cr970 Service Manual PDF

CR920, CR940, CR960, CR970
REPAIR MANUAL
COMPLETE CONTENTS
SECTION 00 - GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 10 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 14 - LIVE PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 21 - TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 25 - FRONT MECHANICAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 29 - HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 33 - BRAKES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 35 - HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 41 - STEERING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SECTION 50 - CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SECTION 55 - ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SECTION 60 - PRODUCT FEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
SECTION 66 - THRESHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
SECTION 72 - DISCHARGE BEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
SECTION 74 - CLEANING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
SECTION 80 - GRAIN STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
SECTION 88 - ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
SECTION 90 - PLATFORM, CAB, BODYWORK, DECALS . . . . . . . . . . . . . . . 98
The following pages are the collation of the contents pages from each section and
chapter of the CR920, CR940, CR960, and CR970 Repair manual. Complete Repair part
# 87600552.
The sections used through out all New Holland product Repair manuals may not be
used for each product. Each Repair manual will be made up of one or several books.
Each book will be labeled as to which sections are in the overall Repair manual and
which sections are in each book.
The sections listed above are the sections utilized for the CR920, CR940, CR960, and
CR970 Combines.
© 2006 CNH America LLC 87600570 10/06

Printed In U.S.A. Replaces 87036612
SECTION 00 - GENERAL INFORMATION
BOOK 1 - 87600553
Chapter 1 - General Information

CONTENTS
Section Description Page

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
About Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Part and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Machine Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Personal Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operational Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Health and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Acids and Alkalis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adhesives and Sealers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery Acids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brake and Clutch Linings and Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chemical Materials -- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clutch Linings and Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Corrosion Protection Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Dewaxing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Do’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Don’ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Dusts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exhaust Fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fiber Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Foams- Polyurethane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2
BOOK 1 - 87600553
Chapter 1 - General Information (Continued)

CONTENTS

Gas Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gas Shielding Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gas Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Workshop Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Glues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
High-pressure Air, Lubrication and Oil Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 12
Legal Aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lubricants and Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Noise Insulation Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Paints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Paint Thinners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressurized Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Resistance Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sealers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Solder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Service Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Straw Chopper (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Powered Rear Axle Wheel Motors (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Minimum Hardware Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Recommended Lubricants And Coolants (North America Only) . . . . . . . . . . . . . . . . . . . . . 21
3
SECTION 10 - ENGINE
BOOK 1 - 87600553
Chapter 1 -- 7.5L Engine Block

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Engine Front Cover and Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Timing Gears Checking and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Gears -- Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Rear Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4
SECTION 10 - ENGINE
BOOK 1 - 87600553
Chapter 1 -- 7.5L Engine Block (Continued)

CONTENTS

Oil Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Camshaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Connecting Rod Bush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Cylinder Block Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Sleeving - Boring and Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Installing Piston Assembly Into Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Front Crankshaft Cassette Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Engine Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Test Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Test Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5
SECTION 10 - ENGINE
BOOK 1 - 87600553
Chapter 2 - 7.5L Cooling

CONTENTS

Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fan Belt Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Idler Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6
SECTION 10 - ENGINE
BOOK 1 - 87600553
Chapter 3 - 7.5L Complete Engine, Remove and Replace

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SECTION 10 - ENGINE
BOOK 1 - 87600553
Chapter 4 - 7.5L Fuel System

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bosch P7100 Mechanically Controlled Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . 7
Bosch P7100 Electronically Controlled Fuel Injection System . . . . . . . . . . . . . . . . . . . . 13
Fuel Injector Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Timing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Set Low Idle and Anti-Surge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fuel Shutoff Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fuel Prefilter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7
SECTION 10 - ENGINE
BOOK 1 - 87600553
Chapter 4 - 7.5L Fuel System (Continued)

CONTENTS

Supply Pump Sedimenter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Low Pressure Fuel Injection Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
High Pressure Fuel Injection Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8
SECTION 10 - ENGINE
BOOK 2 - 87600554
Chapter 5 - 7.8L, 10.3L Description of Operation

CONTENTS

Walk Around . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Engine Block and Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Crankshaft Sealing Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Timing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Auxiliary Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oil Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electronically Controlled Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pump Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 10 - ENGINE
BOOK 2 - 87600554
Chapter 6 - 7.8L, 10.3L Complete Engine, Remove and Replace

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9
SECTION 10 - ENGINE
BOOK 2 - 87600554
Chapter 7 - 7.8L, 10.3L Engine Block
Model Engine Size

CR 960 F2BE0684A*B001 7.8L
CR 970 F3AE0684D*B001 10.3L
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rev Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Timing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Crank Gear and Cylinder Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder Head - Timing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine F2B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine F3A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Plan of Tightening Sequence of Screws Securing Sub-Crankcase . . . . . . . . . . . . . . . . . . . 27
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
System Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Mechanical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assembly and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assembling Crankshaft With Main Bearing Caps, Thrust Bearings and Rings,
Crankshaft End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Assembling Pistons With Piston Rings, Pins, Connecting Rods, Connecting Rod
Caps and Bearings - Checking Protrusion Over the Top Face of the Crankcase . . . . 53
Fitting and Tightening the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fitting Oil Pump, Timing System Intermediate Gears and Gear Box . . . . . . . . . . . . . . 56
Engine Flywheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fitting Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Fitting Injectors - Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10
SECTION 10 - ENGINE
BOOK 2 - 87600554
Chapter 7 - 7.8L, 10.3L Engine Block (Continued)

CONTENTS

Fitting Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Completing the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Assembly Diagram For Fan Drive Belt - Water Pump - Alternator For F2B Engine . . 67
Assembly Diagram For Fan Drive Belt - Water Pump - Alternator For F3A Engine . . 68
Checks, Measurements and Repairs on the Crankcase, Cylinder Liners . . . . . . . . . . 69
Checks, Measurements and Repairs on the Crankshaft, Bearings . . . . . . . . . . . . . . . 72
Selecting Main and Big End Bearing Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Preliminary Appraisal of Data to Make the Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Checks, Measurements and Repairs on the Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Checks, Measurements and Repairs on the Connecting Rods . . . . . . . . . . . . . . . . . . . 89
Piston Connecting Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Checks, Measurements and Repairs on the Cylinder Head . . . . . . . . . . . . . . . . . . . . . 95
Valve Seats On The Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Checks, Measurements and Repairs on the Tappets And Camshaft . . . . . . . . . . . . . . 99
Checks, Measurements and Repairs on the Valve Springs, Rocker Arm Shaft
and Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Checks, Measurements and Repairs on the Lubrication System . . . . . . . . . . . . . . . . 106
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Checks, Measurements and Repairs on the Cooling Circuit . . . . . . . . . . . . . . . . . . . . . 111
Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Injector Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Replacing the Crankshaft Front Cover Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Adjusting Clearance Valve of Intake Exhaust Rocker Arms and Pre-Load of
Pump Injector Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Pump Injector - Removal and Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Bleeding the Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
11
SECTION 10 - ENGINE
BOOK 2 - 87600554
Chapter 8 - Common Engine Compartment Components

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cooling Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Radiator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rotary Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Rotary Screen Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Rotary Screen Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Rotary Screen Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Rotary Screen Brush Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
12
SECTION 14 - LIVE PTO
BOOK 3 - 87600555
Chapter 1 - Engine Gearbox, Clutch Pack Removal/Installation

CONTENTS

Special Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Labor Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clutch Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

BOOK 3 - 87600555
Chapter 2 - Engine Gearbox, Clutch Pack Rebuild

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Main Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Unload Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
13
BOOK 3 - 87600555
Chapter 3 - Engine Gearbox Removal/Installation

CONTENTS

Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Flexplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

BOOK 3 - 87600555
Chapter 4 - Engine Gearbox Rebuild

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component Repair -- Bearing and Race Removal/Installation . . . . . . . . . . . . . . . . 10
Component Repair -- Clutch Cylinder Bushing Removal/Installation . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
14
SECTION 21 - TRANSMISSION
BOOK 3 - 87600555
Chapter 1 - Transmission
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional/Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transmission Cover (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Gearbox Shafts (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Shifting Diagram (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Shifting Disc/Drive Gear (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Shifting Disc/Drive Gear (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Differential (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Differential (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Differential Shafts (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drive Shaft/Cover (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Drive Shaft (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Drive Shaft (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Input Shaft and Bearing Caps (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Input Shaft (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Input Shaft (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
15
SECTION 25 - FRONT MECHANICAL DRIVE
BOOK 3 - 87600555
Chapter 1 - Planetary Final Drive

CONTENTS

General Specification -- Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Type I and Type II Final Drive Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Final Drive -- Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Final Drive -- Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Final Drive -- Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Final Drive -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Final Drive Reducer, Spur Gear -- Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Final Drive Reducer, Spur Gear -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Final Drive Input Shaft -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Final Drive Input Shaft -- Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Final Drive Reducer, Satellite and Planetary -- Exploded View . . . . . . . . . . . . . . . . . . . 13
Overhaul -- Type I Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Final Drive Reducer, Spur Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Final Drive Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Final Drive Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Final Drive Reducer, Satellite and Planetary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
16
BOOK 3 - 87600555
Chapter 1 - Planetary Final Drive (Continued)

CONTENTS

Final Drive Wheel Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Overhaul -- Type II Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Distance Ring Combinations Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Half-shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
17
BOOK 3 - 87600555
Chapter 2 - 11/111 Final Drives

CONTENTS

25 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Final Drive (Standard Seal) -- Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Final Drive (Mud Seal) -- Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wheel Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
18
SECTION 29 - HYDROSTATIC SYSTEM
BOOK 4 - 87600556
Chapter 1 - Hydrostatic Drive System Introduction

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydrostatic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydrostatic Pump (CR920, 940 and 960 Machines W/Hd 11/111 Final Drives) . . . . . . . 2
Hydrostatic Pump (CR940 and 960 Machines W/Planetary Final Drives) . . . . . . . . . . . . 3
Hydrostatic Pump (CR970 and 980 Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydrostatic Drive Motor (CR920, 940 and 960 Machines W/Hd 11/111
Final Drives) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydrostatic Drive Motor (CR940 And 960 Machines W/Planetary Final Drives;
CR970 and 980 Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil Cooler Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydrostatic Brake (External Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydrostatic Brake (Integrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydrostatic Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Powered Rear Axle (PRA) (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydrostatic Drive Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Explanation of Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
19
BOOK 4 - 87600556
Chapter 2 - Hydrostatic System Operation

CONTENTS

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Schematic Circuit for CR920, 940, 960, 970 and 980 Machines . . . . . . . . . . . . . . . . 3
Hydrostatic Block Operation (External Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydrostatic Block Operation (Integrated Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Gear Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Schematic Circuit for CR920, 940, 960, 970 and 980 Machines . . . . . . . . . . . . . . . 11
Multi Function Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Charge Check Valve 8a - 9a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Limiter 8b - 9b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
High Pressure Relief Valve 8c - 9c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Bypass Valve 8d - 9d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Servo Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
System in Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Servo Solenoid Valve 10a Energized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydrostatic Drive Motor Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Shuttle Spool Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Flushing Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pressure Release Valve Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Oil Cooler bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hydrostatic Pump and Drive motor Identification Numbers . . . . . . . . . . . . . . . . . . . . . . 21
Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Variable Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pump Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hydrostatic Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fixed Displacement Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Drive Motor Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
20
BOOK 4 - 87600556
Chapter 3 - Filling the Hydrostatic System and Start-up Procedure

CONTENTS

29 000 Filling the Hydrostatic System and Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

BOOK 4 - 87600556
Chapter 4 - Powered Rear Axle

CONTENTS

Powered Rear Axle -- Style I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Equa-Trac II® Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Low Pressure Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Forward and Reverse Flow Divider Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Forward and Reverse Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Equa-Trac II® Valve Operation – “OFF” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Equa-Trac II® Valve Operation – “INTERMEDIATE” Position . . . . . . . . . . . . . . . . . 13
Equa-Trac II® Valve Operation – “ON” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Powered Rear Axle Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Wheel Motor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Full Supply Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Bottom Neutral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Discharge Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Top Neutral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
21
BOOK 4 - 87600556
Chapter 4 - Powered Rear Axle (Continued)

CONTENTS

Wheel Motor Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Powered Rear Axle Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Powered Rear Axle -- Style II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Flow Regulator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2WD-4WD Hydraulic System -- Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2WD-4WD Hydraulic System -- Detailed View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Selector Valve -- Dynamic Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Hydraulic Line -- Plumbing Schema PRA Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2WD-4WD Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Selector Valve -- Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Two-speed Valve -- Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Two-speed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
22
BOOK 4 - 87600556
Chapter 5 - Pressure Testing and Troubleshooting

CONTENTS

29 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Hydrostatic System, Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Servo Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

BOOK 4 - 87600556
Chapter 6 - Hydrostatic Pump and Motor Repair

CONTENTS

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
29 212 Main Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
29 218 Shaft Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
29 218 Shaft Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
29 218 Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
29 218 Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
29 212 Charge Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
29 212 Charge Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Major Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electric Displacement Control (EDC) Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
23
BOOK 4 - 87600556
Chapter 6 - Hydrostatic Pump and Motor Repair (Continued)

CONTENTS

29 218 Multi-Function Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
29 218 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
29 218 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pump Charge Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
29 212 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Major Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
29 218 Motor Charge Relief Valve -- Style 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
29 218 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Shuttle Spool Valve -- Style 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Motor Pressure Relief Valve - Style 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Pressure Release Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pressure Release Valve Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
24
SECTION 33 - BRAKES AND CONTROLS
BOOK 5 - 87600557
Chapter 1 - Brakes and Controls

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Minimum Hardware Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bleeding the Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake Caliper and Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Parking Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Parking Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Park Brake Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Parking Brake Piston Travel and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Parking Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Bleeding the Hydraulic Parking Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Parking Brake Caliper -- Cross Section View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
25
SECTION 35 - HYDRAULIC SYSTEMS
BOOK 5 - 87600557
Chapter 1 - Introduction
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
High Pressure System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Low Pressure System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Low Pressure Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
High Pressure Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
High Pressure System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
High Pressure Circuit Diagram, Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
High Pressure Circuit Diagram, Main (with Hydraulic Cleaning Fan) . . . . . . . . . . . 10
Main Frame Stack Valve (NA Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Feeder Stack Valve (NA Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Main Frame Stack Valve (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Feeder Stack Valve (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Low Pressure System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Low Pressure System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Low Pressure System with Positive Straw Discharge . . . . . . . . . . . . . . . . . . . . . . . 32
Low Pressure System with Chopper Infeed Roll Motor with Valve
-- Model Year 2004 and Earlier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
-- Model Year 2005 and Later . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
26
BOOK 5 - 87600557
Chapter 2 - Description of Operation

CONTENTS

Closed Center Load Sensing (CCLS) Variable Displacement Pump . . . . . . . . . . . . . . . . 2
Principal of Pump Operation -- Fixed Vs. Variable Displacement . . . . . . . . . . . . . . . . 3
Flow and Pressure Compensating Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Low Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
High Pressure Circuit High Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
High Pressure Circuit Low Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Controlling Maximum System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Main Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Feeder Valve Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Stack Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Header Height Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Accumulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Function Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Rotor Variator/Feeder Variator/Reel Raise--lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Unloading Auger Swing/Feeder Reverser Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Lateral Float Valve/Reel Fore--Aft Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Reel Drive Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Stone Trap Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Hydraulic Cleaning Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Low Pressure System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Chaff Spreader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Chaff Spreader/PSD Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Chopper Infeed Roll Motor Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Low Pressure Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
27
BOOK 5 - 87600557
Chapter 3 - Pressure Testing and Fault Finding

The High and Low Pressure Hydraulic Systems
CONTENTS

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications -- Closed Center Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Low Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CCLS Pump Pressure and Flow Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CCLS Pump Low Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CCLS Pump High Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CCLS Pump Load Sensing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CCLS Pump Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Steering Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Steering Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Steering Relief Valve Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic Cleaning Fan Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Low Pressure System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Low Pressure System – Chaff Spreader Pressure Test . . . . . . . . . . . . . . . . . . . . . . 18
Chaff Spreader/PSD Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Low Pressure System – Regulated Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Low Pressure System – Individual Circuit Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Low Pressure System – Pump Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
28
BOOK 5 - 87600557
Chapter 4 - Hydraulic Pump

CONTENTS

Special Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure and Flow Compensating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
High Pressure Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
29
BOOK 5 - 87600557
Chapter 5 - Stack Valves Overhaul

CONTENTS

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Main Stack Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Feeder Stack Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Low Pressure Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
30
SECTION 41 - STEERING AXLE
BOOK 6 - 87600558
Chapter 1 - Axle, General

CONTENTS

Axle Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Heavy Duty Adjustable Steering Axle (HDASA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Powered Rear Axle (PRA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Height Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Track Width Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Toe In Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Axle Front/Rear Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

BOOK 6 - 87600558
Chapter 2 - Wheel Bearings (HDASA)

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Repacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
31
BOOK 6 - 87600558
Chapter 3 - Steering Pivot (HDASA)

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hub Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

BOOK 6 - 87600558
Chapter 4 - Center Section

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Center Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
32
BOOK 6 - 87600558
Chapter 5 - Powered Rear Steering Axle

BSN HAJ100101
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bolt Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction and General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Troubleshooting - Powered Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Powered Rear Axle Hydraulic Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Powered Rear Axle Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Powered Rear Axle Solenoid Valve Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Start-up Procedure for Powered Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Equa-Trac II Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Wheel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Steering Pin Bushing and Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
33
BOOK 6 - 87600558
Chapter 6 - Hydrostatic Motor

ASN HAJ100101
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydrostatic Motor -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bleeding the Rear Axle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydrostatic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 50 - CLIMATE CONTROL

BOOK 6 - 87600558
Chapter 1 - Heating, Ventilation and Air-Conditioning

CONTENTS

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A/C Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Climate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Automatic Temperature Control (ATC) Above PIN HAJ102270 . . . . . . . . . . . . . . . . . 5
Automatic Temperature Control (ATC) Below PIN HAJ103301 . . . . . . . . . . . . . . . . . 8
Manual Temperature Control (MTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
34
BOOK 6 - 87600558
Chapter 1 - Heating, Ventilation and Air-Conditioning (Continued)

CONTENTS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Problem Solving Pressure Test Results and Temperature/Pressure Chart . . . . . . 14
Air-conditioning Temperature/Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Ventilation System Separator Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ventilation System Blower Motor (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Ventilation System Blower Motor (MTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electrical Control Temperature Control Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Electrical Control Blower Speed Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electrical Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Electronic HVAC Control -- Display Data Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Electronic HVAC Control -- ATC Control Switch and Mode Control Switch . . . . . . . . . 32
Electronic HVAC Control -- ATC Controller Power Supply . . . . . . . . . . . . . . . . . . . . . . . 33
Sensing System High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Sensing System Low Pressure Switch (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Sensing System Low Pressure Switch/Freeze Switch (MTC) . . . . . . . . . . . . . . . . . . . . 38
Sensing System Outlet Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Sensing System Cab Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Sensing System Evaporator Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Evacuating the Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
35
BOOK 6 - 87600558
Chapter 2 - Air Filters

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fresh Air Intake Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Recirculation Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Separator Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

BOOK 6 - 87600558
Chapter 3 - Blower Fans

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Circulation Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Separator Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
36
BOOK 6 - 87600558
Chapter 4 - Compressor
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

BOOK 6 - 87600558
Chapter 5 - Condenser
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
37
BOOK 6 - 87600558
Chapter 6 - Cool Box

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cool Box Damper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

BOOK 6 - 87600558
Chapter 7 - Evaporator
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Evaporator Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
38
BOOK 6 - 87600558
Chapter 8 - Heater Core

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Water Valve Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

BOOK 6 - 87600558
Chapter 9 - High/Low Pressure Cutout Switch

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
39
BOOK 6 - 87600558
Chapter 10 - Receiver/Dryer
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Receiver / Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

BOOK 6 - 87600558
Chapter 11 - Thermal Expansion Valve

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Thermal Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
40
SECTION 55 - ELECTRICAL SYSTEMS
BOOK 7 - 87600559

CONTENTS

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction to Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault Codes and Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
The Digital Multi-Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Measuring Voltage (Volts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Measuring Current (Amps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Measuring Resistance (Ohms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Continuity (Buzzer) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical Test Procedure 1: Continuity Test - Short to Ground . . . . . . . . . . . . . . . . . . . 12
Electrical Test Procedure 2: Voltage Measurement or
Short to Positive Supply Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Test Procedure 3: Resistance Test for Electrical Parts . . . . . . . . . . . . . . . . . 13
Electrical Test Procedure 4: Continuity Test - Check for
Open Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Circuit Components - Basic Description and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Flashers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Resistance Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fluid Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Potentiometer Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electromagnetic Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PWM Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
41
BOOK 7 - 87600559
Chapter 1 - General Information (Continued)

CONTENTS

Speed and Position Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electronic Modules (CCM’s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CCM Power and Ground Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CCM1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CCM2 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CCM3 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Combine Control Module (CCM) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 28
CCM Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Instructional Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal of CCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CCM Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Instructional Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Wiring Harness Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Temporary Wiring Harness Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Harness Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Cab Electrical Connectors X002 and X003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Removal of Rear Speaker Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation of Rear Speaker Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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CONTENTS

55 000 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Service Info Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Active Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Active Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Error History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Network Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Diagnose Info Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Chapter 3 - Electrical Schematics

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55 000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Schematic Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Machine Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component Index, 2003 Production -- SN HAJ100101 to 800 . . . . . . . . . . . . . . . . . . . . 19
2003 Production -- SN HAJ100101 to 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Component Index, 2004 Production -- SN HAJ100801 to 1500 . . . . . . . . . . . . . . . . . . 71
2004 Production -- SN HAJ100801 to 1500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Component Index, 2005 Production -- SN HAJ101501 to 3300 . . . . . . . . . . . . . . . . . 123
2005 Production -- SN HAJ101501 to 3300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Component Index, 2006 Production -- SN HAJ103301 and ABOVE . . . . . . . . . . . . . 175
2006 Production -- SN HAJ103301 and Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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Chapter 4 - CAN Data Bus Network

CONTENTS

CAN Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Troubleshooting a Module Offline Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Troubleshooting Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Troubleshooting “A2000 Communication Lost” Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting Leg 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Data Bus -- Short Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ECU Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HHC Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ASD Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Integrated GPS Receiver Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Front Frame Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Main Frame Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CCM3 Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CCM2 Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cab Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
GPS Receiver Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DLU Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PFD Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cab Roof Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CCM1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Data Bus -- Open Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CCM1 Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cab Roof Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CCM2 Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ECU Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CAN Data Bus Connector Locations -- SN HAJ100800 and Below . . . . . . . . . . . . . . . 16
CAN Data Bus Connector Locations -- SN HAJ100801 and Above . . . . . . . . . . . . . . . 19
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Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Engine Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7.5 Liter Basildon Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7.5 Liter Basildon Electronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
8 Liter Iveco & 10 L Iveco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
12V Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2003 Production -- SN HAJ100101 to 800 (Frame 1) . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2003 Production -- SN HAJ100101 and above (Frame 9) . . . . . . . . . . . . . . . . . . . . . . 9
2003 Production -- SN HAJ100101 and above (Frame 29) . . . . . . . . . . . . . . . . . . . 10
2004 Production -- SN HAJ100801 to 1500 (Frame 1A) . . . . . . . . . . . . . . . . . . . . . . 11
2004 Production -- SN HAJ100801 to 1500 (Frame 2A) . . . . . . . . . . . . . . . . . . . . . 12
2005 Production -- SN HAJ101501 and Above (Frame 1B) . . . . . . . . . . . . . . . . . . 13
Starting System -- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
A -- Key Switch Power Supply Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
B -- Key Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
C – Neutral Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
D – Neutral Start Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
E – 12 V Start Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F – 24 V Start Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
G – 12V Starter Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
H – 24V Starter Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
I -- Starting Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2003 Production -- SN HAJ100101 to 800 (Frame 1) . . . . . . . . . . . . . . . . . . . . . . . . 26
2004 Production -- SN HAJ100801 and Above (Frame 1A) . . . . . . . . . . . . . . . . . . 28
Charging System -- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
A -- Charging System Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
B – RPM Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Alternator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Grid Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Grid Heater Circuit, Iveco Engines -- SN HAJ100800 and Below . . . . . . . . . . . . . . 35
Grid Heater Circuit, Iveco Engines -- SN HAJ100801 and Higher . . . . . . . . . . . . . 36
Grid Heater Circuit, Iveco Engines, Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Grid Heater Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Grid Heater Circuit Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
CCM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Engine Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Right Hand Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
ECU Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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Engine-Related Error Codes -- Automatic Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ECU Related Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Basildon – Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Throttle Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Basildon – Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Air Temperature/ Boost Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Flywheel RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Engine Oil Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Engine Oil Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
IVECO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Engine Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Fuel Filter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Engine Camshaft RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Engine Flywheel RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Style I -- Boost Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Style II -- Boost Pressure/Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fuel Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
All Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Rotary Screen Brush Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Air Filter Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Fuel Pump Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
48
BOOK 8 - 87600560
Chapter 6 - Power Distribution and Lighting

CONTENTS

Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models 920 & 940 (12 Volt System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models 960, 970 & 980 (12/24-Volt System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuse/Relay Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuse/Circuit Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power Distribution: Unswitched and Switched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power Distribution Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power Distribution Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Lighting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Circuit/Fuse Lighting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CR NA Lighting -- Steering Column Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CR European Lighting -- Steering Column Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
CR NA Lighting -- Rocker Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CR European Lighting - Rocker Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Lighting Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Hazard Light Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Marker Light Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Road Lights – Low Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Road Lights – High Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Flip-up Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Brake Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Beacon Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Front Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Rear Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Side Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Stubble Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Grain Tank Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Unload Tube Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Header Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Center Work Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Service Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Backlighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Exterior Lighting System Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
49
BOOK 8 - 87600560
Chapter 7 - Cab Systems

CONTENTS

Description and Operation of Cab Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Power Seat System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Seat Height Adjustment System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power Seat Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power Seat System Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Seat Suspension System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wiper Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cab Roof Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wiper Motor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wiper/Washer System Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wiper/Washer System Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wiper System Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wiper System Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wiper System Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Windowscreen Washer System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Washer System Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Power Mirror System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cab Roof Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Power Mirror Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Power Mirror Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Heated Mirror Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Power Mirror Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Mirror Fuse -- Power and Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Mirror Adjust Switch S-27 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Mirror Select Switch S-57 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Left Hand Mirror Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Right Hand Mirror Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Additional Mirror Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Mirror Heat Switch S-19 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Mirror Heat Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Horn System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Horn System Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Horn System Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Horn System Circuit Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Audio System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Audio System Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Audio System Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Audio System Diagnostic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
50
BOOK 9 - 87600561
Chapter 8 - Hydraulic Systems

CONTENTS

55 000 Gearbox Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic Reservoir Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Reservoir Level Low Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Gearbox Filter Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Return Filter Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control Pressure Low Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

BOOK 9 - 87600561
Chapter 9 - Driveline Systems

CONTENTS

Hydrostatic Ground Drive Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Temperature Control System (TCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydrostat Ground Drive Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydrostat Ground Drive Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Calibration of the Multifunction Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting Multifunction Handle (MFH) Components . . . . . . . . . . . . . . . . . . . . . 7
Ground Speed Potentiometer (R04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Audio Alarm (H01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Park Brake Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Park Brake Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
51
BOOK 9 - 87600561
Chapter 9 - Driveline Systems (Continued)

CONTENTS

Park Brake Electrical Component Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 13
Park Brake Switch S09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Service Brake Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Service Brake Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Gearshifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Special Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gearshift Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gearshift Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gear Select Switch S24 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ground Speed RPM Sensor B17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ground Speed RPM Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Rear Wheel Assist (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Rear Wheel Assist Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Rear Wheel Assist Switch S10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
52
BOOK 9 - 87600561
Chapter 10 - Header Systems

CONTENTS

Reel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Reel Speed Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reel Speed Cannot Be Changed in Manual Mode, or Reel Speed Offset
Cannot be Adjusted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reel Speed Synchronization Cannot Be Engaged, or Will Not Disengage . . . . . . . . . . . 7
Reel Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Reel Positioning Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reel Will Not Raise or Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reel Will Not Move Fore or Aft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Header Height Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Header Height Control Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Header Will Not Raise or Lower Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Head Will Not Tilt Left or Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
One or More of the Header Height Operating Modes Cannot Be
Engaged or Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
53
BOOK 9 - 87600561
Chapter 11 - Feeder Systems

CONTENTS

Feeder Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Feeder Engagement Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Conditions that Prevent Feeder Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Feeder Engage - Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Feeder Engage - Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Feeder Engage Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Feeder Engage - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Feeder Speed (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Feeder Engagement Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Feeder Speed Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Feeder Speed Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Feeder Reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Feeder Reverser - Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Feeder Reverser - Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Feeder Reverser - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Advanced Stone Protection (ASP) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Stone Ejection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ASP System - Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ASP System - Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ASP System - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
54
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Chapter 12 - Threshing Systems

CONTENTS

55 000 Thresher System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Thresher Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Thresher Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Thresher Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
“Thresher Will Not Engage” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
“Thresher Disengages During Operation” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rotor Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rotor Speed Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rotor Speed Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rotor Speed Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
“Rotor Speed Will Not Increase or Decrease” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Concave Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Concave Clearance Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Concave Clearance Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Concave Clearance Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
“Concave Clearance Will Not Increase or Decrease” . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
55
BOOK 9 - 87600561
Chapter 13 - Cleaning Systems

CONTENTS

Self-leveling Cleaning Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cleaning Fan Motor M-05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cleaning Fan Motor (Hydraulic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning System Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lateral Inclination Sensor B02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fan Speed Switch S15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cleaning Fan Rpm Sensor B16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Left Returns Rpm Sensor B06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Clean Grain Elevator Rpm Sensor B08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Right Returns Rpm Sensor B39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Loss Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remote Sieve Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Calibration Of The Upper Sieve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Calibration Of The Lower Sieve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cleaning Fan Motor M05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Loss Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Left Rotor Loss Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Right Rotor Loss Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Sieves Loss Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Remote Sieve Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Upper Remote Sieve Adjust Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lower Remote Sieve Adjust Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Upper Sieve Rear Adjust Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Lower Sieve Rear Adjust Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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Chapter 14 - Clean Grain Systems

CONTENTS

Unload Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Grain Bin Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Unload Tube Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Grain Bin Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
57
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Chapter 15 - Crop Residue

CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Straw Chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chopper RPM Sensor B10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Alarm Code Chopper RPM Sensor B10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Codes for Chopper RPM Sensor B10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chaff Spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chaff Spreader Valve Solenoid L28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Code for Chaff Spreader Valve Solenoid L28 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Positive Straw Discharge (PSD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Straw Chopper Spreader Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Spreader Plate Switch S23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault Codes for Spreader Plate Switch S23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Spreader Plate Motor M11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fault Codes for Spreader Plate Motor M11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Spreader Plate Switch S23 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Spreader Plate Motor M11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
58
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Chapter 16 - Precision Farming

CONTENTS

55 000 Precision Farming Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Moisture Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Grain Yield Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Grain Yield Sensor Offset Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GPS/DGPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Precision Farming Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Precision Farming Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Precision Farming Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

BOOK 10 - 87600562
Chapter 17 - Electrical Connectors

CONTENTS

Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
X001 Cab Main/Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
X002 Cab Main/Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
X003 Cab Main/Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
X004 Main Frame/Cab Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
X006 Cab Main/HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
X007 Front Frame/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
X008 Main Frame/Front Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
X009 Main Frame/Grain Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
X010 Main Frame/Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
X011 Main Frame/Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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Chapter 17 - Electrical Connectors (Continued)

CONTENTS

X012 CCM-3 J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
X013 CCM-3 J2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
X014 CCM-3 J3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
X015 CCM-2 J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
X016 CCM-2 J2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
X017 CCM-2 J3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
X018 CCM-1 J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
X019 CCM-1 J2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
X020 CCM-1 J3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
X021 Front Frame/Feeder Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
X022 Main Frame/Valve Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
X023 Front Frame/Lower Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
X024 Main Frame/Straw Walker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
X025 Straw Walker/Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
X026 RHM J6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
X027 RHM J7A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
X028 RHM J7B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
X029 RHM J8A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
X030 RHM J8B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
X031 Front Frame/Cab Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
X032 Header/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
X033 Cab Main/Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
X034 Expansion/Main Frame A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
X035 Gearbox Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
X036 Cab Roof/Outer Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
X037 Spreader Plate S23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
X038 Alternate Settings S21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
X039 Feeder Reverser S07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
X040 Reel Speed Mode S08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
X041 Neutral Lock S22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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X042 Lower Sieves S14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
X043 Upper Sieves S13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
X044 Concave Clearance S16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
X045 Fan Speed S15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
X046 Rotor Speed S17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
X047 Feeder Speed S18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
X048 Gear Select S24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
X049 On the Road S12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
X050 Dual Range S11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
X051 Rear Wheel Assist 210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
X052 Park Brake S09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
X053 Splice Block A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
X054 Splice Block B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
X055 Thresher Engage S30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
X056 Feeder Engage S31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
X057 Ground Speed R04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
X058 Audio Alarm H01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
X059 Neutral Switch S22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
X060 Throttle S36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
X061 Header Height S04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
X062 Header Width Adjust S06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
X063 Vertical Knives S51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
X064 Main Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
X065 Diagnostics and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
X066 Cold Start Indicator E36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
X067 Acc. Socket J06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
X068 Key Switch S02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
X069 Lighter R08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
X070 Lighter Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
X071 Straw Hood/Straw Walker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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X072 Lower Frame Rear/Straw Walker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
X073 Seat Switch S05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
X074 Seat Pump M26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
X075 Accessory Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
X076 Accessory Outlet J08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
X077 Ground, 3, CM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
X079 Reverser Disengage B09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
X080 Feeder Reverser M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
X081 Lat Float Pot R02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
X082 ASP Amplifier KN2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
X083 ASP Door Position B-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
X084 LH Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
X085 RH Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
X087 Ground Speed RPM B17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
X088 Shoe Motor M03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
X089 Cleaning Fan RPM B16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
X090 Cleaning Fan Motor M05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
X091 Hydrostat Motor Temp B46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
X092 Foot and Inch L05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
X093 Trans Shift Position B37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
X094 Transmission Shift Motor M02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
X095 Ground, 2, FF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
X097 Gearbox Temperature B32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
X098 Control Pressure B35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
X099 Clutch Temperature B45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
X100 Ground Speed Hydrostat L23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
X101 Charge Pressure S37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
X102 Ground, 1, GB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
X103 Reservoir Temperature B18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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X104 Reservoir Level S33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
X105 Unload Tube Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
X106 Left Rear Work Light E27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
X107 3/4 Full Bin Sensor S28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
X108 Grain Tank Light E30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
X109 Full Bin Sensor S29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
X110 Right Rear Work Light E28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
X111 Left Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
X112 Left Outer Work Light E15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
X113 Left Beacon Light E31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
X114 Left Middle Work Light E19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
X115 Left Inner Work Light E17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
X116 Wiper Motor M25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
X117 Right Inner Work Light E18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
X118 Right Middle Work Light E20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
X119 Right Beacon Light 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
X120 Right Outer Work Light E16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
X121 Right Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
X122 Right Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
X123 Left Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
X124 Ground, 4, CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
X124 Ground, 4, CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
X124 Ground, 4, CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
X125 Grain Tank Extensions Switch S42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
X126 Mirror Adjust Switch S27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
X127 Mirror Heat Switch S19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
X128 HVAC Control Panel A09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
X129 Dome Light E34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
X130 Beacon Light Switch S41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
X131 Rear Work Light Switch S44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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X132 Front Work Lights Switch S43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
X133 Splice Block C, Backlighting, CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
X134 Washer Switch S38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
X135 Wiper Switch S20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
X136 Front Left Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
X137 Door Switch S40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
X138 Right Console Light E35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
X139 Front Right Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
X141 Transceiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
X142 G.P.S. Unit A11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
X143 Separator Blower M18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
X145 Ground, 3, AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
X146 Ambient Temp Sensor B25 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
X147 Cold Box Door M15 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
X148 Outlet Temp Sensor B27 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
X149 Cab Temperature Sensor B26 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . 81
X150 Evaporator Probe B28 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
X151 Water Valve M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
X152 Main Blower M17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
X153 Freeze Switch S53 (Manual A/C Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
X155 Ground, Main Blower M17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X156 High Speed, Main Blower M17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X157 Medium Speed, Main Blower M17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X158 Low Speed, Main Blower M17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X159 Data Logger A10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X160 Left Front Hazard Light E03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
X161 Left Front Service Socket J02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
X162 Left Header Light E21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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X163 Left Lower Work Light E23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X164 Left Road Light E13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X165 Right Front Hazard Light E04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X166 Right Front Service Socket J01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
X167 Right Header Light E22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
X168 Right Lower Work Light E24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
X169 Right Road Light E14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
X170 Lateral Inclination Sensor B02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
X171 Wiper Washer Motor M24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
X172 Horn H02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
X172 Horn H02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
X173 Brake Pressure S39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
X174 Feeder Angle R03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
X175 Ground, 2, MF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
X177 Rotor RPM B01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
X178 Mirror Select Switch S-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X181 Left Returns RPM B06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X182 Clean Grain RPM B08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X183 Fuel Pump M23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X184 Fuel Level R01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
X186 Right Returns RPM B39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
X188 RH Rotor Loss B20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
X189 Concave Position R06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
X190 Concave Motor M04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
X191 LH Rotor Loss B19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
X192 ECU Connector A (7.5L Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
X193 ECU Connector B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
X194 Service Socket J05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
X195 Covers Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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X196 Throttle Motor M13 (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
X197 Iveco Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
X198 Splice Block F, Backlighting, RC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
X199 Start Relay Coil K36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X200 Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X201 Engine Oil Pressure B30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X202 Air Filter B07 (SN #HAJ100072 and Below) . . . . . . . . . . . . . . . . . . . . . . . . 96
X202 Air Filter S61 (SN #HAJ100073 and Above) . . . . . . . . . . . . . . . . . . . . . . . . 97
X203 Fuel Injection Pump (Electronic 7.5L Only) . . . . . . . . . . . . . . . . . . . . . . . . . 97
X204 Starter Motor M01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
X205 Starter Solenoid M01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
X206 Rotary Screen Brush M27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
X207 Flywheel RPM B43 (Electronic 7.5L Only) . . . . . . . . . . . . . . . . . . . . . . . . . 98
X208 Ground, 5, EN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
X209 Engine Oil Temperature B03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
X210 Ambient Temperature/Boost Pressure B41 (Electronic 7.5L Only) . . . . . 99
X211 Grid Heater Relay K37/K39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
X212 Fuel Temperature B40 (Electronic 7.5L Only) . . . . . . . . . . . . . . . . . . . . . . . 99
X213 Alternator G01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
X213 Alternator G01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
X213 Alternator G01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
X214 Coolant Temperature B31/B42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
X215 A/C Clutch L07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
X216 A/C High Pressure S47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
X217 A/C Low Pressure S48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
X218 Flip-Up Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
X219 Expansion B/Main Frame B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
X220 Front Ground, 2, EX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
X221 Moisture Sensor B12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
X222 Sample Motor M28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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X223 Yield Sensor R05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
X224 Spreader Plate Motor M11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
X225 Upper Sieve Adjust S35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
X226 Lower Sieve Adjust S46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
X227 Upper Sieve Motor M06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
X228 Lower Sieve Motor M07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
X231 Ground, 1, SW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
X232 Sieves Loss B21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
X233 RWA Solenoid L26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
X234 Sieve Light E37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
X235 Chaff Spreader Solenoid L28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
X236 Left Service Socket J04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
X237 Sieve Light Switch S54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
X238 Gearbox Filter Bypass S34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
X239 Returns Filter Bypass S32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
X240 Swath Plate Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
X243 Left Tail Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
X244 Unload Cradle B38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
X246 Right Tail Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
X247 Rear Beacon Light E-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
X248 Back Up Alarm H-08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
X248 Back Up Alarm H-08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
X251 Rear Ladder B22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
X252 Right Service Socket J03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
X253 Chopper RPM B10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
X255 Flasher Module A05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
X256 Road Lights Switch S26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
X257 Turn Indicator E09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
X258 High Beam/Trailer E10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
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X259 Hazard Switch S25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
X260 ASP Top Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
X261 ASP Bottom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
X262 LH Bottom ASP Sensor B49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
X263 RH Bottom ASP Sensor B48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
X264 RH Top ASP Sensor B50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
X265 LH Top ASP Sensor B51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
X266 Feeder Reverse L21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
X267 Lateral Float CW L18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
X268 Reel AFT L15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
X269 Reel Down L13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
X270 Feeder Forward L20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
X271 Lateral Float CCW L19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
X272 Reel Fore L16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
X273 Reel Up L14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
X274 Reel Drive L17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
X275 Rotor Increase L29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
X276 Unload Tube In L03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
X277 Unload Tube Out L04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
X278 Rotor Decrease L30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
X279 HDR Height Pressure B29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
X280 Accumulator L06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
X281 HHC Module A07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
X282 Feeder Decrease L12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
X283 Feeder Increase L11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
X284 Feeder RPM B14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
X285 Trailer Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
X286 24 Volt Start Relay K38 (Iveco Cursor Only) . . . . . . . . . . . . . . . . . . . . . . . 118
X287 German Third Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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X288 Covers Position B-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
X289 Covers Actuator M-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
X290 Fuel Solenoid L02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
X291 Can Node (7.5L Mech. Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
X292 Stone Door Open L31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
X293 Dual Range Solenoid L27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
X294 LH Brake Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
X295 RH Brake Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
X296 Dome Light Power E-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
X314 FM Radio “B” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
X315 FM Radio “C” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
X316 Center Work LT E38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
X321 GPS Antenna A-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
X322 Unload Tube Work LT E29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
X323 Unload Tube Marker LT E39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
X326 HID Distance LT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
X327 Brake Fluid Level S49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
X329 Brake Limiting Valve L-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
X330 Air Filter Resistor R15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
X331 Flip Up Low Beam Relay K-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
X332 Flip Up High Beam Relay K-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
X333 LH Flip Up Road LT E-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
X334 RH Flip Up Road LT E-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
X335 LH Road LT E-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
X336 RH Road LT E-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
X339 Left Light Switch S-63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
X340 Engine Light Switch S-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
X341 Right Light Switch S-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
X342 LH Shield LTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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X343 RH Shield LTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
X344 Right Shield Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
X345 Left Front Light E-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
X346 Left Rear LIght E-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
X347 Right Front Light E-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
X348 Right Rear Light E-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
X349 Engine Light E-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
X350 RH Position Light E-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
X351 LH Position Light E-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
X352 RH Flashing Light E-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
X353 LH Flashing Light E-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
X354 RH Front Austria Light E-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
X355 LH Front Austria Light E-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
X356 RH Front Turn/Position Light E-04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
X357 LH Front Turn/Position Light E-03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
X358 RH Marker Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
X359 LH Marker Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
X360 RH Rear Marker Light E-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
X361 LH Rear Marker Light E-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
X362 RH License Plate LIght E-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
X363 LH License Plate LIght E-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
X367 Spreader RPM B55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
X368 Park Brake Pressure B53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
X382 Chopper RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
X389 Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
X421 Marker Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
X472 Washer Motor M-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
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CONTENTS

E0000 Stone Trap Closed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E0001 Bin Covers Open Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
E0003 Unload Tube Cradled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
E0004 Fdr Reverser Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
E0006 Return Filter Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
E0007 Gearbox Filter Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
E0008 Left Turn Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
E0009 Front Work Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
E0010 Rear Work Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
E0011 Road Lights Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
E0012 Right Turn Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
E0013 Cleaning Fan RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
E0014 Feeder RPM sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
E0015 Left Returns RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
E0016 Clean Grain Elevator RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
E0018 Right Returns RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
E0023 Hydrostat Motor Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
E0024 Hydraulic Reservoir Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
E0025 Gearbox Temp Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
E0026 Rear Ladder Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
E0029 Lateral Float Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
E0032 Shoe Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
E0033 Lateral Inclination Sens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
E0034 Concave Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
E0037 CCM1 5V Ref Voltage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
E0038 CCM1 8V Ref Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
E0040 CCM1 Key Switch Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
E0041 Current Sense Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
E0042 Current Sense Reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
E0043 Current Sense Lev Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
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E0044 Current Sense Concave CL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
E0045 Current Sense Bin Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
E0046 CCM1 Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
E0047 V Supply Feeder Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
E0050 Isense Feeder Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
E0052 Feeder Clutch Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
E0053 Chaff Spreader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
E0059 Dual Range Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
E0061 Feeder Jog Forward Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
E0062 Fan Sp / Reverser Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
E0065 Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
E0066 Rear Wheel Assist Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
E0067 Feeder Jog Reverse Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
E0068 Unload Tube Light Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
E0069 Covers / Concave Cl Sel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
E0070 Front Work Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
E0071 Rear Work Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
E0072 Side Work Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
E0073 Field Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
E0075 Leveling Shoe Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
E0076 Fan Speed Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
E0077 Reverser Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
E0078 Concave Clearance Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
E0079 Grain Bin Covers Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
E0080 HHC Module Bad Intelligent Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
E0082 Feeder Speed Incr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
E0083 Feeder Speed Decr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
E0084 Voting Conflicts Found . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
E0085 Voting Differences Found . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
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E0128 Trans Shift Gear N sens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E0129 Trans Shift Gear 3 sens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
E0130 Trans Shift Gear 2 sens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
E0133 Hydraulic Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
E0134 Brake Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
E0135 Charge Pressure Switch Valid Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
E0136 Beacon Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
E0137 Open Covers Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
E0138 Hazards Switch Shorted to Low Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
E0140 Operator Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
E0141 Header Reel RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
E0142 Groundspeed RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
E0143 Chopper RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
E0145 Engine RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
E0146 Thresher RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
E0148 Header Type Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
E0151 Thresher Clutch Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
E0152 Coolant Temp / Fuel Filt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
E0153 Engine Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
E0154 Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
E0159 Grain Bin Full Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
E0161 Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
E0162 Control Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
E0163 Engine Air Filter Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
E0164 V Supply Ground Spd Hydro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
E0165 CCM2 5V Ref Voltage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
E0166 CCM2 8V Ref Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
E0168 CCM2 Keyswitch Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
E0169 Current Sense Reel Speed Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
E0171 Curr Sense Transm Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
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E0172 Curr Sense Rot Scr Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
E0173 Curr Sense Eng Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
E0174 CCM2 Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
E0175 V Supply Thresher Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
E0177 Isense Unload Cross Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
E0178 Isense Thresher Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
E0179 LoP Isense Grnd Spd Hydro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
E0180 Thresher Clutch Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
E0181 Parking Brake Disengage Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
E0182 Fuel Shutoff Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
E0183 Brake Limiting Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
E0184 Unload Cross Auger Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
E0185 Header Reel Fore Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
E0186 Header Reel Drive Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
E0187 Header Reel Up Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
E0188 Header Reel Down Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
E0189 Header Reel Back Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
E0191 Thresher Speed Increase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
E0192 Thresher Speed Decrease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
E0193 Unload Tube In Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
E0194 Unload Tube Out Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
E0195 Foot-an-Inch Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
E0196 Grid Heater Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
E0197 Rot Scr Brush / Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
E0198 Backlighting Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
E0199 Brake Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
E0200 Beacon Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
E0201 Flasher System Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
E0202 Ground Speed Hydrostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
E0203 Transmission Shift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
E0204 Header Reel Speed Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
E0206 Rotary Screen Brush Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
E0207 Engine Throttle Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
E0208 ECU Module Data Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
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E0261 Lower Sieve Decrease -- Rear Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E0262 Upper Sieve Decrease -- Rear Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E0263 Lower Sieve Increase -- Rear Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
E0282 Upper Sieve Increase -- Rear Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
E0283 Moisture Temp Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
E0284 Moisture Sensor -- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
E0285 Moisture Sensor + . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
E0287 Upper Sieve Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
E0288 Grain Yield Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
E0289 Spreader Plate Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
E0290 Lower Sieve Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
E0294 CCM3 8V Ref Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
E0297 Current Sense Spreader Pl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
E0300 Current Sense Lower Sieve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
E0301 Current Sense Upper Sieve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
E0310 Bypass Unit Engage Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
E0325 Upper/Lower Sieve Sel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
E0332 Spreader Plates Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
E0334 Lower Sieve Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
E0335 Upper Sieve Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
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CONTENTS

55 000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fault Code Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Code Charts -- (NH675 TA/AB engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fault Code Charts -- (IVECO F2B or F3A engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

BOOK 14 - 87600566
Chapter 22 - HHC Diagnostic Codes

CONTENTS

E0512 Feeder Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E0513 Header Lift Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
E0514 R Stubble Height / Flex R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
E0515 L Stubble Height / Flex L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
E0516 Lateral Float CCW Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
E0517 Lateral Float CW Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
E0518 Header Up Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
E0519 Header Down Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
E0520 HHC 12V Supply Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
E0523 HHC Diagnostic LED Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
E0524 10V Reference Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
E0525 HHC Accumulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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E1280 ASP Top Sensor (One) Line Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E1281 ASP Bottom Sensor (One) Line Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
E1282 ASP Top Sensor (Both) Shorted to High Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
E1283 ASP Bottom Sensor (Both) Shorted to High Source . . . . . . . . . . . . . . . . . . . . . . . . . 15
E1284 ASP Stonedoor Output Unidentified Failure Code . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
E1286 ASP Sensitivity OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
E1287 ASP Sensitivity ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SECTION 55 -- ELECTRICAL SYSTEMS

BOOK 14 - 87600566
Chapter 24 -- RHM Fault Codes

CONTENTS

E0641 RHM 5V Reference Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E0643 MFH Position Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
E0645 Gear Select Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
E0646 CSW Feeder Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
E0647 CSW Vertical Knives Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
E0648 CSW Spreader Plates Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
E0649 CSW HHC Auto Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
E0650 CSW Vertical Knives Right Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
E0652 CSW Throttle Increase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
E0653 CSW HHC Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
E0654 CSW Road Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
E0655 CSW Spreader Plates Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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E0656 CSW Throttle Decrease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
E0657 CSW Reel Speed Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
E0661 CSW Reel Speed Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
E0662 CSW Fan Speed Incr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
E0663 CSW Fan Speed Decr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
E0664 CSW Thresher Speed Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
E0665 CSW Thresher Speed Decr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
E0666 CSW Feeder Speed Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
E0667 CSW Feeder Speed Decr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
E0668 CSW Park Brake On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
E0669 CSW Park Brake Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
E0670 CSW Concave Clear Decr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
E0671 CSW Concave Clear Incr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
E0672 CSW Upper Sieve Decr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
E0673 CSW Upper Sieve Incr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
E0674 CSW Lower Sieve Decr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
E0675 CSW Lower Sieve Incr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
E0676 CSW Header Usage Incr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
E0677 CSW Header Usage Decr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
E0678 Current Protection Line 0 Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
E0681 HSW Unload Tube Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
E0682 HSW Unload Tube Out Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
E0683 HSW Unload Auger Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
E0684 HSW Unload Tube In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
E0685 HSW Unload Tube In Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
E0686 HSW ILM (Handle) Unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
E0688 HSW Reel Fore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
E0689 HSW Reel Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
E0690 HSW Reel Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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E0691 HSW Reel Speed Decr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
E0692 HSW Reel Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
E0693 HSW Reel Speed Incr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
E0694 HSW Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
E0695 HSW Lateral Tilt CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
E0696 HSW Header Down Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
E0697 HSW Header Up Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
E0698 HSW Header Up Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
E0699 HSW HHC Resume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
E0700 HSW Lateral Tilt CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
E0701 HSW Header Down Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
SECTION 60 - PRODUCT FEEDING

BOOK 15 - 87600567
Chapter 1 - Feeder House

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Bolt Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Feeder House . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Feeder Drive Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Feeder Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Front Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Polyethylene Roller Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Polyethylene Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Lateral Float Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cradle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Face Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Feeder Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Front Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Rear Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Hydraulic Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Primary Feeder Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Replacement (Fixed Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Replacement (Variable Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Variable Sheave Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Variable Drive Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Variable Drive Sheave Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Torque Sensing Drive Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cross Shaft and Bearing Replacement (Fixed Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Cross Shaft And Bearing Replacement (Variable Drive) . . . . . . . . . . . . . . . . . . . . . . . . 35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Feeder/Header Drive Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
81
BOOK 15 - 87600567
Chapter 2 - Feeder Drives (Continued)

CONTENTS

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Secondary Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Feeder Reverser Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Feeder Reverser Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Feeder Chain Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Slip Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Pivot Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
82
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Chapter 3 - Stone Ejection System

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bottom Sensor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Top Sensor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Stone Ejection System Actuating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Stone Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal and Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Skid Plate (Inner Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
83
SECTION 66 - THRESHING
BOOK 15 - 87600567
Chapter 1 - Rotor Chamber

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front Infeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Concave Wear Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rotor Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Concave Adjusting Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Concave Adjustment Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Concave Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Separator Grates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
84
BOOK 15 - 87600567
Chapter 2 - Rotors
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BOOK 15 - 87600567
Chapter 3 - Main Threshing Drives

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive Belt (Engine Gearbox Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Main Cross Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rotor Variable Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
85
BOOK 15 - 87600567
Chapter 3 - Main Threshing Drives (Continued)

CONTENTS

Rotor Variable Drive Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rotor Variable Drive Sheave Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Torque Sensing Drive Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Rotor Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Right Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Disassembly (Dual Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Inspection (Dual Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Assembly (Dual Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Disassembly (Single Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Inspection (Single Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Assembly (Single Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Left Rotor Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
86
SECTION 72 - DISCHARGE BEATER
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Chapter 1 - Discharge Beater

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Discharge Beater Grate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Discharge Beater Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Discharge Beater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Beater Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 74 - CLEANING SYSTEMS

BOOK 16 - 87600568
Chapter 1 - Cleaning Shoe Frame

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Upper Cleaning Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Grain Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lower Cleaning Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cleaning Shoe Support Arm Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Connecting Arm Pivot Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Drive and Upper Connecting Arm Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Lower Connecting Arm Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Cleaning Shoe Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Leveling Frame - Pivot Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Leveling Frame - Rear Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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Leveling Frame - Rear Pivot Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

BOOK 16 - 87600568
Chapter 2 - Cleaning Shoe Drive

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Upper Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Lower Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Eccentric Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mechanical Drive Cleaning Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Drive Cleaning Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pump -- Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pump -- Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Motor -- Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Motor -- Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Valve Block -- Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Valve Block -- Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mechanical Variator Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Mechanical Variator Drive Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Minimum Fan Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Maximum Fan Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Mechanical Variator Driven Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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Cleaning Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Canvas Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Deflector Plate Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cleaning Fan Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

BOOK 16 - 87600568
Chapter 4 - Returns System

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Left Returns Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Right Returns Auger (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
91
BOOK 16 - 87600568
Chapter 4 - Returns System (Continued)

CONTENTS

Disassembly -- Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inspection -- Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assembly -- Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Disassembly -- Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspection -- Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Assembly -- Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Returns Auger Safety Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Verify Clutch Slip Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Returns Auger Safety Clutch Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Returns Auger Safety Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Returns Auger Safety Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Returns Auger Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Right Auger Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Left Auger Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Right Auger Paddle Replacement (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Left Auger Paddle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Returns Auger Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
92
SECTION 80 -- GRAIN STORAGE
BOOK 17 - 87600569
Chapter 1 - Clean Grain Transport

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clean Grain Cross Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grain Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Grain Elevator Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Grain Elevator Upper Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Grain Flow Sensor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Moisture Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Sensitivity Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Bubble-up Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
93
SECTION 80 -- GRAIN STORAGE
BOOK 17 - 87600569
Chapter 2 - Unloading System

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Unloading Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Unloading Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Unloading Intermediate Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Unloading Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Vertical Unloading Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Unloading Drive Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Unloading Tube Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Grain Tank Bottom Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
94
SECTION 88 - ACCESSORIES
BOOK 17 - 87600569
Chapter 1 - Straw Chopper

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Secondary Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Primary Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chopper Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Counter Knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Spreader Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Divider Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Divider Plate Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Chopper Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Chopper Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chop/Drop Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
95
BOOK 17 - 87600569
Chapter 2 - Chaff/Corn Spreader

CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Spreader Disc/Blade -- Narrow Spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Spreader Disc/Blade -- Wide Spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Chaff/Corn Spreader -- Narrow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Chaff/Corn Spreader -- Wide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
96
BOOK 17 - 87600569
Chapter 3 - Positive Straw Discharge (PSD)

CONTENTS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PSD (Positive Straw Discharge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PSD Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PSD Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
97
SECTION 90 - PLATFORM, CAB, BODYWORK, DECALS
BOOK 17 - 87600569
Chapter 1 - Cab
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cab Suspension System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air Ride Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Seat Compressor/Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Seat Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Seat Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Steering Column Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Right Hand Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Outside Cab Roof Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
98
BOOK 17 - 87600569
Chapter 2 - Shielding
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Side Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Gas Strut Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Strut Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Front Ladder -- PIN HAJ100800 and Below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mount Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Mount Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Mount Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Platform Extention -- PIN HAJ100800 and Below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Platform Extention -- PIN HAJ100801 and Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
99
BOOK 17 - 87600569
Chapter 3 - Blow Off System

CONTENTS

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Flange Mounted Compressor (CR960-970) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Base Mounted Compressor (CR920-940) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wabco Compressor (411 141 002 0) Base Mount (CR 920--940) . . . . . . . . . . . . . . . . . . . 4
Wabco Unloader Valve (975 303 503 0) for Base Mount Compressor
(CR 920--940) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wabco Compressor (412 352 008 0) Flange Mount (CR 960--970) . . . . . . . . . . . . . . . . . 6
Wabco Unloader Valve (975 303 072 0) for Flange Mount Compressor
(CR 960--970) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
100
SECTION 00 -- GENERAL INFORMATION -- CHAPTER 1
CONTENTS

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
About Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Part and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Machine Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Personal Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operational Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Health and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Acids and Alkalis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adhesives and Sealers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery Acids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brake and Clutch Linings and Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chemical Materials -- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clutch Linings and Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Corrosion Protection Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Dewaxing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Do’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Don’ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Dusts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exhaust Fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fiber Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Foams- Polyurethane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
00-1

Gas Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gas Shielding Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gas Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Workshop Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Glues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
High-pressure Air, Lubrication and Oil Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 12
Legal Aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lubricants and Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Noise Insulation Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Paints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Paint Thinners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressurized Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Resistance Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sealers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Solder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Service Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Straw Chopper (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Powered Rear Axle Wheel Motors (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Minimum Hardware Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Recommended Lubricants And Coolants (North America Only) . . . . . . . . . . . . . . . . . . . . . 21
00-2
FOREWORD
Appropriate service methods and correct repair correct at the time of issue, but New Holland policy
procedures are essential for the safe, reliable is one of continuous improvement, and, the right to
operation of all equipment, as well as the personal change specifications, equipment, or design at any
safety of the individual performing the repair. time, without notice, is reserved.
This Repair Manual provides troubleshooting,

overhaul, and pressure-testing instructions using
ABOUT IMPROVEMENTS
recommended procedures and equipment. Follow- New Holland is continually striving to improve its
ing these instructions will ensure the safe, efficient, products. We must, therefore, reserve the right to
and timely completion of the service or repair. make improvements or changes when it becomes
practical and possible to do so, without incurring any
There are numerous variations in procedures, obligation to make changes or additions to the
techniques, tools, and parts for servicing machines, equipment sold previously.
as well as in the skill of the individual doing the work.
This manual cannot possibly anticipate all such ALL SPECIFICATIONS ARE SUBJECT TO
variations and provide advice or cautions as to each. CHANGE WITHOUT NOTICE.
Accordingly, anyone who departs from the instruc-
tions provided in this manual must first establish that PART AND ACCESSORIES
their personal safety, the safety of others, and the
Genuine NEW HOLLAND parts and accessories
integrity of the machine will not be compromised by
have been specifically designed for NEW HOLLAND
the choice of methods, tools or parts.
MACHINES.
The manual is divided into sections which are
We would like to point out that “NON GENUINE”
subdivided into chapters: Each chapter contains
parts and accessories have not been examined and
information on general operating principles, detailed
released by NEW HOLLAND. The installation and or
inspection, overhaul and, where applicable, specific
use of such products could have a negative effect
troubleshooting, special tools, and specifications.
upon the design characteristics of your machine and
Any reference in this manual to right, left, rear, front, thereby affect its safety. NEW HOLLAND is not liable
top, or bottom is as viewed from the operator’s seat, for any damage caused by the use of “NON
looking toward the normal direction of travel. GENUINE” NEW HOLLAND parts and accessories.
All data and illustrations in this manual are subject to

variations in build specification. This information was
00-3
PRECAUTIONARY STATEMENTS
PERSONAL SAFETY SAFETY PRECAUTIONS
Throughout this manual and on machine decals, you Practically all service work involves the need to drive
will find precautionary statements (“DANGER”, the combine. The operator’s manual, supplied with
“WARNING”, and “CAUTION”) followed by specific each combine, contains detailed safety precautions
instructions. These precautions are intended for the relating to driving, operating, and servicing the
personal safety of you and those working with you. combine. These precautions are as applicable to the
Please take the time to read them. service technician as they are to the operator and
should be read, understood and practiced by all
DANGER personnel.
This word “DANGER” indicates an immediate Prior to undertaking any maintenance, repair,
hazardous situation that, if not avoided, will overhaul, dismantling or reassembly operations,
result in death or serious injury. The color whether within a workshop facility or in the field,
associated with Danger is RED. consideration should be given to factors that may
have an effect upon safety, not only upon the
mechanic carrying out the work, but also upon
WARNING bystanders.
This word “WARNING” indicates a potentially
hazardous situation that, if not avoided, could
result in death or serious injury. The color PERSONAL CONSIDERATIONS
associated with Warning is ORANGE. The wrong clothes or carelessness in dress can
cause accidents. Be sure to wear suitable clothing
when servicing equipment.
CAUTION
This word “CAUTION” indicates a potentially Some jobs require special protective equipment; be
hazardous situation that, if not avoided, may sure to use protective equipment when required.
result in minor or moderate injury. It may also
used to alert against unsafe practices. The color Skin Protection
associated with Caution is YELLOW. Used motor oil may cause skin cancer. Follow work
practices that minimize the amount of skin exposed
FAILURE TO FOLLOW THE “DANGER”, and length of time used oil stays on your skin.
“WARNING”, AND “CAUTION” INSTRUCTIONS
MAY RESULT IN SERIOUS BODILY INJURY OR Eye Protection
DEATH. The smallest eye injury may cause loss of vision.
Injury can be avoided by wearing eye protection
MACHINE SAFETY when engaged in chiselling, grinding, discing,
welding, and painting.
The additional precautionary statement
(“IMPORTANT”) is followed by specific instructions.
This statement is intended for machine safety. Breathing Protection
Fumes, dust, and paint spray are unpleasant and
IMPORTANT: The word “IMPORTANT”is used to in- harmful. These can be avoided by wearing
form the reader of something he needs to know to respiratory protection.
prevent minor machine damage if a certain pro-
cedure is not followed. Hearing Protection
Loud noise may damage your hearing, and the
INFORMATION greater the exposure the worse the damage. If the
noise is excessive, wear ear protection.
NOTE: Instructions used to identify and present
supplementary information.
Lifting Protection
Avoid injury by correctly handling components. Make
sure you are capable of lifting the object. If in doubt
get help.
00-4
Hand Protection Compressed Air
It is advisable to use a protective cream before work The pressure from a compressed-air line often
to prevent irritation and skin contamination. After exceeds 100 PSI (690 kPa). It is perfectly safe if used
work clean your hands with soap and water. Solvents correctly. Any misuse may cause injury.
such as mineral spirit and kerosene may harm the
skin. Never use compressed air to blow dust, filing, and dirt
away from your work area unless the correct type of
Foot Protection nozzle is fitted.
Substantial or protective foot wear with reinforced Compressed air is not a cleaning agent; it will only
toe caps will protect your feet from falling objects. move dust from one place to another. Look around
Additionally, oil-resistant soles will help to avoid before using an air hose as bystanders may get grit
slipping. into their eyes, ears, or skin.
Special Clothing Hand Tools

For certain work it may be necessary to wear flame Many cuts, abrasions and injuries are caused by
or acid-resistant clothing. defective tools. Never use the wrong tool for the job,
as this generally leads either to an injury, a poor job,
EQUIPMENT CONSIDERATIONS or damaged equipment.
Machine Guards When removing or replacing hardened pins, use a
Before using any machine, check to ensure that the copper or brass drift rather than a hammer.
machine guards are in position and serviceable.
These guards not only prevent parts of the body or For dismantling, overhaul, and assembly of major
clothing coming in contact with the moving parts of and sub-components, always use the Special
the machine, but also ward off objects that might fly Service Tools recommended. These will reduce the
off the machine and cause injury. work effort, labor time, and the repair cost.
Lifting Devices Electricity

Always ensure that lifting equipment, such as chains, Electricity has become so familiar in day to day
slings, lifting brackets, hooks and eyes, are usage, that its potentially dangerous properties are
thoroughly checked and in good condition before often overlooked. Misuse of electrical equipment can
use. If in doubt of weight capacity, select stronger endanger life.
equipment than is necessary.
Before using any electrical equipment particularly
Never stand under a suspended load or raised portable appliances - make a visual check to make
implement. sure that the wiring is not worn or frayed and that the
plugs and sockets are intact. Make sure you know
where the nearest isolating switch for your
equipment is located.
00-5
GENERAL CONSIDERATIONS OPERATIONAL CONSIDERATIONS

Solvents Stop the engine, if at all possible, before performing
any service.
Use cleaning fluids and solvents that are known to be
safe. Certain types of fluids can cause damage to Place a warning sign on the combine which, due to
components such as seals and can cause skin service or overhaul, would be dangerous to start.
irritation. Solvents should be checked that they are Disconnect the battery leads if leaving such a unit
suitable not only for the cleaning of components and unattended.
individual parts, but also that they do not affect the
Do not attempt to start the engine while standing
personal safety of the user.
beside the combine or attempt to bypass the safety
start switch.
Housekeeping
Many injuries result from tripping over or slipping on Avoid prolonged running of the engine in a closed
objects or material left lying around by a careless building or in an area with inadequate ventilation as
worker. Prevent these accidents from occurring. If exhaust fumes are highly toxic.
you notice a hazard, remove the hazard. Always turn the radiator cap to the first stop to allow
pressure in the system to dissipate when the coolant
A clean, hazard-free place of work improves the is hot.
surroundings and daily environment for everybody.
Never work beneath a combine which is on soft
Fire ground. Always take the unit to an area which has a
hard working surface, preferably concrete.
Fire has no respect for persons or property. The
destruction that a fire can cause is not always fully If it is found necessary to raise the combine for ease
realized. Everyone must be constantly on guard. of servicing or repair, make sure that safe and stable
supports are installed beneath axle housings,
Extinguish matches, cigars, and cigarettes before casings, etc., before starting work.
throwing them away.
Use ladders or working platforms when servicing
Work cleanly, disposing of waste material into proper those areas of a combine that are not within easy
containers. reach.
Locate the fire extinguishers and find out how to
operate them. WARNING
Do not panic - warn those near and raise the alarm. Do not use your hand to check for leaks. Use a
piece of cardboard or paper to search for leaks.
Do not allow or use an open flame near the combine Stop the engine and relieve pressure before
fuel tank, battery, or component parts. connecting or disconnecting lines.
First Aid Tighten all connections before starting the
engine or pressurizing lines.
In the type of work that mechanics are engaged in,
dirt, grease, and fine dusts settle upon the skin and If any fluid is injected into the skin, obtain medical
clothing. If a cut, abrasion or burn is disregarded it attention immediately or gangrene may result.
may become infected within a short time. Seek
medical aid immediately.
WARNING
Cleanliness Escaping hydraulic/diesel fluid under pressure
can penetrate the skin causing serious injury.
Cleanliness of the combine hydraulic system is
essential for optimum performance. When carrying
out service and repairs, plug all hose ends and Before loosening any hoses or tubes connecting
component connections to prevent dirt entry. implements to remote control valves, etc., switch off
the engine, remove all pressure in the lines by
Clean the exterior of all components before carrying operating levers several times. This will remove the
out any form of repair. Dirt and abrasive dust danger of personal injury by oil pressure.
can reduce the efficiency and working life of
a component and lead to costly replacement. Use
of a high-pressure washer or steam cleaner is
recommended.
00-6
Prior to pressure testing, make sure all hoses and ACIDS AND ALKALIS (SEE BATTERY ACIDS,
connectors of the combine and the test equipment I.E., CAUSTIC SODA, SULPHURIC ACID)
are in good condition and tightly sealed. Pressure
Used in batteries and cleaning materials.
readings must be taken with the gauges specified.
The correct procedure should be rigidly observed to Irritating and corrosive to the skin, eyes, nose and
prevent damage to the system or the equipment, and throat. Causes burns.
to eliminate the possibility of personal injury.
Avoid splashes to the skin, eyes, and clothing. Wear
Always lower equipment to the ground when leaving suitable protective gloves and goggles. Can destroy
the combine. ordinary protective clothing. Do not breathe mists.
Beware of overhead power, electric or telephone Ensure access to water and soap is readily available
cables when travelling. for splashing accidents.
Do not park or attempt to service a combine on an
incline. If unavoidable, take extra care and block all ADHESIVES AND SEALERS (SEE FIRE)
wheels. CAUTION
Observe recommended precautions as indicated in Highly flammable, combustible.
this Repair Manual when dismantling the air
conditioning system as escaping refrigerant can Generally should be stored in “NO SMOKING” areas;
cause frostbite. cleanliness and tidiness while in use should be
observed, i. e., from applications where possible,
Prior to removing wheels and tires from the combine, disposable paper should be dispensed to cover
check to determine whether additional ballast (liquid benches. Containers, including secondary contain-
or weights) has been added. Seek assistance and ers, should be labelled.
use suitable equipment to support the weight of the
wheel assembly. Solvent-Based Adhesives/Sealers (See Solvents)
When inflating tires, beware of over inflation - Follow manufacturer’s Instructions
constantly check the pressure. Over inflation can
cause tires to burst and result in personal injury. Water-Based Adhesives/Sealers
Those based on polymer emulsions and rubber
HEALTH AND SAFETY PRECAUTIONS lattices may contain small amounts of volatile toxic
and harmful chemicals.
Many of the procedures associated with vehicle
maintenance and repair involve physical hazards or Skin and eye contact should be avoided, and
other risks to health. This section lists, alphabetically, adequate ventilation provided during use.
some of these hazardous operations, materials and
equipment associated with them. The precautions Follow manufacturer’s Instructions
necessary to avoid these hazards are identified.
Resin-Based Adhesive/Sealers (i.e., Epoxide and
The list is not inclusive; all operations, procedures, Formaldehyde Resin Based)
and handling of materials should be carried out with
Mixing should only be carried out in well-ventilated
health and safety in mind.
areas as harmful or toxic volatile chemicals may be
released.
Skin contact with uncured resins and hardeners can

result in irritation, dermatitis, and absorption of toxic,
or harmful chemicals through the skin. Splashes can
damage the eyes.
Provide adequate ventilation; avoid skin and eye

contact. Follow manufacturer’s instructions.
00-7
Anaerobic Cyanoacrylate and other Acrylic (North America Only)
Adhesives
Many are irritating, sensitizing, or harmful to the skin. CALIFORNIA
Some are eye irritants. Proposition 65 Warning
Skin and eye contact should be avoided and the Battery posts, terminals and related
manufacturer’s instructions followed. accessories contain lead and lead
compounds, chemicals known to the State
Cyanoacrylate adhesives (super-glues) must not of California to cause cancer and birth
contact the skin or eyes. If skin or eye tissue is defects or other reproductive harm.
bonded, cover with a clean moist pad and get Wash hands after handling.
medical attention. Do not attempt to pull tissue apart.
Use in well-ventilated areas as vapours can cause
irritation of the nose and eyes. BRAKE AND CLUTCH LININGS AND PADS
(SEE LEGAL ASPECTS)
For two-part systems: See Resin-Based Adhesive/ These items create dust and residue which, if
Sealers inhaled, may cause lung damage and, in some
cases, cancer.
Isocyanate (Polyurethane) Adhesive/Sealers
(See Resin-Based Adhesives) The normal handling and fitting of these items should
Individuals suffering from asthma or respiratory not cause any hazard, but any drilling, grinding, or
allergies should not work with, or near, these filling of friction materials may produce dust and
materials as sensitivity reactions can occur. should only be carried out under strictly controlled
conditions.
Any spraying should preferably be carried out in
exhaust ventilated booths removing vapours and Care should be taken to avoid inhalation of dust from
spray droplets from the breathing zone. Individuals clutch and brake systems during servicing of brakes
working with spray applications should wear and clutches. The use of drum cleaning units,
supplied air respirators. vacuum cleaning, or damp wiping is preferred to the
use of air jets for “blowing-out.”
ANTIFREEZE (SEE FIRE, SOLVENTS, I.E., The dust should be collected in a sealed plastic bag
ISOPROPANOL, ETHYLENE GLYCOL, and disposed appropriately, according to local laws
METHANOL) and regulations.
CAUTION
BRAZING (SEE WELDING)
Highly flammable, combustible.
CHEMICAL MATERIALS - GENERAL (SEE
Used in vehicle coolant systems, brake air pressure LEGAL ASPECTS)
systems, and windshield washing solutions. Chemical materials such as solvents, sealers,
adhesives, paints, resin foams, battery acids,
Vapours given off from coolant antifreeze (Glycol)
antifreeze, oils, and grease should always be used
arise only when heated.
with caution, stored and handled with care. They may
Antifreeze may be absorbed through the skin in toxic be toxic, harmful, corrosive, irritating, or highly
or harmful quantities. Swallowed antifreeze is fatal if flammable, causing hazardous fumes and dusts.
not treated; medical attention must be sought
The effects of excessive exposure to chemicals may
immediately.
be immediate or delayed, briefly experienced or
permanent, cumulative, superficial, life threatening,
BATTERY ACIDS (SEE ACIDS AND or may reduce life expectancy.
ALKALIS)
Gases released during charging are explosive.
Never use an open flame or allow sparks near
charging or recently charged batteries.
00-8
CLUTCH LININGS AND PADS (SEE BRAKE Do not apply heat or flame to chemical materials,
AND CLUTCH LININGS AND PADS) except under the manufacturer’s instructions. Some
are highly flammable, and some may release toxic or
CORROSION PROTECTION MATERIALS harmful fumes.
(SEE SOLVENTS, FIRE)
Do not leave containers open. Escaping fumes can
CAUTION build up to toxic, harmful, or explosive concentra-
Highly flammable, combustible. tions. Some fumes are heavier than air and will
accumulate in confined areas, pits, etc.
These materials are varied; the manufacturer’s
Do not transfer chemical materials to unlabeled
instructions should be followed. They may contain
containers.
solvents, resins, and petroleum products. Skin and
eye contact should be avoided. They should only be Do not clean hands or clothing with chemical
sprayed in conditions of adequate ventilation, and materials. Chemicals, particularly solvents and fuels,
not in confined spaces. will dry the skin, and may cause irritation with
dermatitis. Some can be absorbed through the skin
CUTTING (SEE WELDING) in toxic or harmful quantities.
DEWAXING (SEE SOLVENTS AND FUELS - Do not use emptied. containers for other materials,
KEROSENE) except when they have been cleaned under
supervised conditions.
DO’S
Do remove chemical materials from the skin and Do not sniff or smell chemical materials. Brief
clothing as soon as practicable. Change heavily exposure to high concentrations of fumes can be
soiled clothing and have it cleaned. harmful or toxic.
Do carefully read and observe hazard and DUSTS

precaution warnings given on material containers
(labels) and in any accompanying leaflets, poster or Powder or dusts may be an irritant, harmful or toxic.
other instructions. Material health and safety data Avoid breathing dusts from powdery chemical
sheets can be obtained from manufacturers. materials, or those arising from dry abrasion
operations. Wear respiratory protection if ventilation
Do organize work practices by wearing protective is inadequate.
clothing and safety devices to avoid contact with
chemical materials; breathing vapours, aerosols, ELECTRIC SHOCK
dusts, and fumes; inadequate container labelling; or
fire and explosion hazards. Electric shocks can result from the use of faulty
electrical equipment or from the misuse of equipment
Do wash before job breaks, before eating, smoking, even in good condition.
drinking, or using toilet facilities when handling
chemical materials. Ensure electrical equipment is maintained in good
condition and frequently tested.
Do keep work areas clean, uncluttered, and free of
spills. Ensure flexes, cables, plugs and sockets are not
frayed, kinked, cut, cracked, or otherwise damaged.
Do store according to national and local regulations.
Ensure electric equipment is protected by the correct
Do keep chemical materials out of reach of children. rated fuse.
Never use electrical equipment or any other

DON’TS equipment which is in any way faulty. The results
Do not mix chemical materials except under the could be fatal.
manufacturer’s instructions; some chemicals can
form other toxic or harmful chemicals, releasing toxic Use reduced voltage equipment for inspection and
or harmful fumes, or be explosive when mixed working lights, where possible.
together.
Ensure the cables of mobile electrical equipment
Do not spray chemical materials, particularly those cannot get trapped and damaged, such as in a
based on solvents, in confined spaces, i.e., when vehicle hoist.
people are inside a vehicle.
00-9
In Cases of Electrocution: Have a suitable fire extinguisher available when
using welding or heating equipment.
• Switch off electricity before approaching victim.
• If this is not possible, push or drag the victim from
the source of electricity using dry non-conductive FIRST AID
material. Apart from meeting any legal requirements, it is
• Commence resuscitation if trained to do so. desirable for someone in the workshop to be trained
in first aid procedures.
• CALL FOR MEDICAL ASSISTANCE IMMEDI-
ATELY. Splashes in the eye should be flushed with clean
EXHAUST FUMES water for at least ten minutes.
These contain asphyxiating, harmful and toxic Soiled skin should be washed with soap and water.
chemicals, and particles such as carbon oxides,
nitrogen oxides, aldehydes, lead, and aromatic Inhalation affected individuals should be removed to
hydrocarbons. Engines should only run under fresh air immediately.
conditions of adequate extraction, or general
ventilation, not in confined spaces. If chemicals are swallowed, consult a doctor
immediately with (label) information on material used.
(North America Only)
Do not induce vomiting, unless indicated by
CALIFORNIA manufacturer.
Proposition 65 Warning
Diesel engine exhaust and some of its
FOAMS- POLYURETHANE (SEE FIRE)
constituents are known to the State of Used in sound and noise insulation. Cured foams are
California to cause cancer, birth defects used in seat and trim cushioning.
and other reproductive harm.
Follow manufacturer’s instructions.
Diesel Engine Unreacted components are irritating and may be

harmful to the skin and eyes. Wear gloves and
Soot, discomfort, and irritation usually give adequate goggles.
warning signs of hazardous fume concentration.
Individuals with chronic respiratory diseases,
FIBER INSULATION (SEE DUSTS) asthma, bronchial medical problems, or histories of
allergic diseases should not work with or near
Used in noise and sound insulation.
uncured materials.
The fibrous nature of surfaces and cut edge can
The component’s vapours and spray mists can
cause skin irritation. This is usually a physical, not a
cause direct irritation and/or sensitivity reactions and
chemical effect.
may be toxic or harmful.
Precautions should be taken to avoid excessive skin
Vapours and spray mists must not be breathed.
contact through careful organization of work
These materials must be applied with adequate
practices and the use of gloves.
ventilation and respiratory protection. Do not remove
respirator immediately after spraying, wait until
FIRE (SEE WELDING, FOAMS, LEGAL vapour/mists have cleared.
ASPECTS)
Many of the materials found on, or associated with, Burning of the uncured components and the cured
the repair of vehicles are highly flammable. Some foams can generate toxic and harmful fumes.
release toxic or harmful fumes if burned.
Smoking, open flames, or the use of electrical
Observe strict fire safety when storing and handling equipment should not be allowed during foaming
flammable materials or solvents, particularly near operations until vapours/mists have completely
electrical equipment or welding processes. cleared. Any heat cutting of cured foams or partially
cured foams should be conducted with extraction
Before using electrical or welding equipment, be sure ventilation (see Legal Aspects).
there is no fire hazard present.
00-10
FUELS (SEE FIRE, LEGAL ASPECTS, Diesel Fuel (Gas-Oil) (See Fuels-Kerosene)
CHEMICALS - GENERAL, SOLVENTS)
CAUTION
Used as fuels and cleaning agents.
Combustible.
Gasoline (Petrol)
Gross or prolonged skin contact with high boiling gas
CAUTION oils may cause serious skin disorders, including skin
Highly flammable, combustible. cancer.
GAS CYLINDERS (SEE FIRE)

Swallowing can result in mouth and throat irritation;
absorption from the stomach can result in Gases such as oxygen, acetylene, carbon dioxide,
drowsiness and unconsciousness. Small amounts argon, and propane are normally stored in cylinders
can be fatal to children. Aspiration of liquid into the at pressures of up to 2000 PSI (137.8 bar). Great
lungs, i.e., through vomiting, is a very serious hazard. care should be taken in handling these cylinders to
avoid mechanical damage to them or the valve gear
Prolonged or repeated contact with gasoline dries attached. The contents of each cylinder should be
the skin and causes irritation and/or dermatitis. clearly identified by appropriate markings.
Liquid in the eye causes severe pain.
Cylinders should be stored in well-ventilated enclo-
Motor gasoline may contain high quantities of sures and protected from ice, snow, or direct sunlight.
benzene which is toxic upon inhalation; the Fuel gases, i.e., acetylene and propane, should not be
concentrations of gasoline vapours must be kept stored in close proximity to oxygen cylinders.
very low. High concentrations will cause eye, nose
Care should be exercised to prevent leaks from gas
and throat irritation, nausea, headache, depression
cylinders and lines and to avoid sources of ignition.
and symptoms of drunkenness. Very high concentra-
tions will result in rapid loss of consciousness. Only trained personnel should undertake work
involving gas cylinders.
Ensure there is adequate ventilation when handling
and using gasoline. Great care must be taken to
avoid the serious consequences of inhalation in the
GASES (SEE GAS CYLINDER)
event of vapour build-up arising from spillages in GAS SHIELDING WELDING (SEE WELDING)
confined spaces.
GAS WELDING (SEE WELDING)
Special precautions apply to cleaning and mainte-
nance operations on gasoline storage tanks. GENERAL WORKSHOP TOOLS AND
EQUIPMENT
Gasoline should not be used as a cleaning agent. It
must not be siphoned by mouth. It is essential that all tools and equipment are
maintained in good condition and the correct safety
Kerosene (Paraffin) equipment used where required.
Used also as heating fuel, solvent, and cleaning Never use tools or equipment for any purpose other
agent. than for which they were designed.
Never overload equipment such as hoists, jacks,

CAUTION axle and chassis stands, or lifting slings. Damage
Flammable. caused by overloading is not always immediately
apparent and may result in a fatal failure the next time
Irritation of the mouth and throat may result from the equipment is used.
swallowing. The main hazard from swallowing arises if
liquid aspiration into the lungs occurs. Liquid contact Do not use damaged, defective tools or equipment,
dries the skin and can cause irritation and/or dermatitis. particularly high-speed equipment such as grinding
Splashes in the eye may be slightly irritating. wheels. A damaged grinding wheel can disintegrate
without warning causing serious injury.
In normal circumstances, the low volatility does not
Wear suitable eye protection when using grinding,
give rise to harmful vapours. Exposure to mists and
chiselling, or sandblasting equipment.
vapours from kerosene at elevated temperatures
should be avoided (mists may arise in dewaxing). Wear a suitable breathing mask when using
Avoid skin and eye contact; be sure there is adequate sandblasting equipment or using spraying equipment.
ventilation.
00-11
GLUES (SEE ADHESIVE AND SEALERS) CAUTION

Highly flammable.
HIGH-PRESSURE AIR, LUBRICATION AND
OIL TEST EQUIPMENT
(SEE LUBRICANTS AND GREASES) Paints can contain harmful or toxic pigments, driers,
and other components, as well as solvents. Spraying
Always keep high-pressure equipment in good should only be carried out with adequate ventilation.
condition and regularly maintained, particularly joint
and unions. Two-part or catalysed paints can also contain
harmful and toxic unreacted resins and resin-
Never direct a high-pressure nozzle at the skin, as hardening agents. The manufacturer’s instructions
the fluid may penetrate to the underlying tissue and should be followed and the section on resin-based
can cause serious injury. adhesives, isocyanate containing adhesive and
foams should be consulted.
LEGAL ASPECTS
Spraying should preferably be carried out in
Many laws and regulations make requirements
exhausted ventilated booths, removing vapour and
relating to health and safety in the use of materials
spray mists from the breathing zone. Individuals
and equipment in workshops.
working in booths should wear respiratory protection.
Workshops should be familiar, in detail, with these Those doing small-scale repair work in the open
laws and regulations. shop should wear supplied air respirators.
LUBRICANTS AND GREASES PAINT THINNERS (SEE SOLVENTS)

Avoid all prolonged and repeated contact with
PRESSURIZED EQUIPMENT (SEE HIGH-
mineral oils, especially used oils. Gross and
prolonged skin contact with used oils contaminated PRESSURE AIR, LUBRICATION AND OIL
during service, i.e., routine service change sump oils, TEST EQUIPMENT)
are more irritating and more likely to cause serious
effects, including skin cancer.
RESISTANCE WELDING (SEE WELDING)
Wash skin thoroughly after work involving oil. SEALERS (SEE ADHESIVES AND
Proprietary hand cleaners may be of value provided SEALERS)
they can be removed from the skin with water. Do not
use petrol, paraffin, or other solvents to remove oil SOLDER (SEE WELDING)
from the skin. Solders are mixtures of metals in which the melting
Lubricants and greases may be slightly irritating to point of the mixture is below that of constituent metals
the eyes. (normally lead and tin). Solder application does not
normally give rise to toxic lead fumes, provided a
Repeated or prolonged skin contact should be avoided gas/air flame is used. Oxyacetylene flames should
by wearing protective clothing, if necessary. Particular not be used, as they are much hotter and will cause
care should be taken with used oils and greases lead fumes to be released.
containing lead. Do not allow work clothing to be
contaminated with oil. Dry clean or launder such Some fumes may be produced by the application of
clothing at regular intervals. Discard oil-soaked shoes. anyflame to surfaces coated with grease, etc., and
inhalation of these should be avoided.
Do not use previously used engine oils as lubricants
or for any application where major skin contact is WELDING
likely to occur. Used oils may only be disposed of in
When welding on the unit always:
accordance with local regulations.
Refer to the “Recommended Lubricants and • Disconnect the negative ground battery cable.
Coolants Charts”, for the recommended lubricants. • Attach the welder ground cable close to the area
being welded.
NOISE INSULATION MATERIAL (SEE
• Eliminate any fire hazards. Remove crop residue
FOAMS, FIBER INSULATION) from the area around the welding.
PAINTS (SEE SOLVENTS AND CHEMICAL • Ensure a fire extinguisher is immediately
MATERIALS- GENERAL) available.
• Protect hydraulic hoses from weld splatter.
• Protect tires when welding near a mounted tire.
00-12
SERVICE TECHNIQUES
GENERAL should be tightened sufficiently to hold the hose
Clean the exterior of all components before starting without crushing and to prevent chafing.
any type of repair. Dirt and abrasive dust can reduce
After hose replacement to a moving component,
the efficient working life of a component and lead to
check that the hose does not foul by moving the
costly replacement.
component through the complete range of travel.
Time spent on the preparation and cleanliness of
Be sure any hose which has been installed is not
working surfaces will pay dividends in making the job
kinked or twisted.
easier and safer and will result in overhauled
components being more reliable and efficient in Hose connections which are damaged, dented,
operation. crushed or leaking, restrict oil flow and the
productivity of the components being served.
Use cleaning fluids which are known to be safe.
Connectors which show signs of movement from the
Certain types of fluid can cause damage to O rings
original swagged position have failed and will
and cause skin irritation. Solvents should be checked
ultimately separate completely.
that they are suitable for the cleaning of components
and also that they do not risk the personal safety of A hose with a chafed outer cover will allow water
the user. entry. Concealed corrosion of the wire reinforcement
will subsequently occur along the hose length with
Replace O rings, seals or gaskets whenever they are
resultant hose failure.
disturbed. Never mix new and old seals or O rings,
regardless of condition. Always lubricate new seals Ballooning of the hose indicates an internal leakage
and O rings with hydraulic oil before installation. due to structural failure. This condition rapidly
deteriorates and total hose failure soon occurs.
When replacing component parts, use the correct
tool for the job. Kinked, crushed, stretched or deformed hoses
generally suffer internal structural damage which can
HOSES AND TUBES result in oil restriction, a reduction in the speed of
Always replace hoses and tubes if the cone end or operation and ultimate hose failure.
the end connections on the hose are damaged.
Free-moving, unsupported hoses must never be
When installing a new hose, loosely connect each allowed to touch each other or related working surfaces.
end and make sure the hose takes up the designed This causes chafing which reduces hose life.
position before tightening the connection. Clamps
00-13
PRODUCT IDENTIFICATION
The serial number of the combine, the engine and the
attachments can be found on the following locations:
BASE UNIT
On a plate, 1, positioned on the right-hand side of the
operator’s platform.
40021747
1
ENGINE
7.5L Engine
On a plate positioned on top of the rocker cover.
00-14
It’s also stamped in the cylinder block.
3
7.8L and 10.3L Engine
On a plate positioned on top of the rocker cover.
4
It’s also on a plate on the cylinder block.
00-15
STRAW CHOPPER (IF EQUIPPED)

The identification plate, 1, for the straw chopper, if
equipped, is located at the right rear of the chopper.
50021347
6
POWERED REAR AXLE WHEEL MOTORS
(IF EQUIPPED)
The identification plate, 1, for each of the PRA wheel
motors are lcoated on the wheel motor carrier.
50021348
00-16
MINIMUM HARDWARE TIGHTENING TORQUES

