltage (pin 2) must be 0.25 ! supply voltage VS (pin 3). When the front attachment is fully raised, the signal voltage (pin 2) must 0.75 ! supply voltage VS (pin 3). For testing, use measuring adapter 16031484 or 16017182. Signal voltage at maximum raised height (overtravel button, cylinder end-stop): 7.1 Volt. Cut-off threshold when raising the front attachment with the multifunction lever: 6.8 V (signal voltage). Checking the overtravel distance: With the front attachment fully raised, a cylinder travel of at least 30 mm must be available up to the cylinder endstop, i.e. when the overtravel button is pressed, the cylinders must extend a further 30 mm before reaching their end-stop. I After resetting the position sensor, the calibration procedure must be repeated. 1

Position sensor (rotation angle sensor)

2

Clamping lever

3

Position sensor shaft

4

Connector

H0506

Tracker bar sensors – Installation The potentiometers must be fitted to the skids as shown in Figure 31053. The potentiometers (10) must be placed on the skids at an offset angle of 15° to allow the engaging piece to be inserted in the bolt slot. The electrical connection must point upwards. The potentiometer must then be rotated until the fixing screws (11) are located roughly in the middle of the oblong holes. Potentiometer resistance: 4 kΩ The tracker bar sensors are automatically calibrated during the calibration process, i.e. if a tracker bar sensor is changed, full recalibration is necessary.

3

11

10

H 124

31053

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5650H – 5690HTS Electronic cutting table control EMR-D Self-levelling / AutoControl 1

AutoControl version

2

Self-levelling version

8

13-pin socket on the cutting table

10 Tracker bar sensor, left

8 8

7

12 Tracker bar sensor, right

1

6

10 2

4

5

11 Tracker bar sensor, middle

9

11

3 13

Testing the tracker bar sensors (potentiometer)

12

Potentiometer resistance: 4 kΩ Supply voltage: (pin 9): 9.5 V Earth connection (pin 7): 0 V (Pin 5: Tracker bar sensor, Left) Tracker skid:

raised

lowered

Signal voltage:

2.4 V (min.)

6.8 V (max.)

(Pin 8: Tracker bar sensor, Middle) (Pin 11: Tracker bar sensor, Right)

0V

9,5V

2,4–6,8V (∆ 2V)

0V

Make sure that the signal voltage is always within the "signal window" range (2.4 to 6.8 V). The operating range of ≥ ∆ 2 V for the tracker bar sensors is preset by the tracker bar travel (chain length left / right ≈ 400 mm, middle ≈ 350 mm). Note: After replacing or resetting a potentiometer, the calibration procedure must be repeated.

0V

2,4–6,8V (∆ 2V) 9,5V

2,4–6,8V (∆ 2V)

9,5V

0V

9,5V

2,4–6,8V (∆ 2V)

The operating range of the tracker bar sensors must be at least 2 Volt (≥ ∆ 2 V).

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5650H – 5690HTS Electronic cutting table control EMR-D Self-levelling / AutoControl 13-pin connector - Pin layout Cutting table connector: Male

Cutting table potentiometer middle Cutting table potentiometer left

 + rt/ws  S or  – br S

   – rt/bl + sw

Reel speed sensor

Reel speed variator Rape cutting table

Cutting table potentiometer right

Female AutoControl version (3 tracker skids)

Potentiometer Middle

Potentiometer Left

Reel speed sensor Rape cutting table

Female Self-levelling version 1 tracker skid)

9 1

6

10 2

4 5

11

3 13

12

 + rt/ws  S gge  – br

 + bl g g  S ge/gn  – br  + bl g g  S ge/gn  – br

   – br

8 7

 + bl g g  S ge/gn  – br

Potentiometer Middle

S + –

9 1

6

10 2

4 5

11

3 13

 br   bl  bl +   – br

Potentiometer Right

12

g g ge/gn bl br 8 7

Reel speed sensor

Reel speed variator Rape cutting table

H 126

7

 br/sw   bl/rt  g gn/ge g  + g  – br/ge

+ bl

Reel speed variator

8

gn g

+  –

bl

9 1

6

10 2

4 5

br

 br  bl   bl +  – br

11

3 13

12

307.1133.3.6 englisch (en) 10.2006

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Balance Description

5650H – 5690HTS Balance

4 6

Brief description

5 1

BALANCE

3 8

9

AUTO

The purpose of the Balance control is to keep the combine harvester in a horizontal position within certain limits when driving on a slope. The machine is levelled both laterally and longitudinally. Longitudinal levelling can be deactivated in special situations.

AUTO 8 2

7

If hydraulic cutting angle adjustment is installed, the control system can adjust the cutting angle of the cutting table within a certain range so that the cutting table remains parallel with the ground.

NEUTRAL

DEUTZ-FAHR

Pos. Control element/indicator

35395

The Balance control is not operational (4 LED's (9) are lighting), until –

the engine is running,

–

the charge control light is extinguished,

–

the main working switch is on and

–

the parking brake (handbrake) has been released.

Function

1

Key LIFT

- Machine is being lifted horizontally / automatic mode is deactivated - Key (2) simultaneously pressed: Activation of dual-line control - Key (7) simultaneously pressed: Delay cutting angle controller 0 s

2

Key LOWER

- Machine is being lowered horizontally / automatic mode is deactivated - Key (1) simultaneously pressed: Activation of dual-line control - Key (7) simultaneously pressed: Delay cutting angle controller 1 s

3

Key TILT RIGHT

- Machine is being tilted to the right / automatic mode is deactivated - Key (4) simultaneously pressed: Activation of single-line controller** - Key (7) simultaneously pressed: Delay cutting angle controller 3 s

4

Key TILT LEFT

- Machine is being tilted to the left / automatic mode is deactivated - Key (3) simultaneously pressed: Activation of single-line controller* - Key (7) simultaneously pressed: Delay cutting angle controller 2 s

5

Key AUTO

- Switching on automatic mode.. - Keep key (7) simultaneously pressed while switching on: Calibration mode on - Key (1) simultaneously pressed: Slow position controller is being activated - Key (2) simultaneously pressed: Fast position controller is being activated

6

LED AUTO

Display automatic mode On/Off: LED is constantly lighting: Fast position controller is activated LED is flashing: Slow position controller is activated.

7

Key NEUTRAL

- Causes the axle cylinder to travel into half extended position (keep pressed until middle LED (8) is lighting / automatic mode is deactivated - Keep key (5) simultaneously pressed while switching on: Calibration mode on - Key (1) simultaneously pressed: Delay cutting angle controller 0 s - Key (2) simultaneously pressed: Delay cutting angle controller 1 s - Key (4) simultaneously pressed: Delay cutting angle controller 2 s - Key (3) simultaneously pressed: Delay cutting angle controller 3 s

8

LEDs (10 pcs)

Indication of axle cylinder position

9

LEDs AUTO key (4 pcs)

are flashing if calibration mode is selected. When single-line control is active, all LEDs are momentarily lighting while pressing the key (5) AUTO.

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5650H – 5690HTS Balance

Operation Driving on roads Prior to on-road driving the machine shall be completely lowered. Activate Balance for this purpose (activate engine and working master switch, release parking brake) and lower the machine completely by means of pressing the key "LOWER” (2) (both lower LEDs (8) are lighting). Manual operation: The machine can be moved into any required position via the four yellow buttons ("LIFT" (1), "LOWER" (2), "TILT RIGHT" (3) and "TILT LEFT" (4)) on the control unit. The machine then remains in this position. Neutral position: The "NEUTRAL" button (7) is used to set the machine to a neutral middle position in which it remains parallel with the ground. The button must be pressed until the machine has reached its neutral middle position (the middle LEDs (8) light up). However, the machine does not adjust to the topological features in this case.

4 6

5 1

BALANCE

3

9

AUTO

CAUTION! If the gear is engaged or the service brake is activated, the combine harvester is moving forward or backward in case of being lifted or lowered by means of the Balance control.

AUTO 8 2 DEUTZ-FAHR

Automatic mode:

7 NEUTRAL

35395

Activate: – TPress "AUTO” key (5). LED "AUTO” (6) is lighting. The machine is being held in horizontal position through automatic correction. Deactivate: – Press "LIFT” key (1) or "LOWER” key (2) or "TILT RIGHT” key (3) or "TILT LEFT” key (4) or Press "NEUTRAL” key (7). LED "AUTO” (6) extinguishes. The machine is in manual mode.

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H Service Training Single-line and dual-line control:

5650H – 5690HTS Balance

Activation of single-line control (lateral tilt control):

☞ 4

3

The control by the longitudinal axle (longitudinal control) is being deactivated.

–

Press the keys "TILT RIGHT” (3) and "TILT LEFT” (4) simultaneously. - The single-line control is activated.

–

Activate automatic mode by pressing the "AUTO” key (5). - Serving as a function indication all LEDs are momentarily lighting when the automatic mode is activated.

Activation of dual-line control (Logitudinal and lateral tilt control): 35396

1

2

☞

The control by the longitudinal axle (longitudinal control) is being reactivated.

–

Press the keys "LIFT” (1) and "LOWER” (2) simultaneously. - The dual-line control is activated.

–

Activate automatic mode by pressing the "AUTO” key (5). - Serving as a function indication the LEDs are not lit when the automatic mode is activated.

Activation of position controller

☞

35397

4 6

5 1

BALANCE

3 8

9

AUTO

Activation of the fast position controller: – Press the keys "AUTO” (5) and "LOWER” (2) simultaneously.

8 DEUTZ-FAHR

307.1133.3.6 englisch (en) 10.2006

Activation of the slow position controller: – Press the keys "AUTO” (5) and "LIFT” (1) simultaneously. - Status indication: In automatic mode the LED "AUTO” (6) is flashing.

AUTO 2

The fast position controller is activated as factory default and after each calibration.

7

- Status indication: In automatic mode the LED "AUTO” (6) is lighting continuously.

NEUTRAL

35395

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5650H – 5690HTS Balance Calibration of position controller

☞

AUTO

The calibration of the position controller shall be carried out prior to adjusting the EMR-D.

–

Start the engine (charge warning indicator must be off).

–

Switch on the main work switch.

–

Park the combine harvester so that it is level in all directions. Set Balance to "NEUTRAL" (press button down until machine is in a horizontal position).

–

Put on the parking brake (handbrake).

–

Press and hold the buttons "AUTO" and "NEUTRAL".

–

Release the parking brake (handbrake).

NEUTRAL

– After 10 seconds the Balance is switching over to calibration mode. – The four middle LEDs (9) flash. One LED on the right and left light up continuously. The machine begins to move. – The Balance is in calibration mode. –

Press "LIFT" continuously until the machine reaches its upper dead centre.

–

Press "LOWER" continuously until the machine reaches its bottom dead centre.

–

Press "LIFT", "LOWER", "TILT RIGHT" and "TILT LEFT" to adjust the machine until it is absolutely horizontal in all directions. Use a spirit level to check the adjustment if necessary.

Bild 22 BALANCE

9

AUTO

AUTO 9 DEUTZ-FAHR

H 130

NEUTRAL

Bild 23

307.1133.3.6 englisch (en) 10.2006

H Service Training – Briefly press "LIFT" and "LOWER" simultaneously.

5650H – 5690HTS Balance

4 6

The data is being saved.

5 1

BALANCE

3 8

9

AUTO

The calibration process is finished: - The middle LEDs (9) light up. One LED (8) lights up in the middle of the light bands on the right and left. - Lateral and longitudinal levelling is active. - Automatic mode is inactive. - The fast position controller is activated, delay cutting angle controller 0 s - The dual-line control is activated.

AUTO 8

If the machine was not absolutely horizontal during calibration , it may move a few centimetres when switching over between AUTOMATIC and NEUTRAL. The calibration should be repeated if the deviation is too large.

7

2

NEUTRAL

DEUTZ-FAHR

35395

Operation of the automatic cutting angle control

11

Machine requirements:

10

–

All electrical leads connected

–

All position encoders correctly installed and set

☞ 35398

12

By factory default and after each calibration the delay for the cutting angle controller is set to 0 s.

The automatic cutting angle control is active when the Balance control unit is ready for operation and when the cutting angle control has been switched on by simultaneously pressing the keys "CUTTING ANGLE FORWARD” (11) and "CUTTING ANGLE BACKWARD” (10). Indication is done through control lamp (12). When the machine is shut down or when the Balance control unit is switched off, the cutting angle control will also be deactivated and must be reactivated if required.

35430

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5650H – 5690HTS Balance

2

Manual operation:

3

1 35398

Can be used immediately after starting the machine and switching on the main working switch. Otherwise deactivate automatic cutting angle control by simultaneously pressing "CUTTING ANGLE FORWARD" (2) and "CUTTING ANGLE BACK" (3). Indicator (12) is off. The cutting angle can be set as required via the buttons "CUTTING ANGLE FORWARD" (2) and "CUTTING ANGLE BACK" (3) on the multi-purpose lever. Automatic operation:

12

35430

–

Release parking brake (handbrake).

–

Engage threshing section.

–

Set the EMR-D operating mode (pressure or position control).

–

Press (1) to set automatic cutting table control to Automatic.

–

Set required setpoint on EMR-D control.

–

Activate automatic cutting angle control by simultaneously pressing "CUTTING ANGLE FORWARD" (2) and "CUTTING ANGLE BACK" (3). Indicator (12) lights up.

–

Set the machine to a neutral position on level ground.

–

Adjust the cutting table so that the earlifter skids are parallel to the ground.

–

Completely lower the machine and then completely raise it again. With proper calibration and recommended tyres the sliding surfaces of the crop lifters are aligned nearly parallel to the ground during the entire adjusting process. Correct the cutting table position or bearing pressure again if necessary.

Indicator (12) flashes when the cutting table is disengaged and automatic cutting table control (EMR-D) is switched off. Cutting angle control remains active. The cutting angle is also adjusted if the machine is adjusted via the Balance control (e.g. for manoeuvering on a slope). If the cutting angle is changed (e.g. when disengaging the cutting table), the new value upon activation of the automatic system is adopted as the new default. The adjustment must be repeated.

Automatic cutting angle control must be deactivated in order to lower the cutting mechanism onto the transport cart!

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5650H – 5690HTS Balance

10

Calibration / adjust delay for automatic cutting angle control

11

Calibration of cutting angle control limit positions Press the keys "CUTTING ANGLE FORWARD” (10) and "CUTTING ANGLE BACK” (11) simultaneously and keep pressed for at least 10 seconds, until the control lamp (12) flashes fast. 35398

4 6

5 1

BALANCE

3 8

9

AUTO

Adjusting the response delay of the cutting angle controller

AUTO 8 2

The cutting angle adjustment drives to both end positions and stores the values. During operation, the cylinders will be electrically deactivated just before they reach the mechanical end position.

7

☞

It is recommended to work with a response delay of 2 seconds.

NEUTRAL

DEUTZ-FAHR

35395

Delay in seconds 0 1 2 3

Press the keys simultaneously to select: NEUTRAL and LIFT NEUTRAL and LOWER NEUTRAL and TILT LEFT NEUTRAL and TILT RIGHT

(7 and 1) (7 and 2) (7 and 4) (7 and 3)

The selected setting will be memorized until the next change is carried out.

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2 3

1

4

5

7

7

6

9

8 10

11 H 134

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5650H – 5690HTS Balance with automatic cutting angle control 1 Control cabinet 2 Multifunction handle 3 Balance control unit 4 Status light for automatic cutting angle control 5 Pilot control unit MO for Balance hydraulic system 6 Control unit for cutting angle control 7 Angular rotation transmitter Balance axle 8 Control valve block left M1 Connector without colour coding sw (black) M3 -

Connector rt (red)

M2 -

Connector bl (blue)

9 Control valve block right M4 -

Connector without colour coding sw (black)

M6 -

Connector rt (red)

M5 -

Connector bl (blue)

10 Balance Control Unit Observe mounting position: - Adhesive label with arrow for driving direction located at the inner housing opposite to the relay. - Observe the marking of CON1 and of CON2 and of the slot. - The connectors CON1 and CON2 must not be interchanged 11 Angular rotation transmitter for cutting angle (mounted on the right side at the feed passage).

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1

2.2

2

2.1 30

5 3.1

4

30 91 ,3

3 1

26

4

4.1

4

5 4.1

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5650H – 5690HTS Balance Rotation angle transmitter - Balance axle The rotation angle tansmitters are mounted on the left and right side at the cross member and are connected each with the final drive by means of a steering rod. When mounting the transmitter the punch mark (4,1) on the shaft must point at the plug-in connection. The ball head (3.1) for the steering rod must be screwed in at the final drive in the depicted position. Final drive is in neutral position. 1

Balance axle

2

Final drive bearing tube

2.1 lifted position 2.2 lowered position 3

Steering rod

3.1 Ball head for steering rod at final drive 4

Rotation angle transmitter

4.1 Centre punch on the transmitter shaft 5

Clamping lever

Testing / Setting Direction of Travel Voltage supply

Left 8.5 V ± 5 %

Right 8.5 V ± 5 %

Vehicle raised to top end-stop Signal voltage

6.3 V

2.1 V

Vehicle lowered to bottom end-stop Signal voltage

2.1 V

6.3 V

Use test plug (1603 1484) to test the sensors. Basic setting –

Fully lower the Balance system (the tilt adjusting cylinders must be fully retracted; if necessary change to the calibration mode).

–

Set the steering rod (3) to a length of 261 mm

–

Release the clamping lever (5)

–

Set the rotation angle transmitter to the specified signal voltage.

Angle transmitter for cutting angle When mounting the transmitter the punch mark (6) on the shaft must point at the plug-in connection. Precision adjustment of the transmitter by means of twisting turning the shaft inside of clamping lever (5): - Signal voltage approx. 2,1 V with retracted cutting angle adapter

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5650H – 5690HTS Balance Circuit diagram power supply Balance II and cutting angle control

A19

Control unit Balance II

K59

Relay cutting angle upwards

K67

ground at D+

K75, K76 Relay power supply Balance II K80

Relay cutting angle downwards

S54

Push-button switch cutting angle up/down

S55

Hand brake switch

Y11

Solenoid valve cutting angle upwards

Y12

Solenoid valve cutting angle downwards

Relays K59, K80 must not be plugged when equipped with Balance.

H 138

307.1133.3.6 englisch (en) 10.2006

1

2

7

hrt

6

307.1133.3.6 englisch (en) 10.2006

hrt

5

hbl

8

4

4

SW2

87a

1

hrt 30

4 85

2

3

87

5

86

1

87a

4

6

8 85

2

5

dgr

8

2 87

5

87a 87a

4 4

X512.17

2

3 Hand brake switch

5 K76

C

S55

87

sw/gr

1 1 K75

F15 15

S54

2 86 86

X9

4 3

Cutting angle up

87a 30 Light at D+

2

Y11

hbl 85

X30

3

br

8 5 K67

RT3

con2.35 X92.35 GND

87

ge/rt

3

X29

Threshing mechanism on

rs/ws

15b

X30

K59

Working master switch on

con1.9 X91.9 Solenoid valve cutting angle up

1

X30

ws/bl

15a

tr

hrt 30

con2.18 X92.18 +UB

3

bl/sw

bl/rt

2

X29

ws/sw

86

X30

K80 85

con2.5 X92.5 Push-button cutting angle up

5

vi/ws

4

bg/ws

dgr

X9

1

con2.23 X92.23 Push-button cutting angle down con1.8 Solenoid valve cutting X91.8 angle down

A19

Cutting angle down

Y12

H

Service Training

30

15

D+

F40 15

D

3 3 1

30 30 86

5

87 85

D2 2

D3

ws/bl

ws/sw

bl/rt ge/rt .19 .18

X192

3

1

1

2

4

E

Multifunction lever

H 139

H Service Training

5650H – 5690HTS Connector pin assignment Balance II with automatic cutting angle control signal

colour

signification

Connector CON1

signification

colour

signal

17

control unit 12V

bg

12V

16

control unit R3

gr

MUX

15

control unit R2

vi

MUX

14

control unit. R1

rs

MUX

Pin No. 18 35

MUX

rt

control unit SP1

34

MUX

bl-ws

control unit SP2

33

MUX

gn-ge

control unit SP3

32

MUX

ws

control unit SP4

31

MUX

sw-ws

control unit. SP5

30

13 12 MUX

gr-ws

0V

sw

control unit SP6

29

control unit GND

28

11 10 0V

br-ws

12V/0V

27 GND MVs SW

9

MV cutting angle upwards rs-ws

12V/0V

8

MV cutting angle downwards vi-ws

12V/0V

7

Status cutting angle auto or-ws

12V/0V

6*

Freq. longitudinal slope gr-sw

*

26

2kΩ

25 24 23

(Pin 11 EMR-D) 5

Programming connector

22

4

rt

2

sw

RS232-TXD

21

3

bl

RS232-RXD

20

1

br

RS232-GND

4

Boot

---

3 2 19 1

*

H 140

down = 2000 Hz, up = 392,5 Hz

1 2 3 4 5 6 7 8 9

Vehicle ground cable Rotation angle transmitter for cutting angle Rotation angle transmitter balance axle left Rotation angle transmitter balance axle right Solenoid valves M4 - M6 right Solenoid valves M1 - M3 left Connector X28 - X31 at cabinet bottom Programming connector Resistor 2 kOhm 307.1133.3.6 englisch (en) 10.2006

1

H05VV-F 2x1-3200 br bl

307.1133.3.6 englisch (en) 10.2006

H 141 56-200

1 gn-ge

21 20 19

9 24 22

4 3 2 1

3

H05VV-F 3G1-3200 br gn-ge bl

2

H05VV-F 3G1-1250 br gn-ge bl

4

3 2 1

3

H05VV-F 3G1-1250 br gn-ge bl

28

M6 rt

FLYY 6x1-1550 br gn

29

M5 bl

5

ws ge

30

M4 sw

sw rt

Masse

CON 2

31

2 1

M3 rt

FLYY 6x1-1550 br gn

32

M2 bl

6

ws ge

33

M1 sw

sw rt

8

26

3 2 1

÷lflex-100/03 25x0,75-4000 (Lapp 0010034 ) rt-ws gr-ws

18 35 5 23

8

tr bl-sw bg-ws ro

6 34

gr tr-ws

7

sw-ws gr-ws bg sw bl-ws gn-ge ws 6 27

9

7 14 15 9 8 16

X 29

8 7 6 5 4 3 2 1

br-ws or-ws rt-ws vi-ws bl or

8 Service Training

H

H Service Training

5650H – 5690HTS Connector pin assignment Balance II with automatic cutting angle control signal

colour

0V

br

signification

Connector CON2

GND

bl

M0

34

0V/12V

sw

M1

33

0V/12V

ws

M2

32

0V/12V

br

M3

31

0V/12V

sw

M4

30

0V/12V

ws

M5.

29

br

M6

colour

signal

18

+UB

tr

12V

17

M0.GND

or

0V

16

M1.GND

rt

0V

15

M2.GND

ge

0V

14

M3.GND

gn

0V

13

M4.GND

rt

0V

12

M5.GND

ge

0V

11

M6.GND

gn

0V

angle transmitter cutting angle br

8V

6

angle transmitter feed passage tr-ws

2,4V...7,1

5

push button switch SW up

0V/12V

35

0V/12V

0V/12V

signification

Pin No.

28 10 27 9

0V/5V

rt-ws EMR-D-LED green

26 8 25 7

2V...6V

gn-ge angle transmitter SW signal

24

0V12V

bg-ws push button switch SW down 23

0V

bl angle transmitter SW GND

22

8

br angle transmitter left VCC

21

bl-sw

4

1 2 3 4 5 6 7 8 9

2V...6V

gn-ge angle transmitter left signal

20

0V

bl angle transmitter left GND

19

3

angle transmitter right VCC br

8V

2

angle transmitter right signal gn-ge

2V...6V

1

angle transmitter right GND bl

0V

Vehicle ground cable Rotation angle transmitter for cutting angle Rotation angle transmitter balance axle left Rotation angle transmitter balance axle right Solenoid valves M4 - M6 right Solenoid valves M1 - M3 left Connector X28 - X31 at cabinet bottom Programming connector Resistor 2 kOhm

H 142

307.1133.3.6 englisch (en) 10.2006

1

H05VV-F 2x1-3200 br bl

307.1133.3.6 englisch (en) 10.2006

H 143 56-200

1 gn-ge

21 20 19

9 24 22

4 3 2 1

3

H05VV-F 3G1-3200 br gn-ge bl

2

H05VV-F 3G1-1250 br gn-ge bl

4

3 2 1

3

H05VV-F 3G1-1250 br gn-ge bl

28

M6 rt

FLYY 6x1-1550 br gn

29

M5 bl

5

ws ge

30

M4 sw

sw rt

Masse

31

CON 2

2 1

M3 rt

FLYY 6x1-1550 br gn

32

M2 bl

6

ws ge

33

M1 sw

sw rt

8

26

3 2 1

÷lflex-100/03 25x0,75-4000 (Lapp 0010034 ) rt-ws gr-ws

18 35 5 23

8

tr bl-sw bg-ws ro

6 34

gr tr-ws

7

sw-ws gr-ws bg sw bl-ws gn-ge ws 6 27

9

7 14 15 9 8 16

X 29

8 7 6 5 4 3 2 1

br-ws or-ws rt-ws vi-ws bl or

8 Service Training

H

H Service Training

5650H – 5690HTS Balance Troubleshooting Problem

Cause / Remedy

No display on control panel

– Engine not running – Handbrake on – Threshing main switch not ON – Fuse No. 40 (15 A) blown – Microrelay K67, K75 or K76 defective

Balance "hunting" or in constant motion

– Rotation angle transmitter incorrectly set or steering rod bent – Dirt in valve seat, causing lowering and therefore constant readjustment

Uncontrolled movements

– Repeat calibration procedure – Check setting of rotation angle transmitter

Balance rises on one side, lowers on one side

– Check the setting of the rotation angle transmitter and check that the steering rods are correctly fitted

Control panel display indicates end-stop although the tilt adjusting cylinders are not fully extended/retracted

– The rotation angle transmitter are out of adjustment. – heck setting.

Balance no longer extends/retracts fully

– Incorrect calibration values have been stored (calibration error). Repeat calibration procedure

Various push-buttons and LEDs on the control panel are not functioning

– Faulty control panel. – Faulty cable connection between the microcontroller and the control panel

Balance does not remain longitudinally and laterally horizontal after calibration

– Check that the control unit (microcontroller) is mounted parallel to the drive axle in the longitudinal and transverse direction. Compensate with spacing washers.

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H Service Training

Notes

307.1133.3.6 englisch (en) 10.2006

H 145

H Service Training

5650H – 5690HTS Throughput Monitor (Grain Loss Monitor) / On-board Computer LH-865 / 1000 1 1.1 2 3 4 4.1 4.2 5 6 7 8 9 10

Display unit – grain loss monitor Wiring harness (5-core) to control cabinet LH-1000 on-board computer Light sensor (mounted on cab roof) Straw walker sensors (plate sensor) Wiring harness (3-core) from Straw walker sensor, left Wiring harness (3-core) from Straw walker sensor, right Pulse generator, feed passage Sieve pan sensor (pipe sensor) Magnet (2x) at feed passage Junction box with circuit board Wheel sensor Control cabinet

Function check – throughput monitor Switch on the ignition. Tap the left and right straw walker sensors in turn. The needle for "straw walker grain loss" must move. Tap the tubular sensor mounted on the sieve box. The needle for "sieve box grain loss" must move.

Connector pin assignment of distributing circuit board measured values Terminal strip I No. Cable

Function

colour

Connector pin assignment for display unit Pin No

Cable colour Function

Measuring

1

white

Supply for sensors +

value

2

brown

Power supply +

3

green

Power supply -

4

yellow

Signal wheel sensor

5

grey

Brightness sensor

1

black 1

Power supply -

0V

2

black 2

Power supply +

11V

3

black 4

Signal wheel sensor

11V, 1.5V

4

green/yellow Signal sieve pan sensor

5

black 3

Signal straw walker sensor 8.3V .... 6V

6

pink

Brightness sensor

6

blue

wheel sensor

11V

7

blue

Signal straw walker sensor

7

brown

wheel sensor

0V

8

red

Signal sieve pan sensor

8

green/yellow Sieve pan sensor +

11V

9

black 2

Signal sieve pan sensor

8.3V .... 6V

10

black 1

Sieve pan sensor -

0V

8.3V .... 6V

Terminal strip II No Cable

Function

colour

Measuring value

1 2

black 1

Straw walker sensor 1 -

0V

3

black 2

Signal straw walker sensor 1 8.3V .... 6V

4

green/yellow Straw walker sensor 1 +

11V

5

black 1

Straw walker sensor 2 -

0V

6

black 2

Signal straw walker sensor 2 8.3V .... 6V

7

green/yellow Straw walker sensor 2 +

11V

8 9 10

H 146

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H Service Training

H0508-2

H0518-1

307.1133.3.6 englisch (en) 10.2006

H0520-2

H 147

H Service Training

4 2

1

3

33734

7 5

56-202

6

31536

H 148

307.1133.3.6 englisch (en) 10.2006

H Service Training

5650H – 5690HTS Adjustments at grain loss monitor The travel of the pointer for the grain loss indication through sieve pan (3) and straw walker (4) is adjusted with rotary knobs (1, 2). Depending on the cutting mechanism width, the rotary knobs are to be adjusted such that the indicator needle points to the transitional green/red area of the display field indicating that the grain loss is still acceptable.

Depending on the crop, the grain loss sensor sensitivity can be adjusted in three steps:

low sensitivity for big grains like beans or maize medium sensitivity for cereal high sensitivity for small grains like rape, mustard, linseed

Corresponding dot markings (7) at the sensor casing ease proper positioning of the switch. Sieve pan sensor: Adjustment through toggle switch (5) Straw walker sensors: Adjustment through rotary switch (6)

307.1133.3.6 englisch (en) 10.2006

H 149

H Service Training

1

2

3

4 7

6

5

30672

8 30768

10

H0519

9 10

10 56-202

H 150

31534

307.1133.3.6 englisch (en) 10.2006

H Service Training

5650H – 5690HTS On-board Computer LH 1000 Key functions: 1

Working time (hours and minutes)

2

Hectaremeter (partial count)

3

Hectaremeter (total count)

4

Speed (km/h)

5

Working with input in cm

6

Wheel circumference input in cm

7

Resetting of counters (consumption of hectares and time), input of 0

For proper functioning of the work computer the wheel sensor (9) at the rear wheel and the pulse transmitter (8) at the feed passage are required. The pulse transmitter must be adjusted such that both magnets (10) overlap the face side of the transmitter with the cutting mechanism lifted. The clearance between magnet and sensor should be adjusted to 5 – 8 mm.

Cable pin assignment Item 6: blue, power supply 12V Item 5: brown, ground Item 4: Sensor input wheel sensor Item 2: Sensor input pulse transmitter feed passage

307.1133.3.6 englisch (en) 10.2006

H 151

H Service Training

5650H – 5690HTS On-board Computer LH 1000 The work computer is equipped with 3 function sets Function set 1:

Time counting, hectare counting, speed (Working width and wheel circumference must be entered beforehand)

1. Time function Starting the timer Press this key to start the timer (the colon starts flashing)

The on-board computer will now start counting the elapsed time (hours and minutes). If you select another function, the timer will continue running in the background. This key can be pressed at any time to stop and restart the timer.

2. Hectaremeter Hectares per field – "partial area"

ha

Press this key to display the area worked in hectares. The area is indicated with two decimal places in the range from 0 – 99.99 ha and with 1 decimal place in the range from 100 – 999.9 ha.

Hectares per field – "total area"

ha

+

Press this key to display the total area worked in hectares. The area is indicated with two decimal places in the range from 0 – 99.99 ha, with 1 decimal place in the range from 100 – 999.9 ha and without decimals in the range from 1000 – 9999 ha. This function is used to totalize the complete area worked.

3. Speed indicator Press this key to display the forward speed in km/h.

kmh

If the hectaremeter is stopped while the speed indicator is displayed, the letter "r" is displayed in front of the speed.

Function Set 2: Odometer, wheel revolutions 1. Odometer Basic setting

ha

+

Press this key

Then press this key followed by

9 ha H 152

9

9

9

Enter

When you press this key again the distance covered will be displayed in metres. 307.1133.3.6 englisch (en) 10.2006

H Service Training

5650H – 5690HTS On-board Computer LH 1000 2. Wheel revolutions This function is mainly used to count the number of wheel revolutions when determining and entering the wheel diameter. Basic setting

kmh

Press this key

Then press this key followed by:

9 kmh

9

9

9

Enter

When you press this key again the distance covered will be displayed in metres.

Function Set 3: Sensortest First enter a working width of 8888 by pressing the following keys in the order shown below:

8

8

8

8

Then select the timer function:

Press this key to select the timer function.

The display will now read "h", if the wheel sensor is activated "r", if the pulse transmitter of the feed passage is activated Note: the letter "r" is also displayed when the hectaremeter is stopped.

Error message The message "FEJL" appears in the display when the supply voltage is less than 12 Volt.

307.1133.3.6 englisch (en) 10.2006

H 153

H Service Training

Notes

H 154

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H Service Training

Appendix A

Wiring Diagrams

5650H – 5690HTS

307.1133.3.6 englisch (en) 10.2006

HA 1

H Service Training

5650H – 5690HTS Appendix A Wiring layouts

HA 2

307.1133.3.6 englisch (en) 10.2006

H Service Training

5650H – 5690HTS Appendix A Table of contents

running No. 1. 2. 3. 4. 5. 6. 7. 8.

designation wiring diagram wiring diagram wiring diagram wiring diagram wiring diagram cable harness engine cable harness engine cable harness

307.1133.3.6 englisch (en) 10.2006

topic control console control console Steering column cabin cabin Engine 5670 Engine 5680/90 Control valves work hydraulics

drawing No. 1605 2333 page 1605 2333 page 1605 2333 page 1605 2333 page 1605 2333 page

1–1 1–2 4–1 4–2

HA 3

H Service Training

5650H – 5690HTS Wiring layouts

1. Wiring diagram control console

H39 H40 H41 H42 H43 H44 S38 S40 S41 S42 S43 S44 S49 S66 S67

HA 4

1605 2333 page 1 – 1

All-wheel on – off All-wheel differential lock Deflectors left centre Deflectors left outside Deflectors right centre Deflectors right outside Partial width change-over with TERIS/TCS Working master switch All-wheel on-off Colza cutting mechanism on-off Reverse cutting mechanism Grain tank interior light Deflector adjustment Switch straw guide plate Grain tank extension lift – lower

307.1133.3.6 englisch (en) 10.2006

H Service Training

2333_1-1

307.1133.3.6 englisch (en) 10.2006

HA 5

H Service Training

5650H – 5690HTS Wiring layouts

2. Wiring diagram control console

1605 2333 page 1 – 2

H34 Error lamp EEC H35 Indicator light chopper operation H36 Indicator light cutting angle automatic H61 Indicatorlight automatic wind system S2

Ignition start switch

S5

Throttle control half-/full throttle

S33 Switch hazard warning signal flasher S68 Switch mirror adjustment

HA 6

307.1133.3.6 englisch (en) 10.2006

H Service Training

2333_1-2

307.1133.3.6 englisch (en) 10.2006

HA 7

H Service Training

2333_5

HA 8

307.1133.3.6 englisch (en) 10.2006

H Service Training

5650H – 5690HTS Wiring layouts

3. Wiring diagram steering column

307.1133.3.6 englisch (en) 10.2006

1605 2333

page 5

HA 9

H Service Training

5650H – 5690HTS Wiring layouts

4. Wiring diagram cabin

S6

1605 2333 page 4 – 1

Working lights front – rear

S34 Light switch S35 Change-over switch dipped beam – main beam top – down S36 Wind screen wiper S37 Revolving light

HA 10

307.1133.3.6 englisch (en) 10.2006

H Service Training

2333_4-1

307.1133.3.6 englisch (en) 10.2006

HA 11

H Service Training

5650H – 5690HTS Wiring layouts

5. Wiring diagram cabin

HA 12

1605 2333 page 4 – 2

307.1133.3.6 englisch (en) 10.2006

H Service Training

HA-015

X513.3 X513.4 X513.5 X513.6 X513.7 X513.8

X513.16 X513.15 X513.14 X513.1 X513.2

0,34 sw 0,34 ws 0,34 vi 0,34 bl 0,34 gr-ro 0,34 ro

-5000 -5000 -5000 -5000 -5000 -5000

0,34 gr 0,34 ge 0,34 gn 0,34 br 0,34 rt

-5000 -5000 -5000 -5000 -5000

3 4 5 6 7 8

16 15 14 1 2

HA-014

26-13 25-12 24-11 23-10

..

R3 R2 R1 3

2

1

6

5

4

9

8

7

22-9 21-8 20-7 19-6 18-5 17-4 16-3 15-2 14-1

SP1 SP2 SP3 SP4 SP5 SP6 12V GND

12 11 10 15 14 13

HA-013

18 17 16 21 20 19

2333_4-2

307.1133.3.6 englisch (en) 10.2006

HA 13

H Service Training

X2

X1

X3

X4

X21

X22

GE

WS

DGN

SW

HGR

DBL

20

19 21

1

2

42

X1

16

43

HR T

X1

SW

X1

17

40

WS

GE

X1

41

18

3 15 14 4 13

5 6

12

7 11 8 10

9

HA-001

HA 14

307.1133.3.6 englisch (en) 10.2006

H Service Training

5670 6. Cable harness engine

1

Speed monitoring elevator head

2

Connector at engine frame, X140 – X143

3

Minimum pressure switch air filter

4

Junction box grain loss sensors

5

Ground collective terminal at engine frame

br

6

Reverse gear buzzer

vi/ge

7

Sensor grain tank tube

ws/bl

8

Transducer fuel tank level

vi/ws

9

Speed sensor straw walker

ws/ge

10

Temperature sensor hydraulic oil

vi

11

Starter terminal 50

sw

12

Temperature sensor cylinder head

bl/gn

13

Temperature switch cylinder head

bl/sw

14

Oil pressure switch

bl/ge

15

Temperature sensor engine oil

sw/vi

16

Switch at tensioning pulley cooling ventilator belt

bl/rt

17

Generator terminal B+, D+, W

rt, bl, or

18

Servo motor threshing drum variator

sw/ge, sw/gn

19

Screw type terminal B+ at control cabinet

rt

20

Connector X1 – X4, X21, X22 at control cabinet

21

Terminating resistor 120 Ohm (pin 5-6) for CAN bus line

307.1133.3.6 englisch (en) 10.2006

br/ws, br

gn, br

HA 15

H Service Training

5650H – 5690HTS 7. Cable harness engine

1

Speed monitoring elevator head

2.

Connector at engine frame, X140 – X143

3.

Minimum pressure switch air filter

4.

Junction box grain loss sensors

5.

Ground collective terminal at engine frame

br

6.

Temperature sensor/switch engine oil

sw/vi, vi/gn

7.

Reverse gear buzzer

vi/ge

8.

Sensor grain tank tube

ws/bl

9.

Transducer fuel tank level

vi/ws

10.

Speed sensor straw walker shaft

ws/ge

11.

Temperature sensor hydraulic oil

vi

12.

Generator terminal B+, D+, W

rt, bl, or

13.

Oil pressure switch

bl/ge

14.

Temperature sensor/switch coolant

bl/gn, bl/sw

15.

Starter terminal 50

sw

16.

Servo motor threshing drum variator

sw/ge, sw/gn

17.

Screw type terminal B+ at control cabinet

rt

18.

Connector X1 – X4, X21, X22 at control cabinet

19.

Terminating resistor 120 Ohm (pin 5-6) for CAN bus line

HA 16

br/ws, br

gn, br

307.1133.3.6 englisch (en) 10.2006

H Service Training

X2

X1

X3

X4

X21

X22

GE

WS

DGN

SW

HGR

DBL

18

17 19 1

42

43

HR X1 T

X1

SW

X1

WS

16

40

GE

X1 41

2

15

3

14 4 5 6 13

7 12

8 11 9

10 HA-002

307.1133.3.6 englisch (en) 10.2006

HA 17

H Service Training

a

X9

X25

X10

DGR

HGN

ELB

b

b

10 RT

1 BR 2 GE

9 BL 8 SW

3 GR 7 GN

6 OR

4 WS

5 VI

14 BL

c

13 BR

HA-003

11 RT

d 12 SW

SW 12

11 RT

RT

10

1

BR

BL

9

2

GE

SW 8

3

GR

GN

7

4

WS

OR

6

5

VI

d 11 RT

e

BR

13

14 BL 12 SW

HA-012

HA-004

HA 18

307.1133.3.6 englisch (en) 10.2006

H Service Training

5650H – 5690HTS 8. Cable harness for control valves work hydraulics

a

Connector X9, X10, X25 at control cabinet

b

The 2-pin connectors for the control valve solenoids are marked with cable binders in different colours.

c

Control block small consumers

d

Control valve for cutting mechanism bank: In case of Balance combine harvesters this valve is located separately next to the control block.

e

Control valve cutting mechanism lift – lower

307.1133.3.6 englisch (en) 10.2006

HA 19

H Service Training

Notes

HA 20

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000

Appendix B

Commander Control 2000 Operating Instructions

5650H - 5690HTS

307.1133.3.6 englisch (en) 10.2006

HB 1

Commander Control 2000

1

2

3

11 12

4 13

5

Cal

Diag

6

Setup

7

10

☞

9

8

The key functions are only active when the main work switch is on.

35402

HB 2

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000 No

Controls

Function/Operation

1

Screen: Select the main screen here.

2

Status indicators for Grain tank clutch engaged Threshing section clutch engaged Cutting table clutch engaged

Blank field = Disengaged Flashing symbol = Clutch currently engaging Symbol = Engaged

35402

3

35402

Swivel grain tank discharge pipe in/out: Press key I: The grain tank pipe swings out. Press one of the keys again to stop the pipe movement. Press key 0: The grain tank pipe swings in. Press one of the keys again to stop the pipe movement. Pay attention to the indicator "grain tank pipe released" on the central instrument cluster or on the TERIS/TCS screen. The grain tank clutch for emptying the grain tank is engaged with the pedal switch. If the grain tank pipe is fully retracted while the grain tank clutch is engaged, the grain tank clutch will be automatically disengaged.

☞ ☞

4

35402

Engaging/disengaging the threshing section: Key I: Engage threshing mechanism. Key 0: Disengage threshing mechanism (if the cutting table is activated, it too will be disengaged). To engage the threshing section, the main work switch must be switched on, and the engine must be running at slow idling speed. If the straw chopper is activated (straw guide plate in the chopping position), when the threshing key is pressed, the straw chopper will automatically be engaged first, followed by the threshing section. On disengaging, the threshing section is disengaged first, followed by the straw chopper.

☞

5

35402

Engaging/disengaging the cutting table Key I: Engage the cutting table. Key 0: Disengage the cutting table.

☞

307.1133.3.6 englisch (en) 10.2006

To engage the clutch, the threshing section must be activated.

HB 3

Commander Control 2000

1

2

3

11 12

4 13

4

Cal

Diag

6

Setup

7

10

☞

9

8

The key functions are only active when the main work switch is on.

35402

HB 4

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000 No

Controls

Function/Operation Press 1 x – Concave clearances: Open the "Set Clearances" menu to set the concave clearances for the threshing drum and turbo separator (the main work switch must be switched on).

6

35402

Press 2x – Sieve adjustment: Open the "Set Clearances" menu to adjust the sieves (the main work switch must be switched on). Concave rapid opening: Hold down the key for 3 seconds. See section on "Concave rapid opening".

Return to main screen/Load settings.

7

35402

– Open the "Speed Monitor" menu to set the speed warning limits for the tailings elevator, straw walker shaft and grain tank auger. With TERIS/TCS, this function is inactive. Activate the function with the terminal.