IN NEWTON-METERS (FOOT POUNDS) FOR NORMAL ASSEMBLY APPLICATIONS
METRIC NON-FLANGED HARDWARE AND LOCKNUTS

CLASS 5.8 CLASS 8.8 CLASS 10.9 LOCKNUT
NOMINAL CL.8
SIZE UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED W/CL8.8
W/ZnCr W/ZnCr W/ZnCr BOLT
M4 1.7 (15)* 2.2 (19)* 2.6 (23)* 3.4 (30)* 3.7 (33)* 4.8 (42)* 2.3 (20)*
M6 5.8 (51)* 7.6 (67)* 8.9 (79)* 12 (102)* 13 (115)* 17 (150)* 7.8 (69)*
M8 14 (124)* 18 (159)* 22 (195)* 28 (248)* 31 (274)* 40 (354)* 19 (169)*
M10 28 (21) 36 (27) 43 (32) 56 (41) 61 (45) 79 (58) 38 (28)
M12 49 (36) 63 (46) 75 (55) 97 (72) 107 (79) 138 (102) 66 (49)
M16 121 (89) 158 (117) 186 (137) 240 (177) 266 (196) 344 (254) 164 (121)
M20 237 (175) 307 (226) 375 (277) 485 (358) 519 (383) 671 (495) 330 (243)
M24 411 (303) 531 (392) 648 (478) 839 (619) 897 (662) 1160 (855) 572 (422)
NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION
HEX CAP SCREW AND CARRIAGE BOLTS
CLASSES 5.6 AND UP
MANUFACTURER’S IDENTIFICATION
PROPERTY CLASS
HEX NUTS AND LOCKNUTS

CLASSES 05 AND UP
86529681 REV F 5.1 PROPERTY CLASS CLOCK MARKING
00-17

INCH NON-FLANGED HARDWARE AND LOCKNUTS

SAE GRADE 2 SAE GRADE 5 SAE GRADE 8 LOCKNUTS
NOMINAL UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED GR.B GR.C NOMINAL
SIZE or W/ZnCr or W/ZnCr or W/ZnCr w/GR5 w/GR8 SIZE
PLATED PLATED PLATED BOLT BOLT
SILVER GOLD SILVER GOLD SILVER GOLD
1/4 6.2 (55)* 8.1 (72)* 9.7 (86)* 13 (112)* 14 (121)* 18 (157)* 8.5 (75)* 12.2 (109)* 1/4
5/16 13 (115)* 17 (149)* 20 (178)* 26 (229)* 28 (250)* 37 (324)* 17.5 (155)* 25 (220)* 5/16
3/8 23 (17) 30 (22) 35 (26) 46 (34) 50 (37) 65 (48) 31 (23) 44 (33) 3/8
7/16 37 (27) 47 (35) 57 (42) 73 (54) 80 (59) 104 (77) 50 (37) 71 (53) 7/16
1/2 57 (42) 73 (54) 87 (64) 113 (83) 123 (91) 159 (117) 76 (56) 108 (80) 1/2
9/16 81 (60) 104 (77) 125 (92) 163 (120) 176 (130) 229 (169) 111 (82) 156 (115) 9/16
5/8 112 (83) 145 (107) 174 (128) 224 (165) 244 (180) 316 (233) 153 (113) 215 (159) 5/8
3/4 198 (146) 256 (189) 306 (226) 397 (293) 432 (319) 560 (413) 271 (200) 383 (282) 3/4
7/8 193 (142) 248 (183) 495 (365) 641 (473) 698 (515) 904 (667) 437 (323) 617 (455) 7/8
1 289 (213) 373 (275) 742 (547) 960 (708) 1048 (773) 1356 (1000) 654 (483) 924 (681) 1

IDENTIFICATION
CAP SCREWS AND CARRIAGE BOLTS
SAE GRADE 2 SAE GRADE 5 SAE GRADE 8
REGULAR NUTS SAE GRADE 5 SAE GRADE 8

HEX NUTS HEX NUTS
LOCKNUTS
GRADE IDENTIFICATION GRADE IDENTIFICATION

GRADE A NO NOTCHES GRADE A NO MARKS
GRADE B ONE CIRCUMFERENTIAL NOTCH GRADE B THREE MARKS
GRADE C TWO CIRCUMFERENTIAL NOTCHES GRADE C SIX MARKS

MARKS NEED NOT BE LOCATED
AT CORNERS
GRADE A NO MARK
GRADE B LETTER B
GRADE C LETTER C
86529681 REV F 5.2
GRADE IDENTIFICATION
00-18
INSTALLATION OF ADJUSTABLE
FITTINGS IN STRAIGHT THREAD O RING
BOSSES
1. Lubricate the O ring by coating it with a light oil or
petroleum. Install the O ring in the groove
adjacent to the metal backup washer which is
assembled at the extreme end of the groove, 4.
2. Install the fitting into the SAE straight thread boss
until the metal backup washer contacts the face
of the boss, 5.
NOTE: Do not over tighten and distort the metal
backup washer.
8
3. Position the fitting by turning out (counterclock-
wise) up to a maximum of one turn. Holding the
pad of the fitting with a wrench, tighten the
locknut and washer against the face of the boss,
6.
STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS

TUBE NUTS O RING BOSS PLUGS
FOR 37° FLARED FITTINGS ADJUSTABLE FITTING
LOCKNUTS, SWIVEL
JIC - 37° SEATS
TORQUE TORQUE
TUBING THREAD FOOT NEWTON FOOT NEWTON
SIZE OD SIZE POUNDS METERS POUNDS METERS
In. mm Min. Max. Min. Max. Min. Max. Min. Max.
4 1/4 6.4 7/16-20 9 12 12 16 6 10 8 14
5 5/16 7.9 1/2-20 12 15 16 20 10 15 14 20
6 3/8 9.5 9/16-18 21 24 29 33 15 20 20 27
8 1/2 12.7 3/4-18 35 40 47 54 25 30 34 41
10 5/8 15.9 7/8-14 53 53 72 79 35 40 47 54
12 3/4 19.1 1-1/16-12 77 82 104 111 60 70 81 95
14 7/8 22.2 1-3/16-12 90 100 122 136 70 80 95 109
16 1 25.4 1-5/16-12 110 120 149 163 80 90 108 122
20 1-1/4 31.8 1-5/8-12 140 150 190 204 95 115 129 158
24 1-1/2 38.1 1-7/8-12 160 175 217 237 120 140 163 190
32 2 50.8 2-1/2-12 225 240 305 325 250 300 339 407
These torques are not recommended for tubes of solvent or Loctite cleaner and apply hydraulic sealant
1/2″ (12.7 mm) OD and larger with wall thickness of Loctite no. 569 to the 37° flare and the threads.
0.035″ (0.889 mm) or less. The torque is specified for
0.035″ (0.889 mm) wall tubes on each application Install fitting and torque to specified torque, loosen
individually. fitting and retorque to specifications.
Before installing and torquing 37° flared fittings,

clean the face of the flare and threads with a clean
00-19
PIPE THREAD FITTING TORQUE Thread Size Torque (Maximum)

Before installing and tightening pipe fittings, clean 1/8″ -- 27 13 N⋅m (10 ft-lb)
the threads with a clean solvent or Loctite cleaner
and apply sealant Loctite no. 567 for all fittings 1/4″ -- 18 16 N⋅m (12 ft-lb)
including stainless steel or no. 565 for most metal 3/8″ -- 14 22 N⋅m (16 ft-lb)
fittings. For high filtration/zero contamination
1/2″ -- 14 41 N⋅m (30 ft-lb)
systems use no. 545.
3/4″ -- 14 54 N⋅m (40 ft-lb)
INSTALLATION OF ORFS (O-RING FLAT

FACED) FITTINGS
When installing ORFS fittings thoroughly clean both
flat surfaces of the fittings, 1, and lubricate the O-ring,
2, with light oil. Make sure both surfaces are aligned
properly. Torque the fitting to specified torque listed
throughout the repair manual.
IMPORTANT: If the fitting surfaces are not properly

cleaned, the O-ring will not seal properly. If the fitting
surfaces are not properly aligned, the fittings may be 1
damaged and will not seal properly. 2
50011183 1
IMPORTANT: Always use genuine New Holland 9
replacement oils and filters to ensure proper
lubrication and filtration of engine and hydraulic
system oils.
The use of proper oils, grease, and keeping the

hydraulic system clean will extend machine and
component life.
00-20
RECOMMENDED LUBRICANTS AND COOLANTS (NORTH AMERICA ONLY)

Adequate lubrication and maintenance on a regular CAUTION
schedule is vital to maintaining your equipment. To
Some illustrations in this manual show shields
ensure long service and efficient operation, follow the
opened or removed to show areas being
lubrication and maintenance schedules outlined in
serviced. Replace all shields before operating
this manual. The use of proper fuels, oils, grease and
this machine.
filters, as well as keeping the systems clean, will also
extend machine and component life.
Always clean the area around dipsticks, fill caps, and
check plugs when checking fluid levels. Failure to
IMPORTANT: Always use genuine New Holland
clean these areas may allow contamination to enter
replacement parts, oils and filters to ensure proper
the system. Drain, flush and refill the system anytime
operation, filtration of engine and hydraulic systems.
you suspect it is contaminated.
See your New Holland dealer for additional oil
quantities.
Grease Fittings
Wipe dirt from fittings before greasing.
GENERAL INFORMATION
Regular lubrication is the best insurance against Pump fresh grease into fitting to adequately lubricate
delays and repairs. Proper lubrication will extend the component and force out any contamination from
machine life. Refer to the following charts for the grease passage.
lubricants and service intervals.
Wipe off excess grease.
IMPORTANT: Failure to complete the required
maintenance at the recommended intervals can Use a grease gun containing clean high grade of
cause unnecessary downtime. multipurpose grease.
The intervals listed in the Lubrication Chart are Chains

guidelines to be used when operating in normal Stop all drives before lubricating chains.
conditions. Adjust the intervals for operating in
adverse environmental and working conditions. The
intervals should be shortened for sandy, dusty and
extremely hot operating conditions.
CAUTION
Observe these safety precautions before per-
forming lubrication and maintenance.
1. Shut off engine.
2. Disengage all drives.
3. Lower all attachments to the ground or raise
and engage all locks
4. Close all shields opened and reinstall any
shields removed for lubrication and mainte-
nance proposes.
00-21
North America (Only)
Lubricant Type and Description Part Number Container Size
Engine Oil AMBRA SUPER GOLD SSL ENGINE OIL SAE 10W--40 86994335 2.5G / 9.46L
AMBRA SUPER GOLD HSP ENGINE OIL SAE 10W 86641050 5G / 18.93L
AMBRA SUPER GOLD HSP ENGINE OIL SAE 10W--30 9613313 1QT / .946L
86641052 1G / 3.785L
9613314 2.5G / 9.46L
9673508DS 5G / 18.93L
AMBRA SUPER GOLD HSP ENGINE OIL SAE 30 9613286 1QT / .946L
86641043 1G / 3.785L
9613289 2.5G / 9.46L
86641044 5G / 18.93L
AMBRA SUPER GOLD HSP ENGINE OIL SAE 40 9624812DS 55G / 208.2L
AMBRA SUPER GOLD HSP ENGINE OIL SAE 15W--40 86641081 1QT / .946L
86641082 1G / 3.785L
86641084 2.5G / 9.46L
86641083 5G / 18.93L
AMBRA SUPER GOLD HSP ENGINE OIL SAE 20W--50 86994337 5G / 18.93L
AMBRA AUTO SUPREME SAE 5W--30 9673589DS 1QT / .946L
AMBRA AUTO SUPREME SAE 10W--30 86641101 1QT / .946L
Transmission Oil AMBRA MULTI TRAN 86639558 1G / 3.785L
86639559 2.5G / 9.46L
86639560 5G / 18.93L
AMBRA MULTI TRAN SSL 86994339 2.5G / 9.46L
AMBRA MULTI BIO S 86994341 2.5G / 9.46L
Hydraulic Oil AMBRA MULTI G 134 9624655DS 1QT / .946L
9624656DS 1G / 3.785L
9624450 2.5G / 9.46L
9624451 5G / 18.93L
AMBRA HYDROSYSTEM 46 HYD FLUID 86109085 5G / 18.93L
ATF Oil AMBRA HYDRODEX 3 ATF 9613304 1QT / .946L
9613312 2.5G / 9.46L
Gear Oil AMBRA HYPOIDE 90 GEAR LUBE 9613295 1QT / .946L
9613294 2.5G / 9.46L
86994348 16G / 60.6L
AMBRA HYPOIDE 140 GEAR LUBE 87027134* 1QT / .946L
87027135 2.5G / 9.46L
86994351 16G / 60.6L
AMBRA TRANSAXLE FLUID 86994352 5G / 18.93L
AMBRA HYPOIDE SSL GEAR LUBE 86994354 1QT / .946L
Grease AMBRA GR--9 MULTI--PURPOSE GREASE 9613310 TUBE -- 14 OZ.
AMBRA HI--TEMP GREASE 9861804DS TUBE -- 14 OZ.
AMBRA CORN HEAD GREASE 94107DS TUBE -- 14 OZ.
AMBRA GR 75 MD GREASE 87400001 TUBE -- 14 OZ.
AMBRA GR 1000 SYNTHETIC GREASE 86994355 TUBE -- 14 OZ.
LIMITED SLIP ADDITIVE B96606
Brake Fluid BRAKE LHM FLUID ( Mineral Based Oil) 86541699DS 1QT / .946L
Coolant ESE--M97B18--D, Ethylene Glycol Coolant Concentrate FGCC2701DS 1G / 3.785L
Propylene Glycol Concentrate FGCC2711DS 1G / 3.785L
00-22
All Markets Except North America
Lubricant Type and Description
Engine Oil AMBRA SUPER GOLD SSL ENGINE OIL SAE 10W--40
AMBRA SUPER GOLD HSP ENGINE OIL SAE 10W
AMBRA SUPER GOLD HSP ENGINE OIL SAE 10W--30
AMBRA SUPER GOLD HSP ENGINE OIL SAE 30
AMBRA SUPER GOLD HSP ENGINE OIL SAE 40


AMBRA AUTO SUPREME SAE 5W--30
AMBRA AUTO SUPREME SAE 10W--30
Transmission Oil AMBRA MULTI TRAN
AMBRA MULTI TRAN SSL

AMBRA MULTI BIO S
Hydraulic Oil AMBRA MULTI G 134
AMBRA HYDROSYSTEM 46 HYD FLUID

ATF Oil AMBRA HYDRODEX 3 ATF
Gear Oil AMBRA HYPOIDE 90 GEAR LUBE
AMBRA HYPOIDE 140 GEAR LUBE
AMBRA TRANSAXLE FLUID

AMBRA HYPOIDE SSL GEAR LUBE
Grease AMBRA GR--9 MULTI--PURPOSE GREASE
AMBRA HI--TEMP GREASE
AMBRA CORN HEAD GREASE
AMBRA GR 75 MD GREASE
AMBRA GR 1000 SYNTHETIC GREASE
LIMITED SLIP ADDITIVE
Brake Fluid BRAKE LHM FLUID ( Mineral Based Oil)
Coolant ESE--M97B18--D, Ethylene Glycol Coolant Concentrate
Propylene Glycol Concentrate
00-23
RECOMMENDED SEALANTS (NORTH AMERICA ONLY)
Description Part Number Typical Applications Strength Color

Thread Lock L22200 (222) Small screws/hardware Low Purple
L24231 (242) Small screws/hardware Medium Blue
L29000 (290) Wicking Type Medium Green
L26231 (262) Nuts & Bolts High Red
Thread Sealant L54531 (545) Hydraulic/Pneumatic Non-fouling
L56531 (565) Pipe Sealant Controlled strength
L56747 (567) Pipe Sealant High temperature
Silicones L81724 (3.5 oz tube) Ultra Blue RTV Gasket Non-corrosive Blue
L58775 (10.2 oz cartridge) Ultra Blue RTV Gasket Non-corrosive Blue
L82180 (3.35 oz tube) Ultra Blue RTV Gasket Non-corrosive Black
L59875 (10.2 oz cartridge) Ultra Blue RTV Gasket Non-corrosive Black
518 Gasket L51831DS Mating Machined Surfaces Flexible Red
Eliminaor
RECOMMENDED SEALANTS (ALL MARKETS EXCEPT NORTH AMERICA)
Description Part Number Typical Applications Strength Color

Thread Lock 82995773 (2995773)-242 Small screw/hardware Medium Blue
82995772 (2995772)-262 Nuts & Bolts High Red
Thread Sealant 82995768 (2995768)-565 Pipe Sealant Controlled strength
Silicones 82995775 (2995775)-595 Superflex RTV Gasket
50ml
82995776 (2995776)-300 ml
Gasket Dressing 82995774 (2995774)-60 ml Non-hardening sealant-en-
hances sealing of all types of
precut gaskets
Super Flue Gel 82995778 (2995778)-20 ml General purpose non-drip
gel adhesive ideal for repair
of cab trim, bonds to most
materials including wood,
rubber, metals, most plastics
00-24
SECTION 10 -- ENGINE -- CHAPTER 1
SECTION 10 -- ENGINE
Chapter 1 -- 7.5L Engine Block
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Engine Front Cover and Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Timing Gears Checking and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Gears -- Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Rear Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
10-1

Oil Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Camshaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Connecting Rod Bush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Cylinder Block Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Sleeving - Boring and Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Installing Piston Assembly Into Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Front Crankshaft Cassette Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Engine Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Test Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Test Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10-2
SPECIFICATIONS
CR 920 CR 940 CR 920 CR 940
NA NA
Engine Engine
Type CNH675 CNH675 Crankcase Capacity 23 liters
TA/CF TA/AA w/Filter (6.08 US gals.)
Gross Power 190 kW 220 kW Battery 92 Ah
(255 hp) (295 hp) 2 x 12V
Governor Mechanical Electronic Alternator Type 190 Amp
Power Rise/Boost 14/0 16/20 (12 volt)
(kW) (18/0) (21/27) Alternator Speed 5830 rpm
Rated Speed 2100 rpm Starter Motor 4.3 kW
Low Idle Speed 1300 rpm (12 volt)
High Idle Speed 2205 rpm 2100 rpm Air Compressor 2677 rpm
Speed
No. of Cylinders 6
Fuel Tank 750 liters
Cylinder 7500 cc
Displacement (200 US gals)
Bore 112 mm (4-3/8″) Rotary Screen Speed 282 rpm
Stroke 127 mm (5″) Air Conditioning 3616 rpm
Compressor
Water Pump Speed 3859 rpm
Ventilator Speed 1531 rpm
Cylinder Block
Taper of Cylinder Bore 0.025 mm (0.001 in.) Repair Limit
0.127 mm (0.005 in.) Wear Limit
Cylinder Bore Out of Round 0.030 mm (0.0015 in.) Repair Limit
0.127 mm (0.0050 in.) Wear Limit
Cylinder Bore Diameters 111.778 - 111.803 mm (4.4007 - 4.4017 in.)
Rear Oil Seal Bore Diameter 140.77 - 140.87 mm (5.542 - 5.546 in.)
Block to Head Surface Flatness 0.08 mm (0.003 in.) in any 152 mm (6 in.)
0.03 mm (0.001 in.) in any 25.40 mm (1 in.)
Cylinder Head
Valve Guide Bore Diameter 9.469 - 9.495 mm (0.3728 - 0.3738 in.)
Head to Block Surface Flatness 0.03 mm (0.001 in.) in any 25.40 mm (1 in.)
or 0.127 mm (0.005 in.) Overall Limit
Exhaust Valves
Face Angle 44°15′ - 44°30′ Relative to the Head of Valve
Stem Diameter Std: 9.401 - 9.421 mm (0.3701 - 0.3709 in.)
Oversize: 0.38 mm (0.015 in.)
9.781 - 9.802 mm (0.3851 - 0.3859 in.)
Head Diameter 42.88 - 43.13 mm (1.688 - 1.698 in.)
Stem to Guide Clearance 0.048 - 0.094 mm (0.0019 - 0.0037 in.)
Lash Clearance (Cold) 0.43 - 0.53 mm (0.017 - 0.021 in.)
10-3
Intake Valves
Face Angle 29°15′ - 29°30′ Relative to Head of Valve
Stem Diameter Std: 9.426 - 9.446 mm (0.3711 - 0.3719 in.)
Oversize : 0.381 mm (0.015 in.)
9.807 - 9.827 mm (0.3861 - 0.3869 in.)
Head Diameter 47.37 - 47.63 mm (1.865 - 1.875 in.)
Stem to Guide Clearance 0.023 - 0.069 mm (0.0009 - 0.0027 in.)
Lash Clearance (Cold) 0.36 - 0.46 mm (0.014 - 0.018 in.)
Valve Springs
Number per Valve 1
Free Length 60.70 mm (2.390 in.)
Length, loaded at 27.7 - 31.3kg (61 - 69 lbs.) 48.26 mm (1.900 in.)
Length, loaded at 61 - 69kg (135 - 153 lbs.) 35.69 mm (1.405 in.)
Camshaft Lobe Lift

Intake 8.36 mm (0.330 in.)
Exhaust 8.36 mm (0.330 in.)
Installed Valve Recession

Intake 0.86 - 1.32 mm (0.034 - 0.052 in.)
Exhaust 1.17 - 1.65 mm (0.046 - 0.065 in.)
Valve Inserts
Exhaust Valve Insert Intake Valve Seat Insert
Insert Oversize Counterbore Diameter in Counterbore Diameter in
Cylinder Head Cylinder Head
0.254mm (0.010 in.) 44.17 - 44.20 mm 50.01 - 50.04 mm
(1.739 - 1.740 in.) (1.969 - 1.970 in.)
0.508mm (0.020 in.) 44.42 - 44.45 mm 50.27 - 50.29 mm
(1.749 - 1.750 in.) (1.979 - 1.980 in.)
0.762mm (0.030 in.) 44.68 - 44.70 mm 50.52 - 50.55 mm
(1.759 - 1.760 in.) (1.989 - 1.990 in.)
Valve Seats
Exhaust Valve Seat Angle 45°00′ - 45°30′
Intake Valve Seat Angle 30°00′ - 30°30′
Interference Valve Face Angle
to Valve Seat Angle 0°30′ - 1°15′
Concentricity With Guide
Diameter 0.051 mm (0.002 in.) Total Indicator Reading Max
Seat Width Exhaust Valve 1.8 - 2.3 mm (0.072 - 0.092 in.)
Intake Valve 1.9 - 2.5 mm (0.078 - 0.098 in.)
10-4
Camshaft Idler Gear
Number of teeth 47
End Play 0.076 - 0.35 mm (0.003 - 0.014 in.)
Bushing Inside Diameter 50.813 - 50.838 mm (2.005 - 2.0015 in.)
Adaptor Outside Diameter 50.762 - 50.775 mm (1.9985 - 1.9990 in.)
Backlash with Crankshaft Gear 0.10 - 0.36 mm (0.004 - 0.014 in.)
Backlash with Camshaft Gear 0.10 - 0.36 mm (0.004 - 0.014 in.)
Backlash with Fuel Injection Pump 0.10 - 0.48 mm (0.004 - 0.019 in.)
Camshaft Gear
Number of Teeth 52
Timing Gear Backlash with idler 0.10 - 0.36 mm (0.004 - 0.014 in.)
Rocker Arm Shaft

Shaft Diameter 25.40 - 25.43 mm (1.000 - 1.001 in.)
Shaft Support Internal Diameter 25.45 - 25.20 mm (1.002 - 1.004 in.)
Rocker Arm
Inside Diameter 25.48 - 25.50 mm (1.003 - 1.004 in.)
Tappets
Clearance to Bore 0.015 - 0.058 mm (0.0006 - 0.0023 in.)
Tappet Diameter 25.113 - 25.131 mm (0.9889 - 0.9894 in.)
Tappet Bore Diameter 25.146 - 25.171 mm (0.9900 - 0.9910 in.)
Camshaft
Bearing Journal Diameter 60.642 - 60.668 mm (2.3875 - 2.3885 in.)
Bearing Clearance 0.076 - 0.178 mm (0.003 - 0.007 in.)
End Play 0.051 - 0.18 mm (0.0020 - 0.0070 in.)
Connecting Rods
Small End Bushing (Internal Diameter) 44.460 - 44.467 mm (1.7504-1.7507 in.)
Big End Bearing Clearance 0.038 - 0.104 mm (0.0015 - 0.0041 in.)
Clearance Bushing to Piston Pin 0.013 - 0.025 mm (0.0005 - 0.0010 in.)
Side Float 0.13 - 0.33 mm (0.0050 - 0.0130 in.)
Maximum Twist 0.30 mm (0.0120 in.)
Maximum Bend 0.10 mm (0.0040 in.)
Piston Pin
Outside Diameter 44.442 - 44.447 mm (1.7497 - 1.7499 in.)
10-5
Pistons
Skirt to Cylinder Clearance 0.152-0.182 mm (0.0060 - 0.0072 in.) New or unrun engine
0.152-0.194 mm (0.0060 - 0.0096 in.) For run engines
Taper (Out of Round) 0.063-0.127 mm (0.0025- 0.0050 in.)
Grading Diameter (at Right Angles to 111.64 - 111.74 mm (4.3951 - 4.3991 in.)
Piston Pin) in increments of 0.0127 mm (0.0005 in.)
Piston Pin Clearance 0.0127-0.0254 mm (0.0005-0.0001 in.) at 21°C (70°F)
Piston Crown to Block Face 0.005 - 0.015 mm (0.13 - 0.38 in.)
Piston Rings - Engines With Mechanically Controlled Fuel Injection Pump

Top Compression Ring Keystone tapered sides With letter “O” to the top
2nd Compression Ring Parallel side external step
Side Face Clearance to Ring Groove 0.06 - 0.105 mm (0.0023 - 0.0041 in.)
Piston Groove Width 2.435 - 2.455 mm (0.0959 - 0.0967 in.)
Oil Control Ring 1 off - Directly above the Piston Pin
Type Slotted With Expander
Side Face Clearance to Ring Groove 0.030 - 0.070 mm (0.0011 - 0.0028in.)
Piston Rings - Engines With Electronically Controlled Fuel Injection Pump

Top Compression Ring Keystone tapered sides With letter “O” to the top
2nd Compression Ring Keystone Tapered sides With letter “O” to the top
Oil Control 1 off - Directly above the Piston Pin
Type Slotted With Expander
Side Face Clearance To Ring Groove 0.051 - 0.101 mm (0.0020 - 0.0040 in.)
Crankshaft
Main Journal Diameter - Blue 85.631 - 85.644 mm (3.3713 - 3.3718 in.)
- Red 85.644 - 85.656 mm (3.3718 - 3.3723 in.)
Main Journal Length
(except thrust, rear, or intermediate) 36.96 - 37.21 mm (1.455 - 1.465 in.)
Main Journal Wear Limits 0.127 mm (0.005 in.) Maximum
Main and Crankpin Fillet Radius 0.25 mm (0.010 in.)
Thrust Bearing Journal Length 37.06 - 37.11 mm (1.459 - 1.461 in.)
Intermediate Bearing Journal Length 36.96 - 37.21 mm (1.455 - 1.465 in.)
Rear Bearing Journal Length 37.97 - 38.48 mm (1.495 - 1.515 in.)
Crankpin Journal Length 42.62 - 42.72 mm (1.678 - 1.682 in.)
Crankpin Diameter - Blue 69.840 - 69.850 mm (2.749 - 2.7500 in.)
- Red 69.850 - 69.860 mm (2.750 - 2.7504 in.)
End Play 0.10 - 0.36 mm (0.004 - 0.014 in.)
Crankpin Out of Round 0.005 mm (0.0002 in.) Total Indicator Reading
Taper Surface Parallel to Center Line
of Main Journal 0.005 mm (0.0002 in.)
Crankshaft Rear Oil Seal Journal Diameter 122.12 - 122.28 mm (4.808 - 4.814 in.)
Crankshaft Pulley Journal Diameter 51.788 - 51.808 mm (2.0389 - 2.0397 in.)
Crankshaft Timing Gear Journal Diameter 52.131 - 52.146 mm (2.0524 - 2.0530 in.)
Crankshaft Flange Runout 0.038 mm (0.0015 in.) Max
10-6
Crankshaft Drive Gear
Number of teeth 26
Main Bearing
Liner Length (Except Thrust Liner) 27.94 - 28.19 mm (1.10 - 1.11 in.)
Liner Length (Thrust Liner) 39.91 - 39.96 mm (1.453 - 1.455 in.)
Vertical Assembled Bearing Clearance 0.055 - 0.117 mm (0.0021 - 0.0046 in.)
Crankpin Bearings
Liner Length 31.5 - 31.75 mm (1.240 - 1.250 in.)
Vertical Assembled Bearing Clearance 0.038 - 0.104 mm (0.0015 - 0.0041 in.)
Bearing Clearance - Service Limit 0.127 mm (0.005 in.)
Crankshaft Re-grinding
When re-grinding a crankshaft the main and crankpin journal diameters should be reduced the same amount
as the undersize bearings used, and the following dimensions apply. The rear end of the crankshaft should be
located on the 60° Chamfer of the pilot bearing bore.
Undersize Bearing Available Main Journal Diameters

0.051 mm (0.002 in.) 85.580 - 85.593 mm (3.3693 - 3.3698 in.)
0.254 mm (0.010 in.) 85.390 - 85.402 mm (3.3618 - 3.3623 in.)
0.508 mm (0.020 in.) 85.136 - 85.148 mm (3.3518 - 3.3523 in.)
0.762 mm (0.030 in.) 84.882 - 84.894 mm (3.3418 - 3.3423 in.)
1.016 mm (0.040 in.) 84.628 - 84.640 mm (3.3318 - 3.3323 in.)
Undersize Bearing Available Crankpin Journal Diameters

0.051 mm (0.002 in.) 69.789 - 69.799 mm (2.7476 - 2.7480 in.)
0.254 mm (0.010 in.) 69.956 - 69.606 mm (2.7400 - 2.7404 in.)
0.508 mm (0.020 in.) 69.342 - 69.352 mm (2.7300 - 2.7304 in.)
0.762 mm (0.030 in.) 69.088 - 69.098 mm (2.7200 - 2.7204 in.)
1.016 mm (0.040 in.) 68.834 - 68.844 mm (2.7100 - 2.7104 in.)
Flywheel
Runout of Clutch Face (Between Outer
Edge of Friction Surface and Mounting
Bolt Holes) 0.127 mm (0.005 in.)
Ring Gear Runout 0.63 mm (0.025 in.)
Oil Pump
Flow Rate 91 l/min. (20 lmp Gpm) @2100 Engine RPM and
1.38 bar (20 PSI)
Rotor Clearance 0.025 - 0.15 mm (0.001 - 0.006 in.)
Rotor to Pump Housing Clearance 0.15 - 0.28 mm (0.006 - 0.011 in.)
Rotor End Play 0.025 - 0.089 mm (0.001 - 0.0035 in.)
Pump Gear to Camshaft Gear Backlash 0.40 - 0.56 mm (0.016 - 0.022 in.)
10-7
Oil Pressure
Minimum at Low Idle Speed 0.83 bar (12 PSI) at normal operating temperature
Minimum at Engine Rated Speed 2.41 bar (35 PSI) at normal operating temperature
Oil Filter Support

Relief Valve, Operating Pressure 3.8 - 4.1 bar (55 - 60 PSI)
Flow Rate 68.1 - 75.7 l/min. (15 - 16.6 imp gals./min.,18 - 20 US gals./min.)
Engine Oils And Change Periods

Refer to Operator’s Manual.
Engine Oil Capacities

Model Imp Pints U.S Gals. Litres
6 CYL 48.6 6.08 23.0
Grease and Sealants

Code Number Number Name
(All Markets Except (North America Only)
North America)
A NLG1 Grade 2 9861804DS Grease
9861804CDS*
B ESF-M1C43-A N/A Grease - Silicone Light Consistency
C 82995768 L56531 Sealer - Anaerobic Low Strength (Loctite® 565)
D&J 82995776 L81724 Sealer - Silicone
E&F 82995774 N/A Sealer - Polyester Urethane
G 82995773 L24231 Sealer - Anaerobic (Loctite® 565)
K 82995772 L26231 Thread and Stud Lock (Loctite® 565)
L 82995771 L51831DS Flexible Gasket Sealant
* NOTE: Canada Part Numbers Only
Thermostat
Opening Temperature 79 - 83°C (174 - 181°F)
Fully Open 93 - 96°C (199 - 205°F)
Radiator Cap
Opening Pressure 1.0 bar (14.5 PSI)
Water Pump
Type Centrifugal
Drive Poly V Belt, 8 rib
Fan Belt
Belt Tension Maintained by Automatic Tensioner
Cooling System Capacities
Refer to Operator’s Manual.
Cooling Fluid
Content Mixture - Water 50%, Antifreeze 50%
(Antifreeze Specification: NH900A)
10-8
TIGHTENING TORQUES
Torque Values - Various N⋅m ft.-lb
Main Bearing Bolts 81 + 90° 60 + 90°
Connecting Rod Bolts 149 110
Cylinder Head Bolts (with Engine Cold) 55 -- 95+90° 40--70+90°
Cylinder Head through Rocker Shaft Bolts As above +45° As above +45°
Intake Manifold-to-Cylinder Head 35 26
Exhaust Manifold-to-Cylinder Head 61 45
Exhaust Pipe-to-Flange 31 23
Flywheel-to-Crankshaft 197 145
Oil Pan Drain Plug 41 30
Valve Rocker Cover Bolts 24 18
Crankshaft Pulley-to-Crankshaft 224 210
Self-Locking Screw - Valve Rocker Arm 24 18
Injector Attachment Bolts 23 17
Cover Bolts (Blanks Oil Drilling) 31 23
Oil Pump to Block 23 17
Water Pump-to-Cylinder Block 35 48
Water Pump Cover-to-Pump 27 20
Oil Pan-to-Cylinder Block 44 33
Injector Line Nuts 24 18
Leak-off Tube Banjo Fitting Bolts 6 4.4
Injection Pump-to-Front Cover 24 18
Camshaft Idler Drive Gear-to-Block 237 175
Front Cover-to-Cylinder Block 24 18
Thermostat Housing Bolts 24 18
Camshaft Gear Bolt 69 51
Camshaft Rear Gear Plate Bolts 47 35
Oil Filter Adaptor Bolts 42 31
Oil Filter Mounting Bolt Insert 34 25
Starting Motor-to-Rear Adaptor Plate 31 23
Injection Pump-to-Gear Nut 92 68
Oil Pressure Switch Assembly 31 23
Turbocharger-to-Exhaust Manifold Nut 44 33
Fan Blade to Viscous Unit 27 21
Viscous Unit to Pulley 54 40
Crankshaft Rear Oil Seal Retainer 20 15
Belt Tensioner Pulley Bolt 54 40
Temperature Senders 20 15
Tensioner to Water Pump Bolt 54 40
Idler Pulley Bolt 54 40
Pump Connector to Block 24 18
10-9
The following general nut and bolt installation torque requirements (lubricated) apply to any operation not
previously listed.
Inch Series N⋅m ft-lb
1/ - 20 11 8
4
1/ - 28 11 8
4
5/ -18 19 14
16
5/ - 24 23 17
16
3/ - 16 31 23
4
3/ - 24 45 33
4
7/ -14 65 48
16
7/ -20 75 55
16
1/ - 13 88 65
2
1/ - 20 102 75
2
9/
16 -18 122 90
5/ -18 187 138
6
Cylinder Block Plugs
1/ - 27 NPT 11 8
4
1/ - 18 NPT 29.8 22
4
3/ - 18 NPT 38 28
4
3/ - 14 NPT 27 20
4
SPECIAL TOOLS
60°
10mm
(3/8″)
1
Fuel Injection Pump Drive Gear Puller

(Local manufacture or Special Tool No.295042)
1. Bolt 51mm (5/16-UNF x 2 in.) with integral washer (3 bolts required)

2. Bolt 51mm (3/4x16-UNC x 2 in.)
3. Three holes 9.5mm (0.375 in.) dia. on 56.87mm (2.2 in.) dia. equally spaced material of 0.394 in. (10mm) Plate
HRLC P&O Steel
10-10
Description Tool Number SPX Ltd Tool Nuday Tool Tool Number
(All Markets Number Number ( North America
Except North Only)
America)
Engine sling hook, 290740 - - -
(use with brackets 50075 and
50076)
Engine revolving stand 290090 - - -
Engine overhaul brackets kit 293860 - - -
Cylinder pressure test kit 291309 & - - FNH02020 and
295039 FNH00882
Lube pressure check kit 292870 - - FNH02003
Piston ring pliers 296028 - - -
Piston install band 296042 - - -
Crankshaft rear seal installer 297252 or FT.6212 - FNH01301
297194
Crankshaft front seal puller 297670 - - CNH297670
Crankshaft front seal installer 297637/1 - - CNH297637
Valve guide set reamers 295006 FT.6202 2136 FNH02136
(SW.502) (SW.502)
Valve spring compressor 291050 - - -
Water pump impeller seal installer 295007 FT.6209 4672 FNH04672 or
T87T-6312-A
Injector - hand pump tester 290284 - - FNH01721
Injector - cleaning kit 293671 - - -
Injector - splitting block 293760 - - -
Injector - splitting socket kit 293761 - - -
Injection pump drive gear puller 295042 - - -
Adjustable bridge puller 297102 518 9539 FNH09539
Shaft protector 297107 625-A 9212 FNH09212
Step plate adaptors - 630-S 9210 FNH09210
Bushing kit - 818 9514 FNH09514
Con rod bush - remove/install tool FNH00035 - - FNH00053
OTC 134-00002
Camshaft bearing installer 297117 FT.6203 1255 (SW.506) FNH01255
Handle (for camshaft bearing 291896 N6261-A 1442 FNH01442
installer)
Crankshaft timing pin 297672 - - -
Fuel injection pump timing pin 295005 - - FNH00536
(Prior Tool Numbers, where applicable, shown in brackets)
10-11
TROUBLESHOOTING
IMPORTANT: When effecting a repair the cause of The following table lists problems and their possible
the problem must be investigated and corrected to causes with recommended remedial action.
avoid repeat failures.
PROBLEM POSSIBLE CAUSES REMEDY

Engine
g does not 1. Clogged air cleaner 1. Clean or renew element
d
develop
l ffull
ll power
2. Fuel line obstructed 2. Clean
3. Faulty injectors 3. Clean and reset
4. Incorrect valve clearance 4. Check and reset
adjustment
5. Burnt, worn or sticking valves 5. Replace valves with new or
oversize, and/or machine the
valve guide bores
6. Blown head gasket 6. Check head flatness and fit new
gasket
7. Incorrect fuel delivery 7. Check injectors and pump
8. Low cylinder compression 8. Renew piston rings or
re-bore/re-sleeve as necessary
Oil p
pressure warning g 1. Bulb burnt out 1. Renew bulb
li ht ffails
light il tto operate
t
2. Warning Light pressure switch 2. Renew pressure switch
faulty
3. Warning light circuit faulty 3. Check and renew wiring
Excessive exhaust 1. Oil leak on compressor or turbine 1. Overhaul turbocharger
smoke side of turbocharger, where fitted
2. Exhaust leak on exhaust manifold 2. Fit new gasket
side of turbocharger, where fitted
3. Air cleaner dirty or restricted 3. Clean
4. Excessive fuel delivery 4. Overhaul injection pump and
injectors
10-12
Engine knocks 1. Diluted or thin oil 1. Check crankshaft bearings for
damage, change as required.
Drain and refill with specified oil
and renew filter. Ascertain cause
of dilution
2. Insufficient oil supply 2. Check oil level and top up as
necessary. Overhaul or renew
pump as necessary. Check oil
filter is not clogged
3. Low oil pressure 3. Overhaul pump or relief valve as
necessary
4. Excessive crankshaft end play 4. Install new thrust bearing liner
5. Flywheel or ring gear run-out 5. Skim flywheel or fit new ring gear
excessive
6. Excessive connecting rod or main 6. Install new bearing inserts and/or
bearing clearance re-grind crankshaft
7. Bent or twisted connecting rods 7. Renew connecting rods
8. Crankshaft journals out- of-round 8. Re-grind crankshaft and fit
undersize bearing inserts
9. Excessive piston-to- cylinder bore 9. Re-bore/re-sleeve block and fit
clearance new pistons
10. Excessive piston ring clearance 10. Fit new pistons and rings
11. Broken rings 11. Fit new rings, check bore and
pistons for damage
12. Excessive piston pin clearance 12. Fit new piston or pin
13. Piston pin retainer loose or 13. Install new retainer, and check
missing bore/pistons for damage
14. Excessive camshaft play 14. Install new thrust plate
15. Imperfections on timing gear teeth 15. Renew timing gear
16. Excessive timing gear backlash 16. Check and adjust backlash
/renew timing gear
10-13
Engine overheats 1. Hose connection leaking or 1. Tighten hose connection, renew
collapsed hose if damaged
2. Radiator cap defective or not 2. Renew radiator cap
sealing
3. Radiator leakage 3. Repair/renew radiator
4. Improper fan belt adjustment 4. Re-adjust fan belt
5. Radiator fins restricted 5. Clean with compressed air
6. Faulty thermostat 6. Renew thermostat
7. Internal engine leakage 7. Check for source of leakage,
renew gasket or defective parts
8. Water pump faulty 8. Overhaul water pump
9. Exhaust gas leakage into cooling 9. Renew cylinder head gasket,
system check head for damage or
distortion
10. Coolant aeration 10. Tighten all connections and
check coolant level is correct.
Ensure cylinder head gasket has
not blown
11. Cylinder head gasket improperly 11. Renew cylinder head gasket
installed
12. Hot spot due to rust and scale or 12. Reverse flush entire cooling
clogged water jackets system
13. Obstruction to radiator air flow 13. Remove the obstruction
14. Extended engine idling 14. Do not allow engine to idle for
long periods
15. Oil cooler tube blocked 15. Clean
16. Radiator core tubes blocked 16. Check free flow
Water temperature
p gauge
g g 1. Faulty temperature sender 1. Renew sender switch
f il to
fails t reachh normall
2. Incorrect or faulty thermostat 2. Renew thermostat
operating temperature
3. Faulty water temperature gauge 3. Renew temperature gauge
10-14
Low oil p
pressure 1. Engine oil level low 1. Top up, as necessary
2. Wrong grade of oil 2. Drain and refill with correct grade
of oil
3. Blocked oil pump sump screen 3. Clean pump screen
4. Oil pressure relief valve faulty 4. Fit new relief valve
5. Oil pump worn 5. Renew oil pump
6. Excessive oil pump rotor and shaft 6. Overhaul pump
assembly clearance
7. Excessive main or connecting rod 7. Install new bearings inserts and /
bearing clearance or re-grind crankshaft if
necessary
Excessive oil 1. Engine oil level too high 1. Reduce oil level
consumption
ti
2. External oil leaks 2. Renew gaskets and seals, where
necessary. Check mating
surfaces for damage or distortion
3. Worn valves, valve guides or 3. Renew
bores
4. Cylinder head gasket leaking 4. Renew gasket. Check head for
damage or distortion
5. Oil loss past the pistons and rings 5. Renew rings and/or rebore/
re-sleeve block as necessary
6. Oil cooler leak 6. Repair/renew oil cooler assembly
Engine
g tends to keep p 1. Air cleaner dirty or restricted 1. Clean or renew element
fi i
firing after
ft ffuell iis shut
h t off
ff
2. Oil leak on compressor side of 2. Overhaul turbocharger
turbocharger where fitted
10-15
DESCRIPTION AND OPERATION
2
The 7.5 Litre engine is a 6-cylinder turbocharged and Cylinder Block Assembly
aftercooled, having a bore of 111.8 mm (4.4″) and a The cylinder block is an alloy cast iron with deep
stroke of 127 mm (5.0″) which generates a cylinder skirts, and water jackets for cooling the
displacement of 7.5L (456 in3). cylinders. The cylinder bores are machined integral
The engine uses a mechanical or electronically with the cylinder block, during the manufacturing
controlled in line injection pump depending on model process.
and has been designed to meet current emission Cylinders are in line and vertical and numbered 1 to
regulations and must only be serviced by an 6 from the front to the rear of the engine. They can be
authorized service agent. For a detailed description bored oversize for the fitment of sleeves, which are
and operation of the fuel system, reference must be available in service.
made to the “Fuel System” chapter in this Section of
the manual. The oil pan is the reservoir for the engine oil
lubrication system and a cast iron front cover on the
All engines feature cross flow cylinder heads, with the
front of the engine covers the timing gear assembly.
inlet and exhaust manifolds on opposite sides of the
cylinder head. The fuel and air combustion process,
takes place in the specially designed bowl in the
crown of the pistons.
10-16
Cylinder Head Assembly
The cylinder head incorporates an inlet and exhaust
valve per cylinder with the valve rocker arm shaft
assembly bolted to the cylinder block through the
cylinder head. Cylinder head retaining bolts are
evenly spaced with a six point pattern around each
cylinder, this ensures an even clamping load across
the cylinder head area.
The intake and exhaust manifolds are bolted to the
head, the intake manifold is mounted on the right
hand side of the engine, with the diesel injectors
mounted outside the rocker cover. The exhaust
manifold is mounted on the left hand side of the
engine. Water outlet connections and thermostats
3
being attached to the front of the cylinder block.
Valve guides are integral in the cylinder head, and
valves with oversize stems are available in service.
Special replaceable sintered iron valve seats are
pressed into each valve port during manufacture and
oversize valve seats also available in service.
All valves are fitted with positive valve rotators and
valve stem oil seals. Valve clearance is maintained by
adjustment of the self locking adjusting screw,
mounted in each of the rocker arms.
Camshaft Assembly
The camshaft runs in 5 replaceable bearings. The
camshaft drive gear is in mesh with and driven by the
camshaft idler gear which is driven by the crankshaft
timing gear.
Camshaft end thrust is controlled by a thrust plate
bolted to the block, and located between the
camshaft gear and the front camshaft journal.
A helical gear is mounted on the rear of the camshaft,
and drives the engine oil lubrication pump mounted
forward of the flywheel.
396--E--16 TI
4
Crankshaft Assembly
The crankshaft is supported in the cylinder block by
7 main bearings.
The crankshaft is manufactured from steel with
machined finished crank webs
End thrust is controlled by a thrust bearing
incorporated in the center main bearing of the
crankshaft.
An external damper is fitted to the crankshaft pulley
to ensure smooth running operation. Front and rear
crankshaft oil sealing is effected by cassette type
seals that are designed for long and durable service
life. 5
10-17
Connecting Rods
Connecting rods ‘‘Teepee” (wedge) shaped at the
small end have been designed to reduce the
reciprocating weight at the piston end. The
connecting rods are of a heavy beam construction
and are assembled as a matched set to each engine.
They are retained in position by the connecting rod
big end cap and secured by two bolts per rod. The
small end of the connecting rod is fitted with a
replaceable bronze bushing, through which the free
floating piston pin is fitted. The steel pin being held in
place within the piston by two snap rings.
6
Pistons
Pistons are constructed of an aluminium silicon alloy
with an iron insert for the top ring. The combustion
chamber being recessed into the piston crowns.
Each piston has two compression rings and one oil
control ring, to reduce friction and increase positive
sealing. All rings are located above the piston pin.
A Engines with Electronically Controlled
Injection Pump
B Engines with Mechanically Controlled
Injection Pump
7
Manifolds
The cross flow design aluminium intake, and cast iron
exhaust manifolds, are on opposite sides of the
cylinder head. This is designed to maintain balanced
heat distribution within the cylinder head. The
configuration of the manifolds also ensures minimum
heat transfer to the intake manifold.
A grid heater is fitted to the intake manifold to assist
in cold starting of the engine when coolant water
temperature is below 30°C.
10-18
Timing Gears
4 1
The crankshaft timing gear is heated and press fitted
on to the front of the crankshaft, to a high degree of
accuracy during manufacturing. This enables precise
timing being maintained during the life of the engine.
The crankshaft gear, 2, drives the idler gear, 3, which . ..
is attached to the front of the cylinder block. The idler
gear then drives the camshaft gear, 1, and the
injection pump gear, 4. ..
The camshaft gear is bolted to the front of the
camshaft, and is keyed to maintain position of the
3 2
gear on the camshaft.
P396--E--36
9
Lubrication System
10
Engine Lubrication System
Lubrication of the engine, Figure 10, is maintained by

a rotor type oil pump mounted in the rear of the engine
block, forward of the flywheel on the left hand side of
the engine.
TA6010058
11
10-19
The oil pump is driven from the rear of the camshaft
and draws oil from the engine oil pan through a tube
and screen assembly.
12
A spring loaded relief valve is integral with the dummy
oil filter head mounted on the left hand side of the
engine block and prevents over pressurisation of the
system.
396--E--18 TI
13
The spin on type oil filter is mounted at the rear of the

engine.
14
10-20
Oil flows from the filter to the main oil gallery, which
runs the length of the cylinder block and also
intersects the camshaft follower chamber.
The main gallery supplies oil to the crankshaft main
bearings, connecting rods and both big and small
ends. The underside of the pistons and pins, are
lubricated by oil pressure jets mounted adjacent to
each main journal housing.
The camshaft drive gear bushing is pressure
lubricated through a drilled passage from the front
main bearing. The gear has small oil passages
machined on both sides allowing excess oil to
escape. 396--E--26 TI
15
An intermittent flow of oil is directed to the valve
rocker arm shaft assembly via a drilled passage in the 1
cylinder block. This is located vertically above No.1
camshaft bearing, 1, and aligns to a hole in the
cylinder head. The rotation of the camshaft allows a
controlled intermediate flow of lubrication.
396--E--16 TI
16
Timing gears are lubricated by splashed oil from the
cam follower chamber, and the pressure lubricated
camshaft drive gear bushing.
P396--E--36
17
10-21
The turbocharger is supplied with oil from the oil filter
support housing, 1, mounted on the left hand side of
the engine.
18
The fuel injection pump is pressure lubricated from a
port, 1, on the right hand side of the engine block.
The fuel pump is either electronically controlled using
an electronic control unit, Figure 19 or mechanically
controlled depending on model build, Figure 20.
19
20
10-22
OVERHAUL
INTRODUCTION For concerns relating to the fuel system refer to the

“Fuel System” chapter in this manual. On engines
In the following procedures and illustrations the fitted with the electronically controlled fuel injection
engine is shown removed from the vehicle however pump refer to the “Engine Fault Codes” chapter in the
there are certain operations that can be performed electrical section of the manual.
with the engine installed.
Where it is necessary to remove the engine use a
Operations or repairs that can be performed
suitable hoist or overhead gantry and standard
with the engine still in the vehicle.
engineering procedures. Removal of the engine is
described in Section 10, Chapter 3 of this manual. 1. Front timing cover, Pump drive gear and idler
Dismantle the engine following conventional gear. Removal of engine is required in order to
techniques and by referring to the appropriate remove and replace the camshaft timing gear.
overhaul sections of this chapter. Always refer to the 2. Front pulley and damper assembly.
specification section as necessary. 3. Cylinder head and associated inlet and exhaust
NOTE: Where it is necessary to remove additional components.
items to gain access to the components on the engine 4. Fuel injection pump removal and timing.
Refer to Chapter 3 “Remove and Replace, 7.5L
Engine”. 5. Water pump, thermostat, and associated
components .
NOTE: All gaskets, seals, and O-rings must be
replaced during re-assembly. Where new sealant is 6. Oil pump relief valve.
to be applied refer to ‘‘Engine Specifications”. 7. Turbocharger.
10-23
INJECTION PUMP
Timing
If a fuel related concern is identified check the
injection pump timing before proceeding with any
other disassembly.
NOTE: Where it is necessary to remove additional
items to gain access to the components on the engine
Refer to Chapter 3 “Engine Removal and
Replacement”.
1. Remove engine drive belts.
21
2. Remove injection pump timing cover.
22
3. Using 29 mm (1-1/8″) socket rotate crankshaft to
top dead center (TDC) with number 1 cylinder
firing.
23
10-24
4. When engine is at TDC the threaded hole in the
injection pump drive flange aligns with the pump
timing plate.
24
5. To ensure the crankshaft is accurately positioned
at TDC remove the crankshaft timing plug, 1, from
the side of the engine block.
IMPORTANT: DO NOT disturb the timing pin bush, 2.
This has been accurately set during original
manufacture. If the bush is moved then pump timing
CAN NOT be accurately set.
25
6. insert the crankshaft timing pin 297672 into the
side of the block.
26
10-25
7. If necessary gently turn the crankshaft to engage
the rounded end of the timing pin in the slot of the
crankshaft. This is not visible and must be
performed by ‘feel’.
27
8. When the timing pin is located in the slot of the
crankshaft the pin is fully seated.
Do Not attempt to rotate the crankshaft when
timing pin is fully inserted as damage will occur.
28
9. Check that the injection pump go/no-go timing pin
Tool No 295005 (NA-FNH00536-2) will screw into
the pump hub.
IMPORTANT: The engine must never be rotated
while the timing pin is installed.
10. If the pin engages in the pump timing plate (inset,
Figure 30) when the crankshaft is at TDC the
pump timing is correct.
29
10-26
11. If pump timing is incorrect and timing pin can not
be screwed into pump, remove pump timing gear,
install rigid timing pin 295005 (NA-FNH00536-1)
into pump and refit timing gear.
30
NOTE: This injection pump timing check assumes
that the crankshaft and camshaft timing gears were
correctly positioned during engine assembly. To
check the position of these timing gears it is
necessary to remove the engine front cover.
10-27
CYLINDER HEAD
Removal
NOTE: The cylinder head can be removed with the 2
engine installed in the combine.
1. Drain the engine coolant by placing a suitable
container,1, below the coolant drain hose, 2.
1
10013105
31
2. Drain the coolant from the engine block using
drain tap, 1, on left hand side of the radiator, 2.
10013106
32
3. Remove all necessary hardware and
components in order to gain access to the
cylinder head. Refer to Chapter 3 “Remove and
Replace, 7.5L Engine” for further details.
33
10-28
4. Remove the fan belt.
34
5. Clean the area surrounding the fuel injectors.
Disconnect and remove injector lines, 1, and leak
off lines, 2, from the fuel injectors and injection 1
pump. Cap all exposed openings.
2
35
6. Remove injectors from the cylinder head.
36
10-29
7. Remove the turbocharger assembly, ensuring all
openings are capped to prevent dirt ingress.
37
8. Remove the thermostat housing, 1, and water
pump housing, 2.
38
9. Remove the rocker cover and gasket.
39
10-30
10. Loosen the rocker shaft retaining bolts (which
also serve as head bolts) evenly and alternately
and remove the rocker shaft assembly.
40
NOTE: Leave bolts in the rocker shaft supports
during removal, as they retain the support on the
shaft.
11. Remove pushrods in turn and place in a
numbered rack to maintain the same position for
reassembly.
41
12. Remove remaining cylinder head bolts by
working progressively from each end of the
cylinder head towards the center.
13. Carefully lift the cylinder head assembly away
from the engine block.
42
10-31
Disassembly
1. Using a valve spring compressor, Tool No. 1
291050, 1, remove the retainer locks, 2, and
place in a numbered rack.
2. Clean the cylinder head, and remove carbon
deposits from around the valve heads.
TA6010011
43
44
Inlet and Exhaust Valves
1. Keepers 7. Spring
2. Spring Retainer 8. Seal
3. Seal
9. Spring Rotator
4. Spring
5. Inlet Valve 10. Spring Rotator
6. Exhaust Valve 11. Keepers
10-32
Inspection and Repair
1. Replace cylinder head core plugs if discoloured
(rusty), or leaking. Before fitting new plugs
remove all old sealer from the cylinder head.
Apply sealant G to the new plug mating faces, and
drive the new plugs into location, (refer to
‘‘Specifications”).
The core plugs fitted to the cylinder head are:
• 6 off, in the top, and 1 off, in the rear of the cyl-
inder head.
• 5 off, in the intake face.
2. Scrape all gasket surfaces clean, wash cylinder TA6010008
head in a suitable solvent and clean valve guide
bores. 45
NOTE: Ensure injector washers have been removed
prior to cleaning.
3. Inspect cylinder head for nicks and burrs on
mating face. Remove using a suitable abrasive
and ensure faces are clean after repair.
4. Using a straight edge and feeler gauges, check
that the flatness of the cylinder head in all
directions does not exceed, 0.03 mm (0.001 in.)
in any 25.4 mm (1 in.), or 0.127 mm (0.005 in.), 2 3 4 5 6 6 7 8
overall limit.
5. If the cylinder head has been resurfaced,
determine that all head bolt faces will seat by
placing the cylinder head less gasket, on the
cylinder block and installing bolts hand tight.
TA6010012
46
6. Ensure rocker shaft supports are fitted with long
bolts. Using a feeler gauge, check clearance
between underside of bolt heads and cylinder
head or rocker shaft support.
7. If a 0.25 mm (0.010 in.) feeler gauge can be
inserted under the bolt head the bolt has bottomed.
Therefore the cylinder block thread must be
increased using a 9/16″-13 UNC-2A thread tap.
Identify each head bolt to ensure they are
re-installed in the bolt holes they were checked in.
47
10-33
Valve Inserts
Counter Bore in Cylinder Head
Insert Oversize
Exhaust Valve Insert Intake Valve Insert
0.25 mm (0.010 in.) 44.17 - 44.20 mm (1.739 - 1.740 in.) 50.01 - 50.04 mm (1.969 - 1.970 in.)
0.58 mm (0.020 in.) 44.42 - 44.45 mm (1.749 - 1.750 in.) 50.27 - 50.29 mm (1.979 - 1.980 in.)
0.76 mm (0.030 in.) 44.68 - 44.70 mm (1.759 - 1.760 in.) 50.52 - 50.55 mm (1.989 - 1.990 in.)
NOTE: Refacing the valve seat should always be
coordinated with refacing of the valve to ensure a
compression tight fit.
1. Examine the valve seat inserts and reface if
pitted, renew if loose or damaged.
2. To install a new valve insert, the cylinder head
must be counter bored, as described in the above
chart. The new insert must be chilled in dry ice
prior to installation.
Valve Seat Specifications, Figure 48.
1. Valve seat angle 3
Intake 30.0°--30.30° 1
Exhaust 45.0°--45.30°
2. Valve seat width
Intake 1.9 - 2.4 mm (0.078 - 0.098 in.)
Exhaust 1.8 - 2.3 mm (0.072 - 0.092 in.)
3. Valve Head Face to Cylinder Head Face Depth
Intake 0.89 - 1.29 mm (0.035 - 0.051 in.)
Exhaust 1.2 - 1.6 mm (0.048 - 0.064 in.)
NOTE: Valve inserts of 0.25 mm (0.010 in.) and 0.5 2
mm (0.020 in.) oversize on diameter are sometimes TA6010013
installed during manufacture. Cylinder Heads with
48
oversize inserts are stamped so10/os, so20/os, on
the exhaust manifold side in line with the valve seat
concerned.
3. Check the width of the valve seat inserts, and as
required reface by grinding to dimensions
detailed above.
4. Measure the concentricity of valve seats, using a
dial indicator and measure concentricity of seat to
the valve guide bore. Total Indicator Reading
should not exceed 0.051 mm (0.002 in.),
Figure 49.
49
10-34
5. Use a seat cutter to correct any seat eccentricity,
or clean up of pits and grooves. Ensure after any
rework that seat width is within specified limits.
6. Rotate a new or refaced valve in the seat using
engineering blue, ensure all the blue is
transferred to the valve head protrusion, If any
blue remains below or around the seat raise or
lower the seat accordingly, Figure 50, in the
following manner.
7. Lower, the valve seats, 1, Figure 50, by removing
material from the top of seat using a, 30° grinding
wheel for exhaust valves and a 15° grinding
wheel for intake valves. TA6010016
8. Raise, the valve seats, 2, Figure 50, by removing 50
material from the bottom of seat using a, 60°
grinding wheel for exhaust valves and a 45°
grinding wheel for intake valves.
Critical valve points, Figure 51:

1. Valve Land Edge
2. Valve Head
3. Valve Face Angle
4. Valve Face
5. Valve Stem
6. Valve Tip
Valve Guides
1. Using a telescopic gauge, and micrometer,
measure the valve guide bore clearance, and 51
ensure it does not exceed, 0.114 mm (0.0045 in.),
on the intake valve stem, and 0.140 mm
(0.0055 in.), on the exhaust valve stem,
Figure 52.
NOTE: Production cylinder heads may have one or
more machined, oversize valve guide bores, or
valves installed, 0.38 mm (0.015 in.). Such cylinder
heads have 15 or VO15OS stamped on the cylinder
head exhaust manifold side adjacent to the valve con-
cerned.
2. Using reamer set, 295006 (NA-FNH02136),
ream out the valve stem guide, with three reamer
and pilot combinations as follows:
When going from a standard valve stem to an
oversize, always use reamers in sequence
0.38 mm (0.015 in.) oversize reamer, and 0.076 TA6010018
mm (0.003 in.) oversize pilot. 52
10-35
Valve Springs
1. Checked on a flat surface squareness, should not
exceed 1.52 mm (0.060 in.), between the square,
and spring at the top edge, Figure 53.
Length of valve springs should be checked on
both free length, and loaded length.
• Free length = 60.7 mm (2.39 in.)
• Installed length = 47 - 49.6 mm (1.86 -
1.95 in.)
• Loaded length = 48.26 mm (1.9 in.) using a
weight of 28 - 31 kg (61.96 lbs.)
• Loaded length = 35.69 mm (1.4 in.) using a
weight of 61 - 69 kg (135 - 153 lbs.)
53
Ensure the valve spring retainer locks are in good
condition and replace if worn or damaged.
Rocker Shaft Inspection and Reassembly
1 2 3
1. Separate rocker shaft assembly by removing the
cylinder head bolts, 3, and withdraw the supports,
2, springs, 1, rockers, 4, and spacers, 6.
2. Clean all components using approved cleaning
solution and make sure all oil passages are clear.
3. Inspect rocker arm adjusting screws, and push
rod ends of the rocker arm, including the ball end
of the screws for nicks, damage, or excessive
wear.
4. Inspect the inside diameter of the rocker arm for 6 5 4
damage or wear. If any of these characteristics TA6010010
are not to specification replace with new parts. 54
5. Check the ends of the push rods for damage or
wear. If not to specification or push rods were
found not to be straight during dismantling install
new rods.
NOTE: Do not attempt to straighten bent push rods,
replace with new.
6. Check the rocker shaft for signs of wear or
damage on internal and external diameters
respectively.
7. Re-assemble the rocker shaft components onto
the shaft ensuring the shaft identification groove,
1, is positioned forwards and upwards. This
ensures oil grooves and holes face downwards. 55
10-36
Assembly
1. Insert the valves into the guide bores from which
they were removed and lap with a suitable paste.
Ensure all traces of paste is removed after
lapping.
NOTE: Lubricate all components with clean engine
oil on re-assembly.
2. Use a spring compressor to reassemble the
valves, valve springs, retainers, rotators, and
collets, and install new valve stem seals.
TA6010011
56
3. Install new gasket and lower cylinder head into
place while ensuring the gasket remains in
position.
4. loosely position all cylinder head bolts except
those which retain the rocker shaft assembly.
NOTE: Cylinder head bolts may only be removed and
refitted four times after which they must be replaced
with new parts.
57
5. Install rocker push rods in cylinder head and
locate rocker shaft assembly onto cylinder head
using the longer cylinder head bolts.
58
10-37
6. Tighten the cylinder head bolts in sequence
progressively in the following stages, Figure 59.
NOTE: Lightly lubricate the bolts prior to assembly,
and tighten to the torque specification, with the
engine cold.
59
Stage 1, all bolts, 55 N⋅m (40 ft-lb).
60
Stage 2, all bolts, 95 N⋅m (70 ft-lb).
61
10-38
Stage 3, all bolts, a further 90° using a torque angle
gauge, Figure 62.
62
Stage 4, Rocker shaft securing bolts only, tighten
a further 45°, Figure 64, using a torque angle gauge. 8
24 16 2 10 18 26
In sequence, 2, 8, 10, 16, 18, 24, 26.
63
Stage 4 Rocker shaft bolts.
45°
64
10-39
7. Adjust valve clearance setting with each piston in
turn at top dead center, and rockers free to move,
Figure 65.
Intake Valve clearance,
0.36 - 0.46 mm (0.014 - 0.018 in.).
Exhaust Valve clearance,
0.43 - 0.53 mm (0.017 - 0.021 in.).
NOTE: Valve clearance is to be set, only when the
engine is cold.
65
8. Install the injectors with new seat washers, cork
seals, and torque to 23 N⋅m (17 ft-lb) Figure 66.
9. Install the injector lines and torque to 24 N⋅m (18
ft-lb). Install the leak off line with new washers,
and torque the leak off banjo bolts to, 6 N⋅m (4.4
ft-lb).
NOTE: Hold the leak off plastic tubing when
tightening to prevent the pipes pivoting, during torque
up.
10. Exhaust manifold bolts are to be refitted and
tightened to a torque of 38 N⋅m (28 ft-lb).
11. Intake manifold bolts are to be refitted and
tightened to a torque of 38 N⋅m (28 ft-lb).
66
12. Using new gaskets install intake and exhaust
manifolds. Initially install all bolts finger tight
ensuring the gaskets are aligned with the inlet
and exhaust ports.
13. Tighten the bolts to a torque of 61 N⋅m (45 ft-lb)
working from the central bolts outwards.
14. Re tighten the bolts to a torque of 61 N⋅m (45 ft-lb).
NOTE: When the manifold bolts are torqued the
gaskets may show signs of distortion between the
inlet and exhaust ports. This is normal for this type of
gasket and is the reason for the retorquing procedure.
67
10-40
ENGINE FRONT COVER AND TIMING GEARS

Timing Gears Checking and Removal
IMPORTANT: If the injection pump timing has been
checked ensure the timing pins 295005
(NA-FNH00536) and 297672 have been before
removed before proceeding. Refer to ”Injection Pump
Timing Check”, earlier in this chapter.
1. Using puller, 297102 (518 or FT.9539) (NA-
FNH09539), and shaft protector 297107 (625-A
or 9212) (NA-FNH09212), remove crankshaft
damper.
TA6010027
68
2. Remove the front cover plate.
69
3. When the engine timing has been checked (as
described in “Injection Pump Timing Check”
4 1
earlier in this chapter) the timing marks (dots) on
the crankshaft and camshaft timing gears align.
1. Camshaft Gear
.
2. Crankshaft Timing Gear
..
3. Camshaft Idler Gear
4. Injection Pump Drive Gear .
NOTE: The crankshaft timing gear, 2, should not be
removed. The gear is heat shrunk on to the 3 2
crankshaft and aligned to the crankshaft No. 1 pin, to
within 0.10 mm (0.004 in.). If the gear is damaged a P396--E--36
new crankshaft is required. 70
10-41
4. Before removing the timing gears perform the
following checks:
Use a dial indicator or feeler gauge, Figure 71, to
measure the backlash between each set of gears.
Rotate the gears and check the backlash at four
equal points on the gears. Renew if the backlash
exceeds the following:
• Crankshaft to camshaft idler gear, 0.1 - 0.36
mm (0.004 - 0.014 in.)
• Camshaft to camshaft idler gear, 0.1 - 0.36
mm (0.004 - 0.014 in.)
• Fuel injection pump to camshaft idler gear TA6010029
0.10 - 0.48 mm (0.004 - 0.019 in.) 71
5. Check camshaft gear end float as follows:
Pry the camshaft gear using a lever, away from
thrust plate. Using a dial indicator or feeler gauge,
check the clearance.
P396--E--28 TI
72
If clearance is outside 0.05 - 1.8 mm (0.002 -
0.007 in.) limit, fit a new camshaft thrust plate,
item 1, Figure 73. 1
NOTE: The camshaft gear is an interference fit with
the camshaft and removal requires a three legged
puller. It is recommended that this gear is only
removed when necessary and during a total engine
rebuild. This will enable both the gear and camshaft
to be removed from the front of the engine.
396--E--45 TI
73
10-42
6. Check idler gear end float using similar procedure
described for the camshaft gear. If outside limits
of 0.073 - 0.35 mm (0.003 -- 0.014 in) fit a new
idler gear wear plate, 1.
74
7. To remove the fuel pump drive gear remove the
4 retaining bolts.
..
1
..
P396--E--36 TI
75
8. If required the timing gear rear cover plate may
now be removed. Remove the six retaining bolts
and carefully pry the cover from the engine block.
When replacing the cover tighten retaining bolts
to a torque of 24 N⋅m (18 ft-lb).
76
10-43
Gears - Inspection and Repair
1. Wash the gears using a suitable solvent, and
examine gear teeth for wear, burrs, or scratches.
Minor marks can be removed using a fine
abrasive, thoroughly clean before re-assembly.
2. Ensure the camshaft idler gear adaptor is free
from obstruction and bushing is not damaged.
Camshaft key and key-way should be checked for
damage and repaired as required.
TI
77
Installation
1. Position piston No.1 at top dead center and install
timing pin 297672.
78
2. Ensure the timing marks on the pump are aligned
and screw the rigid timing pin 295005 (NA-
FNH00536-1) through the pump flange and
timing plate.
79
10-44
3. If the pump has been removed during engine
overhaul refit pump onto engine.
80
4. Install timing gears ensuring the timing marks on
the crankshaft, idler and camshaft gears align.
5. Fit the pump drive gear and remove pump timing
pin.
6. Torque bolts as follows:
Camshaft gear - 69 N⋅m (51 ft-lb) ..
Idler Gear 204 - 279 N⋅m (150 - 205 ft-lb)
Pump Drive Gear 38 N⋅m (28 ft-lb) ..
P396--E--36 TI
81
7. Remove crankshaft timing pin and install plug.
82
10-45
8. Position gasket on the front cover plate.
9. Install the front cover, ensuring alignment with
dowel pins. Tighten the retaining bolts in the 1 - 4
sequence shown to a torque of 34 - 41 N⋅m (25 -
30 ft-lb).
10. Install the oil pan as described on the following
page.
11. Install new front crankshaft oil seal as described
in “Front Crankshaft Cassette Oil Seal Replace-
ment” later in this chapter.
83
OIL PAN
Removal
1. Remove engine as described in the engine
removal chapter in this section of the manual.
2. Drain engine oil through oil pan drain plug and
remove the dipstick.
3. Remove oil pan bolts and lower pan to the
ground.
84
Inspection and repair
1. Clean gasket material from sump face, clean
sump in a suitable solvent, inspect sump for
cracks damaged threads or damaged sump face.
Installation
+0.15
1. Installation is the reverse of removal but with the --0.22
following requirements.
2. Ensure block face is clean and free of gasket
material.
NOTE: Before installing the oil pan ensure that the
rear oil seal carrier, 2, is correctly aligned with the
block, 1, ie, less than 0.15 mm protrusion or 0.22 mm
recessed. 85
10-46
3. Apply gasket sealant 82995770 (NA-L51831DS,
Loctite® 518) to the areas shown and install a new
gasket to the oil pan.
4. Position the oil pan and install a bolt finger tight at
each corner. Install remaining bolts, and torque to
44 N⋅m (33 ft-lb).
86
FLYWHEEL
Removal
1. To gain access to the flywheel remove the engine.
2. Prior to removing flywheel use a dial indicator to
measure flywheel run-out. The maximum Total
Indicator Reading should be 0.127 mm
(0.005 in.) If not to specification check crankshaft
to flywheel seating.
TA6010053
87
3. Support flywheel, remove retaining bolts and
separate flywheel from crankshaft.
88
10-47
1. Inspect the flywheel ring gear, and if damaged
renew in the following manner,
2. Cut old ring gear free from the flywheel.
3. Clean the mating surfaces of the new ring gear,
and flywheel.
4. Use temperature indicating crayons to mark the
side face of the ring gear in six equal places, mark
with a 204°C (400°F) crayon at a point 13
mm (0.5 in.) below the root of the teeth, and mark
with a 212°C ( 450°F) crayon at a point just below
root of the teeth.
5. Use an oxy-acetylene torch with a tip size of No.
2 maximum, and direct the flame against the 89
internal face of the gear.
6. Quickly place the hot gear on the flywheel, with
flat face against the shoulder on the flywheel. The
gear to flywheel runout should be checked using
a dial indicator and should not exceed a Total
Indicator Reading of 0.63 mm (0.025 in.).
Installation
1. Clean the crankshaft rear flange and mating
surface of the flywheel. Install the flywheel,
torquing the bolts to, 197 N⋅m (145 ft-lb).
10-48
REAR COVER PLATE

Removal 1
1. To gain access to the engine oil pump, camshaft 11 9
gear, or end of crankshaft remove the oil pan and 2 5
flywheel as previously described.
3
2. Remove the 12 attaching bolts, and gently pry off
cover plate, 1. 4
3. Clean off all sealer, remove crankshaft oil seal, 6 1
and check for damage or distortion around the 8
sealing faces. 10 12
P396--E--54 TI
90
Installation
1
1. Install new gasket and rear plate, tightening the
retaining bolts, 2, and, 3, finger tight, Figure 90.
2. Apply a liberal coating of new engine oil on a new
oil seal. and position the rear seal over the end of
the crankshaft. Locate tool No. 297252 (NA-
FNH01301), 1, Figure 91, on the end of the
crankshaft using the three attaching bolts. Tighten
evenly, and squarely, until the seal is fully seated.
As an alternative the rear crankshaft oil seal can be
installed using the following installation tool.
TA6010054
91
3. Apply a liberal coating of clean engine oil to the
rear seal retainer, seal, and journal. A new seal 1
should be mounted on the crankshaft, then bolt
tool 297194, 1, Figure 92, to the crankshaft end
and install the new seal squarely.
4. Secure center stock of tool to crankshaft flange
with two screws. Assemble cylinder end plate to
center stock and secure with nut and washer as
in, Figure 92. Tighten the nut until outer diameter
of tool abuts retainer. Tool must not be over
tightened as stress and distortion could be
imposed on the retainer.
TA6010055
92
10-49
5. Remove the tool after assembly.
NOTE: The first seal replacement should be pushed
into retainer with plain end of tool and subsequent
seals with stepped end of tool which will re-position
seal 1.52 mm (0.060 in.) further in.
TA6010056
93
6. Place a straight edge along the rear of the engine
block above the seal carrier. Ensure the edge of
the carrier is aligned to the block to within 0.15
mm, protruding or 0.22 mm recessed. If not within
this specification orientate the carrier around the
slotted bolts, 2, and, 3, Figure 90. Hand tighten +0.15
this bolt followed by the remaining bolts and --0.22
ensure the carrier is still correctly aligned. Fully
tighten the twelve bolts, in sequence to 11 - 14
N⋅m (8 - 10 ft-lb) and then 16 - 23 N⋅m (12 -
17 ft-lb), Figure 90.
94
7. Place a dial indicator, on the end of the crankshaft
and ensure seal runout is within 0.51 mm
(0.020 in.) Total Indicator Reading.
8. Refit the oil pan.
TA6010056
95
10-50
OIL PUMP
Removal
NOTE: The oil pump can only be removed with the
engine split from the transmission and the flywheel,
back plate, engine oil pan, and oil pump tube
removed.
1. Prior to pump removal check pump gear to
camshaft gear backlash does not exceed, 0.40 -
0.56 mm (0.016 - 0.022 in.).
TA6010057
96
2. Loosen and remove the camshaft gear, to expose
the oil pump, detach the 3 pump mounting bolts,
and withdraw the pump from the block.
TA6010058
97
Disassembly
1. Loosen and remove the pump face plate to body
bolts, 4, off. Disassemble the pump and discard 4
the O rings.
TA6010059
98
10-51
1. Wash all parts in a suitable solvent and inspect
inside of pump plate, and body, for excessive
wear or damage. If visually okay check in the
following manner.
2. Invert pump plate/rotor assembly, and place outer
rotor over inner rotor. Placing a ruler across top of
both, slide a feeler gauge, between ruler and
inner rotor and measure clearance which must be
0.025 - 0.089 mm (0.001 - 0.0035 in.), Figure 99.
TA6010060
99
3. Place outer rotor in pump body and check
clearance, by inserting a feeler gauge between
the rotor and body. Check clearance does not
exceed a maximum of 0.55 mm (0.022 in.). If
exceeded a new pump is required.
NOTE: If not to specification replace the oil pump, as
reduced pump pressure through wear could result in
reduced engine life.
TA6010061
100
Installation 1
1. Clean and coat parts in new engine oil. Place

outer rotor in pump body, and ensure free
rotation. Insert inner rotor, and pump plate
assembly, into the body and ensure that shaft is
fully seated into bushing.
2. Assemble the front plate to the body
and torque the retaining bolts to, 23.0 - 28.4 N⋅m
(17 - 21 ft-lb). 2
NOTE: After tightening ensure the drive gear rotates
freely by hand, at least 5 revolutions, if not TA6010059
disassemble and repeat the exercise. 101
10-52
3. Fit a new O ring, 1, Figure 101, to the output tube,
lubricate and insert the pump into the block
tightening the bolts to 23.0 - 28.4 N⋅m (17 - 21
ft-lb).
4. Fit a new O ring, 2, Figure 101, into the suction
port. Lubricate and insert tube/screen assembly,
2, into pump, 1, through bottom of engine. Fitting
a new gasket, 4, and torque the attaching bolts,
3, Figure 103, to 27 - 34 N⋅m (20 - 25 ft-lb).
TA6010058
102
NOTE: Plug, 5, Figure 103, is factory installed to
facilitate machining, and should not be removed
during the life of the engine. 1
5. Refit gears as previously described along with
the rear plate, and flywheel.
5
2
4
3
TA6010062
103
OIL PRESSURE RELIEF VALVE
Removal
1. Remove plug, 3, spring, 2, and valve, 1, To ensure
correct operation of the pressure relief valve, 3
check spring length:
• Free length = 52.8 mm (2.08 in.).
• Compressed length = 37.0 mm (1.46 in.)
using a weight of 15.6 kgs (34.3 lbs.).
2. Clean assembly in a suitable solvent and ensure
all ports are free of dirt. 3
3. Check the parts for damage, wear, and replace as
necessary. Failure to do so could result in
premature wear to the engine, due to oil 1
bypassing the filter and returning back to the
system. 396--E--18 2 TI
Installation 104
1. Lubricate the pressure relief valve, 1, and spring,
2, and insert into housing, ensuring free
movement. Fit a new O ring to plug, 3, and torque
to 55 N⋅m (42 ft-lb).
10-53
CAMSHAFT
1
Removal
NOTE: The camshaft bearings and tappets can only

be serviced with engine removed from the vehicle.
1. Remove the engine front cover, and cylinder
head.
2. Check the camshaft end play, see timing gears
section, and remove gear, install a new thrust
plate prior to re-assembly if required.
3. After removal of the flywheel, and rear cover, TA6010057
remove the camshaft oil pump drive gear, 1. 105
4. Invert the engine on the stand, if camshaft
bearings are to be replaced, and remove the oil
pan.
5. Carefully withdraw the camshaft from the front of
engine.
396--E--16 TI
106
6. Lift out the tappets and place in a numbered rack
for reassembly.
1. Inspect the camshaft journals, lobes, for damage,
pitting, or heat discoloration. If any of these
conditions exist install a new camshaft.
2. Inspect the oil pump drive gear on camshaft for
broken or worn teeth, and mating gear on oil
pump. If any wear or damage is apparent fit new
gears.
3. Check each tappet for wear or damage and check
diameters, if not to specification renew, 25.113 -
396--E--23 TI
25.131 mm (0.99887 - 0.9894 in.).
107
4. Measure the diameter and out-of-round condition
of bearing journals, if exceeded fit a new
camshaft, 60.642 - 60.668 mm (2.3875 -
2.3885 in.).
10-54
CAMSHAFT BEARINGS
1. Inspect the camshaft bearings for wear or
damage. Measure the clearance between the
internal diameter of bearing and outside diameter
of respective journal, 0.074 - 0.178 mm (0.003 -
0.007 in.).
2. If specification is exceeded install new bearings
using, Remover/Replacer Tool No. 297117
(NA-FNH01255) and handle, Tool No. 291896
(NA-FNH01442).
3. To remove, position tool against bearing to be
removed and attach handle, driving bearing from
bore. TA6010071
4. To install, align oil holes of new bearing with holes 108
in block, and drive bearing into bore using tools as
described.
NOTE: A positive alignment check can only be made
with crankshaft removed when a 4.6 mm (0.018 in.)
rod can be passed down the oil passage from the
crankshaft main bearing. Bearing is correctly
positioned when end of rod passes through oil hole in
the bearing.
Installation
1. Apply petroleum jelly to each tappet foot, and coat
tappet body with oil. Install tappets in bores from
which they were removed.
396--E--23 TI
109
2. Oil camshaft journals and apply petroleum jelly to
the cam lobes.
3. Install camshaft through front of engine.
396--E--16 TI
110
10-55
4. Align the camshaft gear timing mark. Recheck
end play.
..
..
P396--E--36 TI
111
5. Install camshaft pump drive gear, 1, at rear of
engine. Tighten bolt, 2, to torque of 57 - 77 N⋅m
(43 - 58 ft-lb).
112
10-56
PISTONS
Removal
NOTE: The pistons, crankshaft and cylinder block

can only be serviced with the engine removed from
the vehicle.
1. Remove the oil pan.
2. With cylinder head removed clean off any ridge
from the top of the cylinder bores, with a ridge
remover to enable removal of the pistons, this is
essential if old pistons are to be re-used as failure
to do so could result in ring land damage. 113
3. With the piston at the bottom of the stroke remove
the end cap bolts, cap, and liner.
TA6010033
114
4. Using the handle end of a hammer push the
piston assembly out through the top of the block,
and remove the bearing liner from the connecting
rod, Figure 114.
NOTE: Bearing caps and liners must be kept with
their respective connecting rods.
5. Turn the crankshaft again and repeat the process
for the remaining pistons.
115
10-57
1. Remove piston pin snap rings from each side of
piston and remove pin. Using an expander, Tool
No. 296028, remove the piston rings.
2. Ensure each piston and rod assembly, remains
matched together for re-assembly into the
cylinder block.
TA6010034
116
117
Piston Assembly
1. Con Rod 7. Piston Ring (Oil Control)

2. Piston 8. Bolt
3. Piston Pin 9. Bearing Cap
4. Retainer 10. Bearing Liner
5. Piston Ring (Compression) 11. Bearing Liner
6. Piston Ring (Compression) 12. Bush
10-58
3. Clean the piston, and connecting rod assembly,
in a suitable solvent and inspect for damage to
ring lands, skirts, or pin bosses.
4. Check connecting rod components for damage,
and place in an alignment fixture to check for
distortion, and ensure that any distortion, is within
specification as follows.
Maximum Twist 0.30 mm (0.012 in.).
Maximum Bend 0.10 mm (0.004 in.).
5. Check piston pin bushing for damage or wear in
the following manner.
Measure the outside diameter of the piston pin, and
inside diameter of the connecting rod bushing, to the
following:
Piston Pin Outside Diameter:
44.442 - 44.447 mm (1.7497 - 17499 in.).
Connecting Rod Bush Internal Diameter:
44.460 - 44.467 mm (1.750 - 1.751 in.)
CONNECTING ROD BUSH REPLACEMENT

1. If connecting rod bushes are not to specification
replace the old bush using the following
procedure.
2. Place the connecting rod securely in a bench
press. Manufacture from suitable bar stock, a
press tool with the end face ground at an angle,
to suit the connecting rod bush side face. Position
the tool on the bush, and gently drive the bush
from its position. It is recommended a guide is
manufactured to assist alignment of the bar stock
during this operation.
3. A new bush can then be fitted in a similar manner,
by using a suitable piece of bar stock, with an end
face machined flat to suit the standard parallel
bush. Use a guide as described, and gently drive
in the new bush into the connecting rod.
NOTE: Ensure the split in the small end bush is at
right angles to center line of connecting rod.
6010035
118
10-59
4. After installation grind the side faces of the new
bush to match the side faces of the connecting
rod. Ensure all sharp edges are removed, and
loose chippings are cleaned from the connecting
rod before re-assembly into the engine.
5. With a new bush fitted drill a hole through the top
of the connecting rod using a 4.6 mm (0.187 in.)
bit. Drill through the existing oil hole, Figure 119.
TA6010036
119
6. Use an expanding reamer to obtain correct
bushing to piston pin clearance referring to
specification section. Remove burrs, and
chippings, before refitting.
7. On re-assembly of piston lubricate all of the
components with engine oil. Assemble the
connecting rod, and piston, with the letter or
grade mark on the piston, aligned to the pip, 1,
Figure 120, on the connecting rod. Install the
piston pin and retainers.
TA6010045
120
10-60
CYLINDER BLOCK OVERHAUL
T A6010038
3 2 1
121
Cylinder Block Core Plug and Sensor Ports, Front and Left Hand Side
3 1
4 5
T A6010039
2
122
Cylinder Block Core Plug and Sensor Ports, Rear and Right Hand Side
1. Cylinder block plugs, and senders, require Plug, 4, drive in to block. Use sealant G.
changing if leaking or rusty, and must be
replaced. Clean the old sealant off the block, and Figure 122, refers to the rear and right hand side of
fit new plugs with sealer. the block.
Figure 121, refers to the front and left hand side of the Pipe plug, 1, torque to 8 - 14 N⋅m (6 - 10 ft-lb).
cylinder block. Use sealant, E.
NOTE: New part mating faces, and threads, should Pipe plug, 2, torque to 24 - 34 N⋅m (18 - 25 ft-lb).
be coated in sealant, refer to ‘‘Specifications”. Use sealant, E.
Assemble in the following manner.
Plug, 3, drive into block.
Plug, 1, torque to 8 - 14 N⋅m (6 - 10 ft-lb)
Use sealant, G.
Use sealant, E.
Plug, 2, torque 27 - 47 N⋅m (20 - 35 ft-lb) Plug, 4, torque to 54 - 81 N⋅m (40 - 60 ft-lb), Use
Use sealant, E. sealant, E.
Pipe Plug, 3, torque to 24 - 34 N⋅m (18 - 25 ft-lb) Oil Jets, 5, replace with new if damaged, apply engine
Use sealant, E. oil only on reassembly ‘‘Do not use sealant”.
10-61
CYLINDER BORE
1. Check the cylinder bore for scuffing or rings
around the ring travel area. Irregularities can be
felt by running a finger over the surface. To check
out-of-roundness, wear, or taper, use a telescopic
gauge, Figure 123.
Measure lengthwise, A, to B, and C, to D, and
compare dimensions. Variances between the
readings will indicate ‘‘taper”.
Measure crosswise, C, to D, and compare
dimensions lengthwise. A, to B. Variances will
indicate an out-of-round condition.
TA6010040
123
Specifications
C
NOTE: Repair Limit’ refers to the tolerance allowed
after a repair has been performed, i.e. the repair must A
be within the repair limit. The ‘Wear Limit’ is the toler-
ance prior to repair.
Taper of cylinder bore:
repair limit - 0.025 mm (0.001 in.)
wear limit - 0.127 mm (0.005 in.)
Cylinder bore out of round:
repair limit - 0.03 mm (0.0015 in.) B
wear limit - 0.127 mm (0.005 in.)
Cylinder bore diameter:
111.778 - 111.803 mm (4.4007 - 4.4017 in.). TA6010041 D
1. Where only minor imperfections exist and bores 124
are to specification, hone the bores prior to
installing new piston rings. Provided piston to
bore clearance, does not exceed 0.250 mm
(0.011 in.).
2. Sleeving of the cylinder bores becomes
expedient when:
Minor imperfections to the bores are outside of
the specification.
Oil consumption is high.
Replacing sleeves, installed in service.
Cylinder bore is damaged beyond re-boring
limits.
NOTE: Oversize pistons are available in specific
markets only. In markets where these are available
the bore should be bored or honed to fit the next
oversize piston.
Oversize pistons available:
0.020in (0.51 mm)
0.040in (1.00 mm)
10-62
SLEEVING - BORING AND HONING 0.005

0.06
45°
0.040
3. Measure the outside diameter, 1, of the sleeve in
several places, and average the dimension.
Counter bore the cylinder block (see step 2) using
the average dimension to obtain a press fit, 8.31
between bore and sleeve. Interference of sleeve

to the cylinder bore to be 0.025 - 0.076 mm (0.001 8.46 8.06
- 0.003 in.).
4. Counter bore to a depth of 204.7 mm (8.06 in.), 0.38
from the block face, surface finish of the bore is 0.40
not to exceed (80 microns). Leave a step at the

bottom of the bore a minimum of 9.60 - 10.16 mm
4.454/4.456
(0.38 - 0.400 in.), allowing for run out of chamfers. TA6010042