☞

– Return to main screen/Load settings.

8

Setting the winnowing fan speed: (To set the fan speed, the threshing section must be in operation). Setup Setup

Setup

35402

+

key: key:

Increase fan speed (indicator at (13)) Decrease fan speed (indicator at (13))

Setup Menu: Hold down the Setup + and keys simultaneously for 3 seconds. The "Setup Menu" for setting the language appears. See the section on "Language Selection". Only use the Setup menu to set the language version. All other functions are intended for customer service only.

35065

+

35066

307.1133.3.6 englisch (en) 10.2006

35402

HB 5

Commander Control 2000

1

2

3

11 12

4 13

4

Cal

Diag

6

Setup

7

10

☞

9

8

The key functions are only active when the main work switch is on.

35402

HB 6

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000 No

Controls

Function/Operation

9

Threshing drum speed adjustment: (to adjust the drum, the threshing section must be activated). Diag Diag

Diag

+

key: key:

Increase threshing drum speed (indicated by 11)) Decrease threshing drum speed (indicated by (11))

The diagnosis menu is only intended for customer service.

35402

☞ 10

If the diagnosis menu is selected inadvertently, it can be closed by pressing keys Cal + and simultaneously.

Reel speed adjustment: (to adjust the pick-up reel speed, the cutting table must be in operation) Manual speed adjustment: Cal + key: Increase reel speed Cal key: Decrease reel speed

Cal

Activate/deactivate automatic reel speed adjustment: Press Cal + and keys simultaneously. (see section on "Setting automatic reel speed adjustment".)

35402

☞

When automatic reel speed adjustment is activated, the ratio of the reel speed to the travel speed can be adjusted by pressing the Cal + and keys simultaneously.

Calibration menu: Hold down keys Cal menu" will appear.

11

+

and

simultaneously for 3 seconds. The "Calibration

Threshing drum speed display (rpm) 35402

12

Travel speed display (km/h) 35402

13

Winnowing fan speed display (rpm) 35402

307.1133.3.6 englisch (en) 10.2006

HB 7

Commander Control 2000 System start and shutdown CAUTION When switching on the ignition, the clutch servomotors may move, because the clutches are automatically driven to the disengaged position.

The Commander Control 2000 is switched on with the ignition. Two audible signals are sounded, and the start screen is displayed. On starting the engine, the system is restarted.

☞ 35402

35405

The bottom two lines of the start screen show the installed software version with the release date.

The main screen is then displayed, and Command Control 2000 is ready for operation.

☞

If the battery charge lamp is lit or if the message "Low battery" is displayed, the Commander Control 2000 is not ready for operation. If necessary, briefly increase the engine speed.

The Commander Control 2000 is switched off by switching off the ignition.

35429

HB 8

35402

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000 Selecting the language / Setting the view angle To set the desired language and view angle, open the Setup menu. – Hold down the Setup + and simultaneously for 3 seconds.

keys (1)

The Setup menu must only be used to set the language version and the view angle. All other functions are intended for customer service only. Cal

Diag

Setup

Language selection When the Setup menu is displayed, the highlighted cursor bar is on "Language" (if not, select the "Language" line with the Diag (2) keys).

1

– Select the desired language with the Setup (1) keys.

35429

35402

– Save the selection by pressing the Cal + and keys (3) simultaneously. ☞ The selected language is activated immediately. The main screen is displayed again.

Setting the view angle Language:

– Select the view angle with the Diag (2) keys.

English

Front tyres: Radial 800/65R32

– Change the view angle with the Setup (1) keys.

Turbo separator:

– Save the selection by pressing the Cal + and keys (3) simultaneously. ☞ The change is activated immediately.

yes View angle:

Cal

5

Diag

3

Setup

2

☞

1

35402

307.1133.3.6 englisch (en) 10.2006

In the Setup menu, if more than 10 seconds elapse without any user input, the system automatically returns to the main screen. In this case, the settings entered while the Setup menu was open will not be saved.

35406

HB 9

Commander Control 2000 Setting the speed warning limits

☞

With TERIS/TCS, this function is inactive. Activate it on the terminal.

The speeds of the returns elevator, straw walker shaft and grain tank delivery auger are continuously monitored. A minimum warning limit can be set for each speed. If the speed falls to the set warning limit, the audible and visual alarm is activated. The warning limit can be set to a speed reduction of between 5 % and 50 % (relative to the nominal speed). To set the speed warning limits, open the "Speed monitor" menu in the main screen. Cal

Diag

Setup

– Press key (1).

1

35402

☞

The Speed Monitor menu appears.

Setting the warning limits: Grain tank delivery auger – keys (3) Straw walker shaft – keys (4) Returns elevator – keys (5)

Speed Monitor

Deactivating the alarm: – Set the warning limit to the bottom value, i.e. 50 % reduction. – Hold down the key for 5 seconds. The selected warning will be deactivated, and the symbol appears next to the display bar (as shown in the illustration opposite for the delivery auger). Activating the alarm: Press the + key. Cal

Diag

Select each warning limit as required.

Setup

Saving the values: Press key (1). The main screen is displayed.

☞ 5

4

3

2

1

In the absence of any user input for a period of more than 10 seconds, the system automatically returns to the main screen. In this case, any settings previously entered will not be saved. To quit the menu without saving the values, press key (2).

35402

HB 10

35407

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000 Setting the automatic reel speed control (optional) The automatic reel speed control enables the reel speed to be adapted automatically to the travel speed (ground drive speed). Activating/deactivating: – Press the Cal + and

(1) keys simultaneously.

After switching on automatic reel speed control, the symbol appears next to the reel speed symbol to indicate automatic reel speed control mode (2).

Cal

Diag

Standby/active mode: The automatic reel speed control is in standby mode if the symbol (2) remains continuously lit. If the symbol is flashing, automatic control is active. At full throttle in the operating range from 2.0 to 9.0 km/h, the automatic reel speed control automatically switches from standby mode to active mode.

Setup

1 Adjusting the reel speed ratio: Switch on the automatic reel speed control. 35402

Increase the speed ratio

– Cal

Decrease the speed ratio

– Cal

+

key key

When adjusting the ratio, the control is automatically switched to standby mode. Ten seconds after completing the adjustment process, the system automatically returns to active mode with the new ratio of reel speed to travel speed.

☞

35409

2

When automatic reel speed control is deactivated, the reel speed is directly adjusted with the Cal + and keys.

Displaying the adjustment process: Manual or automatic adjustment of the reel speed is indicated by arrows above or below the symbol for automatic reel speed control (2). If the arrow points upwards (3), the reel speed is increasing, and if it points downwards (4) the speed is being reduced.

35411

35410

3

307.1133.3.6 englisch (en) 10.2006

4

HB 11

Commander Control 2000 Setting the concave clearances Caution The servomotors and linkage mechanisms move are moving parts. The clearances of the concave and separator concave can be set in this menu. Precondition: the main work switch must be on. To set the concave clearances in the main screen, open the "Set clearances" menu. Cal

Diag

– Press key (2).

Setup

2

35402

☞ The "Set clearances" menu is displayed. The clearance is set in discrete increments (steps). Set clearances

Selecting clearances: Turbo separator concave Threshing concave, rear Threshing concave, front

– Keys (3) 5 steps – Keys (4) 15 steps – Keys (5) 15 steps

Saving values: Press key (2). The adjustment process is started, and on completion the main menu is displayed.

☞ Cal

Diag

Setup

☞ 5

4

3

2

1

35402

HB 12

If the selected settings are in the prohibited range, they are automatically corrected to the permitted minimum/maximum value when saved (otherwise the threshing drum would strike the concave). In the absence of any user input for a period of more than 10 seconds, the main screen automatically reappears. In this case, any settings previously entered will not be saved. To quit the menu without saving the values, press key (1).

35407

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000

☞

If you attempt to adjust the clearances while adjustment is prohibited (main work switch off), the following message appears on the screen: Set clearances

Clearance adjustment is prohibited.

35402

Switch back to the main screen with key (1) or (2).

Rapid opening of threshing concave/separator concave CAUTION Servomotors and linkage mechanisms are moving parts. The rapid open function immediately opens the threshing concave and separator concave (e.g. to prevent blockage of the threshing mechanism). Activating the rapid opening function: – Hold down key (2) for three seconds. The "Rapid opening" information window is displayed. Cal

Diag

Setup

Rapid opening of thr. drum and Turbosep. active

2

1

35412

35402

When the opening process has been successfully completed, the information window "Rapid opening is terminated" is displayed.

Rapid opening is terminated.

35413

307.1133.3.6 englisch (en) 10.2006

HB 13

Commander Control 2000 Resetting rapid opening: – Briefly press the Setup

+

or

key (3).

The previous settings for the threshing and separator concaves will be restored.

Error message: Interruption of rapid opening is indicated by the "Error" window:

Error Cal

Diag

Setup

Rapid opening not complete. Engine fault!

35414

3

35402

HB 14

Possible causes of failure: – Clogging/fouling by threshed crop. – Servo drives not running smoothly. Switch off the ignition. Remedy the fault and repeat the calibration procedure. If the error message is displayed again, call a specialist workshop.

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000 Sieve adjustment The top and bottom sieves are adjusted in a single window. Activating sieve adjustment: – Press key (2) briefly twice.

4

3

2

1

35402

CAUTION The servomotors are moving parts.

35429

☞ The "Set clearances" window is displayed. The sieve clearances are set in millimetres, with a range of 1 to 14 mm.

Set clearances

Setting the clearances: Top sieve – Cal keys (4) Bottom sieve – Setup keys (3)

Saving values: Press key (2). The adjustment process is started, and then the main menu appears (if the gap has been reduced, the sieves are first closed further before being driven outwards to the new setting). Cal

Diag

4

Setup

3

☞ 2

35402

307.1133.3.6 englisch (en) 10.2006

☞

1

In the absence of any input for a period of more than 10 seconds, the system automatically returns to the main screen. In this case, any settings previously entered will not be saved. To quit the menu without saving the values, press key (1).

35415

HB 15

Commander Control 2000 Calibration

☞

All calibrations are carried out in the factory before delivery.

Recalibration is necessary e.g. after: – Fitting other sieves – Changing the mechanical basic setting – Replacing servomotors – Reinstalling software

☞ Cal

Diag

After changing the sieves several times, check the sieve setting and if necessary calibrate. Recommendation: carry out a sieve calibration at least once a year.

Setup

To open the calibration menu: – Hold down the Cal + and keys (1) simultaneously for 3 seconds.

1 CAUTION The servomotors move during the calibration processes. 35402

☞ The "Calibration menu" is displayed. Selecting the function: Calibration menu

– Mark the line of the desired function with the Diag and keys (2).

Sieves Sieves Straw guide plate Spreader plates Concave clearances

+

– Open the selected function with the Setup + or keys (3). The calibration menu of the selected function is displayed.

☞

Cal

Diag

☞

Setup

☞ 1

2

3

35402

HB 16

The Calibration menu or any specific calibration menu can be closed at any time by pressing the Cal + and keys (1) simultaneously. Any calibration that has started will be aborted. In the absence of any input for a period of more than 10 seconds, the system automatically returns to the main screen. In this case, any settings previously entered will not be saved.

35415

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000 Calibrating sieve adjustment (Electric sieve adjustment optional)

3

2

1

4

CAUTION – Park the combine and secure it against rolling. – The servomotors move during calibration.

5 33992

Preconditions: – The basic sieve setting must be correct. – The engine must be switched off with the ignition on. – The sieve box light must be switched on with button (3). – The sieves must be cleaned.

☞

Calibration menu

6

Sieves Sieves

Straw guide plate Spreader plates Concave clearances

Always make sure that the louvres of the left and right-hand sieve are opened the same distance. If necessary, slightly modify the basic setting.

Calibration: – Hold down the Cal + and keys (1) simultaneously for 3 seconds. The "Calibration" (6) menu is displayed

☞

– In the "Calibration menu", select "Sieves" (with the Diag + and keys). – Press the Setup

Sieve adj. calib.

☞

Calib. Procedure 1.Open sieves 2.Close sieves position and both keys. 3.Close sieves position and both keys.

to 14 mm press

7

to 0 mm* press

35417

Sieve adj. calib.

Top sieve Potentiometer Cal. min. Cal. max.

2.02V 2.02V 6.96V

8

Sieve adj. calib.

2.02V 2.02V 6.96V

Bottom sieve Potentiometer Cal. min. Cal. max.

2.45V 2.45V 6.21V

35419

307.1133.3.6 englisch (en) 10.2006

or

keys.

The "Sieve adj. calib." window (7) appears.

Top sieve calibration: – Fully open the top sieve with key (1). – Close the top sieve with key (2) until the sieve aperture is 14 mm. – Hold down keys (1) and (2) simultaneously for at least 1 second. – Fully close the top sieve with key (2), and then open approx. 0.5 – 1 mm. – Hold down keys (1) and (2) simultaneously for at least 1 second. The calibration values of the top sieve appear in the window (8).

☞

35418

Top sieve Potentiometer Cal. min. Cal. max.

+

9

Bottom sieve calibration: – Fully open the bottom sieve with key (4). – Close the top sieve with key (5) until the sieve aperture is 14 mm. – Hold down keys (4) and (5) simultaneously for at least 1 second. – Fully close the bottom sieve with key (5), and then open approx. 0.5 – 1 mm. – Hold down keys (4) and (5) simultaneously for at least 1 second. The calibration values of the top sieve appear in the window (9).

☞

HB 17

Commander Control 2000

☞

Back to main screen: Press keys Cal

+

and

simultaneously.

Checking the settings: – Set the sieve aperture successively to 4, 8 and 12 mm and check.

☞ Cal

Diag

Setup

35429

HB 18

In the event of any deviations, repeat the basic setup (see section on the "Threshing Section") and calibration.

35402

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000 Calibrating the straw guide plate CAUTION The servomotors move during calibration.

Calibration menu

1

Sieves Straw guide plate Spreader plates Concave clearances

2

Preconditions: – The engine must be switched off, with the ignition on.

Calibration: – Hold down the Cal + and keys simultaneously for 3 seconds. The "Calibration menu" (1) is displayed.

☞

– In the Calibration Menu, select "Straw guide" (2) (with the Diag + and keys).

Str. guide calib. Calibrate …

– Press the Setup

+

or

keys.

3

☞

The "Str. guide calib." window (3) is displayed. The adjusting motor is automatically driven to the two end positions, and the result is evaluated.

4

☞

After successful calibration, the message "Calib.: successful" is displayed in the window with the average values (4).

5

☞

If calibration is unsuccessful, the message "Cal.: Error" is displayed in the window (5).

35420

Str. guide calib. Calib.: successful Potentiometer Cal. min. Cal. max.

2.27V 2.29V 5.70V

35421

Str. guide calib. Cal.: Error

Possible causes of error: – Clogging/fouling with straw – Servomotor not running smoothly. Switch off the ignition and remedy the fault, and then repeat the calibration procedure. If the error message appears again, have the machine inspected by a specialist workshop.

35422

☞ 307.1133.3.6 englisch (en) 10.2006

Back to the main screen: Press keys Cal

+

and

simultaneously.

HB 19

Commander Control 2000 Calibrating the spreader plates

1.1

1

Preconditions: – The engine must be switched off, with the ignition on.

Calibration: – Hold down the Cal + and keys simultaneously for 3 seconds. The "Calibration menu" (4) is displayed.

3

☞

2

1.2

35379

Calibration menu

4

Sieves Straw guide plate Spreader plates Concave clearances

5

Spreader plate calib. Drive the motor to both end positions and press key.

6

– In the Calibration Menu, select "Spreader plates" (5) (with the Diag + and keys). – Press the Setup

☞

+

or

keys.

The "Spreader calib." window (6) is displayed.

– Drive the adjusting motor to the two end positions with key (1): – Key (1.1): drive the straw spreader plates to the right as far as they will go and then check that the straw guide plates are in the end position. – Key (1.2): drive the spreader plates to the left as far as they will go and then check that the straw guide plates are in the end position.

– Press the Setup

+

or

key.

35423

Spreader plate calib. Calib.: successful Potentiometer Cal. min. Cal. max.

0.15V 0.14V 6.43V

7

☞

After successful calibration, the message "Calib.: successful" is displayed in the window with the average values (7).

35424

☞

HB 20

Back to the main screen: Press keys Cal

+

and

simultaneously.

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000 Calibrating the concave clearances Preconditions: – The engine must be switched off, with the ignition on. – The basic mechanical basic must be correct. Calibration menu Sieves Straw guide plate Spreader plates Concave clearances

1

2

CAUTION The servomotors move during calibration.

Calibration: – Hold down the Cal + and keys simultaneously for 3 seconds. The "Calibration menu" (1) is displayed.

☞

– In the Calibration Menu, select "Conc. clearances" (2) (with the Diag + and keys).

Set clearances

3

– Press the Setup

+

or

keys.

☞

Calibration starts automatically. The servomotors are driven to the end positions, and the result is evaluated. The calibration process can be monitored with the clearance indicators in the "Set clearances" menu (3).

☞

After successful calibration, the information window (4) is displayed.

☞

If calibration is unsuccessful, the error message is displayed (5).

35403

Set clearances

Calibration of concv. clearance successful!

4

35421

Set clearances

Error Calibration of concv. clearance has failed!

Possible causes of error: – Clogging/fouling by threshed crop. – Servomotors not running smoothly. Switch off the ignition and remedy the fault, and then repeat the calibration procedure. If the error message appears again, have the machine inspected by a specialist workshop.

5

35422

☞ 307.1133.3.6 englisch (en) 10.2006

Back to the main screen: Press keys Cal

+

and

simultaneously.

HB 21

Commander Control 2000 Error messages and warnings Error messages and warnings appear in the form of a window on top of the existing display. In machines with TERIS/TCS, error messages are generally output on the TERIS/TCS monitor. However, if the connection to TERIS/TCS is blocked due to a fault, the error messages are displayed on the Commander Control. The Commander Control handles error messages as follows: – When an error occurs, a message appears on the display. At the same time, an audible signal is sounded for 2.5 to 5 seconds. – The message disappears when: – the cause of the error is no longer present – the message is acknowledged by pressing a key (except for the warnings "Engine speed/Engine oil temperature too high"). – If more than one incident requiring a message occurs, the incident with the highest priority is displayed. The individual messages are listed in descending order of priority in the list that follows. Messages are displayed as Warnings or Errors. Example "Warning": "Engine speed too high" This message: – has the highest priority and appears when the engine speed rises above 2900 rpm. – cannot be cancelled by pressing a key. – automatically disappears when the engine speed drops back below 2800 rpm.

Warning Engine speed too high!

☞ 35427

When driving downhill, brake and shift down a gear.

Example "Error": "Overload in Command. Control pot supply" This message: – appears when the 5 V potentiometer supply falls below 4.5 V due to overload.

Error

☞

Overload in Command.Control pot supply!

Switch the ignition off and on again. If the error message appears again, call a specialist workshop (servomotors not functioning, possible short circuit).

35428

HB 22

307.1133.3.6 englisch (en) 10.2006

Commander Control 2000 List of warning and error messages Message text

Type*

Engine speed too high

W

Description/Cause

Remedy

– has top priority if the engine speed rises above 2900 rpm.

When driving downhill, brake and shift down a gear.

– cannot be cancelled; automatically disappears when the engine speed falls below 2800 rpm. Engine speed too low

W

– appears when the engine speed falls below the value set in the Setup menu during one second.

– Reduce engine load. – Set a lower warning limit.

Engine oil temperature is too high

W

– appears when the engine oil temperature switch is closed. – cannot be cancelled; automatically disappears when the engine oil temperature drops.

– Reduce engine load. – Allow the engine to idle. – Check/remove any fouling of the radiator.

Cooling water level

W

– appears if the coolant level in the tank is too low

Replenish coolant

Overload in Command.Control pot supply

E

– appears when the 5 V potentiometer supply falls below 4.5 V due to overload.

Switch the ignition off and on again. If the message appears again, call a specialist workshop (servomotors not functioning, possible short circuit).

Chopper speed too slow

W

– appears when chopper speed falls below 1200 rpm for one second at nominal engine speed. – drive belt is slipping.

– Reduce load.

– appears when the speed of the returns elevator falls below the limit set in the Speed Monitor menu for one second. – drive belt is slipping.

– Reduce load.

– appears when the speed of the straw walker shaft falls below the limit set in the Speed Monitor menu for one second. – drive belt is slipping.

– Reduce load. – Set lower warning limit.

– appears when the speed of the grain tank delivery auger falls below the limit set in the Speed Monitor menu for one second. – drive belt is slipping.

– Reduce load. – Set lower warning limit.

– appears when the grain tank extension is extended, with the main work switch off and the ground travel speed is more than 2.0 km/h. – if the grain tank cover is opened.

– Retract grain tank extension

Ret. elevator speed too slow

Straw walker speed too slow

Delivery auger speed too slow

The grain tank cover is extended

* W = Warning

W

W

W

W

– Check drive/belt tension.

– Check drive/belt tension.

– Check drive/belt tension.

– Check drive/belt tension.

– Close grain tank cover

E = Error

307.1133.3.6 englisch (en) 10.2006

HB 23

Commander Control 2000 Message text

Type*

Adjusting motor, concave, rear

E

Description/Cause

Remedy

– appears in the event of adjusting motor malfunction for the rear concave clearance. Possible causes:

– Switch the ignition off and on, and try again.

– clogging of threshing section

– Clear the blockage.

– mechanical defect

– Check the adjusting mechanism.

– Fuse F50 faulty – Relay K60, K81 faulty

– Check the fuse and relay, and replace if necessary.

– Electrical system faulty

– Check the electrical connections. If the fault cannot be remedied, call a specialist workshop.

Adjusting motor, concave, front

E

– appears in the event of adjusting motor malfunction for the rear concave clearance. Possible causes:

– Switch the ignition off and on, and try again.

– clogging of threshing section

– Clear the blockage.

– mechanical defect

– Check the adjusting mechanism.

– Fuse F49faulty – Relay K18, K39 faulty

– Check the fuse and relay, and replace if necessary.

– Electrical system faulty

– Check the electrical connections. If the fault cannot be remedied, call a specialist workshop.

Adjusting motor, turbo separator

E

– appears in the event of adjusting motor malfunction for the rear concave clearance. Possible causes:

– Switch the ignition off and on, and try again.

– clogging of threshing section

– Clear the blockage.

– mechanical defect

– Check the adjusting mechanism.

– Fuse F51 faulty – Relay K19, K49 faulty

– Check the fuse and relay, and replace if necessary.

– Electrical system faulty

– Check the electrical connections. If the fault cannot be remedied, call a specialist workshop.

Grain tank pipe, swivelled in

W

Handbrake applied

* W = Warning HB 24

W

– appears when the grain tank pipe is swivelled out, the main work switch is switched off, and the travel speed is above 2.0 km/h.

– Swivel the grain tank pipe inwards.

– Proximity switch faulty

– Check the proximity switch and replace if necessary.

– appears when the handbrake is applied and the travel speed is above 2.0 km/h.

– Release handbrake.

– switch faulty.

– Check the switch, and replace if necessary.

E = Error 307.1133.3.6 englisch (en) 10.2006

Commander Control 2000 Message text

Type*

TCS/Teris not addressable

E

Description/Cause

Remedy

– appears when the TERIS/TCS is set in Setup but cannot be accessed via the CAN bus (only for TERIS/TCS).

– Switch the ignition off and on.

EMERGENCY MODE No functions are monitored any longer. – Fuse F38 faulty

– Check the fuse, and replace if necessary.

– Fuse (10 A) in voltage stabilisation module A14 faulty.

– Check the fuse, and replace if necessary.

– Voltage stabilisation module A14 faulty.

– Check the indicator lamps, and replace the module if necessary. If the fault cannot be remedied, allow the machine to run until empty and immediately call a specialist workshop.

Sieve adjusting is not addressable

E

– appears when electric sieve adjustment is set in Setup, but the relevant electronic module cannot be accessed via the CAN bus (only for units with electric sieve adjustment).

– Switch the ignition off and on, and try again.

– Fuse F57 faulty.

– Check the fuse, and replace if necessary. If the fault cannot be remedied, call a specialist workshop.

Straw guide is not addressable

E

– appears when electric straw guide plate adjustment is set in Setup, but the relevant electronic module cannot be accessed via the CAN bus (only for units with electric straw guide plate adjustment).

– Switch the ignition off and on, and try again.

– Fuse F56 faulty.

– Check the fuse, and replace if necessary. If the fault cannot be remedied, call a specialist workshop.

Spreader plates are not addressable

E

– appears when electric spreader adjustment is set in Setup, but the relevant electronic module cannot be accessed via the CAN bus (optional equipment).

– Switch the ignition off and on, and try again.

– Fuse F55 faulty.

– Check the fuse, and replace if necessary. If the fault cannot be remedied, call a specialist workshop.

* W = Warning

E = Error

307.1133.3.6 englisch (en) 10.2006

HB 25

Commander Control 2000 Message text

Type*

Straw guide adjusting motor is faulty

E

Description/Cause

Remedy

– appears in the event of malfunction of the adjusting motor for the straw guide plate.

– Switch the ignition off and on, and try again.

– Clogging/fouling

– Clear the blockage/fouling.

– Mechanical fault

– Check the adjusting mechanism.

– Fuse F13 faulty – Relays K16, K37 faulty

– Check the fuse and relays, and replace if necessary.

– Electrical fault

– Check the electrical connections. If the fault cannot be remedied, call a specialist workshop.

Top sieve adjusting motor is faulty.

E

– appears in the event of malfunction of the adjusting motor for the top sieves (optional equipment).

– Switch the ignition off and on, and try again.

– Mechanical fault

– Check the adjusting mechanism.

– Fuse F52 faulty – Relays K20, K41 faulty

– Check the fuse and relays, and replace if necessary.

– Electrical fault

– Check the electrical connections. If the fault cannot be remedied, call a specialist workshop.

Bottom sieve adjusting motor is faulty.

E

– appears in the event of malfunction of the adjusting motor for the bottom sieves (optional equipment).

– Switch the ignition off and on, and try again.

– Mechanical fault

– Check the adjusting mechanism.

– Fuse F53 faulty – Relays K62, K83 faulty

– Check the fuse and relays, and replace if necessary.

– Electrical fault

– Check the electrical connections. If the fault cannot be remedied, call a specialist workshop.

* W = Warning HB 26

E = Error 307.1133.3.6 englisch (en) 10.2006

H Service Training

Appendix C

Commander Control 2000 Setup and Diagnosis 5650H - 5690HTS

307.1133.3.6 englisch (en) 10.2006

HC 1

H Service Training

Setup menu

☞

If there is no input in the setup menu for more than 10 seconds, the main screen automatically reappears. Settings carried out in the meantime will not be saved.

Calling the setup menu: – Press the keys Setup + and simultaneously for 3 seconds.

Cal

Diag

(1)

Setup

1

35429 35402

4

☞ The first page of the setup menu appears.

Setup

1/4

The setup menu consists of 4 pages. The page number (4) is displayed on top at the right side in the menu window: 1/4 = page 1 of 4

Language:: english Front tires: R adial 650/75R32 Turbo separator:

yes

LCD View angle;

5

Page selection: Keys (3): Cal

+

Parameter selection: Keys (2): Diag Cal

Diag

Setup

or

+

Parameter setting: Keys (1): Setup

or

+

or

Saving of adjusted values: Keys (3): Cal + and

3

2

simultaneously.

1

35402/35406

HC 2

307.1133.3.6 englisch (en) 10.2006

H Service Training

Setup menu Example: Adjustment of speed alarm limit Setup

1/4

1

In this example the speed alarm limit is supposed to be adjusted from 0% to -20%.

Language:: english Front tires: R adial 650/75R32 Turbo separator:

yes

LCD View angle;

5

Setup Setup

4/4 4/4

Alternat oo rrss pp :: Alternat DZ Lichtm.:

8040

Eng.sp. factor: MotorDZFaktor

3.32 3.32

DZ Motor: Engine Motore NG: Warngrenze:

2421 2421

W arning limit:

0%

Setup Setup

4/4 4/4

– Press the keys Setup + and simultaneously for 3 seconds.

and

☞ The first page of the setup menu (1) appears. 2

– Press the key Cal

3x.

+

8040 fourth page of the setup menu (2) ☞ The appears. The first line is marked.

0%

Alternat or sp: DZ Lichtm.:

8040 8040

MotorDZFaktor Eng.sp. factor:

3.32 3.32

DZ Motor: Motore NG: Engine Warngrenze: Warngrenze

2421 2421

W arning limit:

0%

Setup Setup

4/4 4/4

0%

Alternat or sp: DZ Lichtm.:

8040 8040

Eng.sp. factor: MotorDZFaktor

3.32 3.32

DZ Motor: Motore NG: Engine Warngrenze: Warngrenze

2421 2421

W arning limit:

-20%

-20%

3x.

– Press the key Diag

☞ The fourth line ”alarm limit” (3) is marked. 3

– Press the key Setup + or as often as necessary in order to set the desired %-value of -20% (4).

4

– Press the keys: Cal

+

and

simultaneously.

main screen appears, the set value is ☞ The saved.

35406/35429 307.1133.3.6 englisch (en) 10.2006

HC 3

H Service Training

SETUP MENU The four pages of the setup menu: Setup

1/4

Machine type: Maschinentyp Maschinentyp:

Language:: english Front tires: R adial 650/75R32 Turbo separator: LCD View angle;

Setup Setup

yes

2/4 2/4 5670 5670

Setup Setup

3/4 3/4

Setup Setup

El.sieve adj:

yes

Alternator sp: DZ Lichtm.:

El.straw guide

no

el.Siebverst.:

ja

4/4 4/4 8040

8040

Chopper:

yes

TERIS/TCS:

yes

ja

el.Häckslerk.: nein El.spread.pl: no

Eng. p. actor: Eng. ss p. ffactor: 3.32 MotorDZFaktor: 3.32

ja no

el.Strohvert.: nein

DZ Motor: Motore NG: Engine Warngrenze

Häcksler:

TerisTCS: GTL sensor #2: KTFS–Geber R evers. drum: #2

nein no

Wendetrommel:

nein

W arning limit:

2421 2421 0%

0%

5

Adjustment range of parameters in the setup menu Parameter

Adjustment range

page 1: language

deutsch - (englisch)

front tyres

Radial 800/65R32

this input is necessary for the exact calculation

Radial 650/75R32

of the ground speed

Radial 620/75R30 Radial 620/75R26 Diagonal 30,5-32 Diagonal 24,5-32 Diagonal 23,1-30 Diagonal 23,1-26

turbo separator

yes - no

LCD viewing angle

0 ... 9

page 2: type of machine

5670 - 5680 - 5690

chopper

yes - no

Teris TCS

yes - no

KTFS transmitter #2 (grain tank level transmitter no. 2)

yes - no

impeller

yes - no

page 3: electrical sieve adjustment*

yes - no

electrical chopper flap adjustment*

yes - no

electrical straw spreader adjustment*

yes - no

page 4: engine speed coefficient

0.10 ... 9.99

dynamo machine speed to engine speed ratio alarm limit engine speed

0% ... -50% ... (aus)

* * Programming of CAN modules see chapter H

HC 4

307.1133.3.6 englisch (en) 10.2006

H Service Training

Diagnosis CAUTION After calling the diagnosis menu no machine functions will be monitored or controlled any more. All safety functions are switched off.

Calling the diagnosis menu: – Press the keys Diag + and (1) simultaneously for 3 seconds.

Cal

Diag

☞ In order to completely engage or disengage,

Setup

actuate the servo motor until the clutch control power unit switches off the servo motor in the final.

1

35429 35402

☞ The diagnosis menu appears. 2 Enabling of the actuators:

☞

Diagnosis menu Speeds Concave Clearances Main Clutches Grain Tank Threshing Mode Ground Drive Mode Indicator Lights CAN

– Press the keys (2) and (3) simultaneously.

☞ The actuators are enabled. 3

Cal

Diag

It is necessary to enable the actuators in the diagnosis menu. Otherwise no adjustment is possible in the diagnosis.

Selecting the function: – Mark the line of the desired function by means of the keys Diag + and (1).

Setup

☞

An arrow at the beginning or at the end of the menu window indicates further hidden lines.

– Call the desired function by means of the keys Setup + or (4).

5 both: Quit menu

1

4

Line

Call

☞ 35402/25Men

307.1133.3.6 englisch (en) 10.2006

☞

The first page of this function appears.

It is possible to quit the menu or any page anytime by means of pressing the keys Cal + und (5) simultaneously. HC 5

H Service Training

1

Diagnosis Speed 1/2 Reel Reel 0UPM Rel.: Faster +I+ Rel.: Slower -IThreshing Drum Rel.: Faster Rel.: Slower

2

Diagnosis Example for display of pages

3

The first page (1) of the menu item ”Speeds” appears after selection by means of the keys Setup + or . page display ”1/2” (2) indicates: Page 1 ☞ The of 2.

0UPM -I-I-

The speed (RPM) is shown in the status display (3).

Fan Speed 1302UPM Rel.: Faster -IRel.: Slower -I-

Diagnosis Speed Reel Rel.: Faster Rel.: Slower

Switching over the status display (3): – Press the keys Diag + und simultaneously.

1/2 2.4Hz -I-I-

4

Threshing Drum Drum 0.0Hz Threshing Rel.: Faster -IRel.: Slower -IFan Speed Rel.: Faster Rel.: Slower

display will be shown successively ☞ The in RPM, Hz and static sensor signal.

21.7Hz -I-I-

Diagnosis Speed

– Press the keys Diag once more.

1/2

5

Reel Rel.: Faster Rel.: Slower

status display will be switched over to Hz ☞ The (4).

+

and

simultaneously

static sensor signal (5) is shown in the ☞ The status display (this only makes sense for evaluation when the drive has stopped).

Threshing Drum Rel.: Faster Rel.: Slower Fan Speed Rel.: Faster Rel.: Slower

Calling of page 2:

6

Diagnosis Speed

2/2

Chopper 0UPM Straw Walker 0UPM Returns Elevator 0UPM Filling Auger 0UPM Dynamo Machine 8050UPM Engine 2424UPM Wheel Imp. 0UPM

– Press the keys (1): Cal

or

.

☞ The page 2/2 will be displayed (6). Switching over of the status display is done on this page in the same way as described before.

☞ HC 6

+

All further key functions are described in the following descriptions of the menu items.

307.1133.3.6 englisch (en) 10.2006

H Service Training

Diagnosis Display of sensor and switching statuses Symbol

Status Sensor dampened

Sensor non dampened

Switch closed

Switch opened

Status display of servo drives Symbol

Status

–|–

Servo drive is switched off

–|+

Failure: Line disconnection or short circuit behind power supply

+|–

Failure: Short circuit to ground

+|+

Servo drive is switched on

Subsequently all menu items with the appropriate pages are discussed in the successive order of the diagnosis menu: Menu items Speeds Concave clearances Main clutches Grain tank Threshing mode Ground drive mode Indicator lights CAN System

307.1133.3.6 englisch (en) 10.2006

Page title Diagnosis Speeds Diagnosis CCo Diagnosis MC Diagnosis GT Diagnosis TM Diagnosis GDM Diagnosis IL Diagnosis CAN Diagnosis Syst.

HC 7

H Service Training

Diagnosis speeds Speed adjustments may only be carried out when the drive is running and the clutch is engaged.

Diagnosis Speed 1/2 Reel Reel 0UPM Rel.: Faster +I+ Rel.: Slower -IThreshing Drum Rel.: Faster Rel.: Slower

0UPM -I-I-

Key functions: Page selection: keys (1): Cal

Fan Speed 1302UPM Rel.: Faster -IRel.: Slower -I-

+

Line selection: keys (2): Diag Cal

Diag

☞ 2

Page

Line

both:

both:

return to the ”Diagnosis menu”

Status display

+

Speed adjustment: keys (3): Setup

Setup

1

or

3

or

+

or

The speed of the drive selected on page 1 (4) is altered directly by means of actuating the servo drive.

Adjustment is done as long as the key is pressed: Setup + – Speed is increased Setup – Speed is decreased

Speed adjustment

Status display: keys (2): Diag 28Diag 35402

☞

+

and

simultaneously

In the status display the speed (RPM), Hz and static sensor signal will be shown successively (this only makes sense when the drive has stopped).

Return to the ”Diagnosis menu”: keys (1): Cal + and simultaneously

4

Diagnosis Speed 1/2 Reel Reel 0UPM Rel.: Faster +I+ Rel.: Slower -IThreshing Drum Rel.: Faster Rel.: Slower

0UPM -I-I-

Fan Speed 1302UPM Rel.: Faster -IRel.: Slower -I-

Diagnosis Speed

A sensor and two relays are assigned to each actuator.

2/2

Chopper 0UPM Straw Walker 0UPM Returns Elevator 0UPM Filling Auger 0UPM Dynamo Machine 8050UPM Engine 2424UPM Wheel Imp. 0UPM

HC 8

Page 1/2: Speeds which can be altered: – Reel speed – Threshing drum speed – Fan speed

Page 2/2: Indication of speeds which cannot be altered with the Commander Control 2000.

307.1133.3.6 englisch (en) 10.2006

H Service Training

Diagnosis DCC Concave controller (concave clearances) Diagnosis CC

1/3

Key functions:

Rear concave Pot. Cal. min. Cal. max. Actual value Rel.: Extend Rel.: Retract

3.21V 0.48V 4.40V 69.4% -I-I-

Page selection: keys (1): Cal

Diag

or

Actuation of servo drive: keys (2): Setup + or

☞ Cal

+

The servo drive of the selected page/function will be activated.

Setup

Adjustment is done as long as the key is pressed: Setup + – Servo drive is extending Setup – Servo drive is retracting

1 Page both:

Return to the ”Diagnosis menu”: keys (1): Cal + and simultaneously

2 Actuate servo drive

return to the ”Diagnosis menu”

30Diag 35402 Diagnosis CC

1/3

Rear concave Pot. Cal. min. Cal. max. Actual value Rel.: Extend Rel.: Retract

Diagnosis CC

3.21V 0.48V 4.40V 69.4% -I-I-

2/3

Front concave Pot. Cal. min. Cal. max. Actual value Rel.: Extend Rel.: Retract

Diagnosis CC

3.97V 0.48V 4.40V 89.0% -I-I-

307.1133.3.6 englisch (en) 10.2006

On each page is displayed: Pot. – the electrical measuring value at the servo potentiometer Cal.min./max. – the calibration values as saved with the last calibration process. Actual value

– the relative position of the servo drive as a result of the measuring value of the potentiometer within the calibrated stroke.

Rel.: Extending/Retracting – Electrical status of the servo drive

3/3

Turboseparator Pot. Cal. min. Cal. max. Actual value Rel.: Extend Rel.: Retract

Page 1/3: Concave adjustment rear. Page 2/3: Concave adjustment front. Page 3/3: Separating grate adjustment of turboseparator

Note: 0.43V 0.48V 4.40V -3.7% +I+ -I-

In case of manual adjustment of the clearances an actual value of 0% resp. 100% must be reached in the limit stop positions. Repeat the calibration procedure if the displayed value differs significantly from the actual value.

HC 9

H Service Training

Diagnosis MC Main clutches Diagnosis MC

The individual outputs can be switched independently from each other and are not subject to any automatic monitoring ensuring proper operation.

1/2

Threshing mechanism mechanism Threshing Status -IRel.: engage +I+ Rel.: disengage -ICutting mechanism Status -IRel.: engage -IRel.: disengage -ISwitch CM

Cal

Diag

Key functions: Page selection: keys (1): Cal

+

Line selection: keys (2): Diag

Setup

+

Actuate servo drive: keys (3): Setup

☞

1

2

3

Page

Line

Actuate servo drive or Status outputs on/off

both: return to the ”Diagnosis menu”

or

or

+

or

The servo drive of the selected clutch (4) is activated.

Adjustment is done as long as the key is pressed: Setup + – engage Setup – disengage 32HK12 35402

In the diagnosis menu it is not possible to operate the grain tank tube and the clutches by means of the respective function keys and 0 . Switching of status outputs: First select the line”Status” (5) of the desired function. keys (3):

Setup Setup

Diagnosis MC

4

1/2

Threshing mechanism mechanism Threshing Status -IRel.: engage +I+ Rel.: disengage -ICutting mechanism Status -IRel.: engage -IRel.: disengage -ISwitch CM

5

Diagnosis MC

2/2

Chopper Status Status Rel.: engage Rel.: disengage

+I+ -I-I-

Grain tank discharge Rel.: engage -IRel.: disengage -ISwitch GTD

HC 10

+

– Switch on status output – Switch off status output

Return to the ”Diagnosis menu”: keys (1): Cal + and simultaneously

Page 1/2: Threshing mechanism clutch Cutting mechanism clutch – Switch CM = Foot switch cutting mechanism stop

Page 2/2: Chopper clutch Grain tank clutch – Switch GTD = Foot switch grain tank discharge

307.1133.3.6 englisch (en) 10.2006

H Service Training

Diagnosis GT Grain tank Diagnosis GT

1/1

Key functions:

Grain tank tube V.: Swing in -IU.: Swing out +I+ Status NS GTT -INS grain tank tube Grain tank top Level transmitter 1 Level transmitter 2

Line selection: keys (2): Diag

Diag

or

Swinging of grain tank tube: Start the swinging procedure by means of the keys (3): Setup Setup

Cal

+

+

– Swing out grain tank tube – Swing in grain tank tube

Setup

Terminate the swinging procedure with the keys (3) Setup

2

3

Page

Line

Swing in/swing out

return to the ”Diagnosis menu”

or

.

Switching of status output: First select the line ”Status” (4).

1 both:

+

keys (3):

Setup Setup

+

– Switch on status output – Switch off status output

Start/Stop

32HK12 35402

Diagnosis GT

4

1/1

Grain tank tube V.: Swing in -IU.: Swing out +I+ Status NS GTT -INS grain tank tube Grain tank top Level transmitter 1 Level transmitter 2

307.1133.3.6 englisch (en) 10.2006

Return to the ”Diagnosis menu”: keys (1): Cal + and simultaneously

The menu item diagnosis ”grain tank” consists of one page.

HC 11

H Service Training

Diagnosis TM

1

1/1

Diagnosis TM Threshing Mode

Working master sw. Straw guide plate Straw chamber warn. sw.#1 Straw chamber warn. sw.#2 Returns elevator #1 Returns elevator #2 Feed passage Angle transmitter 2.75V

One page: Switches and sensors for monitoring of the threshing process.

Diagnosis GDM

Ground Drive Mode GDM

1/1

Overspeed engine +I+ D+ Engine excess temp. Engine oil excess temp. Engine oil pressure sw. Engine cooling fan Engine air filter Hand brake

Return to the ”Diagnosis menu”: keys Cal + and simultaneously

One page: Switches and sensors for monitoring of the ground drive mode. Line selection: keys Diag

+

or

Switching the status output: First select the line”Overspeed Engine” (1). keys:

Setup Setup

+

– Switching on the status output – Switching off the status output

Return to the ”Diagnosis menu”: keys Cal + und simultaneously

HC 12

307.1133.3.6 englisch (en) 10.2006

H Service Training

Diagnosis IL Engine oil pressure Charge control Central warning Hand brake Grain tank level Chopper speed Engine excess temp. Engine cooling fan Engine air filter Straw chamber monitoring Diagnosis IL Returns elevator Grain tank tube Chopper mode Revolving light Buzzer

1/2 +I+ -I-I+I+ +I+ +I+ -I-I+I+ -I-

Diagnosis IL Indicator Lights Pages 1/2 and 2/2: Indicator lights of the combined instrument gauge and further optical and acoustical signal transmitters.