1
5. Bore through diameter, to the diameter of, 114.3 125
- 116.0 mm (4.454 - 4.456 in.).
6. Clean the cylinder bores and thoroughly dry.
7. Grease the sleeve with a general purpose grease
and press the sleeve home to the lip in the bore.
The top of the sleeve should protrude through the
top of the block, 0.127 - 1.0 mm (0.005 -
0.040 in.).
8. Bore the sleeve to, 110.00 - 111.76 mm (4.3985
- 4.400 in.).
9. Skim the block face, and top of sleeves, to
achieve the specified flatness of 0.08 mm
(0.003 in.) in any 152 mm (6 in.) 0.03 mm
(0.001 in.) in any 25.4 mm (1 in.). A chamfer in
the internal diameter at the top of the sleeve to 45°
x 0.5 mm (0.020 in.) should be maintained, to
prevent piston damage on re-assembly.
10. Break the sharp edge at the bottom of the sleeve
prior to honing.
11. Hone the cylinder bore to, Grade B, 111.790 -
111.803 mm (4.4012 - 4.4017 in.).
NOTE: Surface finish to be an average of 20 to 30 Mi-
crons, cross hatched at 35° - 55°.
Maximum Taper:
0.025 mm (0.001 in.) through to bottom of the bore.
Maximum Quality:
0.038 mm (0.0015 in.)
10-63
Reassembly
NOTE: Pistons that are replaced must be of the same
type that were removed and have the same identifica-
tion letters, and numbers, as embossed on the piston
crown
1. Upon reassembly with the piston at top dead
center, ensure the piston to block height is correct
using a dial indicator to, Figure 126:
0.13 - 0.38 mm (0.005 - 0.015 in.)
TA6010043
126
2. Check the piston to bore clearance in the
following manner.
A: Measure the cylinder bore diameter at point A,
82.6 mm (3.25 in.) from the top of the block. A
B: Measure the diameter of the piston at point B,
25.4 mm (1.00in.) from the bottom of the piston.
C: Subtract piston diameter from the bore
diameter and the resultant figure for a new,
unused engine should be:
B
0.152 - 0.178 mm (0.0060 - 0.0070 in.)
TA6010044
127
After an engine has run and settled down the
maximum bore to piston clearance allowed is
0.250 mm. (0.011 in.).
Where pistons are only available as standard.
New pistons should always be fitted if the
clearance exceeds specification.
D: If clearance is ‘‘greater” try a similar new
piston, if limit is still exceeded it will be necessary
to rebore and resleeve.
E: If the clearance is ‘‘less” hone bore to obtain
desired clearance.
3. Lubricate all of the components with engine oil
TA6010045
and assemble the connecting rod, and piston,
with the letter or grade mark on the piston, aligned
to the pip (1) on the connecting rod. Install the
piston pin and retainers. 128
10-64
4. Check the piston ring gap width, using a feeler
gauge, in a vertical position at the top, middle, and
bottom of the bore, Figure 129.
Ring Gap Specifications (new rings and bore):
Top compression ring -

0.29 - 0.53 mm (0.012 - 0.021in.)
2nd compression ring -

0.49 - 0.63 mm (0.020 - 0.029 in.)
Oil control ring -

0.29 - 0.58 mm (0.012 - 0.023in.) TA6010046
129
5. Using a new piston ring, check with a feeler
gauge, the gap between the ring and groove.
Engines with mechanically controlled fuel
injection pump:
2nd compression ring -
0.06 - 0.105 mm (0.0023 - 0.0041 in.)
Oil control ring -
0.030 - 0.070 mm (0.0011 - 0.0028in.)
Engines with electronically controlled fuel
injection pump:
Oil control ring -
0.051 - 0.101 mm (0.0020 - 0.0040in.) 6010048
6. Install the piston rings, but note the following: 130
7. Always ensure the correct expander, Tool No.
296028, is used to remove or install rings,
Figure 130.
6010047
131
10-65
8. Install top and second compression rings with the
word top towards the top of the piston. Ensure the
ring gaps are staggered a minimum of 120° from
each other on the diameter, and with no gap on
the thrust side of the piston.
A Engines with Electronically Controlled
Injection Pump
B Engines with Mechanically Controlled
Injection Pump
NOTE: Before installing new pistons and rings into a
used cylinder bore, remove the high polish from the
cylinder walls by honing as previously described.
132
INSTALLING PISTON ASSEMBLY INTO
BLOCK
1. Select the correct bearing liners as in the
following crankshaft section, and install in the rod
and cap, ensure the liner tang locates in the slots
of the rod and cap.
2. Turn the crankshaft to position No. 1 crankpin at
the bottom of the stroke, and lubricate all parts
with new engine oil.
3. Locate piston into bore ensuring the dot on the
connecting rod and arrow or grade letter on the
pistons face towards the front of the engine.
133
4. Using ring compressor, Tool No. 296042, and a
soft drive, slide pistons into bores.
6010050
134
10-66
5. Ensure the connecting rod bearing liner, seats on
the crankpin with the bearing cap fitted, to the
connecting rod as a matched assembly. Fit new
bolts lubricated with oil, and tighten to a torque
value of 149 N⋅m (15 Kgf m, 110 ft-lb).
6. Using feeler gauges, check the side clearance of
each connecting rod to crankshaft, Figure 135,
0.13 - 0.33 mm (0.005 - 0.013 in.) and continue
for remaining assemblies.
7. Refit the oil pump tube/screen,and oil pan as
previously described, refill engine oil and coolant,
and run the engine checking for leaks.
TA6010051
135
CRANKSHAFT
Removal
1. Remove the engine, flywheel and oil pan as
previously described.
2. Remove the connecting rod caps, main bearing
caps and liners, and identify to facilitate
re-assembly.
396--E--13 TI
136
3. Carefully remove crankshaft from cylinder block.
6010065
137
10-67
NOTE: Current production engines may have a

crankshaft with main or crankpin journals ground 0.25
mm (0.010 in.) undersize. These are identified with
the letters 010 MUS and/or 010 PUS respectively,
letters being stamped on one of the crankshaft
counter balance weights.
1. Thoroughly clean bearings, journals, and caps,
and inspect for wear, scores, or damage replace
as required.
NOTE: It is recommended that all the main bearings
should be replaced if it is found necessary to replace
any one set of main bearings. 138
2. If crankshaft timing gear teeth are worn or
damaged it will be necessary to replace the
complete crankshaft assembly.
139
3. Wash the crankshaft and drilled passages in a
suitable solvent. Dress minor imperfections using
an oil stone but for severely marked journals
machine to the next undersize bearing size.
4. Measure diameter of each journal, Figure 140, in
four places to determine out-of-round, taper, or
wear. B
Measuring, A, compared with B, indicates vertical A D
taper. C
Measuring, C, compared with D, indicates
horizontal taper.
Measuring, A and B, compared with C and D,
indicates journal out-of-round. TA6010067
5. If the journal exceeds specified limits refer to 140
‘‘Specifications” and refinish journal to the next
undersize bearing.
6. Examine the rear oil seal journal for score marks,
remove minor imperfections with fine emery
cloth, and if severely damaged renew the
crankshaft.
10-68
Reassembly
1. Check the crankshaft bearing clearance using a
plastigauge as follows.
2. Position a piece of correct size plastigauge
across the full width of the bearing cap,
approximately 6.35 mm (0.25 in.) off center,
Figure 141.
TA6010068
141
3. Install the cap and tighten bolts to 149 N⋅m
(110 ft-lb).
4. Remove the cap and use the scale to check the
width of the flattened plastigauge, Figure 141.
5. Widest point, of gauge establishes the minimum
clearance.
6. Narrowest point, of gauge establishes maximum
clearance. The difference between the two
readings is the taper.
NOTE: Normally main bearing journals wear evenly
and will not be out-of-round, but if a bearing which is
to specification is fitted to an out-of-round journal, 6010069
ensure liner suits maximum diameter of journal. 142
7. If the combinations of bearings do not produce
specified clearance, refinish crankshaft and fit
appropriate size service bearings.
IMPORTANT: Engines may be assembled with
bearings of different material, but bearings of the
same material must be used on the same journal.
8. Ensure bearing liners are clean and align with the
oil galleries and integral oil jets. The tang on the
bearing must align with the slots in the block and
cap.
396--E--26 TI
143
10-69
9. Coat liners with oil and install crankshaft.
6010065
144
10. Install a thrust bearing cap with flange type
bearing first, installing remaining bearing caps to
their original location and tightening finger tight.
396--E--9 TI
145
11. Tighten the main bearing caps in two stages:
Stage 1 - Tighten all bolts to a torque of 81 N⋅m 81

(60 ft-lb). 60
146
10-70
Stage 2 - using a torque angle gauge tighten all
bolts a further 90° in a single stroke.
12. Check crankshaft end play with a dial indicator
gauge, pry crankshaft towards front of engine and
set dial indicator to zero. Pry crankshaft towards
rear of engine and note reading on dial if end play
exceeds 0.10 - 0.20 mm (0.004 - 0.008 in.) fit a
new thrust bearing.
147
13. If the end play is less than specification check
thrust bearing for burrs, scratches, or dirt, and
re-align thrust bearing as in step 12.
14. Install rear crankshaft oil seal as previously
described in rear cover plate removal.
NOTE: Do not pre-install seal into retainer. To ensure
seal concentricity, it must be assembled with rear
plate and installation tool when fitted to crankshaft.
TA6010070
148
15. Install the camshaft idler gear ensuring the timing
marks are correctly alligned.
..
..
P396--E--36 TI
149
10-71
FRONT CRANKSHAFT CASSETTE OIL

SEAL REPLACEMENT
Removal
1. Remove crankshaft pulley using Tool No. 297102
or 297262 (prior numbers 518 and 938) or
suitable equivalent (NA-FNH09539).
TA6010027
150
2. Remove drive key, 1.
151
3. Remove the shield, 1, from the front of the seal to
expose the lip of the seal outer casing.
152
10-72
Seal, 1, separated from shield, 2.
153
4. Use Seal extractor Tool No. 297670
(NA-CNH297670) to extract the seal from the
engine front cover.
154
5. Position the extractor over the end of the
crankshaft and withdraw the seal.
NOTE: Protect the end of the crankshaft using a
suitable step plate to prevent any damage when
turning the extracting bolt.
155
10-73
6. After extracting the seal, 2, withdraw wear sleeve,
1, and O ring, 3.
NOTE: The wear sleeve is a tight fit on the seal and
may be removed when extracting the seal. If this
occurs separate and retain the sleeve for use during
installation of the new seal.
156
Installation
IMPORTANT: DO NOT apply any lubricant to the
seal, shield or wear sleeve during or after installation.
1. Clean all parts and install the O ring, 1.
157
2. Carefully remove shield from the replacement
seal.
NOTE: It is important that shield is removed as this
will affect the correct positioning of the seal in the
engine front cover during the installation process.
158
10-74
Seal, 1, separated from shield, 2.
159
3. Using fingers push the inner section of seal
forward.
160
4. Position seal on installation Tool No. 297637/1
(NA-CNH297637)
NOTE: The installation tool must be used to install
the seal. Failure to use the tool will result in incorrect
positioning of the seal and consequential leakage
after a few hours of operation.
161
10-75
5. Locate tool onto end of crankshaft.
162
6. Tighten bolt to press seal into end cover.
IMPORTANT: Only tighten the bolt sufficiently to
ensure face of tool touches face of end cover.
163
7. Install shield, 1, onto the seal.
164
10-76
8. Clean and refit the wear sleeve, 1, over
crankshaft and into the seal. Use the seal installer
to push the wear sleeve into the center of the seal.
NOTE: Only fit a new sleeve if the outer surface is

worn or damaged.
165
9. Install drive key, 1.
166
10. Install front crankshaft pulley using T bar Tool No.
297262 (prior number 938) (NA-FNH09506) or
suitable equivalent.
11. Check and top up engine with oil as specified in
the Operator’s manual.
167
10-77
ENGINE COMPRESSION TEST 2. A reading of more than the 1.7 bar (25 PSI) below
Test Procedure the other cylinders indicates leakage at the
cylinder head gasket, piston rings or valves.
1. Be sure battery performance meets specifica-
3. A reading of more than 1.7 bar (25 PSI) above the
tions.
other cylinders indicates excessive carbon
2. Warm up the engine by operating for a minimum deposits on the piston and cylinder head.
of half an hour at 1200 rev/min.
4. A low even compression in two adjacent cylinders
3. Stop the engine and remove the injector and seat indicates a cylinder head gasket leak. Check this
washer from no1 cylinder. item before condemning the rings or valves.
4. Clean the injector bore and crank the engine to
blow out any loose carbon particles.
Test Conclusion
5. Install an engine compression test gauge, From
kit No. 291309 (NA-FNH02020) with fault injector To determine whether the rings or the valves are at
295039 (NA-FNH00882), into the injector bore, fault, squirt the equivalent of a tablespoon of heavy oil
using a new seat washer and the injector into the combustion chamber. Crank the engine to
mounting bolts. distribute the oil and repeat the compression test.
6. Connect the gauge and hose to the adapter. The oil will temporarily seal any leakage past the
7. Crank the engine at 200 rev/min with the electric rings. If approximately the same reading is obtained,
fuel shut off wire disconnected to prevent engine the rings are satisfactory, but the valves are leaking.
start up.
If compression has increased over the original
8. Observe the gauge reading, and repeat the reading, there is leakage past the rings.
compression test, steps 5 - 7 for each cylinder.
During a compression test, if the pressure fails to
climb steadily and remains the same during the first
Test Readings
two successive strokes, but climbs higher on the
1. All cylinder compressions should be uniformly succeeding strokes, or fails to climb during the entire
within 1.7 bar (25 PSI) of each other. test, suspect a sticking valve.
10-78
SECTION 10 - ENGINE
Chapter 2 - 7.5L Cooling
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fan Belt Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Idler Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
10-1

7.5 Liter Engine
The function of the water pump mounted at the front
of the engine is to maintain a continuous flow of water
around the cooling system. This is essential to ensure
correct engine temperature and performance during
vehicle operation.
The water pump, is driven by a Poly V-belt, from the

crankshaft pulley when the engine is running. The
drive belt tension is maintained by a spring-loaded
belt tensioner bolted to the front cover.
1
The thermostats are located in the top of the housing
above the water pump body and control the flow of the
water as required by temperature changes.
NOTE: A faulty thermostat may cause the engine to

operate at a too hot or too cold operating tempera-
ture. If not replaced, this could result in damage to the
engine or impaired engine performance.
IMPORTANT: Do not operate an engine without a

thermostat.
10-2
The cooling system is of the recirculating bypass type
with full-length water jackets for each cylinder. The
coolant is drawn from the bottom of the radiator by the
water pump which passes the coolant to the cylinder
block. The coolant then flows through cored pas-
sages to cool the cylinder walls.
NOTE: These engines are also fitted with an oil cooler

in the circuit. Coolant from the radiator passes
through the oil cooler before entering the cylinder
block.
3
Passages in the cylinder head gasket allow coolant to
flow from the cylinder block into the cylinder head.
Cored passages also direct the coolant to the fuel in-
jector nozzle locations before entering the thermostat
housing. Dependent upon water temperature, water
either re-enters the water pump or is circulated
through the radiator for cooling.
When the thermostat is closed, a recirculating bypass

allows the coolant to recirculate from the head to the
block, to effect faster warm-up.
4
Once the engine has reached its normal operating
temperature, the thermostat will open and allow water
to be drawn through the radiator by the pump action.
Cooled water then returns to the engine system.
Cooling occurs as the coolant passes down through

the radiator cores which are exposed to the air cooling
system. Air is pulled through a rotary screen and the
radiator by means of a powerful engine-mounted fan. 1
Air is also pulled through the ducting, 1, mounted un-
der the radiator and up the front of the rotary screen
to lift large chaff particles off the surface of the rotary
5001459
screen. A brush, mounted inside the rotary screen, 9
dislodges the particles to prevent plugging of the
rotary screen. 5
10-3
TROUBLESHOOTING
IMPORTANT: Whenever effecting a repair, the cause of the problem must be identified and corrected to avoid
repeat failures. The following table lists problems and their possible causes with recommended remedial action.
PROBLEM POSSIBLE CAUSES CORRECTION

Engine overheats Hose connection leaking or Tighten hose connection
collapsed Replace hose if damaged
Radiator cap defective or Replace radiator cap
not sealing
Radiator leakage Repair/replace radiator

Improper fan belt adjustment Check tensioner
Check belt
Radiator fins restricted Clean with compressed air

Faulty thermostat Replace thermostat
Internal engine leakage Check for source of leakage,
replace gasket or defective parts
Water pump faulty Overhaul water pump
Exhaust gas leakage into Replace cylinder head gasket,
cooling system check head for damage or
distortion
Coolant aeration Tighten all connections and
check coolant level is correct.
Ensure cylinder head gasket is
not blown
Cylinder head gasket Replace cylinder head gasket
improperly installed
Hot spot due to rust and Reverse flush the entire

scale or clogged water jackets cooling system
Obstruction to radiator Remove the obstruction
air flow
Extended engine idling Do not allow the engine to
idle for too long a period
Oil cooler tube blocked Clean
Radiator core tubes blocked Check free flow
Water temperature gauge Faulty temperature sender Replace sender switch
fails to reach normal
operating temperature Incorrect or faulty thermostat Replace thermostat
Faulty water temperature gauge Replace temperature gauge
10-4
SPECIFICATIONS
Tightening Torques
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . N⋅m . . . . . . . . Ft-lb
Thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . 18 ........... 24

Temperature senders . . . . . . . . . . . . . . . . . . . . . . 15 ........... 20
Tensioner pulley bolt . . . . . . . . . . . . . . . . . . . . . . . 40 ........... 54
Tensioner front cover . . . . . . . . . . . . . . . . . . . . . . . 40 ........... 54
Idler pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ........... 54
Pump connector to block . . . . . . . . . . . . . . . . . . . 18 ........... 24
Water pump to block . . . . . . . . . . . . . . . . . . . . . . . 48 ........... 65
Fan blade to support body . . . . . . . . . . . . . . . . . . 17 ........... 23
Fan blade to clutch support body . . . . . . . . . . . . 78 ........... 105
Thermostat
Opening temperature . . . . . . . . . . . . . . . . . . . . . . 79° C - 83° C (174° F - 181° F)
Fully open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93° C - 96° C (199° F - 205° F)
Water Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal . . . . . . V-belt drive
Drive Belt
Belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintained by tensioner
Cooling Capacities
See Operator’s Manual.
Coolant Flow
Coolant flow at rated engine speed . . . . . . . . . . . 340.6 L/min (90 US gpm)
Cooling Fluid
See Operator’s Manual.
10-5
OVERHAUL
THERMOSTAT
Removal
1. Drain the coolant system below that of the level
of the thermostat housing.
2. Remove the thermostat housing and withdraw
the two thermostats.
6
Place both thermostats in a container of water and
raise the temperature to 100° C (212° F). If either ther-
mostat fails to open when hot, or close properly when
cooled, it must be replaced.
RI--1--107
7
Installation
Installation of the thermostats is the reverse of the re-
moval procedure, but observe the following:
1. Coat the new gasket with sealer 82995774
(NA-L51831DS) and position on the thermostat
housing, prior to installing the thermostat.
2. Coat the edge of the thermostat with grease and
install, with the heat element located in the cylin-
der head.
3. Refit the thermostat housing and torque the bolts
to 20 - 28 N⋅m (15 - 21 ft-lb).
10-6
8
1
7
4 3
TA6010093B
8
Fan Belt Tensioner
1. Water Pump Pulley 5. 1/2″ Square Drive Hole

2. Air Conditioning Compressor 6. Tensioner Attaching Bolt
3. Crankshaft Pulley 7. Alternator
4. Tensioner Pulley 8. Idler Pulley
FAN BELT TENSIONER attaching bolt. Raise the lever up through an arc
of 20° maximum. If the torque bar does not
Removal
‘‘break” within the range a new tensioner assem-
1. The fan belt should be removed in the following bly is required.
manner. Attach a 1/2″ square drive ratchet into
2. Ensure the tensioner pulley, rotates freely by
the tensioner arm, 5, Figure 8. Rotate clockwise
hand. If not replace with new parts.
and remove the fan belt from the pulley and allow
the tensioner to return to its untensioned position
Reassembly
once the belt has been removed.
1. Fit a new pulley to the assembly if required, and
2. Remove the tensioner from the pump by loosen-
torque the attaching bolt to, 46.5 - 60 N⋅m (34.5
ing and removing the centre attaching bolt.
- 44 ft-lb)
2. To reassemble the arm assembly, position the
Inspection and Repair tensioner on to the front cover, fit the mounting
1. Checking of the tensioner assembly operation bolt through the assembly, and torque the bolt to,
should be carried out, with the tensioner assem- 46.5 - 60 N⋅m (34.5 - 44 ft-lb).
bly still attached to the front cover. To check the 3. Refitment of the fan belt is the reverse of the re-
spring load, place a ‘‘break back” torque bar pre- moval procedure, but ensure the ‘‘Poly V’’ belt, is
set to, 70 - 85 N⋅m (52 - 63 ft-lb) on to the pulley positioned correctly onto all of the pulleys.
10-7
IDLER PULLEY
1. One idler pulley is fitted to the engine. Located on
the right hand side of the engine, under the water
pump, 1.
2. Check that the idler pulley rotates freely, if tight or
worn, replace with new. Removal and replace-
ment is by the attaching bolt through the center of
the idler pulley. Torque the bolt to 46.5 - 60 N⋅m 1
(34.5 - 44 ft-lb).
TA6010093B
9
WATER PUMP
Removal
To overhaul the water pump components, i.e, bear-
ing, impeller or shaft seal, carry out the following:
1. Drain the cooling system.
2. Remove the bolts securing the fan shroud and
move the shroud to gain access to the engine.
3. Remove the fan belt from the vehicle.
4. Disconnect tube, 1, from rear of cylinder head at
the water pump (flexible coupling).
5. Withdraw the four bolts, 2, which pass through the
water pump and into the block, and slide the com-
plete pump forward and away from the block.
Note the sealing O ring which may come off with
the pump or be left on the block. Also, observe the
transfer tube between the water pump and ther-
mostat housing. Ensure the tube and O rings do
not become dislodged and lost.
10
10-8
Disassembly and Repair
1. Remove the securing bolts from the adaptor
cover on the rear of the pump body. Carefully
ease out the adaptor. Remove and discard the
O ring.
11
2. With the adapter cover removed, pry the back-
plate off.
12
3. Place the pump body between the two supports,
3, and by gently pressing on the shaft, push the
shaft and pulley, 4, away from the impeller, 2, and
out of the pump body, 1.
13
10-9
4. With the impeller/shaft assembly removed from
the pump, place the pulley, 1, on supports, 2, and
press out the shaft assembly, 3, from the pulley.
5. The seal assembly attached to the bearing shaft
is not removable or serviceable. During the
manufacturing process, the seal is pressed onto
the shaft and destroyed on removal. This is to
meet pre-load conditions and maintain an effec-
tive wear seal.
14
1. Check the bearing shaft and seal assembly for
signs of wear or leaks and if evident, the assem-
bly must be replaced with new parts.
2. The impeller should be checked for worn or dam-
aged vanes and must be replaced if not to an ac-
ceptable standard.
3. Clean and check the pump body for signs of
cracks, erosion or leaks. If any of these faults are
in evidence and likely to cause pump failure at a
later date, the pump body must be repaired or re-
placed with a new one.
Assembly
1. To install the bearing, 1, into the pump body, 3,
place the body rear face down onto a flat surface.
Install the bearing with the longer stepped end of
the shaft in the body and using a sleeve, 4, that
contacts the bearing outer race only. Use a press,
5, to press the bearing into the body. Once
installed in the body, the bearing case end face
must be flush with the pump front face to within
(0.00 mm - 0.076 mm (0.000 -- 0.006 in), 6.
NOTE: Use Loctite ® 262, NH Part #82995772

(NA-L26231) around the pulley bore chamfer and
press the pulley onto the shaft. 15
10-10
2. With the water pump, 4, placed front face down
and the shaft, 6, supported with suitable blocks,
5, place the seal assembly, 3, on the end of the
shaft with its smallest diameter uppermost. To in-
sert the seal assembly, place tool, 2, over the seal
and use a press, 1, to press until the lip on the seal
body seats on the pump body.
16
3. With the seal installed correctly, the seal working
height should be maintained at 10.9 -- 11.7 mm
(0.430 -- 0.460 in), 1.
17
4. With the water pump rear, 1, face up, and the
shaft supported, place the impeller, 2, over the
shaft, 3, and press the impeller into the water
pump body. Installed correctly the face of the im-
peller fins to the operating face of the water pump
should be 0.25 -- 0.88 mm (0.010 -- 0.035 in).
5. To achieve this, check the dimension from the
rear face of the impeller to the rear face of the
pump. The dimension should be maintained at
28.07 -- 28.58 mm (1.105 -- 1.125 in), 5.
6. With the pump rear face down and the shaft sup-
ported, press the pulley onto the shaft ensuring
the pulley front face to the rear face of the pump
dimension is 157.10 -- 157.86 mm (6.185 -- 6.215
in). 18
10-11
Water Pump Dimensions

1. Seat and Seal Assembly 4. Pulley
2. Impeller 5. Pulley Shaft Mating Face
3. Bearing
7. Ensure a new O ring is fitted and place the water

pump backplate in position. Make sure the water
pump pulley/impeller assembly rotates freely by
hand prior to reassembly. If not, disassemble and
recheck the dimensions.
19
Installation (All Models)
1. Installation of water pump to the engine is the re-
verse of disassembly.
2. Ensure the drive belt tensioner pulley rotates
freely and the swinging arm of the tensioner re-
turns to rest freely. Gently lever the arm up, to en-
able the drive belt to be seated in the grooves on
the pulleys.
3. After installation , refill the cooling system as pre-
viously described and run the engine checking for
leaks.
10-12
SECTION 10 - ENGINE
Chapter 3 - 7.5L Complete Engine, Remove and Replace
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
10-1
OVERHAUL
ENGINE
Removal
NOTE: The engine and cooling system used in the
CR Combine is designed to be removed as a modular
unit. The following engine removal procedure
demonstrates the removal of the engine only from the
module. This procedure takes into consideration the
possible unavailability of proper, or sufficient lifting
equipment for complete module removal. When
possible, remove the engine and cooling system
module as designed.
1. Remove the gearbox and hydraulic pumps from
the engine. (Refer to “Section 14 - Gearbox
Removal”)
2. Place a suitable container, 1, below the coolant
drain hose, 2.
NOTE: The cooling system has a coolant capacity of 2
31.5 liters (8.3 gal.). Be sure to use clean containers
with adequate capacity when draining the cooling
system.
1
10013105
1
3. Turn the drain petcock, 1, on the radiator, 2,
counter clockwise to open the coolant drain.
Drain all of the coolant into the containers.
2
10013106
10-2
4. Remove the plug, 1. Drain all of the engine oil into
suitable containers.
NOTE: The New Holland engine has an oil capacity
of 23 liters (6.07 gal.). Be sure to use clean containers
with adequate capacity when draining the engine oil.
1
40016218
3
5. Loosen and remove the mounting hardware from
the protection covers, 1. Remove the cover from
the engine compartment.
1
20023154
10-3
6. Disconnect the shock absorber, 1, from the
engine lid, 2.
2
1
10013108
5
7. Remove the two retaining rings, 1, washers, 2,
and hinge pins, 3, from the engine lid. Remove 3
the engine lid from the combine.
2
84050265B 1
6
8. Remove the hardware, 1, from the top and bottom
of the engine lid support bar, 2. Remove the
support bar. 1
20023150
10-4
9. Loosen and remove the two exhaust clamps, 1.
Remove the muffler, 2. 4
2
10. Loosen and remove the support clamp, 3.
11. Loosen and remove hardware, 4, securing 5
exhaust pipe, 5, to the turbocharger. Remove
exhaust pipe, 5, from engine. 1
3
20023153
8
12. Loosen and remove the clamps, 1, from the air
intake tube, 2, and remove the retaining bolt, 3, and
nut, 4, from the support bracket, 5. Remove the
hardware securing the air intake tube to the upper
coolant pipe. Remove the air intake tube from the
radiator housing, 6, and intake manifold, 7. 5
2
1
6
4
3
7
1
84073059
9
13. Loosen the hose clamp, 1, and remove the oil
hose, 2, from the bottom of the crankcase vent
filter, 3.
3
2
10013139
10
10-5
14. Loosen the hose clamps, 1, and remove the
1
hoses, 2, from the oil separator, 3, and ventilation
tube, 4.
3
4
15. Loosen the oil tube fittings, 5, and disconnect the
tubes from the oil filter manifold, 6.
5 6
2
10013110
11
16. Loosen and remove the step mounting hardware,
1, securing the step assembly, 2, to the floor and 1
engine. Remove the step assembly, 2, with the
crankcase vent filter, 3, and oil filter manifold, 4,
attached. 3
2
10013110
1
12
17. Loosen the hose clamps, 1, and remove the top
coolant pipe, 2, from the engine and radiator 1
neck.
1
2
10013111
13
10-6
18. Loosen the hose clamps, 1, and retaining
hardware, 2, from the ventilation tubes, 3. 1
2
3
10013112
14
19. Loosen and remove the mounting bolt, 1,
securing the bracket, 2, to the engine. Remove
the bracket and ventilation tubes from the engine
as an assembly.
2
1
10013113
15
20. Loosen the fitting, 1, and remove the oil hose, 2,
from the air compressor, 3.
21. Loosen the three air compressor mounting nuts, 6
4, and turn the tension adjustment bolt, 5,
clockwise to loosen tension on the air compressor 3
drive belt, 6. Remove the drive belt, 6, from the air
compressor, 3, and engine crankshaft pulley.
4
2 1
10013114 5
16
10-7
84073061A
17
22. Loosen the adjusting nut, 1, to release the tension
on the idler pulley, 2. Remove the two fan belts,
3.
23. Loosen the hose clamps, 1, and disconnect the
overflow hoses, 2, from the coolant tank, 3.
24. Loosen the hose clamp, 4, and disconnect the
main coolant supply hose, 5, from the coolant
tank, 3.
1
2
84073060A 5
18
10-8
WARNING
Do not disconnect any of the air conditioning
lines or hoses during evaporator removal from
1
the radiator support frame, as serious injury
could result. 3
25. Loosen and remove the clamp, 1, securing the air

conditioning, 2, to the radiator support frame, 3. 2
Remove the receiver dryer from the support
frame and position to the side.
20016204
19
26. Loosen and remove the radiator support
mounting hardware, 1, and remove the radiator 3 1
support, 2, and coolant tank, 3, as an assembly.
2
1
10013116
20
27. Remove the main drive belt, 1, from the engine.
84073781A
21
10-9
WARNING 1
Do not disconnect any of the air conditioning 1 3
lines or hoses during compressor removal, as
serious injury could result.
28. Disconnect the electrical connectors, 1, and

remove the four mounting bolts and nuts, 2, from 2
the air conditioning compressor, 3. Remove the
compressor from the engine and tie the assembly
against the grain tank wall, out of the way.
10013117
22
29. From inside the grain tank, loosen the mounting
nuts on the carriage bolts, 1, and turn the rotary
screen drive pulley adjusting bolt, 2, counter
clockwise, to release the tension on the drive belt,
3. Remove the drive belt. 1
3
10013118 2
23
30. Loosen the clamps, 1, and remove the intake air
boot, 2, from the air box and turbocharger.
31. Disconnect the connector, 3, from the sensor, 4.
Remove the sensor from the air box. 1
32. Loosen and remove the mounting bolt, 5,
securing the air box to the grain tank wall. 5
2
10013119 3
24
10-10
33. From inside the grain tank, loosen and remove
the mounting bolts, 1, from the air box retaining
brackets, 2. Remove the brackets. Remove the
air box, 3, from the grain tank wall to gain access
to the engine lid bracket mounting bolts.
2
1 3
1 2
10013120
25
34. Loosen and remove the mounting bolts, 1, and
remove the engine lid support bracket, 2, from the 1
grain tank wall.
2
20023150
26
35. Bleed the pressure from the fuel system. Loosen
the hose clamp, 1, and remove the fuel line, 2, at
the fuel injection pump.
1
10013121
27
10-11
36. Loosen the fitting, 1, on the fuel line, 2, and
disconnect the fuel line from the fuel filter, 3. 2 1
10013122
28
37. From inside the grain tank, loosen the hose
clamp, 1, and disconnect the lower coolant hose, 2 3
2, from the engine.
38. Loosen and disconnect the air compressor oil
line, 3, from the back of the engine block.
10013123
29
39. Disconnect the main engine electrical harness
connector, 1.
1
10004682
30
10-12
40. Open the rotary screen door and disconnect the
rotary screen brush electrical connector, 1.
10013132
31
41. Feed the connector and wire loom, 1, and
grommet, 2, through the hole in the radiator 1
frame. Secure the wire loom and connector to the
engine to prevent damage during removal.
NOTE: Removal of the rubber grommet in the
radiator frame hole may be necessary to remove the
radiator screen brush electrical connector. 2
10013133
32
42. Loosen the clamps, 1, and disconnect the air inlet
tube, 2, from the turbocharger, 3.
3
10013124 1
33
10-13
43. Loosen the nut, 1, and remove the oil hose, 2,
from the hose guide, 3.
3
1
10013125
34
44. Cut the wire ties, 1, and separate the engine wire
harness, 2, from the gearbox wire harness, 3.
Secure each harness to prevent damage during 2
engine removal.
10013126
35
rear heater hose, 2, from the engine.
2
50020200
36
10-14
front heater hose, 2, from the engine.
1
10013128
37
47. Remove the nut and bolt, 1, from the front fan
support bracket, 2.
1
10013129
38
48. Remove the banjo bolt, 1, from the engine oil pan,
2. Disconnect the oil hoses, 3, and plug the hole
in the oil pan, 2.
1
2 3
10010863
39
10-15
49. Loosen and remove the nut, 1. Disconnect the
main starter cable, 2, from the starter solenoid, 3. 1
3
10013130
40
50. Attach a suitable chain to the front lift eye, 1, and
to the ECU bracket, 2, at the rear of the engine. 1
10013135
20013162 2
41
51. Connect the lift chain to a suitable lifting device.
52. Raise the lifting device enough to support the
engine during removal of the engine mounting
bolts.
10013136
42
10-16
53. Loosen the two front, engine mounting bolts, 1,
and nuts, 2, on each side of the engine. Do not
remove the mounting bolts at this time.
1
10013137
43
54. Loosen the four rear, engine mounting bolts, 1, on
each side of the engine. Do not remove the
mounting bolts at this time.
55. With the engine securely supported by the lifting
device, remove all of the engine mounting bolts
loosened in the previous steps.
56. Carefully lift the engine from the frame and
remove from the combine.
1
10013138
44
Installation
1
1. Attach a suitable chain to the front lift eye, 1, and
to the ECU bracket, 2, at the rear of the engine.
10013135
20013162 2
45
10-17
3. Carefully lift the engine above the combine and
lower into position in the frame.
10013136
46
4. Position the engine in the frame, aligning the four
front mounting holes. Install the mounting bolts, 3
1. Install the washers, 2, and nuts, 3, on the bolt.
1
3
10013137
47
5. Align the rear mounting holes and install the
mounting bolt, 1, and washer, 2.
6. Tighten and torque the front engine mounting
nuts to 217 N⋅m (160 ft-lb)
2
7. Tighten and torque the rear engine mounting 2
bolts to 240 N⋅m (177 ft-lb)
1
10013138
48
10-18
8. Connect the main starter cable, 1, to the starter
solenoid, 2, and secure with the nut, 3. 3
2
10013130
49
9. Remove the plug from the oil pan, 1, and connect
the two oil hoses, 2, to the oil pan. Secure with the
banjo bolt, 3.
3
1 2
10010863
50
10. Secure the front fan support bracket, 1, with the
bolt and nut, 2. Tighten securely.
2
10013129
51
10-19
11. Connect the front heater hose, 1, to the engine
and tighten the hose clamp, 2, securely.
2
10013128
52
12. Connect the rear heater hose, 1, to the engine
and tighten the hose clamp, 2, securely.
1
50020200
53
13. Secure the gearbox wire harness, 1, to the engine
wire harness, 2, with wire ties.
1
10013126
54
10-20
14. Secure the oil hose, 1, to the hose guide, 2, and
tighten the nut, 3.
2
3
10013125
55
15. Connect the air inlet tube, 1, to the turbocharger,
2, and secure with the clamps, 3. Tighten the
clamps securely. 2
10013124 3
56
16. Feed the rotary screen brush electrical connector
and wire loom, 1, and grommet, 2, up through the 1
hole in the radiator frame.
10013133
57
10-21
17. Connect the rotary screen brush electrical
connector, 1, and secure the wire loom with wire 2
ties, 2.
10013132
58
18. Connect the main engine electrical harness
connector, 1.
1
10004682
59
19. From inside the grain tank, connect the lower
coolant hose, 1, to the engine. Secure with the 1 3
hose clamps, 2. Tighten the clamps securely.
20. Connect and tighten the air compressor oil line, 3,
to the back of the engine block.
10013123
60
10-22
21. Connect the fuel line, 1, to the fuel filter, 2, and
tighten the fitting, 3, securely. 1 3
10013122
61
22. Connect the fuel line, 1, to the fuel pump and
tighten the hose clamp, 2.
10013121
62
23. Use the mounting bolts, 1, to attach the engine lid
support bracket, 2, to the grain tank well. Install 1
and tighten the nuts securely. 1
20023150
63
10-23
24. Install the air box, 1, to the inside of the grain tank
wall and secure with the two brackets, 2. Install
and tighten the bracket bolts, 3.
1
3
3 2
10013120
64
25. Install and tighten the air box mounting bolt, 1.
26. Install the sensor, 2, into the air box and connect
the wire connector, 3.
27. Install the air intake boot, 4, and secure with the 5
clamps, 5. Tighten the clamps securely.
1
4
10013119 3
65
28. Install the rotary screen brush drive belt, 1, onto
the pulley, 2, and engine crankshaft pulley. Turn
the pulley adjusting bolt, 3, clockwise to adjust the
belt tension until the belt is tight. Tighten the lock
nuts on the carriage bolts, 4, when the belt is 4
properly adjusted. Adjustment is correct when the
1
belt deflection is 3 mm (1/8 in) in the center of the
belt, with a force of 23 N (5.2 lbf) applied to the
belt.
2
10013118 3
66
10-24
29. Install the air conditioning compressor, 1, on the
engine and secure with the four mounting bolts 3
3 1
and nuts, 2. Tighten the nuts securely.
30. Connect the electrical connectors, 3, to the
compressor wires.
10013117
67
31. Install the main drive belt, 1, onto the engine.
84073781A
68
32. Install the radiator support, 1, and coolant tank, 2,
assembly onto the radiator frame, 3, and fan 2 5
support frame, 4. 3
33. Install and tighten the mounting hardware, 5.
5
4
10013116
69
10-25
34. Install the air conditioning receiver dryer, 1, and
secure to the radiator support frame, 2, with the
clamp, 3. Tighten the clamp securely.
3
2
20016204
70
35. Connect the main coolant supply hose, 1, to the
coolant tank, 2, and tighten the hose clamp, 3.
36. Connect the overflow hoses, 4, to the coolant
tank, 2, and tighten the hose clamps, 5.
5
4
84073060A
1
71
10-26
37. Install the two fan belts, 1, onto the fan pulley and the gauge, 4. Tighten the nut on the idler pulley,
engine crankshaft pulley. Tighten the adjuster 5, when belt adjustment is correct.
nut, 2, until the washer, 3, is even with the end of
5
4
3
2
84073061B
72
38. Install the air compressor drive belt, 1, onto the air
compressor, 2, and engine crankshaft pulley.
Turn the belt tension adjusting bolt, 3, clockwise
until the belt is tight. Tighten the three air 1
compressor mounting nuts, 4, when the belt is 2
adjusted properly. Adjustment is correct when the
belt deflection is 3 mm (1/8 in) in the center of the
belt, with a force of 23 N (5.2lbf) applied to the 4
belt.
39. Connect the oil hose, 5, to the air compressor, 2,
and tighten the fitting, 6, securely. 5 6
10013114 3
73
40. Install the support bracket, 1, and ventilation
tubes onto the engine and secure with the
mounting bolt, 2. Tighten the mounting bolt
securely.
1
2
10013113
74
10-27
41. Connect the ventilation tubes, 1, to the air box and
tighten the hose clamps, 2. Install and tighten the 2
retaining loops and hardware, 3, onto the support
bracket.
3
1
10013112
75
42. Install the top coolant pipe, 1, to the engine and
radiator neck. Tighten the hose clamps, 2. 2
2
1
10013111
76
43. Install the step assembly, 1, with the attached
crankcase vent filter, 2, and oil filter manifold, 3, 4
to the engine and floor. Install and tighten the
mounting hardware, 4.
44. Connect the oil tubes, 5, to the oil filter manifold, 2
3, and tighten the fittings, 6.
5 6 3
1
10013110 4
77
10-28
45. Connect the hoses, 1, to the oil separator, 2, and
ventilation tube, 3. Tighten the hose clamps, 4.
4
2 3
1
10013110
78
46. Connect the oil hose, 1, to the bottom of the
crankcase vent filter, 2, and secure with the hose
clamp, 3. Tighten the hose clamp.
2
1
10013139
79
47. Connect the air intake tube, 1, to the radiator
housing, 2, and intake manifold, 3. 2
48. Install and tighten the mounting hardware

1
securing the air intake tube, 1, to the upper
coolant pipe, 4.
84073059C
80
10-29
49. Install and tighten the retaining bolt, 5, and nut, 6,
onto the support bracket, 7.
8 5
50. Install and tighten the clamps, 8, onto the air 6
intake tube, 9. 9
84073059C
81
51. Install the exhaust pipe, 1, onto the turbocharger,
2, and secure with hardware, 3. 2
5
52. Attach support clamp, 4.
53. Install muffler, 5, secure with two exhaust clamps,
6. 1
3
6
4
6
20023153
82
54. Install the engine lid support bar, 1, and secure
with the hardware, 2. 4 3 5
1
55. Install the engine lid, 3, onto the mounting
bracket, 4. 6
56. Secure the engine lid to the bracket with the hinge
pins, 5, washers, 6, and retaining rings, 7.
20023151
83
10-30
57. Connect the shock absorber, 1, to the engine lid,
2.
2
1
10013108
84
58. Install the protection cover, 1, and secure with the

mounting hardware, 2.
20023152
85
59. Replace the plug, 1.

60. Fill the engine with the proper amount and type of
oil. See Specifications.
1
40016218
86
10-31
clockwise to close the coolant drain. Fill the
cooling system with the proper amount and type
of coolant. See Specifications. 2
62. Install the gearbox and hydraulic pumps onto the 1
engine. (Refer to “Section 14 - Gearbox
Installation”)
10013106
87
63. Disconnect the fuel pump wire connector, 1, to
disable the fuel pump, 2. 1
64. Check the engine oil level and top off if necessary.
65. Crank the engine over for three ten second
intervals. This will distribute lubricating oil to the
engine operating systems and will allow oil
pressure to be built before starting the engine. 2
50020119
88
66. Connect the fuel pump wire connector, 1, and
bleed the air from fuel injection system, as 1
described in the Operators manual.
67. Start the engine and check all hoses, fittings and
clamps for leaks.
CAUTION
Monitor the instrument warning light bar at all
times during initial engine start up to ensure the
engine has proper oil pressure. Shut down the
engine immediately if oil pressure is not
adequate.
50020119
68. Be certain that all electrical components are 89

working properly.
10-32
SECTION 10 - ENGINE
Chapter 4 - 7.5L Fuel System
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bosch P7100 Mechanically Controlled Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . 7
Bosch P7100 Electronically Controlled Fuel Injection System . . . . . . . . . . . . . . . . . . . . 13
Fuel Injector Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Timing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Set Low Idle and Anti-Surge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fuel Shutoff Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fuel Prefilter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Supply Pump Sedimenter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10-1

Low Pressure Fuel Injection Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
High Pressure Fuel Injection Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10-2
SPECIFICATIONS
CR 920 CR 940 CR 920 CR 940

NA NA
Engine Engine
Type CNH675 CNH675 Power Rise/Boost 14/0 16/20
TA/CF TA/AA (kW) (18/0) (21/27)
Fuel Tank 750 liters Rated Speed 2100 rpm
(200 US gals) Low Idle Speed 1300 rpm
Gross Power 190 kW 220 kW High Idle Speed 2205 rpm 2100 rpm
(255 hp) (295 hp)
Fuel Prefilter and Combined unit change
Governor Mechanical Electronic Water Separator every 600 hours
Injection Pump Set using fixed timing pins Fuel Filter and Water Change every 600 hours
Timing with engine at TDC Separator
TIGHTENING TORQUES
N ⋅m Ft-lb
Injector attachment bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 17
Injector line nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 18
Injection pump drive gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 23
Injection pump rear mounting bolts . . . . . . . . . . . . . . . . . . . 38 28
Injection pump-to-front adaptor plate . . . . . . . . . . . . . . . . . 38 28
Injection pump-to-gear drive bolts . . . . . . . . . . . . . . . . . . . . 67 50
Injection timing gear access cover . . . . . . . . . . . . . . . . . . . 38 28
Leak-off tube banjo fitting bolts . . . . . . . . . . . . . . . . . . . . . . 9 7
Lift pump mounting to main junction pump, nuts, 3 . . . . . 8 6
10-3
SPECIAL TOOLS
Description Tool Number SPX Ltd Tool Nuday Tool Tool Number
(All Markets Except Number Number (North America
North America) Only)
Crankshaft Timing Pin 297672 - - -

Fuel Injection Pump Timing Pin 295005 - - FNH00536
Injector - hand pump tester 290284 - - FNH01721
with
Nozzle Test Adaptor FNH00041
Injector - cleaning kit 293671 - - -
Injector - splitting block 293760 - - -
Injector - Splitting socket kit 293761 - - -
Injection pump drive gear puller 295042 - - -
(Prior Tool Numbers, where applicable, shown in brackets)
60°
10mm
(3/8″)
1
Fuel Injection Pump Drive Gear Puller
(Local manufacture or Special Tool No. 295042)
1. Bolt 51mm (5/16″ - UNF x 2″) with integral washer (3 bolts required)
2. Bolt 51mm (3/4″x16 - UNC x 2″)
3. Three holes 9.5mm (0.375″) dia. on 56.87mm (2.2″) dia.
equally spaced material of 10mm (0.394″) Plate HRLC P&O Steel
10-4

GENERAL
The 7.5 Liter engine is fitted with either a
mechanically controlled governor Bosch P7100 in
line fuel injection pump, Figure 2, or electronically
controlled Bosch P7100 in line fuel injection pump
Figure 3.
2
Further explanation on the operation of these pumps
is given on the following pages.
3
The fuel system irrespective of the type of fuel pump
installed is fitted with a fuel prefilter, 1, and water
separator, 2, located beneath the fuel tank.
The primary purpose of this assembly is to remove 1
water and solid contaminates from the fuel before the
fuel enters the gallery of the injection pump. The
plunger and barrel assemblies (pumping elements) of
the injection pump are matched to each other with an
accuracy of a few ten thousandths of an inch.
Impurities of this size can cause severe damage, or
excessive wear, to the injection pump and injector
assemblies. 2
50020119
10-5
A separate fuel filter, 1, and water separator, 2, is also
installed immediately before the fuel enters the
injection pump.
5
A fuel supply pump is also fitted to all pumps at the
entry point into the injection pump fuel system. The
supply pump is mechanically driven by the injection
pump camshaft. The purpose of the supply pump is
to draw fuel from the tank, and pressurize the fuel to
a minimum of 1.4 bar (20 PSI) in order to cause fuel
to flow through the filter and to provide sufficient
pressure for pumping element filling. The supply
pump housing also contains a sedimenter assembly
consisting of a clear bowl, 2, and strainer screen, 3.
The clear bowl should be inspected for sediment
every 50 hours and cleaned every 600 hours.
On top of the supply pump is fitted a primer pump, 1,
which is used to prime the injection pump with fuel
6
when the filter element has been changed as
10-6
BOSCH P71000 MECHANICALLY

CONTROLLED FUEL INJECTION SYSTEM
The fuel injection pump, the heart of the fuel system,
consists of a number of sub assemblies.
On the mechanically controlled pump the control rack
which adjusts the fuel delivery through the pumping
elements within the pump is controlled by the
flyweights and springs in the mechanical governor
assembly which in turn is influenced by the throttle
lever, pump and engine speed.
7
Fuel Shutoff Solenoid
The purpose of the fuel shutoff solenoid, 1, is to move
the mechanical fuel shutoff lever to the “RUN”
position when the key switch is turned on, and to keep
the lever in that position while the key switch remains
in the “RUN” position. When the key switch is turned
“OFF,” the solenoid is de-energized, and allows
spring force within the governor housing to move the
mechanical shutoff lever to the “FUEL-OFF” position.
Governor
The rear portion of the injection pump assembly
houses the all-speed “RSV” mechanical governor.
The governor receives inputs from the following:
8
• Throttle control lever, 4
• Intake manifold pressure, 2
• Injection pump camshaft speed, 3
• Engine oil pressure, located on engine side of
pump (not shown).
• Mechanical fuel shutoff lever, 5, controlled by the
fuel shutoff solenoid, 1,
10-7
70-150-2205
9
1. Governor housing 10. Torque control & idle speed helical compression
2. Starting spring spring
3. Throttle control lever 11. Full load stop (fuel delivery)
4. Governor housing 12. Fulcrum lever
5. Shutoff idle stop 13. Guide bushing
6. Tensioning lever 14. Flyweight
7. Guide lever 15. Swivelling lever
8. Governor spring 16. Rocker
9. Auxiliary idle speed spring 17. Strap
18. Control rack
Receiving these inputs, the governor, by moving the throttle lever, 3. Also contained within the governor
pumping element control rack, 18, controls engine- housing is the starting spring, 2. This lightweight
off, excess fuel for starting, minimum and maximum spring pulls the fuel control rack fully forward to the
idle speeds, and any mid-range speeds independent excess fuel position whenever the engine is not
of load. A pair of flyweights, 14, are attached to the running. As soon as the engine starts and the
pump camshaft. The force of the flyweights increases flyweights begin to generate force, the starting spring
with engine speed. The force of the weights operates is overcome and the rack returns to normal fuel
against that of the governor spring, 8. The tension on delivery.
the governor spring is varied by the position of the
10-8
Aneroid Assembly
The aneroid assembly prevents excessive smoke
under load by limiting maximum fuel delivery until the
turbocharger is providing sufficient air to effect clean
combustion. An example of this operation would be
starting a load out onto a roadway, when the engine
is idling, and throttle position and load are increased
simultaneously.
1. Headless setscrew
2. Plate washer
3. Governor cover
4. Strap
5. Fulcrum lever
6. Starting spring
7. Governor housing
8. Control rod
9. Bell crank
10. Control shaft
11. Guide bushing
12. Helical compression spring
13. Diaphragm 70-150-2206
14. Charge air pressure
10
The aneroid also contains a hydraulic activator, 1,

which is controlled by engine oil pressure, A. When
there is no oil pressure, B, the activator allows the
control rack full travel to the excess fuel position.
Without this feature, during starting, fuel delivery
would be extremely limited due to lack of
turbocharger boost pressure.
1. Hydraulic activator
2. Bell crank
3. Strap
70-150-2207
11
10-9
Overflow Valve Assembly
The supply pump has a capacity of about twice that
of the requirements of the high-pressure pumping
elements. This excess flow provides cooling and
lubrication for the injection pump. Flow from the
supply pump travels through the filter element and
then to the fuel gallery of injection pump, where it is
available to fill the pumping elements. The fuel must
be pressurized in order to properly fill the pumping
elements. The job of the overflow valve which is
housed within the body of the banjo bolt, 1, is to
maintain a pressure of approximately 1.5 bar
(22 PSI) in the fuel gallery. Once that pressure is
reached, the overflow valve opens and allows the 12
excess fuel to return to the tank.
High-Pressure Pumping Elements
The high-pressure pumping elements, one for each
engine cylinder, supply fuel at a pressure of
approximately 240 bar (3500 PSI) to the injectors.
The pumping elements must provide the fuel in a
precisely measured amount at the proper time.
Operation of the individual element is as follows:
70-150-2209
13
10-10
Fuel Delivery Cycle
Reference (A) - Bottom dead center /
Fuel in
Reference (B) - Spill port closure /
Fuel Pressurized
Reference (C) - Spill port opening /
Fuel delivery ends
(A) With the plunger, 1, at the bottom of the stroke,
fuel flows into the barrel through the spill port, 2,
and fills the space above the plunger.
(B) As the plunger, 1, rises, the spill port in the barrel,
3, is covered and the fuel is trapped. This is the
point of port closure. The continued upward 14
movement of the plunger pressurizes the trapped
fuel until the delivery valve (at the base of each
high-pressure injection line) is lifted from its seat.
High- pressure fuel is transmitted through the line
to the injector and injection takes place through
the injector nozzle.
(C) Injection stops when the upper edge of the helix,
4, uncovers the lower edge of the spill port.
Pressure escapes to the fuel gallery. The drop in
pressure causes the injector to close and
injection to stop. After fuel delivery ceases, the
plunger continues to the top of the stroke and is
returned by a spring for the next cycle.
Because the end of delivery is reached when the
helix on the plunger uncovers the spill port, 1, the
amount of fuel delivered is varied by turning the
pump plunger as shown at D. If the plunger is
turned until the vertical groove completely
uncovers the spill port as shown at E, during the
entire lift of the plunger, there will be no fuel
delivered to the engine. This is because injection
pressure cannot be reached, thereby shutting off
the engine.
The plungers are rotated by a control rack splined
to each plunger. Rack movement is determined
by the control rod, actuated by the governor.
15
10-11
Fuel Delivery and Timing During Starting
The plungers, 1, are equipped with starting grooves,
2, on their crown. The purpose of this groove is to
assist in starting the engine by providing both excess
fuel and slightly retarded timing. When the key switch
is turned on, the fuel shutoff solenoid retracts, moving
the mechanical shutoff lever to the “RUN” position.
The starting spring in the governor housing pulls the
control rack fully forward, beyond the normal
maximum fuel position. This aligns the starting
groove with the spill port. With the starting groove
aligned with the spill port, there is a delay in spill port
closure which, in turn, delays the start of injection.
Note also that there is no helix in this region of the 16
plunger, so once injection begins, it is not cut off until
the plunger reaches the end of its stroke. This
provides a very large amount of fuel to aid starting.
Delivery Valves
A delivery valve is located above each plunger. The A B
delivery valve serves as a one-way valve which
allows fuel under injection pressure to move into the
high pressure tubes and prevents fuel from coming
back. The valve also serves to rapidly reduce
pressure in the injection line once pressure from the
plunger has ceased. Rapid pressure reduction is
required to ensure the injector valve snaps shut to
prevent fuel “dribble,” a condition which can cause
carbon formation on the injector tip.
A. Valve closed
B. Valve open during fuel delivery
17
Components are identified as follows:
1. Delivery valve holder
2. Spring
3. Valve
4. Valve seat
5. Valve holder
10-12
BOSCH P71000 ELECTRONICALLY

CONTROLLED FUEL INJECTION SYSTEM
The electronically managed fuel injection pump is of
similar construction to the mechanical pump
described previously with the exception that the
mechanical governor is replaced with an electronic
actuator located in a housing, 1, on the end of the
pump. Refer to the description and operation of the
mechanically controlled pump for all aspects other
than the electronic actuator.
18
19
Electronically Controlled Fuel Pump Actuator
1. Engine Electronic Control Unit (ECU) 4. Fuel Rack
2. Fuel Rack Actuator 5. Speed Sensor
3. Fuel Rack Position Sensor
The actuator is managed by an engine electronic G. Engine throttle switch setting

control unit which receives signals from: H. Engine speed sensor
C. intake manifold boost pressure and air I. Fuel Rack Position Sensor
temperature sensor These input signals are computed by the electronic
D. Coolant temperature sensor control unit to send a signal to the electronic actuator
E. Fuel temperature sensor (where fitted) which positions the fuel rack in accordance with
F. Engine speed sensor on flywheel fuelling demands on the engine.
10-13
Engine speed
sensor on
Injection Pump
Fuel rack
Position Sensor
Fuel
temperature
sensor
Engine speed
sensor on
flywheel
Boost Pressure
Engine and temperature
sensor
Grid
Heater Coolant
Temperature
Sensor
Engine
Electronic
Control Unit
Engine throttle Vehicle Electronic

switch Control Unit
20
Electronically controlled Bosch P7100 in line fuel injection system
The schematic shown above illustrates the various
features which control or influence pump fuelling, it
also includes the optional cold start aid described
later.
10-14
Servicing of the actuator components and injection
pump must be performed by an authorised service
agent.
Identification of components not located within the
injection pump housing are as follows:
Electronic control unit
Located on the vehicle structure to the left hand side
of the engine. The unit monitors and controls engine
operations. If the unit fails the engine will stop.
21
Boost pressure and temperature sensor
Located on the inlet manifold the sensor is used for
smoke control
if the sensor fails the engine speed and fuel quantity
may be reduced.
22
Coolant temperature sensor
Located adjacent to the water pump and top engine
hose.
The sensor is used for cold start and over heat
protection. If the sensor fails cold start capability may
be reduced and overheat protection will be lost.
23
10-15
Fuel temperature sensor (where fitted)
Located on the body of the fuel injection pump and is
used to compensate for variations in fuel temperature
during engine cold start up.
24
Engine speed sensor (located on the flywheel)
This sensor acts as a back-up should the speed
sensor in the injection pump actuator housing fail.
Should both sensors fail to operate the engine will
shut-down.
Figure 25 identifies the position of the harness
connector to this sensor at the rear of the engine. To
gain access to this sensor the engine must be
removed from the vehicle.
25
Fault Finding
In addition to monitoring and control of the fuelling
system the engine electronic control unit also offers
a comprehensive diagnosis system. When fuelling
faults occur on the engine the appropriate fault codes,
1, are displayed on the info view screen in the vehicle
cab.
26
10-16
When a fault is displayed reference should be made
to the Engine fault codes chapter in this manual to
determine and resolve the concern.
27
Engine Cold Start Aid (Grid Heater)
The engine cold start aid-(grid heater), where fitted is
located in the inlet manifold and assists engine start
up under cold climatic conditions. It increases the
inlet air temperature so that the compressed air
temperature is high enough for definite combustion of
the injected fuel.
28
The grid heater consists of a metallic heater element
with relays so that heating can be controlled in 4
phases. The engine electronic control unit manages
this function and the driver is informed on the status
of the grid heater by the preheat lamp located below
the ignition switch.
29
10-17
Phase 1. Temperature Reading
When the ignition key is turned on the temperature of
the air, fuel and coolant are taken and the lowest of
these is taken as the controlling value.
Phase 2. Pre-Heating
If the lowest of these values is below 30°C (86 °F) and
the battery voltage is between 11-14 volts the
preheating phase will commence. The duration of this
preheat phase is a maximum of 15 seconds but is
determined by the battery voltage.
Phase 3. Cranking
During this period the heater remains on for a period
of 15 seconds. If engine has not started after this
period the heater will turn off for 5 seconds and then
turn back on for a period of 10 seconds.
Phase 4. Post Heating
Once the engine has started the heater will remain on
for a maximum period of 5 minutes as monitored by
the engine electronic control unit.
If however the battery voltage falls below 11 volts
during this period the heater will be turned off.
FUEL INJECTOR ASSEMBLIES

The job of the injector assembly is to atomize the fuel
in order to facilitate proper combustion. The injector
must cleanly deliver the fuel into the combustion
chamber with a good spray pattern. There must also
be a “crisp” start, and end of, injection with no drips
either before or after the injection cycle.
The nozzle is housed within a nozzle holder. In order
to properly place the fuel charge into the combustion
chamber, dowel pins orient the nozzle within the
holder, and a clamp ring orients the holder within the
engine cylinder head.
Operation of the injection nozzle is as follows:
1. High pressure inlet line
2. Edge-type filter
3. Pressure channel
4. Intermediate disc
5. Nozzle-retaining nut
6. Union nut for fuel-injection tubing
7. Holder body
8. Leak-off port
9. Pressure-adjusting shims
10. Pressure spring
11. Pressure spindle
12. Locating pins (locating the nozzle)
13. Injection nozzle
70-150-2210
30
10-18
The high-pressure line delivers the fuel charge from
the injection pump. Fuel enters the inlet and passes
through the edge-type filter. Coarse foreign particles
are retained by the filter.
A passage routes fuel through the nozzle holder to the
nozzle valve. The nozzle valve is lifted off its seat by
the high-pressure inlet fuel, 1, acting on the annulus
in the valve.
When the nozzle valve opens, a definite quantity of
fuel (determined by the injection pump output for
each plunger stroke) is forced out through the
orifices. The fuel becomes finely atomized as it is
sprayed into the combustion chamber at high velocity.
Once fuel flow from the pump ceases, the spring
pressure forces the needle valve back onto its seat
via the spindle and needle valve stem. Fuel dribble
should not occur, as might happen if the nozzle
showed excessive wear.
The nozzle assembly is lubricated by a small amount
of fuel which seeps between the lapped surfaces of
the nozzle and valve which accumulates around the
spring.
The leakage fuel, 2, is routed out the nozzle holder
through a leak-off connector and returned back to the
fuel tank.
70-150-2211
31
Low-Pressure Fuel Lines
The purpose of the low-pressure fuel lines, 3, is to
carry fuel from the tank to the injection pump gallery
and to return excess fuel from the pump and injectors,
2, to the tank.
High-Pressure Fuel Lines
The purpose of the high-pressure fuel lines, 1, is to
carry fuel, under high pressure, from the injection
pump to the injector assemblies. These lines are a
precise length to provide proper fuel delivery. For this
reason, always use the correct line if replacement is
required.
32
10-19
OVERHAUL
INJECTION PUMP
Timing Check
If a fuel related concern is identified check the
injection pump timing before proceeding with any
other disassembly.
1. Remove all necessary hardware and compo-
nents in order to gain access to the front timing
cover.
33
2. Remove the fan belt.
34
3. To remove the fan belt release the tension applied
by the belt tensioning pulley.
35
10-20
4. Remove injection pump timing cover.
36
firing.
37
6. When engine is at TDC the threaded hole in the
injection pump drive flange aligns with the pump
timing plate.
38
10-21
7. To ensure the crankshaft is accurately positioned
at TDC remove the crankshaft timing plug, 1, from
the side of the engine block.
IMPORTANT: DO NOT disturb the timing pin bush, 2.
This has been accurately set during original
manufacture. If the bush is moved then pump timing
CAN NOT be accurately set.
39
8. Insert the crankshaft timing pin 297672 into the
side of the block.
40
41
10-22
Do not attempt to rotate the crankshaft when
42
11. Check that the injection pump timing pin Tool No.
295005 (NA-FNH00536-2) will screw into the
pump hub.
IMPORTANT: The engine must never be rotated
while the timing pin is installed.
12. If the pin engages in the pump timing plate,
Figure 44, when the crankshaft is at TDC the
pump timing is correct.
43
13. If pump timing is incorrect and timing pin can not
be screwed into pump, remove pump timing gear,
install timing pin 295005 (NA-FNH00536-1) into
pump and refit timing gear.
NOTE: This injection pump timing check assumes
that the crankshaft and camshaft timing gears were
correctly positioned during engine assembly. To
check the position of these timing gears it is
necessary to remove the engine front cover.
44
10-23
Set Low Idle and Anti-surge
Electronically Controlled Fuel Injection Pumps
The electronically controlled fuel injection pumps are
controlled by the microprocessor and no adjustment
is necessary in service.
Mechanically Controlled Fuel Injection Pumps
NOTE: Before proceeding, make certain that the
throttle controls are properly adjusted.
NOTE: This is the only adjustment that can be done
to the fuel injection pump by a technician NOT
authorized by Bosch.
1. Ensure the throttle control is in the full idle
position.
2. Back off the low idle auxiliary adjustment screw,
2.
3. Adjust the low idle screw, 1, so that the engine
speed is 1290 ± 10 RPM.
4. Thread the low idle auxiliary screw in until low idle
speed reaches 1310 ± 10 RPM.
5. Run the throttle up to high idle and then back
down to the low idle position to confirm correct
speed settings.
70-150-2236
45
Fuel Shutoff Diagnosis
In cases where the proper function of the fuel shutoff
solenoid is suspect, the following steps will diagnose
both the solenoid and the electrical feed to the pull coil
terminal, hold coil terminal, and common ground
terminal.
Ref Function
1 Ground
2 Pull
3 Hold
70-150-2213
46
Shutoff Solenoid Specifications:
Specifications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . @ Rated voltage 12V and rated temp.
20° C (68° F)
Pull current: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 amps
Hold current: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.87 amps
Pull rating: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.4 N (21 lbs.) @ 25 mm (1″) stroke
Hold rating: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 N (40 lbs.)
Plunger stroke: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4 mm (1″) maximum
10-24
Preliminary Checks
1. Place the transmission in NEUTRAL and set the
parking brake.
2. Check the battery voltage. Must be 12 volts or
higher. 1
3. Verify that the solenoid plunger and pump control
lever, 1, move freely the full range, with no
evidence of binding or sticking.
4. With key switch in the “OFF” position, the control
lever will be in the down position.
5. Turn the key switch to the “RUN” position. With
the engine running the control lever will be in the
“UP” position 47
6. Check the fuel shutoff solenoid linkage
adjustment as described later. If readjusted, try
restarting the engine while observing the
solenoid for proper function.
7. Inspect the electrical connections between the
solenoid and harness to ensure good positive
contacts, and not sign of rust or corrosion.
Checking Electrical Feed
Ref Function
1 Ground
2 Pull
3 Hold
1. Attach the positive lead of the voltmeter to the
“hold coil terminal” of the solenoid. Attach the
negative lead of the voltmeter to the “common
ground terminal” of the solenoid. Turn the ignition
switch to the “RUN” position. The voltmeter
should read a minimum of 9 volts. Less than 9 70-150-2213
volts indicates a bad circuit. Also, there should be 48
a 0.87 amp current draw.
2. Attach the positive lead of the voltmeter to the
“pull coil terminal” of the solenoid. Attach the
negative lead of the voltmeter to the “common
ground terminal” of the solenoid.
Turn the key switch to the “RUN” position. A
voltage of at least 9 volts should be present for
approximately two seconds, and the solenoid
plunger should retract. Also there should be a
60.3 amp draw.
3. Attach the voltmeter leads between the solenoid
“common ground” terminal and a good ground on
the frame. While the solenoid is in the “PULL” and
“HOLD” positions, the voltmeter should read 0
volts. If there is voltage, the ground circuit needs
to be checked.
10-25
Verify Linkage Adjustments
1. Turn the key switch to the “RUN” position. The
solenoid should fully retract.
2. Remove the solenoid rod from the mechanical
fuel shutoff lever.
3. Pull the mechanical fuel shutoff lever to the full
“RUN” position.
4. It should now be possible to insert the fuel shutoff
solenoid ball joint over the mechanical shutoff
lever pin.
5. If necessary, adjust the fuel shutoff solenoid rod
in order to accomplish step 4. 70-150-2238
49
FUEL PREFILTER/WATER SEPARATOR
Replace
Drain the water from prefilter/water separator, 1, 1
daily, proceed as follows:
1. Loosen screw, 2, to allow the water to run out of

the screw orifice.
2. Collect the water/fuel mixture and dispose

according to regulations. 2
50020119
3. Tighten screw, 2, when fuel free of water runs out
of the screw orifice. 50
The fuel prefilter/water separator, 1, should be
changed every 600 operating hours, or earlier, if a
drop in engine performance is experienced.
To change the prefilter/water separator, proceed as

follows:
1. Wipe the top of the prefilter/water separator head

clean.
2. Unscrew the “spin-on” prefilter/water separator,

using a filter wrench.
3. Fill the new prefilter/water separator with clean

fuel and apply a film of fuel to the gasket.
4. Screw on the new prefilter/water separator by

hand. Tighten firmly, but do not use tools.
5. Bleed the fuel system (refer to paragraph entitled

“Bleeding the Fuel System”).
10-26
Op. 10 206
FUEL FILTER/WATER SEPARATOR

Replace
The fuel filter, 1, should be changed every 600
operating hours. Proceed as follows:
1. Wipe the top of the filter head clean.
2. Loosen the screw at the bottom of filter, 1, to allow

the fuel to run out of the screw orifice.
3. Unscrew the spin on fuel filter using a filter

51
wrench.
4. Coat a film of fuel to the seal of the new fuel filter.
5. Screw the new filter on by hand and tighten it

securely (firmly against the head and then an
additional 1/4 to 1/2 turn). DO NOT USE TOOLS.
6. Close the screw at the bottom of the filter.
7. Bleed the fuel system, refer to “Bleeding the Fuel

System”.
8. The fuel filter contains a sediment bowl, 2, at its

bottom side, which collects large particles of dirt
and water. This sediment bowl can be removed
and cleaned.
Op. 10 210
SUPPLY PUMP SEDIMENTER

Inspect
1. Inspect supply pump fuel bowl for sediment every
50 hours and clean, or replace, the screen in the
sedimenter if required.
2. On reassembly ensure the bowl is sealing well
against the housing.
1. Fuel Bowl
2. Fuel Supply Pump
3. O Ring
4. Sedimenter
5. Screen
70-150-178
52
10-27
FUEL SYSTEM
Bleeding
To bleed the fuel system, proceed as follows:
1. Ensure there is fuel in the fuel tank and tap, 1, is

open.
2
1
2. Set the ignition switch in the “contact” position to
engage electrical fuel pump, 2.
50020119
53
3. Loosen fuel line, 3, at the injection pump.
4. Operate fuel lift pump piston, 4, by hand until the

fuel escaping is free from air bubbles.
5. Retighten fuel line, 3, when fuel free of air bubbles

escapes.
6. Continue pumping until the force needed remains

more or less constant. This allows the fuel to be
drawn into the injection pump.
7. Start the engine.
8. Run the engine at low idle until the engine runs 54

smoothly.
IMPORTANT: Check the bleed screw after the engine

starts to ensure there are no fuel leaks.
Injection System Bleeding
1
It may be necessary after injection pump removal or
injector removal to purge the high pressure lines of air
to allow the engine to start.
If the engine fails to start after several turns bleed the
system using the following procedure:
1. Crack open in turn, starting at injector number 1,
the nut, 1, of each high pressure lines. Crank the
engine on the starter motor to expel the air. With
the aid of an assistant, tighten the injector nuts as
the engine begins to fire.
WARNING
Wear suitable eye and skin protective clothing. 55
Fuel may be expelled under high pressure. Take
extreme care of moving belts and pulleys.
10-28
INJECTION PUMP
Removal
IMPORTANT: Internal repairs to the fuel injection
pump must be accomplished through a Bosch
authorized Diesel Service Dealer (DSD). The only
adjustment that can be accomplished to the pump
on-vehicle is low speed idle adjustment.
NOTE: Before removing any fuel lines, clean the
exterior of the fuel injection pump with clean fuel oil or
solvent to help prevent the entry of dirt or other
contamination. The area can be steam cleaned
(which is probably the best method of getting the area
clean), but it can only be done when the engine is cold
and shut off.
IMPORTANT: Do not wash or steam clean the engine

while it is running or still hot from running. Serious
damage to the injection pump could occur.
1. Disconnect the negative battery cables from the
battery and/or batteries.
2. Perform the injection pump timing check
described previously and install the injection
pump timing pin 295005 (NA-FNH00536-1).
56
3. Remove pump drive gear retaining bolts, 1,
retaining plate, 2, and gear, 3.
70-150-2224
57
10-29
4. Disconnect all pipework and fuel lines. Cap all
openings to prevent dirt contamination.
CAUTION
Use two wrenches on these high pressure lines to
prevent distorting or rotating the pumping el-
ement.
5. On electronically controlled injection pumps

disconnect the harness connection to the
electronic actuator.
58
6. On mechanically controlled injection pumps
remove the tube assembly from the boost control
and disconnect the throttle linkage.
59
7. Remove the four retaining nuts and withdraw the
pump from the engine.
60
10-30
Installation
firing (on compression stroke).
0
NOTE: If engine is at TDC with number 1 cylinder on
exhaust stroke the pump timing will be 180° out of
phase.
61
2. insert the crankshaft timing pin 297672 into the
side of the block.
62
63
10-31
Do not attempt to rotate the crankshaft when
64
5. With the pump on the bench, rotate the injection
pump clockwise until the threaded hole in the
pump drive flange aligns with the pump timing
plate. Screw the injection pump timing pin 295005
(NA-FNH00536-1) into the pump.
65
6. Refit pump onto engine and tighten the four
retaining nuts to a torque of 27 - 34 N⋅m (20 - 25
ft-lb).
66
10-32
7. Refit pump gear and plate.
8. Tighten gear retaining bolts to a torque of 54 - 75
N⋅m (40 - 55 ft-lb).
9. Remove timing pins from pump and side of
engine block.
67
10. Re-fit injection pump timing gear cover and fan
belts.
68
10-33
FUEL LIFT PUMP

Removal
1. Remove the fuel inlet and outlet lines from the lift
pump.
2. Remove the three nuts which mount the lift pump
to the fuel injection pump.
3. Remove the lift pump.
4. Clean all old gasket material from the lift pump
and the fuel injection pump mating surfaces.
5. If required, remove the fuel inlet tube fitting.
Discard the seal ring.
Installation
69
1. If needed, rotate the crankshaft so the low side of
the fuel injector pump camshaft lobe is facing out.
2. Install the lift pump gasket onto the fuel injection
pump. Make sure the gasket mating surfaces are
clean.
3. Install the lift pump onto the fuel injection pump.
4. Place the mounting nuts on the studs and tighten
to 7 - 9 N⋅m (5 - 7 ft-lb).
5. Start and stop the engine to check proper
operation of the solenoid.
6. Install the inlet and outlet lines on the fuel lift
pump. Tighten until the coupling contacts the
body shoulder 7 N⋅m (5 ft-lb).
7. Loosen the inlet line to the fuel injection pump.
Operate the hand primer on the lift pump to
displace any air that might be in the fuel lines.
Tighten the connection.
8. Start the engine and run it for approximately two
minutes. Observe all connections for fuel leaks.
9. Stop the engine and check for oil leakage from the
lift pump gasket.
10-34
FUEL SHUTOFF SOLENOID

Removal
1. Disconnect the wire connector from the fuel
shutoff solenoid.
2. Remove the solenoid plunger linkage from the
pump run/stop lever, 1.
3. Remove the two cap screws which hold the fuel
shutoff solenoid to the engine block.
70-150-2242
70
Installation
1. Attach the fuel shutoff solenoid to the engine
block with two cap screws.
2. Torque cap screw to 5 - 7 N⋅m (42 - 60 in.-lbs.).
3. Attach the solenoid plunger linkage to the pump
run/stop lever, 1.
4. Connect the wire connector to the fuel shutoff
solenoid, 1.
5. Check the fuel shutoff solenoid for proper
adjustment.
6. Start and stop the engine to check for proper
operation of the solenoid.
70-150-2243
71
10-35
LOW-PRESSURE FUEL INJECTION LINES

Removal
NOTE: Before removing any fuel lines, clean the
exterior of the fuel lines with fuel oil or solvent to
prevent the entry of dirt into the fuel system when the
fuel lines are removed. Blow dry with compressed air.
1. Disconnect the battery ground cables from all

batteries.
2. Disconnect and remove the low-pressure fuel line
assembly, 3, including the filter. Cap the lines as
they are removed. Inspect the rubber spacers at
the ends of the lines for distortion. Replace as
required.
3. If required, remove the banjo bolt which connects 72
the pump return tube, 2. Remove and discard the
seals on the banjo bolt.
Installation
1. Install the low-pressure fuel lines and filter
assembly back on the engine. Make sure the
tubes have fully seated into their correct fittings
before tightening the retaining nuts to
specification.
2. If removed, install the banjo bolt, 1, with new seals
to the pump return tube. Tighten the valve to 30
- 40 N⋅m (22 - 30 ft-lb).
3. If removed, install the fuel inlet fitting with a new
seal to the pump. Tighten to 30 - 40 N⋅m (22 - 30
ft-lb).
4. Connect the battery ground cable to both
batteries.
5. Run the engine and check for leaks.
73
10-36
70-150-2249
74
Op. 10 218
HIGH-PRESSURE FUEL INJECTION LINES

Removal 5. Carefully wiggle the fuel injection lines, 2, out
from under the intake manifold and remove them
In the case of damage to a single fuel injection line,
from the engine. Start from the back and move
do not attempt to remove it by itself. Always remove
toward the front of the engine.
the fuel injection lines as a set. It is much easier to get
them off the engine, and it helps to prevent damaging Once removed from the engine, individual fuel lines
the injection lines that are still good. can be removed from the assembly for replacement.
Keep in mind when ordering parts that each line is
1. Remove the low-pressure fuel lines following the
different and cannot be interchanged; therefore,
procedures described in this chapter.
order lines individually for the particular cylinder the
2. Disconnect the fuel injection lines at the injectors. line goes to.
As the line is removed, use a plastic cap to
prevent the entry of dirt into the system. Installation
3. Disconnect the fuel lines at the fuel injection
1. Make sure the clamps, 4, holding lines together
pump, 3. Cap each line and pumping element as
are tight.
the line is removed to prevent the entry of dirt into
the system. Use two wrenches on the lines to NOTE: High-pressure fuel lines must be installed as a
prevent accidental rotation of the pumping set. It is much easier than installing them individually.
element. 2. Wiggle the high-pressure fuel injection lines into
4. Detach the bracket, 1, holding the fuel injection position on the engine. Start from the back and go
line assembly to the intake manifold. toward the front of the engine.
10-37
3. Install the injection lines, 2, onto the injection
pump, 3, and tighten the nuts to 22 - 27 N⋅m (16
- 20 ft-lb). Tighten the bracket, 1, holding the
high-pressure fuel lines to the intake manifold.
Use two wrenches to tighten the lines to prevent
accidental rotation of the pumping element.
4. Connect the high fuel injection lines to the fuel
injectors one at a time starting with cylinder No.
1.
NOTE: Do not remove the caps from the fuel lines or
components until they are to be connected. This will
help prevent the entry of dirt into the system.
70-150-2232
5. Tighten the fuel injection line to injector nuts to 22 75
- 27 N⋅m (16 - 20 ft-lb).
6. Install the low-pressure fuel lines and filter
assembly back on the engine. Tighten the nuts to
specification.
7. Connect the battery ground cables to both
batteries.
8. Run the engine and check for leaks.
9. If necessary, purge the high-pressure fuel lines of
air by loosening the connector one-half to one
turn and cranking the engine until solid fuel, free
from bubbles, sprays from the connection. Refer
to “Injection System Bleeding.”
WARNING
Wear safety glasses or a protective face shield
when working with high-pressure fuel. Keep eyes
and hands away from nozzle spray. Fuel spraying
from the nozzle under high pressure can pen-
etrate the skin and cause blood poisoning. Medi-
cal attention should be provided immediately in
the event of skin penetration.
Take extreme care of moving belts and pulleys.
10-38
FUEL INJECTORS
Removal
1. Ensure the areas around the injectors and fuel
pump are clean prior to disassembly.
2. Remove the injector high pressure lines, 1.
3. Remove banjo bolts, 3, holding leak-off line, 4, to
the fuel injector, 2. Start at No. 1 injector and work
back.
4. Remove leak off line and discard the two copper
washers (one either side of the banjo fitting). New
washers must be used for reassembly.
70-150-209
76
5. Remove the injector retaining bolts and washers,
1, and hold-down clamp, 2.
6. Turn the injector, 3, clockwise to loosen it, then
remove from the head.
7. Remove the copper sealing washer, 4, from the
injector. If the washer is not on the injector it has
remained in the head and must be extracted.
Discard the copper washers.
Make sure the injector cavity is clean of carbon
before installing new copper washer.
8. Remove the cork dust seal, 5, from the injector.
NOTE: Each injector should have a cork seal under 70-150-210

the retaining flange, remove the seal from either the 77
cylinder head or injector and discard. New seals
should always be installed on reassembly.
10-39
Testing
WARNING
The spray from a fuel injector tester can pierce
human skin with fatal results. When an injector is
spraying, the nozzle holder should be turned
away from the operator and any other persons.
During the Nozzle Opening Pressure and Spray

Pattern Tests, collect the spray in a container partly
filled with rags to absorb the spray.
When conducting the Nozzle Seat Leakage Test,
release the injector tester pump pressure before
touching the nozzle tip with a sheet of blotting paper.
WARNING
The spray is flammable make sure no open flames
are in the area of the tester and do not generate
excessive vapor.
78
1. Fill the injector tester, Tool No. 290284
(NA-FNH01721), with a calibrating type fuel oil
and leave the filler cap loose to prevent a vacuum
forming during testing.
2. Prime the tester until oil is emitted from the tester
line, then connect the injector.
3. Make sure the knob on the right-hand side of the
tester is screwed in to prevent the gauge being
over-pressurized if the injector nozzle is blocked.
4. Pump the tester and check the nozzle is free to
open. Open the pressure gauge valve and begin
injector testing. If the nozzle is blocked or the
needle jammed, disassemble the injector.
5. Nozzle Opening Pressure Setting - Slowly
pump the injector tester and observe the
pressure at which the needle valve lifts and fuel
is injected from the nozzle tip. The minimum
acceptable opening pressure is 280 bar (4060
PSI) and the specification for new injectors is 300
bar (4350 PSI). If the opening pressure is below
280 bar (4060 PSI) reset to specification by
adding shims to the injector spring as shown in
the injector disassembly procedure.
79
10-40
6. Spray Pattern - Pump the tester rapidly (80 to 90
strokes per/min.) and observe the spray pattern
from the holes. An atomized spray, 1, free from
distortion and irregular streaks of fuel should be
observed. A non uniform or split stream spray, 2,
is not acceptable.
NOTE: The tester is not regarded as providing a

suitable test for atomization under working
conditions, but gives an indication of the working of
the nozzle.
80
7. Nozzle Seat Leakage - Wipe the nozzle tip dry
and apply a pressure 10 bar (145 PSI) below the
opening pressure. The nozzle tip and bottom face
must remain essentially dry and there must be no
tendency for blobs of fuel to collect or drip. A slight
dampness can be ignored. If there is any leakage
from the nozzle seat, the nozzle assembly must
be cleaned or replaced.
81
8. Nozzle Back Leakage - Apply a pressure 10 bar
(145 PSI) below the opening pressure, then
release the handle and time the pressure drop.
The pressure should drop 100 - 150 bar (1450 -
2175 PSI) in 5 - 45 seconds. If below 5 seconds,
the nozzle assembly must be replaced. If above
45 seconds, check for carbon on the valve and/or
blocked back leak drillings.
NOTE: If the injectors meet the tests carried out then

refit the injectors to the engine.
10-41
Disassembly
1. Place the injector in a holding fixture, Tool No.
293760, with the nozzle uppermost. Do not clamp
the injector body in a vice. Use socket tool,
295008, (Kit 293761), to loosen the nozzle
retaining nut.
2. Remove the nozzle retaining nut, complete with
the nozzle body, needle valve and the dowelled
adaptor plate.
TA6010117
82
3. Remove the injector body from the holding fixture,
invert and carefully remove the spring seat,
spring and adjustment shims. To avoid damage,
place all dismantled components in suitable
baths of clean fuel oil.
NOTE: To prevent corrosion of injector components

after cleaning, rinse in clean fuel oil and place in a
suitable bath of clean fuel oil.
TA6010118
83
1. Clean the injector body by soaking in a carbon
solvent and brushing with a brass wire brush.
Inspect the body for damaged threads and
pressure face, making sure the holes in the
injector nozzle are thoroughly clean with no signs
of corrosion or pitting.
2. Clean the spring and spring seat using a brass
wire brush and check for scoring, pitting or
corrosion.
3. Clean the dowelled adaptor plate using a brass
wire brush. Inspect the plate for loose or bent
TA6010113
dowels, a damaged pressure face or corrosion.
84
10-42
4. Clean the needle valve and body by soaking in a
carbon solvent and brushing with a brass wire
brush. Using the tools included in the Injector
Nozzle Cleaning Kit, Tool No. 293671, clean the
nozzle as follows:
NOTE: If the needle valve is in any way damaged or

blued, it must be discarded and a new matched
needle valve and nozzle body assembly obtained. It
is not possible to grind or lap the three special angles
on the valve point.
85
A. Clean the spray holes with a nozzle cleaning wire
held in a pin vise so that it protrudes for only 1.5
mm (0.06″), thereby giving maximum resistance
to bending. Insert the wire into each hole, pushing
and rotating gently until each hole is cleared.
86
B. Clean the needle valve seat using the valve seat
scraper by rotating and pushing the tool onto the
valve seating.
C. Clean the fuel port using the fuel port scraper.
Insert the scraper into the port, press hard against
the side of the cavity and rotate to clear all carbon
deposits from this area.
87
10-43
5. Use a Reverse Flush Nozzle Adaptor on the
injector tester and reverse flush the nozzle to
remove the carbon loosened during cleaning,
Step 4.
6. After flushing the nozzle, polish the valve seat by
placing a very small amount of tallow on the end
of a polishing stick and rotate in the nozzle.
88
7. Clean the top of the needle valve using a needle
valve scraper.
8. Clean the nozzle retaining nut using a brass wire
brush and check to see that the threads are not
damaged and are free from carbon deposits.
89
Assembly
1. Make sure all parts are absolutely clean and
undamaged prior to re-assembly. Rinse all parts
in clean fuel oil and assemble the components
while still wet.
2. Place the shims, spring and spring seat into the
injector body bore. Place the injector body into the
holding fixture.
3. Assemble the needle valve into the nozzle body
and then position the dowelled adaptor plate onto
the nozzle body. Insert this assembly into the
nozzle retaining nut.
TA6010113
90
10-44
4. Carefully assemble the dowelled adaptor plate
and the nozzle retaining nut assembly onto the
injector body, tighten the retaining nut to 45 N⋅m
(33 ft-lb) torque.
To set the nozzle opening pressure, connect the
injector to the test rig as described in ‘‘Testing’’ and
add or subtract shims from the spring until the
specified initial setting opening pressure of between
280 - 300 bar (4060 - 4350 PSI) is achieved.
Installation
The installation is the reverse of the removal
procedure noting the following points.
1. Install a new cork seal to the underside of the
retaining flange.
2. Install a new copper washer on the end of the
injector.
70-150-210
91
3. Install the injector.
92
NOTE: Be sure to install the clamp with the raised
side facing up.
4. Install the retaining bolts and washers. Torque the
bolts evenly to 22 N⋅m (17 ft-lb).
5. Install the leak-off line using new copper washers,
6, Figure 91, on either side of the banjo fitting.
6. Torque the leak-off line retaining bolt, 7, to 4.5
N⋅m (40 in-lb).
7. Install the high pressure line and tighten the
connector to 24 N⋅m (18 ft-lb).
8. Repeat the process on the remaining injectors.
9. It may be necessary to bleed the fuel system of air
in order to start the engine. Refer to, “Injection 93
System Bleeding”.
10-45
10-46
SECTION 10 - ENGINE
Chapter 5 - 7.8L, 10.3L Description of Operation
CONTENTS

Walk Around . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Engine Block and Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Crankshaft Sealing Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Timing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Auxiliary Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oil Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electronically Controlled Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pump Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
10-1
WALK AROUND
Left Side View
1 2 3 4 5 6 7
8 9 10 11 12 13
20015824
Ref. Description
1 Coolant Temperature Sensor (for instrument)
2 Coolant Temperature Sensor (for EDC)
3 Coolant Return Line from Turbocharger
4 Oil Delivery Line to Turbocharger
5 Turbocharger
6 Exhaust Manifold
7 Cam Cover
8 Oil Filter Mount and Intercooler
9 Oil Return Line from Turbocharger
10 Coolant Delivery Line to Turbocharger
11 Proportional Solenoid and VGT Position Sensor
12 Compressed Air Cleaner for VGT
13 Flywheel Sensor
10-2
Right Side View
1 2 3 4 5
6 7 8 9 10
20015825
Ref. Description
1 Cam Cover with Filter and Blow-by Valve
2 Rocker Cover
3 Filter Mount with Fuel Temperature Sensor
4 Sound Absorbing Panel
5 Intake Manifold with Heater Element and Air Sensor
6 Fuel Feed Pump
7 Starter Motor
8 Air Compressor
9 Electronic Control Unit
10 A.C. Compressor
10-3
Front View
3
2 4 5 6
1
7 10
8 9
20015826
Ref. Description
1 Poly-V Belt Tensioner
2 Alternator
3 Fan Pulley
4 Thermostat Case
5 Fixed Drive Pulley for Poly-V Belt
6 Coolant Pump
7 Poly-V Belt
8 Air Conditioner Compressor Drive Belt
9 Tensioner for Belt “I”
10 Viscostatic Damping Flywheel
10-4
Rear View
2
1 3
4 5 6
20015827
Ref. Description
1 Turbocharger
2 Blow by Valve
3 Blow by Filter
4 Engine Flywheel
5 Inspection Hole for Positioning Flywheel During
Adjustments
6 Window for Applying Flywheel Rotation Tool
10-5
Top View
1 2 3
4 5 6 7
20015828
Ref. Description
1 Flywheel Cover Casing
2 Exhaust Manifold
3 Turbocharger
4 Fitting
5 Power Steering Fluid Reservoir
6 Rocker Cover
7 Compressed Air Line
10-6
20015801
6
The engine is a six cylinder turbocharged and
aftercooled diesel engine. The engine uses electroni-
cally controlled mechanical injection pumps and has
been designed to meet current emission regulations.
The injection system on this engines is a high
pressure type with the pump/injector operated by an
overhead camshaft. The electronic control unit is
physically identical for all versions, but contains
software specific to each engine family and to each
different power rating within individual families.
During service, control unit software cannot be
altered, except to enter certain configuration data
when required.
10-7
20015802
7
Unlike conventional injection systems (with a single
injection pump), the new injector pump injection
system reduces particulate levels due to the high
pressures generated. The sophisticated electronic
management system also reduces other pollutants.
The engine must only be serviced by an authorized
service agent. The engine features cross flow
cylinder heads, with inlet and exhaust manifolds on
opposite sides of the cylinder head. The fuel and air
combustion process, takes place in the specially
designed bowl in the crown of the pistons.
10-8
ENGINE BLOCK AND CYLINDER LINERS

The structure comprises and engine block, which is
attached to a separate base. The seal between
engine block and base is ensured by a layer of
sealant. The wet cylinder liners are fitted into the
engine block. They are interchangeable and can be
removed. Water tightness is assured by rubber
washers fitted in the lower part of the cylinder liners.
Cylinder liner protrusion can be adjusted using shims,
which are available as spares. The main journal seats
are machined with both parts of the engine block fitted
together. The inner finish of the cylinder liners and the
liner and engine block structure are so well 20015803
engineered that part deformation is not possible and
engine oil consumption is therefore exceptionally low. 8
Liner bores are sorted into two categories: Category
A and Category B. A piston of corresponding
category must be matched with each liner.
20015829
9
CRANKSHAFT
The crankshaft is steel, with built-in counterweights.
The main journals and crankpins are treated by
induction hardening. The crankshaft is mounted on
half bearings, the last of these is close to the flywheel
and comprises built-in side shoulders. On this
crankshaft, the throws are arranged so that the firing
order is different to that of conventional 6 cylinder in
line engines. The firing order of the engine is
1-4-2-6-3-5. The crankpins and half-bearings are
sorted into three thickness categories, with a
difference of .01 mm between one category and the
next. When servicing, carefully select the category of 20015804
half-bearing to be fitted to each main journal and
crankpin in order to ensure radial clearance is
maintained within specified limits. 10
10-9
CRANKSHAFT SEALING RINGS

The front and rear sealing rings are Rotostat sliding 1
type. The rings take the form of a washer, 1, fitted
directly onto the crankshaft, a sealing lip, 2, and a 4
case, 4, fitted into a seat on the front cover or flywheel 2
cover case.
3
This type of seal offers the advantage of creating a
seal on the washer (at point, 3,) instead of directly on
the shaft. This sort of seal is more effective, because
it is not affected by side-to-side shaft movements and 20015805
the shaft itself does not become grooved. Special
tools must be used to remove and refit these seals. 11
CONNECTING RODS
The connecting rods are oblique-cut type, in pressed
steel, with broaching on mating surfaces between rod
and cap.
Data on weight category, half-bearing seat bore

category and rod/cap mating numbers are stamped
on the connecting rod.
20015806
12
PISTONS
The pistons are fitted with three piston rings. The first
sealing ring is trapezoid in cross-section, the second
sealing ring is chamfered, and the third is a scraper
ring. 1
Pistons are sorted into two categories, 1 and 2,

according to diameter. They are elliptical in shape
and made out of aluminum alloy. The piston crown
includes a high-turbulence combustion chamber. 2
20015807
13
10-10
CAMSHAFT
The camshaft turns on seven mounts (without
removable caps), which are built into the cylinder
head and fitted with bushes. There are three drive
cams per cylinder.
20015808
14
TIMING SYSTEM
The camshaft is driven by a series of helical gears in
a cascade unit located to the rear of the engine. Upper 1
intermediate gear, 2, is fitted on an adjustable mount.
This maintains the correct clearance between this
gear and gear, 1, whose position is affected by head 2
gasket thickness tolerances. The center of rotation of
all other gears is fixed and determined by machining.
Timing gears are not marked with notches or codes
as on conventional models because gear timing
adjustment is no longer necessary on the new
engines.
20015809
15
10-11
FLYWHEEL
A locating dowel is used to ensure the flywheel is
fitted to the crankshaft in a single fixed position.
The flywheel performs conventional functions

(balancing mass, mount for starter ring gear and
friction surface), while also acting as a phonic wheel
for a sensor connected to the electronic control unit.
For this purpose, fifty-four holes have been made.

These are divided into three sectors of eighteen holes
each. Each of these sectors is linked to one pair of
crankpins (1-6, 2-5, 3-4).
The electronic system does not require the holes to

be specially marked, but some (1, 2, 3, 4, lower figure)
1 3
are notched to allow repairers to carry out certain
adjustments and timing settings.
The sixth hole of each sector (1, 2, 3, lower figure) is

marked with a notch. The seventeenth hole of one of
the sectors (4, lower figure) is marked with two
notches.
4
The angular position of the flywheel at every instant
is detected by the EDC control unit by means of an
induction sensor (positioned at 1, upper figure). The
holes marked with notches should be aligned 2
alternatively with the inspection hole (2, upper figure) 20015810
in the flywheel cover casing during adjustment and
timing setting. 16
10-12
AUXILIARY DRIVE BELT

Two Poly V-belts transmit drive to the coolant pump,
alternator, fan pulley and air conditioning compressor
respectively. A calibrated spring in the belt tensioner
automatically adjusts belt tension. A fixed guide
pulley on the bigger belt increases the contact
surface on coolant pump and fan pulleys.
20015811
17
10-13
20015812
18
LUBRICATION
Lubrication is forced circulation type via gear pump.
The pump is gear driven by the crankshaft. An oil
pressure valve is fitted to the pump. A heat exchanger
and oil filter are attached to the lubrication circuit. The
oil thermostat is housed in the heat exchanger case.
The filter mount is fitted with:
• An oil filter by-pass valve
• A pressure sender unit for the pressure
gauge
• A low pressure switch for the warning light
• An oil temperature sender unit
10-14
OIL FILTER
The new generation of filters fitted to this engine are
more effective because they are able to trap more
particles of smaller size than conventional filters with
a paper cartridge.
External Coil
The filter elements are tightly would up in a coil. This
means that each fold is firmly anchored to the coil.
Fluid is therefore filtered evenly over the septum
surface even under difficult conditions, e.g. cold starts
with high viscosity fluid and peak flow rates. This
system also ensures even flow distribution over the
entire length of the filter element. Less load is lost and
the unit lasts longer.
Upstream Mount
The filter is fitted with an exclusive mount to optimize
slow distribution and stiffen the filter element. The
mount takes the form of a sturdy high strength nylon
and synthetic material mesh.
Filter Septum
Consists of inert inorganic fibers bonded with resin of
exclusive manufacture to a structure with graduated
pores. The septum is manufactured in accordance
with precise requirements and is subject to strict
quality control checks.
20015814
Downstream Mount 19
The septum is further strengthened by a mount and
sturdy nylon mesh. This extra mount is particularly
useful during cold starts and long periods of use. Filter
performance remains constant and reliable through-
out its working life and from element to element,
regardless of changes in service conditions.
Structural Parts
The O rings fitted to the filter element ensure an
excellent seal between element and container to
eliminate the risk of bypass and maintain filter
performance constant. Corrosion resistant bases and
a sturdy internal steel core complete the filter element
structure.
10-15
These high filtration devices have so far only adopted
for industrial processes. When used on vehicles, they
enable us to:
1. Reduce wear on engine components with time
2. Maintain oil performance/properties and thus
extend oil change intervals.
OIL SUMP
3 2 1
The oil sump is fastened to the engine block in a new
way, i.e. it is flexibly mounted.
The edge of sump, 1, is enclosed inside a thick rubber

“C” gasket, 2, and is contained and supported by an
aluminum element, 3, bolted to the engine block.
This solution prevents noise and improves the seal.

It also requires fewer bolts than the conventional
system. A further benefit of this system is that the 20015813
gasket does not need changing every time it is
removed. 20
20015815
21
COOLING
The coolant pump is housed in a seat in the engine
block. Many possible sources of leaks are eliminated
by the almost total lack of outer pies, sleeves and
collars.
10-16
ELECTRONICALLY CONTROLLED
INJECTION SYSTEM
The new Bosch PDE 30 pump injectors can achieve
higher injection pressures than conventional systems
with a separate pump and external piping.
The electronic injection management (EDC) already
applied to some conventional engine versions is
similar in basic layout, but the new system is much
more sophisticated and differs in many respects, e.g.
individual management of each individual injector
and advanced fault diagnostics function built into the
electronic control unit. The MS6 electronic control
unit also manages many other systems, including
turbocharging.
Electronic Control Unit

To reduce the number of connections, the length of
injector connection leads and hence signal interfer-
ence, the control unit is fitted directly onto the engine
via a heat exchanger (used for cooling) by means of
flexible blocks which reduce vibrations transmitted by
the engine.
An internal environmental pressure sensor further
improves injection system management.
The control unit is equipped with a highly advanced
self diagnostic system. It is able to take environmen-
tal factors into consideration in order to detect and 20015816
store anomalies (even if intermittent) occurring within
the system during vehicle operation to ensure more 22
effective, reliable repairs.
The MS6.2 electronic control unit manages the
following main functions: fuel injection, accessory
functions, self-diagnosis, recovery.
It also permits: interface with other on-board
electronic systems, EOL and Service programming,
and fault diagnosis.
10-17
PUMP INJECTOR
The pump injector consists mainly of three parts: 1
solenoid, 1, pumping element, 2, and nozzle, 3.
These three parts cannot be individually replaced and
cannot be serviced.
The pumping element is operated mechanically upon
2
each cycle by a rocker. It compresses the fuel in the
delivery chamber.
Nozzle configuration and operation are similar to 3
those of conventional injector nozzles. It is opened by
fuel under pressure to inject a fine spray of fuel into
the combustion chamber. 20015817
The solenoid is controlled directly by the electronic 23

control unit and determines delivery mode on the
basis of a control signal.
An injector case houses the lower part of the pump
injector in the cylinder head.
Filling Stage
During the filling stage, pumping element, 2, moves 1
upward. The highest point of the cam is passed and
the rocker roller moves toward the cam base ring.
Fuel valve, 1, is opened and fuel is free to flow into the
injector from the cylinder head lower channel, 4.
2
Filling continues until the pumping element reaches
the top end of its travel. 3
4
20015818
24
Injection Stage
The injection stage begins when the solenoid is 1
excited at a certain point on the pumping element
descending stroke and fuel valve, 1, closes. The
instant at which delivery starts is processed by the
electronic control unit and varies according to engine 2
service conditions. The cam continues to push
pumping element, 2, via the rocker and the injection 3
stage continues until fuel valve, 1, remains closed. 4
20015819
25
10-18
Flow-back Stage
Injection finishes when fuel valve, 1, opens at a
certain point on the pumping element descending 1
stroke following solenoid de-activation. Fuel flows
through open valve, 1, the injector holes and channel,
4, in the cylinder head. The time for which the
solenoid is excited is processed by the electronic
2
control unit and represents the duration of injection
(output). It varies according to engine service 3
conditions.
4
The electronic control unit is able to monitor current
uptake by the solenoid in order to establish whether
injection has taken place correctly or if mechanical 20015820
problems have occurred, e.g. binding. The control
unit can detect injector errors only when the engine is 26
running or during start up.
10-19
10-20
SECTION 10 - ENGINE
Chapter 6 - 7.8L, 10.3L Complete Engine, Remove and Replace
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10-1
OVERHAUL
ENGINE
Removal
NOTE: The engine and cooling system used in the
CR Combine is designed to be removed as a modular
unit. The following engine removal procedure
demonstrates the removal of the engine only from the
module. This procedure takes into consideration the
possible unavailability of proper, or sufficient lifting
equipment for complete module removal. When
possible, remove the engine and cooling system
module as designed. This procedure covers the 7.8
Liter and 10.3 Liter engines. While some illustrations
may not represent each engine exactly, the
procedure is essentially the same for both versions.
1. Remove the gearbox and hydraulic pumps from

the engine. (Refer to Section 14 - “Gearbox
Removal”).
drain hose, 2.
NOTE: The engine cooling system has a coolant 2
capacity of 42 liters (11.1 gal.). Be sure to use
clean containers with adequate capacity when
draining the cooling system.
1
10013105
1
counter clockwise to open the coolant drain.
Drain all of the coolant into the containers. 2
10013106
10-2
4. Remove the cap, 1, and turn the engine oil drain
valve, 2, to the open position. Drain all of the
engine oil into suitable containers.
NOTE: The 7.8 Liter engine has an oil capacity of
24 liters (6.34 gal.). The 10.3 Liter engine has an
oil capacity of 29 liters (7.7 gals.). Be sure to use
clean containers with adequate capacity when 2
draining the engine oil.
1
10013107
3
5. Loosen and remove the mounting hardware, 1,
from the protection covers, 2. Remove the covers 1
from the engine compartment.
2
40015965
4
6. Disconnect the shock absorber, 1, from the
engine lid, 2. 1
40015206
10-3
7. Remove the two retaining rings, 1, washers, 2,
and hinge pins, 3, from the engine lid. Remove 3
the engine lid from the combine.
2
84050265 1
6
8. Remove the hardware, 1, from the top and bottom
of the engine lid support bar, 2. Remove the 2 1
support bar.
20023150
7
9. Loosen and remove the exhaust clamp, 1, on the
exhaust pipe section, 2. Remove the exhaust
pipe. Loosen and remove flange, 3. Remove
tube, 4.
4
1 3
20023153
10-4
10. Loosen and remove the clamps, 1, from the air
intake tubes, 2. Remove the air intake tubes from 4 5 1
1
the radiator housing, 3, intake manifold, 4, and
turbocharger, 5.
3
1
40015966
9
11. Loosen and remove the step mounting hardware,
1, securing the step assembly, 2, to the floor and
engine. Remove the step assembly, 2, from the
combine
20023150
10
12. Loosen the hose clamps, 1, on the upper coolant
tube, 2. 3
13. Remove the coolant tube from the water pump, 3,
and radiator, 4. 2
1
4
40015967
11
10-5
14. Loosen the hose clamp, 1, and retaining
hardware, 2, from the ventilation tube, 3. 1
40015209
12
15. Loosen and remove the hose clamp, 1, securing
the ventilation tube, 2, to the engine. Remove the
ventilation tube from the engine.
2
40015210
13
16. Loosen the adjusting nut, 1, to release the tension
on the idler pulley, 2. Remove the two fan belts,
3. 3
1
84073061
14
10-6
overflow hoses, 2, from the coolant tank, 3.
1
main coolant supply hose, 5, from the coolant
tank, 3. 3
5
84073060
2
15
WARNING
lines or hoses during evaporator removal from
the radiator support frame, as serious injury
could result.
3
2
19. Loosen and remove the clamp, 1, securing the air
conditioning evaporator, 2, to the radiator support
frame, 3. Remove the evaporator from the
support frame and position to the side. 1
10013115
16
20. Loosen and remove the radiator support
mounting hardware, 1, and remove the radiator 3 1
support, 2, and coolant tank, 3, as an assembly.
10013116
17
10-7
21. Remove the main drive belt, 1, from the engine.
1
MID0378A
18
WARNING
lines or hoses during compressor removal, as
serious injury could result.
2
22. Disconnect the electrical connectors, 1, and
remove the mounting bolts, 2, from the air 1
conditioning compressor, 3. Remove the com-
pressor from the engine and tie the assembly out 3
of the way.
40015211
19
23. From inside the grain tank, loosen the mounting
nuts on the carriage bolts, 1, and turn the rotary
screen drive pulley adjusting bolt, 2, counter 1
clockwise, to release the tension on the drive belt,
3. Remove the drive belt. 3
2
40015956
20
10-8
24. Loosen the clamps, 1, and remove the intake air
boot, 2, from the air box and turbocharger.
5 1
25. Disconnect the connector, 3, from the sensor, 4.
Remove the sensor from the air box.
26. Loosen and remove the mounting bolt, 5, secur-
ing the air box to the grain tank wall. 2
10013119 3
21
27. Loosen and remove the mounting bolts, 1, from
the air box retaining brackets, 2. Remove the
brackets. Remove the air box, 3, from the grain
tank wall to gain access to the engine lid bracket
mounting bolts. 2
2
1
3
1
10013120
22
28. Loosen and remove the mounting bolts, 1, and
remove the engine lid support bracket, 2, from the
grain tank wall. 2
1
20023150
23
10-9
29. Bleed the pressure from the fuel system.
30. Loosen the fitting, 1, and remove the fuel line, 2,
1
at the electronic fuel control block, 3.
2
3
40015957
24
31. Loosen the hose clamp, 1, on the fuel return line,
2, and disconnect the fuel return line from the fuel
pump, 3.
2
3
40015958
25
32. From inside the grain tank, loosen the hose
clamp, 1, and disconnect the lower coolant hose,
2, from the engine.
1
40015959
26
10-10
heater hoses, 2, from the engine. 2
2
40015959
27
34. Disconnect the main engine electrical harness
connector, 1.
1
10004682
28
35. Open the rotary screen door and disconnect the
rotary screen brush electrical connector, 1.
10013132
29
10-11
36. Feed the connector and wire loom, 1, and
grommet, 2, through the hole in the radiator
frame. Secure the wire loom and connector to the
engine to prevent damage during removal.
radiator frame hole may be necessary to remove
the radiator screen brush electrical connector.
1
2
10013133
30
37. Cut the wire ties and separate the engine wire
harness, 1, from the gearbox wire harness, 2.
Secure each harness to prevent damage during
engine removal.
2
1
40015960
31
38. Remove the banjo bolt, 1, from the engine oil pan,
2. Disconnect the oil hoses, 3, and plug the hole
in the oil pan, 2. 3
1
10010863
32
10-12
39. Disconnect the main starter cable, 1, from the
starter, 2.
2
40015961
33
40. Attach a suitable chain to the front lift eye, 1, at the
front of the engine.
40015962
34
41. Attach a suitable chain to the rear lift eye, 1, at the
rear of the engine.
1
40015963
35
10-13
43. Raise the lifting device enough to support the
engine during removal of the engine mounting
bolts.
10013136
36
44. Loosen the two, front, engine mounting bolts, 1,
and nuts, on each side of the engine. Do not
remove the mounting bolts at this time. 1
40015964
37
45. Loosen the four rear, engine mounting bolts, 1, on
each side of the engine. Do not remove the
mounting bolts at this time.
46. With the engine securely supported by the lifting
device, remove all engine mounting bolts
1
loosened in the previous steps.
47. Carefully lift the engine from the frame and
remove from the combine.
10013138
38
10-14
Installation
1. Attach a suitable chain to the front lift eye, 1, at the
front of the engine.
40015962
39
2. Attach a suitable chain to the rear lift eye, 1, at the
rear of the engine.
1
40015963
40
4. Carefully lift the engine above the combine and
lower into position in the frame.
10013136
41
10-15
5. Position the engine in the frame, aligning the four
front mounting holes. Install the mounting bolts,
1. Install the washers and nuts on the bolt. Do not 1
tighten the hardware at this point.
40015964
42
6. Align the rear mounting holes and install the
mounting bolts, 1, and washer.
7. Tighten and torque the front engine mounting
nuts to standard torque.
8. Tighten and torque the rear engine mounting 1
bolts to standard torque.
10013138
43
9. Connect the main starter cable, 1, to the starter,
2.
2
40015961
44
10-16
10. Remove the plug from the oil pan, 1, and connect
the two oil hoses, 2, to the oil pan. Secure with the
banjo bolt, 3. 2
3
10010863
45
11. Secure the gearbox wire harness, 1, to the engine
wire harness, 2, and secure with wire ties.
1
2
40015960
46
12. Feed the rotary screen brush electrical connector
and wire loom, 1, and grommet, 2, up through the
hole in the radiator frame
radiator frame hole may be necessary to remove
the radiator screen brush electrical connector.
2
10013133
47
10-17
13. Connect the rotary screen brush electrical
connector, 1, and secure the wire loom with wire
ties, 2.
2
10013132
48
14. Connect the main engine electrical harness
connector, 1.
1
10004682
49
15. From inside the grain tank, connect the lower
coolant hose, 1, to the engine. Secure with the
hose clamp, 2, and tighten securely.
2
40015959
50
10-18
16. Connect the heater hoses, 1, to the engine and
tighten the hose clamps, 2, securely. 1
1
40015959
51
17. Connect the return fuel line, 1, to the fuel pump,
2, and tighten the hose clamp, 3, securely.
1
2
40015958
52
18. Connect the fuel line, 1, to the electronic fuel
control block, 2.
3
19. Tighten the fitting, 3, securely.
1
2
40015957
53
10-19
20. Attach the engine lid support bracket, 1, to the
grain tank wall and secure with mounting bolts, 2,
and nuts. Tighten the nuts securely. 2
1
20023150
54
21. Install the air box, 1, to the inside of the grain tank
wall and secure with the two brackets, 2. Install
and tighten the bracket bolts, 3.
2
3
1
3
10013120
55
22. Install and tighten the air box mounting bolt, 1.
23. Install the sensor, 2, into the air box and connect 5
the wire connector, 3. 1
24. Install the air intake boot, 4, and secure with the
clamps, 5. Tighten the clamps securely.
4
10013119 3
56
10-20
25. From inside the grain tank, install the rotary
screen brush drive belt, 1, onto the pulley, 2, and
engine crankshaft pulley. Turn the pulley 4
adjusting bolt, 3, clockwise to adjust the belt
tension until the belt is tight. Tighten the lock nuts 1
on the carriage bolts, 4, when the belt is properly
3
adjusted.
40015956
57
26. Install the air conditioning compressor, 1, on the
engine and secure with the mounting bolts, 2.
Tighten the bolts securely.
27. Connect the electrical connectors, 3, to the
compressor wires. 2
3
1
40015211
58
28. Install the main drive belt, 1, onto the engine.
1
MID0378A
59
10-21
29. Install the radiator support, 1, and coolant tank, 2,
assembly onto the radiator frame and fan support 2 3
frame.
30. Install and tighten the mounting hardware, 3.
3
1
10013116
60
31. Install the air conditioning evaporator, 1, and
secure to the radiator support frame, 2, with the
clamp, 3. Tighten the clamp securely.
2
1
10013115
61
32. Connect the main coolant supply hose, 1, to the
coolant tank, 2, and tighten the hose clamp, 3.
5
33. Connect the overflow hoses, 4, to the coolant
tank, 2, and tighten the hose clamps, 5.
2
1
84073060
4
62
10-22
34. Install the two fan belts, 1, onto the fan pulley and
engine crankshaft pulley. Tighten the adjuster
nut, 2, until the washer, 3, is even with the end of 1
the gauge, 4. Tighten the nut on the idler pulley,
5, when belt adjustment is correct.
5
3 4
2
84073061
63
35. Install the ventilation tube, 1, onto the engine and
secure with the hose clamp, 2. Tighten the clamp
securely.
1
40015210
64
36. Connect the ventilation tube, 1, to the air box and
tighten the hose clamp, 2. Install and tighten the 2
retaining loop and hardware, 3, onto the support
bracket.
3
40015209
65
10-23
37. Install the upper coolant tube, 1, to the water
pump, 2, and radiator, 3. 2
38. Install and tighten the hose clamps, 4, on the
upper coolant tube, 1. 1
4
3
40015967
66
39. Install the step assembly, 1, onto the combine
40. Install and tighten the step mounting hardware, 2,
securing the step assembly, 1, to the floor and
engine.
20023150
67
41. Install the air intake tubes, 1, onto the radiator
housing, 2, intake manifold, 3, and turbocharger, 3 4 5
5
4.
42. Install and tighten the clamps, 5, on the air intake
tubes, 1.
1
2
5
40015966
68
10-24
43. Install and secure the exhaust tube, 1, with the
flange, 2.
44. Install the exhaust pipe section, 3, by tightening
the exhaust clamp, 4, on the exhaust pipe
section.
1
4 2
20023153
69
45. Install the engine lid support bar, 1.
46. Install the hardware, 2, onto the top and bottom 1 2
of the engine lid support bar, 1.
20023150
70
47. Secure the engine lid, 1, to the support bracket
with the hinge pins, 2, washers, 3, and retaining 2
rings, 4.
1
3
84050265 4
71
10-25
48. Connect the shock absorber, 1, to the engine lid,
2. 1
40015206
72
49. Install the engine covers, 1, and secure with the
mounting hardware, 2. Tighten all mounting 2
hardware securely.
1
40015965
73
50. Close the engine oil drain valve, 1, and replace
the cap, 2.
51. Fill the engine with the proper amount and type of
oil. See “Specifications”.
NOTE: The 7.8 Liter engine has an oil capacity of
24 liters (6.34 gal.). The 10.3 Liter engine has an
oil capacity of 29 liters (7.7 gal.). 1
2
10013107
74
10-26
clockwise to close the coolant drain.
53. Fill the cooling system with the proper amount 2
and type of coolant. See “Specifications”.
NOTE: The engine cooling system has a coolant
capacity of 42 liters (11.1 gal.). 1
54. Install the gearbox and hydraulic pumps onto the
engine. (Refer to Section 14 - “Gearbox
Installation”).
10013106
75
55. Disconnect the fuel pump wire connector, 1, to
disable the fuel pump, 2.
56. Check the engine oil level and top off if necessary.
57. Crank the engine over for three ten second 2
intervals. This will distribute lubricating oil to the
engine operating systems and will allow oil
pressure to be built before starting the engine. 1
50013163
76
58. Connect the fuel pump wire connector, 1, and
bleed the air from fuel injection system, as
59. Start the engine and check all hoses, fittings and
clamps for leaks.
CAUTION
Monitor the instrument warning light bar at all 1
times during initial engine start up to ensure the
engine has proper oil pressure. Shut down the
engine immediately if oil pressure is not
adequate.
50013163
60. Be certain that all electrical components are 77

working properly.
10-27
10-28
SECTION 10 - ENGINE
Chapter 7 - 7.8L, 10.3L Engine Block
Model Engine Size

CR 960 F2BE0684A*B001 7.8L
CR 970 F3AE0684D*B001 10.3L
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rev Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Timing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Crank Gear and Cylinder Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder Head - Timing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine F2B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine F3A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Plan of Tightening Sequence of Screws Securing Sub-Crankcase . . . . . . . . . . . . . . . . . . . 27
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
System Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Mechanical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assembly and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assembling Crankshaft With Main Bearing Caps, Thrust Bearings and Rings,
Crankshaft End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Assembling Pistons With Piston Rings, Pins, Connecting Rods, Connecting Rod
Caps and Bearings - Checking Protrusion Over the Top Face of the Crankcase . . . . 53
Fitting and Tightening the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fitting Oil Pump, Timing System Intermediate Gears and Gear Box . . . . . . . . . . . . . . 56
Engine Flywheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fitting Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Fitting Injectors - Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10-1

Fitting Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Completing the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Assembly Diagram For Fan Drive Belt - Water Pump - Alternator For F2B Engine . . 67
Assembly Diagram For Fan Drive Belt - Water Pump - Alternator For F3A Engine . . 68
Checks, Measurements and Repairs on the Crankcase, Cylinder Liners . . . . . . . . . . 69
Checks, Measurements and Repairs on the Crankshaft, Bearings . . . . . . . . . . . . . . . 72
Selecting Main and Big End Bearing Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Preliminary Appraisal of Data to Make the Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Checks, Measurements and Repairs on the Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Checks, Measurements and Repairs on the Connecting Rods . . . . . . . . . . . . . . . . . . . 89
Piston Connecting Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Checks, Measurements and Repairs on the Cylinder Head . . . . . . . . . . . . . . . . . . . . . 95
Valve Seats On The Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Checks, Measurements and Repairs on the Tappets And Camshaft . . . . . . . . . . . . . . 99
Checks, Measurements and Repairs on the Valve Springs, Rocker Arm Shaft
and Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Checks, Measurements and Repairs on the Lubrication System . . . . . . . . . . . . . . . . 106
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Checks, Measurements and Repairs on the Cooling Circuit . . . . . . . . . . . . . . . . . . . . . 111
Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Injector Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Replacing the Crankshaft Front Cover Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Adjusting Clearance Valve of Intake Exhaust Rocker Arms and Pre-Load of
Pump Injector Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Pump Injector - Removal and Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Bleeding the Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
10-2
SPECIFICATIONS
GENERAL
Engine, technical type:
-- Mod. CR 960 – type F2B E0684A*B001 . . . . . . . . . . . . . . . . . . . . . . . . . . . see data pages 3 - 5
-- Mod. CR 970 – type F3A E0684D*B001 . . . . . . . . . . . . . . . . . . . . . . . . . . . see data pages 3 - 5
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diesel, 4 - stroke
Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . direct
Number of on-line cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . wet force-fitted in cylinder

block
Piston diameter
-- Mod. CR 960 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 mm (4.5″)
-- Mod. CR 970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 mm (4.9″)
Piston stroke
-- Mod. CR 960 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 mm (4.9″)
-- Mod. CR 970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5.5″)
Total displacement
-- Mod. CR 960 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7790 cm3 (475 in3)
-- Mod. CR 970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10300 cm3 (629 in3)
Compression ratio mod. CR 960 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 ± 0.8
Compression ratio mod. CR 970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ± 0.8
Maximum power:
-- Mod. CR 960 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 kW (333 HP)
-- Mod. CR 970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 kW (428 HP)
Maximum power speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 rpm
Maximum power speed for Mod. CR 960 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 rpm
Maximum power speed for Mod. CR 970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1380 rpm
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . steel
10-3
Engine, technical type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2B F3A
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diesel, 4 - stroke turbocharged with

aftercooler
Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . direct
Number of on-line cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . wet force-fitted in cylinder block
Cylinder liner diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 mm (4.5″) 125 mm (4.9″)
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 mm (4.9″) 140 mm (5.5″)
Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7790 cm3 10300 cm3

(475 in3) (629 in3)
Compression ratio mod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 ± 0.8 17 ± 0.8
Maximum power for:
-- Mod. CR 960 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 kW (333 HP)
-- Mod. CR 970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 kW (428 HP)
Maximum power speed for Mod.: . . . . . . . . . . . . . . . . . . . . . . . . . 2100 rpm
Maximum power speed for Mod. CR 960 . . . . . . . . . . . . . . . . . . . 1500 rpm
Maximum power speed for Mod. CR 970 . . . . . . . . . . . . . . . . . . . 1380 rpm
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10-4
LUBRICATION
forced, with gear pump
Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . from crankshaft
Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . 1:1.6
Oil cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mesh filter on oil intake and high-filtration

cartridge on delivery line
Oil filter quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2
Normal oil pressure with engine warm

(100°C ± 5°C [212°F ± 9°F]) and at top speed . . . . . . . . . . . . . . 5 bar (5 kg/cm2) (72.5 psi)
Normal oil pressure with engine warm

(100°C ± 5°C [212°F ± 9°F])
and at idling speed of 1300 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . 4 bar (4 kg/cm2) (58 psi)
Minimum permissible pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 bar (36.3 psi)
Adjustment valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in the oil pump body
Valve initial opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 bar (5 kg/cm2) (72.5 psi)
For further lubrication technical data . . . . . . . . . . . . . . . . . . . . . . . See page 10-106
COOLING SYSTEM
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . water circulation
Fan, attached to the water pump pulley . . . . . . . . . . . . . . . . . . . . intake, 7-blade in sheet metal
Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . poly-V belt driven centrifugal vane type
Engine speed/water pump speed ratio . . . . . . . . . . . . . . . . . . . . . 1:1.62 1.83

start of opening = 85 oC (185°F) 80 oC (176°F)
max = 95 oC (203°F) 95 oC (203°F)
For further cooling system technical data . . . . . . . . . . . . . . . . . . See page 10-111
REV COUNTER
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . incorporated in control panel
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . from gear on camshaft
10-5
TIMING SYSTEM
F2B F3A
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by rocker arms

via the camshaft located in the engine
block; the camshaft is driven by the
crankshaft using helical gears
Intake:
-- start: before T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17o 16o
-- end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31o 32o
Exhaust:
-- start: before T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48o 51o
-- end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9o 11o
Valve-rocker arm clearance for timing check: . . . . . . . . . . . . . . . mm mm
Valve-rocker arm clearance (with engine cold):
-- intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 ± 0.05 mm (0.016 ± 0.002″)
-- exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 ± 0.05 mm (0.016 ± 0.002″)
For further timing system technical data . . . . . . . . . . . . . . . . . . . See page 10-103
10-6
FUEL SYSTEM
F2B F3A
Air cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual cartridge dry air filter, with clogged

filter indicator with centrifugal pre-filter and
automatic dust ejector
Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gear pump
Gear operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . operated via the engine timing system
Fuel filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . via mesh filter in the tank, sediment
pre-filter, replaceable cartridge filter on the
delivery line to the injectors-pump
Electronic injection type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOSCH EDC MS6.2
Turbocharger:
-- HOLSET type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HX40W HX50W
8584 M/AB 19HD8 9861 B A/P 22PC3
Injectors: pump electro-injectors governed by the
camshaft and controlled by the electronic
control unit
BOSCH type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PDE 30 12 Volt PDE 31 12 Volt
Nozzle: BOSCH type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DLLA 143P894 DLLA 140
Number of nozzle holes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 8
Nozzle hole diameter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.192 mm 0.21 mm
(0.0076″) (0.0083″)
Pressure setting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 ± 12 bar 296 ± 6 bar
(4060 ± 174 psi) (4292 ± 87 psi)
Injection pressure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 bar (21,750 psi)
Injection sequence: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-2-6-3-5
10-7
CRANK GEAR AND CYLINDER DATA
F2B F3A
mm (in)
Diameter of cylinder liner bores on block:
-- upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130.200 ÷ 130.225 142.000 ÷ 142.025
(5.1260″ ÷ 5.1270″) (5.5906″ ÷ 5.5915″)
-- lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128.510 ÷ 128.535 140.000 ÷ 140.025
(5.0595″ ÷ 5.0604″) (5.5118″ ÷ 5.5128″)
Cylinder liners – external diameter:
-- upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130.161 ÷ 130.186 141.961 ÷ 141.986
(5.1245″ ÷ 5.1254″) (5.5890″ ÷ 5.5900″)
-- lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128.475 ÷ 128.500 139.890 ÷ 139.915
(5.0581″ ÷ 5.0591″) (5.5075″ ÷ 5.5085″)
Cylinder liner interference – bores on block:
-- upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.014 ÷ 0.064 0.014 ÷ 0.064
(0.0006″ ÷ .0025″) (0.0006″ ÷ 0.0025″)
-- lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 ÷ 0.060 0.085 ÷ 0.135
(0.0004″ ÷ 0.0024″) (0.0033″ ÷ 0.0053″)
Cylinder liner external diameter oversizes . . . . . . . . . . . . . . . . - -
Cylinder liners – internal diameter driven in and machined:
-- class A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115.000 ÷ 115.012 125.000 ÷ 125.013
(4.5276″ ÷ 4.5280″) (4.9213″ ÷ 4.9218″)
-- class B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115.010 ÷ 115.022 125.011 ÷ 125.024
(4.5280″ ÷ 4.5284″) (4.9217″ ÷ 4.9222″)
-- protrusion of cylinder liner from crankcase . . . . . . . . . . . . 0.035 ÷ 0.065 0.045 ÷ 0.075
(.0014″ ÷ .0026″) (0.0018″ ÷ 0.0030″)
Pistons:
Standard piston diameter measured from skirt base: 18 19
-- class A* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114.888 ÷ 114.900 124.881 ÷ 124.890
(4.5232″ ÷ 4.5236″) (4.9166″ ÷ 4.9168″)
-- class B** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114.898 ÷ 114.910 124.890 ÷ 124.899
(4.5235″ ÷ 4.5240″) (4.9168″ ÷ 4.9137″)
Pin seat diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.010 ÷ 46.018 50.010 ÷ 50.018
(1.8114″ ÷ 1.8117″) (1.9689″ ÷ 1.9692″)
0.100 ÷ 0.124 0.110 ÷ 0.134
Piston assembly clearance – cylinder liners . . . . . . . . . . . . . .
(0.0039″ ÷ 0.0049″) (0.0043″ ÷ 0.0053″)
Piston diameter oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - -
45.994 ÷ 46.000 49.994 ÷ 50.000
Piston pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(1.8108″ ÷ 1.8110″) (1.9683″ ÷ 1.9685″)
0.010 ÷ 0.024 0.010 ÷ 0.024
Piston pin – pin seat clearance . . . . . . . . . . . . . . . . . . . . . . . . .
(0.0004″ ÷ 0.0009″) (0.0004″ ÷ 0.0009″)
* Pistons supplied as spare parts.

** Class B pistons are assembled solely in production and are not supplied as spares.
10-8
F2B F3A
mm (in)
1st seat* . . 2.71 ÷ 2.74 2.94 (0.116″)

(0.107″ ÷ 0.108″)
Piston ring seat depth: 2nd seat . . 2.55 ÷ 2.57 3.05 ÷ 3.07
(0.100″ ÷ 0.101″) (0.120″ ÷ 0.121″)
3rd seat . . . 4.02 ÷ 4.04 4.02 ÷ 4.04

(0.158″ ÷ 0.159″) (0.158″ ÷ 0.159″)
* measured on ∅ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 (4.410″) 120 (4.724″)
1st ring* . . . 2.575 ÷ 2.595 2.796 ÷ 2.830

(0.1014″ ÷ 0.1022″) (0.1101″ ÷ 0.1114″)
Piston ring thickness: 2nd ring . . . 2.470 ÷ 2.490 2.970 ÷ 3.000

(0.0972″ ÷ 0.0980″) (0.1169″ ÷ 0.1181″)
3rd ring . . . 3.975 ÷ 3.990 3.970 ÷ 3.990

(0.1565″ ÷ 0.1571″) (0.1563″ ÷ 0.1571″)
* measured on ∅ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 (4.410″) 120 (4.724″)
1......... 0.115 ÷ 0.165 0.110 ÷ 0.144

(0.0045″ ÷ 0.0065″) (0.0043″ ÷ 0.0057″)
Piston ring – seat clearance 2......... 0.060 ÷ 0.100 0.050 ÷ 0.100

(0.0024″ ÷ 0.0039″) (0.0020″ ÷ 0.0039″)
3......... 0.030 ÷ 0.065 0.030 ÷ 0.070

(0.0012″ ÷ 0.0026″) (0.0012″ ÷ 0.0028″)
Piston ring end gap in cylinder liner:
1st ring . . . 0.35 ÷ 0.50 0.35 ÷ 0.50

(0.0138″ ÷ 0.0020″) (0.0138″ ÷ 0.0020″)
2nd ring . . . 0.70 ÷ 0.95 0.60 ÷ 0.75

(0.0028″ ÷ 0.0374″) (0.0024″ ÷ 0.0295″)
3rd ring . . . 0.30 ÷ 0.60 0.35 ÷ 0.65

(0.0012″ ÷ 0.0024″) (0.0138″ ÷ 0.0256″)
Small end bushing seat diameter . . . . . . . . . . . . . . . . . . . . 49.975 ÷ 50.000 54.000 ÷ 54.030

(1.9675″ ÷ 1.9683″) (2.1260″ ÷ 2.1272″)
10-9
F2B F3A
mm (in)
Small end bearing seat diameter:

-- nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.000 ÷ 77.030 87.000 ÷ 87.030
(3.0315″ ÷ 3.0327″) (3.4252″ ÷ 3.4264″)
-- class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.000 ÷ 77.010 87.000 ÷ 87.010
(3.0315″ ÷ 3.0319″) (3.4252″ ÷ 3.4256″)
-- class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.011 ÷ 77.020 87.011 ÷ 87.020
(3.0319″ ÷ 3.0323″) (3.4256″ ÷ 3.4260″)
-- class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.021 ÷ 77.030 87.021 ÷ 87.030
(3.0323″ ÷ 3.0327″) (3.4260″ ÷ 3.4264″)
Small end bushing diameter:

-- external diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.555 ÷ 50.080 54.085 ÷ 54.110
(1.9904″ ÷ 1.9717″) (2.1293″ ÷ 2.1303″)
-- internal diameter (with bushings fitted) . . . . . . . . . . . . 46.015 ÷ 46.030 50.019 ÷ 50.035
(1.8116″ ÷ 1.8122″) (1.9693″ ÷ 1.9699″)
Small end bushing – seat interference . . . . . . . . . . . . . . . . 0.055 ÷ 0.105 0.055 ÷ 0.110

(0.0022″ ÷ 0.0041″) (0.0022″ ÷ 0.0043″)
Piston pin – bushing clearance . . . . . . . . . . . . . . . . . . . . . . 0.015 ÷ 0.036 0.019 ÷ 0.041

(0.0006″ ÷ 0.0014″) (0.0007″ ÷ 0.0016″)
Connecting rod half bearing undersizes . . . . . . . . . . . . . . . 0.127 ÷ 0.254 - 0.508

(0.0050″ ÷ 0.0100″ - 0.0200″)
Tolerance for parallelism between the two connecting
rod axes:
measured 125 mm (4.921″) from the connecting rod
stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 (0.0031″)
10-10
F2B F3A
mm (in)
Main journal diameter:
-- nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.910 ÷ 82.940 92.970 ÷ 93.000
(3.2642″ ÷ 3.2654″) (3.6602″ ÷ 3.6614″)
-- class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.910 ÷ 82.919 92.970 ÷ 92.979
(3.2642″ ÷ 3.2645″) (3.6602″ ÷ 3.6606″)
-- class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.920 ÷ 82.929 92.980 ÷ 92.989
(3.2646″ ÷ 3.2649″) (3.6606″ ÷ 3.6610″)
-- class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.930 ÷ 82.940 92.990 ÷ 93.000
(3.2650″ ÷ 3.2654″) (3.6610″ ÷ 3.6614″)
Connecting rod journal diameter:
-- nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.915 ÷ 72.945 82.970 ÷ 83.000
(2.8707″ ÷ 2.8719″) (3.2665″ ÷ 3.2677″)
-- class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.915 ÷ 72.924 82.970 ÷ 82.979
(2.8707″ ÷ 2.8710″) (3.2665″ ÷ 3.2669″)
-- class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.925 ÷ 72.934 82.980 ÷ 82.989
(2.8711″ ÷ 2.8714″) (3.2669″ ÷ 3.2673″)
-- class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.935 ÷ 72.945 82.990 ÷ 83.000
(2.8715″ ÷ 2.8719″) (3.2673″ ÷ 3.2677″)
Standard main journal half bearing thickness:
-- red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.000 ÷ 3.010 2.965 ÷ 2.974
(0.1181″ ÷ 0.1185″) (0.1167″ ÷ 0.1171″)
-- green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.011 ÷ 3.020 2.975 ÷ 2.984
(0.1185″ ÷ 0.1189″) (0.1171″ ÷ 0.1175″)
-- yellow* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.021 ÷ 3.030 2.985 ÷ 2.995
(0.1189″ ÷ 0.1193″) (0.1175″ ÷ 0.1179″)
Standard main journal half bearing thickness:
-- red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.000 ÷ 2.010 1.970 ÷ 1.980
(0.0787″ ÷ 0.0791″) (0.0776″ ÷ 0.0780″)
-- green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.011 ÷ 2.020 1.981 ÷ 1.990
(0.0792″ ÷ 0.0795″) (0.0780″ ÷ 0.0783″)
-- yellow* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.021 ÷ 2.030 1.991 ÷ 2.000
(0.0796″ ÷ 0.0799″) (0.0784″ ÷ 0.0787″)
Main bearing diameter:
-- nominal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.000 ÷ 89.030 99.000 ÷ 99.030
(3.5039″ ÷ 3.5051″) (3.8976″ ÷ 3.8988″)
-- class 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.000 ÷ 89.009 99.000 ÷ 99.009
(3.5039″ ÷ 3.5043″) (3.8976″ ÷ 3.8980″)
-- class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.010 ÷ 89.019 99.010 ÷ 99.019
(3.5043″ ÷ 3.5047″) (3.8980″ ÷ 3.8984″)
-- class 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.020 ÷ 89.030 99.020 ÷ 99.030
(3.5047″ ÷ 3.5051″) (3.8984″ ÷ 3.8988″)
10-11
F2B F3A
mm (in)
Half bearing – main journal clearance . . . . . . . . . . . . . . . 0.040 ÷ 0.098 0.050 ÷ 0.090

(0.0016″ ÷ 0.0039″) (0.0020″ ÷ 0.0035″)
Connecting rod half bearing clearance . . . . . . . . . . . . . . . 0.035 ÷ 0.093 0.040 ÷ 0.080
(0.0014″ ÷ 0.0037″) (0.0016″ ÷ 0.0031″)
Main bearing undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.127 - 0.254 - 0.508
(0.0050″ - 0.0100″ - 0.0200″)
Main journal length per thrust . . . . . . . . . . . . . . . . . . . . . . 39.96 ÷ 40.04 45.95 ÷ 46.00
(1.5732″ ÷ 1.5764″) (1.8091″ ÷ 1.8110″)
Main journal width per thrust . . . . . . . . . . . . . . . . . . . . . . . 32.94 ÷ 32.99 38.94 ÷ 38.99
(1.2969″ ÷ 1.2988″) (1.5331″ ÷ 1.5350″)
Thrust ring thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38 ÷ 3.43 3.38 ÷ 3.43
(0.1331″ ÷ 0.1350″) (0.1331″ ÷ 0.1350″)
Crankshaft thrust clearance . . . . . . . . . . . . . . . . . . . . . . . . 0.11 ÷ 0.34 0.10 ÷ 0.30
(0.0043″ ÷ 0.0134″) (0.0043″ ÷ 0.0118″)
Thrust ring oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254 - 0.508 (0.0100″ - 0.0200″)
Maximum tolerance for alignment of main journals
(total dial gauge reading) . . . . . . . . . . . . . . . . . . . . . . . . . .  0.0050 (0.0002″)
Maximum tolerance for alignment of connecting rod
journals in relation to main journals . . . . . . . . . . . . . . . . . . ÷ 0.005 (0.0002″)
Maximum ovality of main journals and the connecting
rod after grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0.0004″)
Maximum taper of main journals and the connecting rod
after grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0.0004″)
10-12
CYLINDER HEAD - TIMING SYSTEM
F2B F3A
mm (in)
12.980
Diameter of valve guide bores in the cylinder head . . . . # 14.980 - 14.997
12.997 (0.5898″ - 0.5904″)
(0.5110″ - 0.5117″)
Valve guide external diameter . . . . . . . . . . . . . . . . . . . . . . 13.012 - 13.025 15.012 - 15.025
(0.5123″ - 0.5128″) (0.5910″ - 0.5915″)
Valve guide internal diameter
(after fitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.023 - 8.038 9.015 - 9.030
(0.3159″ - 0.3165″) (0.3549″ - 0.3555″)
Valve guide and bore interference in head . . . . . . . . . . . . 0.015 - 0.045 0.015 - 0.045
(0.0006″ - 0.0018″) (0.0006″ - 0.0018″)
Valve guide oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 - 0.4 (0.0079″ - 0.0157″)
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.970 - 7.985 8.960 - 8.975
(0.3138″ - 0.3144″) (0.3528″ - 0.3533″)
Valve seat angle: intake . . . . . . . 60o 30’ ± 7’ 30”
exhaust . . . . . 45o 30’ ± 7’ 30”
Valve stem and relative guide assembly clearance . . . . 0.038 - 0.068 0.040 - 0.070
(0.0015″ - 0.0027″) (0.0016″ - 0.0028″)
Internal diameter of bore on head for valve seat:
intake . . . . . . . 41.985 - 42.020 44.185 - 44.220
(1.6530″ - 1.6543″) (1.7396″ - 1.7409″)
exhaust . . . . . 40.985 - 41.020 42.985 - 43.020
(1.6136″ - 1.6150″) (1.6923″ - 1.6937″)
Valve seat external diameter: intake . . . . . . 42.060 - 42.075 44.260 - 44.275
(1.6559″ - 1.6565″) (1.7425″ - 1.7431″)
exhaust . . . . . 41.060 - 41.075 43.060 - 43.075
(1.6165 - 1.6171″) (1.6953″ - 1.6959″)
Valve seat angle in cylinder head: intake . . . . . . 60° - 30’
exhaust . . . . . 45° - 30’
Valve depth in relation to cylinder
head surface: intake . . . . . . 0.5 - 0.8 0.65 - 0.95
(0.0197″ - 0.0315″) (0.0256″ - 0.0374″)
exhaust . . . . . 1.6 - 1.9 1.8 - 2.1
(0.0630″ - 0.0748″) (0.0709″ - 0.0827″)
Valve seat and bore fit on cylinder head (interference) . 0.040 - 0.090 (0.0016″ - 0.0035″)
Valve mushroom-head diameter:
intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.85 - 40.15 42.985 - 43.015
(1.5689″ - 1.5807″) (1.6923″ - 1.6935″)
exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.85 - 39.15 41.985 - 42.015
(1.5689″ - 1.5413″) (1.6530″ - 1.6541″)
Maximum off-centring of the valve with the indicator
resting in the centre of the contact surface . . . . . . . . . . . 0.03 (0.0012″)
10-13
F2B F3A
mm (in)
Valve spring height:

free spring height . . . 62.6 -
(2.4646″)
under a load of N – (kg) [lbs.]
454 ± 22 5 (46.3 ± 2.2) [102 ± 5 lbs.] height . . . 48.5 -
(1.9094″)
840 ± 42 9.5 (85.7 ± 2.2) [189 ± 5 lbs.] height . . . 36.5 -

(1.4370″)
free spring height . . . - 75
(2.9528″)
under a load of N – (kg) [lbs.]
500 ± 25 N (50 ± 2.5) [110 ± 5.5 lbs.] height . . . - 61
(2.4016″)
972 ± 48 N (97.2 ± 2.5) [214 ± 5.5 lbs.] height . . . - 47.8
(1.8819″)
Injector protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 (0.0276″) 1.14 - 1.4
(0.0449″ - 0.0551″)
10-14
F2B F3A
mm (in)
Camshaft bushing seat diameter in cylinder head . . . . . 80.000 - 80.030 88.000 - 88.030
(3.1496″ - 3.1508″) (3.4646″ - 3.4657″)
Camshaft support journal diameter . . . . . . . . . . . . . . . . . . 75.924 - 75.940 82.950 - 82.968

(2.9891″ - 2.9898″) (3.2657″ - 3.2665″)
Camshaft bushing external diameter . . . . . . . . . . . . . . . . 80.090 - 80.115 88.153 - 88.183

(3.1532″ - 3.1541″) (3.4706″ - 3.4718″)
Internal diameter of finished bushings in seats . . . . . . . . 75.990 - 76.045 83.018 - 83.085

(2.9917″ - 2.9939″) (3.2684″ - 3.2711″)
Bush and seat interference in block . . . . . . . . . . . . . . . . . 0.060 - 0.115 0.123 - 0.183

(0.0024″ - 0.0045″) (0.0048″ - 0.0072″)
Coupling between bushings and support journals

of the camshaft (assembly clearance) . . . . . . . . . . . . . . . 0.050 - 0.121 0.050 - 0.135
(0.0020″ - 0.0048″) (0.0020″ - 0.0053″)
Cam lift: intake . . . . . . . . . . . . 8.07 (0.3177″) 9.30 (0.3661″)

exhaust . . . . . . . . . . 7.63 (0.3004″) 9.45 (0.3720″)
injector-pump . . . . . 8.80 - 8.82 11.21 (0.4413″)
(0.3465″ - 0.3472″)
Rocker arm support shaft diameter . . . . . . . . . . . . . . . . . . 37.984 - 38.000 41.984 - 42.000

(1.4954″ - 1.4961″) (1.6529″ - 1.6535″)
Seat diameter for rocker arm support shaft bushings in

rocker arms:
-- intake valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.000 - 41.016 45.000 - 45.016
(1.6142″ - 1.6148″) (1.7717″ - 1.7723″)
-- exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.000 - 41.016 59.000 - 59.019
(1.6142″ - 1.6148″) (2.3228″ - 2.3236″)
-- injectors-pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.000 - 42.016 46.000 - 46.016
(1.6535″ - 1.6542″) (1.8110″ - 1.8117″)
Bushing external diameter for rocker arms:

-- intake valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.097 - 41.135 45.090 - 45.130
(1.6180″ - 1.6195″) (1.7752″ - 1.7768″)
-- exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.097 - 41.135 59.100 - 59.140
(1.6180″ - 1.6195″) (2.3268″ - 2.3283″)
-- injectors-pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.066 - 42.091 46.066 - 46.091
(1.6561″ - 1.6571″) (1.8136″ - 1.8146″)
10-15
F2B F3A
mm (in)
Bushing internal diameter for rocker arms with bushing

fitted:
-- intake valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.025 - 38.041 42.025 - 42.041
(1.4970″ - 1.4977″) (1.6545″ - 1.6552″)
-- exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.025 - 38.041 56.030 - 56.049
(1.4970″ - 1.4977″) (2.2059″ - 2.2067″)
-- injectors-pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.015 - 38.071 42.015 - 42.071
(1.4967″ - 1.4989″) (1.6541″ - 1.6563″)
Clearance between bushings and rocker arm support

shaft:
-- intake valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 - 0.057 0.025 - 0.057
(0.0010″ - 0.0022″) (0.0010″ - 0.0022″)
-- exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 - 0.057 0.025 - 0.057
(0.0010″ - 0.0022″) (0.0010″ - 0.0022″)
-- injectors-pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.087 0.015 - 0.087
(0.0006″ - 0.0034″) (0.0006″ - 0.0034″)
Coupling between bushings and seats in rocker arms:

-- intake valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.081 - 0.135 0.074 - 0.130
(0.0032″ - 0.0053″) (0.0029″ - 0.0051″)
-- exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.086 - 0.156 0.081 - 0.140
(0.0034″ - 0.0061″) (0.0032″ - 0.0055″)
-- injectors-pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 - 0.091 0.050 - 0.091
(0.0020″ - 0.0036″) (0.0020″ - 0.0036″)
10-16
TORQUE SETTINGS
ENGINE F2B
TORQUE
PART Thread
N⋅m (ft-lb) kgm
Screws securing sub-crankcase to crankcase
(see Figs. 1-2-3-4-5) ♦
External screws: First phase: pre-torque . . . . . . . . . . . . . M 10x1.25 25 2.5
(18 ft-lb)
Internal screws: Second phase: pre-torque . . . . . . . . . . . M 16x2 140 14
(103 ft-lb)
Internal screws: Third phase: angle closed . . . . . . . . . . . M 16x2 60°
Internal screws: Fourth phase: angle closed . . . . . . . . . . M 16x2 60°
External screws: Fifth phase: angle closed . . . . . . . . . . . M 10x1.25 90°
Piston cooling nozzle union . . . . . . . . . . . . . . . . . . . . . . . . M 12x1.5 35±2 3.5±0.2
(25±1 ft-lb)
Screw securing heat exchanger to crankcase
(see Figure 9) ♦ M 8x1.25
-- pre-torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5±3.5 1.15±0.35
(8±2 ft-lb)
-- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19±3 1.9±0.3
(14±2 ft-lb)
-- plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 42x1.5 125±15 12.5±1.5
(92±11 ft-lb)
Screws securing spacer and oil sump (see Figure 10) . M 10x1.5 41.5±3.5 4.1±0.3
(30±2 ft-lb)
Screws securing gearbox to crankcase . . . . . . . . . . . . . . M 10x1.25 41.5±3.5 4.1±0.3
(30±2 ft-lb)
M 12x1.75 63±7 6.3±0.7
(46±5 ft-lb)
M 8x1.25 19±3 1.9±0.3
(14±2 ft-lb)
Screw securing cylinder head (see Figure 16) ♦ M 16x2
First phase: pre-torque . . . . . . . . . . . . . . . . . . . . . . . . . 50 (37 ft-lb) 5
Second phase: pre-torque . . . . . . . . . . . . . . . . . . . . . . . . . 100 (73 ft-lb) 10
Third phase: angle closed . . . . . . . . . . . . . . . . . . . . . . . 90°
Fourth phase: angle closed . . . . . . . . . . . . . . . . . . . . . . . 75°
♦ New screw threads are treated with MOLYCOTE and need no further lubrication whatsoever. It can be re-
used for the next five disassemblies. If in doubt about the number of disassemblies already performed, al-
ways change it.
• Before assembly, lubricate with graphitized oil.
10-17
TORQUE
PART Thread
N⋅m (ft-lb) kgm
Screw securing rocker arm shaft ♦ M 14x1.5
Second phase: angle closed . . . . . . . . . . . . . . . . . . . . . . . 60°
Lock nut for rocker arm adjustment screw . . . . . . . . . . . . M 10x1.25 39±5 3.9±5
(28±3 ft-lb)
Screw for injector fixing brackets ♦ . . . . . . . . . . . . . . . . . . M 10x1.5 36.5 3.65
(27 ft-lb)
Screw securing thrust plates to the head ♦ . . . . . . . . . . . M 8x1.25 23.5 2.35
(17 ft-lb)
Screw securing camshaft gear♦ M 12x1.75
First phase: pre-torque . . . . . . . . . . . . . . . . . . . . . . . . . 50 5
(37 ft-lb)
Screw securing phonic wheel to timing system gear . . . M 6x1 8.5±1.5 0.8±0.1
(6±1 ft-lb)
Screws securing exhaust manifold • (see Fig. 7) . . . . . . M 10x1.5
-- pre-torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.5±7.5 3.2±0.7
(24±5 ft-lb)
-- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47±2.5 4.7±0.2
(34±2 ft-lb)
ways change it.
• Before assembly, lubricate with graphitized oil
10-18
TORQUE
PART Thread
N⋅m (ft-lb) kgm
Screw securing connecting rod cap ♦ . . . . . . . . . . . . . . . . . M 12x1.75
First phase: pre-torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 5
(37 ft-lb)
Second phase: angle closed . . . . . . . . . . . . . . . . . . . . . . . . . 40°
Screws securing engine flywheel ♦ . . . . . . . . . . . . . . . . . . . M 16x1.5x58
(73 ft-lb)
Screws securing engine flywheel ♦ . . . . . . . . . . . . . . . . . . . M 16x1.5x110
(73 ft-lb)
Screws securing pulley to crankshaft ♦ . . . . . . . . . . . . . . . . M 14x2
-- pre-torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 7
(51 ft-lb)
-- angle closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50°
Screw securing damper flywheel ♦ . . . . . . . . . . . . . . . . . . . . M 12x1.75 115±15 11.5±1.5
(84±11 ft-lb)
Screws securing middle gear pins ♦ . . . . . . . . . . . . . . . . . . M 12x1.75
(22 ft-lb)
Screw securing connecting rod for transmission gear
adjustment ♦ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8x1.25 24.5±2.5 2.4±0.2
(18±2 ft-lb)
Screw securing oil pump suction hose . . . . . . . . . . . . . . . . . M 8x1.25 24.5±2.5 2.4±0.2
(18±2 ft-lb)
Screw securing front cover to crankcase . . . . . . . . . . . . . . . M 8x1.25 19±3 1.9±0.3
(14±2 ft-lb)
Screw securing control unit to crankcase . . . . . . . . . . . . . . . M 8x1.25 19±3 1.9±0.3
(14±2 ft-lb)
Screw securing fuel pump to gearbox . . . . . . . . . . . . . . . . . M 8x1.25 19±3 1.9±0.3
(14±2 ft-lb)
Screw securing fuel filter mount to cylinder head . . . . . . . . M 10x1.5 37±3 3.7±0.3
(27±2 ft-lb)
ways change it.
10-19
TORQUE
PART Thread
N⋅m (ft-lb) kgm
Screws and nuts securing turbocharger • (see Fig. 8) . . . . M 10x1.5
-- pre-torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.5±7.5 3.2±0.7
(24±5 ft-lb)
-- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46±2 4.6±0.2
(34±1 ft-lb)
Screw securing water pump to crankcase . . . . . . . . . . . . . . M 8x1.25 24.5±2.5 2.4±0.2
(18±2 ft-lb)
Screw securing pulley to hub . . . . . . . . . . . . . . . . . . . . . . . . . M 10x1.25 55±5 5.5±0.5
(40±3 ft-lb)
Screw securing rocker arm cover (see Fig. 12) . . . . . . . . . M 6x1 9 0.9
(6 ft-lb)
Screw securing thermostat box to crankcase . . . . . . . . . . . M 8x1.25 24.5±2.5 2.4±0.2
(18±2 ft-lb)
Screw securing automatic tightener to crankcase . . . . . . . M 10x1.5 45±5 4.5±0.5
(33±3 ft-lb)
Screw securing fixed tightener to crankcase . . . . . . . . . . . . M 12x1.75 105±5 10.5±0
(77±3 ft-lb)
Screw securing fan mount to crankcase . . . . . . . . . . . . . . . M 8x1.25 24.5±2.5 2.4±0.2
(18±2 ft-lb)
Screw securing starter motor . . . . . . . . . . . . . . . . . . . . . . . . . M 10x1.5 44±4 4±0.4
(32±3 ft-lb)
Air heater to the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . M 10x1.5 30±3 3±0.3
(22±2 ft-lb)
ways change it.
10-20
TORQUE
PART Thread
N⋅m (ft-lb) kgm
Screw securing air-conditioner compressor to mount . . . . . M 10x1.5 44±4 4.4±0.4
(32±3 ft-lb)
Screw securing air-conditioner compressor mount to
crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10x1.5 44±4 4.4±0.4
(32±3 ft-lb)
Screw securing alternator mount to crankcase . . . . . . . . . . . M 10x1.5 44±4 4.4±0.4
(32±3 ft-lb)
Screw securing alternator bracket to crankcase . . . . . . . . . . M 8x1.25 24.5±2.5 2.4±0.2
(18±2 ft-lb)
Water pipe fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 30x1.5 35 3.5
(25 ft-lb)
Water temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16x1.5 32.5±2.5 3.2±0.2
(24±2 ft-lb)
Screw securing flywheel speed sensor . . . . . . . . . . . . . . . . . M 6x1 8±4 0.8±0.2
(6±3 ft-lb)
Screw securing camshaft speed sensor . . . . . . . . . . . . . . . . M 6x1 8±4 0.8±0.2
(6±3 ft-lb)
Screw securing pump injector connector . . . . . . . . . . . . . . . . M 3x0.5 1.62±0.3 0.1±0.3
(14±2 in. lbs.)
Screw securing overboost pressure sensor . . . . . . . . . . . . . M 6x1 8±2 0.8±0.2
(6±1 ft-lb)
Screw securing absolute pressure sensor . . . . . . . . . . . . . . . M 12x1.5 22.5±2.5 2.2±0.2
(16±2 ft-lb)
Coolant/fuel temperature sensor . . . . . . . . . . . . . . . . . . . . . . . M 18x1.5 35 3.5
(25 ft-lb)
Coolant temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16x1.5 23.5±2.5 2.3±0.2
(17±2 ft-lb)
Filter clogging sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 gas 25±1 2.5±0.1
(18±.5 ft-lb)
Oil temperature switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 14x1.5 25±1 2.5±0.1
(18±.5 ft-lb)
Oil pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 14x1.5 25±1 2.5±0.1
(18±.5 ft-lb)
Oil clogging sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4-16 UNF 55±5 5.5±5
(40±3 ft-lb)
Screws securing electric cables . . . . . . . . . . . . . . . . . . . . . . . M 6x1 8±2 0.8±0.2
(6±1 ft-lb)
Screws securing heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 6x1 12.5±2.5 1.2±0.2
(9±2 ft-lb)
M 8x1.25 12.5±2.5 1.2±0.2
(9±2 ft-lb)
10-21
ENGINE F3A
TORQUE
PART Thread
N⋅m (ft-lb) kgm
Screws securing sub-crankcase to crankcase
(see Figs. 1-2-3-4-5) ♦
External screws First phase: pre-torque . . . . . . . . . . . . . . M 12x1.75 30 (22 ft-lb) 3
Internal screws Second phase: pre-torque . . . . . . . . . . . M 17x2 120 (88 ft-lb) 12
Internal screws Third phase: angle closed . . . . . . . . . . . M 17x2 90°
Internal screws Fourth phase: angle closed . . . . . . . . . . M 17x2 45°
External screws Fifth phase: angle closed . . . . . . . . . . . . M 12x1.75 60°
Piston cooling oil nozzle union . . . . . . . . . . . . . . . . . . . . . . M 12x15 35±2 3.5±0.2
(25±1 ft-lb)
Screws securing heat exchanger to crankcase
(see Fig. 9) ♦ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8x1.25
-- pre-torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 (8 ft-lb) 1.15
-- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 (14 ft-lb) 1.9

Screws securing spacer and oil sump (see Fig. 11) . . . . M 10x1.5
-- pre-torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 (28 ft-lb) 3.8
-- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 (33 ft-lb) 4.5

Screws securing gearbox to crankcase . . . . . . . . . . . . . . M 12x1.25 63±7 6.3±0.7
(46±5 ft-lb)
Screw securing cylinder head (see Fig. 6) ♦ . . . . . . . . . M 17x2
Second phase: pre-torque . . . . . . . . . . . . . . . . . . . . . . . . . 120 (88 ft-lb) 12
Fourth phase: angle closed . . . . . . . . . . . . . . . . . . . . . . . 60°
Screw securing rocker arm shaft ♦ . . . . . . . . . . . . . . . . . M 16x1.5
Lock nut for rocker arm adjustment screw . . . . . . . . . . . . M 10x1.25 39±5 3.9±0.5
(28±3 ft-lb)
Screw for injector fixing brackets ♦ . . . . . . . . . . . . . . . . . . M 8x1.25 26 (19 ft-lb) 2.6
Screw securing thrust plates to the head . . . . . . . . . . . . M 8x1.25 19 (14 ft-lb) 1.9
Screw securing engine bracket to cylinder head M 18x2
♦ Before assembly, lubricate with engine oil

10-22
TORQUE
PART Thread
N⋅m (ft-lb) kgm
Screw securing engine bracket to timing system gear-
box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16x2
Screw securing camshaft gear ♦ . . . . . . . . . . . . . . . . . . . M 14x2
Screw securing phonic wheel to timing system gear . . . M 6x1 8.5±1.5 0.8±0.1
(75±13 in. lbs.)

10-23
TORQUE
PART Thread
N⋅m (ft-lb) kgm
Screws securing exhaust manifold • (see Figure 7) . . . . M 10x1.5
-- pre-torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.5±7.5 3.2±0.7
(24±5 ft-lb)
-- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45±5 4.5±0.5
(33±3 ft-lb)
Screw securing connecting rod cap ♦ . . . . . . . . . . . . . . . M 14x2
Screws securing engine flywheel ♦ . . . . . . . . . . . . . . . . . M 18x1.5
Screws securing pulley to crankshaft ♦ . . . . . . . . . . . . . . M 14x2
-- pre-torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 (51 ft-lb) 7
-- angle closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50°

Screws securing middle gear pins ♦ . . . . . . . . . . . . . . . . M 12x1.75
Screw securing connecting rod for transmission gear M 8x1.25 25±2.5 2.5±0.2
adjustment ♦ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (18±2 ft-lb)
Screw securing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . M 8x1.25 25±2 2.5±0.2
(18±1 ft-lb)
Screw securing oil pump suction hose and pipe to M 8x1.25 25±2 2.5±0.2
crankcase . . . . (18±1 ft-lb)
Screw securing fuel filter to cylinder head . . . . . . . . . . . . M 10x1.5 37±3 3.7±0.3
(27±2 ft-lb)
Screw securing crankshaft gasket cover . . . . . . . . . . . . . M 8x1.25 25±2 2.5±0.2
(25±1 ft-lb)
Screw securing control unit mount to crankcase . . . . . . M 8x1.25 19±3 1.9±0.3
(14±2 ft-lb)
Screw securing fuel pump to flywheel cover box . . . . . . M 8x1.25 19±3 1.9±0.3
(14±2 ft-lb)
Screw securing thermostat box to cylinder head . . . . . . M 8x1.25 19±3 1.9±0.3
(14±2 ft-lb)
Screw securing rocker arm cover (see Fig. 13) . . . . . . . M 6x1 8.5±1.5 0.8±0.1
(75±13 in. lbs.)
10-24
TORQUE
PART Thread
N⋅m (ft-lb) kgm
Screws and nuts securing turbocharger •
(see Figure 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10x1.5
-- pre-torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.5±7.5 3.3±0.7
(24±5 ft-lb)
-- torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46±2 4.6±0.2
(34±1 ft-lb)
Screw securing water pump to crankcase . . . . . . . . . . . . M 8x1.25 25±2 2.5±0.2
(18±1 ft-lb)
Screw securing spacer/pulley to fan . . . . . . . . . . . . . . . . . M 8x1.25 30±3 3±0.3
(22±2 ft-lb)
Screw securing automatic tightener to crankcase . . . . . M 10x1.5 50±5 5±0.5
(37±3 ft-lb)
Screw securing fixed tightener to crankcase . . . . . . . . . . M 12x1.75 105±5 10.5±0.5
(77±3 ft-lb)
Screw securing fan mount to crankcase . . . . . . . . . . . . . M 12x1.75 100±5 10±0.5
(73±3 ft-lb)
Screw securing starter motor . . . . . . . . . . . . . . . . . . . . . . . M 12x1.75 74±8 7.4±0.8
(54±6 ft-lb)
Screw securing air heater to the cylinder head . . . . . . . . M 10x1.5 37±3 3.7±0.3
(27±2 ft-lb)

10-25
TORQUE
PART Thread
N⋅m (ft-lb) kgm
Screw securing air-conditioner compressor drive belt
automatic tightener to crankcase . . . . . . . . . . . . . . . . . . . . . M 8x1.25 26±2 2.6±0.2
(19±1 ft-lb)
Screw securing alternator bracket to crankcase L = 35mm M 10x1.5 30±3 3±0.3
(22±2 ft-lb)
L = 60mm M 10x1.5 44±4 4.4±0.4
(32±3 ft-lb)
L = 30mm M 8x1.25 24.5±2.5 2.4±0.2
(18±2 ft-lb)
Screw securing air-conditioner compressor mount . . . . . . . M 8x1.25 24.5±2.5 2.5
(18±2 ft-lb)
Screw securing guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8x1.25 24.5±2.5 2.5
(18±2 ft-lb)
Filter clogging sensor fixing . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4-16 UNF 55±5 5.5
(40±3 ft-lb)
Pressure transmitter fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . M 6x1 8±2 0.8±0.2
(70±17 in. lbs.)
Coolant/fuel temperature sensor fixing . . . . . . . . . . . . . . . . . M 16x1.5 32.5±2.5 3.2±0.2
(24±2 ft-lb)
Temperature switch/transmitter fixing . . . . . . . . . . . . . . . . . M 16x1.5 23±2.5 2.3±0.2
(17±2 ft-lb)
Air temperature transmitter fixing . . . . . . . . . . . . . . . . . . . . . M 16x1.5 32.5±2.5 3.2±0.2
(24±2 ft-lb)
Pulse transmitter fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 6x1 8±2 0.8±0.2
(70±17 in. lbs.)
Connections to injector-pump . . . . . . . . . . . . . . . . . . . . . . . . M 3x0.5 1.36±1.92 0.13±0.19
(12±17 in. lbs.)
Screw securing electric cables . . . . . . . . . . . . . . . . . . . . . . . M 6x1 8±2 0.8±0.2
(70±17 in. lbs.)
10-26
PLAN OF TIGHTENING SEQUENCE OF SCREWS SECURING SUB-CRANKCASE
First phase
external screw pre-torque:
A
-- F2B 25 N⋅m (18 ft.-lbs.)
-- F3A 30 N⋅m (22 ft.-lbs.)
MID0261A
1
Second phase
internal screw pre-torque:
-- F2B 140 N⋅m (103 ft.-lbs.)
-- F3A 120 N⋅m (88 ft.-lbs.)
MID0262A
2
Third phase
internal screw angle closed:
-- F2B 60°
-- F3A 90°
MID0263A
3
Fourth phase
-- F2B 60°
-- F3A 45°
MID0264A
4
Fifth phase
external screw angle closed:
-- F2B 60°
-- F3A 60°
A = front side A
MID0265A
5
10-27
Plan of tightening sequence

of screws securing cylinder
head
MID0266A
6
of screws securing exhaust
manifold
MID0267A
7
of screws and nuts securing
turbocharger
Sequence:
pre-torque 4-3-1-2
torque 1-4-2-3
MID0268A
8
of screws securing heat
exchanger
MID0269A
9
of screws securing engine oil
sump
Engine F2B
MID0270A
10
10-28
of screws securing engine oil
sump
Engine F3B
First phase: from 1 to 16
Second phase: from 17 to 32
MID0271A
11
of screws securing rocker
arm cover
Engine F2B
MID0272A
12
of screws securing rocker
arm cover
Engine F3A
MID0273A
13
10-29
SPECIAL TOOLS
CAUTION
The operations described in this section can only
be carried out with the ESSENTIAL tools indi-
cated by an (X).
To work safely and efficiently and obtain the best
results, it is also necessary to use the recom-
mended specific tools listed below and certain
other tools, which are to be made according to the
drawings included in this manual.
PART DESCRIPTION
380000368 Valve guide reamer (F3A engine only)
380000219 Drift to remove valve guide (F2B engine only)
380000220 Clamp to insert piston in cylinder liner (60 - 125 mm)
291777 Valve guide reamer (F2B engine only)
291980 Tool to remove oil filter
380000363 Tool to retain cylinder liners
380000370 Tool to remove remains of injector sheath
380000304 Pair of gauges for angular torque with 1/2” and 3/4” square connection
380000549 Percussion extractor
380000362 Crankshaft lifting tool
380000361 Revolving telescopic service stand (capacity 2000 daN, torque 375 daN/m)
380000360 Engine removal and installation tool
380000324 Pliers for piston ring disassembly and reassembly (105 - 160 mm)
380000364 Tool for measuring cylinder liner protrusion (use with 380000167)
380000365 Drift to remove valve guide (F3A engine only)
380000366 Tool to remove cylinder liners (use with specific rings)
380000118 Tool to remove crankshaft front gasket (F2B engine only)
380000119 Tool to remove crankshaft rear gasket (F2B engine only)
380000120 Tool to remove crankshaft front gasket (F3A engine only)
380000121 Tool to remove crankshaft rear gasket (F3A engine only)
380000122 Tool to remove injectors (F2B engine only)
380000123 Extractor for injector sheath
380000124 Key for fitting crankshaft front gasket (F2B engine only)
380000125 Key for fitting crankshaft rear gasket (F2B engine only)
10-30
PART DESCRIPTION
380000126 Key for fitting crankshaft front gasket (F3A engine only)
380000127 Key for fitting crankshaft rear gasket (F3A engine only)
380000128 Tools (12+6) to retain rocker arm adjustment screw sliding blocks when
disassembling and reassembling the rocker arm shaft
380000129 Caps (6) protecting injector seats (F2B engine only)
380000130 Caps (6) protecting injector seats (F3A engine only)
380000131 Tool to disassemble and reassemble engine valves (use with specific plates)
(F3A engine only)
380000132 Plate to disassemble and reassemble engine valves (use with 380000131 –
F3A engine only)
380000133 Tool to disassemble and reassemble engine valves (F2B engine only)
380000134 Key to fit gasket on valve guide (F2B engine only)
380000135 Drift to reassemble valve guide (use with 380000219) (F2B engine only)
380000136 Drift to reassemble valve guide (use with 380000365 – F3A engine only)
380000137 Tool for engine flywheel rotation (use with 380000138 – F3A engine only)
380000138 Spacer (use with 380000137 – F3A engine only)
380000139 Key to fit gasket on valve guide (F3A engine only)
380000140 Tool for compression to measure cylinder liner protrusion (use with 380000364
and specific plates)
380000141 Plate for cylinder liner compression (use with 380000140 –

F2B engine only)
380000142 Spacers (use with 380000140 – F3A engine only)
380000143 Plate for cylinder liner compression (use with 380000140 - 380000142 –
F3A engine only)
380000144 Tool to retain engine flywheel
380000145 Drift to disassemble and reassemble camshaft bushings

(F2B engine only)
380000146 Drift to disassemble and reassemble camshaft bushings

(F3A engine only)
380000147 Bracket to disassemble and reassemble engine flywheel
380000148 Tool to assemble and install rocker arm shaft (use with 380000128 –
F3A engine only)
380000149 Tool to assemble and install rocker arm shaft (use with 380000128 –
F2B engine only)
380000150 Tool for engine TDC positioning
380000151 Tool for phonic wheel timing on camshaft
10-31
PART DESCRIPTION
380000152 Ring (115 mm) (use with 380000366 – F2B engine only)
380000153 Ring (115 mm) (use with 380000366 – F3A engine only)
380000154 Brackets fixing engine to rotary stand 380000361 (F2B engine only)
380000155 Brackets fixing engine to rotary stand 380000361 (F3A engine only)
380000156 Tool for upsetting injector sheath (F2B engine only)
380000157 Tool for upsetting injector sheath (F3A engine only)
380000159 Tool for threading injector sheaths to remove (use with 380000160)
380000160 Guide bushing (use with 380000159 – F3A engine only)
380000161 Guide bushing (use with 380000163 or 380000164 – F2B engine only)
380000162 Guide bushing (use with 380000163 or 380000164 – F3A engine only)
380000163 Milling cutter to rebore injector seat (use with: 380000162 for F3A engine –
380000161 for F2B engine)
380000164 Reamer to rebore bottom of injector sheaths (use with: 380000161 for F2B engine,
380000162 for F3A engine)
380000165 Gauge to determine centre distance between camshaft and transmission gear
(F2B engine only)
380000167 Gauge to determine centre distance between camshaft and transmission gear
(F3A engine only)
380000168 Crankshaft front gasket cover centring ring (F2B engine only)
380000169 Crankshaft front gasket cover centring ring (F3A engine only)
10-32
SYSTEM DIAGRAMS
Oil by gravity
Oil under pressure
MID0274A
14
Lubrication diagram
10-33
MID0275A
15
F2B Engine – Fuel supply system diagram
1. Temperature sensor – 2. Bleeder – 3. Secondary fuel filter – 4. Bypass valve (0.3 - 0.4 bars [4.4 - 5.8 psi])
– 5. Fuel supply pump – 6. Integrated valve (3.5 bars [50.8 psi]) – 7. Pressure relief valve (5 bars [72.5 psi]) –
8. Fuel tank – 9. Priming pump – 10. Primary fuel filter – 11. Check valve (opening 0.1 bars [1.5 psi]) – 12. Heater
– 13. Electronic control unit – 14. Fuel return fitting with incorporated valve (0.2 bars [3 psi]) – 15. Injectors - pump
– 16. Electric fuel pump
10-34
MID0276A
16
F3A Engine – Fuel supply system diagram
1. Temperature sensor – 2. Bleeder – 3. Secondary fuel filter – 4. Bypass valve (0.3 - 0.4 bars [4.4 - 5.8 psi])
– 5. Fuel supply pump – 6. Integrated valve (3.5 bars [50.8 psi]) – 7. Pressure relief valve (5 bars [72.5 psi]) –
8. Fuel tank – 9. Priming pump – 10. Primary fuel filter – 11. Check valve (opening 0.1 bars [1.5 psi]) – 12. Heater
– 13. Electronic control unit – 14. Fuel return fitting with incorporated valve (0.2 bars [3 psi]) – 15. Injectors - pump
10-35
MECHANICAL TROUBLESHOOTING
Preliminary conditions
• Electric troubleshooting has to have been performed with specific instruments.
• The air system must be efficient.
• The engine must have the proper oil pressure.
If the engine works but has occasional or non-constant trouble, check the earth connections on connector
B of the control unit PIN 1 and PIN 2.
1 THE ENGINE FAILS TO START
DEFECT CAUSE REMEDY

1.a Batteries: -- Low charge -- Recharge
-- Connections to terminals not -- Clean, check, tighten the ter-
efficient minals or replace them
1.b Starter motor: -- Not efficient -- Check or replace
1.c Heater: -- Not efficient -- Check supply and earth con-
nection. Replace.
-- Check heater relay perform
active diagnosis
1.d Main relay -- Not efficient -- Check, replace
-- Fuse -- Replace
1.e Fuel supply pump -- Fails to prime (incoming air) -- Check seal on intake branch.
Check pressure on filter inlet.
1.f Fuel circuit -- Not correctly filled (air in the -- Check seal
circuit) -- Bleed
1.g Fuel filter and pre-filter -- Clogged -- Replace
2 ENGINE OVERHEATS
DEFECT CAUSE REMEDY

2.a Coolant level -- Under minimum -- Check for leaks
-- Top up to level
2.b Fan and water pump drive belt -- Not efficient -- Check tension
-- Replace
-- Check whether water leaks
from drainage hole
2.c Water pump -- Not efficient -- Replace
2.d Thermostat -- Jammed shut or partially open -- Replace
2.e Radiator -- Clogged outside -- Wash or replace
2.f Air filter -- Clogged -- Check filter clogging indicator
-- Sleeves close -- Replace filter
2.g Cylinder head gasket -- Compression blow-by from -- Check water circuit pressure
cylinder head gasket -- Replace
2.h Fan -- It cuts in late -- Replace
-- It slips too much
10-36
3 POOR ENGINE PERFORMANCE
(LOW POWER, CONSUMPTION TOO HIGH, NOISY)
DEFECT CAUSE REMEDY

3.a Fuel circuit -- Mesh filter on tank clogged -- Clean
-- Fuel pre-filter clogged -- Replace
-- Fuel filter clogged -- Replace
-- Air in circuit -- Check intake seals (quick
-- Valve 0.8 bars on fuel return couplings when hot)
from cylinder head:
a) Jammed open -- Replace
(low pressure)
b) Jammed shut -- Replace
(high temperature)
-- Bad fuel leakage -- Check, repair
-- Supply pump broken (seized, -- Check pressure on filter inlet
broken coupling, pressure Replace
adjustment valve, etc.)
3.b Injectors -- Irregular operation -- Replace
-- Diesel leakage from O rings -- Check for fuel in the engine
3.c Air supply to engine -- Air filtration -- Check cartridge clogging indi-
(constriction clogged filter) cator.
Eliminate constriction
Replace filter
3.d Gas exhaust -- Leakage on exhaust manifold -- Check - eliminate
3.e Turbocharger -- Sound blades -- Check
-- Sound bearings (clearance, -- Replace turbocharger
etc.)
-- Waste--gate valve off setting -- Adjust or replace waste-gate
or inefficient valve and adjust
3.f Injector control cams -- Wear -- Check, replace
3.g Valves -- Too much or no clearance -- Check, replace
4 GREY-WHITE SMOKE FROM ENGINE
DEFECT CAUSE REMEDY

4.a Water in cylinders -- Leakage from head gasket -- Check water circuit pressur-
-- Leakage from injector sheaths ization liquid level
-- Incoming water from intake -- Check tank cleaning
system
-- Water in diesel
10-37
5 BLUE SMOKE FROM ENGINE
DEFECT CAUSE REMEDY

5.a Oil in cylinders -- Too much oil consumption --
-- Oil blow-by from turbine
-- Blow-by from valve guide
6 ENGINE STOPS
DEFECT CAUSE REMEDY

6.a Fuel tank -- No diesel -- Refuel and bleed circuit
6.b Mesh filter -- Clogged -- Clean, replace
Pre--filter
Fuel filter
6.c Trouble with fuel circuit -- See 3.a -- See 3.a
6.d Speed -- Idling speed too low -- Adjust
6.e Main relay -- Broken down -- Replace
10-38
OVERHAUL
ENGINE
Disassembly and Assembly
CAUTION
Handle all parts carefully. Do not put your hands
or fingers between parts. Wear suitable safety
clothing - safety goggles, gloves and shoes.
Protect the electric parts before any washing with

high-pressure jets.
Here we describe and illustrate the operations for
disassembling the F2B engine that, unless stated 1
otherwise, hold for the F3A engine, too.
Before securing the engine on the rotary stand,
remove:
1. the electric cable of the engine, disconnecting it 3
from the control unit and from all the sensors/
transmitters to which it is connected.
F3A engine only:
2. With an appropriate tool, 3, act in the direction of
the arrow on the tightener, 5, and remove the 2 5
compressor drive belt, 1. MID0277A
3. Remove the compressor, 2, together with the en-

gine mount. 17
For both engines:

4. Remove the oil pressure adjustment valve, 1.
MID0278A
18
5. Remove the engine mounts.
6. Remove the drive, 1.
MID0279A
19
10-39
7. Secure the engine to the rotary stand with the
brackets:
-- 380000155, for the F3A engine;
MID0280A
20
-- 380000154, for the F2B engine.
8. Drain the lubricating oil from the sump.
MID0281A
21
F2B engine only.
9. Using a suitable tool, 6, act in the direction of the
arrow on the tightener, 5, and remove the belt, 4.
Both engines.
10. Using a suitable tool, 3, act in the direction of the
MID0282A
22
10-40
Remove:
11. the air-conditioner compressor, 3, and its mount,
4, F2B engine only;
12. the alternator, 2;
13. the mounts, 2 and 5.
MID0283A
23
Remove:
14. thermostat assembly, 8;
15. pipes together with coolant, 6;
16. pulley, 4;
17. water pump, 7;
18. automatic tightener mount, 1;
19. fixed tightener, 5;
20. damper flywheel, 3, and pulley beneath;
21. automatic tightener, 2.
MID0284A
24
22. With the extractor, 2:
-- 380000118, F2B engine;
-- 380000120, F3A engine, applied as illustrated in
the Figure, remove the gasket, 4. Unscrew the
screws, 3, and take off the cover, 1. Disconnect all
1
4
the electric connections and sensors.
MID0285A
25
10-41
From the engine exhaust side, remove the following
parts:
23. oil delivery pipe, 1;
24. air pipe for actuator, 5;
25. oil return pipe, 4;
26. turbocharger, 3;
27. exhaust manifold, 2.
MID0286A
26
28. disconnect the oil pipes, 3 and 4, and disengage
them from the clamps (←).
29. remove the fixing screws, 1, and the heat ex-
changer, 2;
MID0287A
27
30. disconnect the fuel pipes, 1, from the supply
pump, 2. 3
Remove:
31. the supply pump, 2; 4
32. the mount, 3, together with the fuel filter, 4, and
pipes, 1.
1
MID0288A
28
33. with tool 291980 unscrew the oil filters, 1.
MID0289A
F2B F3A
29
10-42
34. Disconnect the pipes, 2 and 3, from the mounts,
1 or 4, disengaging them from the clamps, and re- 4
move them. 1
35. Take out the screws, 5, and remove the mounts,
1 or 4.
2 5
3
5
MID0290A F2B F3A
30
36. Remove the screws, 2, (Figs. 31 and 32), and in-
take manifolds, 1.
MID0291A F2B
31
MID0292A F3A
32
Remove:
37. the starter motor, 1;
38. the control unit, 2, and the relevant mount;
39. the oil dipstick, 3, from the crankcase.
MID0293A
33
10-43
40. Remove the rocker arm cover, 1.
41. Remove the timing system cover, 2.
1
2
MID0294A
34
42. Unscrew the screws, 2, and take out the gear, 1,
together with the phonic wheel.
MID0295A
35
43. Unscrew the five screws, 1.
44. Take out the thrust plate, 2, together with the ring
seal as follows:
-- for the F2B engine, screw three screws
10x1.5 in the holes (A, B, C) for screws, 1, 1
and, pulling on them, extract the plate, 2.
-- for the F3A engine, screw three screws
10x1.5 in the holes (A, B, C) to extract the 2
thrust plate, 2. Remove the sheet metal
gasket beneath.
MID0296A
36
45. Unscrew the screws, 1, and remove the trans-
mission gear, 2.
2
MID0297A
37
10-44
46. With an appropriate wrench, unscrew the screw
(2) and remove the transmission gear, 1.
2
MID0298A
38
47. Block rotation of the engine flywheel, 3, with tool
380000144, 1. Unscrew the fixing screws, 2, and
remove the engine flywheel.
1
2
3
MID0299A
39
48. With the extractor (a):
-- 380000119, for engine F2B;
-- 380000121, for engine F3A, applied as illus-
trated in the Fig., remove the ring seal, 1, from
the timing box.
1
2
MID0300A
40
49. Unscrew the screws, 1, and remove the timing
gear box, 2.
2
1
MID0301A
41
10-45
50. Unhook the springs, 3, lever check, 2, engine F3A
only.
51. Unscrew the rocker arm shaft fixing screws, 1.
MID0302A
42
52. With tool 380000128, 2, constrain the sliding
blocks, 3, to the rocker arms, 1.
MID0303A
43
53. With the tool, 1:
-- 380000149, for the F2B engine; 1
-- 380000148, for the F3A engine, applied as in
the Fig., remove the rocker arm shaft
assembly.
MID0304A
44
54. Remove the cross-pieces from the valves.
55. Unscrew the screws and remove the electric con-
nections, 1, from the solenoid valves.
56. Unscrew the screws, 3, fixing the brackets, 4, re-
taining the pump injectors, 2.
57. Remove the pump injectors, 2.
MID0305A
45
10-46
Engine F2B only
58. If it proves difficult to remove the pump injectors,
2, use the extractor 380000122, 1.
1
MID0306A
46
59. Fit the caps, 1, in place of the injectors:
-- 380000129, for the F2B engine;
-- 380000130, for the F3A engine.
60. Remove the camshaft, 3.
61. Remove the screws, 2, fixing the cylinder head. 2 1
MID0307A
47
62. With specific ropes and lift, take off the cylinder
head, 1.
63. Remove the gasket, 2.
2
MID0308A
48
64. Unscrew the screws, 2, and remove the engine oil
sump, 1, together with the spacer, 3, and the gas-
ket.
MID0309A
49
10-47
65. Unscrew the screws and remove the suction
hose, 1.
MID0310A F2B F3A