Line selection: keys Diag

+

or

2/2 +I+ -I-I+I+ -I-

Switching the status output: First select the desired function. keys:

Setup Setup

+

– Switching on the status output – Switching off the status output

Return to the ”Diagnosis menu”: keys Cal + and simultaneously

307.1133.3.6 englisch (en) 10.2006

HC 13

H Service Training

Diagnosis CAN CAN modules Diagnosis CAN

1/4

Key functions:

El. adjustment: Upper sieve Pot. Cal. min. Cal. max. Actual value Extend key Retract key Rel.: extend Rel.: retract

Page selection: keys (1): Cal

3.41V 2.22V 6.02V 31.3%

+

Line selection: keys (2): Diag

-I-I-

+

Actuating servo drive: keys (3): Setup Cal

Diag

Setup

☞

2

3

Page

Line

Swing in/Swing out

both:

or

+

or

The servo drive of the selected function is activated.

Adjustment is done as long as the key is pressed: Setup + – Servo drive is extending Setup – Servo drive is retracting

1

return to the ”Diagnosis menu”

or

Switching the power outputs: First select the line of the desired function. keys (3):

Start/Stop

Setup Setup

+

– Switch on power output – Switch off power output

32HK12 35402

Return to the ”Diagnosis menu”: keys (1): Cal + und simultaneously

Diagnosis CAN El. adjustment Straw guide plate

4

Option is not available!

3/4

It is possible to check the proper function of the CAN modules by means of the CAN diagnosis. The CAN modules must be activated in the menu ”Setup”. If a CAN module is not activated or if it is not displayed on the bus, the message "Option not available” appears on the corresponding page. See example opposite (4).

Note: In case of manual operation of the individual functions an actual value of 0% resp. 100% must be reached in the limit stop positions. Repeat the calibration procedure if the displayed value differs significantly from the actual value.

HC 14

307.1133.3.6 englisch (en) 10.2006

H Service Training

2 1

Diagnosis CAN

1/4

El. adjustment: Upper sieve Pot. Cal. min. Cal. max. Actual value Extend key Retract key Rel.: extend Rel.: retract

3.41V 2.22V 6.02V 31.3% -I-I-

3 Diagnosis CAN

2/4

El. adjustment: Lower sieve Pot. Cal. min. Cal. max. Actual value Extend key Retract key Rel.: extend Rel.: retract

4.05V 2.61V 5.91V 43.4% -I-I-

4 Diagnosis CAN

3/4

El. adjustment: Straw guide plate Pot. Cal. min. Cal. max. Actual value Chopper switch Rel.: Extend Rel.: Retract

4.41V 2.05V 6.17V 57.0% -I+I+

5 6

Diagnosis CAN

4/4

El. adjustment: Deflector Pot. Cal. min. Cal. max. Actual value 0% ... 20% 20% ... 40% 60% ... 80% 80% ... 100%

Diagnosis CAN CAN modules

3.6V 0.00V 8,07V 45.0% -I+I+ -I-I-

307.1133.3.6 englisch (en) 10.2006

Pages 1/4 and 2/4: Electrical adjustment upper sieve and lower sieve. On these pages is depicted: Pot. – the electrical measuring value at the servo potentiometer Cal.min./max. – the calibration values as saved with the last calibration process. Actual value – the relative position of the servo drive as a result of the measuring value of the potentiometer within the calibrated stroke. Key extending/retracting – Operating keys for sieve adjustment at the rear ladder Rel.: extending/retracting – Electrical status of the servo drive

Page 3/4: Electrical adjustment straw guide plate. On this page is depicted: Pot. – the electrical measuring value at the servo potentiometer Cal.min./max. – the calibration values as saved with the last calibration process. Actual value – the relative position of the servo drive as a result of the measuring value of the potentiometer within the calibrated stroke. Chopper switch – Switch at the straw guide plate Rel.: extending/retracting – Electrical status of the servo drive

Page 3/4: Electrical adjustment deflectors. On this page is depicted: Pot. – the electrical measuring value at the servo potentiometer Cal.min./max. – the calibration values as saved with the last calibration process. Actual value – the relative position of the servo drive as a result of the measuring value of the potentiometer within the calibrated stroke. 0% ... 100%. – Status of the four indicator lights

HC 15

H Service Training

Diagnosis Syst.

1/1

Commander Control: Battery 12.4V pot. Exc. 4.97V CAN modules: El. sieve adjustment pot. Exc. 0.01V El. straw guide plate pot. Exc. 7.95V El. deflector pot. Exc. 8.04V

Component

Range of operation

Commander Control 2000 Battery Pot. Exc.

10,00 ... 16,00 V 4,80 ... 5,20 V

El. sieve adjustment Pot. Exc.

7.75 ... 8.25V

El. straw guide plate adjustment Pot. Exc.

7.75 ... 8.25V

El. deflector adjustment Pot. Exc.

7.75 ... 8.25V

HC 16

Diagnosis Syst. System One page: Electric power supply, Commander Control 2000 and CAN modules.

Return to the ”Diagnosis menu”: keys: Cal + and simultaneously

The opposite table shows the permissible range for the electric power supply and the supply voltage of the servo potentiometers (pot. Exc.).

307.1133.3.6 englisch (en) 10.2006

I Service Training

5650H - 5690HTS Air condition Table of Contents Type of combine harvester

5650H 5680H 5660HTS 5690HTS

Safe maintenance and repair of air condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 – 03

X

X

Overview function elements in cabin roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04 – 05

X

X

Circuit diagram for electric system heating und cooling system in cabin roof . . . . . . . . . . . . . .06 – 07

X

X

Functional description of the air condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .08 - 09

X

X

Refrigerant and PAG oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 - 11

X

X

Components of the air condition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

X

X

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 - 13

X

X

Magnetic clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

X

X

Compressor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

X

X

Components of the air condition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 - 17

X

X

Expansion valve (TEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 - 19

X

X

307.1133.3.6 englisch (en) 10.2006

I1

I Service Training

Safe maintenance and repair of air condition Qualification of personnel For all persons involved in maintenance or repair of the air condition system it is mandatory - to be qualified for these works and to be adequately trained - to carefully observe the instructions in the repair manual. You and your employees should be trained and specially instructed for maintenance works on air condition systems. Training can be carried out by the after-sales service of SAME DEUTZ.

SZ-0115

Personal safety equipment Liquid refrigerant evaporates under atmospheric pressure. The skin of your hands may freeze when contacting with refrigerant. PAG oils damage the skin surface upon frequent contact. Protect your hands and eyes from refrigerant and refrigerant oil (PAG). ® Wear solid safety gloves (leather)! ® Wear safety goggles or face screen!

Handle refrigerant and refrigerant container carefully. SZ-0102

Never touch liquid refrigerant and refrigerant bottles without wearing safety goggles! Do not expose refrigerant bottles to direct heat impact and never heat above 50 °C. Do not expose to direct sunlight or to heat radiators. Rising temperatures cause the pressure inside the container to increase. A strong pressure increase may cause thin-walled bottles to explode! Do not fill refrigerant bottles to maximum level. By doing this the refrigerant can expand when temperature is rising. Shut multiple-use steel bottles immediately by means of a shutoff valve after taking out refrigerant. Protect the shutoff valve against damage! Screw on safety plug and screw cap. Always move refrigerant bottles carefully. Avoid shock! Never refill damaged bottles. Mark the containers clearly, e.g. "Bottle damaged. Do not refill - Danger of accident!” When opened, drain non-returnable refrigerant bottles into the service station for safety reasons. Close drained bottles.

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Safe maintenance and repair of air condition Refrigerant is heavier than ambient air. It will sink down in case of a leakage in refrigerant pipes. In the course of this high refrigerant concentrations are occuring in the ambient air. There is danger of suffocation! Leave the room immediately. Re-enter the room only after sufficient ventilation. If possible, use breathing protection, e.g. a compressed air breathing apparatus. Never drain refrigerant in closed rooms. Make sure that there is good ventilation, e.g. switch on the air exhauster. Maintenance works in the driver’s cabin: Never allow refrigerant to be drained into the closed cabin. Open the cabin door and make sure that there is good ventilation!

SZ-0010

First aid in case of contact with refrigerant After inhaling: Take the person to fresh air immediately and lay down carefully. Call a medical doctor! Give artificial respiration in case of unconsciousness or respiratory paralysis. After contact with the eyes: Do not rub out the eyes. Force apart the eyelids and rinse with plenty of lukewarm water for at least 15 minutes. Go and see a medical doctor immediately! After contact with the skin: In case of contact of refrigerant with the skin sponge down with plenty of water. Safety measures with welding works In case of temperatures above 800 °C, e.g. contact of refrigerant with naked flame or glowing metal (welding works), the R134a is decomposed chemically. In the course of this highly toxic phosgene gases (chlorocarbonic oxide gases) are formed. Inhaling of these gases is causing serious damage to health! A pungent stench is a clear sign of the formation of such toxic gases. Leave the room immediately. Ventilate the place of work extensively. Observe with soldering and welding works: By all means avoid heat exposure to the components of the air condition! Parts of the system may explode due to strong heat during welding. Never touch refrigerant with naked flames or glowing metal (e.g. welding works)! Do not smoke while carrying out maintenance and repair works! While varnishing the machine: Drain the air condition in advance, if the vehicle is supposed to stay in the drying oven for more than 20 minutes with 80 °C. Never varnish the evaporator and the condenser! 307.1133.3.6 englisch (en) 10.2006

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K1

K3

K4

4

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2

2

5

X135 X136

K5

6 12.1 7

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13

12

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10

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20

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5650H – 5690HTS Overview function elements in cabin roof

1

Relay for cooling compressor and blower

2

Blower

3

Wiper motor

4

Connector X135, X136 for headlamps

5

Coolant hoses

5.1 Pressure hose 5.2 Flexible suction tube 6

Hoses for heating

7

Heating valve with servo motor Observe proper mounting position: In header line, in direction of flow!

8

Connector X115, X134, X182

9

Interior lighting

10

Temperature sensor air recirculation, no longer utilised as of year of construction 2002

11

Circulating air filter

12

Control panel air condition, heating

12.1 Control unit air conditioning (electric thermostate) 13

Temperature sensor

14

Heat exchanger heating

15

Evaporator air condition system

16

Expansion valve

17

Fresh air filter left and right

18

Master cylinder service brake

19

Disconnect for coolant- and heating hoses

20

Refrigerator section

21

Cabin floor

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5650H – 5690HTS Circuit diagram for electric system heating und cooling system in cabin roof Relay K1-K4 are mounted in the cabin roof

Low/high pressure switch: Switch is opening at 1.2 bar and at 28 bar resp. Switch is closing at 2,4 bar and at 19,5 bar resp.

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Low/high pressure switch

Compressor

Malfunction control

Water potentiometer

Electrical thermostat

Air conditioning potentiometer Air conditioning switch

Water valve

Evaporator fan M2

Fan switch

Evaporator fan M1

I

Service Training

5650H – 5690HTS Circuit diagram for electric system heating und cooling system in cabin roof

56-077

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12

8

9 11

16

15

14

13

3

2

1 3 5 7

4

X142

6

I0074

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5650H – 5690HTS Functional description of the air condition Coolant circuit Position

Designation

Function

1

Compressor

Takes in gaseous refrigerant from the evaporator for compression. In the course of this the refrigerant is warming up (pressure build-up).

2

Belt pulley with magnetic clutch

The compressor is driven via v-belt, belt pulley and magnetic clutch. Activation and deactivation of the magnetic clutch causes the compressor to be separated from the drive.

3

Filling connections (service valves)

The pressure gauge ports in the refrigerant pipes at the compressor are equipped with spindle valves made by Schrader.

4

Condenser

The compressed refrigerant is cooled down in the condenser. In the course of this it is liquefied (condensed).

5

Container (part of the dryer)

Absorbs the liquid refrigerant.

6

Dryer (1

The dryer withdraws possibly existing humidity (water) of the refrigerant.

7

High/low pressure switch

Deactivates the cooling system if the pressure between compressor and expansion valve falls below 1.2 bar or exceeds 28 bar. At the same time the red failure lamp is lighting.

8

Fresh air blower

Blows the intake air through the evaporator

9

Expansion valve

Point of separation between high pressure and low pressure side. From there a metered quantity of liquid refrigerant is entering the evaporator and starts to expand here.

10

Evaporator

In the evaporator the refrigerant is expanding and completely evaporating, changing into gaseous condition at the same time. The required energy (heat) for this is withdrawn from the ambient air flowing by the evaporator fins. The air is cooled down, taken in by the blower and routed to the cabin.

11

Temperature sensor

Captures the temperature of the cooled down air after the evaporator.

12

Control unit (electronic thermostat)

Activates or deactivates the refrigerating compressor by means of K1.

13

Rotary potentiometer

Air temperature adjustment (cooling capacity)

14

Toggle switch

Used for commissioning of the air conditioning system The rotary switch for the fan must be switched at least to stage 1.

15

Failure lamp red

Lighting as soon as the air conditioning system is deactivated by means of the high/low pressure switch.

16

Rotary switch for fan

Activation /deactivation of the fresh air fan; with 3 speed stages.

(1 Installed in front of the cooler package.

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Refrigerant and PAG oils Refrigerant In the air condition system of the combine harvester the refrigerant R 134a is used which is free from chlorine. Its pressure and temperature response is similar to the type R 12 applied in the past. CAUTION! Danger of injury!

Observe the safety regulations when handling refrigerants! Read the EC safety data sheet of the refrigerant producer. The refrigerant R 134a is a low-boiling agent. Boiling point: -26,1 °C at normal atmospheric pressure of approx. 1 bar. Boiling point temperatures depending on the pressure Determine the corresponding evaporation temperature with the following table.

Temperature in °C

Pressure in bar (absolute pressure)

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

2,92 3,49 4,14 4,88 5,71 6,65 7,69 8,86 10,16 11,59 13,17 14,90 16,81 18,89 21,17 23,65 26,35 29,29 32,48 35,95 39,72

Absolute pressure is measured pressure minus ambient pressure. Ambient pressure is air pressure. For the pressure in the closed system subtract 1 bar of the value in the table.

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Refrigerant and PAG oils Refrigerant Refrigerant R 134a is able to absorb heat quickly (thermal absorption) and to also dissipate it quickly (heat dissipation). Due to these qualities R 134a is very well suitable for serving as heat transport agent in air condition systems. ● If appropriately handled R 134a is not inflammable or explosive, neither in liquid condition nor in gaseous condition

However, R 134a may light off if mixed with an air concentration of more than 60% and the pressure is above the atmospheric pressure. Therefore: Never fill pressurized air into refrigerant bottles, the air condition system or into the filling station! ● It is colourless and odourless. ● Refrigerant in vapour state does not change the quality of food. It will not be poisoned or become inedible. However, liquid R 134a enriched with PAG oil may corrode copper and a few types of plastic. ● In case of a strong enrichment of R 134a in the breathing air difficulties of breathing may occur, as the oxygen will be displaced by the gaseous refrigerant. IMPORTANT! Material damage!

Do not fill up the air condition system with the refrigerant R 12. Never mix the refrigerant R 134a with R 12! Refrigerator oil, seal and piping materials as well as the system pressure are different with R 12 and R 134a air condition systems. Using the wrong refrigerant may cause chemical reactions with the refrigerator oil and corrosion of the components.

PAG oils PAG oils are synthetic oils that are very hygroscopic, i.e. they are storing up humidity. Humidity reduces the efficiency of an air condition system. Therefore: – Only use PAG oils in small barrels if possible. – Consume immediately. – Dispose of the remainders properly. In case of storage in larger barrels, e.g. in the filling station: – Store the oil in airtight containers!

Filling amounts

Refrigerant

Filling amount

R 134 a

2000 g

Refrigerator oil

Filling amount

PAG (Polyglycol) *

207 cm3 (in case of new compressors)

* The type of oil filled in ex works is printed on the rating plate of the compressor!

IMPORTANT! Material damage!

Too much refrigerator oil in the compressor - reduces the refrigerating capacity of the air condition and - may damage the system!

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3 4 7

8

5 2

1 6 2 I0001

I0014

2

1

5

3

6

4

2

I0002

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Components of the air condition system Compressor The combine harvester is equipped with an axial-flow cornpressor with constant working volume. The compressor is driven by means of a v-belt. Frictional connection is achieved through a magnetic clutch which is activated when the air condition is switched on. The compressor takes in gaseous refrigerant from the evaporator, then compresses and pumps it into the cooling circuit. Function The compressor is of the axial-flow type with 7 pistons and constant working volume. A slanted swash plate is actuating the double action pistons. The pistons are guided by guide shoes. During downstroke of the piston cold gaseous refrigerant is taken into the piston chamber. For that purpose an inlet valve is opening between valve plate and piston chamber. During upstroke of the piston the refrigerant is compressed. For that purpose the inlet valve is closing and the exhaust valve between valve plate and cylinder head cover is opening. 1 2 3 4 5 6 7 8

Magnetic clutch Connecting plug (electrical connection) Oil fill screw Connection pressure line to condenser (high pressure) Connection suction line from evaporator (suction pressure) Pressure relief valve (built-in only with compressor Sanden type C) Gauge and filling port high pressure Gauge and filling port suction pressure

Pressure relief valve The pressure relief valve protects the compressor against damage in case of an air condition system malfunction. IMPORTANT! Material damage!

Chillers are suitable only for gas compression. In case of taking in liquid refrigerant the compressor will be damaged! Never fill up the inlet side of the compressor with liquid refrigerant!

Compressor Magnetic clutch The refrigerating capacity of the air condition system is controlled by activating and deactivating of the magnetic clutch. The control unit in the cabin controls activation and deactivation of the magnetic clutch. The high/low pressure switch located in the high pressure circuit of the system opens the magnetic clutch when the shut down pressure (28 bar) is exceeded or when the pressure falls below 1,2 bar.

1 2 3 4 5 6

Solenoid Retaining ring Ball bearing Belt pulley Dust cover Driving plate

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Compressor Lubrication The compressor is filled with 207 cm3 of special refrigerator oil. This oil quantity is mixed with the refrigerant. It permanently circulates in the circuit and lubricates all movable components, e.g. pistons and expansion valve. The compressor bearings are lubricated through oil holes and splash lubrication. Checking the oil level During operation the oil contained in the compressor is distributed within the entire system by means of the refrigerant. When the air condition is shut down the refrigerator oil is depositing in the individual components. Therefore the oil level cannot be checked at the compressor. The exact oil level can only be checked by draining every component where refrigerator oil is depositing. For this reason filling up the oil everytime requires the exact acquisition of the sampled oil amount. IMPORTANT! Material damage!

Too much refrigerator oil in the compressor reduces the refrigerating capacity of the air condition and may damage the system! Service notes Types of oil

Quantities

PAG oil for R 134a *

207 cm3 (with new compressors)

* The type of oil filled in ex works is printed on the rating plate of the compressor! Prior to refilling the air condition system with refrigerant – Check the oil level in the compressor. – Substitute the oil quantity (collects in the filling station) which is separated during suction resp. evacuation of the system. – Refill new refrigerator oil on the inlet side of the compressor. – Check the attachment of the compressor. – Check the v-belt tension and its proper condition. – Switch on the air condition once a month for about 10 minutes. By this means the refrigerator oil is distributed and provides for lubrication and corrosion protection of all components in the system.

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Notes

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3

5

2

4 gaseous

1

8

liquid

6 7 1 2 3 4 5 6 7 8

Container Inlet connection Outlet connection Sight glass Inlet pipe Fine filter Hygroscopic material Connection pressure switch

I0069

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Components of the air condition system Container with dryer The liquid refrigerant is flowing directly from the condenser into the dryer. The container with dryer has the following functions: ● The liquid refrigerant is collected in the container. ● The solid-state dryer stores up water and dirt particles of the refrigerant. The dryer consists of a mixture of silica gel, molecular sieves and aluminium oxide. These components are agglomerated to a solid body by means of resin. Function The liquid refrigerant enters the container at the side where it is collected. Inside of the container the refrigerant flows through the solid-state dryer which filters off existing humidity and dirt particles. Subsequently it continues to flow towards the expansion valve. Humidity is the biggest problem of an air condition system. The dryer is able to store up 6 – 12 g of water, depending on the type. The solid-state dryer is saturated when it has stored up this amount of liquid. In this case the water existing in the liquid refrigerant is flowing until reaching the nozzle of the expansion valve. There the water is freezing, thus clogging the nozzle opening. You can recognize a frozen expansion valve when the air is flowing into the cabin alternating between cooled and uncooled.

Temperature in the cabin is decreasing, Refrigerating capacity normal

Expansion valve frozen

Temperature in the cabin increasing, no refrigerating capacity

Expansion valve defrosting

Service notes – Read liquid level at sight glass with running compressor. The system is filled sufficiently with refrigerant: White ball is floating inside of sight glass. – Read water absorption at sight glass. Dryer is saturated with humidity: Oval blue ball has changed its colour to violet. – Replace container. IMPORTANT! Material damage!

Never leave the dryer unsealed. The humidity of the air is saturating the solid-state dryer causing it to become defective. Open the sealing plug short time before mounting. Replace the dryer every time when works are carried out at the air condition system. Rusty spots can be seen in the sight glass: – Replace container. When refrigerant temperatures exceed 112 °C a safety fuse is smelting in the container. After draining the refrigerant the container is defective. – Replace container.

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9 6 5

7

4

3

1

2

8

I0068

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Components of the air condition system Expansion valve (TEV - Thermostatic Expansion Valve) The thermostatic expansion valve (TEV) is the point of separation between high pressure and low pressure area in the refrigeration cycle. The refrigerant evaporates at this location. Through the TEV always the exact amount of liquid refrigerant – evaporating under optimum conditions - is flowing into the evaporator. This is preventing overdosing of refrigerant in the evaporator. This control is depending on: ● Suction pressure (compressor side) ● Temperature at evaporator outlet

Layout Position

Designation

Function

1

Connection

Liquid refrigerant is flowing from the dryer into the TEV.

2

Connection

Liquid refrigerant is flowing from the dryer into the evaporator.

3

Connection

Gaseous refrigerant is flowing from the evaporator into the TEV.

4

Connection

The compressor is taking in gaseous refrigerant.