50
66. Turn the crankcase, 1, upright.
MID0311A
51
67. Unscrew the screws, 2, fixing the connecting rod
cap, 3, and remove it.
68. From the top, take out the piston connecting rod 2
assembly, 1. Repeat the same operations for the
other pistons. 1
CAUTION
Keep the connecting rod half bearings in their
housings and/or note their assembly position
since, if they are to be reused, they will need to be
fitted in the same position found in disassembly.
3
MID0312A
52
69. Using an appropriate wrench and a hex wrench
unscrew the screws, 1 and 2, and remove the
sub-crankcase, 3.
1
CAUTION
Note down the assembly position of the top and
bottom main bearing shells since, if they are to be 2
reused, they will need to be fitted in the same
position found in disassembly.
3
MID0313A
53
10-48
70. Using tool 380000362, 1, remove the crankshaft,
2.
MID0314A
54
71. Take out the main bearing shells, 1.
Unscrew the screws and remove the oil nozzles,
2.
72. Remove the cylinder liners as described in the rel-
evant paragraph on page 68.
MID0315A
55
-- When fitting the oil filter, lubricate the seal with en-
gine oil.
General Notes
-- After taking down the engine, clean the parts
carefully. CAUTION
-- The following pages illustrate the assembly oper-
ations that must be read extremely carefully to be The following pages give the instructions for the
able to assemble the parts correctly. main checks and measurements to make to deter-
mine whether the parts are sound enough to be
-- The torques of the parts and the instructions that reused after reassembly.
must be followed meticulously are given begin-
ning on pages 14 through 27.
In Addition It Is Necessary To Bear In Mind CAUTION

That:
-- When totally or partially stripping the engine, all between parts and use the most suitable tools to
the gaskets need to be replaced. align holes.
-- Before inserting the rotary parts and gaskets in Wear the required safety clothing - safety goggles,
the coupling, it is necessary to lubricate the parts gloves and shoes.
with engine oil.
10-49
ASSEMBLING CRANKSHAFT WITH MAIN
BEARING CAPS, THRUST BEARINGS AND
RINGS, CRANKSHAFT END FLOAT
2
1
Fitting the Crankshaft Bearings 3
CAUTION
On finding there is no need to replace the
crankshaft bearings, it is necessary to fit them
back on in the same sequence and position found
during disassembly. If you need to replace them,
select the crankshaft bearings according to the
selection described on pages 75 through 78. MID0316A
56
If dismantled, refit the oil nozzles, 2, tightening the
union, 3, to the required torque. Put the half bearings,
1, on the crankshaft mounts of the crankcase.
The crankshaft bearings are supplied as spare parts
with an undersized internal diameter of 0.127 - 0.254
- 0.508 mm (.005 - .010 - .020″).
CAUTION
Do not make any adjustments to the bearings.
Using a hoist and hook 380000362, 1, mount the

crankshaft, 2.
MID0317A
57
Put the half bearings, 1, on the main bearings in the
sub-crankcase, 2.
1
MID0318A
58
10-50
Apply Loctite® 5699 sealant on the crankcase with an
appropriate tool, 1, as shown in the Figure.
The box contains a diagram for applying Loctite®
1
5699 sealant.
CAUTION
Fit the sub-crankcase within 10 min. of applying
the sealant.
MID0319A
59
Fit the sub-crankcase, 1, using a hoist and
appropriate hooks.
1
2
MID0320A
60
CAUTION
2 3 4
The sub-crankcase fixing screws of the F2B en-
gine are treated with MOLYCOTE lubricant and
need no lubrication whatsoever.
They can be reused for up to five disassemblies;
replace them if in doubt.
The sub-crankcase fixing screws of the F3A en-
gine must, before assembly, be lubricated with
engine oil. 1
1
Screw down the screws, 1, and tighten them
according to the torques and phases shown in the
MID0321A
following Figures.
61
First phase
external screw pre-torque:
-- F2B 25 N⋅m (18 ft.-lbs.)
A
-- F3A 30 N⋅m (22 ft.-lbs.)
MID0322A
62
10-51
Second phase
internal screw pre-torque:
-- F2B 140 N⋅m
(103 ft.-lbs.)
-- F3A 120 N⋅m
(88 ft.-lbs.)
A
MID0323A
63
Third phase
-- F2B 60°
-- F3A 90°
MID0324A
64
Fourth phase
-- F2B 60°
-- F3A 45°
MID0325A
65
Fifth phase
-- F2B 90°
-- F3A 60°
A = front side
A
MID0326A
66
10-52
Checking Crankshaft Shoulder Clearance
The shoulder clearance is checked by placing a dial
gauge, 1, with a magnetic base on the crankshaft, 2,
as shown in the Figure.
If the clearance is found to be greater than as
required, replace the rear main thrust bearing shells
and check the clearance again.
2
1
MID0327A
67
With the centering ring, 2:
-- 380000169, for the F3A engine, position the front
cover, 1, on the crankcase, screws down the
screws, 3, and tighten them to the required torque.
1
MID0328A
68
Key the ring seal, 1, onto the crankshaft, on which you
should apply the tool, 2:
-- 380000126, for the F3A engine. 1
Screw down the nut, 3, to mount the ring seal, 1,
completely in the cover, 2. 2
MID0329A
69
ASSEMBLING PISTONS WITH PISTON
RINGS, PINS, CONNECTING RODS,
CONNECTING ROD CAPS AND BEARINGS
– CHECKING PROTRUSION OVER THE TOP
1
FACE OF THE CRANKCASE
Fit the rings, 1, on the pistons, 2, with the pliers 2
380000221, 3. The rings have to be fitted with the 3
word “TOP”, 4, facing upwards, also arrange the
openings of the piston rings so they are out of step
with each other by 120°.
MID0330A 4
70
10-53
CAUTION
On finding there is no need to replace the connect- 1
ing rod bearings, it is necessary to fit them back on
in the same sequence and position found during
disassembly. If you need to replace them, select the 2
connecting rod bearings according to the selection
described on pages 75, 79, 81 and 82.
1
Lubricate the half bearings, 1, and fit them on the
connecting rod, 2, and on the cap, 4.
4
CAUTION
MID0331A
Do not make any adjustments to the half bea-
rings. 71
Lubricate the pistons, piston rings and the inside of

the cylinder liners. With the aid of the clamp
380000220, 2, fit the connecting rod-piston
assemblies, 1, in the cylinder liners according to the
diagram of Figure 73, checking that:
-- The number of each connecting rod corresponds 1
to the cap coupling number.
-- The symbol, 2, (Figure 73), punched on the top of
the pistons faces towards the engine flywheel; or 2
the cavity in the shell of the pistons corresponds
to the position of the oil nozzles.
CAUTION MID0332A
Class A pistons are supplied as spares and they 72

can also be fitted in a class B cylinder liner.
Outline for Fitting the

Connecting Rod-Piston
Assembly in the Cylinder 2
Liner
1. Connecting rod-piston as-
sembly.
2. Punched zone on the top of
the piston with symbol for the
assembly position and class
of selection.
3. Connecting rod punching
zone. 1
MID0333A
73
10-54
Connect the connecting rods to the relevant pins of
the crankshaft. Fit on the caps of the connecting rod, 3
1, together with the half bearings.
Screw down the fixing screws, 2, and tighten them in

two stages to the torques given in the following table:
1
F2B F3A 1
50 N⋅m (5 kgm 60 N⋅m (6 kgm
1st phase 2
[37 ft.-lbs.]) [44 ft.-lbs.])
2
2nd phase, angle 40° 60°
MID0334A
74
CAUTION
The connecting rod cap fixing screws of the F2B CAUTION
engine are treated with MOLYCOTE lubricant and Lubricate the relevant parts before final assem-
need no lubrication whatsoever. They can be re- bly. Before reusing the connecting rod cap fixing
used for up to five disassemblies; replace them if screws, measure the thread diameter is no lower
in doubt. The connecting rod cap fixing screws of than:
the F3A engine must, before assembly, be lubri- 11.4 mm (.449″) - Engine F2B
cated with engine oil. 13.4 mm (.528″) - Engine F3A
Replace the screw if its diameter is any lower.
Angle closing is performed with tool 380000304, 3.
FITTING AND TIGHTENING THE CYLINDER
HEAD
Check that the pistons 1 - 6 are exactly at the TDC Put
the gasket, 2, on the crankcase. 1
Fit the cylinder head, 1, and tighten the fixing screws
according to the tightening sequence given in the
diagram of Figure 76 and in four successive stages
as shown in the Figures.
CAUTION 2
The cylinder head fixing screws of the F2B engine
are treated with MOLYCOTE lubricant and need
no lubrication whatsoever. They can be reused MID0335A
for up to five disassemblies; replace them if in
doubt. The cylinder head fixing screws of the F3A 75
engine must, before assembly, be lubricated with
engine oil.
Tightening sequence of the cylinder head fixing

screws.
MID0336A
76
10-55
Pre-tightening with torque wrench, 1.
F2B F3A
1
1st 50 N⋅m 60 N⋅m
phase (5 kgm [37 ft.-lbs.]) (6 kgm [44 ft.-lbs.])
2nd 100 N⋅m 120 N⋅m
phase (10 kgm [73 ft.-lbs.]) (12 kgm [88 ft.-lbs.])
MID0337A
77
Angle closing with tool 380000304, 1.
F2B F3A
1a fase 90° 120°
2a fase 75° 60°
MID0338A
FITTING OIL PUMP, TIMING SYSTEM
INTERMEDIATE GEARS AND GEAR BOX 78
Fit the oil pump, 4, intermediate gears, 2, together
with connecting rod, 1, and tighten the screws, 3, in
two stages:
-- pre-torque 30 N⋅m (22 ft.-lbs.) 1
-- closed angle 90°
2
CAUTION
3
The screws, 3, fixing the intermediate gear of the
F2B engine are treated with MOLYCOTE lubricant 4
and require no lubrication whatsoever. They can
be reused for up to five disassemblies; replace
them if in doubt. The screws fixing the intermedi-
MID0339A
ate gear of the F3A engine must, before assembly,
be lubricated with engine oil.
79
Apply Loctite® 5699 silicone on the gear box, 2, with
an appropriate tool, 1, as shown in the Figure.
CAUTION 1
Fit the gear box within 10 min. of applying the sea-
lant. 2
MID0340A
80
10-56
Tighten the fixing screws of the timing system box

to the torques indicated here and according to the
given sequence.
F2B ENGINE
13 screws M12 x 1.75 x 80; 63 N⋅m (46 ft.-lbs.)
: 3 screws M10 x 1.5 x 35; 42 N⋅m (31 ft.-lbs.)
1 screw M10 x 1.5 x 100; 42 N⋅m (31 ft.-lbs.)
MID0341A
81
F3A ENGINE

: 2 screws M12 x 1.75 x 193; 63 N⋅m (46 ft.-lbs.)
MID0342A
82
Key the ring seal, 1, onto the crankshaft, on which
you should apply the tool, 2: 1
-- 380000127, for the F3A engine. 2
Screw down the nut, 3, to mount the ring seal, 1,
completely in the gear box, 4. 3
MID0343A
83
10-57
ENGINE FLYWHEEL ASSEMBLY
Detail of punching on engine flywheel of piston
position:
A C
A Hole on flywheel with 1 notch, corresponding to
the TDC of pistons 3 - 4.
B Hole on flywheel with 1 notch, corresponding to
C Hole on flywheel with 1 notch, corresponding to
D Hole on flywheel with 2 notches, position corre-
sponding to 54°. D
CAUTION
If the teeth of the rim mounted on the engine fly- View of holes: A – B – C B View of holes: D
wheel, for starting the engine, are badly dam-
aged, replace the rim. Assembly must be done MID0344A
after heating the rim to a temperature of 200°C

(392°F).
84
Fit the engine flywheel without locking the fixing
screws, 2, and insert the pin 380000150, 1.
CAUTION
1
The engine flywheel fixing screws of the F2B en-
gine are treated with MOLYCOTE lubricant and re- 2
quire no lubrication whatsoever. They can be re-
used for up to five disassemblies; replace them if
in doubt. The engine flywheel fixing screws of the
F3A engine must, before assembly, be lubricated MID0345A
with engine oil.

85
Lock rotation with tool 380000144, 1; tighten the
screws, 2, in the following phases:
F2B F3A
100 N⋅m (10 kgm 120 N⋅m (12 kgm 2
1st phase
[73 ft.-lbs.]) [88 ft.-lbs.])
MID0346A
86
Second phase: closed angle with tool 380000304, 1.
F2B F3A
2nd phase 60° 60°
3rd phase - 30° 1
MID0347A
87
10-58
FITTING CAMSHAFT
Mount the camshaft, 4, arranging it with the holes (→)
positioned as in Figure 88.
Lubricate the ring seal, 3, and fit it on the shoulder
plate, 2.
Mount the shoulder plate, 3, with the sheet metal
gasket, 1, and tighten the screws, 5, to the required
torque.
MID0348A
88
Apply the gauge, 1:
-- 380000167, for the F3A engine.
Check and adjust the position of the connecting rod,
3, for the transmission gear, lock the screw, 2, to the 1
required torque.
2
3
MID0349A
89
Fit the transmission gear, 1, back on and lock the
screws, 2, with an appropriate hex wrench to the
required torque.
MID0350A
2
90
Fit the gear, 2, back on the camshaft, without fully
locking the screws, 5, positioning it so that the 4 slots
are centered with the camshaft fixing holes. Using a 1
dial gauge with a magnetic base, 1, check the clear-
ance between the gears, 2 and 3, which must be:
-- 0.15 - 0.20 mm (.006 - .008″) for the F2B engine;
-- 0.073 - 0.195 mm (.0029 - .0077″) for the F3A 2
engine.
5
If this is not so, adjust the clearance as follows: loosen
the screws, 4, fixing the transmission gear, 3, loosen 3
the screw, 2, (Figure 89), fixing the lever, move the
connecting rod, 3, (Figure 89), to obtain the required 4
clearance; lock the screw, 2, (Figure 89), fixing the MID0351A
connecting rod and the screws, 4, (Figure 91), fixing
the transmission gear to the required torque. 91
10-59
FITTING INJECTORS - PUMP
Mount the ring seals, 1, 2 and 3, on the injectors.
MID0352A
92
Fit the injectors and, with a torque wrench, 2, lock the
screws fixing the brackets, 1, for the injectors to the
required torque. Screw down the screws for the elec-
tric connections, 4, locking them with a torque screw-
driver, 3, to the torque of 1.36 – 1.92 N⋅m (0.136 –
2
0.192 kgm [12 - 17 in.-lbs.]).
-- Position the exhaust and intake valve control
crosspieces. 3
CAUTION
Position the cross-pieces on the valve stem, all
4
with the largest hole on the same side.
MID0353A
93
FITTING ROCKER ARM SHAFT
CAUTION
Before refitting the rocker arm shaft assembly, 1 5
make sure that all the adjustment screws have
been fully unscrewed.
With tool 380000128, 3, constrain the sliding blocks,

4, to the rocker arms, 3.
Apply tool, 1, to the rocker arm shaft, 5: 2
-- 380000149 for the F2B engine,
-- 380000148 for the F3A engine,
4
and position it on the cylinder head.
3
MID0354A
94
10-60
CAUTION
The screws, 2, of the F2B engine are treated with 2
MOLYCOTE lubricant and require no lubrication
whatsoever. They can be reused for up to five dis-
assemblies; replace them if in doubt. The screws, 1
2, of the F3A engine must, before assembly, be lu-
bricated with engine oil. 3
Tighten the screws, 2, fixing the rocker arm shaft in

two phases:
1st phase: tightening with torque wrench, 1, to a
torque of:
-- 40 N⋅m (4 kgm [29 ft.-lbs.]) for the F2B engine;
-- 100 N⋅m (10 kgm [73 ft.-lbs.]) for the F3A engine. MID0355A
2nd phase: closing, with tool 380000304, 3, with an

angle of 60°. 95
For the F3A engine only
Constrain the levers, 1, to the spacer, 3, with the
springs, 2.
1
2
MID0356A 3
96
Camshaft Timing
Apply the tool for flywheel rotation to the gear box, 2:
-- 380000137, 7, for the F2B engine;
-- 380000137, 7, and spacer 380000138, 6, for the
F3A engine. 1
CAUTION
The arrow indicates the direction of rotation of
2 6
the working engine. With the above-mentioned
tool, turn the engine flywheel, 1, in the direction
of rotation of the engine so as to take the piston 7
of cylinder no.1 to approximately the TDC in the 3
phase of combustion. This condition is accom-
plished when the hole with one notch, 4, after the
hole with two notches, 5, on the engine flywheel,
1, can be seen through the inspection window, 3.
MID0357A
97
10-61
The exact position of the piston of cylinder No.1 at the
TDC is obtained when, in the above-described condi-
tions, the tool 380000150, 1, enters the hole, 3, on the
engine flywheel, 4, through the seat, 2, of the engine
speed sensor. If this is not the case, orient the engine
flywheel, 4, appropriately.
Remove the tool 380000150, 1.
MID0358A
98
Position the dial gauge with a magnetic base, 1, with
the rod on the roller, 2, of the rocker arm governing the
injector of cylinder no.1 and pre-load it by approx. 6
mm (0.236″).
Using tool 380000137, turn the crankshaft clockwise
until the pointer of the dial gauge reaches the 1
minimum value under which it cannot go.
Zero the dial gauge.
Turn the engine flywheel anti-clockwise until on the dial
gauge you read the cam lift value of the camshaft of:
-- 4.9 – 0.05 mm (0.193 - 0.002″), for the F2B
engine;
-- 4.44 – 0.05 mm (0.175 - 0.002″), for the F3A en- 2
gine.
MID0359A
99
The camshaft timing is correct if the above cam lift
values correspond to the following conditions:
1. The hole with a single notch, 5, can be seen
through the inspection window.
2. The tool 380000150, 1, through the seat, 2, of the
engine speed sensor, enters the hole, 3, in the en-
gine flywheel, 4.
MID0360A
100
10-62
If the conditions described in Figure 100 and indi-
cated in points 1 and 2 were not obtained, proceed as
follows.
Loosen the screws, 2, fixing the gear, 1, to the cam-
shaft, 3.
Take appropriate action on the engine flywheel to
1
bring about the conditions indicated in points 1 and 2,
but the cam lift must not be affected.
Lock the screws, 2, and repeat the check as de- 2
scribed above.
Tighten the screws, 2, to the required torque.
MID0361A
101
When the slots, 1, are not sufficient to recover the tim-
ing, the camshaft turns because it becomes integral
with the gear, 2. The reference value of the cam lift
changes accordingly and it is necessary to proceed
as follows:
Make sure the screws, 2, (Figure 101), are locked.
Turn the engine flywheel clockwise by approx. 1/2
turn. Turn the engine flywheel anti-clockwise until the
dial gauge shows a camshaft cam lift value of:
1
-- 4.9 ± 0.05 mm (0.193 - 0.002″), for the F2B
engine;
-- 4.44 ± 0.05 mm (0.175 - 0.002″), for the F3A en-
gine. 2
Take out the screws, 2, (Figure 101) and remove the
gear, 2, from the camshaft. Repeat the steps de-
scribed in Figure 100.
Mount the gear, 2, (Figure 101) on the camshaft and
tighten the fixing screws to the required torque. MID0362A
102
Phonic Wheel Timing
In the conditions described in Figure100, check that the
pin 380000151, 2, is positioned on the marked tooth of
the phonic wheel, 1. If this is not so, loosen the screws,
3, and orient the phonic wheel, 1, appropriately. Then
tighten the screws, 3, to the required torque. 1
MID0363A
103
10-63
COMPLETING THE ENGINE
Mount the rocker arm cover, 1, and the timing system 1
cover, 2, with new gaskets, tightening the fixing
screws to the required torque.
CAUTION 2
The fixing screws of the rocker arm cover, 1, must
be tightened in the sequence shown in the dia-
grams on page 26.
MID0364A
104
Mount the suction hose, 1, and tighten the fixing
screws to the required torque.
MID0365A F2B F3A

105
Place the gasket, 4, on the oil sump, 1, position the
spacer, 3, and fit the sump on the crankcase screwing
down the screws, 2, to the required torque.
MID0366A
106
Mount the following, tightening the fixing screws to
the required torque:
-- starter motor, 1;
-- control unit, 2, and its mount;
-- oil dipstick, 3, in the crankcase.
CAUTION
Check the state of the elastic elements of the con-
trol unit mount and replace them if they are deter-
iorated.
MID0367A
107
10-64
Fit the intake manifolds, 1, (Figure 108 or 109) and
tighten the fixing screws, 2, to the required torque.
MID0368A F2B
108
MID0369A F3A
109
Fit the mount, 1, (for the F2B engine) or 4, (for the F3A
engine) and tighten the fixing screws to the required
torque.
Connect the oil pipes (2/7) to the mounts (1/4)
tightening the fittings to the required torque.
MID0370A F2B F3A

110
Fit the oil filters, 1, on the relevant mounts as follows:
-- Oil the gaskets;
-- Screw down the filters until the gaskets come into
contact with the supporting bases;
-- Tighten the filter to a torque of 35 - 40 N⋅m
(25 - 29 ft.-lbs.).
MID0371A
F2B F3A
111
10-65
Mount the following with their gaskets and tightening
the screws to the required torque:
-- fuel pump, 2;
3
-- mount, 3, with fuel filter, 4, and pipes, 1;
-- connect the pipes, 1, to the fuel pump, 2. 4
1
2
MID0372A
112
Fit the heat exchanger, 2, with its gasket and tighten
the fixing screws, 1, to the required torque.
Tighten the screws, 4, fixing the pipe clamps, 3 and 1
5, to the spacer.
3 4
5
MID0373A
113
Mount the following with new gaskets:
-- exhaust manifold, 2;
-- turbocharger, 3;
-- oil pipe, 1 and 4;
-- pipe to actuator, 5.
MID0374A
114
Mount the following parts with their gaskets and
tightening the screws to the required torque:
-- automatic tightener mount, 1;
-- automatic tightener;
-- damper flywheel, 3, and the pulley beneath;
-- fixed tightener, 5;
-- water pump, 7;
-- pulley, 4;
-- pipes with coolant, 6;
-- thermostat assembly, 8.
MID0375A
115
10-66
Mount the following, tightening the screws to the
required torque:
-- mounts, 1;
-- alternator, 2;
-- for the F2B engine only, the mount, 4, and the
supercharger, 3.
MID0376A
116
F2B engine only
With a suitable tool, 6, operate the tightener, 5, in the
direction of the arrow and fit the belt, 4.
Both engines
With a suitable tool, 3, operate the tightener, 2, in the
direction of the arrow and fit the belt, 1.
CAUTION
The tighteners are automatic, so no further ad-
justments are required after assembly. 7
MID0377A
117
ASSEMBLY DIAGRAM FOR FAN DRIVE
BELT - WATER PUMP - ALTERNATOR FOR
F2B ENGINE
1. Alternator
2. Water pump
3. Crankshaft
4. Supercharger
MID0378A
118
10-67
ASSEMBLY DIAGRAM FOR FAN DRIVE
BELT - WATER PUMP - ALTERNATOR FOR
F3A ENGINE
1. Alternator
2. Water pump
3. Crankshaft
4. Supercharger
MID0379A
119
Put the tool 380000360 on the engine lifting hooks,
fasten this on the hoist. Remove the screws fixing the
brackets:
-- 380000154 for the F2B engine;
-- 380000155 for the F3A engine;
to the rotary stand, lift the engine and disconnect the
above-mentioned brackets. Complete assembly of
the engine with the following parts and tighten the
fixing screws or nuts to the required torque:
-- fit the drive, 1;
-- fit the engine mounts;
MID0380A
120
-- fit the oil pressure adjustment valve, 1.
MID0381A
121
F3A engine only
Fit the engine mount together with the air-conditioner 1
compressor, 2. With an appropriate tool, 3, operate in
the direction of the arrow and fit the belt, 1.
For both engines, connect the engine electric cable to
the sensors and to the control unit. Replenish the en-
gine with the required amount and grade of lubricat- 3
ing oil.
2
MID0382A
122
10-68
CHECKS, MEASUREMENTS AND REPAIRS
ON THE CRANKCASE, CYLINDER LINERS
CAUTION
1
clothing – safety goggles, gloves and shoes.
CAUTION
2
Check the inside diameter of the cylinder liners to
verify the extent of ovalization, taper and wear
with the gauge, 2, equipped with a dial gauge, 1,
3
previously zeroed on the ring gauge, 3:
-- 380000152 of diameter 115 mm (4.528″)
(F2B engine);
-- 380000153 of diameter 125 mm (4.921″)
(F3A engine).
MID0383A
123
If the ring gauge is not available, use a micro-
meter.
Outline for Checking the Diameter of the

Cylinder Liners (dimensions in mm)
1. 1st measurement
2. 2nd measurement
3. 3rd measurement
The measurements have to be made on each single
cylinder liner at three different heights and on two
planes (A - B) at right angles to each other, as shown
in Figure 124.
MID0384A
124
Selection X
class F2B F3A
115 - 115.012 125 - 125.013
A
(4.5276 - 4.5280″) (4.9213 - 4.9218″)
115.010 - 115.022 125.011 - 125.024
B A-B
(4.5280 - 4.5284″) (4.9217 - 4.9222″)
(Dimensions in mm [inches])
On finding greater wear than 0.150 mm (0.0059″) or
maximum ovalization of 0.100 mm (0.0039″) over the
values given in the Figure, it is necessary to replace
the cylinder liner as grinding, lapping and dressing
are not permitted.
CAUTION
MID0385A
The cylinder liners are supplied as spares with
selection Class A. Class B is mounted solely in
125
production.
X = Selection class marking area.
10-69
Ø F2B F3A
130.200 - 130.225 142.000 - 142.025
A
(5.1260 - 5.0591″) (5.5906 - 5.5915″)
128.510 - 128.535 140.000 - 140.025
B
(5.0595 - 5.0604″) (5.5118 - 5.5128″)
130.161 - 130.186 141.961 - 141.986
C
(5.1245 - 5.1254″) (5.5890 - 5.5900″)
128.475 - 128.500 139.890 - 139.915
D
(5.0581 - 5.1270″) (5.5075 - 5.5085″)
The diagram illustrated in Figure 126 gives the out- MID0386A
side diameters of the cylinder liner and the inside di-
ameters of their seats. If necessary, the cylinder liners 126
can be taken out and fitted in different seats a number
of times. Check the state of the plugs of the cylinder
assembly: if rusty or there is any doubt at all about
their seal, replace them.
Replacing the Cylinder Liners
Disassembly
1
Position the parts, 2, and the plate, 4, of tool
380000366 as illustrated in the Figure, checking that
the plate, 4, rests correctly on the cylinder liner. Screw
down the nut of screw, 1, and extract the cylinder liner, 2
3, from the crankcase.
4
MID0387A
127
Assembly
Always replace the water ring seals, 3, 4 and 5.
Fit the adjustment ring, 1, on the cylinder liner, 2.
Lubricate its bottom portion and fit it in the cylinder
assembly with an appropriate tool. 1
CAUTION
The adjustment ring (1) is supplied as a spare in 2 4
the following thicknesses: 0.08 mm - 0.10 mm -
0.12 mm (0.003 - 0.004 - 0.005″). 3
5
MID0388A
128
10-70
Checking Protrusion
Check the protrusion of the cylinder liners with tool 1
380000140, 2, and tightening the screw, 1, to the
torque of: 2
-- 170 N⋅m (125 ft.-lbs.) for the F2B engine;
-- 220 N⋅m (162 ft.-lbs.) for the F3A engine.
Measure, with the dial gauge, 3, that the protrusion of 3
the cylinder liner from the supporting surface of the
cylinder head is the value X indicated in the table of
Figure 130. If this is not so, replace the adjustment
ring, 1, (Figure 128), supplied as a spare in several
thicknesses.
MID0389A
129
Cylinder Liner Protrusion
X
Protrusion F2B F3A
0.035 - 0.065 0.045 - 0.075
X
(0.0014 - 0.0026″) (0.0018 - 0.0030″)
MID0390A
130
On completing assembly, lock the cylinder liners, 1,
to the crankcase, 2, with the pins 380000363, 3.
1
2
MID0391A
131
10-71
ON THE CRANKSHAFT, BEARINGS
CAUTION
clothing - safety goggles, gloves and shoes. 1
2
Measuring Main Journals and Crankpins

Before grinding the pins, measure the pins of the
shaft, 2, with a micrometric gauge, 1, and establish,
depending on the level of undersizing of the bearings,
to what diameter you need to reduce the pins.
The classes of undersizing are 0.127 - 0.254 - 0.508
mm (0.0050 - 0.0100 - 0.0200″).
Measuring Main Journals
CAUTION
All the main journals and crankpins should al-
ways be ground to the same class of undersizing
so as not to alter the balance of the crankshaft.
MID0392A
It is advisable to note down the measurements in a
table Figure 133. 132
10-72
MAIN JOURNALS
MINIMUM ∅
MAXIMUM ∅
CRANKPINS
MINIMUM ∅
MAXIMUM ∅
MID0393A
133
Top main bearing shells
.
.
.
. .
.
.
.
.
.
.
.
.
.
. .
. .
.
.
.
. .
.
.
.
Bottom main bearing shells

. .
.
MID0394A
134
F2B Engine – Main Data of Crankshaft and Main Bearing Shells
Check the state of the main journals and crankpins of the crankshaft. They must have no scoring, ovalization
or excessive wear. The data given refer to the normal diameter of the pins.
10-73
F2B Engine
X. Detail of the fittings of the main journals.
(dimensions in mm)
POLISHED
GND
GND
MID0395A
135
F2B Engine
Y. Detail of the fittings of the main journals.
(dimensions in mm)
POLISHED
GND
GND
MID0396A
136
.
.
.
.
. .
.
. .
. Top main bearing shells .
.
. .
.
. .
. .
.
.
.
.
.
.
. .
. Bottom main bearing shells .
MID0397A
137
Engine F3A - Main data of crankshaft and main bearing shells
10-74
F3B Engine
X. Detail of the fittings of the main journals.
(dimensions in mm)
POLISHED
.
. . --
GROUND
GROUND
. .
MID0398A
138
F3B Engine
Y. Detail of the fittings of the main journals.
(dimensions in mm)
POLISHED .
. . -- .
GROUND
. .
MID0399A
139
Replacing Oil Pump and Timing System Gear
Check that the teeth of the gear are neither damaged
nor worn, but if they are then take it out with an ap-
propriate extractor. When fitting the gear, 1, on the .
crankshaft, 2, heat it for approx. 15 minutes in an oven
at a temperature of 180°C. After driving it home, leave 1
it to cool.
CAUTION 2
For engine F3A only:
After heating the gear, 1, fit it on the shaft by apply-
ing a load of 6000 N⋅m (1350 ft.-lbs.) to the gear,
positioning the load at the distance shown in Fig-
ure 140. After cooling, the gear must have no axial
movement under a load of 29100 N⋅m (6547.5 ft.-
lbs.).
MID0400A
140
10-75
SELECTING MAIN AND BIG END BEARING SHELLS
To obtain the required assembly clearances, the main Depending on the thickness, the half bearings are se-
and big end bearing shells need to be selected as de- lected in classes of tolerance, marked by a color (red
scribed below. - green - red/black - green/black).
This operation makes it possible to identify the most The following tables give the characteristics of the main
suitable half bearings for each of the pins of the shaft and big end bearing shells available as spares in the
(the half bearings may even be of a different class standard (STD) sizes and in the permissible oversizes
from one pin to another). (+0.127, +0.254, +0.508 [0.0050, 0.0100, 0.0200″]).
STD +0.127 +0.254 +0.508
F2B 2.000 - 2.010 2.127 - 2.137 2.254 - 2.264

red
F3A 1.970 - 1.980 2.097 - 2.107 2.224 - 2.234
red F2B 2.063 - 2.073

black F3A 2.033 - 2.043
F2B 2.011 - 2.020 2.138 - 2.147 2.265 - 2.274

green
F3A 1.981 - 1.990 2.108 - 2.117 2.235 - 2.244
green F2B 2.074 - 2.083

black F3A 2.044 - 2.053
yellow
* F2B 2.021 - 2.030
F3A 1.991 - 2.000
yellow * F2B 2.084 - 2.093

black F3A 2.054 - 2.063
STD +0.127 +0.254 +0.508
F2B 3.000 - 3.010 3.127 - 3.137 3.254 - 3.264

red
F3A 2.965 - 2.974 3.092 - 3.102 3.219 - 3.229
red F2B 3.063 - 3.073

black F3A 3.028 - 3.037
F2B 3.011 - 3.020

green F3A 2.975 - 2.984
green F2B 3.074 - 3.083

black F3A 3.038 - 3.047
yellow
* F2B 3.021 - 3.030
F3A 2.985 - 2.995
yellow * F2B 3.084 - 3.093

* Mounted in production only and not supplied as
black F3A 3.048 - 3.058 spares. MID0401A
141
10-76
PRELIMINARY APPRAISAL OF DATA TO MAKE THE SELECTION
For each of the pins of the crankshaft, it is necessary to carry out the following:
Main Journals Crankpins
-- determine the class of diameter of the seat in the -- determine the class of diameter of the seat in the
crankcase; connecting rod;
-- determine the class of diameter of the main jour- -- determine the class of diameter of the crankpin;
nal; -- choose the class of half bearings to fit.
-- choose the class of half bearings to fit.
Selecting Small End Bearings (Pins With Nominal Diameter)
Two sets of figures are marked on the front of the crankcase, in the position shown, (Figure 142 at top):
-- a four-digit number represents the coupling number of the crankcase with its respective sub-crankcase;
-- the following seven digits, taken singly, represent the class of diameter of each of the main bearing seats to
which they refer, (Figure 142 at bottom);
-- each of these digits may be 1, 2 or 3.
CLASS MAIN BEARING NOMINAL DIAMETER

F2B F3A
1 89.000 - 89.009 99.000 - 99.009
2 89.010 - 89.019 99.010 - 99.019
3 89.020 - 89.030 99.020 - 99.030
MID0402A
142
10-77
Selecting the Main Bearing Shells (Pins With Nominal Diameter)
Main journals and crankpins: determining the class of diameter of the pins.
Three sets of figures are marked on the crankshaft, in the position shown by the arrow (Figure 143 at top):
-- the first number, comprising five digits, is the serial number of the shaft;
-- underneath this number, on the left, a set of six digits refers to the crankpins and is preceded by a single digit,
which indicates the status of the pins (1 = STD, 2 = -0.127 [0.0050″]), the other six digits, taken singly, repre-
sent the class of diameter of each of the crankshafts to which they refer (Figure 143 at top).
-- the set of seven digits, on the right, refers to the main journals and is preceded by a single digit, which indi-
cates the status of the pins (1 = STD, 2 = -0.127 [0.0050″]), the other seven digits, taken singly, represent
the class of diameter of each of the main journals to which they refer (Figure 143 at bottom).
CLASS CRANKPIN NOMINAL DIAMETER

F2B F3A
1 72.915 - 72.924 82.970 - 82.979
2 72.925 - 72.934 82.980 - 82.989
3 72.935 - 72.945 82.990 - 83.000
40019
CLASSE MAIN JOURNAL NOMINAL DIAMETER

F2B F3A
1 82.910 - 82.919 92.970 - 92.979
2 82.920 - 82.929 92.980 - 92.989
MID0403A 3 82.930 - 82.940 92.990 - 93.000
143
10-78
Selecting the Main Bearing Shells (Pins With Nominal Diameter)
After measuring the essential data, for each of the main journals, on the crankcase and crankshaft, choose the
type of half bearings to use, according to the following table:
STD.
CLASS 1 2 3
green green green
1
green green green
red green green
2
red green green
red red red
3
red red red
MID0404A
144
10-79
Selecting the Main Bearing Shells (Ground Pins)
If the pins have been ground, the procedure described so far cannot be applied.
In this case, it is necessary to check that the new diameter of the pins is as indicated in the table and to fit the
only type of half bearings contemplated for the undersize at issue.
F2B F3A
red/black 3.063 - 3.073 3.028 - 3.037

green/black 3.074 - 3.083 3.038 - 3.047
-0.127 Class 1 2 3
F2B 82.784 green/black green/black green/black
82.793
F3A 92.843 1 green/black
92.852 green/black green/black
F2B 82.794 red/black green/black green/black

82.803
F3A 92.853 2
92.862 red/black green/black green/black
F2B 82.804 red/black red/black green/black

82.814
F3A 92.863 3
92.873 red/black red/black green/black
F2B F3A
red 3.127 - 3.137 3.092 - 3.102
-0.254 1 2 3
F2B 82.666 red red red

82.686
F3A 93.224
93.234 red red red
F2B F3A
red 3.254 - 3.264 3.219 - 3.229
-0.508 1 2 3
F2B 82.412
82.432
red red red
F3A 93.468
93.508 red red red
MID0405A
145
10-80
Selecting the Big End Bearing Shells
(Pins With Nominal Diameter)
On the body of the connecting rod, in position “A”,
there are three markings:
3. Letter specifying the weight classes:
VIEW FROM ”A”
F2B F3A
A = 2890 - 2920 g. 3973 - 4003 g.
(6.4 - 6.44 lbs.) (8.76 - 8.83 lbs.)
B = 2921 - 2950 g. 4004 - 4034 g.
3
(6.44 - 6.5 lbs.) (8.8 - 8.89 lbs.)
C = 2951 - 2980 g. 4035 - 4065 g. 2
(6.5 - 6.6 lbs.) (8.9 - 8.96 lbs.)
1
4. Number specifying the selection of the diameter
of the big end bearing seat:
F2B F3A
1 = 77.000 - 77.010 mm 87.000 - 87.010 mm
(3.0315 - 3.0319″) (3.4252 - 3.4256″) A
2 = 77.011 - 77.020 mm 87.011 - 87.020 mm
(3.0319 - 3.0323″) (3.4256 - 3.4260″) MID0406A
3 = 77.021 - 77.030 mm 87.021 - 87.030 mm
(3.0323 - 3.0327″) (3.4260 - 3.4264″) 146
5. Numbers identifying the cap-connecting rod cou-
pling.
The number specifying the class of the diameter of
the half-bearing seat may be: 1, 2 or 3. Determine the
type of big end bearing shell to fit on each pin, following
the guidelines of the table (Figure 147).
10-81
green green green
green green green
red green green
red green green
red red red
red red red

MID0407A
147
10-82
Selecting the Big End Bearing Shells (Ground Pins)
If the pins have been ground, the procedure described so far cannot be applied. In this case, it is necessary to
check (for each undersize) which field of tolerance contains the new diameter of the big-end journals and to fit
the half bearings identified according to the relevant table.
F2B F3A
red/black 2.074 - 2.083 2.044 - 2.053

green/black 2.063 - 2.073 2.033 - 2.043
-0.127 Class 1 2 3
F2B 72.789 green/black green/black green/black
72.798
F3A 82.843 1 green/black
82.852 green/black green/black
F2B 72.799 red/black green/black green/black

72.808
F3A 82.853 2
82.862 red/black green/black green/black
F2B 72.809 red/black red/black green/black

72.818
F3A 82.863 3
82.873 red/black red/black green/black
F2B F3A
red 2.127 - 2.137 2.097 - 2.107

green 2.138 - 2.147 2.108 - 2.117
-0.254 1 2 3
F2B 72.671 red green green
72.680
F3A 82.726
82.735
red green green
F2B 72.681 red red green

72.691
F3A 82.736
82.746 red red green
F2B F3A
red 2.254 - 2.264 2.224 - 2.234

green 2.265 - 2.274 2.235 - 2.244
-0.508 1 2 3
F2B 72.417 red green green
72.426
F3A 82.472
82.481
red green green
F2B 72.427 red red green

72.437
F3A 82.482
MID0408A 82.492 red red green
148
10-83
Checking Main Journal Assembly Clearance
If dismantled, mount the oil nozzles, 3, making the 1
3
grub screw coincide with the hole, 2, on the
crankcase. 2
CAUTION
Clean the parts carefully and remove every trace
of oil.
Put the half bearings, 1, on the main bearings.
MID0409A
149
With a hoist and hook 380000362, 1, fit on the
crankshaft, 2.
MID0410A
150
Place the half bearings, 1, on the main bearings in the
sub-crankcase, 2. Check the assembly clearance
between the main journals of the crankshaft and the 1
respective bearings, proceeding as follows:
MID0411A
151
Put a length of calibrated wire on the pins of the
crankshaft, 2, parallel to the longitudinal axis. With a
hoist and appropriate hooks, mount the
sub-crankcase, 1. 1
MID0412A
152
10-84
CAUTION
The screws, 1, of the F2B engine are treated with
MOLYCOTE lubricant and need no lubrication
whatsoever. They can be reused for up to five dis- 2
assemblies; replace them if in doubt. The screws,
1, of the F3A engine must, before assembly, be lu- 1
bricated with engine oil.
Screw down the internal screws, 1, and tighten them

in the sequence given in the diagram of Figure 154
MID0413A
and to the torques given on page 24.
The closed angle is done with tool 380000304, 2. 153
Diagram of the
Tightening Sequence of
the Screws Fixing the
Sub-Crankcase Under the
Crankcase.
FRONT SIDE
MID0414A
154
Remove the Sub-Crankcase
The clearance between the crankshaft bearings and
the relevant pins is measured by comparing the width 1
taken on by the calibrated wire, 2, at the point of
greatest crushing, with the graduated scale on the
case, 1, containing the calibrated wire. 2
The numbers given on the scale give the clearance of
the coupling in millimetres. If you find the clearance
is not as required, replace the half bearings and re-
peat the check.
MID0415A
155
Checking Crankshaft End Float
The end float is checked by placing a dial gauge, 1,
with a magnetic base on the crankshaft, 2, as shown
in Figure 156. If you find the clearance is higher than
as required, replace the rear main thrust bearing
shells and repeat the clearance check.
2
1
MID0416A
156
10-85
ON THE PISTONS
CAUTION
Clean the parts thoroughly before doing any work.

Check the pistons, they must have no sign of seizure,
scoring, cracking or excessive wear; if this is not so,
replace them.
Piston
Remove the piston rings, 2, from the piston, 3, with
the pliers 380000221, 1. 2
3
1
MID0417A
157
Remove the split rings, 2, holding the piston pin with
round-nose pliers, 1. 1
MID0418A
158
Remove the piston pin, 1. If disassembly is difficult,
use an appropriate drift.
MID0419A
159
10-86
Measuring Piston Diameter
Using a micrometer, 2, measure the diameter of the
1
piston, 1, to determine the assembly clearance.
2
CAUTION X
The diameter has to be measured at the distance
X from the base of the piston skirt:
X = 18 mm (0.709″), for the F2B engine;
X = 19 mm (0.748″), for the F3A engine.
The pistons are selected in two classes A and B ac- MID0420A
cording to the diameter.

160
As spares they are supplied in class A and can also
be mounted in the cylinder liners with inside diameter
class B. The clearance between piston and cylinder
liner can also be measured with a feeler gauge, 1.
1
MID0421A
161
Piston Pin
The pins are mounted with clearance both on the
small end and on the piston. 2
Measure the diameter of the pin, 1, with a micrometer,
2.
MID0422A
162
Conditions for Correct Pin-Piston Coupling
When fitting new pins, 1, check they couple correctly
with the seat on the piston in the following manner: 1
-- Lubricate the pin and seat on the piston pin
bosses with engine oil.
-- Holding the pin upright, insert it into the piston pin
bosses.
-- The pin has to be able to go in by simply pressing
it.
-- The pin must not slip out of the bosses on its own.
MID0423A
163
10-87
MID0424A
164
F2B Engine - Main Data For Piston, Piston Rings And Pin
* Measured on ∅ 112 mm.
2.940 2.550 4.020 2.796 2.970 3.970 A=124.881-124.890

2.570 4.040 2.830 3.000 3.990 B=124.890-124.899
19
50.010 49.994
MID0425A 50.018 50.000
165
F3A Engine - Main Data For Piston, Piston Rings And Pin
* Measured on ∅ 120 mm.
Piston Rings
Check the thickness of the piston ring, 2, with a
micrometer, 1.
1
MID0426A
166
10-88
Check the clearance between the ring seals, 2, and
their seats on the piston, 1, with a feeler gauge, 3. 3
1
2
MID0427A
167
The ring seal, 2, of the 1st slot is trapezoidal in shape.
The clearance “X” between the ring seal and its seat 1
is measured by placing the piston, 1, with the ring in
the cylinder liner, 3, so that the ring seal is half out of
the cylinder liner.
3
MID0428A
168
Using a feeler gauge, 2, check the opening between
the ends of the ring seals, 1, inserted in the cylinder
liner, 3. On finding a higher or lower distance between 1
the ends than as required, replace the piston rings.
2
MID0429A
169
ON THE CONNECTING RODS .
.
CAUTION
. . .
Handle all parts carefully. Do not put your hands . . .
clothing – safety goggles, gloves and shoes. .
.
Clean the parts thoroughly before doing any work.
F2B Engine - Main Data for the Connecting Rod, .
Bushing, Pin and Half Bearings (Dimensions in .
mm) MID0430A
*Dimension to be obtained after driving home the
bushing. 170
10-89
F3A Engine - Main Data for the Connecting Rod,
Bushing, Pin and Half Bearings (Dimensions in .
mm) .
* Dimension to be obtained after driving home the . . .
bushing. . . * .
The data for the classes of selection for the big-end
bearing seat and weights are punched on the big end .
of the connecting rod. .
CAUTION .
.
When fitting the connecting rods, check they are MID0431A
all of the same class.
171
Outline of Connecting-Rod Punch-Marks
1. Letter specifying class of weight:
F2B F3A
VIEW FROM ”A”
A = 2890 - 2920 g. 3973 - 4003 g.
(6.371 - 6.437″) (8.759 - 8.825 lbs.)
1
B = 2921 - 2950 g. 4004 - 4034 g.
(6.440 - 6.504″) (8.827 - 8.893 lbs.) 2
C = 2951 - 2980 g. 4035 - 4065 g.
(6.506 - 6.570″) (8.896 - 8.962 lbs.)
2. Number indicating the selection of the big-end
bearing seat diameter:
3
MID0432A
F2B F3A
172
1 = 77.000 - 77.010 mm 87.000 - 87.010 mm
(3.0315 - 3.0319″) (3.4252 - 3.4256″)
2 = 77.011 - 77.020 mm 87.011 - 87.020 mm
(3.0319 - 3.0323″) (3.4256 - 3.4260″)
3 = 77.021 - 77.030 mm 87.021 - 87.030 mm
(3.0323 - 3.0327″) (3.4260 - 3.4264″)
3. Numbers identifying the cap-connecting rod cou-
pling.
1 2
Bushings
The bushing, 2, is disassembled and assembled with
the appropriate drift, 1.
CAUTION
After driving home the bushing in the small end
of the connecting rod, scalp the portion that
comes out of the side then rebore the bushing in MID0433A
order to obtain the required diameter.
173
10-90
Rebore the small-end bushing with a boring machine.
MID0434A
174
Checking Connecting Rods
The alignment of the connecting rod, twisting and
bending are checked with the appropriate tool.
Checking Alignment
Check the alignment of the connecting rods, 1, as
follows:
-- Fit the connecting rod, 1, on the spindle of the 1
tool, 5, and lock it with the screw, 4.
-- Place the spindle, 3, on the V-prisms resting the 2
connecting rod, 1, on the stop bar, 2. 3
5
4
MID0435A
175
Checking Twisting
Check the twist of the connecting rod, 5, by compar-
ing two points (A and B) of the pin, 3, on the horizontal
plane of the connecting rod.
1
Position the mount, 1, of the dial gauge, 2, so that the
latter is pre-loaded by approx. 0.5 mm (0.020″) on the 2
pin, 3, at point A and zero the dial gauge, 2. Move the
spindle, 4, with the connecting rod, 5, and on the op-
posite side (B) of the pin, 3, compare any deviation: 3
the difference between A and B must be no greater
than 0.08 mm (0.003″). 5
MID0436A
176
10-91
Checking Bending
Check the bend of the connecting rod, 5, by compar-
ing two points C and D of the pin, 3, on the vertical
plane of the connecting rod. Position the vertical
mount, 1, of the dial gauge, 2, so that the latter rests 1
on the pin, 3, at point C. 2
Swing the connecting rod forwards and backwards, C
searching for the highest position of the pin and zero D
the dial gauge, 2, in this condition.
Move the spindle with the connecting rod, 5, and on
the opposite side D of the pin, 3, repeat the check for 5
the highest point. The difference between points C 3
and D must be no greater than 0.08 mm (0.003″).
4
MID0437A
177
PISTON CONNECTING ROD ASSEMBLY
Piston-Connecting Rod Assembly

1. Connecting rod body 1 10
2. Half bearings 5
3. Connecting rod cap
2
4. Cap fixing screws 3 8
5. Split ring
6. Oil scraper ring with slots with spiral spring
7. Ring seal
8. Trapezoidal ring seal 7
9. Piston pin
10. Piston 9
4
6
5
MID0438A
178
Connecting Rod-Piston Coupling
CAUTION
The piston, 1, has to be fitted on the connecting
rod, 2, so that the symbol, 4, showing the assem-
bly position in the cylinder liner and the punch
mark, 3, of the connecting rod are observed as
shown in the Fig.
MID0439A
179
10-92
Mount the pin, 2, and constrain it to the piston, 1, with
the split rings, 3.
1
2
3
MID0440A
180
Fitting the Piston Rings
To fit the piston rings, 1, on the piston, 2, use the pliers
380000324, 3.
The rings need to be fitted with the word “TOP”, 4, 1
facing upwards, also direct the openings of the rings
so they are staggered 120° apart. 2 3
MID0441A 4
181
Fitting the Connecting Rod Piston Assemblies
in the Cylinder Liners
1
Fit the half bearings, 1, selected as described under
the heading “Selecting the main and big end bearing
shells”, on both the connecting rod and the cap.
MID0442A
182
10-93
MID0443A
183
Diagram for Fitting the Connecting Rod-Piston Assembly in the Cylinder Liner
1. Connecting rod-piston assembly – 2. Punch mark area on the top of the piston with symbols for assembly posi-
tion and selection class – 3. Connecting rod punch mark area.
10-94
With the aid of the clamp 380000220, 1, (Fig. 184),
mount the connecting rod-piston assemblies, 2, in the
cylinder liners, checking that:
-- The openings of the piston rings are staggered 1
120° apart.
-- The pistons are all of the same class, A or B.
-- The symbol punched on the top of the pistons is
facing towards the engine flywheel; or the cavity
in the piston skirt corresponds to the position of 2
the oil nozzles.
MID0444A
184
Checking Connecting Rod Pin Assembly
Clearance 3
Carry out the following operations to measure the
clearance. Connect the connecting rods to the rel-
evant pins of the crankshaft, place a length of cali- 1
brated wire on the pins of the crankshaft.
Mount the connecting rod caps, 1, with the half bear- 1
ings. Tighten the screws, 2, fixing the connecting rod
caps to the following torques:
2
F2B F3A 2
50 N⋅m (5 kgm 60 N⋅m (6 kgm
1st phase MID0445A
[37 ft.-lbs.]) [44 ft.-lbs.])
2nd phase, 185
40° 60°
angle
CAUTION CHECKS, MEASUREMENTS AND REPAIRS

The screws, 2, of the F2B engine are treated with ON THE CYLINDER HEAD
MOLYCOTE lubricant and need no lubrication
whatsoever. They can be reused for up to five dis- CAUTION
assemblies; replace them if in doubt. The screws,
2, of the F3A engine must, before assembly, be lu- Handle all parts carefully. Do not put your hands
bricated with engine oil. or fingers between parts. Wear suitable safety
The closed angle is performed with the tool

380000304, 3. Remove the caps and determine the Checking the Hydraulic Seal
existing clearance, comparing the width of the Before removing the cylinder head, check the hy-
calibrated wire with the graduated scale on the bag draulic seal with appropriate equipment: replace the
containing the wire. cylinder head if there is any leakage.
CAUTION
Lubricate the relevant parts prior to final assemb-
ly. Before reusing the screws fixing the connect-
ing rod caps, measure to check the diameter of
the thread is no less than:
11.4 mm (0.449″) – F2B engine;
13.4 mm (0.528″) – F3A engine.
For lower values, replace the screw.
10-95
Removing the Valves
With the bracket, 4, secure the tool, 2: 1 3
-- 380000133 for the F2B engine;
-- 380000131 - 380000132, for the F3A engine to 2 5
the cylinder head.
Screw down with the lever, 1, until it is possible to 6
remove the cotters, 3. Remove the tool, 2, and extract 3
the top plate, 5, spring, 6, and bottom plate, 7. Repeat
7
this process for all the valves. Turn the cylinder head
over and extract the valves, 8. 8
4
MID0446A
186
Checking Head Mating Surface on Cylinder
Assembly
Check the mating surface, 1, of the head on the
cylinder assembly with a rule, 2, and a feeler gauge,
3. If you find any deformation greater than 0.2 mm
(0.008″), replace the cylinder head.
CAUTION
After this process you need to check the valve
cavity and injector protrusion. 1 2 3
MID0447A
187
Valves - Decarbonizing and Checking
Decarbonize the valves using the specific metal
brush.
Check that the valves show no signs of seizure or
cracking and, in addition, check with a micrometer
that the diameter of the valve stem comes within the
required values (see Figures 189 - 190); if it does not,
replace the valves.
MID0448A
188
10-96
Check with a micrometer that the diameter of the
valve stems is as specified in the Fig.:
-- 7.985 – 8.000 for the F2B engine;
(0.3144 - 0.3150″) .
.
-- 8.960 – 8.975 for the F3A engine. .
.
(0.3528 - 0.3533″)
1 2
.
.
F2B Engine - Main Data of the Valves and Valve
Guides (Dimensions in mm)
*Measurement to make after driving in the valve
guides.
. . . .
1. Intake
2. Exhaust
MID0449A
189
F3A Engine - Main Data of the Valves and Valve

Guides (Dimensions in mm)
*Measurement to make after driving in the valve
guides. 8.960
1. Intake 8.975
2. Exhaust 15.012
15.025
1 2
Valve Grinding
9.015
If necessary, grind the seats on the valves with a 9.030
grinding machine, scalping as little material as
possible. 45°30’±7’30”
60°30’±7’30”
Checking Clearance Between Stem-Valve and
Relevant Valve Guide 45.85-43.15 41.85-42.15
Using a dial gauge with a magnetic base, check the
clearance between the valve stem and the relevant
MID0450A
guide. If the clearance is too great, replace the valve
and, if necessary, the valve guide. 190
10-97
VALVE SEATS ON THE
HEAD 1 2
Reboring
Engine F2B - Main Data

on the Intake and Exhaust
Valve Seats
(Dimensions in mm)
1. Intake valve seat

2. Exhaust valve seat
MID0451A
191
Engine F3A - Main Data on the
Intake and Exhaust Valve 1 2
Seats (Dimensions in mm)
CAUTION
The valve seats on the cylinder
head are ground every time the
valves or valve guides are
ground or replaced.
1. ntake valve seat

2. Exhaust valve seat MID0452A
192
Check the valve seats, 2. If you find any slight scoring
or burns, rebore them with the tool, 1, according to the
angles given in Figures 191 and 192. If you need to 1
replace them, with the same tool and taking care not
to damage the cylinder head, scalp as much material 2
as possible from the valve seats until it is possible,
with a punch, to extract them from the cylinder head.
Heat the cylinder head to 80 - 100°C (176 - 212°F)
and, using a suitable drift, mount the new valve seats
(chilled in liquid nitrogen), 2, in them. Using the tool,
1, rebore the valve seats according to the angles
given in Figures 191 and 192.
After reboring the valve seats, use tool 380000364
MID0453A
and the dial gauge to check that the position of the
valves in relation to the face of the cylinder head is: 193
For engine F2B: For engine F3A:
-- -0.5 - -0.8 mm (-0.0197 - -0.0315″) (cavity) -- -0.65 - -0.95 mm (-0.0256 - -0.0374″) (cavity)
intake valves; intake valves;
-- -1.6 - -1.9 mm (-0.0630 - -0.0748″) (cavity) -- -1.8 - -2.1 mm (-0.0709 - -0.0827″) (cavity)
exhaust valves. exhaust valves.
10-98
ON THE TAPPETS AND CAMSHAFT
CAUTION
The surfaces of the supporting pins of the shaft and

those of the cams must be extra smooth. If they show
any sign of seizing or scoring, replace the shaft and
the relevant bushings.
MID0454A
194
F2B Engine – Main Data of the Camshaft and Tolerances (Dimensions in mm)
.
.
. .
. .
. .
.
. . . . .
.
. . .
. .
. . .
. . .
.
MID0455A .
. . .
195
F3A Engine – Main Data of the Camshaft and Tolerances (Dimensions in mm)
TOLERANCES SUBJECT OF TOLERANCE GRAPHIC SYMBOL

ORIENTATION Perpendicularity ⊥
POSITION Concentricity or co-axiality
OSCILLATION Circular oscillation ↗

CLASSES OF IMPORTANCE ATTRIBUTED TO THE CHARACTERISTICS OF THE PRODUCT GRAPHIC SYMBOL
CRITICAL ©
IMPORTANT ⊕
SECONDARY ⊝
10-99
Checking Cam Lift and Pin Alignment
Place the camshaft, 4, on the tailstock centers, 1, and,

1 2 1
using a dial gauge, 2, check that the lift of the cams,
3, corresponds to the values given in the following
table:
F2B F3A
8.07 9.30 3 4
Intake Cam mm
(0.3177″) (0.3661″)
7.63 9.45
Exhaust Cam mm
(0.3004″) (0.3720″)
MID0456A
8.80 - 8.82 11.21
Pump Injector
(0.3465- (0.4413″) 196
Operating Cam mm
0.3472″)
Again with the camshaft, 4, on the tailstock centers,

1, using a dial gauge, 2, check the alignment of the 1
supporting pins, 3: it must be no greater than 0.020
1 2
mm (0.0008″). If there is any greater misalignment,
replace the shaft.
3 4
MID0457A
197
To check the assembly clearance, measure the inside

diameter of the bushings (Figures 199 and 200) and
the diameter of the pins (Figures 194 and 195) of the 1
camshaft: the difference will give the actual clear-
ance.
If the clearance is greater than 0.160 mm (0.0063″),
replace the bushings and, if necessary, the camshaft
as well.
MID0458A
198
10-100
Bushings
MID0459A
199
F2B Engine - Main Data for the Camshaft Bushings and Seats on the Cylinder Head
(Dimensions in mm)
*Inside diameter of bushings after driving them in
. - .
. - .
. - .
MID0460A
200
F2B Engine - Main Data for the Camshaft Bushings and Seats on the Cylinder Head
(Dimensions in mm)
*Inside diameter of bushings after driving them in
10-101
A B C D E F D N G H D I
MID0461A
201
Replacing Camshaft Bushings -- 380000145 for the F2B engine;
The surfaces of the bushings must have no sign of -- 380000146 for the F3A engine.
seizing or scoring, replace them if they do. A. Drift – B. Bushing positioning grub screw – C.
Using a bore gauge, measure the inside diameter of Reference for fitting the 7th bushing – D. Reference
the bushings. If it is above the tolerance value, for fitting bushings: 1 – 2 – 3 – 4 – 5 – 6, reference
replace the bushings. mark for the F2B engine, red mark for the F3A engine
– E. Guide bushing – G. Guide bushing to secure to
To disassemble and reassemble the bushings of the the 7th bushing mount – H. Plate for securing bushing
camshaft, use the drift: G to cylinder head – I. Grip – L. Extension coupling.
Disassembly
1 2 3 4 5
CAUTION A E F M G L D I
To remove the bushings from
the cylinder head it is
necessary to make the grub
screw of the drift 286197
(F2B engine), 380000146
(F3A engine) coincide with
the bushing.
MID0462A N
202
Assembly 3. When driving in the bushing, make the reference

Assemble the drift with the extension. mark F coincide with the mark M. In this way, after
To fit the bushings 1 - 2 - 3 - 4 - 5 - 6, proceed as driving it home, the hole in the bushing for lubrica-
follows: tion coincides with the oil duct in its seat.
1. Position the bushing to mount on the drift A mak- The bushing is completely driven home when the
ing its grub screw coincide with the seat on the bu- first yellow reference mark D is flush with the
shing. guide bushing G.
2. Position the guide bushing E and secure the
guide bushing G on the seat of the 7th bushing
with the plate H.
10-102
To mount the bushing 6:
-- Unscrew the grip 1 and the N E A G I
extension N. 6
-- Position the extension N
and the guide bushing E
as shown in the Figure.
-- Repeat steps 1, 2, 3 per-
formed for driving in the
bushings 1, 2, 3, 4, 5.
MID0463A D
203
To mount the 7th bushing:
-- Remove the grip and the
guide bushing G secured
to the cylinder head (Fig- N E G A I
ure 203). 7
-- Fit the guide G back on
without securing it with the
plates.
-- Position the bushing on
the drift A and bring it up to
its seat, make the hole in
the bushing coincide with
the lubrication hole on the
head, then fit the bushing.
MID0464A
C
204
CAUTION
The bushing is driven in correctly when the refer-
ence C is flush with the bushing seat.

ON THE VALVE SPRINGS, ROCKER ARM
SHAFT AND ROCKER ARMS
CAUTION
Before assembly, the flexibility of the valve springs

needs to be checked with an appropriate tool. Com- MID0465A
pare the load and elastic deformation data with the
data of the new springs given in the following Figure. 205
10-103
F2B Engine - Main Data for Checking the Valve
Springs (Dimensions in mm [foot-pounds]) Free spring
1. Load of 454 ± 22 N⋅m (102 ± 5 ft.-lbs.).
2. Load of 840 ± 42 N⋅m (189 ± 9.5 ft.-lbs.)
62,6
2
48,5
36,5
MID0466A
206
F3A Engine - Main Data for Checking the Valve
Springs (Dimensions in mm [foot-pounds])
1. Load of 500 ± 25 N⋅m (112.5 ± 5.6 ft.-lbs.)
2. Load of 972 ± 25 N⋅m (218.7 ± 5.6 ft.-lbs.)
1
2
75
61
47,8
MID0467A
207
Fitting Valves and Oil Seal
Lubricate the stem of the valves and insert them in
their valve guides. Mount the bottom plates, 3, with a
key:
-- 380000134 for engine F2B;
-- 380000139 for engine F3A.
Fit the oil seal, 1, on the valve guide, 2, then mount the
valves as follows.
2
3
MID0468A
208
10-104
Mount the springs, 6, and top plate, 5.
On the cylinder head, fit the tool, 2: 1 3
-- 380000133 for engine F2B; 2
-- 380000131 and 380000132 for engine F3A. 5
And secure it with the bracket, 4. Screw down the
6
lever, 1, until it is possible to mount the cotters, 3, re-
move the tool, 2. 3 7
Rocker Arm Shaft
Check that the mating surfaces have no scoring or 8
signs of seizing. If they do, replace the damaged
parts.
MID0469A 4
Check the clearance between the bushings of the
rocker arms and the shaft. If you find the bushings 209
worn, replace the entire rocker arm.
2 2 3 2 3 2 3 2 3 2 3
1 3 1 1 1 1 1
MID0470A
210
F2B Engine
1. Intake valve rocker arm – 2. Injector rocker arm – 3. Exhaust valve rocker arm.
1
2 2 3 2 3
1 2 3 1 2 3 1 3 1 2 3 1 1
MID0471A
211
F3A Engine
1. Intake valve rocker arm – 2. Injector rocker arm – 3. Exhaust valve rocker arm.
F2B F3A
37.984 41.984
38.000 42.000
MID0472A
212
Main Data of the Rocker Arm Shaft (Dimensions in mm)
10-105
ROCKER ARMS
Intake Valve Rocker Arms
(Dimensions in mm) SECTION A-A
SECTION B-B
F2B F3A
38.025 42.025
38.041 42.041
MID0473A
213
Exhaust Valve Rocker Arm
Main data for rocker arms
(Dimensions in mm) SECTION A-A
SECTION B-B
F2B F3A
38.025 56.030
38.041 56.049
MID0474A
214
Injector Pump Rocker Arms
(Dimensions in mm)
SECTION A-A
SECTION B-B
CHECKS, MEASUREMENTS AND REPAIRS F2B F3A

ON THE LUBRICATION SYSTEM 38.015 42.015
38.071 42.071
MID0475A
215
CAUTION
Lubrication is by forced circulation, obtained with a

gear pump, 1. The pump is governed, via gearing, by
the crankshaft, 2. Check that the gears have no sign 1
of wear or seizure; if they do, replace the entire pump. 2
To replace the gear, 2, see under the relevant heading
on page 73.
MID0476A
216
10-106
SECTION B-B
MID0477A
217
F2B Engine - Oil Pump Section
1. Overpressure valve – Pressure of starting opening 10.1 ± 0.7 bars (146 ± 10 psi).
F2B Engine - Main Data for Checking the

Overpressure Valve Spring
1. Load of 190 ± 6 N⋅m (42.8 ± 1.4 ft.-lbs.)
2. Load of 324 ± 9 N⋅m (72.9 ± 2 ft.-lbs.)
2
43.65
33.5
25.5
MID0478A
218
10-107
F3A Engine - Oil Pump
Section B
SECT. B-B
1. Overpressure valve
Pressure of starting A SECT. A-A
opening 10.1 ± 0.7 bars
(146 ± 10 psi).
B
MID0479A
219
F3A Engine - Main Data for Checking the

Overpressure Valve Spring
1. Load of 334 ± 22 N⋅m (75.1 ± 5 ft.-lbs.)
2. Load of 526 ± 24 N⋅m (118.4 ± 5.4 ft.-lbs.)
1
2
.
MID0480A
220
Oil Pressure Control Valve
Pressure of starting opening 5 bars (72.5 psi).
The oil pressure control valve is located on the left
side of the crankcase.
MID0481A
221
10-108
Main Data for Checking the Oil Pressure Control
Valve Spring
F2B F3A 1
1. Load N 168.9 194.5 ± 5 2
(38 ft.-lbs.) (43.8 ± 1.1 ft.-lbs.)
308 ± 15 450.5 ± 20
2. Load N
(69.3 ± 3.41 (101.4 ± 4.5
ft.-lbs.) ft.-lbs.)
A mm 63 (14.2 ft.-lbs.) 68.1 (15.3 ft.-lbs.)
B mm 51 (11.5 ft.-lbs.) 56 (12.6 ft.-lbs.) MID0482A
C mm 41 (9.2 ft.-lbs.) 40 (9.0 ft.-lbs.) 222

Heat Exchanger SECT. A-A
F2B
The heat exchanger is fitted with:
A. Oil filter clogging indicator.
B. Oil temperature transmitter.
C. Oil pressure transmitter.
D. Low oil pressure switch.
E. Filter bypass valve.
F. Thermostat
Number of heat exchanger elements: F3A
-- F2B engine, 7;
-- F3A engine, 9.
SECT. B-B F2B
MID0483A
223
A B
A
B
MID0484A
D A B
224
10-109
Bypass Valve
The valve quickly opens at a pressure of:
-- F2B engine, 3.4 ± 0.3 bars (49.3 ± 4.4 psi)
-- F3A engine, 3 bars (43.5 psi)
MID0485A
225
Thermostat Valve
Start of opening
-- travel 0.1 mm (0.004″) at a temperature of 82 ±
2°C (179.6 ± 3.6°F)
End of opening
-- travel 8 mm (0.315″) at a temperature of 97°C
(206.6°F).
MID0486A
226
Oil Filter
High-filtration oil filter.
CAUTION
Always replace the ring seals every time after re-
moving the pipes or taking the covers off the oil
filter mount.
When fitting the filters, observe the following:

-- Oil the seals.
-- Screw the filters down to bring the seals into con-
tact with the bases.
-- Tighten the filter to a torque of 35 - 40 N⋅m
(25 - 29 ft.-lbs.).
MID0487A
227
10-110
COOLING
ON THE COOLING CIRCUIT
Before doing any work, clean the various parts
thoroughly.
The engine cooling system is supplied with
permanent fluid composed of a mixture of water and
“AMBRA AGRIFLU” fluid (50% in volume) that
cannot freeze down to:
oC -8 -15 -25 -35
(oF) (17.6) (5) (-13) (-31)
% in volume of
“AMBRA 20 30 40 50
AGRIFLU”
This mixture, moreover, has antioxidant, anticorro-

sive, antifoaming and anti-scaling properties such as
to ensure the system is protected for a long time.
It is possible to keep the permanent fluid in the cooling
circuit for at most 2 years or no longer than 1600
hours of operation; after which, it has to be replaced.
Water Pump
The water pump is a centerfugal vane pump. The
pump bearing forms a single piece with the impeller
shaft, the drive pulley is keyed onto this shaft.
Section on the Water Pump
MID0488A
228
F2B Engine Thermostat
Check the thermostats work properly, replace them if
there is any doubt. TO THE HEATER
1. Start of travel at 85°C ± 3°C (185°F ± 15°F)

2. Travel 9.5 mm at 98°C ± 0.2°C (208°F ± 1°F)
Water circulating in the engine.
TO THE BYPASS FROM THE HEAD
MID0489A
229
10-111
Water leaving the thermostat.
TO THE HEATER
TO THE RADIATOR
TO THE EXPANSION
TANK
FROM THE HEAD
MID0490A
230
F3A Engine Thermostat
Temperature of start of travel 84°C (183.2°F)
Minimum travel 15 mm at 94°C ± 2°C
(201.2°F ± 3.6°F)
Water circulating in the engine.
TO THE
EXPANSION
TANK
FROM TO THE
THE BYPASS
ENGINE
MID0491A
231
Water leaving the thermostat.
TO THE
RADIATOR
TO THE
EXPANSION
TANK
TO THE
BYPASS
FROM
THE
ENGINE
MID0492A
232
10-112
FUEL SUPPLY
Fuel is supplied via a fuel pump, fuel filter and pre-
filter, 6 pump-injectors governed by the camshaft by
means of rocker arms and by the electronic control
unit.
Fuel Pump
A. Fuel inlet
B. Fuel delivery
C. Bypass nut
D. Fuel return from the pump-injectors
E. Pressure relief valve
Opening pressure: 5 - 8 bars (72.5 - 116 psi)
MID0493A
233
Section of the Fuel Pump
1. Oil or fuel leakage gauge
MID0494A 1
234
Pump-Injector
The pump-injector is composed of a pumping el-
ement, nozzle and solenoid valve.
1. Diesel/oil ring seal – 2. Diesel/diesel ring seal – 3.
Diesel/exhaust gas ring seal.
Pumping Element
The pumping element is operated by a rocker arm
that, in its turn, is directly governed by the cam of the
camshaft. The pumping element can ensure a high 1
delivery pressure. Its return stroke is activated by a
spring. 2
Nozzle 3
The fault diagnosis program, of the control unit,
checks the operation of each injector (it deactivates
one at a time and checks the capacity of the other
five). Fault diagnosis makes it possible to distinguish
between errors of an electrical origin from those of a
mechanical/hydraulic origin. It indicates broken
pump-injectors. It is therefore necessary to interpret
all the control unit’s error messages correctly. Any de- MID0495A
fects in the injectors require them to be replaced as
no repairs are permitted. 235
10-113
Solenoid Valve
The solenoid, which is energized at each active
phase in the cycle, governs a slide valve, with a signal
from the control unit, that shuts off the delivery pipe
of the pumping element.
When the solenoid is not energized, the valve is open.
Fuel is pumped but it flows back into the return pipe
with the standard transfer pressure of approximately
5 bars.
When the solenoid is energized, the valve shuts. As
the fuel cannot flow back into the return pipe, it is
pumped into the nozzle at high pressure, causing the
needle to lift.
The amount of fuel injected depends on the closing
time of the slide valve and hence on how long the
solenoid is energized.
The solenoid valve is joined to the injector body and
cannot be removed.
On the top there are two screws securing the cables
transmitting the signal from the control unit.
To ensure signal transmission, tighten the screws
with a torque wrench to a torque of 1.36 - 1.92 N⋅m
(0.136 - 0.192 kgm [12 - 17 in.-lbs.]).
Replacing the Pump-Injectors

The injectors have to be replaced with great care (see
the description on pages 57 - 61 for disassembly).
CAUTION
If the job is done with the engine on the vehicle,
before disassembling the pump-injectors, drain
off the fuel contained in the pipes in the cylinder
head by unscrewing the delivery and return fit- 0 411 700 002
tings on the cylinder head. XXXXXX XXXX X
868 USA /
For each injector replaced, hook up to the electronic

diagnosis station or instrument and, when directed by
the program, enter the code number stamped on the
injector (Figure 236) to reprogram the control unit.
CAUTION MID0496A
If the electronic diagnosis instrument is not avail- 236

able, it is exceptionally possible to replace an in-
jector without control unit identification.
CAUTION
When checking the rocker arm clearance, you
need to check the pump-injector pre-load.
10-114
VALVE GUIDES F2B

Replacement
CAUTION
The valve guides are removed with drift:

-- 380000219, for engine F2B;
-- 380000365, for engine F3A.
Assembly is performed with drift:
-- 380000219 equipped with part 380000135, for
engine F2B;
-- 380000365 equipped with part 380000136, for
engine F3A. MID0497A
CAUTION 237
Parts 380000135 (F2B) and 380000136 (F3A) de- F3A
termine the exact position of assembly of the
valve guides in the cylinder head. If they are not
available, it is necessary to drive the valve guides
into the cylinder head so they protrude from it by:
-- 16.3 - 16.7 mm (0.642 - 0.657″) (Fig. 237), for
engine F2B;
-- 31.3 - 31.7 mm (1.232 - 1.248″) (Fig. 238), for
engine F3A.
After driving in the valve guides, rebore their hole with

the reamer:
-- 291777 for engine F2B;
-- 380000368 for engine F3A.
MID0498A
*Dimension to be obtained after driving in the valve
guides. 238
10-115
INJECTOR CASE
Replacement
CAUTION
A
To replace the injector case, 2, proceed as follows:

-- Thread the case, 2, with tool 380000159, 1.
The steps described in Figures 239, 240, 241 1
and 242 must be performed by securing the tools with
bracket A to the cylinder head.
MID0499A
239
-- Screw the extractor 380000123, 2, into the case,

3. Screw down the nut, 1, and extract the case
from the cylinder head.
1
MID0500A
240
10-116
-- With tool 380000370, 2, remove any residues, 1,
left in the groove of the cylinder head.
MID0501A
241
-- Lubricate the ring seals, 3, and fit them on the
case, 4. 1
With tool, 2:
-- 380000156 for engine F2B; 2
-- 380000157 for engine F3A;
Secured to the cylinder head with bracket A, drive in A
the new case, screw down the screw, 1, pressing the
bottom of the case.
4
MID0502A
242
Rebore the hole in the case, 3, with the reamer
380000164, 1.
3
MID0503A
243
10-117
Rebore the seat of the injector in the case, 3, with the
milling cutter 380000164, 1 and 2, equipped with
guide bushing:
-- 380000161, for engine F2B;
-- 380000162, for engine F3A.
MID0504A
244
Checking Injector Protrusion
Check injector protrusion, 2, with a dial gauge, 1. The
protrusion needs to be:
-- 0.7 mm (0.028″), for engine F2B;
1
-- 1.14 - 1.4 mm (0.045 - 0.055″), for engine F3A.
MID0505A
245
10-118
REPLACING THE CRANKSHAFT FRONT

COVER SEAL
Removal - Refitting
CAUTION
7
Drain off the coolant from the engine cooling system.
Disconnect the pipes from the thermostat box. 1
Disconnect the engine cooling fan.
Using a suitable tool, 6, turn in the direction of the 2
Using a suitable tool, 3, turn in the direction of the 3 5
Take out the fixing screws and remove the damper 4 6
flywheel, 7, and the pulley beneath.
MID0506A
246
With the extractor, 2:

-- 380000118 for engine F2B;
1
-- 380000120 for engine F3A, applied as shown in 4
the Figure
Extract the seal, 4. Unscrew the screws, 3, and take 2
off the cover, 1.
Disconnect all the electrical connections and
sensors. 3
MID0507A
247
Key the ring seal, 1, onto the crankshaft and onto this
apply tool, 2:
-- 380000124, 1, for engine F2B;
-- 380000126, for engine F3A. 1
Screw the nut, 3, down to mount the ring seal, 1,
completely in the cover. 2
Fit the remaining parts back on, following the
opposite sequence to disassembly. 3
On completion, fill the cooling system with the re-
quired type and amount of coolant.
MID0508A
248
10-119
ADJUSTING CLEARANCE VALVE OF INTAKE

EXHAUST ROCKER ARMS AND PRE-LOAD
OF PUMP INJECTOR ROCKER ARMS
CAUTION
Adjusting the clearance between the rocker arms and

the intake and exhaust valve cross-pieces and ad-
justing the pre-load of the pump injector rocker arms
must be done extremely conscientiously.
Take the cylinder associated with the valves involved
in the clearance adjustment into the combustion
phase. The valves of this cylinder will be closed while
they balance those of the symmetrical cylinder.
The symmetrical cylinders are 1 - 6, 2 - 5 and 3 - 4. To
perform these operations correctly, proceed as de-
scribed below and as shown in the table.
Adjusting Clearance Between Rocker Arms and

Intake and Exhaust Valve Cross-Pieces
-- With a polygonal wrench, loosen the nut locking
the adjustment screw, 1.
-- Insert the blade of the feeler gauge, 3.
-- With an appropriate wrench, screw or unscrew
the adjustment screw.
-- Check that the blade of the feeler gauge, 3, can
slide with a slight amount of friction.
-- Lock the nut, 1, holding the adjustment screw still. 1 4
Pre-Loading Pump Injector Rocker Arms 2
-- With a polygonal wrench, loosen the nut locking 5
3
the rocker arm adjustment screw, 5, pump injec-
tor rocker arm screw, 6.
-- With an appropriate wrench, 4, screw the adjust-
6
ment screw to take the pumping element to the
end of its travel. MID0509A
-- Using a torque wrench, tighten the adjustment
screw to a torque of 5 N⋅m (0.5 kgm [44 in.-lbs.]). 249
-- Unscrew the adjustment screw by 1/2 - 3/4 of a
turn.
-- Tighten the locknut.
Ignition sequence: 1-4-2-6-3-5 CAUTION

Adjust Adjust To make the above-mentioned adjustments cor-
Balance clearance pre-load of rectly, you must follow the sequence given in the
Start and valves of of valves injectors of table, checking correct positioning at each phase
clockwise cylinder of cylinder cylinder of rotation with pin 380000150 to be inserted in
rotation no. no. no.
the 11th hole of each of the three sectors of 18
1 and 6 at TDC 6 1 5 holes each.
120° 3 4 1
120° 5 2 4
120° 1 6 2
120° 4 3 6
120° 2 5 3
10-120
PUMP INJECTOR - REMOVAL AND

REFITTING
Removal
CAUTION
From underneath the vehicle, take the inspection

cover off the timing system gearbox.
Fit the flywheel rotation tool on the gearbox, 2: 1
-- 380000137 7 for engine F2B;
2 6
-- 380000137 7 and spacer 380000138, 6, for en-
gine F3A.
CAUTION 7
The arrow shows in which direction the engine 3
turns. Using the above-mentioned tool, turn the
engine flywheel, 1, in the direction of rotation of
the engine so as to bring the piston of cylinder no.
1 approximately to the TDC in the phase of com-
bustion. This condition is accomplished when
the hole with one reference mark, 4, after the hole 5
with two reference marks, 5, on the engine fly-
wheel, 1, can be seen through the inspection win-
dow, 3. 4
MID0510A
250
The exact position of the piston of cylinder no. 1 at the
TDC is obtained when, in the above-described condi-
tions, the tool 380000150, 1, enters the hole, 3, in the
engine flywheel, 4, through the seat, 2, of the engine
speed sensor.
If this is not the case, turn the engine flywheel, 4, ap-
propriately.
Remove the tool 380000150, 1.
MID0511A
251
10-121
From the engine bay:
Take out the fixing screws and remove the tappet
cover. Disconnect the fuel pipes from the fuel filter
and from the cylinder head. Unhook the springs, 3,
lever check, 2, engine F3A only. Unscrew the rocker
arm shaft fixing screws, 1.
MID0512A
252
With tool 380000128, 2, constrain the sliding blocks,
MID0513A
253
With the tool, 1:
-- 380000149 for the F2B engine; 1
-- 380000148 for the F3A engine, applied as in the
Figure, remove the rocker arm shaft assembly.
MID0514A
254
Remove the cross-pieces from the valves. Unscrew
the screws and remove the electric connections, 1,
from the solenoid valves. Unscrew the screws, 3,
fixing the brackets, 4, retaining the pump injectors, 2.
Remove the pump injectors, 2.
MID0515A
255
10-122
For Engine F2B Only
If you have any difficulty in removing the pump
injectors, 2, use the extractor 380000122, 1.
MID0516A
256
Refitting
Thoroughly clean the pump-injector seat and the
pump-injectors.
Fit the ring seals, 1, 2 and 3, onto the injectors.
MID0517A
257
Mount the injectors and, using a torque wrench, 2,
lock the screws fixing the injector brackets, 1, to the
required torque. Screw down the screws for the elec-
trical connections, 4, locking them with a torque
screwdriver, 3, to a torque of 1.36 - 1.92 N⋅m (0.136 2
- 0.192 kgm [12 - 17 in.-lbs.]).
-- Position the intake and exhaust valve cross-
pieces. 3
CAUTION
Position the cross-pieces on the valve stem, all
with the largest hole on the same side. 4
MID0518A
258
10-123
CAUTION
Before reassembling the rocker arm shaft assem-
bly, make sure all the adjustment screws are fully 1 5
unscrewed.
Using tool 380000128, 3, constrain the sliding blocks,

Apply tool, 1, to the rocker arm shaft, 5:
-- 380000149 for engine F2B; 2
-- 380000148 for engine F3A.
And position it on the cylinder head.
4
3
MID0519A
259
Tighten the screws, 2, fixing the rocker arm shaft in
two stages:
Stage 1: tightening with a torque wrench, 1, to a
torque of:
2
-- 40 N⋅m (4 kgm [29 ft.-lbs.]), for engine F2B;
-- 100 N⋅m (10 kgm [73 ft.-lbs.]), for engine F3A.
Stage 2: closing, with tool 380000304, 3, with an 1
angle of 60°.
3
MID0520A
260
For Engine F3A Only
Constrain the levers, 1, to the spacer, 3, with the
springs, 2. Adjust the rocker arm clearance Op. 10
106 12. Mount the rocker arm cover. With a new
gasket, tightening the fixing screws to the required
torque and in the tightening sequence given on page 1
26.
2
3
MID0521A
261
10-124
Bleeding the Fuel Supply System
CAUTION 3
Handle all parts carefully. Do not put your hands 1
Before starting the engine, bleed the fuel system as

follows:
MID0522A
262
For the bled fuel to run off into a container, fit tubes to
the bleed screws:
-- 1, (Figure 262), on the pre-filter mount; 2
-- 2, (Figure 263), situated on the support filter;
-- 4, (Figure 264), on the front of the cylinder head.
-- Operate the pump, 3, Figure 262, on the pre-filter
mount until fuel flows out through the screw, 1,
without any bubbles of air in it. Tighten the screw,
1.
-- Repeat these steps for screw, 2, Figure 263.
MID0523A
263
-- Repeat these steps for screw, 4, Figure 264.
CAUTION
Never let fuel foul the drive belts of the alternator,
water pump, etc.
MID0524A
264
10-125
WATER PUMP
Removal - Refitting
CAUTION

Using a suitable tool, 3, turn in the direction of the
arrow on the tightener, 2, and remove the drive belt,
1.
Take out the fixing screws and remove the water
pump, 5.
For refitting, reverse the removal operations, fitting a
new ring seal on the water pump and tightening the
fixing screws to the required torque. On completion, MID0525A
fill the cooling system with the required type and
amount of coolant. 265
THERMOSTAT
Removal - Refitting
CAUTION

Disconnect the coolant pipes from the thermostat
box, 4, (Figure 265).
Take out the fixing screws and disconnect the thermo-
stat box, 4, (Figure 265).
Replace the thermostat and fit the box back on by
carrying out the operations for removal in reverse
order, fitting a new gasket and tightening the fixing
screws to the required torque. On completion, fill the
cooling system with the required type and amount of
coolant.
10-126
SECTION 10 - ENGINE
Chapter 8 - Common Engine Compartment Components
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cooling Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Radiator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rotary Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Rotary Screen Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Rotary Screen Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Rotary Screen Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Rotary Screen Brush Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10-1
OVERHAUL
COOLING FAN DRIVE
Removal
the protection cover, 1. Remove the cover from
the engine compartment.
84050265f
1
2. Unbolt support frame, 1, at 2, and remove the
frame from the combine.
1
20016204
2
3. Unbolt support frame, 1, at 2.
2
20016216
10-2
4. Unbolt support frame, 1, at 2. Remove the frame
from the combine. 1
2
20016207
4
5. Loosen and remove the six cap screws, nuts and
washers, 1, from the fan shaft hub. 2
6. Remove the fan, 2, from the combine.
20016205
5
7. Remove fan drive belts, 1.
8. Loosen and remove fan drive pulley cap screw,
2.
2
20016206
10-3
9. Loosen and remove the fan drive belt tensioning
spring, 1.
10. Apply blows with a mallet to the fan drive pulley,
to remove the pulley from the tapered end of the
shaft. Capture the shaft key when the pulley 1
comes off.
20016208
7
11. Remove the circle clip, 1, from the inside of the
shaft bearing housing, 2.
1
12. Apply blows with a mallet to the shaft hub, 3, to
remove the assembly from the housing. 3
20016209
8
Disassembly
1. Set the shaft assembly, 1, in a press with the
tapered end up. Push the shaft from the bearing,
2.
1
20016210
10-4
2. Remove the circle clip, 1, from the shaft
assembly.
3. Set the shaft assembly in a press with the
tapered end up. Push the shaft from the bearing,
2.
1
2
20016211
10
Inspection
Inspect the shaft for cracks and wear.
Inspect the bearings for grease leakage. Replace the

bearings if they roll rough, or there are indications
that grease has been leaking past the seals.
Inspect the inside of the bearing housing. Replace

the housing and frame if there are indications that the
outer bearing races have been turning inside the
housing.
Inspect the circle clips for cracks. Inspect the fan for 20016212
cracks.
11
Assembly
1. Place the large circle clip, 1, onto the shaft hub.
20016213
12
10-5
2. Set the shaft in a press and push on the larger
bearing, 1.
20016214
13
3. Secure the large bearing in place using the small
circle clip, 1.
20016211
14
4. Set the shaft in a press and push on the smaller
bearing, 1.
20016215
15
10-6
Installation
1. Set the shaft assembly into the bearing housing,
1
1, with the hub end of the shaft, 2, toward the
radiator. Apply blows with a mallet on the hub to 3
drive the shaft assembly into the housing if
required.
2. Install the circle clip, 3, into the housing to secure
the shaft in place. 2
20016209
16
NOTE: The pulley can only be installed one way.
3. Set the shaft key, 1, into place. Apply a light film