5

Temperature sensor

Measures the temperature at the evaporator outlet. It is filled with an agent which is expanding when heated up.

6

Diaphragm

Below, the pressure of the temperature probe agent is acting (evaporator side); above, the suction pressure is acting (compressor side).

7

Valve tappet

Actuates the valve 8. It is firmly connected with the diaphragm. The movement of the valve tappet is determined by the movement of the diaphragm.

8

Valve

Is opened by the valve tappet. At the same time liquid refrigerant is injected into the evaporator.

9

Insulating cap

An insulating cap must be mounted at the temperature probe of the expansion valve.

Function Above the diaphragm (6) the pressure of the temperature sensor is acting, below the diaphragm (6) the suction pressure of the evaporator outlet is acting. When the air condition is switched off, equal pressure prevails at the diaphragm and the compression spring is closing the valve (8). When the air condition is switched on, the compressor takes in gaseous refrigerant from the evaporator. At the same time the pressure in the evaporator is decreasing and because of that also the pressure below the diaphragm (6). A differential pressure is acting at the diaphragm, as the pressure of the temperature sensor above the diaphragm is higher. The diaphragm (6) is moved downwards. The valve tappet (7) is following this movement and opens the valve (8). At this moment liquid refrigerant is ejected into the evaporator. The temperature arising in the evaporator (evaporation heat) is determined by the temperature sensor. The agent inside of the temperature sensor is changing its volume depending on the temperature and hereby determines the pressure above the diaphragm (6). When the temperature is decreasing, the pressure is decreasing and the valve (8) is closed. This continuous control process ensures: - that only an amount of liquid refrigerant which can be vaporized under optimum conditions is allowed to enter the evaporator - that the compressor only takes in gaseous refrigerant.

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Notes

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5650H - 5690HTS Threshing mechanism Table of contents Combine Harvester Types

5650H 5680H 5660HTS 5690HTS

Threshing section clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 – 03

X

X

Installation of the threshing drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04 – 05

X

X

Electrical concave adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 – 07

X

X

Concave suspension, disawner plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .08 – 09

X

X

Installation of the rear beater drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 – 11

X

X

Drum variator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 – 13

X

X

Assembling the variator gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 – 15

X

X

Setting the variator adjusting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 – 17

X

X

Changing the variator belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 – 19

X

X

Dust shields and sealing at threshing mechanism . . . . . . . . . . . . . . . . . . . . . . . . . .20 – 21

X

X

Drum reduction gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 – 27

X

X

Electrical turbo separator clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .28 – 31

X

X

Installation of maize threshing concave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 – 33

X

X

Threshing drum - maize threshing, weld drum bars with rosettes . . . . . . . . . . . . . . .34 – 35

X

X

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5650H – 5690HTS Threshing section clutch Spring tension (A) with clutch engaged. Gauging length (B) for the servomotor stroke (maximum stroke: 100 mm) Length A

Length B

5650, 5660

142 mm

80 mm

5680, 5690

140 mm

82 mm

The spring tension (A) is set at the potentiometer of the relevant load relay (see Chapter C). The stroke (gauging length (B)) of the servomotor is set by the setscrew (4). After setting, lock the nuts firmly. Always set length A first, then length B. If the adjustment range of the setscrew (4) is insufficient, the mounting (2) of the guide pulley (3) can be adjusted in height. By turning the support (2) through 180°, the guide pulley (3) can be positioned even higher. After each adjustment of the guide pulley (3), the upper belt guide must also be readjusted. 1

Clutch pulley

2

Support

3

Guide pulley

4

Setscrew

Belt guide for clutch belt 5

Hold-down device

6

Upper belt guide

7

Front belt guide

8

Lower belt guide

Adjust belt guides with engaged belt such that the belt is not rubbing. The front belt guide (7) shall have a clearance of 8 mm to the backside of the belt on the entire circumference. The hold-down device (5) must be adjusted such that the disengaged belt will not rub at the drive pulley and cannot escape laterally leaving the running grooves.

K2

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K006-1

5

6

8 mm

8m

m

8

7 K 0037

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K Service Training

5650H – 5690HTS Installation of the threshing drum 1

Flanged shafts

1.1 Flanged shaft with reducing gear 2

M12x40 screws adhesive-bonded. Screw quality 10.9 (Loctite 243)

3

Tightening torque of the slotted nut to the left and right: 140 Nm

4

Screw quality 10.9

For repairs, please note: Always change the drum bars in pairs. Always mount the balancing weights in the same position as they were mounted by the manufacturer.

K4

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2

3

K0010

4

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K Service Training

5650H – 5690HTS Electrical concave adjustment

A concave clearance adjustment front, left view (1) Servo motor for concave clearance front (3) Bearing shaft concave suspension front (4) Tension brackets front concave suspension B Servo motor: (8) Potentiometer in servo motor (9) Slide shaft of the servo motor C Concave clearance adjustment rear, right view: (2) Bearing shaft concave suspension rear (5) Tension brackets rear concave suspension (6) Servo motor for rear concave clearance (motor is mounted horizontally!) The stroke of both servo motors is 127 mm max. An integrated potentiometer (8) measures the displacement of the slide shaft (9). The signal voltage of the potentiometer is processed in the Commander Control 2000 in order to display and control the concave clearance. Observe upon mounting the servo motors: The resistance of the potentiometer is approx. 800Ω, measured at the yellow and grey cable when the slide shaft (9) is completely retracted.

Basic adjustment of concave adjustment and concave clearance: 1. Assembly dimension of the retracted servo motors: - left servo motor (1): 402 mm - right servo motor (6): 413 mm Firmly secure nuts M16 (7) after adjustment. The tension brackets (4,5) must not touch the bearing shaft (2,3) with retracted servo motor (1,6). 2. Basic adjustment of the clearance between concave and threshing drum by means of readjusting the tension brackets (4,5). Servo motors are completely retracted: The display - indication for the Concave Clearance front (11) and rear (12) is set to position 1. Concave clearance

concave Cereals

maize

Front

4th rail: 6 mm

3rd rail: 30 mm

Rear

last rail: 3 mm

last rail: 10 mm

After installing (or replacing) the servo motors calibration of the concave adjustment must be carried out with the Commander Control 2000. At the same time both servo motors are completely extended and retracted and the corresponding potentiometer values are stored.

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2 3

A

4

1

5

402

7

2x 3

Set clearances

35 16052636-1

11

12 1

1

2

1

35403

9

C

6

7

B 8 5 413

16052636-2

56-078

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3 2 4

5 5

4

7 7 6

K0601-2

1

2 1

3

1

4

3

K0038

K0039

2

3

K8

K0040

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5650H – 5690HTS Concave suspension, disawner plates 1

Servo motor for concave clearance front

2

Bearing tube for concave suspension rear

3

Bearing tube for concave suspension front

4

Tension plates front

5

Tension plates rear

6

Servo motor for concave clearance rear

7

Sealing plate

Disawner plates 1

Disawner plates 1 to 5

2

Control lever

3

Locking rod for fifth disawning plate

4

Tightening screw for locking rod

The fifth disawning plate can be removed if required. For this purpose loosen screw (4) and remove locking rod (3). Adjustment of actuation via oblong hole at control lever: Upon closing of the disawning plates the control lever must revolve under tension beyond the dead centre.

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K Service Training

5650H – 5690HTS Installation of the rear beater drum 1

Premounting dimension for inserting the shaft in the rear beater drum

2

Radial eccentricity of the installed shaft max. 0.2 mm

3

Assembly dimension for the complete beater drum

4

Check that the beater drum is positioned centrally in the threshing channel

5

Direction of rotation

6

Lubrication hole Check prior to assembly of a new bearing whether the lubrication hole (6) in the bearing case and the lubrication groove in the outer bearing race are lying upon each other.

5650H – 5690HTS Rear beater with synchronous drive (as of year of manufacture 2007) 1

Threshing drum shaft

2

Beater shaft, tubular shaft and stub shaft screwed together

3

Beater mounted on shaft (2)

4

Right bearing cover

5

Inner bearing flange

6

Outer bearing flange

7

Tension device for v-belt

Dimension A: Assembly dimension for beater on the shaft Dimension B: Reference dimension for beater with shaft and frame Mounting instruction: – Install pre-assembled shaft in beater. – Insert pre-assembled beater in the frame and tighten outer bearing flange (6) while supporting beater on the right side. – Align v-belt pulley on the threshing drum shaft with the v-belt pulley for the beater.

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6

2

1

0,2

3

150

298.5

4 5

1

7 298.5

A 2

89.5

3

283.5

B 4

5 6

20 K0036

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K0017

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5650H – 5690HTS Drum variator 1

Nut tightening torque 460 Nm, secured with DW 59 adhesive. Fit the fixed pulley by hammering the sliding pulley. Retighten the nut with 460 Nm. Special tool for loosening the fixed pulley: 0043 6020

2

Clean the cavity, especially before and after rape threshing

3

The journal must be parallel to the beater drum: align with shims if necessary.

4

Shim

5

Paste cover with silicone

6

Inspection dimension for belt alignment

7

Loosen support strut only when belt is slack

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5650H – 5690HTS Threshing section Assembling the variator gear 1

Shims for aligning the reduction gear

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K0018

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5

K0019

5

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5650H – 5690HTS Setting the variator adjusting mechanism – Remove the belt and adjusting mechanism of the variable-speed drive. – Push the sliding pulley on to the fixed pulley. Insert the 1 mm feeler gauge between the contact surfaces. – Measure dimension D with inserted pressure ring (1). – At the variator adjusting mechanism, screw the adjusting ring (3) on to the adjusting sleeve until dimension D is attained. – Adjust the guide ring (2) so that the cams of the setter ring (2) and adjusting disc (3) prevent any further rotation of the adjusting disc (3), and an axial distance of at least 0.5 mm is provided in the cam area. – Secure the setter ring (2) with 2 cheese-head screws. – Turn the adjusting disc (3) back one turn; the cams must not touch each other. – Install the variator adjusting mechanism and set the drive to reduced speed. – Set the variator adjusting mechanism to higher speed until the chain sprocket blocks. – Check gap S of 1 mm between the control pulleys. If the variator was dismantled: screw the stop-nuts (4) on to the guide bolts so that when the adjusting mechanism is set to reduced speed the variator belt does not slip out of the lower control pulleys nor stick in the upper control pulleys. Note: The variator adjustment must be reset for all machines in which the control pulleys stick when increasing the speed.

Individual components of the variator adjusting mechanism 1

Pressure disc (check installation position)

2

Setter ring

3

Adjusting disc

4

Stop nuts

5

Ball-bearing C4 (more bearing tolerance as normal)

D

Determine dimension D between inserted pressure disc and gap S = 1 mm

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5650H – 5690HTS Changing the variator belt 1. Set the variator to maximum speed in order to open the driven pulley. 2. Screw in the two hexagon-head screws (M16x140) in order to hold the driven pulley open to its maximum distance (the screws are included in the on-board tool kit). 3. Open chain of servo motor. 4. Turn sprocket (1) clockwise in order to open the traction sheave. 5. Take out nuts (C) and swivel struts sidewards. Replace belt. Thoroughly clean the space between the pulley halves. 6. Reassemble in reverse sequence. 7. After mounting a new variator belt, set the variator to maximum and minimum speed. Check that the belt does not stick in one pulley set or jump over the rim of the other pulley set. If necessary, readjust the stop nuts of the upper variator pulley or reset the adjusting mechanism. The servomotor (B) for adjusting the speed of the threshing drum is fixed to the mounting plate (A). The pressure spring (2) of the idling pulley must be set to a length Q = 150 mm.

1

Sprocket

2

Pressure spring

A Mounting plate B Servomotor C Nuts

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M16 M16

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5650H – 5690HTS Dust shields and sealing at threshing mechanism 3 Sealing 4 Dust shield in front of threshing drum (should be removed when threshing maize) 5 Dust shield with sealing strip (5.1) above the threshing drum 6 Dust plate (spring-loaded) behind the rear beater; only in case of combines without turbo separator. 7 Deflector curtain 8 Sealing 9 Sealing (felt strip) The clearance X of the dust shield (4) and the sealing strip (5.1) must not exceed 10 mm. If the clearance is too big or in case of a damaged dust shield excessive dust formation may occur at the feed passage inlet.

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5 5.1

X 6

X 4

3

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5650H – 5690HTS Drum reduction gear I

Direct drive 1:1 Belt pulley (6) connected to driver (7) by stud (5).

II

Reduced speed 1:1.93 Driver (7) connected with frame side wall via stud M16 x 1.5 (5) (position approx. 11 o'clock)

3

Screw tightening torque 210 Nm

4

Molykote long-term 2PLU

5

Stud

6

Belt pulley

7

Driver

8

Fitting washer if necessary

Important: If required, install washers (8) between inner raceway of the bearing and shaft shoulder for proper centring of the threshing drum in the threshing canal. On mounting the reduction gear shaft, first tighten the M16 screw (3) and then the clamping sleeve bearing on the left. Tighten the stud (5) at the latest after 10 operating hours at reduced speed.

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120 Nm

8

K0025-1

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II

1

K0026-2

56-079 K0027

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5650H – 5690HTS Drum reduction gear Converting to reduced speed Fix driver of the gear at the sidewall by means of threaded bolt (position approx. 11 o'clock). 1

Threaded hole for puller screw M16 x 1,5

5650H – 5690HTS Oil changing, Checking oil level To drain the transmission oil, rotate the reduction gear so that the screw (1) is at the bottom. Oil filling: 1 litre transmission oil SAE 90, API GL 5 To check the oil level, rotate the gear so that both shafts (planetary gear set and compensating weight) are horizontal and the inspection screw (1) is at the bottom left. 1

Control and drain plug

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5650H – 5690HTS Drum reduction gear Replacing individual parts The components of the reduction gear are individually interchangeable, except for the special features described below. When replacing the V-belt pulley (1) or the complete housing, it is necessary to balance the gear unit statically with approx. 1 litre of oil at a speed of at least 300 rpm after completing assembly (balancing holes on the web of the V-belt pulley with R 202, Ø 20). Balancing on the balancing block or balancing without oil are not permitted. The driver (2) must be separately balanced with the stud (3) and O-ring (4).

1

V-belt pulley

2

Driver

3

Stud

4

O-ring

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K0028

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3

4

5

6 K0029-1

1

2

3

4

405

5

5 A

B

K 28

25

5

30

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5650H – 5690HTS Turbo separator Distance of the turbo separator drum to the separator concave in the lowest position. Distance B – last bar 25 mm Distance A – first bar approx. 30 mm 1

Installation length for turbo separator shaft

2

Tightening torque for the clamping sleeve bearing to left and right: 140 Nm

3

Fixing of the paddle bars with Allen screw M12x30 and support washer 1601 5594 Tightening torque 120 Nm for screw and nut quality 10.9 Always replace paddle bars in pairs

4

Adjusting movement

5

The transfer rack must rest on the separator concave

6

Separating grate

5650H – 5690HTS Electrical turbo separator clearance adjustment 1

Servo motor

2

Control shaft

3

Tie rod

4

Bearing plate

5

Guide plates

Basic adjustment: Assembly dimension of the retracted servo motor: Clearance between turbo separator drum and separating grate:

405 mm 30 mm (at grate inlet)

Adjustment at the tie rods (3) left and right must be done with completely retracted servo motor. The basic adjustment of the turbo separator drum can be checked approximately from outside: – Vertical distance between bearing plate (4) and guide plates (5) = approx. 5 mm.

Control and calibration of the servo motor is identical with the concave adjustment.

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5650H – 5690HTS Turbo separator - drive The turbo separator is driven by a double V-belt from pulley A to pulley B. Pulleys A and B are of 2-stage diameter for two speed ranges. The speed ranges and drum spacing are selected on the basis of the threshing table. Speed range

Speed rpm

Pulley

V-belt on: Pulley

I

790 ± 20

A1

B1

II

380 ± 20

A2

B2

For maize and sunflower threshing, the slow speed must be set. Moving of v-belt: Slacken tensioning pulley C, (attach tube at pin (1)) lock clamping arm with bolt (2).

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B

A

C

2

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K0034

1 33648

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5650H – 5690HTS Installation of maize threshing concave When converting to maize threshing, the standard-fitted stone trap (3) and front plate (4) must be removed. Mark out the operating rods (6) for the stone trap on the intake plate (2). Remove the dust cover (7) for maize threshing. Hook maize concave into lower borehole (1) of the front tension plates. Basic setting of the concave Concave intake

Concave discharge Last bar

Maize concave version Maize concave (10 Concave bars))

3rd bar

30 mm

10 mm

CCM-concave

2nd bar

30 mm

10 mm

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5650H – 5690HTS Threshing drum - maize threshing Weld drum bars with rosettes 1

Start of seam

2

Weld rum bars with rosettes

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K0035

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Notes

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5650H - 5690HTS Cleaning system Table of contents Combine Harvester Types

5650H 5680H 5660HTS 5690HTS

Straw walker drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 – 03

X

X

Setting the drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04 – 05

X

X

Mounting the straw walker bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 – 07

X

X

Mounting the straw walker shafts and straw walkers . . . . . . . . . . . . . . . . . . . . . . . .08 – 09

X

X

Mounting of straw walker guide rakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 – 11

X

X

Sieve pan drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 – 13

X

X

Grain pan with removable segments

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 – 15

X

X

Grain pan, sieve box with drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 – 17

X

X

Fan variator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 – 19

X

X

Fan – Airflow guide system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 – 21

X

X

Returns elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 – 23

X

X

Electrical sieve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 – 25

X

X

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1

3

2

L0005

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5650H – 5690HTS Straw walker drive The rear straw walker shaft is driven by V-belt. The compression spring (1) for the idling pulley is set to a tension length of 70 mm. The guide pulley (2) is height-adjustable. The straw walker speed can be adjusted if required by mounting or removing additional spacing discs (3) on the rear V-belt pulley.

1

Compression spring

2

Guide pulley

3

Spacing discs

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5650H – 5690HTS Setting the drives spring-loaded idling pulley 1

Spring tension 72 mm.

Idling pulley for sieve crankshaft drive belt 2

Spring tension 65 mm.

Tensioning sprocket for the grain auger drive chain 3

Spring tension 60 mm.

Slipping clutch as overload protection for the grain auger. Response torque approx. 400 Nm with cup spring bias set to a dimension of 22 mm.

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L0006

2 L0007

3

L0008

L0009-1

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L0010

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5650H – 5690HTS Mounting the straw walker bearings Mounting instructions: – Degrease shaft and sleeve – Wet the inner bearing ring with oil (hydraulic fluid) – Set the sleeves by hammering in the axial direction – Observe equal distance of clamping sleeve halves to each other

1

Slotted nut Mount outer bearing with the slotted nut facing the centre of machine.

2

Degrease the bearing seat and outer bearing ring. Secure the outer ring at 3 points of its circumference with liquid locking agent.

3

Tightening the slotted nut: Pretighten to 50 Nm Then tighten fully by turning 180° Slotted nut wrench 0041 6050

4

Cover plate In case of combines without turbo separator, a cover plate is mounted at the front straw walker shaft on all bearings.

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5650H – 5690HTS Mounting the straw walker shafts and straw walkers 1.

Centre the straw walker shafts axially in the frame, so that the distance of the outer straw walker bearings to the side wall is equal. The distance between the rear straw walker shaft and front straw walker shaft must be equal on the left and right-hand sides (orientation on the paint mark of the rear bearing housing).

2.

Install all straw walkers and tighten the front straw walker bearing securely; the rear straw walker bearing should be hand-tightened only. Turn the straw walker shafts by hand to synchronise the cranks.

3.

Tighten the bearings of the outer straw walkers and turn the shafts by hand. The effort required must be equal. If this is not the case, loosen the bearings again and turn the rear shaft slightly to set precise synchronism with the front shaft. Repeat the process. If the oblong holes in the rear straw walker bearing blocks are not sufficient, the rear shaft must be shifted horizontally (oblong holes in the straw hood).

4.

Tighten the other straw walker bearings one by one, in each case turning the straw walker shafts by hand. At the bearings that have still not been tightened, there must be no displacement between the bearing housing and straw walker bearing block during one revolution. If different resistance is encountered when turning the straw walkers, one of the straw walker shafts may be bent or twisted (if there is no bearing damage). Bent or twisted straw walker shafts must be replaced.

5650H – 5690HTS Installation dimensions for straw walker shafts and bearings 1

Straw walker shaft, rear

2

Straw walker shaft, front

3

The long shaft end must be on the right-hand side

Combine Harvester Number of Types Straw Walkers

a

b

Dimensions c

d

e

Tightening torque

5650 – 5660

5

206

206

252

237

1008

Prethigtening torque 50 Nm

5670 – 5690

6

206

206

252

237

1260

+ Retightening angle180°

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left machine side

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4

5

3 2 1

1

2

3

5650 – 5660

4

5

1

2

3

4

5

5670 – 5690 L0020

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5650H – 5690HTS Mounting of straw walker guide rakes (Optional extra) Arrangement of straw walker rakes 8 units for 5650 – 5660 9 units for 5670 – 5690

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5650H – 5690HTS Sieve pan drive

Mounting the sieve crankshaft 1

Special tool for tightening the slotted nut: 0043 6070

Crank drive 1

Bearing support

2

Support plate

2.1 Bolt M14, 10.9 2.2 Bolt M10 3

Swinging arm

4

Connecting rod

5

Head bearing

The support plate (2) must rest in parallel at the face side of the bearing support shaft (1). Tighten bolt M14 (2.1) first and then check the position of the support plate versus the bolting face at the frame. Adjust support plate or add spacer discs as necessary.

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L0015

4

3

5

2.2

2

1

2.1

L0015

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5650H – 5690HTS Grain pan with removable segments

When installing the segments (2), make sure that they engage in the catch (1.1). The segments are fixed to the grain pan frame (1) through the front cover (3). Front cover (3) is attached at the grain pan frame by means of 3 nuts (4).