1
of anti--seize compound to the shaft and key.
4. Set the fan drive belts into place on the pulley.
Line up the keyway in the pulley with the keyed
shaft and slide the pulley onto the shaft as far as
possible. Apply light blows with a mallet if
required.
20016217
17
5. Install and tighten the fan drive pulley cap screw,
1.
6. Ensure that the drive belts are properly
positioned in the grooves of the idler, crankshaft
and fan drive pulleys.
1
20016206
18
10-7
7. Install the fan drive belt tensioning spring, 1.
Tighten the adjusting nut, 2, until the bottom of
the spring holder, 3, is even with the spring
gauge, 73 mm (3″), 4. 4
8. Check the torque of the fan drive pulley cap
screw and tighten if required. 3
1
2006208
19
9. Set support frame, 1, into place. Install the
hardware at 2, but do not tighten until instructed. 2
20016216
20
10. Set support frame, 1, into place and install
hardware at 2.
11. Tighten all hardware for support frame, 1 and 3. 1
3
20016204
21
10-8
12. Install the protection cover, 1, and secure with the
mounting hardware previously removed.
84050265f
22
RADIATOR UNIT
Removal
NOTE: The radiator assembly can be removed as
individual components. Not all steps must be
performed to remove some components. 1
• To remove the intercooler, neither the engine

cooling system or the oil system need to be
drained.
• To remove the engine radiator, only the
cooling system needs to be drained.
• To remove the oil cooler, all steps will need to
be performed.
the protection covers, 1 and 2. Remove the
covers from the engine compartment.
2
84050265
23
NOTE: Drain the cooling system only if the engine
radiator is to be remove. 2
drain hose, 2.
NOTE: The cooling system has a capacity of
approximately 31.5 L (8.3 gals.). Be sure to use clean
containers with adequate capacity when draining the
cooling system.
1
10013105
24
10-9
counter clockwise to open the coolant drain. 2
Drain all of the coolant into the containers.
10013106
25
4. Drain the remaining engine coolant into suitable
containers by breaking the joint at 1 on the cab
side of the engine.
5. Remove pipe bracket, 2.
1
40016220
26
NOTE: Drain the engine gearbox and hydraulic
reservoir only if the corresponding cooler is to be
removed.
NOTE: Verify the origin of each drain hose before

draining any oil.
NOTE: The engine gearbox holds approximately

11 L (11.6 qts.) of oil.
6. Remove the plug from the engine gearbox drain

line. Empty the contents of the gearbox into a
suitable, clean storage container. ZDA2617A
NOTE: The hydraulic reservoir holds approximately 27

60 L (16 gals.) of oil.
7. Remove the plug from the hydraulic reservoir

drain line. Empty the contents of the reservoir
into a suitable, clean storage container.
10-10
8. Drain the remaining oil in the hydraulic system by
loosening the hydraulic oil filter outlet line, 1. 1
40016219
28
9. Unbolt support frame, 1 at 2, and remove the
10. Loosen clamp, 3. Move the air conditioning 1
receiver/dryer so that it is out of the way.
20016204
29
11. Unbolt support frame, 1, at 2.
2
20016216
30
10-11
12. Unbolt support frame, 1, at 2. Remove the frame
from the combine. 1
2
20016207
31
13. Unbolt and remove the coolant reservoir hold
down straps, 1. 1
14. Unbolt support frame, 2, at 3 and remove the 2
15. Tie up or otherwise support the coolant reservoir.
40016221
32
16. Loosen or remove pipe bracket, 1.
17. Disconnect the intercooler inlet and outlet lines,
2. 3
18. Remove all hardware along the top and down
each side securing the fan shroud, 3, to the 1 2
radiator assembly.
19. Turn out the two cap screws at the bottom of the
shroud to detach it from the rotary screen cleaner
channel.
40016222
33
10-12
20. Turn off the nuts securing the top vibration
dampers, 1, to the rotary cleaning screen frame, 2
2.
NOTE: It is not necessary to remove the dampers
1
from the intercooler.
40016224
34
NOTE: Do not attempt to completely remove the
shroud from the engine compartment. 1
21. Pull the top of the shroud, 1, back, away from the
radiator assembly. 2
22. Turn out sixteen cap screws, 2, from both
attaching plates, 3.
3
40016223
35
NOTE: Foam rubber strips are installed between
each component to prevent damage from rubbing. To
remove each component, gently pry the unit being
removed from the one below it.
1
23. Lift the intercooler, 1, from the radiator assembly.
40016225
36
10-13
NOTE: If the engine coolant radiator is to be
removed, ensure the coolant has been drained as
described earlier in this procedure. 1
24. Disconnect the radiator inlet, 1, and drain, 2, on

the back side of the unit.
25. Disconnect the radiator outlet and overflow lines
on the cab side of the unit. 2
40016226
37
NOTE: Foam rubber strips are installed between
each component to prevent damage from rubbing. To 1
remove each component, gently pry the unit being
removed from the one below it.
26. Lift the coolant radiator, 1, from the oil cooler, 2.
40016227
38
NOTE: If the oil coolers are to be removed, ensure
the gearbox and hydraulic oil has been drained as
described earlier in this procedure.
27. Turn off the four nuts, 1, securing the oil cooler to
the engine module support frame.
40016229
39
10-14
NOTE: Some residual oil will be present in the
coolers. When disconnecting the lines, drain the
residual oil into a suitable container.
28. Disconnect the gearbox, 1, and hydraulic, 2, 1

cooler lines from the unit on both sides. Plug the
oil lines and cap the cooler ports to prevent
foreign material from entering the system.
29. Remove the oil cooler assembly from the engine 2
module frame.
40016228
40
Disassembly
Intercooler 2
1. Turn out the four cap screws, 1, and two cap 1
screws, 2, to remove the frame from the cooler.
1
2
40016230
41
Oil Coolers
1. Turn out the four cap screws, 1, to remove the
side frames from the oil coolers.
2. Remove six caps screws, 2, along the bottom of
the cooler. Detach the lower frame from the 1
cooler.
2
40016232
42
10-15
3. Remove the engine gearbox cooler fittings, 1.
4. Turn out the hydraulic system cooler fittings, 2.
1
Inspection
Inspect the cooling fins of all units for dirt and other
debris. Clean the fins as required.
40016232
43
Inspect the accessible areas inside the coolant
radiator for corrosion or debris. Clean the inside of
the radiator as necessary. If excessive corrosion is
observed, replace the engine coolant radiator.
Fill the engine coolant radiator with water and

perform a leak check to a pressure of 1 bar (14.5 psi).
No leakage from the body of the unit is allowed.
Seepage from capped and test connections is
acceptable. Repair or replace the radiator as
required.
40016231
44
Inspect the accessible areas inside the intercooler
for debris. Clean the inside of the intercooler as
necessary.
Inspect the entire outside surface of the intercooler

for cracks. Repair or replace as required.
40016230
45
10-16
Inspect the accessible areas inside the oil cooler
assembly for debris. Clean the inside of the
assembly as necessary.
Inspect the entire outside surface of the cooler

assembly for cracks. Repair or replace as required.
40016232
46
Assembly
Intercooler 2
1. Attach the side frames to the intercooler using 1 3
four cap screws at 1, and two cap screws at 2.
Torque all cap screws to 24 Nám (17 ft.-lbs.).
2. Apply black RTV sealant along the edges of the
frames at 3.
3. Attach a 1/2″ wide foam rubber strip along the
inside bottom edge of the cooler. 3 1
2
4. Install vibration dampers into the outside face of
40016230
the cooler.
47
Oil Coolers
1. Attach the side frames to the oil cooler using four
cap screws at 1. Torque the cap screws to 24 Nám 3
(17 ft.-lbs.).
2. Attach the lower frame to the oil cooler using six
cap screws at 2. Torque the cap screws to 24 Nám 1
(17 ft.-lbs.).
3
3. Apply black RTV sealant along the edges of the
frames at 3.
4. Attach 1/2″ wide foam rubber strip along the
inside top edge of the cooler. 40016232
2
48
10-17
5. Install the engine gearbox cooler fittings, 1.
Torque the fittings to 70 Nám (51 ft.-lbs.).
1
6. Turn in the hydraulic system cooler fittings, 2.
Torque the fittings to 186 Nám (137 ft.-lbs.).
7. Install vibration dampers, 3, into the lower cooler
frame.
3
40016232
49
Coolant Radiator
1. Attach a 1/2″ wide foam rubber strip along the 1
outside top and bottom edges of the radiator, 1.
1
40016231
50
Installation
NOTE: This step only needs to be performed if the oil 1
cooler had been removed.
1. Set the oil cooler, 1, into place. Turn on nuts, 2,

until snug.
40016229
51
10-18
NOTE: These two steps only need to be performed
if the engine coolant radiator had been removed.
2. Set the engine coolant radiator, 1, in place on top 1

of the oil cooler, 2. Orient the radiator with the
overflow line closest to the cab. 3
3. Adjust the position of the engine coolant radiator
so that the outside face and sides are even with
the oil cooler.
4. Apply a 1/2″ wide foam rubber strip along the
2
front and back edges of the radiator tanks, 3.
40016233
52
5. Set the intercooler, 1, in place on top of the
coolant radiator, 2.
6. Adjust the position of the intercooler so that the 1
outside face and sides are even with the radiator
and oil cooler.
7. Insert the formed rubber pads, 3, on the top and 3
bottom, front and back corners of the radiator.
40016235
53
8. Install the front and back attaching frames, 1.
Tighten the front and back attaching frame cap
screws. Torque the cap screws to 24 Nám (17
ft.-lbs.).
1
40016234
54
10-19
NOTE: This step only needs to be performed if the oil
cooler had been removed.
9. Push and hold the bottom of the radiator

assembly against the rotary screen cleaner
frame. Tighten the four bottom vibration damper
nuts, 1, to secure the unit in place.
40016229
55
10. Secure the intercooler vibration dampers, 1, to
the rotary screen cleaner frame.
1
40016236
56
NOTE: This step only needs to be performed if the oil
cooler had been removed. 3
11. Connect engine gearbox oil lines, 1, using new
O rings. Connect hydraulic system oil lines, 2,
using new O rings.
NOTE: This step only needs to be performed if the
engine coolant radiator had been removed. 1
4
12. Attach the engine coolant radiator inlet, 3, and 2
outlet hoses. Connect the drain line to the
petcock, 4, and verify that the petcock is shut. 40016237
Attach the overflow line to the radiator.
57
10-20
13. Set the bottom edge of the fan shroud, 1, into the
two clips located across the lower radiator frame.
14. Secure the shroud to the radiator assembly using 1
the nine previously removed cap screws.
15. Connect the intercooler inlet and outlet hoses, 2. 3 2
16. Install the pipe bracket, 3.
40016222
58
NOTE: These two steps only need to be performed
if the engine coolant radiator had been removed.
17. Install the pipe bracket, 1. 2

18. Verify coolant return connections, 2, are tight.
40016220
59
19. Secure the support frame, 1, to the combine. Set
the coolant reservoir into the lower straps. Install 2
the upper straps, 2, to secure the reservoir to the 1
frame.
40016221
60
10-21
20. Secure the support frame, 1, to the combine.
20016216
61
21. Secure the support frame, 1, to the combine at 2.
NOTE: This step only needs to be performed if the
engine coolant radiator had been removed. 1
22. Fill the engine coolant system through the

reservoir with the previously removed fluid.
NOTE: These two steps only need to be performed 2
if the oil cooler had been removed.
23. Fill the engine gearbox with the previously

removed oil.
20016204
24. Fill the hydraulic system with the previously
removed oil. 62
NOTE: The following retest procedure only needs to
be performed if the oil cooler or engine coolant
radiator had been removed.
25. Verify static pressure leak tightness by checking
all coolant and oil joints broken.
26. Start the combine engine.
27. Verify operating pressure leak tightness of all
gearbox and hydraulic system joints broken. 1
28. Run the engine until the coolant reaches normal
operating temperature. Verify operating pres-
sure leak tightness by checking all coolant joints
broken.
29. Secure the combine engine.
30. Install the top, 1, and rear, 2, engine
compartment shields.
2
84050265
63
10-22
ROTARY SCREEN
Removal 4
1. Pull the tensioner, 1, down and remove the drive
belt, 2. 2
2. Turn out the two cap screws, 3, along the bottom
of the plastic channel. Turn off the nut, 4, and
3
remove the channel.
3. If equipped, unplug the brush positioning motor.
1
10020102
64
4. Loosen and remove the two bolts, 1, on the air
conditioning condenser and pivot condenser
away from rotary screen. 1
1
50020199
65
5. Remove the idler spring, 1.
NOTE: The jam nuts and cap screws, 2, are located
inside the rotary screen cavity and can be accessed 2
from underneath the air conditioning condenser.
6. Loosen the two jam nuts, 2, and turn out the cap
screws holding the rotary screen shaft.
1
CAUTION
The rotary screen is awkward and moderately
heavy. Two individuals should be used to
remove the screen from the combine. 20020103
7. Carefully remove the screen from the combine by 66

pulling it away from the engine.
10-23
Disassembly
1. If equipped, unplug the brush positioning motor
at connector, 1. 2
2. Remove cap screw, nut and washer at 2.
1
10020104
67
3. Turn out the three cap screws, 1, from the
bearing holder. Capture the plate on the other
side of the screen.
4. Remove the bearing assembly by turning out cap
screw, 2.
1 2
20020105
68
5. Disengage the bearing lock, 1.
6. Remove the three carriage bolts, washers and
nuts, 2, holding the bearing to the frame. 1
20020106
69
10-24
7. Remove the shaft assembly from the rotary
screen.
20020107
70
8. Slide the bearing, 1, flangetts, 2, and lock, 3, from
the shaft. 3
1 2
20020108
71
Inspection
9. Inspect the outside bearing, 1, for damage and
smooth rotation. 1
20020109
72
10-25
10. Inspect the inside bearing, 1, for damage and
smooth rotation. 2
11. Inspect the shaft, 2, for damage or wear.
12. Inspect the wire for worn insulation and broken
connectors. 1 3
20020108
73
Assembly
2
1. If equipped, route the brush positioning wire
through the shaft so that the male connector, 1,
will be positioned as shown. Assemble the
connector with the blue wire in the “B” socket. 4
2. Slide the locking ring, 2, onto the shaft. 3
3. Assemble the bearing, 3, onto the shaft with a
flangette, 4, on either side.
1
20020108
74
4. Work the shaft assembly, 1, into position in the
rotary screen.
20020107
75
10-26
5. Attach the inside bearing using three carriage
bolts, washers and nuts, 1.
20020106
76
6. Insert the plate, 1, into place between the shaft
and screen.
7. Turn the cap screw and bearing into the shaft
from the front of the screen. Secure the bearing
assembly to the screen with three cap screws 1
and washers.
8. Engage the inside bearing locking collar by
turning it in the direction of rotation.
20020110
77
9. Orient the shaft so that the wire runs into the top.
This will line up the dimple on the underside of the
shaft with the inside set screw.
1
10. Attach the brush frame to the shaft using cap
screw, washer and nut, 1.
11. If equipped, plug in the brush positioning motor
at 2.
2
10020104
78
10-27
Installation
CAUTION
1
The rotary screen is awkward and moderately
heavy. Two individuals should be used to install
the screen onto the combine.
1. Carefully install the screen by pushing it toward

the engine.
2. Rotate the shaft until cap screw, 1, is vertical.
10020104
79
3. Turn in the set screw closest to the engine at 1
until finger tight. Rock the shaft back and forth to
verify that the cap screw is seated inside the
dimple. 2
4. Turn in the second cap screw at 1. Tighten both
cap screws and lock in place with the jam nuts.
5. Install the idler spring, 2. 1
20020103
80
6. Route the drive belt, 1, around the rotary screen,
drive pulley, 2, and tensioning idler. 3
7. Set the plastic channel into place and turn on nut
at 3.
2
8. Install cap screws, 4. Tighten all hardware.
1
10020102
81
10-28
9. Close the air conditioning condenser and install
the two bolts, 1.
1
1
50020199
82
ROTARY SCREEN DRIVE SHAFT
Removal
1. Pull the tensioner, 1, down and remove the drive 2
belt, 2.
1
10020102
83
2. Loosen and remove cap screw, 1.
3. Remove drive shaft pulley, 2. 1
4. Loosen and remove two carriage bolts, washers 2
and nuts, 3, from the bearing housing.
10020178
84
10-29
5. Remove access cover, 1, in grain tank.
1
10020181
85
6. Loosen and remove belt tension bolt, 1,
completely.
7. Remove the drive belt, 2.
2
10020182
86
8. Loosen and remove two carriage bolts, washers
and nuts, 1, from the bearing housing.
9. Remove drive shaft from combine.
10020183
87
10-30
Installation
1. Install drive shaft, and replace drive belt, 1.
1
2. Install and tighten two carriage bolts, washers

and nuts, 2, to bearing housing.
10020183
88
3. Install belt tension bolt, 1 and check belt for
proper tension. Tension is correct when the belt
deflection is 3 mm (1/8″) in the center of the belt,
with a force of 23 Nám (5.2 ft.-lbs.) applied to the
belt.
1
10020182
89
4. Replace access cover, 1.
1
10020181
90
10-31
5. Install and tighten two carriage bolts, washers
and nuts, 1, to bearing housing. 3
6. Install drive shaft pulley, 2. 2
7. Install and tighten cap screw, 3.
10020178
91
8. Pull down on tensioner, 1 and install drive belt, 2.
2
1
10020102
92
10-32
ROTARY SCREEN SEAL

Replacement 1
1. Remove the rotary screen, 1, from the combine
in accordance with the removal procedure.
10020102
93
2. The rotary screen seal, 1, is installed in three
sections. Drill out or chisel off the pop rivets from
each section to remove the seal.
3. Secure the three sections of the new seal into
place with pop rivets.
4. Install the rotary screen onto the combine in 1
accordance with the installation instructions.
10020112
94
10-33
ROTARY SCREEN BRUSH

Removal
NOTE: Removal of the rotary screen is not required
for brush replacement. 1
1. Remove the clip, 1, from the brush positioning
motor ball joint.
2. Pry the ball joint apart.
10020111
95
3. Remove the carriage bolts, washers and nuts, 1.
Lift the brush assembly, 2, from the rotary screen.
1
2
10020113
96
4. Remove the snap ring, 1, from both ends of the
brush holder.
5. Slide the brushes from the shaft.
10020114
97
10-34
6. Press the bearing, 1, from each brush wheel.
10020115
98
7. The inside brush wheel bearings, 1, may not
come off with the brushes. Remove the inside
bearings.
8. Using emery cloth or a light sandpaper, clean all
rust and debris from the brush shafts.
10020116
99
Installation
1. Press the new inner brush wheel bearings, 1,
onto the wheel shafts.
10020116
100
10-35
2. Press a new bearing, 1, into each brush wheel.
10020115
101
3. Install the rotary screen brush wheels onto the
shafts. Secure the brushes in place with snap
rings, 1.
10020114
102
4. Set the brush assembly, 1, into place and secure
to the rotary screen using carriage bolt, washers
and nuts at 2.
2
1
10020113
103
10-36
5. Assemble the actuating motor ball joint and
secure using clip, 1.
10020111
104
ROTARY SCREEN BRUSH ACTUATOR
Removal
NOTE: Removal of the rotary screen is not required
for actuator replacement. 1
1. Remove the clip, 1, from the brush positioning
motor ball joint.
2. Pry the ball joint apart.
10020111
105
3. Unplug connector, 1.
4. Turn off nut, 2. Lift the actuator from the cleaning
brush frame.
2
10020104
106
10-37
Installation
1. Attach the actuator to the cleaning brush frame
with washer and nut at 1.
1
2. Orient the actuator so the motor side, 2, is
furthest from the screen.
3. Plug the actuator into the brush control wiring
harness at 3. 2
10020104
107
4. Assemble the actuating motor ball joint and
secure using clip, 1.
10020111
108
10-38
SECTION 14 -- LIVE PTO -- CHAPTER 1
Chapter 1 - Engine Gearbox, Clutch Pack Removal/Installation
CONTENTS

Special Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Labor Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clutch Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
14-1
SPECIAL TORQUE
Item Torque
Thresher shaft rolling torque 1250 -- 1500 N⋅m (11 -- 13 in-lb)
Thresher shaft spur gear cap screws 110 -- 120 N⋅m (81 -- 88 ft-lb)
Hydraulic pump drive housing 190 -- 210 N⋅m (140 -- 155 ft-lb)
Hydraulic pump drive rolling torque 300 -- 400 N⋅m (2 -- 3 in-lb)
Engine flange cap screws 80 -- 90 N⋅m (59 -- 66 ft-lb)
Input shaft rolling torque 1400 -- 1500 N⋅m (12 -- 14 in-lb)
Clutch housing cover cap screws 45 -- 50 N⋅m (33 -- 37 ft-lb)
Main clutch cylinder cap screws 35 N⋅m (26 ft-lb)
Unload clutch piston cap screws 35 N⋅m (26 ft-lb)
Clutch housing spur gear cap screws 45 -- 50 N⋅m (33 -- 37 ft-lb)
SPECIAL TOOL
Tool #380000660 - Modified chisel
The modified chisel shown should be used to
disengage the locknuts installed on various 6.5 - 7.5 mm
components in the gearbox. An unmodified tool will 1/4 in
not have the capability to pull the indentation from the
shaft slot, and will make removal more difficult. If a
tool similar to the one shown is not available,
carefully cut the locknut free of the shaft. Any
damage to the shaft threads caused by this operation 12 - 13 mm
must be repaired prior to installation of the new 1/2 in
locknut.
10006348
14-2
GENERAL
Do not pack the tapered bearings with grease. The Cap screws must be free of oil and/or grease prior to
bearings used in this gearbox are oil lubricated. installation.
Races and bearings must not be mixed up. Securing the slotted nut: Swage the retaining edge of
the adjusted slotted nut into the longitudinal groove
For easier assembly, all bearings may be pre-heated of the shaft by means of a rounded mandrel. The
to a maximum temperature of 100°C (212°F). When retaining edge must be deformed evenly into the
checking the pre-load and roll torque of the shafts, longitudinal groove until it is in contact with the
bearings must be cooled to normal temperature. mid-section of the groove bottom. The retaining edge
must not tear. If necessary, it should therefore not be
Radial seals are to be mounted in the housing free swaged entirely to the bottom of the groove. (Groove
from oil and grease. width - mandrel dia; Approx. 2 mm)
Apply an oil film to ease assembly of all fitting
surfaces, bearing seats, sealing rings, spacer
washers and piston rings.
LABOR GUIDE
Gearbox Removal - 8 hours Main Clutch Assembly - 2 hours
Gearbox Disassembly - 4 hours Unload Clutch Disassembly - 2 hours
Gearbox Assembly - 6 hours Unload Clutch Assembly - 2 hours
Gearbox Replacement - 8 hours Clutch Cylinder Bushing Removal - 5 minutes
Main Clutch Disassembly - 2 hours Clutch Cylinder Bushing Installation - 5 minutes
14-3
OVERHAUL
CLUTCH PACK
The engine gearbox clutch packs can be serviced
without removing the gearbox from the combine.
Although it is physically possible to remove the clutch
packs, great care must be exercised when working
at the gearbox level. The main clutch pack weighs
approximately 31.7 kg (70 lbs), the unload clutch
pack will be slightly less.
Any operation or repair to the clutch packs that would

change the stack height of the unit, such as bearing
replacement, will require the entire gearbox be
removed from the machine. Improperly shimmed
clutch packs may cause early bearing failure.
Removal
11 liters (11.6 qts) of oil.
1. Attach a hose to the engine gearbox drain line, 1,

and direct the open end to a suitable storage
container. Drain the oil from the gearbox.
NOTE: The hydraulic reservoir holds approximately 1 2
60 liters (16 gals) of oil.
2. Attach a hose to the hydraulic reservoir drain line,

2, and direct the open end to a suitable storage 50012171
container. Drain the oil from the reservoir.
2
3. Loosen the unloading auger belt tensioning
spring, 1. Lift the belt from the gearbox sheave 1
and store it out of the way.
10012180
14-4
4. Turn out cap screws, 1, and remove the belt
tensioner from the combine. Cap screw, 2, may
have to be loosened to gain access to the lower
1 1
mounting cap screws. Store the tensioner in a
suitable location.
1
2
10012191
4
5. Loosen the main thresher drive belt tensioning
spring, 1. Lift the belt from the gearbox sheave
1
40020125
5
6. Loosen the straw chopper drive belt tensioning
spring, 1. Lift the belt from the combine and store
in a suitable location.
1
40020126
14-5
NOTE: When disconnecting hydraulic lines, have a
suitable container readily available to capture any
1
residual hydraulic oil.
7. Disconnect and cap the two low pressure

hydraulic pump lines, 1.
10012183
7
8. Disconnect and cap the four high pressure
1
1
10012184
8
9. Loosen but do not remove the pump mounting
nuts, 1.
NOTE: Remove left-hand side shield before the
removal of the high/low pressure hydraulic pump.
(Refer to the Repair manual, Section 90, “Platform
and Cab”.)
10012185
14-6
NOTE: The high/low pressure hydraulic pump
weighs approximately 29 kg (63 lbs).
10. Securely attach the high pressure pump to a tow

motor. Remove the mounting nuts and lift the
pump from the combine. Store the pump in a
suitable location.
10012186
10
NOTE: The gearbox may be shown removed from
the combine. 2
1
11. Using a wrench on the flats of the unloading
sheave, 1, turn out the cap screw, 2.
10013330
11
NOTE: The unloading shaft is tapered. Heat may
need to be applied to remove the sheave.
12. Attach a puller onto the unloading sheave, and

remove the sheave from the shaft.
10013331
12
14-7
13. Using a wrench on the flats of the main output
sheave, 1, turn out the cap screw, 2. 1
10013332
13
NOTE: The main output shaft is tapered. Heat may
14. Attach a puller onto the main output sheave, and

10013333
14
15. Remove the threaded sensor, 1, from the
gearbox. 1
IMPORTANT: DO NOT lose the shim washers. The
washers will be required upon reassembly to
maintain minimum acceptable clearance.
10004283
15
14-8
16. Remove the unload shaft key, 1.
2 1
17. Remove the housing cover cap screws, 2.
10004281
16
18. Install jacking bolts, 1. Tighten the bolts until the
housing cover, 2, has broken loose from the 1 1
gearbox. Remove the housing cover.
NOTE: When taking off the housing cover, protect
the radial seal, 3, against damage from the key way
of the unload clutch shaft.
3 2
10004282
17
NOTE: The unload clutch shaft is heavy. Exercise
care when removing the unit from the gearbox.
1
19. Pull the unload clutch, 1, straight out until the
rings have disengaged from the cylinder on the
inside end of the shaft.
10013341
18
14-9
20. Angle the outside end of the shaft toward the
front of the combine until the gear will clear the
main clutch pack. Carefully pull the shaft from the
gearbox and store in a suitable location.
10013342
19
NOTE: The main clutch shaft is heavy. Exercise care
when removing the unit from the gearbox. 2
1
21. Insert a tool or rod, 1, such as a 1/2″ drive breaker
bar, into the female spline of the main clutch
pack, 2. Work the clutch pack back and forth
while pulling on it to ease the rings from the
cylinder on the inside end of the shaft. Continue
to pull the main clutch out until the rings have
disengaged from the cylinder.
10013343
20
22. Angle the outside end of the shaft, 1, toward the
front of the combine. Carefully pull the shaft from 1
the gearbox and store in a suitable location.
Refer to the appropriate chapter in this section to

repair the desired component.
IMPORTANT: If any clutch pack bearings are

damaged and require replacement, the gearbox
must be removed from the combine. Shimming of the
clutch packs cannot be performed while the gearbox
is installed. Machine damage may result from
improperly shimmed bearings. 10013344
21
14-10
Installation
1
1. Set the main clutch shaft, 1, in the gearbox.
10013344
22
2. Raise the inside end of the shaft to the cylinder.
Work the main clutch shaft, 1, back and forth 1
using a tool, 2, inserted into the female spline of 2
the shaft. Carefully push the shaft into the
cylinder and line the gear up with the thresher
shaft gear.
10013343
23
3. Set the unload clutch shaft in the gearbox.
10013342
24
14-11
4. Raise the inside end of the shaft to the cylinder.
Work the unload clutch shaft, 1, back and forth to
push the inside end into the cylinder while lining 1
up the gear with the inside main clutch shaft gear.
10013341
25
NOTE: The gearbox may be shown removed from
the combine. 2 1
5. Set the unload shaft key, 1, into place.

6. Remove all grease, oil, or dirt from the sealing
surfaces of the housing. Apply a thin coat of
Loctite® 518 to the gearbox casing sealing
surface.
IMPORTANT: Use of any other gasket compound
could effect the pre-load of the bearings.
7. Place the housing cover on the gearbox and 10004281

secure using mounting cap screws, 2. Torque to
45 -- 50 N⋅m (33 -- 37 ft-lb). 26
8. Install the clutch temperature sender, 1, into the

gearbox. 1
10004283
27
14-12
9. Using the appropriate lifting gear, set the

hydraulic pump into place and secure using two
mounting nuts and washers, 1.
10012185
28
10. Attach the four high pressure hydraulic pump
lines, 1, to the pump. 1
1
10012184
29
11. Connect the two low pressure hydraulic pump
lines, 1, to the pump.
1
10012183
30
14-13
12. Install the unloading auger belt tensioner to the
gearbox using the cap screws, 1.
1 1
1
1
10012191
31
13. Set the main output sheave, 1, onto the shaft,
and turn in cap screw, 2.
1 2
10013332
32
14. Set the unloading sheave, 1, onto the shaft, and
turn in cap screw, 2. 2
1
10013330
33
14-14
15. Route the straw chopper drive belt and tighten
the adjuster to the spring gauge, 1, 100 mm (4 in). 1
10012182
34
16. Route the main thresher drive belt and tighten the
adjuster to the spring gauge, 1, 122 mm (4-13/16
in).
1
40020125
35
17. Route the unloading auger drive belt and tighten
the adjuster to the spring gauge, 1, 130 mm
(5-1/8 in).
1
40020126
36
14-15
18. Shut or verify shut the engine gearbox and
hydraulic reservoir drain line connections.
19. Fill the engine gearbox with 11 liters (11.6 qts) of
hydraulic oil.
20. Fill the hydraulic reservoir with 60 liters (16 gals)
of hydraulic oil.
21. Start the engine and allow the oil level in the
gearbox to stabilize. Fill the gearbox as
necessary with hydraulic oil to maintain the level
in the sight glass, but below the red full mark.
50012171
37
14-16
Chapter 2 - Engine Gearbox, Clutch Pack Rebuild
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Main Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Unload Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
14-1
OVERHAUL
MAIN CLUTCH
Disassembly
1. Remove the piston rings, 1, from the main clutch 1
shaft. First unhook, then slightly expand the
piston ring and take it off.
NOTE: Remove the piston rings without using any
tools. Do not apply excessive force.
10004291
1
2. Undo the deformed retention of the threaded
bushing. If necessary, break open the threaded 1
bushing by means of a modified chisel, 1.
3. Remove the threaded bushing from the main
clutch shaft.
10006344
2
4. Using a bearing puller, remove the tapered
bearing, 1, from the pump side of the main clutch 1
assembly.
NOTE: All bearings and races removed should be
labeled, if not being replaced, to ensure they are
installed into their original locations. If a bearing is to
be replaced, the outer race must also be replaced.
10004292
14-2
5. Attach a gear puller to the pump side gear of the
main clutch assembly.
10004293
4
6. Pull the pump side gear, 1, and tapered bearing,
2, off together. 1
10004294
5
7. Remove only two cap screws from the multi-disk
clutch assembly 180° apart.
WARNING
Do not, under any circumstances, loosen all
fastening screws of the multi-disk clutch. The
pressure plate is under very high spring
pressure. Improper disassembly of the multi-
disk clutch will cause severe personal injury.
8. Turn two M8 all-thread rods, 1, (203 - 254 mm [8

- 10 in] in length) into the clutch assembly where
the cap screws were installed.
10004295
14-3
9. Attach a puller to the clutch assembly as shown.
10004296
7
10. Remove the assembly along with the tapered
bearing, 1, and spacer ring, 2. 1
2
11. Place the multi-disk clutch assembly on a sturdy
working surface with the piston side up.
10004297
8
12. Remove only four of the cap screws. Leave two
cap screws installed, 1, 180° apart.
WARNING
Do not, under any circumstances, loosen all
fastening screws of the multi-disk clutch. The
pressure plate is under very high spring
pressure. Improper disassembly of the multi-
disk clutch will cause severe personal injury.
13. Turn two M8 x 30 mm cap screws with washers,

2, into the assembly to be used as jacking bolts.
1
14. Remove the remaining allen head cap screws.

15. Loosen the jacking bolts evenly allowing the
internal springs to push the piston from the
assembly. Tension on the jacking bolts will
slacken when the springs have been fully
expanded.
2 2
10004298
14-4
16. Remove the piston, 1, from the clutch plates, 2.
1
17. Lift the clutch plates from the inner clutch body,
3.
3
10004299 2
10
18. Carefully separate the piston, 1, from the
cylinder, 2.
1 2
19. Remove the seals, 3, from the piston.
3
10004300
11
20. Lift the spring assemblies, 1, from the inner
clutch body, 2.
2
10004301
12
14-5
21. Remove the pressure plate, 1, from the inner
clutch body. 1
10004304
13
Assembly
1
1. Install the inner O ring, 1, into the groove of the
piston.
10004303
14
2. Compress the slide ring to give it a kidney shape
without producing any sharp kinks, 1.
1
3. Insert the slide ring into the lower part of the
groove and press it into the groove in an outward
direction, 2. 2
4. Install the outer O ring into the groove of the
piston.
10004302
15
14-6
5. Heat the outer slide ring to about 80°C (170°F) in
an oil or water bath.
CAUTION
The slide ring is very hot. Failure to use
insulating gloves could cause serious personal
injury.
6. Expand the outer slide ring by pushing it over the

guide chamfer on the piston and let it snap into
the groove. As the expanded slide ring cools
down to room temperature, it resumes its original
10004305
shape.
16
7. Lubricate the inner piston O ring with clean
hydraulic fluid. Insert the piston onto the inner 1
clutch body making sure the alignment holes in
the piston, 1, line up with the alignment holes in 2
the clutch body, 2.
10004306
17
8. Turn the assembly over. Mesh the teeth of the
clutch body with the ring gear of the piston.
Evenly push the clutch body into the piston.
10004307
18
14-7
9. Turn the assembly over. Line the cap screw holes
of the cylinder, 1, up with the threaded holes in 1 2
the piston, 2.
10. Apply Loctite® 242 and install two hex head cap
screws. Tighten them evenly to draw the cylinder
down onto the piston.
10004308
19
11. Apply Loctite® 242 to the four remaining allen
head cap screws and torque them to 35 N⋅m (26
ft-lbs). The assembly can be temporarily
installed on the main clutch shaft to help in
tightening the cap screws.
10004309
20
12. Set the double spring assemblies into the inner
body.
10004310
21
14-8
13. Set the clutch disks onto the inner body. Place a
metal disk on the piston followed by a friction
disk. Continue placing the disks in an alternating
fashion until ten metal and nine friction disks
have been stacked onto the clutch assembly.
10004311
22
14. Set the pressure plate, 1, onto the clutch
assembly. Line up the cap screw holes of the 1
2
pressure plate with the threaded holes of the
clutch assembly.
15. Insert two M8 x 30 mm cap screws as jacking
bolts, 2, into the clutch assembly.
2
16. Tighten the jacking bolts evenly until the
pressure plate has been seated. Loosen each
jacking bolt 1/2 turn only.
17. Apply Loctite® 242 and install four allen head cap
screws into the remaining holes of the clutch
assembly. Tighten the cap screws until snug. 10004312
18. Remove the two jacking bolts, apply Loctite® 23

242, and install the last two allen head cap
screws. Torque all pressure plate cap screws to
35 N⋅m (26 ft-lbs).
19. Position the main clutch shaft and spur gear
assembly, 1, in a press. Set the clutch pack, 2,
onto the spline of the shaft and press them
together until the pack is seated against the spur
2
gear.
10012223
1
24
14-9
20. Press the tapered roller bearing, 1, on in the
same manner. Set a spacer ring, 2, on top of the 2 1
roller bearing.
10012224
25
21. Lower the outer basket and spur gear, 1, onto the
assembly. 1
10012225
26
22. Press the tapered roller bearing, 1, onto the
assembly until it is seated against the outer 1
bearing race in the spur gear.
10012226
27
14-10
23. Press the tapered roller bearing, 1, on in the
same manner with the taper oriented toward the
1
end of the shaft as shown.
10012227
28
24. Turn the nut, 1, onto the end of the main clutch
shaft. Tighten the nut to 250 - 265 N⋅m (185 - 196
ft-lbs) and secure the nut by deforming the front 1
collar into the shaft groove, 2. 2
NOTE: Swage the retaining edge of the nut into the
groove of the shaft by means of a rounded mandrel.
The retaining edge must be deformed evenly into the
longitudinal groove until it is in contact with the
mid-section of the groove bottom. The retaining edge
swaged entirely to the bottom of the groove. (Groove
width - mandrel dia.; Approx. 2 mm)
10012228
29
25. Mount the piston rings, 1, without using any tool.
Bend with care, hook up the piston rings and
make sure that they are free to turn smoothly in
the shaft groove. 1
10004291
30
14-11
UNLOAD CLUTCH
Disassembly
1. Remove the piston rings, 1, from the main clutch
shaft. First, unhook then slightly expand the
piston rings and take them off.
NOTE: Remove the piston rings without using any
tools. Do not apply excessive force.
10012229
31
2. Undo the deformed retention of the threaded
bushing. If necessary, break open the threaded 1
bushing by means of a modified chisel, 1.
3. Remove the threaded bushing from the unload
clutch shaft.
10006345
32
IMPORTANT: Do not apply force to the inner roller
bearing. This bearing must be removed after the 1
shaft has been extracted from the assembly.
4. Place the unload clutch assembly on the hub of

the cylinder in a press. Push the complete shaft,
1, and inner roller bearing, 2, out of the spur gear
and the multi-disk clutch.
be replaced, the race must also be replaced.
10005482 2
5. Lift the outer roller bearing, spur gear, and outer 33
gear bearing from the assembly.
14-12
6. Lift the spacer ring, 1, and inner gear bearing, 2,
from the clutch. 1
7. Place the clutch on a clean working surface with 2
the pressure plate side down.
8. Remove only two cap screws from the multi-disk
clutch assembly 180° apart.
WARNING
Do not, under any circumstances, loosen all cap
screws of the multi-disk clutch. The pressure
plate is under very high spring pressure.
Improper disassembly of the multi-disk clutch 10005483
will cause severe personal injury.
34
9. Turn two M6 x 20 mm cap screws, 1, with

washers into the assembly to be used as jacking 2
bolts. 1
10. Remove the remaining allen head cap screws, 2.
11. Loosen the jacking bolts evenly allowing the
internal springs to push the piston from the 1
assembly. Tension on the jacking bolts will
slacken when the springs have been fully
expanded.
2
10005484
35
12. Lift the piston, 1, from the cylinder, 2.
1
10005485 2
36
14-13
13. Remove the cylinder, 1, from the inner clutch
body, 2. 2 3
14. Take out the double spring assemblies, 3, from
the inner clutch body.
15. Lift the metal and friction disks, 4, from the inner 1
clutch body.
4
10005486
37
16. Orient the inner clutch body over so that the
1
pressure plate, 1, is facing up. Turn out the six 2
cap screws, 2, holding the pressure plate to the
clutch body.
10005487
38
17. Remove the eight cap screws holding the spur
1 2
gear, 1, to the outer clutch housing, 2. Bearing
races, 3, and 4, can be taken out if the bearings
are to be replaced.
be replaced, the race must also be replaced.
3 4
10005488
39
14-14
18. Press the roller bearing, 1, off in the direction of
the shaft taper. 1
10005497
40
Assembly
1
1. Install the inner O ring, 1, into the groove of the
piston.
10004303
41
2. Compress the slide ring to give it a kidney shape
without producing any sharp kinks, 1.
1
3. Insert the slide ring into the lower part of the
groove and press it into the groove in an outward
direction, 2. 2
4. Install the outer O ring into the groove of the
piston.
10004302
42
14-15
5. Heat the outer slide ring to about 80°C (170°F) in
an oil or water bath.
CAUTION
The slide ring is very hot. Failure to use
insulating gloves could cause serious personal
injury.
6. Expand the outer slide ring by pushing it over the

guide chamfer on the piston and let is snap into
the groove. As the expanded slide ring cools
down to room temperature, it resumes its original
10004305
shape.
43
7. Place the clutch cylinder, 1, on a working surface
with the gear ring up. 2
8. Lubricate the inner clutch body and cylinder seal, 1
3, with oil.
9. Insert the inner clutch body, 2, into the cylinder.
Align the teeth of the inner body with the cylinder
and push the inner body as far as it will go.
3
10005489
44
10. Lubricate the piston seal and inner surface of the
cylinder with oil. 1 2
11. Line up the cap screw holes in the piston with the
inner body. Gently slide the piston, 1, into the
cylinder, 2.
12. Apply Loctite® 242 and install the six cap screws
into the piston and torque to 35 N⋅m (26 ft-lbs).
10005490
45
14-16
13. Orient the assembly so that the piston and
cylinder are on the bottom. Set the clutch disks 2
onto the inner body. Place a metal disk, 1, on the
cylinder followed by a friction disk, 2. Continue
placing the disks in an alternating fashion until
seven metal and six friction disks have been
stacked onto the clutch assembly.
1
10005491
46
14. Set the double spring assemblies, 1, into the
inner body.
15. Set the pressure plate, 2, onto the clutch
assembly. Line up the cap screw holes of the
pressure plate with the threaded holes of the
clutch assembly. 2
1
10005492
47
16. Install two M6 x 30 mm cap screws as jacking
bolts, 1, into the clutch assembly. 1 1
17. Tighten the jacking bolts evenly until the
pressure plate has been seated. Loosen each
jacking bolt 1/2 turn only.
18. Apply Loctite® 242 and install four allen head cap 2
screws, 2, into the remaining holes of the clutch 2
assembly. Tighten the cap screws until snug.
19. Remove the two jacking bolts. Apply Loctite®
242 and install the remaining allen head cap
screws. Torque all pressure plate cap screws to
35 N⋅m (26 ft-lbs). 10005493
48
14-17
20. Apply Loctite® 242 to the eight hex head cap
1 2
screws, and attach the spur gear, 1, to the outer
clutch housing, 2. Torque the cap screws to 45 -
50 N⋅m (33 - 37 ft-lbs).
21. Install the outer bearing races, 3 and 4, if
previously removed.
3 4
10005488
49
22. Support the unload clutch shaft, 1, vertically with
the tapered end down.
23. Slide the clutch assembly, 2, onto the shaft. 3
24. Press the spur gear inner bearing, 3, onto the
clutch shaft with the tapered end up.
1
10005494
50
25. Set the spacer ring, 1, onto the spur gear inner
bearing.
1
10005495
51
14-18
26. Slide the spur gear assembly, 1, over the clutch
until the inner race of the spur gear is seated on
3
the inner bearing.
27. Press the spur gear outer bearing, 2, and the 1
clutch shaft bearing, 3, onto the shaft assembly.
10005496
52
28. Turn the nut, 1, onto the end of the clutch shaft.
Tighten the nut to 225 - 240 N⋅m (166 - 177 ft-lbs)
1
2
and secure the nut by deforming the front collar
into the shaft groove.
NOTE: Swage the retaining edge of the nut into the
10012229
29. Mount the piston rings, 2, without using any tool. 53

Bend with care, hook up the piston rings and
make sure that they are free to turn smoothly in
the shaft groove.
14-19
14-20
Chapter 3 - Engine Gearbox Removal/Installation
CONTENTS

Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Flexplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
14-1
GEARBOX
Removal
1. Support the left combine door open with an
appropriate lifting device.
10012172
1
2. Remove the nut and bolt, 1, and allow the door
opener, 2, to rest on the ground.
1
10012173
2
3. Turn off nut at 1, and disengage cable end from
the operating mechanism. Loosen the jam nut at
2. 3
3
4. Remove the four cap screws, 3, and take the
door opener from the combine. Store the opener
5. Carefully lower the door until it is vertical. 2
Remove the lifting gear used to support the door.
1
10012174
14-2
6. Mark and drill 12 mm (7/16″) holes, 1, in the front
and rear left combine door hinges.
NOTE: While marking where to drill the holes, take
into account the equipment that will be used to lift the 1
door from the combine. Ensure that sufficient space
is available to remove the hinges while the lifting
equipment is attached.
10012175
4
NOTE: The weight of the combine door is
approximately 68 kg (150 lbs).
CAUTION
The door is heavy and awkward. Improper
handling of the door during removal could cause
serious injury.
7. Attach the appropriate lifting equipment to the

combine door hinges as shown. Support the
weight of the door with a tow motor and
disengage the hinges. Store the door in a 10012176
suitable location.
5
8. If hydraulic pressure is available to operate the
unloading auger, rotate the auger away from the 2
combine and securely block it in place.
9. If hydraulic pressure is not available to operate
the unloading auger, loosen the hydraulic lines,
1, to the unloading auger cylinder. Detach the rod
end of the cylinder, 2, from the auger.
10. Rotate the unloading auger away from the
combine, tie and block it securely in place.
1
CAUTION
As the auger is rotated further away from the 40020127
combine, the force on the auger to return to its
standby position increases. Only move the auger 6
far enough to allow sufficient room to remove the
gearbox with a tow motor.
14-3
11 liters (11.6 qts) of oil.
11. Attach a hose to the engine gearbox drain line, 1,

and direct the open end to a suitable storage
container. Drain the oil from the gearbox.
NOTE: The hydraulic reservoir holds approximately
60 liters (16 gals) of oil. 1 2
12. Attach a hose to the hydraulic reservoir drain line,
2, and direct the open end to a suitable storage
container. Drain the oil from the reservoir.
50012171
7
13. Loosen the clamp, 1, on the air filter outlet
connection. 1
40012177
8
14. Detach the access cover, 1, from the air filter
housing. Remove the two air filters from the unit 1 2
and store in a suitable location.
15. Remove the two bolts, washers and nuts, 2, and
lift the air filter from the combine. Store the air
filter housing in a suitable location.
40020128
14-4
16. Loosen the unloading auger belt tensioning
spring, 1. Lift the belt from the gearbox sheave 1
10012180
10
tensioner from the combine. Cap screw, 2, may
have to be loosened to gain access to the lower
1 1
mounting cap screws. Store the tensioner in a
suitable location.
1
2
10012191
11
18. Loosen the main thresher drive belt tensioning
spring, 1. Lift the belt from the gearbox sheave
1
40020125
12
14-5
tensioner from the combine. Store the tensioner 1
10012192
13
20. Loosen the straw chopper drive belt tensioning
spring, 1. Lift the belt from the combine and store
1
40020126
14
1
21. Disconnect and cap the two low pressure

10012183
15
14-6
22. Disconnect and cap the four high pressure
1
1
10012184
16
23. Loosen but do not remove the pump mounting
nuts, 1.
10012185
17
24. Securely attach the high pressure pump to a tow

motor. Remove the mounting nuts and lift the
pump from the combine. Store the pump in a
suitable location.
10012186
18
14-7
25. Disconnect and cap hydraulic line, 1, from the

main hydrostatic pump. Turn four cap screws out 2
from each fitting, 2, to disconnect the hydraulic
lines from the pump. Cap the lines just removed.
26. Disconnect and cap hydraulic line, 3, from the
main hydrostatic pump.
1 3
10012187
19
27. Disconnect and cap hydraulic line, 1 from the
main hydrostatic pump. Detach the connector, 2,
from the oil pressure switch. Unplug the 1
connector, 3, from the Electronic Displacement
Control (EDC) valve.
10012188 2
20
28. Disconnect and cap hydraulic line, 1, at both
ends and remove from the combine. Store the 3
1
line in a suitable location. 2
29. Turn off oil filter, 2.
30. Loosen but do not remove the four hydrostatic
pump mounting cap screws, 3.
10012189
21
14-8
NOTE: The main hydrostatic pump weighs approxi-
mately 137 kg (303 lbs).
31. Securely attach the main hydrostatic pump to a

tow motor. Remove the mounting cap screws
and lift the pump from the combine. Store the
pump in a suitable location.
10012190
22
32. Turn out the two cap screws, 1, to detach the pipe
bracket, 2, from the gearbox.
40020129
23
33. Loosen the two hose clamps, 1, remove and cap
the hydraulic lines from the gearbox.
34. Detach electrical connector, 2.
10012194
24
14-9
35. Disconnect and cap hydraulic lines, 1, from the
filler tube. Turn out the three cap screws, 2, and
remove the filler tube, 3, from the gearbox. 3
10002715
25
36. Turn out the four cap screws, 1, securing the
manifold to the gearbox. Tie the manifold up
away from the gearbox. Remove the O rings.
10002717
26
37. Loosen all twelve gearbox mounting cap screws.
10002719
27
14-10
38. Several of the cap screws are better accessible
from inside the grain tank.
10012195
28
NOTE: The engine gearbox weights approximately
246 kg (543 lbs).
NOTE: Make sure that the gearbox is properly

supported. Too much or too little tension may cause
the gearbox spline shaft, 1, to bend.
39. Securely attach the engine gearbox to a tow

motor. Remove the mounting cap screws and lift 1
the gearbox from the combine. Set the gearbox
on the floor in a stable position.
10003679
29
14-11
Installation
NOTE: The engine gearbox weighs approximately
246 kg (543 lbs).
1. Lubricate the gearbox spine input shaft with an

anti-seize compound.
NOTE: Make sure that the gearbox is properly
supported. Too much or too little tension may cause
the gearbox spline shaft, 1, to bend.
1
2. Securely attach the engine gearbox to a tow
motor and lift the gearbox to the engine mounting 10003679
flange.
30
3. Slide the gearbox spline into the engine flywheel
until the flanges are against each other.
4. Turn in all twelve gearbox mounting cap screws.
Do not tighten any hardware until all cap screws
have been started.
10002719
31
5. Several of the cap screws are better accessible
from inside the grain tank.
6. Apply Loctite® 242 and tighten the gearbox
mounting cap screws to 80 - 90 N⋅m (59 - 66
ft-lbs).
10012195
32
14-12
7. Lubricate and set into place on the gearbox six
manifold O rings.
8. Carefully rest the manifold on the gearbox and
secure using four long cap screws, 1. Torque four
cap screws to 28 N⋅m (21 ft-lbs). 1
10002717
33
9. Attach the oil filler tube, 3, to the gearbox with
three cap screws, 2. Connect the hydraulic lines,
1, to the filler tube. 3
10002715
34
10. Secure the pump suction and gearbox drain
lines, 1, to the appropriate fittings with hose
clamps.
11. Attach the sump oil temperature sender
connector, 2.
2
10012194
35
14-13
12. Connect the pipe bracket, 2, to the gearbox with
two cap screws, 1.
40020129
36
13. Lift the hydrostatic pump into place and attach to

the gearbox with four cap screws. Torque the
mounting cap screws to 190 - 210 N⋅m (140 - 155
ft-lbs).
10012190
37
14. Turn on a new oil filter, 2. Install the hydraulic line,
1.
1
2
10012189
38
14-14
15. Attach the hydraulic line, 1, to the hydrostatic
pump. Plug the connector, 3, in the Electronic
Displacement Control (EDC) valve. Connect the 1
wire, 2, to the oil pressure switch.
10012188 2
39
16. Secure the main hydrostatic pump lines, 2, using
four cap screws on each fitting. Torque the cap
screws to 159 N⋅m (117 ft-lbs). Secure hydraulic
line, 1 and 3, to the main hydrostatic pump.
1 3
10012187
40
17. Using the appropriate lifting gear, set the

hydraulic pump into place and secure using two
mounting nuts and washers, 1.
10012185
41
14-15
18. Attach the four high pressure hydraulic pump
1
1
10012184
42
19. Connect the two low pressure hydraulic pump
1
10012183
43
20. Route the straw chopper drive belt and tighten
the adjuster to the spring gauge, 1.
40020126
44
14-16
21. Install the thresher drive belt tensioner to the
gearbox using the cap screws, 1. 1
10012192
45
22. Route the main thresher drive belt and tighten the
adjuster to the spring gauge, 1, 122 mm
(4-13/16″).
1
40020125
46
23. Install the unloading auger belt tensioner to the
gearbox using the cap screws, 1.
1 1
10012191
47
14-17
24. Route the unloading auger drive belt and tighten
the adjuster to the spring gauge, 1. 1
10012180
48
25. Set the air filter and housing, 1, into place and
secure using removed hardware, 2. 1 2
40020128
49
26. Attach the air filter outlet connection.
40012177
50
14-18
27. Shut or verify shut the engine gearbox and
hydraulic reservoir drain line connections.
28. Fill the engine gearbox with 11 liters (11.6 qts) of
hydraulic oil.
29. Fill the hydraulic reservoir with 60 liters (16 gals)
of hydraulic oil.
30. Start the engine and allow the oil level in the
gearbox to stabilize. Fill the gearbox as
necessary with hydraulic oil to maintain the level
in the sight glass, but below the red full mark.
50012171
51
31. If the unloading auger is attached to the
operating cylinder, rotate the auger into its 1
standby position.
32. If the cylinder has been disconnected from the
auger, carefully rotate the auger into its standby
position.
33. Attach the rod end, 1, of the cylinder to the hinge
point on the auger. Tighten or verify tight the
hydraulic lines, 2, to the unloading auger
cylinder. 2
40020127
52
NOTE: The weight of the combine door is
approximately 68 kg (150 lbs).
CAUTION
The door is heavy and awkward. Improper
handling of the door during installation could
cause serious injury.
34. Attach the appropriate lifting equipment to the

combine door hinges and set the door into place.
Insert the hinge pins and secure them in place
using cotter pins. 10012176
53
14-19
35. Using the appropriate lifting equipment, raise the
combine door until it is open.
3
36. Secure the door opener to the combine using 3
four cap screws, 3.
37. Connect the operating cable, 2, to the
mechanism and secure with nut, 1.
2
10012174
54
38. Raise the inside end of the door opener and
attach it to the combine with a nut and bolt, 1.
39. Remove the lifting equipment used to hold the
door open.
40. Place the door in the desired position.
1
10012173
55
14-20
FLEXPLATE
Removal
1. Remove the engine gearbox in accordance with
the “Gearbox - Removal” procedure in this
section.
10012184
56
For CR960, 970, 980:
1. Turn out the eight cap screws with lock washers, Gearbox Side
1. Lift the flexplate, 2, from the flywheel.
2. Clean all old thread locking compound from the Engine Side
cap screws.
1
20015717
57
14-21
For CR920, 940:
1. Turn out the eight cap screws with lock washers, Gearbox Side
1. Lift the flexplate, 2, from the flywheel.
Engine Side
2. Clean all old thread locking compound from the
cap screws.
1
20015718
58
14-22
Installation
Gearbox Side
For CR960, 970, 980:
1. Apply Loctite® 242 to the eight cap screws. Engine Side
3
2. Set the gearbox flexplate, 1, on the engine
flywheel with the flexplate cap screw heads, 2,
oriented toward the gearbox. Secure using eight
lock washers and cap screws, 3. Torque the cap
screws to 97 N⋅m (72 ft-lbs).
2
20015717
59
14-23
For CR920, 940:
1. Apply Loctite® 242 to the eight cap screws. Gearbox Side
2. Set the gearbox flexplate, 1, on the engine
Engine Side
flywheel with the flexplate cap screw heads, 2,
oriented toward the engine flywheel. Secure
using eight lock washers and cap screws, 3.
Torque the cap screws to 56 N⋅m (41 ft-lbs). 3
2
20015718
60
3. Install the engine gearbox in accordance with the
Gearbox - Installation procedure in this section.
10012184
61
14-24
Chapter 4 - Engine Gearbox Rebuild
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component Repair -- Bearing and Race Removal/Installation . . . . . . . . . . . . . . . . 10
Component Repair -- Clutch Cylinder Bushing Removal/Installation . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
14-1
OVERHAUL
GEARBOX
1
Disassembly
1. Support the gearbox with the engine flange/input
shaft pointing in the downward direction.
2. Using a wrench on the flats of the unloading
2
10013330
1
NOTE: The unloading shaft is tapered. Heat may
3. Attach a puller onto the unloading sheave, and

10013331
2
4. Using a wrench on the flats of the main output
2
1
10013332
14-2
NOTE: The main output shaft is tapered. Heat may
5. Attach a puller onto the main output sheave, and

10013333
4
6. Remove the unload shaft key, 1.
2 1
7. Remove the housing cover cap screws, 2.
10004281
5
8. Install jacking bolts, 1. Tighten the bolts until the
housing cover, 2, has broken loose from the 1 1
gearbox. Remove the housing cover.
NOTE: When taking off the housing cover, protect
the radial seal, 3, against damage from the key way
of the unload clutch shaft.
3 2
10004282
14-3
9. Remove the threaded sensor, 1, from the
gearbox. 1
IMPORTANT: DO NOT lose the shim washers. The
washers will be required upon reassembly to
maintain minimum acceptable clearance.
10004283
7
NOTE: The unload clutch shaft and main clutch shaft
are heavy. Exercise care when removing the units 1
from the gearbox.
10. Lift the main clutch shaft, 1, out of the gearbox.
10004284
8
11. Lift the unload clutch shaft, 1, out of the gearbox.
10004285
14-4
12. Remove the drive housing, 1, from the gearbox.
1
10002713
10
13. Lift the hydrostatic drive from the gearbox.
14. Turn the gearbox over and support it with the
engine flange/input shaft pointing in the upward
direction.
10004286
11
15. Remove cap screws, 1, holding the engine flange
onto the gearbox. 1 2
16. Separate the engine flange, 2, from the gearbox.
NOTE: When removing the engine flange, protect
the shaft seal against damage from the multi-spline
profile of the spur gear shaft.
10004290
12
14-5
17. Remove the input shaft assembly, 1, from the
gearbox. 1
10004287
13
18. Turn the gearbox over and support it with the
thresher shaft pointing in the upward direction. 1
19. Remove the thresher shaft key, 1.
2
20. Pry the thresher shaft seal, 2, from the gearbox.
10004289
14
14-6
21. Using a modified chisel, force the indented
portion of the slotted nut from the shaft. Turn the
nut from the thresher shaft.
NOTE: It may be necessary to destroy the slotted nut
to remove it from the thresher shaft.
10006346
15
22. Remove plug, 1, to gain access to the cap screws
with a long extension. 4 3
23. Secure the thresher shaft to keep it from turning
by blocking the spur gear rim against the
housing. 2
24. Turn out the cap screws, 2, holding the gear to 1
the flanged shaft, 3.
25. Lift the thresher shaft drive gear, 4, from the
gearbox.
26. Drive the flanged shaft out of the bearing seat in
the housing neck towards the inside. 10004288
NOTE: The bearings have been heat shrunk to the 16
shaft. Use a large sledge hammer and hardwood
block to separate the shaft from the outer bearing.
27. Remove the flanged shaft from the gearbox.
14-7
Inspection
1. Inspect all sealing surfaces, 1, for grooves or
nicks.
1 1
10012230
17
2. Inspect the unload clutch brake washer, 1, for
wear. 1
10006354
18
14-8
3. Check gears, 1, for broken or badly worn teeth.
1
1
1
10012230
19
4. Inspect the piston rings and cylinder bushings, 1,
for grooves or nicks.
10012230
20
14-9
Component Repair -- Bearing and Race Removal/
Installation
If a tapered roller bearing requires replacement, the
outer race must also be replaced at the same time.
Some outer races are inserted on top of shim packs.

These packs are installed to provide a pre-load to the
bearings. The original shim pack should be used
when replacing the bearing and race. Perform the
measurement to determine if proper pre-load exists,
and adjust the thickness of the shim pack
appropriately.
10012217
All of the tapered roller bearings used in this gearbox
are installed using an interference fit. Most bearings 21
can be removed and installed using bearing pullers
and presses. The thresher shaft bearings are heat
shrunk onto the shaft. To install new bearings onto
the shaft, heat them in a bearing oven, 80 - 85°C (170
- 180°F) for 30 - 45 minutes. Remove the bearing
from the oven and carefully slide it onto the shaft in
the proper orientation. Ensure that the bearing slides
on evenly. When the bearing is in contact with the
shaft, it will cool very quickly and start to shrink.
Component Repair -- Clutch Cylinder Bushing

Removal/Installation
1. With snap ring pliers, lift the snap ring, 1, from the 1
gearbox.
10006349
22
2. Using a pin spanner, or other suitable tool, hook
one oil port of the cylinder bushing and pull
straight up to extract the bushing from the bore.
NOTE: The bushing is held in place by a snap ring
and O rings.
10006350
23
14-10
3. Remove the O ring and backing ring at 1 and 2.
1
2
10006351
24
4. Lubricate and install the O ring and backing ring
at 1 with the backing ring on top.
5. Lubricate and install the O ring and backing ring
at 2 with the backing ring on the bottom.
1
2
10006352
25
14-11
6. Push the cylinder bushing into the bore with the
nib directed into the indent at the bottom of the 1
bore, 1.
10006351
26
7. Secure the bushing into place using the snap
ring, 1.
1
10006349
27
14-12
Assembly
1. Heat the thresher shaft outer bearing, 1, in an 3
oven to 80 - 85°C (170 - 180°F). 2
2. Insert the thresher shaft, 2, from inside the
housing and brace it against the inner wall of the
housing by means of blocking, 3.
3. Drop the heated bearing onto the installed shaft
with the tapered end down. Ensure that the
bearing slides down the shaft evenly.
1
CAUTION
10006336
The bearing is very hot!
28
4. Turn the slotted nut, 1, onto the thresher shaft 1
finger tight. Mark the nut and shaft so that their
relative positions can be monitored.
5. Turn the thresher shaft while applying light blows
to the housing in order to set the bearings.
10006337
29
NOTE: The slotted nut must be tightened in small
increments. Due to the tight fit of the bearing, it will be
difficult to loosen the bearing if running torque
becomes excessive.
6. Hold the shaft from turning with a pin spanner on

the flanged end of the shaft. Tighten the slotted
nut to produce a rolling torque on the thresher
shaft of 1250 - 1500 N⋅m (11 - 13 in-lbs).
10006338
30
14-13
7. Secure the nut by deforming the front collar into
the shaft groove.
NOTE: Securing the slotted nut: Swage the retaining
edge of the adjusted slotted nut into the longitudinal
10006339
31
8. Place the spur gear, 1, on the centering of the
flanged shaft. Mount the gear with new cap 1
screws, 2, and tighten to 110 - 120 N⋅m (81 - 88
ft-lbs). Use a crowbar or large screwdriver to hold
the gear in place while tightening the cap screws.
CAUTION
For safety reasons, new M12 cap screws must be
used for assembly.
2
10006340
32
9. Slide the previously removed shim pack, 1, and
bearing race, 2, into the upper housing, 3. 2 1
10012217
3
33
14-14
10. Set the hydraulic pump drive gear, 1, into the
casing. Lubricate the O ring, 2, with petroleum 2
jelly and install it into the groove of the upper
housing.
10006341
34
11. Orient the housing so that the oil feeding groove,
1, is located at the top.
12. Secure the housing, 2, to the gearbox with four 1
nuts and washers, 3, and tighten to 190 - 210 N⋅m 2
(140 - 155 ft-lbs).
13. Turn the spur gear shaft while applying light
blows to the housing in order to set the bearings.
14. Remove the nuts and washers.
10012214 3
35
15. Wrap a few turns of electrical tape around a 28
mm (1-1/8″) socket and press the socket into the
female spline of the gear.
10012215
36
14-15
16. Check the roll torque of the hydraulic pump drive
for compliance with the nominal value of 300 -
400 N⋅m (2 - 3 in-lbs).
10012216
37
17. If necessary, the shim thickness must be
adjusted to reach the nominal value of 300 - 400
N⋅m (2 - 3 in-lbs).
10012217
38
18. Turn the housing over and support it with the
opening for the engine flange pointing in the 1
upward direction.
19. Install the inner bearing race and the previously
removed shim pack at 1, if it had been removed.
10012219
39
14-16
20. Insert the input shaft and gear, 1, into the
housing. 1
21. Mount the outer race of the roller bearing into the
engine flange, if it had previously removed.
22. Lubricate the O ring with petroleum jelly and
install it into the groove of the engine flange.
10006343
40
IMPORTANT: Use extreme care while installing the
3 2
engine flange. The sealing O ring can come out of the
groove and become pinched.
1
23. Install the engine flange with the oil feeding
groove, 1, toward the top of the gearbox.
IMPORTANT: Use of any gasket compound on the
engine flange will effect the bearing pre-load.
24. Secure the flange to the gearbox with cap

screws, 2, and tighten to 80 - 90 N⋅m (59 - 66
ft-lbs).
10004290
25. Turn the spur gear shaft, 3, while applying light
blows to the housing in order to set the bearings. 41
26. Check the combined roll torque of the input shaft

for compliance with the nominal valve 1400 -
1650 N⋅m (12 - 14 in-lbs).
10012218
42
14-17
27. If necessary, the shim pack thickness under the
input shaft outer race, 1, must be adjusted. 1
10012219
43
28. Turn the housing over and support it with the
engine flange pointing in the downward direction. 2 1
29. Insert the main clutch shaft, 1, into the casing. It
is absolutely necessary to introduce it in the
vertical position so as to insert the piston rings,
to ensure meshing of the gears, and center the
main clutch shaft in the bearing race.
30. Insert the unload clutch shaft, 2, in the casing. It
is absolutely necessary to introduce it in the
vertical position so as to insert the piston rings,
to ensure meshing of the gears, and center the
unload clutch shaft in the bearing race. 10004284
44
31. Remove the unloading clutch brake washer and
any shims, 1, by turning out the four cap screws, 1
2.
10006354
45
14-18
32. Set the housing cover on the gearbox. Turn in two
jacking screws, 1, and four attaching cap screws, 2 1
2. Adjust the screws as required so the cover is 1
secured to but not touching the gearbox.
2
2
10013326
46
33. Remove the snap ring, 1, and one shim, 2, from
each clutch pack bearing assembly. Label each 1
shim removed noting its location. Install the snap
rings back into their respective grooves.
34. Remove the jacking screws from the cover.
Tighten the attaching cap screws to 45 - 50 N⋅m
(33 - 37 ft-lbs).
2
10013327
47
35. Turn the unloading shaft several revolutions to
seat the bearings.
36. Set up a magnetic base dial indicator as shown
on the unloading shaft. Measure the end play by
pulling up on the shaft and noting the amount of
needle deflection. Measure the thickness of the
shim removed from the unloading shaft. Using
the formula provided, calculate the pre-load on
the bearings.
Shim Calculated
End play
Thickness Pre-load
10013328
- = 48
37. Pre-load on the unloading shaft bearings is to be
.1 - .2 mm (.004 - .008″). If the calculated pre-load
is less than that specified, increase the thickness
of the shim pack. If the calculated pre-load is
more than that specified, decrease the thickness
of the shim pack.
14-19
38. Turn the unloading shaft several revolutions to
seat the bearings.
39. Set up a magnetic base dial indicator as shown
on the main clutch pack. Measure the end play by
pulling up on the shaft and noting the amount of
needle deflection. Use a device or combination
of tools that will allow raising the clutch pack from
inside the female spline.
40. Measure the thickness of the shim removed from
the main clutch pack. Using the formula
provided, calculate the pre-load on the bearings.
10013329
Shim Calculated
End play 49
Thickness Pre-load
- =
41. Pre-load on the main clutch bearings is to be .1

- .2 mm (.004 - .008″). If the calculated pre-load
is less than that specified, increase the thickness
of the shim pack. If the calculated pre-load is
more than that specified, decrease the thickness
of the shim pack.
42. Loosen the four attaching cap screws, and raise
the cover with the jacking screws. 1
43. Remove the snap rings, 1, and install the
appropriate thickness of shims, 2. Install the
snap ring to secure the shim pack. Perform this
step for both bearing sets.
2
10013327
50
44. Turn an M12 cap screw into the end of the
unloading shaft. Measure the rolling torque of the
shaft without the brake installed.
10006353
51
14-20
45. Turn out the four attaching cap screws, 1. Tighten
the jacking screws, 2, to lift the cover from the 1 2
gearbox. 2
1
1
10013326
52
46. Secure the unloading clutch brake, 1, to the
cover with four cap screws, 2. 1
10006354
53
47. Set the housing in place and draw it to the sealing
surface with four cap screws, 1. 1
1
1
10013326
54
14-21
48. With the M12 cap screw in the end of the
unloading shaft, measure the rolling torque of the
shaft with the brake installed. Subtract the
smaller value from the larger value. The resulting
differential rolling torque should be 15 - 25 N⋅m
(11 - 18 ft-lbs).
10006353
55
49. If the differential rolling torque falls out of low
range of 15 - 25 N⋅m (11 - 18 ft-lbs), the unload 2 1
clutch brake, 2, will require replacement or
addition of shims under the brake.
50. If the differential rolling torque is out of range
high, shims must be removed from under the
brake washer. Perform the rolling torque
measurement again to verify proper shimming.
51. To remove the brake washer, lift the clutch
housing from the gearbox. Turn out the four cap
screws, 1, securing the brake washer to the 1
housing. Set a new brake washer in place, and 10006354
apply locking compound to the threads of the cap
screws. Perform the previous steps to verify the 56
action of the brake.
52. Turn out the four attaching cap screws. Tighten
the jacking screws to lift the cover from the
gearbox.
53. Remove all grease, oil, or dirt from the sealing
surfaces of the housing. Apply a thin coat of 1 2
Loctite® 518 to the gearbox casing sealing
surface.
IMPORTANT: Use of any other gasket compound
could effect the pre-load of the bearings.
54. Place the housing cover, 1, on the gearbox and

secure using mounting cap screws, 2. Torque to
45 - 50 N⋅m (33 - 37 ft-lbs).
10004281
57
14-22
55. Measure the distance from the machined surface
of the clutch temperature sender bore, 1, to the 1
main clutch pack.
10012220
58
56. Measure the length of the clutch temperature
sender from the shoulder outside the threads, to
the tip.
10012221
59
57. Measure thickness of the shim washer.
58. Insert the measured values into the following
equation and perform the calculation.
Length of Effective
Thickness
Temperature Sender
of Shim
Sender Length
- =
The effective clutch temperature sender length is to

be 2 - 2.5 mm less than the depth of the bore.
10012222
59. Install the appropriate shims and perform the
calculation again. 60
14-23
60. Install the clutch temperature sender into the
bore.
IMPORTANT: Do not over tighten the temperature
sender. The unit is made of plastic and could break.
10004283
61
61. Set the main output sheave, 1, onto the shaft,
and turn in cap screw, 2.
10013332
62
62. Set the unloading sheave, 1, onto the shaft, and
turn in cap screw, 2. 1
10013330
63
14-24
SECTION 21 -- TRANSMISSION -- CHAPTER 1
SECTION 21 - TRANSMISSION
Chapter 1 - Transmission
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional/Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transmission Cover (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Gearbox Shafts (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Shifting Diagram (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Shifting Disc/Drive Gear (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Shifting Disc/Drive Gear (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Differential (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Differential (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Differential Shafts (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drive Shaft/Cover (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Drive Shaft (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Drive Shaft (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Input Shaft and Bearing Caps (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Input Shaft (Sectional View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Input Shaft (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
21-1
SPECIFICATIONS
CR970
CR940 CR980
CR920 CR960 CR9340/960 Optional
Differential ratio 16/71 16/71 20/61
Differential lock Yes/No Yes/No Yes/No
Gear ratio
1st gear ratio 18/58 18/58 18/58
2nd gear ratio 35/62 35/62 35/62
3rd gear ratio 45/61 45/61 45/61
4th gear ratio 63/44 63/44 63/44
Max. input rpm (high idle) 3178 3027 2752
Max. input rpm (full load) 3027 3027 2752
Max. input torque 632 N⋅m (466 ft-lb) 632 N⋅m (466 ft-lb) 823 N⋅m (607 ft-lb)
Max. output rpm (high idle) 1025 977 1292
Max. output torque (1st gear) 8227 N⋅m (6067 ft-lb) 8242 N⋅m (6078 ft-lb) 7378 N⋅m (5441 ft-lb)
Max. power (motor - transmission 196 kW (262 HP) 187 kW (250 HP) 221 kW (296 HP)
input)
Brake disc diam. 330 mm (13 in) 330 mm (13 in) 400 mm (15.7 in)
Approx. total weight 402 kg (886 lbs) 402 kg (886 lbs) 420 kg (926 lbs)
TIGHTENING TORQUES
Nut on drive shaft 150 -- 170 N⋅m (111 -- 125 ft-lb)

Nut on input shaft 150 -- 170 N⋅m (111 -- 125 ft-lb)
Shifting disc shaft castle head lock nut 25 -- 30 N⋅m (19 -- 22 ft-lb)
Nut on indicator plate 8 -- 12 N⋅m (71 -- 106 in-lb)
Sensor bolts 4 -- 6 N⋅m (36 -- 53 in-lb)
Shifting disc housing insert 190 -- 210 N⋅m (140 -- 155 ft-lb)
Top cover bolts 45 -- 55 N⋅m (33 -- 41 ft-lb)
Drain plug 90 -- 110 N⋅m (66 -- 81 ft-lb)
Breather 90 -- 110 N⋅m (66 -- 81 in-lb)
21-2
SPECIAL TOOLS
Nut Spanner Wrench (45 mm)
Special Tool No. 380001074
Used for disassembly and assembly of the drive and

input shafts.
50030182
21-3
SECTIONAL/EXPLODED VIEWS
1
TRANSMISSION COVER (EXPLODED VIEW) 6. Retaining ring
7. Differential lock control shaft
1. Bolt
8. O-ring
2. Cover
9. Retaining ring
3. Seal
10. Fork
4. Pin
5. Lever
21-4
2
GEARBOX SHAFTS (SECTIONAL VIEW)
1. Input shaft
2. Drive shaft
3. Differential
4. Differential shafts
21-5
3
SHIFTING DIAGRAM (SECTIONAL VIEW)
1. Gear : 1 - 5 - 8 - 10
2. Gear : 2 - 6 - 8 - 10
3. Gear : 3 - 7 - 8 - 10
4. Gear : 4 - 9 - 8 - 10
21-6
19
18
4
SHIFTING DISC/DRIVE GEAR (SECTIONAL 9. Nut
VIEW) 10. Indicator plate
11. Cotter pin
1. Bolt, M6 x 10 mm
12. Castle nut
2. Special bolt, M6
13. Bolt, M12 x 90 mm, countersunk head with nib
3. Bolt, M6 x 30 mm
14. Shifting disc housing
4. Friction washer and retaining ring
15. Shifting disc
5. Drive gear housing
16. Bushing
6. Shifting drive gear
17. O-ring
7. O-ring
18. Sensor
8. Electric motor
19. Bolt, M6 x 16 mm
21-7
19
18
ZDA3353A
5
SHIFTING DISC/DRIVE GEAR (EXPLODED 9. Nut
VIEW) 10. Indicator plate
11. Cotter pin
1. Bolt, M6 x 10 mm
12. Castle nut
2. Special bolt, M6
13. Bolt, M12 x 90 mm, countersunk head with nib
3. Bolt, M6 x 30 mm
14. Shifting disc housing
4. Friction washer and retaining ring
15. Shifting disc
5. Drive gear housing
16. Bushing
6. Shifting drive gear
17. O-ring
7. O-ring
18. Sensor
8. Electric motor
19. Bolt, M6 x 16 mm
21-8
6
DIFFERENTIAL (SECTIONAL VIEW) 6. Differential output gear
7. Planet gear shaft
1. Bearing
8. Planet gear
2. Bearing
9. Differential output gear
3. Bolt
10. Ring gear
4. Lock plate
5. Differential housing
21-9
7
DIFFERENTIAL (EXPLODED VIEW) 6. Differential output gear
7. Planet gear shaft
1. Bearing
8. Planet gear
2. Bearing
9. Differential output gear
3. Bolt
10. Ring gear
4. Lock plate
5. Differential housing
21-10
8
DIFFERENTIAL SHAFTS (EXPLODED VIEW) 8. Differential shaft
9. Housing
1. Differential shaft
10. Bearing
2. Seal
11. Differential
3. Retaining ring
12. Spring
4. Bearing
13. Differential lock
5. Housing
14. Retaining ring
6. Bearing
7. O-ring
21-11
9
DRIVE SHAFT/COVER (EXPLODED VIEW)
1. Cover
2. Seal
3. Shim pack
4. O-ring
5. Drive shaft
21-12
10
DRIVE SHAFT (SECTIONAL VIEW) 9. Washer
10. Retaining ring
1. Bearing
11. Gear
2. Drive shaft
12. Needle bearings
3. Gear
13. Washer
4. Needle bearings
14. Bearing
5. Selector ring
15. Washer
6. Selector housing
16. Lock washer
7. Ball
17. Nut
8. Spring
21-13
11
DRIVE SHAFT (EXPLODED VIEW) 9. Washer
10. Retaining ring
1. Bearing
11. Gear
2. Drive shaft
12. Needle bearings
3. Gear
13. Washer
4. Needle bearings
14. Bearing
5. Selector ring
15. Washer
6. Selector housing
16. Lock washer
7. Ball
17. Nut
8. Spring
21-14
12
INPUT SHAFT AND BEARING CAPS
(EXPLODED VIEW)
1. Input shaft
2. Oil baffle plate
3. Threaded shaft
4. Cap
5. O-ring
6. Seal
7. Bearing
8. Shims
9. Cap
21-15
13
INPUT SHAFT (SECTIONAL VIEW) 9. Washer
10. Selector ring
1. Nut
11. Ball
2. Lock washer
12. Spring
3. Washer
13. Selector housing
4. Bearing
14. Gear
5. Washer
15. Needle bearing
6. Gear
16. Input shaft
7. Needle bearing
8. Retaining ring
21-16
14
INPUT SHAFT (EXPLODED VIEW) 9. Washer
10. Selector ring
1. Nut
11. Ball
2. Lock washer
12. Spring
3. Washer
13. Selector housing
4. Bearing
14. Gear
5. Washer
15. Needle bearing
6. Gear
16. Input shaft
7. Needle bearing
8. Retaining ring
21-17
OVERHAUL
TRANSMISSION
Removal
WARNING
Always ensure transmission and rear axle
sections of the tractor are fully supported to
prevent any movement when the transmission is
removed.
WARNING
Lift and handle all heavy components using
lifting equipment of appropriate lifting capacity.
Ensure that units or parts are supported by
suitable slings or hooks. Ensure that no-one is in
the vicinity of the load to be lifted.
1. Remove half shafts. See Section 25 -- Chapter 1

-- “Final Drive -- Half-Shaft --Removal”.
2. Remove shield bracket and shield, 1.
1
40034844
15
3. Remove hose clamp, 1.
40034846
16
21-18
4. Drain the transmission oil into a suitable container
for disposal. The transmission contains 19 L (5
U.S. gal).
Remove the magnetic drain plug, 1, to drain oil.
5. Clean the drain plug and reinstall hand tight.
1
ZDA2797A
17
6. Remove hydrostatic motor, 1:
• Loosen hydrostatic line, 2, on top of the
hydrostatic motor.
• Support the hydrostatic motor, 1, and loosen
four nuts, 3.
• Pull hydrostatic motor, 1, out of the gearbox.
NOTE: In some cases it will be necessary to remove

the left-hand side traction wheel to take the
hydrostatic motor out of the gearbox.
ZDA3251A
18
7. Disconnect parking brake hydraulic line, 1.
ZDA3252A
19
21-19
8. Disconnect brake lines, 1, and caliper guards, 2,
on both sides of the transmission.
Remove the protective skid plate, 3, in front of the
transmission.
3
ZDA2797C
20
9. If equipped with differential lock, disconnect the
differential lock cable yoke end, 1, from the lock
control lever, 2. 4
Disconnect the lock cable, 3, from the transmis-
sion cover mounting bracket, 4.
1
3
2
66060017
21
10. Disconnect brake shoe wear wires, 1, on both
sides of the transmission.
ZDA3255B
22
21-20
11. Disconnect electrical connectors:
• Combine speed sensor
• Gear shift sensor
• Gear shift motor
WARNING
The gearbox is heavy (420 kg [926 lbs]). Take
extreme caution when removing the gearbox!
Use a supporting device which can handle this
weight!
12. Install a suitable and safe support underneath the ZDA3254A

gearbox. (e.g. a wooden pallet on a forklift)
23
13. Loosen three bolts, 1, at left-hand side of
transmission.
ZDA3255A
24
14. Loosen three bolts, 2, at right-hand side of the
transmission.
15. Lower the transmission and remove it from
underneath the combine.
ZDA3256A
25
21-21
Disassembly
1. Remove service brakes. See Section 33 --
Chapter 1, “Brakes and Controls”.
2. Remove parking brake. See Section 33 -- Chapter
1, “Brakes and Controls”.
Transmission Cover
WARNING
Raised equipment or machine movement without
an operator can cause injury or death. Before you
service this machine do the following:
• Park the machine on a level surface.
• Support or lower the equipment (backhoe,
blade, boom, bucket, etc.) to the ground (if
equipped).
• Apply the parking brake (if equipped).
• Stop engine.
• Block the machine (wheels, tracks, etc.) to
prevent machine movement.
3. Remove all bolts, 1, and cover, 2.
ZDA3257A
26
21-22
4. If necessary, remove pin, 1, and differential lock
control lever, 2.
NOTE: Removal of the differential control lever and
differential lock control shaft is necessary only if fork
and/or O-ring need to be replaced.
ZDA3258A
27
5. Remove retaining ring, 1, and differential lock
control shaft, 2.
ZDA3259A
28
6. Remove and discard O-ring, 1.
7. Remove retaining ring, 2, to remove fork, 3.
ZDA3260A
29
21-23
Differential and Shafts
CAUTION
8. On the left-hand side differential shaft, remove

seal, 1, and discard.
NOTE: It is not possible to remove seal, 1, without
damaging it.
ZDA3262A
30
9. Remove retaining ring, 1.
ZDA3263A
31
21-24
10. Pull out shaft, 1, together with bearing, 2.
ZDA3264A
32
11. Remove bearing, 1, from the differential shaft, 2.
ZDA3271A
33
12. Remove six nuts and washers, 1.
13. Remove two bolts and washers, 2.
ZDA3265A
34
21-25
14. Install two (M10 x 60 mm) bolts, 1, to push bearing
housing, 2, out of the gearbox housing, 3. 2
15. Remove the two (M10 x 60 mm) bolts.
3
ZDA3266A
35
16. Support the differential to prevent it from falling
into the gearbox. 2
1 1
17. Remove four nuts and washers, 1, right-hand
side differential shaft housing.
3
18. Remove two Allen screws, 2.
19. Remove two bolts and washers, 3.
3
1
1
2
56060012
36
20. Install two (M10 x 60 mm) bolts, 2, to push bearing
housing, 1, out of the gearbox housing, 3. 1
NOTE: If transmission is equipped with optional
differential lock, lock collar and spring will remain on
shaft when bearing housing is removed.
21. Remove the two (M10 x 60 mm) bolts. 2

3
56060013
37
21-26
22. Remove bearing, 1, from the differential shaft, 2.
ZDA3271A
38
23. Remove the differential, 1.
56060016
39
24. Remove oil baffle plate, 1, by removing the four
bolts and washers securing it.
ZDA3443A
40
21-27
Selector Shaft
56060015
41
ZDA3327A
42
27. Remove the selector shaft, 1, from the right-hand
side of the transmission housing.
If necessary, remove the selector shaft O-rings 1
from both sides of the housing where the shaft
was removed.
56060014
43
21-28
Drive Shaft
1
NOTE: If the shifting disc is not removed from the 2
transmission, first proceed with steps 46 -- 48 of
“Shifting Disc and Drive Gear” further in this section,
to bring the shifting disc in its highest position.
28. Remove five nuts and washers, 1.