Installation of the grain pan rocker A: Standard combine harvester B: Balance combine harvester 5

Rocker

6

Distance plate

7

Spacing sleeve

Assembly and length (L) of the grain pan rockers (5) is different for standard and balance combine harvesters. A: Standard combine harvester: L = 232 mm. A distance plate (6) shall be installed on the frame between the lower bearing case and the bearing support B: Balance combine harvester: L = 210 mm. The spacing sleeve (7) shall be installed between upper bearing case and grain pan.

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L0024-3

A

5

L 6 L0049

7

B

5

L L0050

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L0027-2

L0028

L 16

L0029

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5650H – 5690HTS Grain pan, sieve box with drive 1

Pitman rod – basic setting 584 mm

2

Rocking lever

2.1 Sleeve bearing 3

Bearing block – horizontally adjustable on the left-hand side

4

Grain pan

4.1 Grain pan rocker 5

Sieve box, top

5.1 Graepel sieve cartridge 6

Sieve box, bottom

7

Straw walker return pan

8

Suspension for bottom section of sieve box, straw walker return pan

9

Rocker for top section of sieve box and straw walker return pan

9.1 M12 screws 9.2 Bearing blocks The grain pan and sieve box sections must rock longitudinally in parallel in the frame. The guide shoes (a) must not touch the frame side walls. If necessary, the length of the pitman rod (1) must be adjusted to the left or right. Also, the left-hand bearing block (3) can be slightly adjusted horizontally. During assembly, the grain pan and sieve box top and bottom sections (4, 5 and 6) on the rocking lever journals must be precisely adjusted to one another in the axial direction to ensure sufficient clearance between the moving parts. The axial play of the sleeve bearing (2.1) must be compensated with spacing discs. The housings of the rubber bearings for the suspension (8) of the grain pan, sieve box bottom section, straw walker return pan and the M12 screws (9.1) of the rocker (9) must be tightened with the rocking lever (2) in the mid position. The rockers (9) must be mounted free of strain. The guide shoes (b) of the straw walker return pan must not make contact with the frame side walls. If necessary, adjust the position of the bearing blocks (9.2). Observe different length L of grain pan rocker with standard and balance combine harvesters: Standard: L = 232 mm Balance: L = 210 mm The Graepel sieve cartridge (5.1) is screwed in the upper part of the sieve pan (5) and its inclination is adjustable. The inclination shall be in parallel with the grain pan (4).

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5650H – 5690HTS Fan variator 1

Servomotor

2

Swivelling variator

3

Tensioner for lower variator belt Spring tension 90 mm at maximum revs

4

Compression spring

5

Adjusting nuts

6

Nuts

7

Bearing pin

8

Sliding pulley

9

Fixed pulley halfs

10 Grease nipple Settings on the variator

I

Retightening the variator belt: – Set the swivelling variator (2) to the mid-position. – Loosen the bearing pin (7). – Retighten the belt with the adjusting nuts (5), fully turning the threshing mechanism. – Retighten the bearing pin (7).

II

Setting the variator adjustment range: – Set the swivelling variator to the end positions (maximum and minimum speeds). – A gap S of at least 1 mm must remain between the sliding (8) and fixed (9) pulley halves. – Set the adjustment range using the nuts (6) on the mounting of the servomotor (1). – After adjusting, lock the nuts (6) tightly against one another again. Check the adjustment range with every belt change.

Notes for operation and maintenance: The variator should not be run continuously at constant speed for a long period. At least once a day, the fan speed should be slightly modified. The contact surface of the sliding pulley half must be lubricated at least once a day. Grease nipple (10).

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L0042

L0040

L0041

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5650H – 5690HTS Fan – Airflow guide system 1

Fan drum

2

Sealing plate

3

Diffuser wedge, lower

4

Diffuser wedge, upper

5

Adjusting lever left and right

6

Tuning scale left and right

7

Cover

It is possible to adjust the slope of the upper diffuser wedge (4) around the centre of rotation (z) by means of the adjusting levers (5). The numerical value on the tuning scale (6) corresponds to the clearance between the leading edge of the diffuser wedge (4) and the top of the wind duct. The adjustement affects the amount of wind at the step between the grain pan and the sieve pan. Small tuning scale value: less amount of wind at the step High tuning scale value: more amount of wind at the step A scale value of 20 is factory pre-adjusted. In case of slightly granular threshing material (e. g. rape, oat) adjusting a smaller scale value (e. g. 15) might possibly be more advantageous. By this, observe a balanced adjustment on the left and on the right side.

Sequence for inspecting or setting the installation position: a

Ensure that the fan drum (1) is parallel to the trough and is axially centred.

b Ensure that the sealing plate (2) is parallel to the fan drum. The sealing plate (2) must lie flush with the air housing over the full width of the machine. c Ensure that the diffuser wedge (3, 4) is parallel in the air passage.

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1

2

4

12-1

Z 20 – 5

100

0,

–2

12+1

92 – 2

5

7

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6

3

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L0045

4.1

4

5

35

6.1

4 M005

6 L0046

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5650H – 5690HTS Returns elevator 1

Elevator auger

2

Scoop wheel

3

Stepped pulley – slow speed for threshing maize and beans

4

Cover with replaceable friction insert – smooth or fluted

5

Momentary-contact switch ("make" contact) on left and right for monitoring the cover (when the cover is closed, the switch is pressed).

6

Speed monitor – distance between sensor (6) and puls transmitter (6.1): 4 mm

Centre the scoop wheel (2) in the housing before wedging it to the auger shaft. Check installation position: the smooth surface of the scoop must face the direction of rotation. Replace damaged scoop wheels – risk of damage due to unbalance. Check the installation position of the pressure clip (4.1) for the returns elevator cover (4). The short side of the pressure clip must press against the cover (4). Compression spring tension: 35 mm

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5650H – 5690HTS Electrical sieve adjustment 1

Servo motor (stroke 115mm) with integrated potentiometer (1kΩ)

2

Control shaft, integrated in the sieve pan

3

Lever bracket on control shaft in upper sieve pan

4

Lever bracket on control shaft in lower sieve pan Observe mounting position of lever brackets. Brackets for upper and lower sieve are different.

5

Ball pivot for sieve adjustment (1 ball pivot for every sieve unit)

6

Ball socket

7

Adjusting device on every sieve unit

8

Adjusting rail for sieve plates

9

Upper resp. lower sieve

Function of adjusting device: The stroke of the servo motor (1) is transferred to the adjusting rail (8) of the sieves (9) via the control shaft (2) through the ball sockets (6). The sieve plates are opening when the servo motor is retracting, the sieve plates are closing when the servo motor is extending. Basic adjustment of the adjusting device (7): When the sieve plates are closed the ball socket (6) must project 42 mm over the front edge of the sieve. With mounted sieves the servo motor must be completely extended when the sieve plates are closed. Removal of the sieves: – Loosen sieve fixation (it is mandatory to always loosen both sieves, even if only one sieve shall be removed). – Press push-button switch for ”opening sieves” until the servo motor is completely retracted; at the same time the ball pivot (5) is swinging out of the ball socket (6). – The sieves can now be drawn out. Installation of the sieves: (servo motor must be completely retracted) – Clear sieve guides from grains and chaff, especially the front sieve stop. – Insert sieve in sieve pan until ball socket (6) engages in ball pivot (5). – Press push-button switch for ”closing sieves”; check at the same time whether the sieve is pulled to the front resp. whether the sieve plates are closing. – Mount the sieve fixation. – Completely open upper and lower sieves by means of push-button switch and close halfway; check whether the sieve opening at the right and the left side is the same. If the sieve opening is not the same the ball socket (6) at the adjusting device must be readjusted. Calibration of the sieve adjustment for upper and lower sieve: (see instruction manual TERIS/TCS)

L 24

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+ + POTI ROT 1 Signal signal POTI TRANS 2‡ — POTI SCHWARZ3‡–

6‡ Blindstopfen 5‡ MOTOR SCHWARZ 4‡ MOTOR GELB

2

3

1

4 2

115 9

2

8

25

9

27

6

31

5

42

7

6

25

307.1133.3.6 englisch (en) 10.2006

22

L 25

L Service Training

Notes

L 26

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M Service Training

5650H - 5690HTS Grain elevator, grain tank Table of contents Combine Harvester Types

5650H 5680H 5660HTS 5690HTS

Grain elevator with elevator head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 – 03

X

X

Elevator head, speed monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04 – 05

X

X

Elevator head at grain tank extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 – 07

X

X

Elevator head with TCS (grain throughput measurement) . . . . . . . . . . . . . . . . . . . . . . . . . .08 – 09

X

X

Grain tank clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 – 11

X

X

Grain tank unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 – 13

X

X

Unloading system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 – 15

X

X

Angular gear inside of tube bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 – 17

X

X

Support for grain tank tube, Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 – 19

X

X

Level transmitter, sensor for grain tank cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 – 21

X

X

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M1

M Service Training

5650H - 5690HTS Grain elevator with elevator head

1

Grain tank filling auger

2

Fixing plates for elevator chain

3

Chain wheel for elevator chain

4

Distance collar

5

Chain wheel Z13, or Z18 for increased speed in case of maize threshing

6

Cardan joint

6.1

Connection cardan joint - filling auger

7

Elevator housting

8

Elevator chain

9

Grain auger

10

Ratchet clutch

Assembly instructions: -

Shift grain auger (9) entirely to the right while assembling, so that the distance collar (4) is resting against the inner raceway of the bearing. Tighten the adjusting ring at the right side first.

-

The elevator chain (8) must be guided by the chain wheels (3) centrically inside of the elevator shaft. Center the chain wheels (3) in the elevator shaft by means of adjusting washers if necessary, resp. shorten the distance collars (4).

Tensioning of the elevator chain: Readjust fixing plates (2) evenly by means of the tightening screws left and right. The elevator chain is to be tensioned only as far as the chain links can still be moved laterally at the lower chain wheel (3).

The belleville springs of the ratchet clutch are arranged individually in an opposite direction on the hub.

M2

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1 4

4

3

2

2

5

M030

6.1

6

M040-1

M 001-1

7

9

10

3 4

6°

M031

8

22

10

L0001-1

307.1133.3.6 englisch (en) 10.2006

M3

M Service Training

1

2 3

6 6°

7 4

5

M032-1

M4

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M Service Training

5650H - 5690HTS Elevator head, speed monitoring

1

Sealing at feed pipe

2

Fixing plate for elevator chain

3

Elevator head

4

Sealing between elevator housing and bottom of grain tank

5

Running direction of elevator chain

Speed monitoring: 6

Pulse transmitter

7

Inductive sensor (distance to pulse transmitter 4 mm)

307.1133.3.6 englisch (en) 10.2006

M5

M Service Training

5650H - 5690HTS Elevator head at grain tank extension

1

Feed pipe with auger, swiveling to the top together with extending the grain tank extension.

2

Pedestal bearing

2.1

Sealing washer

3

Auger flight

4

Short Feed auger

5

Full floating axle

Observe the right position of the feed augers and of the auger flights (3) to each other while assembling.

M6

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1 2

20 o

X

3 4

5

M011

X 2 2.1

M010

307.1133.3.6 englisch (en) 10.2006

M7

M Service Training

1 2

5 M013

M014

1 3

4

2

M012

M8

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M Service Training

5650H - 5690HTS Elevator head with TCS (grain throughput measurement)

Tensioning the elevator chain Check the following dimension subsequent to tensioning of the elevator chain: The dimension (A) between guide plate (1) and rubber sheet (2) amounts to 12 mm

Replacement of elevator chain or guide plate Subsequent to replacing the elevator chain or the guide plates: Adjust the dimension (A) between rubber sheet (2) and guide plate (1) to 12 mm.

Checking cover with sealing Observe passage (B) while mounting the cover (3) or the deflecting plate (4)! Mount resp. adjust the cover slightly lower as against the deflecting plate, as shown in fig. M012.

Replacement of the grain humidity sensor Observe the mounting position while replacing the sensor (5)! The arrow on the sensor must point from the ascending pipe to the outside.

Service notes Clean the deflecting plate (4) at the throughput sensor periodically. At ascending pipe in front: Clean grain humidity sensor (5) periodically.

307.1133.3.6 englisch (en) 10.2006

M9

M Service Training

5650H - 5690HTS Grain tank clutch

1

Tensioning rocker

2

Belt guides

3

Compression spring

4

Servo-motor

5

Adjusting nut

Adjustments when engaged: -

Initial tension of spring A = 135 mm (for adjustment at clutch control power unit, see chapter C)

-

Stroke of the servo-motor B = 60 mm (adjustment at the adjusting nuts (5). Fix nuts strongly by a locknut.

-

Clearing between the belt guides (2) and the V-belt 8 mm.

M 10

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2

M037

2

3

2

1 4 M021

5

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M 11

M Service Training

3

4 2

31653

1

M 12

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M Service Training

5650H - 5690HTS Grain tank unloading

1

Feed auger inside of grain tank

2

Roofing sheet

3

Mounting for roofing sheet on right side

4

Adjusting plates

The purpose of the adjusting plates (4) is to limit the flow of material to the feed auger, depending on the pourability of the harvest material. In case of overload of the unloading system (slipping through of V-belt) the adjusting plates must be adjusted lower. In case of hardly pourable harvest material (e.g. grass seed) it is possible to hang up the roofing sheet (2) on the right side in the upper borehole of the mounting (3).

307.1133.3.6 englisch (en) 10.2006

M 13

M Service Training

5650H - 5690HTS Unloading system

1

Lower angular gear

2

Slewing rim

3

Ascending auger

4

Close-tolerance bolt M12, 10.9

5

Belleville spring

6

Locknut M12

7

Upper angular gear

7.1

Fastening screws

8

Tappet with bushings

9

Feed auger inside of unloading tube (divided at 5 m tube)

10

Pedestal bearing at 5 m tube

11

Bearing

12

Supporting rings

13

Spring pin

Assembly instructions: 1. Observe the mounting position of the pedestal bearing (10) and the position of the auger flights while mounting the augers inside of the unloading tube. A projection length of 88 mm between auger shaft and unloading tube is to be adjusted by means of a corresponding number of supporting rings (12) between bearing (11) and spring pin (13). 2. Observe the position of the auger flight of the ascending auger (3) and of the tube auger (9) while assembling the unloading tube to the tube bend. 3. Subsequent to mounting of unloading tube the fastening screws (7.1) for the angular gear (7) are to be loosened. Rotate the unloading system slowly. In the course of this the angular gear will be aligned towards the augers. Retighten the fastening screws (7.1).

Tighten the locknut M12 (6) on the close-tolerance bolt (4) carefully such that the belleville spring (5) is being tensioned. Secure nut with loctite. Observe mounting position: Plate spring (5) and locknut (6) must be mounted on the spot faced circular area of the auger shaft.

M 14

307.1133.3.6 englisch (en) 10.2006

M Service Training

9

7

A

9

B

C

3 M028

B

2 1

A

4

90Nm

10

M038

8

7

8 11

7.1

4

12

13

C

5 6

90Nm M019

M036-1

88

C

M039

307.1133.3.6 englisch (en) 10.2006

M 15

M Service Training

2 3

2

1 3

M022

2

3

M023

1 5 4

M025

M 16

M024

307.1133.3.6 englisch (en) 10.2006

M Service Training

5650H - 5690HTS Angular gear inside of Tube bend

1

Insert the pinion shafts such that the boreholes are out-of-line to each other by one tooth.

2

Adjust tooth clearance of 0,2 mm between casing cover and bearing by means of fitting washers.

3

Fill hollow space between casing cover and bearing with grease. Packing of grease inside of casing approx. 250g EP of gear grease

5650H - 5690HTS Lower angular gear Oil filling Gear oil SAE 90, GL5

0,75 l

Tooth clearance

0,15 - 0,40 mm

Moment of friction primary shaft (1)

0,4 - 0,8 Nm

Moment of friction output shaft (2)

0,1 - 0,4 Nm

3

Hollow space between bearing and rotary shaft seal at the output shaft (2) is to be filled with grease.

4

Oil-level plug,

5

Lubricant nipple,

Check contact pattern of the tooth faces subsequent to replacing pinion shafts resp. bevel wheels or bearings.

307.1133.3.6 englisch (en) 10.2006

M 17

M Service Training

5650H - 5690HTS Support for grain tank tube, Interlock

1

Support, adjustable in height

2

Latch

3

Tension spring

4

Unlatching cylinder

5

Inductive sensor

The message "grain tank tube swivelled out” in the cabin is activated through the inductive sensor (5). The inductive sensor (5) continues to be connected with the electronic control system for the grain tank clutch: When the grain tank tube is swung in, the grain tank clutch will automatically be disengaged if no manual shut-down has been caused by the driver. The grain tank clutch control is blocked in case of a defective or not connected sensor (5).

Before driving on public roads, check whether the latch (2) of the grain tank tube is engaged!

5650H - 5690HTS Hydraulic actuation grain tank tube swivel 1

Console

2

Supporting screw with Insulating plastic tube

3

Lifting cylinder

4

Head piece

5

Shift lever

6

Ascending pipe

Screw down supporting screw (2) as far as the sidewall of the frame. Adjust head piece (4) on the piston rod such that the unloading tube is pulled entirely into the support (pos. 1 on top).

M 18

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4

5

2

1 3 4

M026-1

2 1

3 6 4

5 112°

M027

307.1133.3.6 englisch (en) 10.2006

M 19

M Service Training

3

TOP

1 2

1

2 4

25

4

3

M035

M 20

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5650H - 5690HTS Level transmitter, sensor for grain tank cover

1

Level transmitter ”Grain tank full”

2

Level transmitter ”Grain tank 80% full”

3

Sensor for grain tank cover

4

Position of closed Grain tank cover and lowered Grain tank extension

A clearing of at least 25 mm between the face of the transmitter and the clamping jaws must be observed while mounting the level transmitters (1) and (2). Clean level transmitters periodically. The message "Grain tank full” will not be deactivated any more by the transmitter in case of adsorption of humid dust or chaff.

307.1133.3.6 englisch (en) 10.2006

M 21

M Service Training

Notes

M 22

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P Service Training

5650H - 5690HTS Cutting mechanism Table of contents Typ of cutting mechanism

HMW 1131-1133

Schematic diagram of drives, Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 – 03

X

Cutting mechanism drive, Reel variator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04 – 05

X

Slip clutch for feed auger and reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 – 07

X

Feed auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .08 – 09

X

Settings of feed auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 – 11

X

Cutter gear unit

80 mm stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 – 13

X

85 mm stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 – 15

X

Inspection of cutter actuation, Cutter replacement . . . . . . . . . . . . . . . . . . . . . . . . . .16 – 17

X

Potentiometer installation in case of cutting mechanism control . . . . . . . . . . . . . . .18 – 19

X

Connector pin assignment 13-pole plug-socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

X

Wiring layout and circuit diagram for hydraulic system at rape attachment . . . . . . . .22 – 23

X

Rape attachment drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 – 25

X

307.1133.3.6 englisch (en) 10.2006

P1

P Service Training

HMW 1131 - 1133 Schematic diagram of drives, Speeds

Speed 1

Drive shaft

480 ± 20 min 1

2

Reel variator

260 - 860 min-1

3

Double chain wheel (series Z55/7)

–

4

Reel at double chain wheel (3) Z55/7

15 - 49 min-1

at double chain wheel (3) Z75/7 5

Cutter gear unit with 80-90 mm stroke 130 mm stroke

6

P2

11 - 36 min-1 600 ± 20 min-1 580 ± 20 min-1

Feed auger

192

min-1

reduced speed

172

min-1

307.1133.3.6 englisch (en) 10.2006

P Service Training

4 3 2

1

5 6

32861/2-1

307.1133.3.6 englisch (en) 10.2006

P3

P Service Training

12 11 8

9

10

7 6 4 4.1 P001

X 5

4

3

200 Nm

5.1

3.1

7

6

9

8

11

10

63,5 2.2

2.1

2

P002

1 225

P4

307.1133.3.6 englisch (en) 10.2006

P Service Training

HMW 1131 - 1133 Cutting mechanism drive, Reel variator

1

Drive shaft

2

Variator pack - driving

2.1

Chain wheel for feed auger drive

2.2

Thread hole M16 for pressing on the sliding pulley in case of v-belt replacement

3

Variator pack - driven

3.1

Chain wheel for reel drive

4

Thrust washer

4.1

Counter nut

5

Bearing shaft for variator pack

5.1

Locating screw

6

Tie rod

7

Stop washer

8

Adjusting spindle

9

Distance bush

10

Circlip

11

Driving pin

12

Angular motor

Control dimension 63,5 mm for belt alignment, measured between fixed pulley and fixed pulley. Setting of variator adjustment: (v-belt is removed) Pull in the tie rod (6) by means of angular motor until the adjusting spindle (8) is blocked. Screw on thrust washer (4) to the tie rod (6) as far as there remains a distance of 1 mm at the bottom of the pulley halves (X). Secure thrust washer (4) by means of counter nut M10 (4.1).

307.1133.3.6 englisch (en) 10.2006

P5

P Service Training

HMW 1131 - 1133 Slip clutch for feed auger and reel

A

Slip clutch for feed auger, chain wheel 3/4”.

B

Slip clutch for reel

1

Hub

2

Pressure plate

3

Chain wheel

4

Friction linings (the chamfer (a) of the linings must point to the pressure plate in case of clutch C)

5

Plain bearing bush, install by applying grease

6

Round head cap screws, grade 8.8

7

Ratchet, blocking the slip clutch while reversing

Slipping moment with factory setting: Slip clutch

A: 700 Nm B: 350 Nm

Release slip clutch after a longer standstill period and let it slip through.

P6

307.1133.3.6 englisch (en) 10.2006

P Service Training

A

4

4 1

40

6

5

1

5

2 P003

4

75 Nm

7

P005

3

B 3

1 21

P047

6

a

2 4 P006

307.1133.3.6 englisch (en) 10.2006

P7

P Service Training

5

5

8

12

2

6

1

3

12

7

2

4

P007

P050

5

6

12

4

5 14

13 10 9 7 8 M008

11 12

P8

307.1133.3.6 englisch (en) 10.2006

P Service Training

HMW 1131 - 1133 Feed auger

1

Drive shaft

2

Bearing plate

3

Adjusting segment for feed finger

4

Bearing shaft and drive shaft right

5

Bearing shaft for feed finger

6

Intermediate shaft with bearing

7

Single finger

8

Feed finger in centre of auger

9

Finger stroke

10

Spring clip

11

Spring pin (loss protection)

12

Clamping piece

13

Attachment screw M12x50; 10.9

14

Close-tolerance bolt M12x70; 10.9

Removing feed auger: Disassemble adjusting segment (3) and bearing plate (2) on left and right side. Roll out auger from the cutting mechanism trough on the right side.

307.1133.3.6 englisch (en) 10.2006

P9

P Service Training

HMW 1131 - 1133 Settings of the feed auger

1

Bearing plate for feed auger

2

Adjusting segment for feed finger control

3

Stripper, two pieces

4

Feed finger

5

Drive shaft for feed finger

The standard distance between auger flight and cutting mechanism trough amounts to 6 - 12 mm. In case of coarse harvest material (e.g. rape, field beans) it may be necessary to adjust the auger higher, to approx. 20 mm distance. The height adjustment is done on the left and on the right side at the bearing plate (1). Afterwards the strippers (3) are to be readjusted: Adjust stripper as close as possible to the auger flight in order to avoid coiling up of the auger. The drive shaft (5) for the feed fingers is turned round by means of the adjusting segment (2).

6

Extension for auger flight (mounted in case of combine harvesters equipped with 5 straw walkers)

7

Feed angle between the feed fingers: - 1x long, 2x short feed angle toothed feed angle as from year of construction 2001

P 10

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P Service Training

5 2 1

4

3

P046

6-12 mm P011

6

7

6 P048

307.1133.3.6 englisch (en) 10.2006

P 11

P Service Training

3

1

7 5

1.1 X

6

1 2

8 P014

9 X

10

A

B 4.1

3 4 H X 4.1

P013-1

C P015

3

4

11

5 6

8

12

9

3

13

4

P016

P 12

307.1133.3.6 englisch (en) 10.2006

P Service Training

HMW 1131 - 1133 and rape attachment Cutter gear unit 80 mm stroke

up to cutting mechanism no. 29107 from 3 m up to 7,20 m as from cutting mechanism no. 29108 from 3 m up to 4,80 m

1

Belt pulley halves

1.1

Spacer disks, 4 pieces

2

Casing

3

Rotor

4

Crank (colour mark in tooth gap to crankpin)

4.1

Crankpin

5

Needle roller bearing

6

Sealing washer

7

Borehole for lubricating grease, ø 6 mm

8

Circlip

9

Pinion (dot mark on face)

10

Gear ring

11

Crank end

12

Crankshaft bearing

13

Adjusting washers

X

Bearings are glued in place at the outer ring, DW 59

H

Direction of stroke of the crankpin (4.1)

Charge of grease approx. 100 g lithium-base saponified grease K2. Relubrication every 200 operating hours.

Assembly of the gear unit In case of a properly assembled gear unit the crankpin (4.1) must move parallel to the screw-down bores A-B (longer side) inside of the casing

☞

1. Assembly of pinion (9) and crank (4) in the rotor (3): Marked pinion tooth (9) must be diametrically opposite to the marked tooth gap on the crank (4). 2. Assembly of rotor (3) with crank (4) in the casing (2): Turn crank (4) inside of rotor (3) such that the centre points of rotor, of crank and of crankpin (4.1) are aligned (direction of stroke H), letting the crankpin (4.1) point towards the outside of the rotor. Insert the rotor into the casing in this position, whereas the crankpin (4.1) must point exactly towards the casing side B-C. It must be possible to slide the pinion (9) and gear ring (10) into each other without twisting. Fill the bearing and the gear ring with grease prior to assembly.

307.1133.3.6 englisch (en) 10.2006

P 13

P Service Training

HMW 1131 - 1133 and rape attachment as from 5,40 m, as from cutting mechanism no. 30988 Cutter gear unit 85 mm stroke 1

V-belt pulley halves (flywheel mass)

2

Spacer disks (2x2 mm between the pulleys, 1x2 mm, 1x1 mm outside)

3

Casing

4

Rotor

5

Gear ring

5.1*

O-ring, sheet gasket

6

Pinion shaft, (replace together with item 5 in case of repair)

7

Crank base

8

Screws M8x35; 12.9; glued in place

9

Screws M10x35, 12.9

10

Bearing support

11

Head bearing

H

Direction of stroke of the head bearing

The 4 dot marks (P) must lie on top of each other while assembling (1x casing, 2x rotor, 1x crank base). Fill casing and gear ring with grease prior to assembly. Relubricate head bearing and casing with lithium-base saponified grease K2 every 50 operating hours.

*) In the year of production 2001 the fixation of the gear ring (5) has been changed to screw connection from the inside of the casing. At this occasion the o-ring and the sheet gasket 5.1 were being dropped.

P 14

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P Service Training

1

2

4 3

5

P

P P 10

H P025

11

8

6

7

P026

80 9 Nm 4

10

5 6

5.1

7

11

P027

8

307.1133.3.6 englisch (en) 10.2006

P 15

P Service Training

80 8 Nm

7

3 2

6

7

Y 5 P028

1

P029

4

x

1.1

1

P030

z

z

H

P 16

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P Service Training

HMW 1131 – 1133 Inspection of cutter actuation, cutter replacement 1

Cutter head

2

Screws M6 x 28 - 10.9, tightening torque 15 Nm

3

Screws M6 x 18 - 10.9, tightening torque 15 Nm

4

Insert nut

5

Plastic sleeve

6

Head bearing

7

Bearing support

8

Screws M10 x 35

1. Synchronous operation of head bearing (6) and cutter: The head bearing (6) must move in parallel to the direction of stroke of the cutter. The cutter head (1) must not be pushed against the cutter guide in the cutter bar neither in horizontal (X) nor in vertical direction (Y). In case of a relative movement of the head bearing (6) in X - direction the cutter gear unit in the gear console must be slightly turned round.

2. Checking the stroke change: H = Cutter stroke. In case of stroke change of the cutter the overlap (Z) between blade centre and finger centre must be equal. If the deviation is too big the cutter gear unit in the gear console must be displaced towards the direction of stroke.

Cutter replacement, as from cutting mechanism 5,40 m -

Unscrew screws (8) at bearing support.

-

Extract cutter with head bearing from the cutter bar.

-

Insert head bearing loosely into new cutter.

-

Tighten screws (8). Tightening torque 80 Nm.

-

Vertically align cutter head (1) on the head bearing (6).

-

Tighten screw (1.1), take care at the same time that the cutter head will not move any more on the head bearing.

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P Service Training

HMW 1131 – 1133 Potentiometer installation in case of cutting mechanism control 1

Sensing skid (1 piece in case of level control, 3 pieces in case of autocontrol)

2

Skid support

3

Bearing plate

4

Centering ring for potentiometer

5

Driving pin

6

Potentiometer

7

Screw M5 with spring lock washer and plain washer

Observe the installation position of the potentiometers. The plug-in connection must be on top and at the same time the casing is tightened in the center of the oblong holes. Verify while mounting that the pendulum angle A (approx. 30°) of the sensing skid is located within the angle of rotation B (120°) of the rotary potentiometer (otherwise the potentiometer will be destroyed). A return spring inside of the potentiometer pulls its moving part towards the lower position of the sensing skid. The driving pin (5) must not jam in radial or axial direction inside of the potentiometer: Check the groove depth in the sensing skid and the length of the driving pins (5). Tighten screw (7) but moderately (danger of potentiometer seizing). Adjustment of the potentiometers (see also chapter H): Signal voltage between 2,4 V and 6,8 V with lifted resp. freely hanging sensing skid. In case of underflow or overflow of the voltage range turn round the potentiometer casing inside of the oblong holes. The signal voltage is supposed to change for more than 2 V from the lowest to the highest position of the sensing skid. Pendulum angle of the sensing skids approx. 30°.

P 18

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B 120° 30°

A

310 mm

30°

6 P-41

1

4 5 7 6 3

2

307.1133.3.6 englisch (en) 10.2006

1

P034

7

6

31053

P 19

P Service Training

Notes

P 20

307.1133.3.6 englisch (en) 10.2006

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HMW 1131 – 1133 Connector pin assignment 13-pole plugsocket

Plug

Plug-socket Type Autocontrol (3 sensing skids)

Plug-socket Type Level control (1 sensing skid)

Rape cutting mechanism

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Wiring layout and circuit diagram for hydraulic system at rape attachment

1

Hydraulic system pump, driven by cutter gear unit (pump capacity 11cm3/rev.)

2

Oil container with return line filter

3

Pressure relief valve 150 bar

4

Control valve for left side cutter

5

Hydraulic system motor right (absorption capacity 12,5 cm3/rev.)

6

Hydraulic system motor left

7

Pressure lines

8

Return lines

9

Leakage oil line for right hydraulic system motor (being dropped, if only the right side cutter is mounted)

10

Shunt diode inside of plug at emergency valve

(absorption capacity 12,5 cm3/rev.)

In case of a de-energized control valve (4) only the right hydraulic system motor (5) is in operation. In case of an energized control valve both hydraulic system motors are connected in series.

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P

3

1

2

6

5

4

Service Training

4

7

10

5

P037

7

7

1

2

8

6

4

9

P038

8

3

P039

307.1133.3.6 englisch (en) 10.2006

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5

A

X

2 2.1 4 P040

1

B

3

3

4

P041

1

3

6

6

2 1

P043

7 P044

P 24

7.1

3 307.1133.3.6 englisch (en) 10.2006

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Rape attachment drive

A

HMW 1131 – 1133 up to 7,20 m

B

HMW 1133 8,10 m and 9 m (cutter gear unit with angle drive)

1

Cutter gear unit at rape attachment

2

Hydraulic system pump

2.1

Flexible disk

3

Deflection pulleys

4

Tensioning pulley

5

Reel bracket

6

Cutter gear unit at cutting mechanism

7

V-belt pulley with free-wheel

7.1

Bearing

When mounting the rape attachment the reel lifting cylinders in the lower borehole (X) at the reel bracket must be detached. For driving of the rape attachment 8,10 m and 9 m the v-belt pulleys of the cutter gear unit are to be replaced. At the cutter gear unit for the cutting mechanism the v-belt pulley (7) with bearing free-wheel is to be mounted.

307.1133.3.6 englisch (en) 10.2006

P 25

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Notes

P 26

307.1133.3.6 englisch (en) 10.2006

U Service Training

5650H - 5690HTS Straw Chopper Table of Contents Combine harvester type

5650H 5680H 5660HTS 5690HTS

Adjustment of the straw guide plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02 – 03

X

X

Belt coupling for chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04 – 05

X

X

Speed monitoring, touch contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06 – 07

X

X

Modification of the chopper for threshing of maize or sunflowers . . . . . . . . . . . . . . .08 – 09

X

X

Lining for straw hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 – 11

X

X

Electrical adjustment of straw guide plate (chopper flap) . . . . . . . . . . . . . . . . . . . . .12 – 13

X

X

Electrical adjustment of deflectors at chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 – 17

X

X

307.1133.3.6 englisch (en) 10.2006

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A

4

4 2

1

2.1

6 a

A

U001

5 3

6 7 U003

2 2.1 1

U006

U2

307.1133.3.6 englisch (en) 10.2006

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5650H – 5690HTS Adjustment of the straw guide plates

1

Lower straw guide plate

2

Front limit stop for lower straw guide plate

2.1

Turn lock

3

Rear limit stop for lower straw guide plate

4

Upper straw guide plate

5

Tie rod

6

Gas strut

7

Swath rake (in case of combine harvesters equipped with 5 walkers only 1 rake is permitted to be installed)

The rear limit stop (3) and the tie rod (5) must be adjusted such that the straw guide plates (1 and 4) are forming a plane surface in position long straw. The lower straw guide plate must rest against the limit stop (a) of the upper straw guide plate.

It is possible to fold down the lower straw guide plate (1) to the front. For this purpose loosen the turn locks (2.1) outside at the straw hood, slew the limit stops (2) upwards and unhook the tie rod (5).

307.1133.3.6 englisch (en) 10.2006

U3

U Service Training

3

3

1

2 U012

3

D

2

5

B

C

A

B

A

4

C0110

U4

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5650H – 5690HTS Belt coupling for chopper

1

Clutch pulley

2

Servo-motor

3

Belt guides

4

Tensioning device

5

Adjusting nuts

Belt coupling adjustment: Adjust the spring load A at the potentiometer (10) of the power relay with belt engaged. When the potentiometer is turned to the right the load current will increase (dimension A will decrease), turning the potentiometer to the left will cause the load current to decrease (dimension A will increase). Adjust stroke B of the servo-motor (2) by means of nuts (5). If the dimension D falls below D = 115 mm (belt displacement) adjust the intermediate drive downwards.

Spring load A

= 110 mm

Stroke B

= 60 mm

307.1133.3.6 englisch (en) 10.2006

U5

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A B

4

4

3

1 2

U016-1

U6

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5650H – 5690HTS Speed monitoring, touch contact

1

Proximity switch (speed sensor)

2

Pulse transmitter

3

Proximity switch for position of straw guide plates

4

Lower straw guide plate

A

Straw guide plate in position chopper on

B

Straw guide plate in position chopper off

Function of switch 3 The switch (3) activates or deactivates the speed monitor and controls the connection of the chopper clutch when the straw guide plates (4) are set to chopper operation (position A).

307.1133.3.6 englisch (en) 10.2006

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Modification of the chopper for threshing of maize or sunflowers 1

V-belt pulley for reduced speed

2

V-belt pulley on the chopper shaft

3

Deflection pulley, in case of KPAB chopper

4

Double pulley at intermediate drive, in case of KPAB SRX chopper

5

Upper straw guide plate

6

Deflector

7

Tie rod

8

Cover plate for shear bar casing, in case of KPAB chopper

9

Rasp bar

1.

Speed reduction: A v-belt pulley (1) with a bigger diameter is to be mounted on the drive pulley (2) of the chopper. Place the deflection pulley (3) higher in case of KPAB chopper.

1.1

Speed reduction in case of KPAB chopper type SR (5650H-5660HTS, 5680H-5690HTS as of year of manufacture 2007): Mount v-belt pulley (4) from the intermediate drive to the v-belt pulley (2) on the chopper.

2.

Installation of a deflector (6) in the straw hood in alignment with the upper straw guide plates (5). Unhook the tie rod (7) for the upper straw guide plate.

3.

Remove the shear bar. In front of the shear bar casing a cover plate (8) is to be mounted in case of the KPAB chopper. Remove every second swinging flail.

4.

U8

Remove rasp bars (9) in the bottom plate.

307.1133.3.6 englisch (en) 10.2006

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3

2 33645

33646

1

KPAB-SRX

4

2 U017-1

6

5

4 7 KPAB

8

33686

307.1133.3.6 englisch (en) 10.2006

9 U018

U9

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495

1

U020

U 10

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5650H – 5690HTS Lining for straw hood

KPAB chopper

The lining (1) in the straw hood is an optional feature (see price list). It helps to support the straw flow to the chopper in case of coarse-fibred rape straw.

KPAB 5650 – 5660

1602 6810

5680 – 5690

1602 6812

307.1133.3.6 englisch (en) 10.2006

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5650H – 5690HTS Electrical adjustment of straw guide plate (chopper flap) (Changeover from chopping to long straw shedding)

1

Servo motor for straw guide plate

1.1

Fork head

1.2

Circuit diagram

1.3

Connector view

2

Inductive sensor for straw guide plate position

3

Speed sensor straw chopper

4

Socket outlet for servo motor of chopper deflectors

5

Straw guide plate limit stop

A26

CAN module

F13

Fuse for servo motor

F56

Fuse for CAN module A26

K16

Relay straw guide plate chopper operation

K37

Relay straw guide plate long straw shedding

S66

Straw guide plate switch

X5

Connector at control cabinet

X146 Connector at engine frame X705 Connector at servo motor X320 Analog ground, insulated ground strip inside of control cabinet

Mounting instruction for the servo motor: Adjust the fork head (1.1) such that the straw guide plate completely abuts the stop limits (5) in both positions in the straw hood. Before initial commissioning or after replacement of the servo motor the calibration of the chopper flap adjustment shall be carried out at the Commander Control.

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K37/3

X5

S66

X146

A26

1

A26/13

5 6 2 1 3 8 7 3 4 2

5 6 2 1 3 8 7 3 4 2

9

br 8

A26/16

X320

K16/3

16

ws br vi ws sw sw sw

X705 5 4 3 2 1 sw

ge

rt

tr

sw

U-004

1.3

X705

+ Signal –

U-001

1.2 U-003

5 4

5 4 mm

1

1.1

2

3

307.1133.3.6 englisch (en) 10.2006

U-005

U 13

U Service Training H43

H41

K38/3

X26

H42

S49

A25/16

X320

K17/3

A25/13

5

6

2

3

1

8

7

3

2

4

5

6

2

3

1

8

7

3

2

4

gn

rt

br

bl

sw

2/54 g

1L

3/31

6/54

7/58 L

gn

rt

br

bl

sw

gn

rt

br

bl

sw

5

3

2

1

sw

bl

br

H44 35379

A25

1

8

X145 9

16

U-006

X706

4 gn ws

ge rt

2

R 1 kOhm

U-007

1.1

1

X706

U-008

U 14

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5670H – 5690HTS, until of year of manufacture 2006 Electrical adjustment of deflectors at chopper

1

Servo motor for deflectors

1.1

Circuit diagram for servo motor

2

Socket outlet at the straw hood

A25

CAN module

F14

Fuse for servo motor

F55

Fuse for CAN module

K17

Relay for deflector adjustment to left side

K38

Relay for deflector adjustment to right side

S49

Switch for deflector adjustment with position lights

X26

Connector at control cabinet

X145 Connector at engine frame X706 Connector at servo motor X320 Analog ground, insulated ground strip inside of control cabinet

Before initial commissioning or after replacement of the servo motor the calibration of the chopper deflector adjustment shall be carried out at the Commander Control.

307.1133.3.6 englisch (en) 10.2006

U 15

U Service Training H43

H41

K38/3

X26

H42

S49

A25/16

X320

K17/3

A25/13

5

6

2

3

1

8

7

3

2

4

5

6

2

3

1

8

7

3

2

4

gn

rt

br

bl

sw

2/54 g

1/L

3/31

6/54

7/58 L

sw

rt

rt

ws

bl

H44 35379

A25

1

8

X145 9

16

U-006

2

R 1 kOhm

U-007

1.1

1

U-008

U 16

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5650H – 5660HTS 5680H – 5690HTS, as of year of manufacture 2007 Electrical adjustment of deflectors at chopper

1

Servo motor for deflectors

1.1

Circuit diagram for servo motor

2

Socket outlet at the straw hood

A25

CAN module

F14

Fuse for servo motor

F55

Fuse for CAN module

K17

Relay for deflector adjustment to left side

K38

Relay for deflector adjustment to right side

S49

Switch for deflector adjustment with position lights

X26

Connector at control cabinet

X145 Connector at engine frame X320 Analog ground, insulated ground strip inside of control cabinet

Before initial commissioning or after replacement of the servo motor the calibration of the chopper deflector adjustment shall be carried out at the Commander Control.

307.1133.3.6 englisch (en) 10.2006

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Notes

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307.1133.3.6 englisch (en) 10.2006

Der Nachdruck des Textes und der Abbildungen ist, auch auszugsweise, verboten. La reproduction du présent ouvrage, du texte et des ìllustratìons, mème partìelle est interdite. Text and illustrations herewith enclosed may not be reproduced, not even in part and by any means. E’ vietata la riproduzione, anche parziale, del testo e delle illustrazioni. Se prohibe la reproducciòn total o parcial del texto y de las ilustraciones. A proibida a reproduçào, até mesmo parcial, do texto e das ilustracòes.

Der zeitliche Unterschied zwischen der Aktualisierung der Druckschriften und der Durchführung technischer Veränderungen (die ständig vorgenommen werden, um immer hochwertigere Erzeugnisse auf den Markt zu bringen) erfordern aus Gründen der Korrektheit des Hinweises, dass die in dieser Ausgabe enthaltenen Daten jederzeit geändert werden können und deshalb unverbindlich sind. Le temps qui s’écoule entre la mise à jour en impression et les modifications techniques (ces dernières changeant continuellement afin d’offrir aux utilisateurs des produits toujours plus qualifiés) nous oblige a vous signaler que les données de la présente publication pourraient être susceptibles de variations. Elles sont données sans engagement de notre part. Because of the possible time lag between the introduction of technical modifications (an on-going process the aim of which is to offer products which are being continually improved) and the latest update of the manual, we must point out, for the sake of correctness,that the data contained in this edition are liable to change at any time and are therefore not binding. La differenza tra i tempi di aggiornamento in stampa e i tempi delle modifiche tecniche (variando queste ultime continuamente, ciò al fine di offrire prodotti sempre più qualificati) impongono di dichiarare, per correttezza, che i dati contenuti nella presente edizione sono suscettibili di variazione in qualsiasi momento e che quindi non sono impegnativi. La diferencia entre los tiempos necesarios para poner al dia la impresiòn y los tiempos de las modificaciones tècnicas (las que se verifican continuamente, con el objeto de ofrecer productos cada vez màs calificados) nos imponen declarar, por corrección, que los datos contenidos en la presente ediciòn estàn sujetos a variaciones en cualquier momento y que portanto no son obligativos. A diferença entre os tempos necessãrrios para actualizar a impressão e os tempos das modificacões técnicas (que se verificam continuamente, a fim de oferecer um produto cada vez mais qualificado), obrigam-nos a declarar, que os dados contidos neste manuel são susceptiveis de variacão em qualquer momento e que portanto não são vinculatórios.

NOTES

02 - 2007 By Personal computing

cod. 307.1132.3.6 Technical Publications Dep.

02-2007

307. 1133. 3. 6