29. Remove the cover, 2, by tapping around the
edges of the cover and/or radial tapping on the
drive shaft, 3, with a soft face hammer.
3
NOTE: Keep shim pack and O-ring with the cover.
56060011
44
30. Remove drive shaft, 1, and selector fork, 2, with
a hoist.
ZDA3334A
45
31. If necessary, remove the bearing cup, 1.
ZDA3335A
46
21-29
Input Shaft
32. Remove selector fork, 2, from the input shaft.
ZDA3336A
47
33. Remove threaded shaft, 2, and seal ring.
ZDA3340
C
48
34. Remove oil baffle plate, 1, by turning out cap
screws, 2.
ZDA3440A
49
21-30
35. Remove three Allen screws, 1.
ZDA3339A
50
36. Remove seal housing, 2, with the lip-seal and the
O-ring.
ZDA3339A
51
37. Remove five nuts and washers, 1.
ZDA3340A
52
21-31
38. Remove cover, 1.
NOTE: Keep shims and O-ring with the cover.
ZDA3341A
53
39. Support the input shaft on a hoist to avoid from
falling into the gearbox.
40. Drive the shaft in the direction shown, toward the
motor side of the transmission. Remove bearing
cup, 1.
ZDA33342
A
54
41. Pull bearing cone, 1, from the input shaft.
42. Remove the input shaft out of the gearbox.
ZDA3343A
55
21-32
43. If necessary, remove bearing cup, 1, from the
bearing cover side of the input shaft.
ZDA3344A
56
21-33
Shifting Disc and Drive Gear
WARNING
Raised equipment or machine movement without
an operator can cause injury or death. Before you
service this machine do the following:
• Park the machine on a level surface.
• Support or lower the equipment (backhoe,
blade, boom, bucket, etc.) to the ground (if
equipped).
• Apply the parking brake (if equipped).
• Stop engine.
• Block the machine (wheels, tracks, etc.) to
prevent machine movement.
NOTE: It is possible to remove and to install the

shifting disc and the shifting drive gear without
disassembly of the gearbox shafts.
44. Remove nut, 1, and indicator plate, 2.
ZDA3344A
57
45. Remove five bolts, 1, and remove sensor, 2.
ZDA3344A
58
21-34
46. Bring the shifting disc up to the highest position by
turning shifting disc housing, 1, outward until the
shifting disc blocks are against the gearbox
housing.
NOTE: This step is only necessary when the drive
shaft and the input shaft need to be removed from the
transmission without removal of the shifting disc.
ZDA3331A
59
47. Remove four bolts with washers, 1. Remove
electric motor, 2.
ZDA3345A
60
48. Remove four special bolts, 1, and bolt, 2.
ZDA3346A
61
21-35
49. Remove retaining ring, 1, and the friction washer
behind it.
50. Slide shifting drive gear, 3, out of housing, 2, and
remove it from the inside of the transmission.
Remove shifting drive gear housing, 2.
ZDA3347A
62
51. Remove and discard O-ring, 1, from the shifting
drive gear, 2.
2
ZDA3348A
63
52. Remove the cotter pin and castle nut, 1. Discard
cotter pin.
53. Remove bolt, 3, and the shifting disc from the
inside of the gearbox.
54. Remove shifting disc housing, 2.
ZDA3349A
64
21-36
55. Remove bushing, 3, from housing, 2.
56. If necessary, replace O-ring, 4, inside housing, 2.
ZDA3350A
65
21-37
Assembly
Shifting Disc and Drive Gear

1. If necessary, replace O-ring, 4, inside shift disc
housing, 2. Lubricate the O-ring with NH AMBRA
GR9 multi-purpose grease prior to installation.
Replace bushing, 3, if necessary, and install in
housing, 2.
ZDA3350A
66
2. Apply a few drops of Loctite 242/243 thread-lock-
er to the threaded insert, 1, of shifting disc
housing, 2. 2
Turn the shift disc housing, 2, into the gearbox
1
and then torque to 190 -- 210 N⋅m (140 -- 155
ft--lb).
If the M8 x 40 mm bolt, 3, is removed, apply
Loctite 242/243 thread-locker, install the M8 x 40 3
mm bolt, 3, with the bushing, and then torque to
8 -- 12 N⋅m (71 -- 106 in-lb).
ZDA3505A
67
3. Install the shift disc from inside of the
transmission housing with sensor target, 2, 4
positioned in the middle of the gearshift sensor
slot, 3.
5 1
Install the M12 x 90 mm countersunk bolt, 4, with
its nib on the countersunk head through the shift
disc and shift disc housing. Ensure the nib is
aligned into the slot on the shift disc when
tightening. 2
Install the castle nut, 5, with Loctite 515/573
gasket eliminator applied.
Torque the castle nut, 5, to 25 -- 30 N⋅m (19 -- 22 3
ZDA3505A
ft-lb), and then torque further to align the castle
nut slot to the cotter pin hole in bolt, 4. 68
Install new cotter pin.
IMPORTANT: Ensure that the followers on the
selector forks are positioned into the notches on the
shifting disc.
NOTE: If the input shaft, the drive shaft and the

differential are not assembled into the gearbox, bring
the shifting disc up to the highest position by turning
the shifting disc housing outward until the shifting disc
blocks against the gearbox housing.
21-38
4. Lubricate the O-ring on the bottom of the sensor,
2, with NH AMBRA GR9 multi-purpose grease.
Install the sensor, 2, with five M6 x 16 mm bolts
and washers,1.
Tighten and torque the bolts to 4 -- 6 N⋅m (35 -- 53
in-lb).
ZDA3330A
69
5. Install indicator plate, 2, and tighten nut, 1, to a
torque of 8 -- 12 N⋅m (71 -- 106 in-lb).
ZDA3329A
70
6. Apply a continuous bead of Loctite 515/573
sealant around the mating surface and around
the bolt holes. Spread evenly, with no gaps and
then wipe off any excess from the edges.
ZDA3351A
71
21-39
7. Install shifting drive gear housing, 3.
Apply Loctite 242/243 thread-locker to the four
special bolts, 1, and M6 x 30 mm bolt, 2.
Torque the five M6 housing bolts to 10 -- 11 N⋅m
(89 -- 97 in-lb).
ZDA3346A
72
8. Apply NH AMBRA GR9 multi-purpose grease to
a new O-ring, 1.
Install the new O-ring on the shift drive gear, 2.
2
ZDA3348A
73
9. Insert the shifting drive gear, 3, from the inside of
the gearbox through the drive gear housing, 2.
Install the friction washer, 4.
Install retaining ring, 1.
ZDA3347A
74
21-40
10. Install electric motor, 2.
Install four M6 x 10 mm bolts with lock washers,
1.
Torque the M6 x 10 mm bolts to 10 -- 11 N⋅m (89
-- 97 in-lb).
NOTE: If necessary to change gears manually while
assembling the input shaft, the drive shaft and the
differential into the gearbox, wait for installing the
electric motor until the end.
ZDA3345A
75
Input Shaft
CAUTION
11. To install the input shaft in the transmission, first

install shim pack, 2, of 1.5 mm (0.06 in).proceed
as follows:
Apply NH AMBRA GR9 multi-purpose grease to
O-ring, 3.
12. Install O-ring, 3, on cover, 1.
ZDA3414A
76
13. Install bearing cup, 1.
ZDA3344A
77
21-41
14. Install cover, 2, with shim pack and O-ring.
15. Tighten the five nuts, 1.
Torque the five M10 nuts to 46 -- 53 N⋅m (34 -- 38
ft-lb).
Support the input shaft on a hoist with sling and
move it into the transmission.
ZDA3329A
78
CAUTION
Use insulated gloves or mittens when working
with hot parts.
16. Heat bearing, 1, to 80°C (176°F) and install it on

the input shaft.
ZDA3415A
79
ZDA3433A
80
21-42
18. If necessary, replace seal, 1, and O-ring, 2, on
seal housing, 3. 1 3
the seal and O-ring prior to install.
2
56060010
81
19. Install seal housing, 1.
Apply Loctite 242/243 to the three Allen screws,
1, and tighten. Torque Allen screws to 50 -- 60 N⋅m
(37 -- 44 ft-lb). 2
ZDA3339A
82
20. Install a dial gauge, 2, in the gearbox housing and
locate the probe perpendicular against the side of
gear, 1.
21. Apply a load in one direction and oscillate the
shaft several times while the load is applied.
22. Set the dial gauge to zero.
23. Apply the load in the opposite direction, oscillate
and read the axial movement of the shaft.
24. Make three measurements at 120° of the input
shaft. The average of the readings should be 0.1
-- 0.2 mm (0.004 -- 0.008 in).
ZDA3436A
25. If required, adjust the shims. To decrease the 83
axial movement, decrease the quantity of shims.
IMPORTANT: Be sure to measure on gear, 1, as the
other gears are mounted on needle bearings.
21-43
26. Install selector fork, 1.
84
27. Install oil baffle plate, 1. Install bolts, 2.
Torque the M8 bolts to 23 -- 26 N⋅m (17 -- 19 ft-lb).
IMPORTANT: After tightening of the nuts, rotate the
input shaft and verify that the oil baffle does not
interfere with the input shaft.
85
28. Insert threaded shaft, 2, and sealing washer.
Torque to 50 -- 60 N⋅m (37 -- 44 ft-lb).
86
21-44
Drive Shaft
CAUTION
ZDA3335A
87
30. If necessary, replace the seal, 2. Apply NH
AMBRA GR9 multi-purpose grease to the seal,
and then install O-ring, 5, on cover, 1.
Install bearing cup, 3.
Install shim pack, 4, of 1.5 mm (0.06 in).
the O-ring, and then install O-ring, 5, on cover, 1.
NOTE: Ensure the shim pack is installed before the
O-ring.
88
31. Support the drive shaft, 1, on a hoist and bring it
into the transmission. 3
NOTE: If the shifting disc, 3, is installed, the selector
fork, 2, should be installed together with the drive
shaft.
ZDA3334A
89
21-45
32. Install the cover, 2, with shims, seals and bearing
cup, and then install and tighten nuts, 1. 1
2
33. Torque the M12 nuts to 80 --90 N⋅m (59 -- 66 ft-lb).
56060011
90
34. Install a dial gauge, 1, on the gearbox housing
and locate the probe perpendicular against the
side of gear, 2.
35. Apply a load in one direction and oscillate the
36. Set the dial gauge to zero.
37. Apply the load in the opposite direction, oscillate
38. Make three measurements at 120° of the
intermediate shaft. The average of the three
readings should be 0.15 -- 0.25 mm (0.006 -- 0.01
in).
91
39. If required, adjust the shims. To decrease the
axial movement, decrease the quantity of shims.
IMPORTANT: Be sure to measure on gear, 2, as the
other gears are mounted on needle bearings.
Selector Shaft
3
40. Install new selector shaft O-rings into both sides
2
of the gearbox housing, where the selector shaft,
1
1, is installed, if removed for replacement. Apply
NH AMBRA GR9 multi-purpose grease to new or
existing O-rings.
Install selector shaft, 1, from the right-hand side
of the transmission into the transmission housing,
2.
Guide the selector forks, 3, onto the shaft. Ensure
fork guide blocks are installed on selector forks.
56060014
92
21-46
41. Install retaining ring, 2.
ZDA3327
93
1
56060015
94
21-47
Differential and Shafts
CAUTION
43. Install oil baffle plate, 1, with cap screws and

washers.
44. Torque the M8 x 16 mm cap screws to 24 -- 26 N⋅m
(17 -- 19 ft-lb).
ZDA3443A
95
45. Support the differential, 1, on a hoist and bring it
into the gearbox.
56060016
96
46. On differential shaft housings, replace O-rings, 1.
the O-rings prior to installation.
ZDA3273A
97
21-48
47. Install a new bearing, 1, on each differential shaft,
2.
ZDA3271A
98
48. If transmission has differential lock option, insert
the left-hand differential shaft into the left bearing
housing.
Slide the differential lock, 1, and spring, 2, onto
the differential shaft and into the housing, 3.
ZDA3441A
99
49. Install both differential housings, 1 and 2, with the
M12 nuts, 4. Tighten the nuts for each housing
evenly in order to draw the housings straight into
the transmission gearbox.
Torque the M12 nuts to 80 -- 90 N⋅m (59 -- 66 ft-lb).
Apply Loctite 242/243 thread-locker to the hex
socket screws, 3. Install the hex socket screws on
the right-hand side differential housing, 1.
Torque the M16 hex socket screws to 90 -- 100
N⋅m (66 -- 74 ft-lb).
Install the M10 x 12 mm (maintenance hole
protection) bolts into both housings.
Torque the M10 nuts to 46 -- 52 N⋅m (34 -- 38 ft-lb). 100
21-49
50. Install shafts, 1, with bearings, 2, into the bearing
housings, 3.
If transmission is equipped with an optional
differential lock, ensure that the differential lock
collar and spring are assembled onto the
left-hand differential shaft, inside the transmis-
sion housing, before the shaft engages the
differential as described above.
3
ZDA3264A
101
ZDA3262A
102
new bearing seals, 1.
Install new seals, 1, recessed into bearing
housings.
Remove hoist and sling.
ZDA3262A
103
21-50
Transmission Cover
new O-ring, 1, to fork shaft, 4, and lock control 4
shaft, 5.
54. Install new O-ring, 1, onto control shaft, 5. 5
55. Install fork, 3, and secure with retaining ring, 2.
ZDA3260A
104
56. Install differential lock control shaft, 2.
Install retaining ring, 1.
ZDA3259A
105
57. Install differential lock control lever, 2.
Secure control lever with retaining pin, 1, as
shown.
NOTE: Control lever can be installed in two positions.
The correct position is shown.
ZDA3258A
106
21-51
58. Install cover, 2.
If equipped with differential lock control, ensure
that the differential lock control fork is correctly
positioned.
Install cover bolts, 1.
Tighten and torque the cover bolts evenly, in a
cross pattern, to 45 -- 55 N⋅m (33 -- 41 ft-lb).
ZDA3262A
Installation 107
WARNING
Always ensure transmission and rear axle sections
of the tractor are fully supported to prevent any
movement when the transmission is removed.
WARNING
1. Using a suitable jack, lift the transmission, 1, into

its cradle in the machine.
40033843
108
2. Align the holes in the transmission housing with
the holes of the transmission support brackets.
Ensure alignment on left-hand side first.
Apply Loctite 242/243 thread-locker to the three
M16 x 50 mm transmission mounting bolts, 1.
1
Install the bolts on the left-hand side of the
transmission. Hand tighten only at this time.
ZDA3255B
109
21-52
3. Align the right-hand transmission housing and
support bracket bolt holes.
Apply Loctite 242/243 thread-locker to the three
M16 x 50 mm transmission mounting bolts, 2.
Install the bolts on the right-hand side of the
transmission.
Tighten and torque all six M16 x 50 mm
transmission mounting bolts to 235 -- 260 N⋅m
(173 -- 192 ft-lb).
ZDA3256A
110
4. Connect the brake shoe wear wire, 1, on both
sides of the transmission.
ZDA3255B
111
5. Connect the electrical connectors: Combine
Speed Sensor, Gear Shift Sensor, and Gear Shift
Motor.
ZDA3254A
112
21-53
6. If equipped with differential lock, connect the
differential lock cable yoke end, 1, to the lock
control lever, 2. 4
Connect the lock cable, 3, to the transmission
cover mounting bracket, 4.
1
NOTE: Adjustment to the differential lock cable is only
necessary if; a new cable is installed, the cable is 3
stretched resulting in no differential lock action or the
lock self-disengages, or the shift yoke is worn.
2
66060017
113
7. Connect the brake lines, 1, on both sides of the
transmission.
Install the left and right-hand side caliper guards,
2.
Install the protective skid plate, 3, in front of the
transmission.
3
ZDA2797C
114
8. Connect the hydraulic line, 1, for the parking
brake.
ZDA3252A
115
21-54
9. Connect the half shaft drive axles, 1, to both sides
of the transmission. See Section 25 -- Chapter 1
-- “Final Drive -- Half-Shaft -- Installation”.
ZDA3262A
116
10. Apply a coat of Molykote Type G-n Metal
Assembly Paste to the hydrostatic motor splines,
and then install the motor, 1, into the
transmission.
Connect the hydraulic hoses, 2, if they are
removed.
Install, tighten, and torque the motor bolts to 269
-- 297 N⋅m (198 -- 219 ft-lb).
IMPORTANT: The hydrostatic motor spins at high

speed and requires the above specified paste
lubricant or equivalent applied to the splines for its
high speed application, anti-sieze and anti-fretting ZDA3251A
properties. Do not substitute NH AMBRA GR75 MD 117
GREASE
or equivalent as this is for low speed applications.

11. Remove and clean the magnetic drain plug, 1.
Install the drain plug.
Torque drain plug to 90 -- 110 N⋅m (66 -- 81 ft-lb).
1
ZDA2797A
118
21-55
12. Remove the filler/breather plug, 1, from the
transmission cover, 2.
Fill the transmission with 19 L (5 U.S. gal) of NH
AMBRA HYPOID 90 or oil with an SAE 80W90 EP
API GL5 specification.
Install the filler/breather plug, 1.
Torque filler/breather plug to 90 -- 110 N⋅m (66 --
81 ft-lb).
2
1
ZDA2885A
119
13. Install the hydraulic hose routing clamp, 3, with
four bolts, 1 and 2. 1
2
40034846
120
14. Install the shield bracket and shield, 1, back onto
the machine. 1
Bleed the service brakes. See Section 33 --
Chapter 1 -- “Brakes and Controls; Bleeding the
Brake System”.
Check all lines are secure and tight.
Remove the blocks or wheel chocks from the unit.
IMPORTANT: Be sure to check the fluid level of
transmission fluid before operation, failure to do so
could result in transmission failure.
40034844
121
21-56
DIFFERENTIAL
Disassembly
1. Remove bearing, 1.
122
2. Turn over the differential and remove bearing, 2.
123
3. Unlock lock plates, 1, and remove bolts, 2, and
the lock plates.
124
21-57
4. Remove cover, 1, of the differential housing.
125
5. Remove differential output gears, 1 and 2.
6. Remove two planet gear shafts, 3, with the planet
gears, 4. 4
ZDA3392A
126
21-58
Assembly
1. Replace thrust washers, bushings, gears and
shafts as necessary.
2. Apply a coating of NH AMBRA GR75 MD Grease 2
to all surfaces of the internal parts (bushings,
thrust washers, differential output gears, planet
gears, and thrust washers with the planet gear
shafts).
Assemble the lubricated internal components, 2,
into the gear housing, 3.
3
3. Install differential housing cover, 1.
NOTE: The two castings of the housing are machined
together and are marked in this position. When 127
reassembling, make sure that these marks are
towards each other.
4. Install lock plates, 1, and bolts, 2.
Torque the M10 bolts to 46 -- 53 N⋅m (34 -- 38 ft-lb).
5. Secure bolts, 2, by bending the tabs of the lock
plate to lock the head of the bolt.
128
6. Install bearing, 2.
129
21-59
7. Turn the differential over. Install bearing, 1.
130
DRIVE SHAFT
Disassembly
1. Unlock lock washer, 2.
2. Remove nut, 1, using Tool No. 380001074, lock
washer, 2, and washer, 3.
131
3. Remove gear, 2, and bearing, 1, together with a
puller.
132
21-60
4. Remove needle bearings, 1.
133
5. Remove selector ring, 1, at the same time remove
two balls, 2, and the springs behind them.
NOTE: Balls, 2, are spring-loaded, do not lose them.
6. Remove retaining ring, 3, and the washer.
134
7. Remove housing, 1, and gear, 2.
135
21-61
136
9. Remove and discard bearing cone, 1, on the
opposite end.
NOTE: Bearing cone, 1, will be damaged when it is
removed. Replace bearing cup and cone with a new
bearing set.
137
21-62
Assembly
CAUTION
with hot parts.

the drive shaft.
138
2. Install needle bearings, 1.
3. Install gear, 2.
4. Install selector housing, 3.
5. Install washer, 4.
139
7. Install two springs.
8. Install two balls, 2, on the springs and at the same
time install selector ring, 1.
NOTE: Be careful not to lose the balls.
140
21-63
141
10. Install gear, 2.
CAUTION
with hot parts.
11. Install washer, 3, and heat bearing, 4, to 80°C

(176°F) and install it on the drive shaft.
142
13. Install lock washer, 2.
14. Install nut, 1, using Tool No. 380001074, and
tighten it to a torque of 150 -- 170 N⋅m (111 -- 125
ft-lb).
15. Secure nut, 1, by bending a lip of the lock washer
in one of the notches of the nut.
143
21-64
INPUT SHAFT
Disassembly
1. Unlock lock washer, 2.
2. Remove nut, 1, using Tool No. 380001074, lock
washer, 2, and washer, 3, securing the bearing
cone, 4.
144
3. Remove gear, 2, bearing, 1, and the washer
between the two parts with a puller.
145
5. Remove selector ring, 2, at the same time remove
two balls, 3, and the springs behind it.
NOTE: Balls, 3, are spring-loaded, do not lose them.
146
21-65
7. Remove washer, 2, and selector housing, 3, at
the same time.
8. Remove gear, 4.
147
148
Assembly
2. Install gear, 2
3. Install selector housing, 3.
149
21-66
150
6. Install the two springs and two balls, 3, and at the
same time install selector ring, 2.
NOTE: Be careful not to lose the balls.
151
8. Install gear, 1.
152
21-67
CAUTION
with hot parts.

the input shaft.
11. Install washer, 3
12. Install lock washer, 2.
13. Install nut, 1, using Tool No. 380001074, and
tighten to a torque of 150 -- 170 N⋅m (111 -- 125
ft-lb).
14. Secure nut, 1, by bending a lip of the lock washer 153
in one of the notches of the nut.
21-68
SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1
Chapter 1 - Planetary Final Drive
CONTENTS

General Specification -- Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Type I and Type II Final Drive Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Final Drive -- Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Final Drive -- Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Final Drive -- Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Final Drive -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Final Drive Reducer, Spur Gear -- Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Final Drive Reducer, Spur Gear -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Final Drive Input Shaft -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Final Drive Input Shaft -- Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Final Drive Reducer, Satellite and Planetary -- Exploded View . . . . . . . . . . . . . . . . . . . 13
Overhaul -- Type I Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Final Drive Reducer, Spur Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
25-1

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Overhaul -- Type II Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Distance Ring Combinations Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Half-shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
25-2
GENERAL SPECIFICATION -- FINAL DRIVE

SPECIFICATIONS
Gear ratio 1/13.09
Maximum Input rpm 30 km/h (18.6 mph) 1300 rpm
Maximum Output rpm 30 km/h (18.6 mph) 100 rpm
Nominal input torque 1500 N⋅m (1140 ft-lb)
Nominal output torque 20500 N⋅m (15120 ft-lb)
Output shaft pre-load 0.35 mm (0.014 in)
Input shaft axial end play 0.01 -- 0.006 mm (0.0004 -- 0.0025 in)
Approximate total weight 340 kg (750 lb)
Oil capacity 6.70 L (1.77 US gal)
1 1
66060025
1
Type I Type II
TYPE I and TYPE II Final Drive Identification The TYPE II Planetary Final Drive has a separate
In the comparative illustration above, the TYPE I and Filler Plug, 1, located at the 12 o’clock position on the
TYPE II Planetary Final Drives can be differentiated inside housing cover, and a separate Breather Plug,
by the identification and location of the Oil Fill Plug, 2, located at the 10 o’clock position on the right-hand
Oil Filler/Breather Plug, and the Oil Breather Plug. side final drive, and at the 2 o’clock position on the
left-hand side final drive, facing the forward direction
The TYPE I Planetary Final Drive has a single of travel.
Filler/Breather Plug, 1, located at the 12 o’clock
position on the inside housing cover.
25-3
FINAL DRIVE -- TORQUE

(TYPE I) Torque List
Bolts, Output (Wheel) Shaft 310 -- 330 N⋅m (229 -- 243 ft-lb)
Bolts, Input Shaft Cover 50 N⋅m (37 ft-lb)
Bolts, Gearbox Housing 305 -- 335 N⋅m (225 -- 247 ft-lb)
Threaded Studs, Housing Separator 25 -- 35 N⋅m (19 -- 26 ft-lb)
Bolts, Final Drive to Axle Mounting 670 N⋅m (495 ft-lb)
Plug, Oil Level Gauge 8 -- 12 N⋅m (71 -- 106 in-lb)
(Always located at the lower, 8 o’clock, position of the inner housing)
Plug, Replacement 5 -- 15 N⋅m (45 -- 132 in-lb)
(Always located at the upper, 10 o’clock, position of the inner housing)
Plug, Oil Magnetic Drain 60 -- 80 N⋅m (45 -- 59 ft-lb)
Plug, Oil Filler / Breather 90 -- 110 N⋅m (67 -- 81 ft-lb)
Plug, (Wheel Stud) Maintenance 100 -- 120 N⋅m (74 -- 89 ft-lb)
Nuts, Wheel Mounting 710 -- 790 N⋅m (525 -- 580 ft-lb)
(TYPE II) Torque List

Bolts, Input Shaft Cover 45 -- 55 N⋅m (34 -- 40 ft-lb)
Bolts, Gearbox Housing 305 -- 335 N⋅m (225 -- 247 ft-lb)
Threaded Studs, Housing Separator 15 -- 25 N⋅m (11 -- 18 ft-lb)
Bolts, Final Drive to Axle Mounting 635 -- 705 N⋅m (469 -- 520 ft-lb)
Plug, Oil Level Gauge 8 -- 12 N⋅m (71 -- 106 in-lb)
(Always located at the lower 8 o’clock position of the inner housing)
Plug, Replacement 5 -- 15 N⋅m (45 -- 132 in-lb)
(Always located at the upper 10 o’clock position of the inner housing)
Plug, Oil Magnetic Drain 60 -- 80 N⋅m (45 -- 59 ft-lb)
Plug, Oil Fill 60 -- 80 N⋅m (45 -- 59 ft-lb)
Plug, Oil Breather 15 -- 25 N⋅m (11 -- 18 ft-lb)
Plug, (Wheel Stud) Maintenance 100 -- 120 N⋅m (74 -- 89 ft-lb)
25-4
FINAL DRIVE -- SPECIAL TOOLS

NOTE: NOT SHOWN: SPECIAL TOOL (380002654)
FINAL DRIVE BEARING RING NUT SPANNER --
For removal and installation of the outer ring nut on
the output shaft of TYPE II Final Drives.
For removal and installation of the inner ring nut on

the output shaft of TYPE II Final Drives.
ZEIL06SPT001A0A
2
380002596 Final Drive Bearing Ring Nut Spanner
25-5
OVERVIEW
FINAL DRIVE -- SECTIONAL VIEW
1 12 14
13 16
2
15
3
4
10
17
11 18
ZDA4162A
3
Planetary Final Drive (TYPE I) -- Primary Components
1. Input Shaft 10. Inner Housing

2. Cover, Input Shaft 11. O-ring, Ring Gear
3. Reducer Spur Gear 12. Ring Gear
4. Bearings, (Reducer Spur Gear) Ball 13. O-ring, Outer Housing
5. Sun Gear 14. Planet Gear
6. Cover, Drive Shaft 15. Mud Seals
7. Lock Plate, Three Bolt 16. Output (Wheel) Shaft
8. Mounting Plate 17. Bearing, Tapered Roller
9. Bearing, Tapered Roller 18. Planet Gear Carrier
25-6
1 15 16 17 18 19
3
4
6
21
20
7
22
8
10
11
23
12 13 14
ZEIL05CX0516H0B
4
Planetary Final Drive (TYPE II) -- Primary Components
1. Input Shaft 13. Bearing, Tapered Roller

2. Cover, Input Shaft 14. O-ring, Ring Gear
3. Reducer Spur Gear 15. Ring Gear
4. Sun Gear 16. O-ring, Outer Housing
5. Cover, Drive Shaft 17. Planet Gear
6. Lock Plate, Two Bolt 18. Outer Housing
7. Mounting Lock Plate 19. Output (Wheel) Shaft
8. Locknut, (Outer) Bearing Ring 20. Spacers, Distance Ring
9. Bearing, Tapered Roller 21. Bearing, Tapered Roller
10. Lock Ring 22. Mud Seals
11. Locknut, (Inner) Bearing Ring 23. Planet Gear Carrier
12. Bearing, Tapered Roller
25-7
FINAL DRIVE -- EXPLODED VIEW

1 2 3 4 12 13 14 15
11
16
5
6
7
8
9 17
10
ZDA4668A 18 19 20 21 22 23 24 25 26 27
5
Planetary Final Drive (TYPE I) -- Assembly
1. Bolt, M10 x 30 mm (and lock washer) 15. Retaining Ring
2. Cover, Input Shaft 16. Sun Gear
3. Shim Pack 17. Retaining Ring
4. Input Shaft 18. O-ring, Ring Gear
5. Cover, Drive Shaft 19. Ring Gear
6. Bolt, M16 x 45 mm 20. O-ring, Outer Housing
7. Lock Plate, Three Bolt 21. Retaining Ring
8. Mounting Plate 22. Planet Gear Carrier (assembled)
9. Shim Pack 23. Outer Housing
10. Bearing, Tapered Roller 24. Bolt, M16 x 90 mm (and lock washer)
11. Threaded Stud (to separate housing) 25. Bearing, Tapered Roller
12. Inner Housing 26. Seal
13. Dowel Pin 27. Output Shaft
14. Reducer Spur Gear (Pre-assembled with Ball Bearings)
25-8
1 2 3 4
12
11
13
5
6
7
8
14 9
15 10
16
17
18
19
20
21 24
22
23
25
26
27 32
ZEIL05CX0517H0B
28 29 30 31
6
Planetary Final Drive (TYPE II) -- Assembly
1. Bolt, M10 x 30 mm 12. Inner Housing 23. Retaining Ring
2. Cover, Input Shaft 13. Dowel Pin 24. Planet Gear Carrier (assembled)
3. Shim Pack 14. Retaining Ring 25. O-ring, Ring Gear
4. Input Shaft 15. Lock Ring 26. Ring Gear
5. Cover, Drive Shaft 16. Locknut, (Inner) Bearing Ring 27. O-ring, Outer Housing
6. Bolt, M16 x 45 mm (and lock 17. Bearing, Tapered Roller 28. Outer Housing
washer) 18. Reducer Spur Gear 29. Bolt, M16 x 90 mm (and lock
7. Lock Plate, Two Bolt 19. Spacers, Distant Ring washer)
8. Lock Plate, Mounting 20. Bearing, Tapered Roller 30. Bearing, Tapered Roller
9. Locknut, (Outer) Bearing Ring 21. Retaining Ring 31. Seal
10. Bearing, Tapered Roller 22. Sun Gear 32. Output Shaft
11. Threaded Stud (to separate
housing)
25-9
FINAL DRIVE REDUCER, SPUR GEAR --

SECTIONAL VIEW
1. Retaining Ring 6
2. Bearing, Ball
3. Shim Spacer
4. Bearing, Ball
5. Spacer Ring
7
6. Reducer Spur Gear
7. Retaining Ring 8
8. Sun Gear
1
2
3
66060024
5
7
(TYPE I) Reducer, Spur Gear
FINAL DRIVE REDUCER, SPUR GEAR --

EXPLODED VIEW
1. Retaining Ring
2. Bearing, Ball
3. Shim Spacer
4. Bearing, Ball 5 6
5. Spacer Ring
6. Reducer Spur Gear
7. Retaining Ring 7
8. Sun Gear 8
1
2
3
4
66060023
8
(TYPE I) Reducer Spur Gear
25-10
FINAL DRIVE INPUT SHAFT --

EXPLODED VIEW
2
5
6
ZDA4350A
3
9
Input Shaft (TYPE I and TYPE II)
1. Input Shaft 4. Bearing

2. Housing 5. Seal
3. Bearing 6. O-ring
25-11
FINAL DRIVE INPUT SHAFT -- OVERVIEW
1 4
zda4664a
10
Input Shaft (TYPE I and TYPE II)
1. Bolt 3. Shim Pack

2. Cover with Seals 4. Input Shaft with Bearings
25-12
FINAL DRIVE REDUCER, SATELLITE AND

PLANETARY -- EXPLODED VIEW
1. Planet Gear Carrier
2. Retaining Ring
3. Shaft
4. Spacer
5. Planet Gear
6. Needle Roller
ZDA4033A
11
Planetary Carrier and Gears (TYPE I and TYPE II)
25-13
OVERHAUL -- TYPE I FINAL DRIVE

REMOVAL
CR Type I Planetary Final Drive
To remove a planetary final drive, proceed as follows:
WARNING
Unexpected machine motion or moving parts
can cut and crush. Apply parking brake and shut
down the engine before working on the machine.
Put the machine on blocks only if the surface is
solid, even, and level. Make sure that any blocks
used to support the machine are solid, one-piece
units. Put blocks next to the tires that are not
being raised to prevent movement of the
machine.
CAUTION
A final drive is heavy. Take extreme caution when
removing the final drive! Use a supporting device
which can handle this weight!
1. Remove the drive tire from the combine.

2. Remove half-shaft, 1. See “Half-shaft --
Removal.” Support the final drive with a hoist.
NOTE: If the planetary final drive needs to be

Disassembled, drain the oil before the final drive is
removed from the combine. (Refer to the Operators
Manual, Section 4 -- “Lubrication and Maintenance.”).
20036405 1
12
3. Loosen the bolts, 1, from the flange and remove
the final drive.
The final drive is piloted onto the axle by two 1
dowel pins. When all the bolts are removed, pry
the final drive away from the axle flange.
20036406
13
25-14
DISASSEMBLY
To disassemble a planetary final drive, proceed as
follows:
1. Drain the oil from the planetary final drive. (Refer
to the Operator’s Manual, Section 4 -- “Lubrica-
tion and Maintenance.”)
2. Remove bolts, 1, and lock washers.
Remove cover, 2.
NOTE: The seal in the cover will be damaged when

it is removed.
ZDA4663A
14
3. Keep shim pack, 3, together with the cover, 2.
Remove the input shaft, 4.
NOTE: The bearings on the input shaft will be

damaged when they are removed.
ZDA4664A
15
4. Pry cover, 1, from the inner housing.
Unlock lock plate, 3, from bolt heads.
Remove bolts, 2, lock plate, 3, mounting plate, 4,
and shim pack, 5.
ZDA4666A
16
25-15
5. Place the final drive as shown and remove bolts,
1, and lock washers.
ZDA4639A
17
6. Identify three housing separator studs, 1.
1
Open the final drive by simultaneously tightening
the hex socket threaded studs, 1, into the inner
housing.
1 1
66060018
18
7. Lift the inner housing cover, 1, from the outer
cover, 2. 1
Remove the bearing cone from the removed
inner housing section.
Remove the housing separator studs.
IMPORTANT: Steady the housing as lifted to prevent

damage to the output shaft bearing.
2
ZDA4638A
19
25-16
8. Remove O-ring, 1, from ring gear, 2.
ZDA4362A
20
9. Install three M16 bolts, 3, into the threaded jack
holes located around the face of the ring gear, 2. 3 4
Turn the bolts equally to raise the ring gear off of
the planet gear carrier, 4. Remove the ring gear.
Remove the two dowel pins, 1, from the inner or
outer housing, as required.
Remove the second ring gear O-ring from the 2
outer housing cover.
1
ZDA4361A
21
1
zda4359a2
22
25-17
11. Remove planet gear carrier, 1, with the planet
gears.
NOTE: To disassemble the planetary carrier,

reference “Final Frive Reducer, Satellite and
Planetary -- Disassembly.”
ZEIL05CX0523A0B
23
12. Remove outer housing, 1, from output shaft, 2.
NOTE: The bearing on the output shaft will be

damaged when it is removed. It is advised to use a
lathe to remove the damaged bearing.
IMPORTANT: Ensure no damage occurs to the

output shaft.
NOTE: The seal in the planetary final drive housing

will be damaged when it is removed, except for mud
seals.
ZDA4357A
24
13. On the inner final drive housing, remove retaining
ring, 1, and the sun gear, 2. 1
NOTE: The sun gear, 1, and the reducer spur gear, 3

3, are marked. If for any reason the marks are not
visible, apply a mark on both gears before taking
them apart.
ZDA4356A
25
25-18
1
Lift the reducer spur gear, 2, with the bearings
from the inner housing, 3.
NOTE: To disassemble the reducer spur gear and

sun gear, reference “Final Drive Reducer, Spur Gear
-- Disassembly.” 3
2
ZDA4354A1
26
ASSEMBLY
NOTE: Prior to assembly of the Type I Final Drive,
the following operations must be performed:
-- Final drive Reducer, Spur Gear -- Assembly
-- Final drive Input Shaft -- Assembly
-- Final drive Output Shaft -- Assembly
-- Final Drive Reducer, Satellite and Planetary --
Assembly
1. Install bearing cup, 2, into inner final drive

housing, 1. 1 2
Ensure bearing cup is fully seated in the housing.
Place inner final drive housing, 1, as shown.
ZDA4352A
27
2. Install pre-assembled reducer spur gear, 2, in
final drive housing, 1. 2
1
ZDA4353A
28
25-19
3. Install retaining ring, 1. Ensure retaining ring is
properly seated.
ZDA4354A1
29
4. Install sun gear, 2, in reducer spur gear, 1.
IMPORTANT: Both reducer spur gear and sun sears

are marked as a set. Align the marks when
assembling.
ZDA4355A
30
Ensure the retaining ring is fully seated.
ZDA4356A1
31
25-20
6. Install bearing cup, 2, into the outer housing, 1.
Ensure the bearing cup is fully seated in the outer
housing.
Install seal, 3, in outer housing, 1.
NOTE: If equipped for mud seals, proceed with steps

7 and 8, otherwise proceed to step 9.
ZDA4636A
32
25-21
7. Install mud seal, 1.
IMPORTANT: When installing the mud seal, ensure

the outer sides of the mud seal are free of dirt and old
oil.
ZDA4637A
33
8. Measure distance X mm (X in) in at least four
places 90 ° apart.
The difference in height around the ring must not
be more than 1 mm (0.04 in).
X mm (X in) = the distance from mud seal surface
to the top containment ring on the housing.
ZDA4162B
34
9. If not equipped with mud seals, apply NH
AMBRA HYPOID 90 to the standard seal and to
the output shaft where the seal makes contact.
If equipped with mud seals, apply a thin coat of
NH AMBRA HYPOID 90 to the entire seal face of
both seals. Oil must not contact surfaces other
than the sealing faces.
Install final drive outer housing, 1, on pre-as-
sembled output shaft, 2.
ZDA4357A
35
25-22
10. Install the pre-assembled planet gear carrier, 1.
ZEIL05CX0523A0B
36
ZDA4359A
37
12. Apply a light coat of NH AMBRA GR9
MULTI-PURPOSE GREASE on O-ring, 1, and
install O-ring, 1, in outer final drive housing, 2.
2
ZDA4360A
38
25-23
13. Insert two dowel pins, 1, in ring gear, 2, and install
ring gear, 2, with the seal groove, 4, facing 3
upward. 4
If the two jacking bolts, 3, are installed, remove
them when the ring gear is set.
1
ZDA4361A
39
install O-ring, 1, in ring gear, 2.
ZDA4362A
40
15. Install inner final drive housing, 1, onto ring gear,
2. 1
IMPORTANT: Steady the inner housing when

lowering it over the output shaft as to not damage the
shaft or bearing.
ZDA4638A
41
25-24
16. Apply Loctite 242/243 to bolts, 1.
Install the twelve bolts, 1, with lock washers.
Torque to 305 -- 335 N⋅m (225 -- 247 ft-lb).
ZDA4639A
42
17. Install bearing cone, 1.
Apply a downward direction load of 150 kg (330 1
lb) on the bearing cone back face, 1.
Turn the final drive housing around the output
shaft, one turn, to correctly seat the bearing
cone.
Measure distance X mm (X in) between the back
face of the bearing cone, 1, and the upper flat 2
surface of the output shaft, 2.
IMPORTANT: Be sure the 12 bolts, 1, are tightened

to the specified torque before measuring distance X. ZDA4163B
Measure distance X with the load applied on the
bearing cone back face. 43
NOTE: The required shim pack can be defined as

follows: Shim pack = X-- 0.35mm (X-- 0.014 in).
18. Install shim pack, 5.
Install mounting plate, 4, locking plate, 3, and
bolts, 2.
Torque bolts to 310 -- 330 N⋅m (229 -- 243 ft-lb).
After assembly and torque, bend two lips of lock
plate, 3, for each bolt to two non-adjacent faces.
Apply a continuous bead of Loctite 638 sealant
to the rim of the drive shaft cover, 1.
ZDA4666A
44
25-25
19. Install the output shaft cover, 1, into the inner
housing cover.
ZDA4665A
45
20. Apply Loctite 242/243 to the three threaded hex
socket studs, 1. 1
Install the studs.
Torque to 25 -- 35 N⋅m (19 -- 26 ft-lb).
1 1
66060018
46
21. Install bearing cup, 1, into outer final drive
gearbox housing.
Bearing cup must be fully seated into outer
housing.
ZDA4900A
1
47
25-26
22. Install pre-assembled input shaft, 1. See “Final
Drive Input Shaft -- Assembly.”
ZDA4901A
48
23. Install the shim pack and bearing cover, 1, with
seal, O-ring, and bearing cup.
NOTE: The thickness of the shim pack should allow

axial end play on the input shaft as measured and
adjusted in the following steps.
ZDA4902A
1
49
24. Install bolts, 1, with lock washers.
Torque to 50 N⋅m (37 ft-lb).
Measure axial end play of the input shaft as
follows:
Install a dial gauge on the housing and locate the
probe on top of the shaft.
Apply a load in one direction and oscillate the
Set the dial gauge to zero.
Apply the load in the opposite direction, oscillate
ZDA4903A
Make three measurements at 120° of the shaft.
Average the three readings. The axial end play 50
should be 0.01 -- 0.06 mm (0.0004 -- 0.0024 in).
If required, adjust the thickness of the shim pack.
To decrease the axial end play, decrease the
thickness of the shim pack.
When the thickness of the shim pack is
determined, apply Loctite 242/243 to bolts, 1.
Tighten bolts to a torque of 50 N⋅m (37 ft-lb).
25-27
INSTALLATION
6
CAUTION
handling the final drive! Use a supporting device
To install a planetary final drive, proceed as follows:

1. Insert two dowel pins, 2, in the planetary final
drive housing, 1.
7
Install the planetary final drive onto the drive axle 5
of the combine. ZDA4669A
Apply Loctite 242/243 on bolts, 3, to prevent 51

them from loosening.
Tighten bolts, 3, to a torque of 670 N⋅m (495 ft-lb).
Ensure the magnetic plug, 5, is cleaned, installed,
and torqued to 60 -- 80 N⋅m (45 -- 59 ft-lb).
Remove the filler/breather plug, 6.
Fill the planetary final drive with 6.7 L (1.77 US
gal) of NH AMBRA HYPOID 90.
Install the filler/breather plug, 6. Torque to 60 -- 80
N⋅m (45 -- 59 ft-lb).
Ensure oil level is in the middle of the oil level
gauge plug, 7. Drain or add as required.
Install the drive wheel and tighten wheel nuts, 4,
to a torque of 710 -- 790 N⋅m (525 -- 580 ft-lb).
IMPORTANT: The final wheel nut torque specifica-

tion, indicated above, must be obtained by following
the proper tightening and progressive torque
sequence procedure. The sequence is dependent on
the drive wheel configuration. Reference the
Operator’s Manual, Section 4 -- “Lubrication and
Maintenance -- Drive Wheel Mounting.”
25-28
FINAL DRIVE REDUCER, SPUR GEAR

1 2
Disassembly
To disassemble the reducer spur gear, proceed as
follows:

Turn the reducer spur gear over and remove the
two bearings, 2.
NOTE: The sun gear was disassembled from the ZDA4346A

reducer spur gear at removal from the housing.
52
Assembly
1. If replacing the gear set, the new sun gear, 1, and
reducer spur gear, 2, are delivered as a matched
and marked set, as indicated at, 3.
Separate the sun gear from the reducer spur
gear in order to assemble the new bearing into
the reducer spur gear.
ZDA4341A
53
2. Place reducer spur gear as shown and install
ring, 1.
IMPORTANT: The chamfered side of ring, 1, should

be against splines.
ZDA4342A
54
25-29
3. Install bearing, 1.
ZDA4343A
55
4. Install shim spacer, 1.
ZDA4344A
56
5. Install second bearing, 1.
1
ZDA4345A
57
25-30
6. Install retaining ring, 1, and ensure it is properly
seated. 1
ZDA4346A
58
25-31
FINAL DRIVE INPUT SHAFT

1
Disassembly
1. Pull the bearing cone, 2, off of the input shaft, 1. 2
ZDA4347A
59
2. On the opposite end of the input shaft, 1, remove
the bearing cone, 2. 2
ZDA4348A
60
3. Remove the O-ring, 1, bearing cup, 3, and
sealing washer, 4, from the inputs shaft cover, 2. 2 3 4
ZDA4349A
61
25-32
Assembly
1
1. Heat the new bearing, 2, to 80 °C (176 °F) and
install on input shaft, 1.
CAUTION
2
with hot parts.
ZDA4347A
62
2. Heat the new bearing, 2, to 80 °C (176 °F)and
install on input shaft, 1. 2
ZDA4348A
63
3. Apply NH AMBRA GR9 MULTI-PURPOSE
GREASE to O-ring, 1. 2 3 4
Install O-ring, 1, on input shaft bearing cover, 2.
Install seal, 4, in bearing cover, 2.
Install bearing cup, 3, in bearing cover, 2. Bearing
cup must be fully seated in cover.
ZDA4349A
64
25-33
FINAL DRIVE OUTPUT SHAFT

Disassembly
1. Carefully remove bearing cone, 2, from the
output shaft, 1.
IMPORTANT: Do not damage the shaft when

removing the bearing. If the bearing cone can not be
pulled from the shaft, it may be necessary to use a
lathe to remove the bearing.
ZDA4631A
65
2. As required, the wheel studs can be driven out of
the shaft.
1
ZDA4631B
66
3. If equipped with mud seals, remove the mud
seal. 1
IMPORTANT: Do not damage the mud seal

containment ring, 1, when removing the bearing, 3,
or the wheel studs, 2.
3
ZDA4632A
2
67
25-34
Assembly
CAUTION
with hot parts.

install on output shaft, 1.
IMPORTANT: Bearing cone, 2, must be fully seated

on output shaft.
ZDA4631A
68
2. As required, install any removed or replacement
wheel studs, 1. (Ten studs per output shaft.)
Ensure the notch on the head of each wheel stud
is aligned with the step on the output shaft.
1
ZDA4631B
69
3. If equipped with mud seals, install the mud seal
as follows: 1

containment ring, 1, when installing the bearing, 3, or
the wheel studs.
3
ZDA4632A
2
70
25-35
4. Install mud seal, 1, on the output shaft.
the outer sides are free of dirt and oil. 1
ZDA4633A
71
places 90 ° apart.
to the top of the containment ring on the housing.
ZDA4162C
72
25-36

PLANETARY 1
Disassembly
ZDA4041A
73
2. Push out the pin, 1, and then remove the planet
gear, 2, the needle rollers, and the spacers on
both sides of the planet gear. To prevent the 2
needle bearings from dropping everywhere, 1
locally obtain or manufacture a pin replacement
shaft tool with a 50.5 mm (1.98 in) outer diameter
x 47 mm (1.85 in) length. Use this shaft to
displace the pin, 1, that holds the planet gear, 2,
in the carrier.
Ensure all needle bearings are cleared from the
carrier. There are twenty-three (23) needles per
planet gear.
ZDA4039A
Repeat the procedure for the other two planet
gears. 74
NOTE: The shaft replacement tool described above

is necessary for the assembly procedure.
25-37
Assembly
1
1. Apply NH AMBRA HYPOID 90 to the spacer, 1.
ZDA4034A
75
2. Apply NH AMBRA HYPOID 90 to the inside, 1, of
the planet gear, 2, and place it onto the lubricated 3
spacer, above. 1
Obtain or manufacture the described shaft, 3,
below, for installation of the needle bearings and
assembly of the planet gear into the carrier.
Shaft diameter and length is 50.5 mm (1.98 in)
OD x 47 mm (1.85 in).
Place the tool, 1, in the middle of gear, 2.
ZDA4035A
2
76
3. Insert twenty-three (23) needle rollers, 1.
1
ZDA4036A
77
25-38
4. Apply NH AMBRA HYPOID 90 to the needle
bearings, 1, and spacer, 2. 2
Place spacer onto gear, 3. 1
3
ZDA4037A
78
5. Insert pin, 2, into the planet gear carrier, 1, as
shown. 1
2
IMPORTANT: The shaft must be inserted from the
side of the carrier with the flat shoulder.
50020124
79
6. Insert the planet gear, 1, with spacers and needle
rollers.
Insert the pin, 2, and remove the tool. 1 2
ZDA4039A
80
25-39
IMPORTANT: Make sure the notch (A) on the pin is
in line with the notch on the planet gear carrier.
ZDA4040A
81
7. Install retaining ring, 1. Repeat steps 1 -- 7 for the
other two planet gears. 1
ZDA4041A
82
8. The pre-assembled planet gear carrier is heavy,
use a lifting device to handle it.
ZDA4042A
83
25-40
FINAL DRIVE WHEEL STUD

Replacement
CAUTION
Install a suitable and safe support underneath
the combine traction axle to support the
combine.
NOTE: In order to position a specific wheel stud, 2,

to the maintenance hole, 1, remove the half-shaft as
described in “Half-shaft -- Removal.”
ZDA4662A
1. Remove the drive wheel.
84
Turn the output shaft of the planetary final drive
until wheel stud, 2, the stud to be replaced, is in
front of maintenance plug, 1.
Remove maintenance plug, 1.
Drive out wheel stud, 2, into the maintenance
hole. Remove the wheel stud.
Insert the head of the new wheel stud, 2, into the
maintenance hole, and then insert the threaded
end into the output shaft. Ensure the notch on the
wheel stud head is in line with the step on the
output shaft.
To fully seat the wheel stud in the output shaft,
turn a wheel nut onto the stud. Tighten the nut
until fully seated, and then remove nut.
Repeat the procedure for each wheel stud to be
replaced.
Apply Loctite 242/243 to the maintenance plug,
1, and install.
Tighten and torque the plug to 100 -- 120 N⋅m
(74--89 ft-lb).
Install the drive wheel. Tighten the wheel nuts
and torque to 710 -- 790 N⋅m (525 -- 580 ft-lb).

25-41
OVERHAUL -- TYPE II FINAL DRIVE

REMOVAL
CR Type II Planetary Final Drive
To remove a planetary final drive, proceed as follows:
WARNING
Unexpected machine motion or moving parts can
cut and crush. Apply parking brake and shut
used to support the machine are solid, one-piece
being raised to prevent movement of the machine.
CAUTION
removing the final drive! Use a supporting device
1. Remove the drive tire from the combine.

2. Remove half-shaft, 1. See “Half-shaft --
Removal.” Support the final drive with a hoist.
NOTE: If the planetary final drive needs to be

disassembled, drain the oil before the final drive is
removed from the combine. (Refer to the Operator’s
Manual, Section 4 -- “Lubrication and Maintenance.”)
20036405 1
85
3. Loosen the bolts, 1, from the flange and remove
the final drive.
The final drive is piloted onto the axle by two 1
dowel pins. When all the bolts are removed, pry
the final drive away from the axle flange.
20036406
86
25-42
DISASSEMBLY
1. Drain the oil from the planetary final drive. (Refer
to the Operator’s Manual, Section 4 -- “Lubrica-
tion and Maintenance.”)
2. Remove bolts, 1, and lock washers. Remove
cover, 2.
NOTE: The seal in the cover will be damaged when

it is removed.
ZDA4663A
87
3. Keep shim pack, 3, together with the cover, 2.
Remove the input shaft, 4.
NOTE: The bearings on the input shaft will be
damaged when they are removed.
ZDA4664A
88
4. Remove the output shaft cover, 1.
ZDA4665A
89
25-43
5. Unlock the bolt lock plate, 2, and remove the
bolts, 1, and lock plate.
Remove the mounting lock plate, 3.
ZEIL05CX0518A0B
90
6. Using special tool (380002654) remove the
bearing ring locknut, 1.
NOTE: The locknut, 1, was assembled with Loctite.

To facilitate nut removal, heat the nut to 170 -- 200 °C
(338 -- 392 °F) until the Loctite breaks apart.
ZEIL05CX0519A0B
91
7. Place the final drive as shown and remove bolts,
1, and lock washers.
ZDA4639A
92
25-44
8. Identify three housing separator (hex socket)
studs, 1.
1
Open the final drive by simultaneously tightening

the hex socket threaded studs, 1, into the inner
housing.
1 1
66060018
93
9. Lift the inner housing cover, 1, from the outer
cover, 2.
Remove the bearing cone from the removed
inner housing section.
Clean all sealant from the outer edges of both the
inner and outer housing,
Remove the housing separator studs.
IMPORTANT: Steady the housing as lifted to prevent

damage to the output shaft bearing. 2
ZDA4638A
94
10. Remove the retaining ring, 1, the lock ring, 2.
Remove the bearing ring locknut, 3, using special
tool 380002596.
NOTE: The locknut, 1, was assembled with Loctite.

To facilitate nut removal, heat the nut to 170 -- 200° C
(338 -- 392° F) until the Loctite breaks apart.
ZEIL05CX0520A0B
95
25-45
11. Remove the assembled reducer spur gear, 1,
and the sun gear.
NOTE: The sun gear is assembled to the reducer

spur gear, and will be removed together with the
reducer spur gear. Also, the reducer spur gear
tapered roller bearings will be removed at the same
time.
ZEIL05CX0521A0B
96
12. Check for free movement of the sun gear, 3, in
the reducer spur gear, 1. If the sun gear moves 1 2 3
freely, it is advised to not disassemble the two
gears and to continue with step 14.
If determined as necessary to clean and service,
proceed to step 13 to disassemble the sun gear
from the reducer spur gear.
ZEIL05CX0524A0B
97
13. Remove the retaining ring, 2, to remove the sun
gear, 3, from the reducer spur gear, 1. 2 2
Push the retaining ring, 2, to the bottom of the
groove (B) by inserting a small screw driver
through the hole (A).
Insert a weld wire at (W) with a diameter of 1 -- 1.5
mm (0.04 -- 0.06 in) above the retaining ring in the
foot of the teeth of the sun gear, 3.
1
Repeat this for every hole (A) in the reducer spur
gear; there are eleven holes.
Pull the sun gear, 2, out.
Clean and service to obtain free movement when ZEIL05CX0533A0B
assembled. 98
25-46
14. Remove the distance rings, 1, and the bearing
cone, 2.
ZEIL05CX0525A0B
99
15. Remove O-ring, 1, from ring gear, 2.
ZDA4362A
100
16. Install three M16 bolts, 3, into the threaded jack
holes located around the face of the ring gear, 2. 3 4
Turn the bolts equally to raise the ring gear off of
the planet gear carrier, 4. Remove the ring gear.
Remove the two dowel pins, 1, from the inner or
outer housing, as required.
Remove the second ring gear O-ring from the
outer housing cover.
ZDA4361A
101
25-47
17. Remove the retaining ring, 1, from the output
shaft.
ZEIL05CX0522A0B
102
18. Remove planet gear carrier, 1, with planet gears.
ZEIL05CX0523A0B
103
19. Remove outer housing, 1, from output shaft, 2.
NOTE: The bearing on the output shaft will be

damaged when it is removed. It is advised to use a
lathe to remove the damaged bearing.
IMPORTANT: Ensure no damage occurs to the

output shaft.
NOTE: The seal in the planetary final drive housing

will be damaged when it is removed, except for mud
seals.
zda4357a
ZDA4357A
104
25-48
ASSEMBLY
NOTE: Prior to assembly of the Type II Final Drive,
the following operations must be performed: 5
-- Final Drive Input shaft -- Assembly
-- Final Drive Output shaft -- Assembly
-- Final Drive Reducer, satellite and planetary -- 1
Assembly
2
1. Before assembly of the final drive, perform the
shimming of the reducer spur gear/sun gear
assembly on the output shaft as follows:
Install the bearing cups, 7, and, 2, in the reducer
spur gear, 5.
3 6
Install the sun gear, 4, in the reducer spur gear,
5, with the retaining ring, 3.
4
Obtain from service parts two complete sets of 7
the five available size distance rings. Available
sizes are 4.60, 4.65, 4.75, 4.85, 4.90 mm (0.181,
0.183, 0.187, 0.191, 0.193 in).
Select the two distance rings with a maximum
thickness each of 4.90 mm (0.193 in).
Combine the two distance rings, 6, and measure
the effective height (X) of the two rings (18).
Support the output shaft, 8, so the center line is 8
vertical.
On the output shaft, 8, install the bearing cone, ZEIL05CX0526B0B
7, the reducer spur gear, the two distance rings, 105
6, the bearing, 2, and the bearing ring locknut, 1.
Torque the locknut, 1, to 1300 N⋅m (959 ft-lb)
using special tool 380002596.
Put a ball (A) with diameter 8 mm (0.32 in) in the
cleaned center hole of the output shaft, 8.
Place a dial indicator (B) with its magnetic base
on the reducer spur gear, 5, and its measuring
needle, which is halfway its stroke, on the ball
(A).
Free rotate the reducer spur gear, 5, five
rotations around the output shaft, 8.
Reset the indicator of the dial indicator to zero.
25-49
2. Now support the reducer spur gear, 1, perfectly
horizontal using a tripod without touching the dial
indicator.
Free rotate the output shaft, 2, five times around
the reducer spur gear, 1.
Now read the maximum axial play (Y) of the
bearings on the dial indicator (A).
Support the output shaft, 2, so the center line is A
vertical and remove the reducer spur gear/sun 1
gear assembly from the output shaft.
ZEIL05CX0527B0B
106
3. Using the table below, combine two distance
rings to obtain a measured height Z = (X -- Y) --
0.075 mm (Z = (X -- Y) -- 0.003 in). Measure the
selected pack. This may not deviate more than
+/--0.25 mm (0.001 in) of (Z).
NOTE: From the two sets of five distance rings, only

two rings effectively get installed.
Distance Ring Combinations Table

Distance Ring 4.60 mm 4.65 mm 4.75 mm 4.85 mm 4.90 mm
Sizes (0.181 in) (0.183 in) (0.187 in) (0.191 in) (0.193 in)
4.60 mm 9.20 mm 9.25 mm 9.35 mm 9.45 mm 9.50 mm
(0.181 in) (0.362 in) (0.364 in) (0.368 in) (0.372 in) (0.374 in)
4.65 mm 9.25 mm 9.30 mm 9.40 mm 9.50 mm 9.55 mm
(0.183 in) (0.364 in) (0.366 in) (0.370 in) (0.374 in) (0.376 in)
4.75 mm 9.35 mm 9.40 mm 9.50 mm 9.60 mm 9.65 mm
(0.187 in) (0.368 in) (0.370 in) (0.374 in) (0.378 in) (0.380 in)
4.85 mm 9.45 mm 9.50 mm 9.60 mm 9.70 mm 9.75 mm
(0.191 in) (0.372 in) (0.374 in) (0.378 in) (0.382 in) (0.384 in)
4.90 mm 9.50 mm 9.55 mm 9.65 mm 9.75 mm 9.80 mm
(0.193 in) (0.374 in) (0.376 in) (0.380 in) (0.384 in) (0.386 in)
25-50
4. Install the bearing cup, 2, in the outer housing, 1.
Ensure the bearing cup is fully seated in the outer
housing.
Install the seal, 3, in the outer housing, 1, and
apply a light coat of NH AMBRA GR9
MULTI-PURPOSE GREASE between the oil lip
and the dust lip of the seal.
NOTE: If equipped with mud seals, proceed with

steps 5 and 6. Otherwise proceed with step 7.
ZDA4636A
107
5. If equipped with mud seals, install the mud seal,
1.

the outer sides of the mud seal is free of dirt and old
oil.
1
ZDA4637A
108
places 90° apart.
ZDA4162B
109
25-51
7. If not equipped with mud seals, apply NH
AMBRA HYPOID 90 to the standard seal and to
the output shaft where the seal makes contact.
If equipped with mud seals, apply a thin coat of
NH AMBRA HYPOID 90 to the entire seal face of
both seals. Oil must not contact surfaces other
than the sealing faces.
Install final drive outer housing, 1, on pre-as-
sembled output shaft, 2.
ZDA4357A
110
8. Install the pre-assembled planet gear carrier, 1.
ZEIL05CX0523A0B
111
9. Install the retaining ring, 1, on the output shaft.
NOTE: Tap radially on the retaining ring to be sure it
seats well in the groove.
ZEIL05CX0522A0B
112
25-52
install O-ring, 1, in outer final drive housing, 2.
2
ZDA4360A
113
11. Insert two dowel pins, 1, in the ring gear, 2, and
install the ring gear, 3, with the seal groove at the 2
1 1
upper side on the gearbox housing.
3
ZEIL05CX0530A0B
114
install O-ring, 1, in ring gear, 2.
ZDA4362A
115
25-53
13. Install the bearing cone, 2, and the distance two
rings, 1, with an overall thickness Z mm (Z in).
NOTE: The value of Z mm (Z in) is determined in the

first three steps of this assembly instruction.
Reference instruction steps 1, 2, and 3.
ZEIL05CX0525A0B
116
14. Install the sun gear assembly, 1.
ZEIL05CX0521A0B
117
15. Install the bearing cone, 1.
1
ZEIL05CX0531A0B
118
25-54
16. Remove all old thread locking compound from
the thread-well of the bearing ring locknut, 1, and 1 2
the corresponding threads on the output shaft, 2.
Degrease the thread-wells of the locknut and the
shaft using Loctite 7063 degreasing compound.
Apply Loctite 273 to the thread of the lock nut, 1,
and the corresponding thread on the output B
shaft, 2, as shown, five spots (A) on the thread of
the nut and five spots (B) on the output shaft.
NOTE: Degreasing is successful when a white dull

layer appears on the thread.
A
ZEIL05CX0528A0B
NOTE: Apply enough thread locking compound so 119

that all clearance is filled up when installing the nut.
NOTE: Act rapidly after applying the thread locking

component (Loctite 273), as the thread locking
component hardens rapidly.
17. Install the locknut, 3.
Using special tool 380002596, tighten and
torque the nut to 1300 N⋅m (959 ft-lb).
Install the lock plate, 2, so that there are always
two lips lying in the cams of the nut, 3, without
rotating the nut.
Install the retaining ring, 1.
NOTE: The lock ring, 2, has five installation positions

on each side, a total of ten positions, and is designed
in such a way that two lips can always be aligned into
the cams of the nut, 2, no matter the position of the ZEIL05CX0520A0B
nut.
120
18. Install bearing cup, 2, into inner final drive
housing, 1. 1 2
Ensure bearing cup is fully seated in the housing.
ZDA4352A
121
25-55
19. Install inner final drive housing, 1, onto ring gear,
2. 1
IMPORTANT: Steady the inner housing when

lowering it over the output shaft as to not damage the
shaft or bearing.
ZDA4638A
122
20. Apply Loctite 242/243 to bolts, 1.
Install the twelve bolts, 1, with lock washers.
Torque to 305 -- 335 N⋅m (225 -- 247 ft-lb).
ZDA4639A
123
21. Install the bearing cone, 1.
1
ZEIL05CX0532A0B
124
25-56
Use special tool (380002654) to tighten and
torque the locknut to 300 N⋅m (221 ft-lb).
Rotate the final drive housing one turn on the
output shaft.
Remove the locknut, 1.
ZEIL05CX0519A0B
125
23. Remove all old thread locking compound from
the thread-well of the bearing ring locknut, 1, and B 2
the corresponding threads on the output shaft, 2. 1
Degrease the thread-wells of the locknut and the
shaft using Loctite 7063 degreasing compound.
Apply Loctite 273 to the thread of the lock nut, 1,
and the corresponding thread on the output
shaft, 2, as shown, five spots (A) on the thread of
the nut and five spots (B) on the thread of the
output shaft.
A
NOTE: Degreasing is successful when a white dull 66060027
layer appears on the thread.
126
NOTE: Apply enough thread locking compound so
that all clearance is filled up when installing the nut.
NOTE: Act rapidly after applying the thread locking

component (Loctite 273), as the thread locking
component hardens rapidly.
Use special tool (380002654) to tighten and
torque the locknut to 20 N⋅m (15 ft-lb).
Rotate the final drive housing one turn.
Repeat the torque and one turn procedures until
the locknut, 1, does not rotate anymore at 20 N⋅m
(15 ft-lb).
Additionally tighten the locknut, 1, by turning it
another three-quarter turn (73 -- 77°) on the shaft.
IMPORTANT: Ensure the twelve housing bolts are

tightened to the specified torque before performing ZEIL05CX0519A0B
the bearing preload adjustment.
127
25-57
25. Install the lock plate, 3, without rotating the
installed locknut, in such a way that four lips can
be bent into the cams of the nut.
Install the lock plate, 2, and the bolts, 1.
Tighten and torque the bolts to 45 -- 55 N⋅m (34
-- 40 ft-lb).
Bend two lips per bolt after assembly.
NOTE: The lock plate, 3, has five installation

positions on each side, a total of ten positions, and is
designed in such a way that four lips can always be
bent into the cams of the locknut no matter the ZEIL05CX0518A0B
position of the nut.
128
NOTE: Install the bolt lock plate, 3, with its bend to
the middle as shown, otherwise interference with the
output shaft cover can occur.
26. Apply a continuous bead of Loctite 638 sealant
to the inner rim/lip of the drive shaft cover, 1.
Install the output shaft cover, 1, into the inner
housing cover.
ZDA4665A
129
27. Apply Loctite 242/243 to the three threaded hex
socket studs, 1.
1
Install the studs.

Torque to 15 -- 25 N⋅m (11 -- 18 ft-lb).
1 1
66060018
130
25-58
28. Apply a continuous bead of Loctite 5065 sealing
paste (S) around and between the inner housing, 1 S 2
1, and the outer housing, 2, circumference.
ZEIL05CX0535A0B
131
INSTALLATION
8
1. Insert two dowel pins, 6, in the planetary final
drive housing, 3.
1
Install the planetary final onto the traction axle of
7
the combine.
Apply Loctite 242/243 on bolts, 7, to prevent
them from loosening. 2
Tighten bolts, 7, to a torque of 635 -- 705 N⋅m
(469 -- 520 ft-lb).
3 4 5 6
Ensure the magnetic plug, 5, is cleaned,
installed, and torqued to 60 -- 80 N⋅m (45 -- 69 66060021
ft-lb). 132
Remove the fill plug, 8.
Fill the planetary final drive with 6.7 L (1.77 US
gal) of NH AMBRA HYPOID 90.
Install the fill plug, 8. Torque to 60 -- 80 N⋅m (45
-- 59 ft-lb).
If the breather plug, 2, was loosened, tighten and
torque to 15 -- 25 N⋅m (11 -- 18 ft-lb).
Ensure oil level is in the middle of the oil level
gauge plug, 4. Drain or add as required.
Install the drive wheel and tighten wheel nuts, 1,
to a torque of 710 -- 790 N⋅m (525 -- 580 ft-lb).

25-59
FINAL DRIVE INPUT SHAFT

1
Disassembly
1. Pull the bearing cone, 2, off of the input shaft, 1. 2
ZDA4347A
133
2. On the opposite end of the input shaft, 1, remove
the bearing cone, 2. 2
ZDA4348A
134
3. Remove the O-ring, 1, bearing cup, 3, and
sealing washer, 4, from the inputs shaft cover, 2. 2 3 4
ZDA4349A
135
25-60
Assembly
1
install on input shaft, 1.
CAUTION
2
with hot parts.
ZDA4347A
136
install on input shaft, 1. 2
ZDA4348A
137
3. Apply NH AMBRA GR9 MULTI-PURPOSE
GREASE to O-ring, 1. 2 3 4
Install O-ring, 1, on input shaft bearing cover, 2.
Install seal, 4, in bearing cover, 2.
Install bearing cup, 3, in bearing cover, 2. Bearing
cup must be fully seated in cover.
ZDA4349A
138
25-61
FINAL DRIVE OUTPUT SHAFT

Disassembly 1
1. Carefully remove bearing cone, 2, from the
output shaft, 1. 2
IMPORTANT: Do not damage the shaft when
removing the bearing. If the bearing cone can not be
pulled from the shaft, it may be necessary to use a
lathe to remove the bearing.
66060019
139
2. As required, the wheel studs, 1, can be driven out
of the shaft.
66060019
140
3. If equipped with mud seals, remove the mud
seal. 1
containment ring, 1, when removing the bearing, 3,
or the wheel studs, 2.
3
2
ZDA4632A
141
25-62
Assembly
CAUTION 1
with hot parts.
2
install on output shaft, 1.
IMPORTANT: Bearing cone, 2, must be fully seated
on output shaft.
66060019
142
2. As required, install any removed or replacement
wheel studs, 1. (Ten studs per output shaft.)
Ensure the notch on the head of each wheel stud
is aligned with the step on the output shaft. 1
66060019
143
3. If equipped with mud seals, install the mud seal
as follows: 1
containment ring, 1, when installing the bearing, 3, or
the wheel studs.
3
2
ZDA4632A
144
25-63
4. Install mud seal, 1, on the output shaft.
the outer sides are free of dirt and oil. 1
ZDA4633A
145
places 90 ° apart.
ZDA4162B
146
25-64

PLANETARY
Disassembly
1
ZDA4041A
147
2. Push out the pin, 1, and then remove the planet
gear, 2, the needle rollers, and the spacers on
both sides of the planet gear. To prevent the 2
needle bearings from dropping everywhere, 1
locally obtain or manufacture a pin replacement
shaft tool with a 50.5 mm (1.98 in) outer diameter
x 47 mm (1.85 in) length. Use this shaft to
displace the pin, 1, that holds the planet gear, 2,
in the carrier.
Ensure all needle bearings are cleared from the
carrier. There are twenty-three (23) needles per
planet gear.
ZDA4039A
Repeat the procedure for the other two planet
gears. 148
NOTE: The shaft replacement tool described above

is necessary for the assembly procedure.
25-65
Assembly
1. Apply NH AMBRA HYPOID 90 to the spacer, 1.
1
ZDA4034A
149
2. Apply NH AMBRA HYPOID 90 to the inside, 1, of
the planet gear, 2, and place it onto the lubricated 3
spacer, above. 1
Obtain or manufacture the described shaft, 3,
below, for installation of the needle bearings and
assembly of the planet gear into the carrier.
Shaft diameter and length is 50.5 mm (1.98 in)
OD x 47 mm (1.85 in).
Place the tool, 1, in the middle of gear, 2.
2
ZDA4035A
150
3. Insert twenty-three (23) needle rollers, 1.
1
ZDA4036A
151
25-66
4. Apply NH AMBRA HYPOID 90 to the needle
bearings, 1, and spacer, 2. 2
Place spacer onto gear, 3. 1
3
ZDA4037A
152
5. Insert pin, 2, into the planet gear carrier, 1, as
shown. 1
IMPORTANT: The shaft must be inserted from the 2
side of the carrier with the flat shoulder.
50020124
153
6. Insert the planet gear, 1, with spacers and needle
rollers.
Insert the pin, 2, and remove the tool. 2
1
ZDA4039A
154
25-67
IMPORTANT: Make sure the notch (A) on the pin is
in line with the notch on the planet gear carrier.
ZDA4040A
155
7. Install retaining ring, 1. Repeat steps 1 -- 7 for the
other two planet gears. 1
ZDA4041A
156
8. The pre-assembled planet gear carrier is heavy,
use a lifting device to handle it.
ZDA4042A
157
25-68
FINAL DRIVE WHEEL STUD

Replacement
CAUTION
Install a suitable and safe support underneath
the combine traction axle to support the
combine.
NOTE: In order to position a specific wheel stud, 2,

to the maintenance hole, 1, remove the half-shaft as
ZDA4662A
described in “Half-shaft -- Removal.”
158
1. Remove the drive wheel.
Turn the output shaft of the planetary final drive
until wheel stud, 2, the stud to be replaced, is in
front of maintenance plug, 1.
Remove maintenance plug, 1.
Drive out wheel stud, 2, into the maintenance
hole. Remove the wheel stud.
Insert the head of the new wheel stud, 2, into the
maintenance hole, and then insert the threaded
end into the output shaft. Ensure the notch on the
wheel stud head is in line with the step on the
output shaft.
To fully seat the wheel stud in the output shaft,
turn a wheel nut onto the stud. Tighten the nut
until fully seated, and then remove nut.
Repeat the procedure for each wheel stud to be
replaced.
Apply Loctite 242/243 to the maintenance plug,
1, and install.
Tighten and torque the plug to 100 -- 120 N⋅m
(74--89 ft-lb).
Install the drive wheel. Tighten the wheel nuts
and torque to 710 -- 790 N⋅m (525 -- 580 ft-lb).

25-69
HALF-SHAFT
Removal
1. Remove the bolts and nuts from the outer and
inner drive shaft couplers. Slide both couplers, 1,
completely outward, over the transmission and
final drive shafts.
20036405 1
159
2. Slide the drive shaft, 1, completely toward the
final drives, and slide the retaining ring, 2, from
the groove to the smallest shaft diameter at the 1
transmission end.
NOTE: Be careful to not over expand retaining ring
during removal, to avoid excessive yielding and ring
damage.
50021343
160
3. Slide the drive shaft completely towards the
transmission and slide the snap-ring from the
groove to the smallest diameter at the final drive
end.
NOTE: Be careful to not over expand retaining ring
damage.
4. Push both couplers, fully onto the drive shaft.

5. Remove the drive shaft assembly.
6. Remove the coupler and rings over the splined
end of shaft. Do not remove retaining rings
unless they will be replaced.
7. Repeat for the opposite side.
25-70
Installation
IMPORTANT: Do not expand the retaining rings
more than necessary to avoid excessive yielding and
ring damage.
1. Slide both snap rings over the splines, beyond

the groove and position on the smallest diameter
part of the drive shaft.
2. Slide the couplers completely over the splines
with the undercut towards the snap ring.
3. Place the pre-assembled drive shaft assembly
between the output shaft of the transmission and
input shaft of the final drive.
4. Slide both couplers completely outwards over
the transmission and final drive shafts.
transmission and install the retaining ring at the
final drive side in its groove.
50021343
161
6. Slide the drive shaft completely towards the final
drive and install the retaining ring at the
transmission side in its groove.
7. Slide the drive shaft coupler, 1, in its middle
position. Install the bolts and nuts. Tighten and
torque the bolts and nuts to 5 N⋅m (3.7 ft-lb).
IMPORTANT: Do not over torque the coupler bolts,
as the bolts may yield and cause coupler failure.
20036405
1
162
25-71
25-72
Chapter 2 - 11/111 Final Drives
CONTENTS

25 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Final Drive (Standard Seal) -- Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Final Drive (Mud Seal) -- Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wheel Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
25-1
SPECIFICATIONS
Gear ratio 11/111
Max. input rpm (30 km/hr - 18.6 mph) 998 rpm
Max. output rpm (30 km/hr - 18.6 mph) 132
Nominal input torque 1630 N⋅m (1200 ft-lb)
Nominal output torque 16500 N⋅m (12170 ft-lb)
Output shaft pre-load (Standard Seal) 0.27 -- 0.33 mm (0.011 -- 0.013 in)
(Mud Seal) 0.27 -- 0.35 mm (0.011 -- 0.014 in)
Input shaft axial end play 0.08 -- 0.13 mm (0.003 -- 0.005 in)
Approximate total weight 274.3 kg (605 lb)
Oil capacity 7.85 liters (2.07 US gal)
TIGHTENING TORQUES
Bolts, Input Shaft Cover 54 -- 60 N⋅m (40 -- 44 ft-lb)
Bolts, Type I Output Shaft (drilled head) -- Safety- 235 -- 260 N⋅m (173 -- 192 ft-lb)
wire tie locking (early model Combines)
Bolts, Type II Output Shaft (chemical treated) 252 -- 278 N⋅m (186 -- 205 ft-lb)
Locking (late model Combines)
Bolts, Final Drive to Axle Mounting 656 -- 725 N⋅m (484 -- 535 ft-lb)
Plug, Oil Magnetic Drain 90 -- 110 N⋅m (66 -- 81 ft--lb)
Plug, Breather 90 -- 110 N⋅m (66 -- 81 ft-lb)
Plug, Filler 70 -- 90 N⋅m (52 -- 66 ft-lb)
SPECIAL TOOLS
Description Part Number
Output shaft Bearing Driver Procure Locally
Steel Pipe 105 mm ID x 115 mm OD x 200 mm length
Input shaft Bearing Driver Procure Locally
Steel Pipe 43 mm ID x 51 mm OD x 127 mm length
25-2
OVERVIEW
FINAL DRIVE (STANDARD SEAL) -- SECTIONAL VIEW
16
15
18
17
14
19
13 12
20
11
21
10
1
9
2
7
3
6
5
20021345
4
1
1. Axle Hub 12. Bearing Cap
2. Housing 13. Shim(s)
3. Outer End Cap 14. Inner Bearing
4. Bearing (2) 15. Front Cover
5. O-ring 16. 111T Gear
6. Inner End Cap 17. Outer Bearing
7. Input Shaft 18. Wheel Bolt
8. Oil Seal 19. Seal
9. Shim(s) 20. Spacer
10. Retaining Washer 21. Spacer
11. Retaining Bolt (3)
25-3
FINAL DRIVE (MUD SEAL) -- SECTIONAL VIEW
17
19
16
20 18
15
14
13
12
21
11
10
9
1
8
22
2
7
6
4 5
50021346
2
1. Axle Hub 12. Retaining Bolt (3)
2. Housing 13. Bearing Cap
3. Outer End Cap 14. Shim(s)
4. Bearing (2) 15. Inner Bearing
5. O-ring 16. Front Cover
6. Inner End Cap 17. 111 Gear
7. Input Shaft 18. Outer Bearing
8. Oil Seal 19. Wheel Bolt
9. Shim(s) 20. Mud Seal
10. Spacer 21. Spacer
11. Retaining Washer 22. Sealing Ring
25-4
OVERHAUL
WHEEL BOLT
Replacement
NOTE: Left side shown, right side is similar.
1. Park the combine on a level surface. Engage the

parking brake, turn the combine ignition switch to
the “OFF” position and remove the key. Chock
the tire on the opposite side of the wheel bolt that
is to be removed. The front and rear of the tire
must be chocked.
2. Using a jack with a minimum capacity of 10 tons,
raise the side of the combine the wheel bolt will
be removed from. Support the front axle with a 10
ton minimum capacity jack stand.
3. Remove the drive wheel from the combine.
4. Remove the bolt from the drive shaft coupler, 1,
and slide the coupler toward the final drive. 2
Remove the retaining clip, 2, from the recess in 1
the drive shaft. Once the retaining clip is
removed, slide the coupler completely onto drive
shaft, 3.
NOTE: Be careful to not over extend retaining ring
damage.
3
50021343
3
5. Turn the input shaft of the final drive until the
wheel bolt, 1, to be replaced is aligned with the 2
notch, 2, in the final drive housing.
6. Drive the wheel bolt out of the output shaft wheel
1
flange.
7. With the notch on the new wheel bolt aligned with
the step on the wheel flange, pull the wheel bolt
into the flange using a lug nut.
8. Connect the drive sleeve back to the final drive.
9. Install the drive wheel. Torque the lug nuts to 710
– 790 N⋅m (525 -- 580 ft-lb).
IMPORTANT: The final wheel nut torque specifica- 4
25-5
FINAL DRIVE
Removal
NOTE: Left side shown, right side is similar.
1. Park the combine on a level surface. Engage the

parking brake, turn the combine ignition switch to
the “OFF” position and remove the key. Chock
the tire on the opposite side of the final drive that
is to be removed. The front and rear of the tire
must be chocked.
2. Using a jack with a minimum capacity of 10 tons,
raise the side of the combine the final drive will be
removed from. Support the front axle with a 10
ton minimum capacity jack stand.
3. Remove the traction tire from the combine.
4. Drain the oil from the final drive unit by removing
the drain plug, 1, from the bottom of the final
drive. Have a 5 gallon container ready to catch
the oil draining from the final drive.
1
50021330
5. Remove the bolts and nuts, 1, from the outer and

inner drive shaft couplers, 2. Slide both couplers 1
completely outward, over the transmission and
final drive shafts.
6. Slide the drive shaft completely toward the final
drives, and slide the snap ring from the groove to
the smallest diameter at the transmission end.
transmission and slide the snap ring from the
groove to the smallest diameter at the final drive 2
end.
8. Push both couplers, fully onto the drive shaft. 50030311
9. Remove the drive shaft assembly. 6

10. Remove the coupler and rings from the drive
shaft. Slide snap rings over splined end of shaft.
25-6
CAUTION
Each final drive unit weighs approximately 274.3
Kg (605 lb). Use care when handling the final
drive unit to avoid bodily injury or equipment
damage.
11. Using lifting straps or chains and a suitable lifting

device, support the weight of the final drive.
12. Remove the eight mounting bolts which secure
the final drive to the front axle beam. Separate
the final drive from the axle beam, using a pry bar
50021342
if necessary.
7
Disassembly
1. Place the final drive on a clean work area capable 1 4
if supporting 274.3 Kg (605 lb). The axle hub
should face down.
2. Remove the two dowel pins, 1, from the final
drive housing.
3. Remove the 18 bolts, 2, which secure the front
cover, 3, to the final drive housing. Pry the cover
off the housing, using care not to lose the special
flat washer on each bolt. 2 3
4. Pry the bearing cap, 4, out of the final drive 50021331
housing.
8
5. Remove the three bolts from the hub.
• Type I -- Lock wire secured. Note the wire path
through and around the drilled head bolts as an 1
example of how to lock wire the bolts at
reassembly. Remove the locking wire from the
bolts and discard the used wire. Do not reuse
lock wire.
• Type II -- Chemical threated lock bolts. Remove
and save these bolts for use when seating the
bearings and determining axial plat at reassemb-
2
ly.
50021332
NOTE: Replace the chemical treated locking bolts
with new treated locking bolts at final installation of 9
the shaft hub bolts to ensure proper torque values
are applied and full locking quality.
6. Remove the retaining washer, 2, from the hub.
25-7
7. Remove the shims, 1, located between the
retaining washer and the hub. Use care not to
lose any shims. 1
8. Drive the axle hub out of the final drive housing.
The large outer bearing will remain on the hub,
while the inner bearing will be forced off the hub.
Two spacers will also be removed from the final
drive housing when the hub is removed.
9. The large gear can then be removed from the
final drive housing out of the front cover opening.
50021333
10
10. Remove the bearing races and seal, 1, remaining
in the final drive housing. If the final drives are 2
equipped with mud seals, a sealing ring, 2,
located on the outer front portion of the housing
must be removed.
50021336/20021345
11
11. Remove the bolts securing the input shaft end
caps 1, 2, onto the final drive housing. Remove 1
the end caps. 2
19991089
12
25-8
12. Remove the shims, 1, located between the final
drive housing and inner input shaft endplate.
13. Drive the input shaft, 2, out of the final drive 2
housing using a dead blow hammer or other
suitable mallet. Strike the splined end of the input
shaft. The outer bearing race will be removed
with the shaft. 1
14. Use a suitable hammer and punch to remove the
race remaining in the housing.
50021334
13
Inspection
1
1. Clean all parts using a suitable solvent. Be sure
to remove all gasket material from components.
Allow the parts to air dry.
2. Inspect the bearings, 1, on the input shaft for
damage or excessive play. Inspect the races for
scoring, cracks, or excessive wear. If the
bearings or races are damaged, worn, or do not
turn freely, replace the bearings and races as a
set. Use a bearing separator and press to
remove the bearings from the input shaft.
19991090
3. Inspect the splines, teeth and body of the input
shaft. Replace if damaged or worn. 14
19991091
15
25-9
4. Remove and replace the seal, 2, and O-ring, 1,
from the inner end cap. Coat the new O-ring and
seal with petroleum jelly before installation into 2 1
the end cap.
19991092
16
5. Inspect the axle hub splines, flange, and bearing
surfaces for cracks, chips, and any other damage
or excessive wear. Inspect the wheel bolts for
damage or excessive wear. Replace compo-
nents as necessary.
6. Check the inner and outer hub bearings and
races for smooth rotation excessive axial play,
scoring or any other damage. Remove and
replace the bearing and races as a set, if
necessary.
7. Inspect the final drive housing components for
damage such as cracks, holes dents, etc. 50021335
Replace as necessary.
17
Assembly
1. If the bearings, 1, were removed from the input
shaft, press the bearings onto the shaft using a
piece of pipe that has a minimum inner diameter
of 43 mm (1.69 in), a maximum outer diameter of
51 mm (2.0 in) and a length of 127 mm (5.0 in).
2. Coat the bearings in NH AMBRA HYPOID 90
gear oil. 1
19991095
18
25-10
3. To aid installation, chill the input shaft bearing
races in ice or a freezer for 15 minutes. Be sure 1
the races are dry before installation. Install the
input shaft into the final drive housing. Install the
bearing races, 1, into the housing using a
hammer and a brass punch to drive the races into 1
the housing. Be sure the races are properly
seated against the bearing.
19991096
19
4. Install the outer endplate, not shown, for the input
shaft onto the drive housing, using a new gasket
between the plate and housing. Apply LocTite
242/243 to the four endplate mounting bolts and 2
install the bolts into drive housing. Torque the
bolts to 54 -- 60 N⋅m (40 -- 44 ft-lb).
5. Place the inner endplate and shims, 1, for the 1
input shaft onto the drive housing. Use care not
to damage the oil seal when installing the plate.
Torque the bolts to 54 -- 60 N⋅m (40 -- 44 ft-lb).
This will seat the bearing races.
50021334
20
6. Use a dial indicator to check input shaft, 1,
endplay. Endplay should be 0.08 – 0.13 mm
(0.0032 – 0.0051 in). If the endplay is not as
specified, add or remove shims as necessary to
obtain the proper endplay. Shims are available in
three different thickness’:
• 0.05 mm (0.0019 in) 1
• 0.2 mm (0.0079 in)
• 0.5 mm (0.0197 in)
2
7. Once endplay is as specified, remove the four
inner endplate mounting bolts. 50021337
8. Re-install the endplate, 2, onto the final drive
housing, using care not to damage the oil seal. 21
Coat the endplate mounting bolts with LocTite
242/243 and install them into the endplate and
housing. Evenly torque the bolts to 54 -- 60 N⋅m
(40 -- 44 ft-lb).
25-11
9. Chill the bearing races for the axle hub in ice or
a freezer for 15 minutes. Be sure the races are 1
dry before installing into the final drive housing.
10. Using a suitable hammer and brass drift, tap in 1
the bearing races, 1, for the axle hub.
11. If the final drive is not equipped with mud seals
(reference illustration: Mud Seal Final Drive; at
the beginning of this chapter), install the standard
oil seal, 2, into the housing as described in the
following step. (See detail -- Figure 23). 2
20021345
22
12. Before installing the oil seal, 1, lightly lubricate
the lips and fill the seal gaps, 2, with NH AMBRA 2
GR9 grease.
Seat the oil seal, 1, into the housing 6.5 -- 7.5 mm
(0.25 -- 0.35 in) as indicated by, A.
IMPORTANT: The oil seal must be carefully driven

1
into the final driving housing to the specified depth
between 6.5 -- 7.5 mm (0.25 -- 0.35 in).
Ensure the flat section of the seal, 1, faces 3
outward, away from the housing, 3, and the lip of
the seal faces inward torward the housing. 66063383 A
23
13. If the final drive is equipped with mud seals, 3,
install the sealing ring, 4, into the final drive 1 1
housing. Make sure the beveled portion of the
sealing ring faces out, away from the housing.
50021346
2
24
25-12
IMPORTANT: Do not overheat the bearing inner race
when installing the bearing onto the axle hub.
14. If the outer axle hub bearing, 1, was removed, 1

install the bearing onto the axle hub. Heat the
inner race of the bearing to 80° C (176° F). Using
a piece of pipe that has an ID of 105 mm (4.150
in), an OD of 115 mm (4.5 in), and a length of 200
mm (8.0 in), press the bearing onto the axle hub.
15. Coat the bearings with NH AMBRA HYPOID 90
gear oil, then install the large spacer, 2, onto the
axle hub. 50021338
25
16. Install the large gear, 1, into the final drive
housing.
IMPORTANT: Make sure all components of the mud
seals are clean and oiled with NH AMBRA HYPOID
90 gear oil before installation. 1
17. If the final drives are equipped with mud seals,
install the seal into the rear lip of the axle hub.
18. Install the axle hub into the final drive housing
and through the large gear, 1.
50021336
26
19. Position the final drive so the weight of the
assembly is supported by the wheel flange on the
axle hub (The wheel flange will be on the
bottom.).
20. Install the small spacer, 1, onto the axle hub
shaft.
CAUTION
with hot parts.
2 1
21. Heat the inner race of the inside axle hub bearing 50021339
to 80° C (176° F). Using heat resistant gloves,
place the bearing, 2, onto the axle hub shaft. 27
25-13
22. Determine and shim the axle hub bearing
pre-load as described in the following steps.
NOTE: Be aware of two variables for this procedure; 1
standard seal and mud seal units have a different
pre-load range, and final torque (range) on the
mounting bolts for Type I and Type II bolts is different.
NOTE: Final drives that use the chemical treated

lock bolt should reuse the removad bolts only for
setting the axle pre-load, and then install new
chemical treated bolts at final torque.
2
50021341
23. Install the large retaining washer, 1, onto the final
drive and secure using the three retaining bolts, 28
2. Torque the bolts to 90 N⋅m (66 ft-lb). This
ensures the races are properly seated in the final
drive housing.
24. Loosen the three bolts evenly to allow for free
play.
25. Take a large dead blow hammer and strike the
axle hub to create a small amount of endplay in
the final drive axle hub.
26. Use a dial indicator to measure the amount of
end play in the axle hub. Tighten the three
retaining bolts evenly until zero end play is
achieved. DO NOT tighten the bolts any more
than what is necessary to achieve zero end play.
27. Remove the three bolts and retaining washer.
25-14
28. Measure the distance, X, between the end of the
axle hub and the top, outer edge of the bearing.
29. To calculate shimming, subtract 0.5 mm (0.020
in) from X, the value obtained in step 26.
X
20021345
29
30. Install the appropriate amount of shims, 1, onto
the axle hub to obtain a pre-load measurement
as follows:. 1
• For standard seal final drive -- 0.27 -- 0.33
mm (0.011 -- 0.013 in)
• For mud seal final drive -- 0.27 -- 0.35 mm
(0.011 -- 0.014 in)
Shims are available in three thickness’:

• 0.05 mm (0.0019 in)
• 0.2 mm (0.0079 in)
• 0.5 mm (0.0197 in) 50021333
30
31. Install the retaining washer onto the hub and
secure using the three mounting bolts. Torque
the bolts as follows.
• Type I (drilled head for lockwire) -- 235 -- 260
N⋅m (173 -- 192 ft-lb)
• Type II (chemical treated) -- 252 -- 278 N⋅m
(186 -- 205 ft-lb)
32. Secure Type I bolts using 1.85 mm (0.073 in) tie

wire. The wire must be routed as shown so that
if the bolts were to loosen, the wire is stretched
tighter. Use a minimum of five twists at the wire
ends to secure the wire in the bolts. Position the
wire ends against the retaining washer. 31
25-15
33. Coat the two dowel pins, 1, with LocTite
anti-seize. Install the pins into the final drive 1
housing. 4
34. Coat the sealing edge of the bearing cover, 4,
with LocTite 638. Install the bearing cover, 4,
onto the final drive housing.
35. Coat both sides of a new front cover seal with
LocTite Hi-Tack™ gasket sealant. Install the front
cover, 3, and gasket onto the final drive housing.
Coat the cover mounting bolts, 2, with LocTite 3
242/243 and thread them into the cover and final 2
drive. Torque the bolts to 46 – 60 N⋅m (36 – 44 50021331
ft-lb), starting in the center of the cover and
working out to the ends of the cover and final 32
drive housing, alternating sides while tightening
the bolts.
Installation
CAUTION
Each final drive unit weighs approximately 274.3
Kg (605 lbs). Use care when handling the final
drive unit to avoid bodily injury or equipment
damage.
1. Using lifting straps or chains and a suitable lifting

device, support the weight of the final drive.
2. Raise the final drive up to the front axle beam,
aligning the dowel pins with the proper holes in
the axle beam.
3. Coat the eight mounting bolts which secure the
final drive to the axle beam with LocTite 242/243.
Install the mounting bolts into the final drive and
axle beam and torque to 656 -- 725 N⋅m (484 --
535 ft-lb).
50021342
33
25-16
For each side of a drive shaft:

2
IMPORTANT: Do not stretch the snap rings more
than necessary to avoid excessive yielding.
4. Slide both snap rings, 1, over the splines, beyond
the groove and position on the smallest diameter
part of the drive shaft.
5. Slide the couplers, 2, completely over the splines 1
with the undercut towards the snap ring. 3
6. Place the pre-assembled drive shaft assembly
between the output shaft of the transmission and
50021343
input shaft of the final drive.
7. Slide both couplers completely outwards over 34
the transmission and final drive shafts.
transmission and install the snap ring at the final
drive side in its groove.
9. Slide the drive shaft completely towards the final
drive and install the snap ring at the transmission
side in its groove.
10. Slide the drive shaft in its middle position.
11. Install the bolts and nuts, 3. Tighten and torque
the bolts and nuts to 5 N⋅m (3.7 ft-lb).
12. Make sure the final drive drain plug is torqued to
90 – 110 N⋅m (65 – 80 ft-lb) and fill the final drive
with NH AMBRA HYPOID 90 gear oil.
13. Install the drive wheel, torquing the lug nuts to
710 – 790 N⋅m (525 – 580 ft-lb).
14. Check wheel motor mounting bolt torque and lug

nut torque after 50 hours of operation.
25-17
25-18
SECTION 29 -- HYDROSTATIC SYSTEM -- CHAPTER 1
Chapter 1 - Hydrostatic Drive System Introduction
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydrostatic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydrostatic Pump (CR920, 940 and 960 Machines W/Hd 11/111 Final Drives) . . . . . . . 2
Hydrostatic Pump (CR940 and 960 Machines W/Planetary Final Drives) . . . . . . . . . . . . 3
Hydrostatic Pump (CR970 and 980 Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydrostatic Drive Motor (CR920, 940 and 960 Machines W/Hd 11/111
Final Drives) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydrostatic Drive Motor (CR940 And 960 Machines W/Planetary Final Drives;
CR970 and 980 Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil Cooler Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydrostatic Brake (External Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydrostatic Brake (Integrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydrostatic Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Powered Rear Axle (PRA) (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydrostatic Drive Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Explanation of Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
29-1
SPECIFICATIONS
HYDROSTATIC OIL
Specification (Europe) Ambra Hydrosystem 46 (ref. NH646)
Ambra Hydrosystem 45 BIO-S (ref. NH646BS)
Ambra Hydrosystem 46 BIO-V (ref. NH646BV)
or oil to International Specification ISO VG 46,
DIN 51524-2 or ISO VG 46
Specification (North America) M2C 134 - D

Reservoir Capacity Approximately 50 Liters (13 US gals.)
Total System Capacity (Hydraulic and Hydrostatic) Approximately 70 Liters (74 qts.)
HYDROSTATIC PUMP (CR920, 940 AND 960 MACHINES W/HD 11/111 FINAL DRIVES)
Manufacturer Sauer Danfoss
Type 90 Series Variable Displacement, Closed Circuit
Control Electric Displacement Control (EDC)
Frame Size 130
Direction of Rotation Counterclockwise
Displacement 110 cc/rev (mechanically limited) (6.7 in3/rev)
Minimum Speed 500 rpm
Rated Speed 3100 rpm
Maximum Speed 3400 rpm
Charge Pump Displacement 26 cc/rev (1.6 in3/rev)
Charge Pump Pressure 38 bar (551 PSI)
Brake Manifold Pressure Setting 180 bar (2610 PSI)
29-2
HYDROSTATIC PUMP (CR940 AND 960 MACHINES W/PLANETARY FINAL DRIVES)

Frame Size 130
Displacement 130 cc/rev (7.9 in3/rev)
HYDROSTATIC PUMP (CR970 AND 980 MACHINES)

Frame Size 130
HYDROSTATIC DRIVE MOTOR (CR920, 940 AND 960 MACHINES W/HD 11/111 FINAL
DRIVES)
Type 90 Series Fixed Displacement, Closed Circuit
Frame Size 100
Direction of Rotation Bi-Directional
System Pressure - Rated 420 bar (6090 PSI)
System Pressure - Maximum 480 bar (6960 PSI)
Flow at Rated Speed 365 l/min (96.4 gal/min)
Case Pressure - Continuous 3 bar (43.5 PSI)
Case Pressure - Maximum (Cold Start) 5 bar (72.5 PSI)
29-3
HYDROSTATIC DRIVE MOTOR (CR940 AND 960 MACHINES W/PLANETARY FINAL DRIVES;
CR970 AND 980 MACHINES)
Type 90 Series Fixed Displacement, Closed Circuit
Frame Size 130
Direction of Rotation Bi-Directional
System Pressure - Rated 420 bar (6090 PSI)
System Pressure - Maximum 480 bar (6960 PSI)
Flow at Rated Speed 442 l/min (117 gal/min)
Case Pressure - Continuous 3 bar (43.5 PSI)
Case Pressure - Maximum (Cold Start) 5 bar (72.5 PSI)
OIL COOLER BYPASS VALVE

Manufacturer Parker
Maximum Operating Pressure 17.2 bar (249 PSI)
Cooler Port Opening Temperature 46 - 52°C (114.8 - 125.6°F)
Cooler Port Fully Open Temperature 63°C (-145.4°F)
Maximum Operating Temperature 91°C(-195.8°F)
Minimum Operating Temperature -34°C (-29.2°F)
Maximum Flow Rate 227 l/min. (60 gal/min)
Relief Valve Pressure 2.8 to 3.4 bar (40.6 - 49.3 PSI)
29-4
INTRODUCTION
The CR Combine Hydrostatic System contains five
main components, an oil reservoir, hydrostatic pump,
brake manifold, drive motor and oil cooler.
Some machines are equipped with an optional

powered rear axle (PRA).
OIL RESERVOIR
A single oil reservoir, 1, is used for both the hydraulic 1
and hydrostatic systems. The reservoir is located at
the upper left hand side of the machine behind the
engine compartment. Each of the hydraulic and
hydrostatic circuits have their own filtering systems.
2
A suction screen, 2, is mounted inside the reservoir
to provide some filtration for the hydrostatic pump
suction oil.
10020026
1
HYDROSTATIC PUMP
4 7 6 2
The hydrostatic pump, 1, is mounted to and driven by
the engine gearbox. The hydrostatic pump assembly 5
includes the charge pump, charge relief valve, 2, 3
brake manifold, 3, charge pressure filter, 4, and
charge pressure sensor (switch), 5. The hydrostatic
pump also houses the servo displacement valve, 6,
and multi function valves, 7. 7
1
10020024
2
HYDROSTATIC BRAKE (EXTERNAL
3
BLOCK)
1 2
The brake manifold, 1, is mounted directly onto the
hydrostatic pump assembly, 2. The brake manifold is 4
used to protect the engine and hydrostatic pump
from over speeding during hydrostatic stop or when
driving down hill in too high a gear.
The brake manifold contains two brake flow valves,

3, a pressure limiter valve, 4, and a pressure relief
valve, 5. The pump high pressure and suction hoses 5
are also connected to the brake manifold.
10020025
29-5
HYDROSTATIC BRAKE (INTEGRATED)

The hydrostatic drive integral brake is a device used
to aid in deceleration and braking with combustion
engines with low braking characteristics. Engines
with large displacement and high compression have
internal characteristics to prevent over-speeding
from occurring. The integral brake feature allows the
machine to have the characteristics of a larger
engine, by having the capability to decelerate a
vehicle of high weight or high speed. This high kinetic
energy that occurs can also over-speed the engine
through the hydrostatic pump, and overpower the
service brakes. When over-speed is sensed, the 56062059
integrated hydro brake feature prevents the machine
4
from over-speeding the engine, over-speeding the
hydrostatic pump, and allows the vehicle sufficient
deceleration and braking.
HYDROSTATIC DRIVE MOTOR

4
The hydrostatic motor, 1, is mounted to the main
transmission and is driven hydraulically by the
hydrostatic pump. The hydrostatic motor supplies
the drive input to the main transmission. 1
The shuttle spool valve, 2, flushing relief valve, 3, and

pressure release solenoid valve, 4, are all located in
the backplate of the motor.
2
3
10013278
5
The hydraulic oil cooler, 1, is mounted under the
engine radiator in the main cooler assembly. The oil
cooler bypass valve, 2, is thermostatically controlled, 1
and only directs oil to the cooler when the oil
temperature is above 49°C (120°F).
2
BSC1259A
29-6
POWERED REAR AXLE (PRA) (OPTIONAL)

Each wheel of the powered rear axle is driven
independently by its own hydrostatic motor. Each
motor is driven hydraulically by the hydrostatic pump
and controlled by a single Equa-Trac II® control
valve.
Refer to Section 29 Chapter 4 of this manual for more

information on the powered rear axle.
NOTE: Equa-Trac II ® is a registered trademark of

Tuthill Transport Technologies.
BSC1360A
29-7
HYDROSTATIC DRIVE SCHEMATIC
Schematic Legend
1. Reservoir 12. Reverse High Pressure Line

2. 100 Micron Filter Screen 13. Check Valve
3. Charge Pump 14. Check Valve
4. Hydrostatic Pump 15. Brake Manifold Block
4a. Hydrostatic Pump Servo Cylinders 15a. Brake Flow Valve (180 bar [2610 PSI] for CR920,
5. Filter 940 and 960 Machines)
6. Charge Pressure Sensor (switch) (280 bar [4060 PSI] for CR970 and 980 Machines)
7. Charge Pressure Relief Valve 15b. Brake Flow Valve (180 bar [2610 PSI] for CR920,
8. Forward Multi Function Valve 940 and 960 Machines)
(280 bar [4060 PSI] for CR970 and 980 Machines)
8a. Charge Check Valve
15c. Pressure Limiter Valve (400 bar) (5800 PSI)
8b. Pressure Limiter (420 bar) (6090 PSI)
15d. Pressure Shock Relief Valve (450 bar) (6525 PSI)
8c. High Pressure Relief Valve (450 bar) (6525 PSI)
15e. Check Valve
8d. Bypass Valve
15f. Orifice
9. Reverse Multi Function Valve
16. Hydrostatic Drive Motor
9a. Charge Check Valve
16a Shuttle Spool Valve
9b. Pressure Limiter (420 bar) (6090 PSI)
16b. Flushing Relief Valve
9c. High Pressure Relief Valve (450 bar) (6525 PSI)
16c. Pressure Release Solenoid Valve
9d. Bypass Valve
16d. Pressure Release Spool
10. Servo Valve Assembly
17. Oil Cooler Bypass Valve
10a. Servo Solenoid Valve
18. Oil Cooler
10b Orifice Check Valve
19. Temperature Sender
10c. Servo Valve Spool
11. Forward High Pressure Line
29-8
Schematic Circuit for CR920, 940, 960, 970 and 980 Machines with External Brake Manifold
20020023
29-9
HYDROSTATIC DRIVE SCHEMATIC

Schematic Circuit for CR920, 940, 960, 970 and 980 Machines with Integrated Braking Function
12
2 6
13
14
15 7
3
10
11
66062990
Schematic Legend
1. Reservoir 9. Forward High Pressure Line

2. Charge Pump 10. Reverse High Pressure Line
3. Hydrostatic Pump 11. Integrated Braking Components
4. Filter 12. Hydrostatic Drive Motor
5. Charge Pressure Sensor (switch) 13. Oil Cooler Bypass Valve
6. Forward Multi Function Valve 14. Oil Cooler
7. Reverse Multi Function Valve 15. Temperature Sender
8. Servo Valve Assembly
29-10
EXPLANATION OF HYDRAULIC SYMBOLS
Symbol Description
Servo Valve Spool
Orifice Check Valve
High pressure pump with variable displacement and fixed capacity charge pump
Charge pump pressure relief valve
Pressure filter (charge pressure)
Temperature sender
Servo Solenoid Valve
Shuttle spool Valve
Non-return check valve
Multi function valve - relief valve set at 420 bar (6090 PSI)
Hydrostatic pressure release valve
Drive motor with fixed displacement
Pressure release solenoid valve
Fixed flow flushing relief valve
Hydrostatic oil cooler bypass valve (thermostatically controlled)
Hydrostatic oil cooler
Charge pressure sender (switch)
29-11
29-12
Chapter 2 - Hydrostatic System Operation
CONTENTS

Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydrostatic Block Operation (External Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydrostatic Block Operation (Integrated Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Gear Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Schematic Circuit for CR920, 940, 960, 970 and 980 Machines . . . . . . . . . . . . . . . 11
Multi Function Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Charge Check Valve 8a - 9a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Limiter 8b - 9b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
High Pressure Relief Valve 8c - 9c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Bypass Valve 8d - 9d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Servo Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
System in Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Servo Solenoid Valve 10a Energized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydrostatic Drive Motor Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Shuttle Spool Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Flushing Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pressure Release Valve Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Oil Cooler bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hydrostatic Pump and Drive motor Identification Numbers . . . . . . . . . . . . . . . . . . . . . . 21
Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Variable Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pump Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hydrostatic Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fixed Displacement Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Drive Motor Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
29-1
DESCRIPTION OF OPERATION
HYDROSTATIC SYSTEM forward side of the servo valve spool, 10c, moving
The CR Combine Hydrostatic System contains a the spool and allowing oil to flow to the forward servo
reservoir, Charge Pump, Hydrostatic Pump, Brake cylinder, 4a.
Manifold, Drive Motor and optional powered steering
The charge pressure oil acting on the forward servo
axle.
cylinder, 4a, will move the hydrostatic pump swash
The hydrostatic pump assembly incorporates the plate creating axial movement of the pistons
charge pump and brake manifold and is connected increasing the pressure in the forward high pressure
to and driven from the engine gearbox. line, 11, towards the drive motor, 16.
The increased pressure in the forward high pressure

Neutral line, 11, will create rotational movement of the drive
With the engine running and the hydrostatic lever in motor pistons, causing the drive motor output shaft
neutral the charge pump receives oil from the to turn in the forward direction. The oil will return by
reservoir, 1, through a 100 micron filter screen, 2, into the return line, 12, through the brake manifold and to
the charge pump, 3. The oil is then pumped through the hydrostatic pump, 4.
filter, 5, to the multi function valves, 8 and 9. The
charge pressure will open the check valves, 8a and Also the increase in pressure will close the forward
9a, allowing charge pressure to fill the hydrostatic multi function valve charge check valve, 8a,
pump, 4, high pressure lines, 11 and 12, brake preventing the charge pressure circuit receiving
manifold, 15, and drive motor, 16. Charge pressure drive pressure from the hydrostatic pump, 4.
oil will also fill the servo valve assembly, 10, and
servo cylinders, 4a. The charge pump, 3, will continue to charge the
reverse high pressure line, 12, through the reverse
The hydrostatic pump swash plate stands square to multi function valve charge check valve, 9a, to
the input shaft. With no axial movement of the pistons replace the oil used for lubrication and flushing and
there is no flow of high pressure oil in the high any oil lost through internal leakage.
pressure lines, 11 or 12.
The return oil from the drive motor, 16, is passed
When the charge pump pressure in the system through the flow valves of the brake manifold and
increases to 34 bar (493 PSI) the charge pressure back to the pump.
relief valve, 7, will open and oil will flow into the
hydrostatic pump casing through the thermostatical- If there is more than a 13 bar (188.5 PSI) pressure
ly controlled oil cooler bypass valve, 17, to the difference across the drive motor, 16, the drive
reservoir, 1. pressure from the hydrostatic pump, 4, moves
shuttle spool valve, 16a, in the drive motor assembly,
If the oil temperature is below 49°C (120°F) the oil will 16, connecting the return line, 12, to the flushing
flow directly to the reservoir, 1, when the oil relief valve, 16b.
temperature is above 49°C (120°F) the thermostati-
cally controlled oil cooler bypass valve, 17, will move The flushing relief valve, 16b, will open at a lower
diverting the oil flow through the oil cooler, 18. pressure than the charge pressure relief valve, 7,
causing some of the charge pressure oil to flow
Forward through the flushing relief valve, 16b, to the drive
motor case drain. The oil will then flow to the oil cooler
When the hydrostatic lever is moved forward the
through the pump case drain, cooling the motor and
servo solenoid will move the servo solenoid valve,
pump bodies.
10a, proportional to the position of the hydrostatic
lever. Charge pressure oil can then flow to the
29-2
Schematic Circuit for CR920, 940, 960, 970 and 980 Machines
20020023
29-3
If the resistance on the drive motor, 16, increases To prevent this, if the drive motor return oil pressure
(machine travelling up hill) then the pressure in the exceeds 280 bar (4060 PSI) (CR970 and 980) or 180
forward high pressure line, 11, will increase. As the bar (2610 PSI) (CR920, 940 and 960), brake flow
pressure reaches 420 bar (6090 PSI) (delta p) the valves,15a, and 15b, in the brake manifold will begin
pressure limiter valve, 8b, will open allowing oil to to close. The oil flowing through brake flow valves,
flow to the hydrostatic pump reverse servo cylinder 15a, and 15b, will convert much of the energy into
piston, 4a, reducing the swash plate angle and pump heat thereby absorbing part of the brake energy.
flow, protecting the hydrostatic system from
overpressure. The orifice, 15f, will allow the brake valves, 15a, and
15b, to close fully from a certain point (flow) onwards.
To make sure the pressure acting on the reverse Pressure towards the pump will again increase and
servo cylinder piston, 4a, does not exceed charge as displacement decreases, the torque towards the
pump pressure, as the oil flows through the pressure engine will be kept at maximum.
limiter valve, 8b, the pressure (420 bar [6090 PSI])
will open the check valve, 13, and the charge check At 400 bar (5800 PSI) (delta p) the pressure limiter
valve, 9a, allowing the oil to flow into the charge valve, 15c, will open allowing oil to flow to the
pressure circuit. In this circuit the pressure is limited hydrostatic pump forward servo cylinder piston, 4a,
by the charge pressure relief valve, 7. which will attempt to reduce the braking pressure by
keeping the pump at a displacement which results in
If the pressure in the high pressure line exceeds 450 a pressure of 400 bar (5800 PSI) (delta p).
bar (6525 PSI) (shock) then the relief valve, 8c, will
open allowing oil to flow directly from the high To make sure the pressure acting on the forward
pressure line, 11, into the return line, 12, through the servo cylinder does not exceed charge pressure, the
charge check valve 9a (the pump is bypassed in this 400 bar (5800 PSI) pressure flowing through the
instance). pressure limiter valve, 15c, will open the check valve,
14, connecting forward servo line directly to the
Hydrostatic Block Operation (External Block) charge pressure circuit. In this circuit the pressure is
limited by the charge pressure relief valve, 7.
When carrying out a hydrostatic stop (rapid
movement of the hydrostatic control lever from drive If the pressure exceeds 450 bar (6525 PSI) (shock)
to neutral), or if descending a steep hill in too high a then the relief valve, 15d, will open allowing oil to
gear, the drive motor, 16, will operate as the pump, flow directly from the return line, 12, (high
driving the pump, 4, as the motor, possibly causing the pressure) into line, 11.
engine to over rev which may damage the engine and
the hydrostatic pump, 4.
29-4
Hydrostatic Block Operation (Integrated Brake)
The pressure regulator valve body, 1, is located in the 3
pump’s end cap. It is held open (start position) by
means of a compression spring, 2, above it. The 6
pressure regulator valve becomes active when the
pilot valve, 3, (high pressure relief valve, non-adjust-
2
able) opens due to increasing pressure and allows
an oil flow through an axial orifice in the pressure 4
regulator valve body, 1. This will cause a differential
pressure on the valve body and the valve will move
to the top against the spring force. While moving 5 1
forward, it will increasingly throttle the oil flow in the
circuit. In reverse driving direction, the check valve, 56062058
4, allows fluid to bypass the pressure regulator with
2
low pressure drop. The bypass orifice, 5, is
integrated into the pressure regulator valves body in
the form of two radial bores. These bores will remain
open although the pressure regulator may close the
circuit completely.
The travel of the pressure regulator valve is locked by

means of a special spring guide, 6. This guide has
two big radial bores and one small axial bore. When
the pressure regulator valve contacts the spring
guide, all the flow to the pilot valve has to pass
through the small axial bores in the valve body and
in the spring guide successively. This will restrict this
flow. This saves the pilot relief valve if the high
pressure is excessive and will prevent excessive loss
of vehicle speed in reverse direction when opening
the relief valve. The oil through the pilot valve goes
back into the charge line.
Reverse
When the hydrostatic lever is moved to reverse the
system operates the same as in forward other than
high pressure line, 11, becomes the return line and
high pressure line, 12, becomes the drive line. Also
the drive pressure flows through the check valve,
15e, in the brake manifold block, 15.
In reverse braking is achieved by the motor acting as

a pump and its pressure is controlled by the multi
function valve, 8, only and not by the brake manifold.
29-5
20020023
3
29-6
4
6
20062052 20062053
4
Sectional View of Integrated Hydrostatic Brake
Position Description
1 Pressure regulator valve body (with
by-pass bores)
2 Spring on pressure regulator valve body
3 Spring Guide
4 Pilot Relief valve (SCR-type)
5 Check Valve
6 Spring on check valve
29-7
3
6
2
5
1
56062054
5
Exploded View of Integrated Hydrostatic Brake
Position Description
1 Pressure regulator valve body (with
by-pass bores)
2 Spring on pressure regulator valve body
3 Spring Guide
4 Pilot Relief valve (SCR-type)
5 Check Valve
6 Spring on check valve
29-8
2
4
5 7
56062051
6
Integrated Hydrostatic Brake Schematic
Item Description
1 To hydrostatic pump
2 To pressure limiter
3 Check valve
4 Orifice
5 To charge pump
6 Pressure regulator valve
7 Pilot valve
29-9
Gear Changing Temperature Control
When changing gear under certain conditions (i.e. The hydrostatic system also includes a high
changing gear while stood on a hill side) the pressure temperature control. The motor case drain line
in the system may prevent the selection of a different temperature sender monitors the temperature in the
drive gear. return line sending the information to the CCM1
Module.
To assist in the gear selection, when a gear change
operation is required the drive motor, 16, electric If the temperature exceeds 95°C (203°F), CCM1 will
solenoid is energized moving the pressure release automatically reduce the current to the electric
solenoid valve, 16c, to connect the charge pressure displacement proportional solenoid, reducing the
line through the shuttle spool valve, 16a, to the swash plate angle independent of the hydrostatic
pressure release spool, 16d. lever position. An alarm message “A0008 HY-
DROSTATIC MOTOR TEMP HIGH” will be displayed
The pressure on the pressure release valve moves to the operator on the instrument panel display. The
the spool, 16d, connecting the high pressure line to temperature in the system will be reduced by the
the return line relieving the pressure in the system. reduced power in the system.
This will allow the gear selection to take place.
29-10
20020023
7
29-11
MULTI FUNCTION VALVES

The multi function valve has four functions, and three A. Bypass Actuator
different valves. B. Pressure Limiter Adjustment Screw
C. Pressure Limiter Locknut
The valves with in the multi function valve are as D. Pressure Limiter Housing
follows: E. Pressure Limiter Spring
F. Spring Seat
• A Charge Pressure Check Valve to keep the G. Check Valve Carriage
system full of oil. H. High Pressure Relief/check Valve Poppet
• A Pressure Limiter Valve to make the work J. Valve Seat
pressure (delta p) does not exceed 420 bar (6090 K. Spring
PSI). L. Pressure Limiter Poppet Seat
M. Pressure Limiter Valve Poppet
• A High Pressure Relief Valve to protect the
8a - 9a. Charge Check Valve
system from shock loads above 450 bar (6525
8b - 9b. Pressure Limiter (420 bar) (6090 PSI)
PSI) (delta p).
8c - 9c. High Pressure Relief Valve (450 bar) (6525 PSI)
The multi function valve also includes a bypass valve 8d - 9d. Bypass Valve
to enable the vehicle to be moved at very low speeds
for short distances if an engine failure occurs.
The bypass valve is a manually operated valve and

oil flow generated by the drive motor (acting as a
pump) is allowed to flow to the suction side of the
motor.
29-12
BSC1328A
8
Multi Function Valve Cross Section
BSC1299A
9
Multi Function Valve Schematic
29-13
Charge Check Valve 8a - 9a
When the charge pressure in port, Y, becomes higher
than the pressure in the high pressure port, X, and
enough to overcome the tension of spring, B, carrier,
A, will move to he left taking along poppet C. Oil from
the charge pump will flow from port, Y, to port, X,
filling the system.
10
Pressure Limiter 8b - 9b
When high pressure exceeds 420 bar (6090 PSI),
poppet, D, will move to the left, compressing spring,
E, due to the pressure behind the poppet pressurized
oil will flow from port, X, into port, Z, to the main servo
cylinder. The main servo cylinder will then move the
swash plate of the hydrostatic pump towards neutral
when the transmission is in drive mode and towards
maximum displacement when the transmission is in
brake mode.
11
High Pressure Relief Valve 8c - 9c
When the pressure limiter opens at 420 bar (6090
PSI) a certain oil flow will escape through port, Z. If
the pressure from the high pressure port, X,
increases to 450 bar (6525 PSI) due to shock
loading, the pressure difference which is created
over the plunger, C, will move the plunger towards
the left against spring, B, and high pressure oil will be
allowed to flow from port, X, to port, Y. In this phase,
the pressure limiter function remains active as well
(oil keeps flowing from port, X, to port, Z).
12
29-14
Bypass Valve 8d - 9d
When the bypass actuator, H, is turned 31/2 turns
counterclockwise the force on poppet, J, is reduced.
This sets the pressure limiter valve at near zero
setting. When the pump is not turning but pressure is
generated in the high pressure lines by the motor
(motor acting as a pump), poppet, J, moves to the
left, oil flows from port, X, through opening, G, to port,
Z. Plunger, C, will also move easily to the left allowing
the pressurized oil from port, X, to flow to port, Y. As
pressure increases to the valve which equals spring
B, plunger, C, will move to the left and allowing oil to
flow directly from port, X, to port, Y, (oil keeps flowing
from port, X, to port, Z).
13
29-15
SERVO VALVE
System in Neutral As the oil flow increases to the servo cylinder through
Charge pump oil flows to both cavities, 20, from port, port, 31, the displaced oil on the opposite servo
21, oil also flows from port, 21, through the check cylinder will flow back through port, 32, and orifice,
valve orifice, 22, to the central land of servo spool 33, past the spool, 28, through to the case drain
valve, 28. through orifice, 34, and port, 35.
Charge pressure oil flows equally from cavity, 21, NOTE: When the opposite direction of travel is
through the orifices, A and B, to cavity, 23, to the case selected spools, 26, and 28, will move to the left. The
drain. As the electric solenoid, 24, is not energized oil feed pressure to the servo cylinder will be through
flow from cavities, 20, into cavity, 23, is the same, so orifice, 33, and port, 32. Displaced oil from the
the pressure in cavities, 25 and 27, will be equal and opposite cylinder will flow to case drain through port,
the spool assembly will remain in neutral. 36, and orifice, 37.
Servo Solenoid Valve 10a Energized As the swash plate moves the mechanical feed back
linkage will move to the right compressing its internal
Anchor, 29, of the servo solenoid valve 10a moves to
spring when the spring force is equal to the pressure
the left when the solenoid is energized. The
in cavity, 25, spool, 28, will move back to neutral
movement of anchor, 29, is proportional to the
holding the swash plate in its new position.
current through the solenoid dependant on the
position of the hydrostatic lever. Any movement of the swash plate or hydrostatic
control lever will affect the balance of spring force
Oil flow from the left hand cavity, 20, to case drain
and cavity pressure. The spool, 28, will then move to
cavity, 23, will decrease and the flow from the right
a position where the balance is restored
hand cavity, 20, to cavity, 23, will increase. The
pressure in cavity, 25, on the left side of the servo If a shock load occurs in the system it will be felt by
spool, 26, is higher than the pressure in cavity, 27, on the pump swash plate and will create an increase in
the right hand side of the spool, 28, causing the pressure in the servo cylinder lines and servo valve.
spools, 26 and 28, to move to the right. To protect the servo valve from the increased
pressure in the system the check valve 10c will open
The charge pump oil can now flow from the center of
connecting the servo cylinder lined directly to the
spool, 28, through the check valve orifice, 22, to the
charge pressure circuit. In this circuit the pressure is
hydrostatic pump servo cylinder through orifice, 30,
limited by the charge pressure relief valve.
and port, 31, causing the pump swash plate to move.
10. Servo Valve Assembly 28. Spool

10a. Servo Solenoid Valve 29. Anchor
10b. Orifice Check Valve 30. Servo Cylinder Port
10c. Servo Valve Spool 31. Orifice
20. Oil Cavity 32. Servo Cylinder Port
21. Oil Feed Port 33. Orifice
22. Check Valve Orifice 34. Orifice
23. Case Drain Cavity 35. Case Drain Port
24. Electric Proportional Solenoid 36. Case Drain Port
25. Spool Cavity 37. Orifice
26. Spool 38. Swash Plate Assembly (Feed Back)
27. Spool Cavity
29-16
A B
BSC1291A
14
Servo Valve Cross Section
BSC1290A
15
Servo Valve Schematic
29-17
HYDROSTATIC DRIVE MOTOR VALVES

Shuttle Spool Valve
When the pressure in either of the drive lines
increases (forward or reverse selected) pilot
pressure will act on one side of the shuttle spool
valve, moving the spool valve to connect the return
line to the flushing relief valve and pressure release
solenoid valve.
Flushing Relief Valve

With the motor running in forward or reverse the
pressure in the return line will act on the flushing relief
valve opening the valve to case drain.
Pressure Release Valve Circuit

With the pump in neutral, pressure on each side of
the motor may prevent gear changing (transmission
lock up). When a gear change control is moved the
pressure release solenoid, 16c, Figure 17, will
energized, moving the solenoid valve, connecting
the low pressure side of the circuit (through the
shuttle spool valve) to the pressure release valve
pilot. The pressure release valve will move
connecting the motor drive lines to equalize the
pressure in both lines allowing a smooth gear change
to take place.
16
Drive Motor Shuttle Spool
and Flushing Valve
16. Drive Motor

16a. Shuttle Spool Valve
16b. Flushing Relief Valve
16c. Pressure Release Solenoid Valve
16d. Pressure Release Spool
29-18
17
Drive Motor Shuttle Spool and Flushing Valve
18
Drive Motor Schematic
29-19
OIL COOLER BYPASS VALVE

The oil cooler bypass valve is thermostatically
controlled and its function is to allow the hydrostatic
system oil to reach maximum operating temperature
in the shortest possible time.
When the hydrostatic system oil temperature is
below approximately 49°C (120°F) the oil cooler
bypass valve thermostat assembly, 1, is closed and
the oil will flow from port, A, down the center of
sleeve, 2, and through port, B, to the oil reservoir.
When the oil temperature rises above 49°C (120°F)

the thermostat assembly, 1, will begin to open,
moving sleeve, 2, down towards seal, 3. The oil will
continue to flow from port, A, down the center of
sleeve, 2, and through port, B, to the oil reservoir, it
will also flow through open thermostat valve, 1, and
through port, C, to the oil cooler.
When the oil temperature reaches 63°C (145°F) the

thermostat valve, 1, will be fully open and sleeve, 2,
will seat against seal, 3, closing off the oil flow from
port A to port B. The oil flow will now flow from port
A through the thermostat valve, 1, through port, C, to
the oil cooler.
If the oil flow through the oil cooler becomes

restricted and the cooler oil pressure rises to above
approximately 3.1 bar (45 PSI), the oil pressure
acting though the center of sleeve, 2, onto seal, 3, will
compress the spring, 4, allowing oil to flow through
the center of sleeve, 2, through port, B, to the
reservoir.
19
1. Thermostat Assembly
2. Sleeve
3. Seal
4. Spring
A. Inlet Port
B. Reservoir Port
C. Oil Cooler Port
29-20
HYDROSTATIC PUMP AND DRIVE MOTOR

IDENTIFICATION NUMBERS
Each pump has a name plate attached to the
housing. The name plate will include the model
number, model code and serial number.
Model Code A
The Sauer Danfoss model code defines the specific
build configuration of each unit and must be used
when ordering spare parts or a new pump.
Model Number B
The Sauer Danfoss model number is used by the
factory in manufacturing. A new unit can be ordered
by the model number.
Serial Number C
The Sauer Danfoss serial number identifies the
location and date of manufacture and the unit
sequence in the build.
The letter coding indicates the location of original

assembly “A” indicates assembly in Ames, Iowa,
USA “N” indicates assembly in Neumunster,
Germany.
The first number (two digits) indicates the year of

manufacture. For example, a unit built in 2001 would
have the number “01” in this space.
The second number (two digits) indicates the

calendar week of manufacture, from week 1 to week
52.
The third number (five digits) is the sequential build

number identifying the specific unit.
29-21
BSC1349A
20
Pump Identification Name Plate
BSC1348A
21
Motor Identification Name Plate
29-22
HYDROSTATIC PUMP
Variable Displacement Pump
The variable displacement pump is designed to The swash plate angle can be varied by the control
convert an output power from the engine into piston, altering the swash plate angle varies the
hydraulic power. The input shaft turns the pump displacement of the oil. A larger angle causes greater
cylinder which contains a ring of pistons. The pistons displacement, a smaller angle reduces the displace-
run against a tilted plate (swash plate), this causes ment per revolution which in turn will result in a higher
the pistons to compress the hydraulic oil which and also respectively lower speed of the motor.
converts the input energy into the hydraulic oil. The
high pressure oil then provides power to the motor.
2 3 5
4
6
7
1 10 9
11
DS00M007
22
Hydrostatic Pump
1. Charge Pump 7. Feed Back
2. Cradle Hold Down 8. Cradle Bearing
3. Slider Block 9. Cradle Guide
4. Servo Piston 10. Cradle
5. Servo Arm 11. Cradle Lever
6. Servo Valve
29-23
Pump Characteristics
The pump characteristics can be found on the pump identification plate.
(CR920, 940 and 960 w/HD 11/111 Final Drives) [w/External Brake Manifold]
90 L 130 KA 5 NN 80 L R F1 F 03 GBZ 42 42 34
90 Series 90, closed circuit

L Left hand (counterclockwise rotation)
130 Maximum displacement 130 cc/rev (7.9 in3/rev), Limited to 110 cc/rev (6.7 in3/rev)
KA Electrical displacement control, MS connector
5 Pressure limiter function in ports A and B
NN No auxiliary mounting pad
80 Twin ports
L Integrated pressure filtering (long)
R Mechanical displacement limitation on both sides (non adjustable)
F1 Splined shaft - 13 teeth - pitch 8/16
F Charge pump displacement 26 cc/rev (1.6 in3/rev)
03 Control orifice dia P=0.81 mm (0.032″) TA/TB =1.3 mm (0.051″)
GBZ External brake manifold installed [pressure reducing valves set at 180 bar (2610 PSI)]
42 420 bar (6090 PSI) high pressure setting port A
42 420 bar (6090 PSI) high pressure setting port B
34 34 bar (493 PSI) charge pressure setting at 1500 rpm [on the machine 38 bar (551 PSI) will be measured
at 2100 rpm]
(CR940 and 960 w/Planetary Final Drives) [w/External Brake Manifold]
90 L130 KA 5 NN 80 L 3 F1 F 03 GBZ 42 42 34

130 Maximum displacement 130 cc/rev (7.9 in3/rev)
KA Electrical displacement control, MS connector
80 Twin ports
3 No mechanical displacement limitation
03 Control orifice dia P=0.81 mm (0.032″)
TA/TB =1.3 mm (0.051″)
GBZ External brake manifold installed [pressure reducing valves set at 180 bar (2610 PSI)]
at 2100 rpm]
29-24
(CR970 and 980) [w/External Brake Manifold]
90 L130 KA 5 NN 80 L 3 F1 F 03 GBL 42 42 34

130 Maximum displacement 130 cc/rev (7.9 in3/rev)
KA Electrical displacement control - standard linear
80 Twin ports
3 No mechanical displacement limitation
03 Control orifice dia P=0.81 mm (0.032″)
TA/TB =1.3 mm (0.051″)
GBL External brake manifold installed [pressure reducing valves set at 280 bar (4060 PSI)]
at 2100 rpm]
29-25
HYDROSTATIC DRIVE MOTOR

Fixed Displacement Motors
The fixed displacement motor is designed to convert
input hydraulic power into output torque, it operates
in reverse to the hydrostatic pump. The high
pressure hydraulic oil enters through the input port,
the oil pressure increases behind the pistons causing
them to rotate down the swash plate (path of least
resistance). As the piston rides up the swash plate
again, the hydraulic oil is allowed to exit through the
outlet port. The spinning pistons are housed in a
cylinder which is connected to the output shaft, the
output torque can be applied to the transmission
input.
5
3 2
DS00N035
23
Hydrostatic Drive Motor, Style 1
1. Swash Plate 4. Cylinder Block

2. Piston 5. Shuttle Spool
3. Flushing Valve
29-26
7 2 4
5
8 6
1
10 3
50050063
24
Hydrostatic Drive Motor Cutaway View, Style 2
1. Input shaft 6. Output shaft

2. Valve plate 7. Loop flushing valve
3. Cylinder block 8. Charge relief valve
4. Piston 9. Pressure release solenoid valve
5. Swash plate 10. Pressure release spool
29-27
Drive Motor Characteristics
The drive motor characteristics can be found on the pump identification plate.
(CR920, 940 and 960 w/HD 11/111 Final Drives)
90 M 100 NC 0 N U N 0 F1 B 00 PAA 0000 H0 Style 1
90 M 100 NC 0 N U N 0 F1 C 00 PAA 0000 H0 Style 2

M Fixed displacement bi-directional rotation
100 Displacement 100 cc/rev (6.1 in3/rev)
NC Standard
0 Standard
N Standard
U Axial ports (SAE J518C code 62) (special end cap with FOI and increased flushing)
N Standard
0 Standard
B/C With special loop flushing valve for increased flushing / dual position loop flushing system
00 Standard
PAA Hardware special feature - longer endcap screw
0000 Standard
H0 Loop flushing orifice diameter 2.4 mm (0.094″), 16 bar (232 PSI) opening pressure
(CR940 and 960 w/Planetary Final Drives; CR970 and 980)
90 M 130 NC 0 N U N 0 F1 H 00 NNN 0000 NH Style 1
90 M 130 NC 0 N U N 0 F1 D 00 LAA 0000 NH Style 2

M Fixed displacement bi-directional rotation
130 Displacement 130 cc/rev (7.9 in3/rev)
NC Standard
0 Standard
N Standard
U Axial ports (SAE J518C code 62) - special end cap with FOI and increased flushing
N Standard
0 Standard
H/D Special loop flushing spool for increased flushing / dual position loop flushing system
00 Standard
NNN/LAA Standard hardware / hardware special feature -- longer end cap screw
0000 Standard
NH Non adjustable orifice valve for loop flushing - special execution
29-28
Chapter 3 - Filling the Hydrostatic System and Start-up Procedure
CONTENTS

29 000 Filling the Hydrostatic System and Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
29-1
FILLING THE HYDROSTATIC SYSTEM AND START-UP PROCEDURE

To fill and start-up the hydrostatic system after repair
or replacement of hydrostatic components, proceed
as follows:
NOTE: Before installing a new motor or a new pump,

shipment oil should be drained from the new pump or
motor case.
IMPORTANT: Oil quality and cleanliness is of utmost

importance for the reliability and life of the hydrostatic
system. Deviation of the described oil specification
may lead to severe damage and void the warranty!
1. Put suitable wheel chocks in front and behind the

front wheels to prevent the machine from
moving. For machines not equipped with
powered rear axles also put blocks in front and
behind the rear wheels.
For machines equipped with a powered rear
axle, the rear axle must be jacked up and placed
on suitable jack stands so that the rear tires do
not touch the ground. Turn the powered rear axle
off using the switch in the cab.
WARNING
Ensure the powered rear axle is securely
suspended off the ground and is turned off to
prevent unexpected movement of the combine.
2. Remove the transmission drive shaft couplings,

1, Figures 1 and 4. Make sure the couplings are
secured to the drive shafts.
CAUTION
Before disconnecting the drive shafts, secure
the machine safely in place by placing adequate
wheel chocks against the front and rear of both
traction and steering wheels. 1
3. Fill the hydrostatic system with oil through the oil

reservoir, 1. Use oil with the following specifica-
tion: 1
All Markets Except North America
Ambra hydrosystem 46HV (ref. NH 646H),
Ambra hydrosystem 46 B10-S (ref. NH 646BS),
Ambra hydrosystem 46 B10-V (ref. NH 646BV)
North America Only

M2C134-D or an oil meeting the following
specification:
DIN 51524 or ISO VG 46. BSC1264
The reservoir should hold approximately 50 liters 2

(13 US gals.).
29-2
4. Loosen the suction line, 3, at the pump until oil
leaks out. Tighten the suction line, 3.
3
5. Loosen the hydrostatic motor drain plug, 2.
4
6. Disconnect hose between the hydrostatic pump
and the oil cooler bypass valve at the pump, L2,
port. Fill the pump with oil through port, L2, until
oil leaks out of the hydrostatic motor.
7. Tighten the hydrostatic motor drain plug, 2,
Figure 4, to a torque of 34 N⋅m (25 ft.-lbs.) and
continue to fill up the pump to obtain maximum oil
level in the pump case.
8. Connect and tighten hose from the oil cooler
bypass valve to the hydrostatic pump at port L2.
29-3
CR920
9. Disconnect the fuel stop solenoid electrical
connector, 4, at the engine fuel injector pump to
prevent the engine from running during cranking.
6
CR940, 960, 970 and 980
10. Remove fuse F-01, 1, from the fuse panel to 1
prevent the engine from running during cranking.
50020070
7
11. Install pressure gauges (range 0 - 600 bar) (0 -
9000 PSI) to the hydrostatic pump test ports M1,
Figure 8, and M2, Figure 9.
12. Shift the transmission into neutral and crank the M1
engine with the starter motor until a pressure
gauge reading of 2.0 bar (29 PSI) is obtained.
NOTE: Only crank the engine for a maximum of 30
seconds at a time. Wait at least 1 minute before
recranking to avoid damaging the starter motor.
13. Fill the reservoir to the maximum level. Connect

the fuel stop solenoid connector, 4, Figure 6
(CR920 only), or reinstall fuse F-01, 1, Figure 7
(CR940, 960, 970, 980). Start and run the engine 8
at low idle until a minimum pressure gauge
reading of 20 bar (290 PSI) is obtained.
CAUTION
Make sure all people are clear and remain clear of
the machine before starting the engine.
29-4
CAUTION
Never operate the engine in a closed building.
Proper ventilation is required under all circum-
stances. M2
14. Shift the transmission into 4th gear and hold the
brake pedals down.
15. Move the hydrostatic lever slightly forward until
the forward (M1), Figure 8, pressure gauge
reading is a minimum of 30 bar (435 PSI) and a
maximum of 300 bar (4350 PSI). Do this for
approximately 1 minute.
16. Move the hydrostatic lever slightly rearward until 9
the reverse (M2), Figure 9, pressure gauge
reading is a minimum of 30 bar (435 PSI) and a
maximum of 300 bar (4350 PSI). Do this for
approximately 1 minute.
17. Shut off the combine. Check the oil level, add oil
if necessary. Check for oil leaks.
18. Restart the combine engine. Gearshift to neutral
and engine speed on low idle. Position the
hydrostatic lever at half stroke for one minute,
both forward and reverse.
19. Gearshift remains in neutral and engine speed
on high idle. Position the hydrostatic lever at
maximum stroke for two minutes, both forward
and reverse.
20. Gearshift to 4th gear and engine speed on high
idle. Apply both brake pedals firmly. Apply
maximum stroke on the control lever in forward
position for a maximum of 10 seconds. Pressure
should be 420 to 460 bar (6092 - 6672 PSI).
Repeat the procedure for reverse.
21. Switch off the engine. Check the oil level, add oil
if necessary. Check for oil leaks.
22. For machines equipped with powered rear axles
continue to remove the air from the system. Refer
to Section 41 Chapter 5 “Start-up Procedure for
Powered Rear Axle”.
For machines not equipped with powered rear axles,
install the transmission drive shafts and tighten the
retaining bolts.
29-5
29-6
Chapter 4 - Powered Rear Axle
CONTENTS

Powered Rear Axle -- Style I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Equa-Trac II® Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Low Pressure Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Forward and Reverse Flow Divider Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Forward and Reverse Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Equa-Trac II® Valve Operation – “OFF” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Equa-Trac II® Valve Operation – “INTERMEDIATE” Position . . . . . . . . . . . . . . . . . 13
Equa-Trac II® Valve Operation – “ON” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Powered Rear Axle Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Wheel Motor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Full Supply Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Bottom Neutral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Discharge Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Top Neutral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Wheel Motor Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Powered Rear Axle Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Powered Rear Axle -- Style II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2WD-4WD Hydraulic System -- Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2WD-4WD Hydraulic System -- Detailed View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Selector Valve -- Dynamic Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Hydraulic Line -- Plumbing Schema PRA Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
29-1

2WD-4WD Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Selector Valve -- Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Two-speed Valve -- Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Two-speed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
29-2
The powered rear axle is available as a factory installed The wheel motors are cam lobe type units with a fixed
or field installed option. This system will provide displacement. The amount of wheel torque obtained
additional traction when the machine is operated in from the wheel motors is directly related to the
tough field conditions. The system can be engaged or hydrostatic system pressure. The higher the system
disengaged electronically by a switch in the operators pressure the greater the wheel torque will be.
cab.
NOTE: It is not necessary to synchronize the front
Both rear wheels are driven by hydraulic motors and wheels (transmission mounted pump driven) with the
the system receives its oil supply directly from the rear wheels (wheel motor driven) as the system
hydrostatic pump. pressure and hydraulic fluid flow hydraulic will do this
automatically.
The high pressure lines from the hydrostatic pump
supply the wheel motors through a selector valve It is very important to maintain traction to the front
mounted near the rear axle. wheels. If a front wheel loses traction and begins to
slip, the system pressure will decrease. The spinning
There are two styles of powered rear axle system: wheel requires less pressure to rotate. The oil in the
pressure lines will take the least path of resistance,
Style I – Used on combines before serial number
therefore the amount of power assistance from the
HAJ100102.
rear wheels will be reduced because of the lower
Style II – Used on combines after serial number pressure. Shifting to a higher gear (if possible) will
HAJ100102. This style uses a newer model selector reduce the amount of torque at the front wheels to
valve and wheel motor, offers optional flow stop the wheel slippage. Also, lightly touching the
regulators, and has considerable mechanical brakes will help.
differences. Mechanical layouts are shown in detail
in the section describing each style. NOTE: Troubleshooting and testing of the PRA
system is covered in Section 41, Chapter 5.
The powered rear axle system operates as a function
of the main hydrostatic drive system. A standard
hydrostatic system utilizes one pump and one drive
motor (transmission mounted), whereas the pow-
ered rear axle system utilizes one pump and three
motors (one transmission-mounted and two wheel-
mounted).
29-3
11
10
7
1
3
5
8 9
20015297
Powered Rear Axle System, Style I
1. Equa-Trac II® Control Valve 7. Motor Case Drain Line

2. Right Wheel Motor 8. Drain Valve (part of Equa-Trac II® Valve)
3. Left Wheel Motor 9. Case Drain to Cooling Circuit Line
4. Forward High Pressure Inlet Line 10. Hydraulic Fluid Reservoir
5. Reverse High Pressure Inlet Line 11. Hydrostatic Pump
6. Return to Tank (Reservoir) Line
29-4
POWERED REAR AXLE -- STYLE I

EQUA-TRAC II® CONTROL VALVE
The Equa-Trac II® control valve block assembly is The lower tier contains the low pressure shuttle
mounted near the rear axle and is a two tier valve. A valve, solenoid valve, forward flow divider, forward
drain valve is mounted below the Equa-Trac II® valve check valve and forward drive pressure outlet ports.
and is considered part of the Equa-Trac II® valve.
The low pressure shuttle valve, solenoid valve and
The upper tier contains the forward and reverse inlet selector spool supply and control the oil supply to
pressure ports, selector spool valve, reverse flow both upper and lower tier valves of the assembly, as
divider, reverse check valve and reverse drive well as supply and control oil flow to the drain valve.
pressure outlet ports.
9 8
12 1
13 6
14
17 4
5
10
11
18 15
2 16
3 19
20016111
Equa-Trac II® Control Valve Assembly
1. Equa-Trac II® Valve Block 11. Reverse System Pressure Test Port
2. Drain Valve Block (part of Equa-Trac II® valve) 12. Pilot Pressure to Disengage Port
3. Solenoid Valve 13. Forward System Pressure Port
4. Forward Pressure Inlet 14. Valve Selector Spool Location
5. Reverse Pressure Inlet 15. Drain Valve Selector Spool Location
6. Left Wheel Motor Reverse Pressure Port 16. Left Wheel Motor Drain Port
7. Left Wheel Motor Forward Pressure Port 17. Right Wheel Motor Drain Port
8. Right Wheel Motor Reverse Pressure Port 18. Inlet Drain Port from Reverse Pressure Port
9. Right Wheel Motor Forward Pressure Port 19. Valve Drain Port to Hydraulic Fluid Tank
10. Pilot Pressure to Engage Port
29-5
10 11 12 11 10
13 13
8 9
7
6
5
14
4
1
F 2 R
DS00M074
Cross Section of Equa-Trac II® Control Valve Upper Tier
1. Solenoid Valve Passage 9. Spring

2. Selector Spool 10. Check Valve Ball Seat
3. Spring 11. Check Valve Ball
4. Case Drain Orifice 12. Check Valve Spring
5. Pilot Pressure to Engage Port 13. Reverse Outlet Pressure Ports
6. Lower Tier Supply Passage 14. Pilot Pressure to Disengage Port
7. Flow Dividers F. Forward Inlet Pressure Port
8. Spring R. Reverse Pressure Port
29-6
Drain Valve
NOTE: References to directions are as if viewing the
valve from the rear, facing the front of the combine.
The drain valve, 1, which is considered part of the

Equa-Trac II® valve, helps to drain the hydraulic fluid
that is pushed from the wheel motor pistons when the
powered rear axle is switched off. The drain valve also
contains a galley that allows the left and right wheel
motor case drain lines to be connected together to a
common line back to the hydrostatic system cooling
circuit. The drain valve is mounted below the main
portion of the Equa-Trac II® valve and is bolted to the
same mounting bracket. Several hydraulic lines 50016117
1
connect the two portions of the valves together.
4
9 1
5 9
4
3
4
8 6
7 2
50016118
5
Exploded View of Equa-Trac II® Drain Valve
1. Drain Valve Body 6. Pressure to Engage Port Fitting

2. Valve Spool 7. Drain Supply Port
3. Spring 8. Return to Tank Port
4. End Plug 9. Motor Case Drain Port
5. Pressure to Disengage Port Fitting
The drain valve is operated by hydraulic fluid under return port to a port on the front of the drain valve.
charge pressure. A spool inside the valve will shift left Hydraulic fluid will then flow past the drain valve
or right, depending upon what side of the spool spool land, and out to the valve case drain
charge pressure is applied to. When the PRA is connection through an external tube. The fluid then
“OFF”, hydraulic fluid from the pressure to disengage is returned to tank.
side of the Equa-Trac II® valve is directed to the right
side of the spool, which moves the spool to the left. When the PRA is “ON”, hydraulic fluid from the
This opens a path for the hydraulic fluid draining from pressure to engage side of the Equa-Trac II® valve
the wheel motors to the hydraulic fluid reservoir is directed to the left side of the drain valve spool,
(tank). Hydraulic fluid will flow through an external which moves the spool to the right. This closes the
line, from the “tee” at the reverse pressure supply/ path for hydraulic fluid to return to tank.
29-7
Low Pressure Shuttle Valve pressure on the forward side will seat the check ball,
The low pressure shuttle valve provides hydraulic 3, which will move the spacer, 2, to unseat the
fluid under charge (pilot) pressure to the solenoid opposite check ball, on the forward side will seat the
valve to engage or disengage the PRA system. The forward check ball, 3, which will move the spacer, 2,
solenoid valve, in turn, supplies hydraulic fluid under to unseat the reverse check ball, 4, on the reverse
charge pressure to either end of the selector spool to side of the valve. The pressure will flow past the
move the spool. Depending upon what direction the check ball, 4, and spacer, 2, through the passage, 5,
spool moves, hydraulic fluid to the wheel motors will to the solenoid valve, 1.
be switched “ON” or “OFF”. This fluid also controls
the spool in the drain valve, opening (disengaged) or When the combine is in reverse, the reverse side “R”
closing (engaged) a path for hydraulic fluid to flow receives the high pressure flow and the forward “F”
back to the hydraulic fluid reservoir. The charge side becomes low pressure (charge pressure). The
pressure is available from the return side of the PRA reverse check ball, 4, will seat, and will move the
hydrostatic system. spacer, 2, unseating the forward check ball, 3. This
allows hydraulic fluid under charge pressure to flow
The spacer, 2, always holds one of the check balls, past the check ball, 3, and spacer, 2, into the
3, 4, off the seat in the valve cavity. This ensures passage, 5, to the solenoid valve.
charge pressure is always available, even if the
combine’s main hydrostatic system is in neutral. The solenoid valve determines which side of the
When the combine is driven forward, the forward side selector spool charge pressure is directed to,
“F” receives high pressure flow and the reverse side depending upon whether or not current is being
“R” is low pressure (charge pressure). The high supplied to the solenoid.
4
3
F R
1 5
DS00M058
6
1. Solenoid Valve Location 4. Reverse Check Ball
2. Spacer 5. Oil Passage
3. Forward Check Ball
29-8
Forward and Reverse Flow Divider Valves fluid flow to the slipping wheel at the same time
There are two flow divider valve assemblies in the maintaining the pressure on the non-slipping wheel.
Equa-Trac II® valve block, one for the forward drive
and one for the reverse drive. Each flow divider valve When the drive pressure equalizes in both wheel
assembly is a split spool valve and contains two motor drive lines, the flow divider will move back to
separate flow dividers. the center position.
If traction is lost to one rear wheel (wheel slip), the The flow divider also limits the maximum hydraulic
drive pressure to that wheel will have the least fluid flow to each wheel motor. If both wheel motors
resistance and the pressure will fall, making the should begin to spin, the split flow dividers will
wheel spin faster. separate due to the pressure acting on the 10.3 mm
(0.406″) orifice, 4, in each half of the spool. As the
To compensate for this the higher pressure on the spools move apart the pressure to each drive motor
non-slipping wheel side of the flow divider will move will be limited to approximately 77.2 lpm (20.4 gpm).
the flow divider valve assembly towards the lower The rear wheel drive system is therefore limited to a
pressure (slipping wheel) side, limiting the hydraulic total of 154.4 lpm (40.8 gpm).
4
2 2
1 1
3 3
DS00M069
7
1. End Cap 3. Flow Divider Valve (2 per valve)
2. Spring (2 per valve) 4. 0.406″ Orifice
29-9
Forward and Reverse Check Valves motors from flowing back through the check valve
There are two check valve assemblies in the seats and flow divider orifice(s). This hydraulic fluid
Equa-Trac II® valve block, one for the forward drive flow would create a large pressure drop. The return
and one for the reverse drive. Each check valve hydraulic fluid pressure from the wheel motors will
assembly contains two check ball seats, two check move the check balls off their seats allowing some oil
balls and one spring. to flow through the check valve and through the
center passage. The remaining oil will flow into each
The check valves prevent the full amount of return end of the flow divider, past the selector spool to the
hydraulic fluid (at charge pressure) from the wheel return side of the hydrostatic pump.
2 3 2
1 1
DS00M070
8
1. Check Valve Seat (2 per valve) 3. Spring (1 per valve)
2. Check Valve Ball (2 per valve)
29-10
Equa-Trac II® Valve Operation – “OFF” Position
(Reference Figures 9 and 10)

1
When the PRA switch in the combine cab is in the

“OFF” position, current is no longer supplied to the
solenoid valve, 1, Figure 9. This causes the spring
loaded spool in the solenoid to move away from the
solenoid coil. When this happens, hydraulic fluid flow
from the low pressure spool will be closed off from port
A to port B (which flows to the pressure to engage side
of the selector spool, 2, Figure 10, in the “ON” position)
and allow fluid to flow from port A to port C, Figure 9
(pressure to disengage side of the selector spool). B
The return spring, 3, Figure 10, and charge pressure A

directed from the low pressure spool, through port C
of the solenoid valve, and through the drilled passage, C
14, Figure 10, will move and keep the spool, 2,
Figure 10, to the left side of the spool bore. This is the
disengaged position for the spool and the forward and
reverse high pressure ports are closed off.
The rear wheels of the combine will now “free wheel”.

As the wheels rotate, the wheel motor pistons are
pushed back into their bores. The hydraulic fluid
behind the pistons is directed back to the wheel DS00M060
D
motor supply/return ports, 12, 13, Figure 10, of the
Equa-Trac II® valve. From there, the fluid from the 9
right wheel motor flows through the flow dividers, 7, A. Oil Supply from Low Pressure Spool
and the right check valve, 8, and center passage, 9. B. From Left Side of Selector Spool Via External Line
Hydraulic fluid then flows to the left side wheel motor C. To Right Side of Selector Spool
reverse supply/return port, 12, and to the selector D. To Case Drain
spool, 2. Hydraulic fluid that exits the valve at the
reverse supply/return port, 12, and from the left
wheel motor is directed to the drain valve by a “tee”
connection at the reverse supply/return port, 12,
Hydraulic fluid flows from the “tee” to the drain valve
through an external tube. A drilled passage, 15, in the
selector spool allows hydraulic fluid that does not
flow out of the valve through the reverse
supply/return port, 12, to flow through the spool, 2,
through the case drain orifice, 4, and out of the valve
at the pressure to engage port, 5. From there, fluid is
directed back to the solenoid valve via external tube
where the fluid drains back to tank.
When the PRA is off, charge pressure that is directed

from the solenoid valve to the selector spool is also
directed to the drain valve out of the pressure to
disengage port, 11, through an external tube. This
pressure shifts the spool in the drain valve that allows
hydraulic fluid from the wheel motors (from the “tee”
at the reverse supply/return port, 12) to flow through
the drain valve and out. From the drain valve,
hydraulic fluid is directed back to tank through an
external tube that connects to the valve drain.
29-11
REAR
10 8 10
13 12
7
6
11 5
4
14
50016593
F 2 15 R
10
Cross Section of Equa-Trac II® Control Valve - Off Position
29-12
Equa-Trac II® Valve Operation –
“INTERMEDIATE” Position
(Reference Figures 11, 12, and 13)
1
When the rear wheel drive is switched “ON”, the

system will momentarily go into an “INTERMEDI-
ATE” position. The “INTERMEDIATE” position allows
hydraulic fluid under charge pressure to fill the
system and wheel motors before full drive pressure
is achieved. This reduces the shock load exerted on
the pistons and motor housing.
B
When the PRA switch in the combine cab is turned
to the “ON” position, current is supplied to the
solenoid valve, 1, Figure 11. This energizes the coil A
and causes the spring loaded spool to move towards
the coil. Hydraulic fluid under charge pressure will C
flow through the solenoid valve from port A to port B
and to the pressure to engage (left) side, 5, of the
selector spool, 2, Figure 12, in the Equa-Trac II®
valve through an external tube.
As the selector spool, 2, Figure 12, moves left,

against the pressure of the spring, 3, and will
momentarily allow hydraulic fluid under charge
pressure to enter both forward and reverse flow DS00M060
D
dividers, 7, Figure 12, and 17, Figure 13, through the
feathering lands, 16, Figure 12, on the selector 11
spool. Hydraulic fluid flowing through the upper, 9, A. Oil Supply from Low Pressure Spool
Figure 12, and lower, 6, Figure 12, center channels B. From Right Hand Side of Selector Spool Via
will keep the check valves, 8, Figure 12 and 20, External Line
Figure 13, closed. The hydraulic fluid will then flow C. From Right Side of Selector Spool
through the forward, 18, 19, Figure 13, and reverse, D. To Case Drain
12, 13, Figure 12, pressure supply/return ports to the
wheel motors.
The hydraulic fluid on the pressure to disengage

(right) side of the selector spool, 2, Figure 12, will
flow through the drilled passage, 14, Figure 12, to
port C of the solenoid valve, 1, Figure 11. The
hydraulic fluid will flow through the valve and exit at
port D and out of the Equa-Trac II® valve through the
case drain. The hydraulic fluid then returns to tank.
When hydraulic fluid under charge pressure flows

into the pressure to engage port on the Equa-Trac II®
valve, a “tee” fitting at the port allows hydraulic fluid
to flow to the drain valve as well. The charge pressure
shifts the spool in the drain valve so hydraulic fluid
from the wheel motors is no longer allowed to drain
back to tank through the drain valve.
29-13
13 13
12
7
6
11 5
14 4
F R
16 2 15 16
50016594
12
Cross Section of Equa-Trac II® Control Valve Upper Tier - “INTERMEDIATE” Position
20
18 19
6 17
DS00M068
13
Cross Section of Equa-Trac II® Control Valve Lower Tier - “INTERMEDIATE” Position
29-14
Equa-Trac II® Valve Operation – “ON” Position When high pressure hydraulic fluid is supplied to the
(Reference Figures 14, 15, and 16) forward pressure port, “F”, Figure 15, the selector
spool allows the hydraulic fluid to flow past the spool
NOTE: References to directions are as if viewing the land, 21, Figure 15, through the center passage, 6,
valve from the rear, facing the front of the combine. Figure 15, on lower tier of the valve, to the flow
dividers, 17, Figure 15. Hydraulic fluid also flows to
When the powered rear axle is switched “ON”, the the forward check valves, 10, Figure 15, keeping the
system will momentarily go into an “INTERMEDI- valves closed. This assures hydraulic flow is directed
ATE” position to fill the wheel motors with hydraulic out of the valve to the wheel motors. From the flow
fluid. When the system is full, the selector spool will dividers high pressure fluid is directed out of the
move completely to the to the right in the Equa-Trac forward pressure supply/return ports, 18, 19,
II® valve, to the “ON” position, allowing the wheel Figure 15, to the wheel motors. The high pressure oil
motors to be driven. will drive the motors forward. If the flow of drive oil
should differ from one motor to the other (loss of
When the PRA switch in the combine cab is turned traction to one wheel), the flow dividers, 17,
to the “ON” position, current is supplied to the Figure 15 will compensate for the differential by
solenoid valve, 1, Figure 14. This energizes the coil shifting in the Equa-Trac II® valve. Refer to the flow
and causes the spring loaded spool to move towards divider description of operation described previously
the coil. Hydraulic fluid under charge pressure will in this chapter.
flow through the solenoid valve from port A to port B
and to the pressure to engage (left) side, 5, of the Return hydraulic fluid from the wheel motors will flow
selector spool, 2, Figure 15, in the Equa-Trac II® into the reverse pressure supply/return ports, 12, 13,
valve through an external tube. The hydraulic fluid Figure 16. The fluid is then directed to the flow
shifts the selector spool to the right and once the dividers, 7, and reverse check valves, 8, Figure 16.
system is full of hydraulic fluid, the spool will shift fully The check valves will open when hydraulic flow
to the right against the spring, 3. exceeds the amount of fluid allowed to flow through
the 10.3 mm (0.406 in.) orifice in each flow divider.
Forward The hydraulic fluid will flow through the center
passage, 9, Figure 16 past the selector spool land,
NOTE: The selector spool controls whether or not 22, Figure 15, and out of the reverse high pressure
hydraulic fluid flows to the wheel motors, but does not port, “R”, Figure 15.
control forward or reverse movement in the wheel
motors.
29-15
hydraulic fluid will flow through the valve and exit at 1
port D and out of the Equa-Trac II® valve through the
case drain. The hydraulic fluid then returns to tank.
When hydraulic fluid under charge pressure flows

into the pressure to engage port, 5, Figure 15 on the
Equa-Trac II® valve, a “tee” fitting at the port allows
hydraulic fluid to flow to the drain valve. The charge
pressure shifts the spool in the drain valve so
hydraulic fluid from the wheel motors is no longer
allowed to drain back to tank through the drain valve.
B
DS00M060
D
14
A. Oil Supply from Low Pressure Spool
B. To Left Side of Selector Spool Via External Line
C. From Right Side of Selector Spool
D. To Case Drain
29-16
10
18 19
17
6
11 5
14 4
F R
21 2 22
50016595
15
Cross Section of Equa-Trac II® Control Valve Forward Lower Tier Valves and
Upper Tier Selector Spool- On - Forward Position
13 12
7
DS00M064
16
Cross Section of Equa-Trac II® Control Valve (Reverse Valves Upper Tier) - On - Forward Position
29-17
Reverse Return hydraulic fluid from the wheel motors will flow
(Reference Figures 14, 17, and 18) into the forward pressure supply/return ports, 18, 19,
Figure 18. The fluid is then directed to the flow
NOTE: References to directions are as if viewing the dividers, 17, and forward check valves, 10,
valve from the rear, facing the front of the combine. Figure 18. The check valves will open when
hydraulic flow exceeds the amount of fluid allowed to
flow through the 10.3 mm (0.406 in.) orifice in each
NOTE: The selector spool controls whether or not
flow divider. The hydraulic fluid will flow through the
hydraulic fluid flows to the wheel motors, but does not
center passage, 6, Figure 18 past the selector spool
control forward or reverse movement in the wheel
land, 21, Figure 17, and out of the forward high
motors
pressure port, “F”, Figure 17.
When high pressure hydraulic fluid is supplied to the
reverse pressure port, “R”, Figure 17, the selector
spool, 2, Figure 17, allows the hydraulic fluid to flow
past the spool land, 22, Figure 17, through the center
passage, 9, Figure 17, on lower tier of the valve, to
hydraulic fluid will flow through the valve and exit at
the flow dividers, 7, Figure 17. Hydraulic fluid also
port D, Figure 14, and out of the Equa-Trac II® valve
flows to the reverse check valves, 8, Figure 17,
through the case drain. The hydraulic fluid then
keeping the valves closed. This assures hydraulic
returns to tank.
flow is directed out of the valve to the wheel motors.
From the flow dividers high pressure fluid is directed When hydraulic fluid under charge pressure flows
out of the forward pressure supply/return ports, 12, into the pressure to engage port, 5, Figure 17, on the
13, Figure 17, to the wheel motors. The high Equa-Trac II® valve, a “tee” fitting at the port allows
pressure oil will drive the motors in reverse. If the flow hydraulic fluid to flow to the drain valve. The charge
of drive oil should differ from one motor to the other pressure shifts the spool in the drain valve so
(loss of traction to one wheel), the flow dividers, 7, hydraulic fluid from the wheel motors is no longer
Figure 17 will compensate for the differential by allowed to drain back to tank through the drain valve.
shifting in the Equa-Trac II® valve. Refer to the flow
divider description of operation described previously
in this chapter.
29-18
13 12
7
6
11 5
14 4
F R
21 2 22
50016596
17
Cross Section of Equa-Trac II® Control Valve(Upper Tier Valves) - “ON”-“REVERSE” Position
10
18 19
6 7
DS00M064
18
Cross Section of Equa-Trac II® Control Valve (Forward Valves Lower Tier) - “ON”-“REVERSE” Position
29-19
POWERED REAR AXLE MOTORS

Wheel Motor Operation The hydraulic fluid passage, 2, and port, 4, are
To start the drive cycle, hydraulic fluid under high partially aligned allowing oil to begin entering the
pressure is delivered from the hydrostatic pump cavity behind the piston, 6. The high pressure
through the Equa-Trac II® valve and supplied equally pushes the piston outwards causing roller to make
to the high pressure port, 1, of each motor. The contact with cam, 7, just after the peak (highest point)
hydraulic fluid is diverted through passage, 2, in the of the lobe. This contact causes the cylinder block, 5,
distributor block, 3, and port, 4, in the cylinder block, 5. to start rotating.
1
7
2 4
20013707
19
29-20
Full Supply Position -
As a piston (and roller), 1, moves towards the bottom
(valley), 2, of two cam lobes, the MAXIMUM (full)
supply of hydraulic fluid momentarily is directed
through the aligned ports, 3, of distributor, 4,
(remaining stationary) and cylinder block, 5,
(rotating) with continuation on to the piston, 1. The
hydraulic fluid supply then begins to taper off as the
piston approaches the bottom of two cam lobes, 2,
towards a neutral (no power drive) position.
20
Bottom Neutral Position
When a piston, 1, is in a valley, 2, between cam lobes,
the hydraulic fluid supply is cut off. Ports, 3, in the
distributor, 4, and cylinder block, 5, are NOT aligned
with each other. In this neutral position the piston
does NOT provide drive power to the cylinder block
however, the piston (and roller) remain in contact
with the cam surface.
In order to continue driving power, another piston

must take over for the first one to drive the cylinder
block in the direction shown, enabling the first piston
to climb the next cam lobe in a smooth and
uninterrupted manner.
21
Discharge Position
As the piston, 1, starts to climb the next cam lobe, 2,
passages, 3, in the distributor, 4, and cylinder block,
5, begin to align with each other, thus starting the
discharge cycle. This allows the hydraulic fluid
(under charge pressure) to return to the pump as
another piston takes over the drive cycle.
22
29-21
Top Neutral Position
During the final cycle of the piston, 1, the piston
continues to climb another cam lobe, 2. As this
happens, ports, 3, in the distributor block, 4, and
cylinder block, 5, progressively close off the return oil
flow as the piston (and roller) reaches the top neutral
position.
When the roller is at the top of the cam lobe the ports
are no longer aligned, thus ending a full drive cycle.
The piston and its roller will then repeat the cycle
starting with a gradual supply of high pressure oil,
while other pistons continue their cycles in a similar
manner.
23
29-22
Wheel Motor Power Distribution
SYSTEM ENGAGED
Since each wheel motor contains 20 pistons and

eight cam lobes, there are a total of 160 power
strokes by the pistons in one revolution of the cylinder
block, which is splined to the wheel shaft. Each piston
(and roller) travels up and down each of the eight cam
lobes in a smooth, uninterrupted manner, producing
a constant torque output with a low noise level. With
an even number of pistons and cam lobes, the forces
of the motor are balanced allowing the motor
bearings to be totally available to accept high radial
and axial loads. 24
To change the direction of rotation of the motor, the

input supply of high pressure oil is directed through
the (reverse) high pressure port and diverted through
the distributor of the motor in a manner opposite to
that of the forward rotation of the motor.
SYSTEM DISENGAGED
When the drive system is shut off or disengaged, the

Equa-Trac II® valve prevents high pressure oil from
being supplied to the wheel motors.
In addition, the system pressure supply lines from the

valve to the motors are opened directly to the
reservoir through the drain valve so that any
pressure in these lines is dissipated.
The lack of pressure on either side of the pistons

enables the pistons (and rollers) to retract into their
cylinder bores when the rollers are pushed inward by
the cam lobes as the cylinder block rotates. With the 25
rollers clear of the cam lobes, the cylinder block and
wheel shaft are able to rotate in a “free-wheeling”
(non-drive) mode.
29-23
POWERED REAR AXLE HYDRAULIC SCHEMATIC
26
1. Equa-Trac II® Valve Assembly 2. Wheel Motor
1a. Low Pressure Shuttle Valve 3. Wheel Motor
1b. Solenoid Valve 4. Drain Valve
1c. Selector Spool
1d. Flow Divider Valve A. To Reservoir
1e. Flow Divider Valve B. Forward High Pressure From Pump A3 Port
1f. Check Valve C. Reverse High pressure From Pump B3 Port
1g. Check Valve
29-24
POWERED REAR AXLE -- STYLE II

SPECIFICATIONS
56061400
1
Selector Valve Identification
1. Serial Number
2. Build Date
Each selector valve has a Serial Number and a build

date stamped in the side of the valve body.
SELECTOR VALVE
Description Specification
Valve Type 4 way, 2-position
1 spool, Pilot operated
Flow Rate 238 L/min (63 US gpm)
Maximum Operating Pressure 450 bar (6500 psi)
Cartridge Valve 3-way, 2-position
12 volts DC solenoid
29-25
1 2
53061401
2
Flow Regulator Identification
1. Flow Rate (gpm)
2. Direction of regulated flow
Each Flow Regulator shows the direction of

regulated flow and has a flow rate (gpm) stamped in
the outer housing. (Text on regulator may be different
than shown.)
FLOW REGULATOR (OPTIONAL)
Description Specifications
Valve Type Pressure compensated flow control, free flow return
Flow Rate 57 -- 152 L/min (15 -- 40 US gpm)
Maximum Operating Pressure 450 bar (6500 psi)
29-26
2WD-4WD HYDRAULIC SYSTEM -- OVERVIEW
3
4
66060571
3
Hydrostatic System with Powered Rear Axle -- Schematic
1. Hydrostatic Pump (mounted at PTO gearbox)

2. Hydrostatic Motor (mounted at ground drive transmission)
3. Powered Rear Axle Selector Valve (mounted in front of rear axle)
4. Powered Rear Axle Wheel Motors
The optional powered rear axle provides additional of oil flow to the powered rear axle will vary based on
tractive effort when operating in muddy or hilly fields. the path of least resistance; as the load against the
The powered rear axle is connected in parallel with hydrostatic motor, 2, increases as compared to the
the hydrostatic system on the combine, and receives rear axle wheel motors, oil will be diverted to the
oil flow to the wheel motors from the hydrostatic powered rear axle wheel motors to provide additional
pump, 1. When the powered rear axle is engaged, tractive effort. In severe muddy or hilly conditions
some of the hydrostatic system oil flow will be where rear axle slippage occurs, optional flow
diverted through the powered rear axle selector regulators may need to be installed to limit the
valve, 3, to power the wheel motors, 4. The amount amount of oil flow to the wheel motors.
29-27
The forward and reverse high pressure lines for the
powered rear axle connect across the main drive 1
lines of the hydrostatic pump. Each line is paralleled
across its corresponding main drive line at adapter
block, 1.
NOTE: The hydrostatic pump shown is the newer

model with integrated brake function (IBF). This
model does not require a brake block and is used on
1
combines serial number HAJ 100800 and above.
For combines below HAJ 100800, but HAJ 100102
and above, the PRA lines are connected to the brake
block as in PRA Style I. 86060572
4
Case drain for the selector valve is returned directly
to the hydraulic fluid reservoir at 1. Case drain for the 1
PRA motors, 2, passes through the hydraulic cooling
circuit before returning to the reservoir.
86060573
5
29-28
9
10
2
8
4 5 1
6
3
66060570
6
Powered Rear Axle System, Style II
1. Selector Valve 6. Return to Tank (Reservoir) Line

2. Right Wheel Motor 7. Motor Case Drain Line
3. Left Wheel Motor 8. Case Drain to Cooling Circuit Line
4. Forward High Pressure Inlet Line 9. Hydraulic Fluid Reservoir
5. Reverse High Pressure Inlet Line 10. Hydrostatic Pump
NOTE: Motor shown is Integrated Brake Function (IBF) type, requiring no brake block. Used in SN HAJ 10080
and above.
29-29
2WD-4WD HYDRAULIC SYSTEM -- DETAILED VIEW
4
5
6
3
A
B
C
D
E 1 2
56061422
7
Component Identification
1. Two speed valve A. High Pressure

2. Single speed valve B. Charge Pressure
3. Valve location on wheel hub C. Pilot Pressure (From two speed or single
4. Wheel motor top pin (hose connections) speedvalve)
5. Two speed spool D. Case Drain
6. Wheel motor pistons E. Grease cavities
Oil flow enters the wheel motors through the hose On axles equipped with a two speed valve, 1, a
connections in the top pin, 4, of the wheel motors, solenoid valve is used to either allow the oil to drain
and travels across the two speed spool, 5, to the from the spring end of the two speed spool, 5, or pilot
wheel motor pistons, 6. On single speed axles, the pressure oil from the cartridge valve is directed to
valve, 2, allows oil to drain from the spring end of the shift the two speed spool inwards against the spring
two speed spool, 5, allowing the spring to keep the to engage the “Full Speed -- Half Torque” operating
spool positioned in the “Full Torque -- Half Speed” mode.
position. Case drain oil from the wheel motor also
flows through the valve and out the wheel motor top
pin.
29-30
Forward Full Torque - Half Speed (All Axles)
3
4
A
B
C
D
E
1 2
56061423
8
Forward Full Torque (Half Speed)
A. High Pressure D. Case Drain

B. Charge Pressure E. Grease Cavities
C. Pilot Pressure
Oil flow from the forward high pressure lines passes wheel motor at a time. Because the forward high
through the wheel motor top pin, 3, and flows to the pressure oil is acting on so many pistons, the wheels
two speed spool, 4. The spring end of the spool is turn slowly but with high torque capabilities.
open to case drain through the single speed, 2, or two
speed, 1, valve, so the spring positions the two speed In this operating mode, the two speed valve, 1,
valve to allow oil flow to half of the pistons in the solenoid is not energized.
29-31
Forward Full Speed - Half Torque (Two Speed Axle Only)
A
B 2
C
D
E
56061424
9
Forward Full Speed (Half Torque)

C. Pilot Pressure
Charge pressure oil (or high pressure oil, depending one quarter of the pistons are supplied with oil from
on direction of travel) is supplied from the reverse the forward high pressure circuit. Because the
high pressure side of the circuit to port (P) of the two forward high pressure oil is acting on fewer pistons,
speed valve. The cartridge valve, 2, acts as a the wheels turn quickly but with lower torque
regulator valve to reduce the pressure to a lower capabilities. This can be useful for severe muddy or
level for use as pilot pressure oil. hilly field conditions where powered rear wheel
slippage is a problem by reducing the drive torque at
When the two speed valve solenoid, 1, is energized, the wheel motors.
pilot pressure supplied from the cartridge valve, 2,
flows through the solenoid valve to the spring end of The wheel motor pistons that are not supplied with oil
the two speed spool, 3, causing it to be shifted simply pump the oil trapped in them back and forth
inwards against the spring. This blocks off one of the between themselves.
supply galleries to the wheel motor pistons, so only
29-32
Powered Rear Axle OFF (Free Wheeling Mode)
A
B
C
D
E
1 2
56061427
10
Powered Rear Axle OFF (Free Wheeling Mode)

C. Pilot Pressure
The high pressure lines, 4, of the wheel motors are Because of the slight [approximately 1.5 bar (22 psi)]
connected directly to the hydraulic fluid reservoir pressure differential between the two case drain
through the case drain line on the powered rear axle pressures, the pistons of the motor are pushed into
selector valve (not part of the steerable motor). The the cylinder block to avoid hard contact between the
wheel motor case drain, 3, however, is connected to piston rollers and the motor cam ring due to
the oil cooling circuit line in order to circulate the centrifugal force while driving.
wheel motor case drain oil through the oil cooler.
29-33
Cam Lobe Motor Operation
20042895
11
Operation and Tests
1. Power Stroke 7. Piston

2. Transition to Return 8. Manifold
3. Return Stroke 9. Pressure Oil
4. Transition to Power 10. Oil in Transition
5. Cam 11. Return Oil
6. Carrier
Pressure oil, 9, is routed through the inner cover to motor. This gives a force balance on the carrier and
the manifold, 8. Each of the 16 passages in the axle assembly. With motor engaged, one group of
manifold is timed to one ramp on the cam, 5. pistons, 1, is in power stroke. As the piston follower
is forced down the cam ramp, the carrier is forced to
The oil manifold is pressed against the piston carrier, turn. Group, 3, pistons push return oil, 11, back
6, with only a thin film of oil separating the manifold through the manifold. Pressure, 10, indicates oil in
and the carrier surfaces. The piston carrier is splined transition from one port to another. As carrier turns,
to the axle. Pressure oil is fed from the pressure pistons, 4, at the top of the lobes begin their power
passages in the manifold through passages in the stroke and the pistons, 2, at the bottom begin their
carrier and into the piston bores. return stroke.
Return oil, 11, is routed from piston bores, through As one group ends its power stroke another group
the carrier passages and into the manifold return has begun. This overlapping of strokes, both power
passages. The cam lobe motor is designed so there and return, serve to smooth the power (torque)
are two pistons (in a 10 piston motor) doing the same applied to the axle.
thing at equal (180 degrees) distances around the
29-34
20042891
12
Cam Lobe Motor Operation (Full Supply Position)
As the piston and roller, 1, makes its way toward the block, 5, rotating, with continuation on to the piston,
bottom (valley) of the cam lobe, 2, the Maximum (full) 1. The oil supply then begins to taper off as the piston
supply of high pressure hydraulic oil momentarily is approaches the bottom of the cam lobe, 2, toward the
directed through the aligned ports, 3, of the neutral (no drive power) position.
distributor, 4, (remaining stationary) and cylinder
29-35
20042892
13
Bottom Neutral Position
When the piston, 1, is at the bottom of the cam lobe, contact with the cam surface. In order to continue
2, the oil supply is cut off. The ports, 3, in the driving power, another piston must take over for the
distributor, 4, and the cylinder block, 5, are NOT in first one to drive the cylinder block in the direction
alignment with each other. In this neutral piston the shown, enabling the first to climb the next cam lobe
piston does NOT provide power to the cylinder block, in a smooth and uninterrupted manner.
however, the piston (and roller) remains in the
29-36
20042893
14
Discharge Position
As the piston, 1, starts to climb the next cam lobe, 2, the discharge cycle. This allows the hydraulic oil
ports (passages), 3, in the distributor, 4, and cylinder (under charge pressure) to return to the pump as
block, 5, begin to align with each other, thus starting another piston takes over to continue the drive cycle.
29-37
20042894
15
Top Neutral Position
During the final cycle of the piston, 1, the piston When the roller is at the top of the cam lobe, the ports
continues to climb another cam lobe, 2. As this are no longer in alignment, thus ending a full drive
happens, ports, 3, in the distributor, 4, and the cycle. The piston and its roller will then repeat the
cylinder block, 5, progressively close off return oil cycle starting with a gradual supply of high-pressure
flow as the piston (and roller) reaches the top oil, while other pistons continue their cycles in a
(neutral) position. similar manner.
29-38
Selector Valve - Exploded View
2
3
1
12
5
11 10
18 14 4 17 17
17
16
4
7 17
15
10 13
11
56061402 5 8
16
Selector Valve
1. Solenoid, 12 volts with wire leads 10. Check Ball (2)

2. Connector 11. Roll Pin (2)
3. Pin, Terminal (2) 12. Spool
4. Plug, 02 ORB-M Hex Socket Head (5) 13. Valve Body, machined
5. Plug, 04 ORB-M Hex Socket Head (3) 14. Spring
6. Seal (2) 15. Reverse Adapter
7. Forward Adapter 16. Dowel Pin
8. Drain Adapter 17. Flow Regulator (optional) (4)
9. Plug, M33 18. Seal Kit
29-39
Flow Regulator - Exploded View
5
6
53061403
17
Flow Regulator
1. Adapter, M33 5. Piston, Flow Regulator

2. Baffle, Flow Regulator 6. Body, Flow Regulator, M33
3. Spring 7. O-ring M33 Boss
4. Washer, Hardened
29-40
SELECTOR VALVE -- DYNAMIC

DESCRIPTION
Low Pressure Shuttle (Forward)
The low-pressure shuttle system of the powered rear
axle selector valve is a combination of two check
valves between the forward and reverse sides of the
hydrostatic circuit, ahead of the selector spool. The PF
shuttle system provides pilot (control) pressure oil to
passage (A) at all times; even when the powered rear
axle is off. Passage (A) feeds to the solenoid
cartridge valve which directs charge pressure oil to B
engage the selector spool. There is always charge
pressure on the return side of the hydrostatic circuit;
for example, in the forward operating mode there is A
system pressure oil in the pump forward (PF) cavity
and charge pressure oil in the pump reverse (PR)
C
cavity. In this situation, the system pressure will be
higher than the charge pressure. In forward
operation system pressure oil will close off check ball
(B). When the check ball closes off, check ball (C) will
open up due to the dowel pin between check balls (B)
and (C). This pin will not allow both balls to seat at the
same time. When check ball (C) opens, this allows
1
charge pressure oil to flow from the return (reverse)
side of the circuit, past the check ball (C), past the 2
spacer and into passage (A). 53061404
18
Low Pressure Shuttle (Forward)
1. System Pressure
2. Charge Pressure
29-41
Low Pressure Shuttle (Reverse)
In the reverse operating mode there is system
pressure oil in the pump reverse (PR) cavity and
charge pressure oil in the pump forward (PF)cavity. PF
System pressure oil will close off check ball (C).
When the check ball closes off, check ball (B) will
open up due to the dowel pin between balls (B) and
(C). This pin will not allow both balls to seat at the B
same time. When check ball (B) opens, this allows
charge pressure oil to flow from the forward side of
the circuit, past the check ball (B), past the spacer A
and into passage (A).
C
1
2
53061405
19
Low Pressure Shuttle (Reverse)
1. System Pressure
2. Charge Pressure
Solenoid Valve
P T
The solenoid valve is a 3-way valve that controls the
positioning of the selector spool (A) using charge
pressure from the low pressure shuttle (P). When the
powered rear axle is turned “OFF”, the solenoid is
de-energized, and the charge pressure from the low
pressure shuttle (P) is blocked internally in the S
solenoid valve. Cavity (S) of the selector spool (A) is 1
connected to tank (T).
2
A
56061406
20
Solenoid Valve Energized -- Selector Spool OFF
1. Drain
2. Charge Pressure
29-42
When the powered rear axle is turned “ON”, the
solenoid valve is energized, and the charge pressure P T
oil (P) is now directed to passage (S) of the selector
spool (A), shifting it into the ON position.
S
1
2
A
53061407
21
Solenoid Valve Energized -- Selector Spool ON
1. Drain
2. Charge Pressure
The powered rear axle selector valve is designed for

use on machines having nominal flow rates greater
2
than 227 L/min (60 US gpm) to the rear wheel assist
drives. The valve is a spool type valve incorporating
ON-OFF control of the assist axle and can be
1
equipped with optional flow regulators, 1, for
improved traction control when required.
When the selector valve solenoid is not activated, the

selector valve spool, 2, blocks the high pressure oil
flow and all motor and valve cavities are connected
to tank.
56061409
22
An ON-OFF switch on the right console in the
operator’s cab sends a 12 volts signal into the right
hand module (RHM). The RHM sends a message 1
across the CAN bus to CCM1, which activates the
electric solenoid valve. The solenoid valve directs
pilot pressure to move the selector spool, 1. This
movement of the spool opens up internal passages
within the valve to permit high system pressure oil to
flow to the wheel motors. The oil flow is split between
the wheel motors.
56061408
23
29-43
Selector Spool (OFF Position)
PF
53061410
24
Selector Spool -- OFF Position
1. Drain
2. System Pressure
3. Charge Pressure
With the powered rear axle system OFF, charge In the off position the spool cavities (PF) and (PR) are
pressure oil in the control valve is blocked at the closed off from motor cavities (MF) and (MR).
solenoid valve. Cavity (S) is exposed to tank through Cavities (PF) and (PR) are the forward and reverse
the solenoid cartridge. The spring pressure in cavity pressure inlet cavities; they will always be exposed
(D) holds the spool (A) in the OFF position. The spool to either system pressure or return (charge) pressure
prevents system pressure oil from entering both the oil depending on direction of the machine. Cavity
forward or reverse inlet port and the rest of the valve; (MF) opens an oil flow path to the forward pressure
therefore no high pressure oil is delivered to the ports of the wheel motors. Cavity (MR) similarly
wheel motors. opens an oil flow path to the reverse pressure ports
of the motors.
29-44
Selector Spool (On Position)
3
S
PF
D
53061411
25
Selector Spool -- On Position
1. Drain
2. System Pressure
3. Charge Pressure
When the switch in the cab is in the ON position, the open to passage (PR), which allows return flow (at
coil within the solenoid valve is energized. Passages charge pressure) to come from the motors and back
in the solenoid valve cartridge are opened and to the return side of the hydrostatic circuit. In the
charge pressure oil is delivered to cavity (S) and reverse operation mode, the process is switched;
shifts the spool (A), compressing the spring in cavity where passages (MR) and (PR) are open to each
(D). When the spool arrives at its full ON position, other to provide reverse system pressure to the
passage (PF) is open to passage (MF), which reverse pressure inlet ports of the motor. Passages
provides forward system pressure to the forward (PF) and (MF) allow return flow to come from the
pressure inlet ports of the motors. Passage (MR) is motors.
29-45
FLOW REGULATOR (OPTIONAL)

The Flow Regulator purpose is to limit maximum flow
to a wheel drive motor due to the loss of traction. The
normal result of losing traction is wheel spin out at the
affected wheel. The effect of this is that the speed of
the spinning motor can increase to the limit of
available system flow. The torque is lost at other
wheels due to pressure reduction in the system. The
Flow Regulator mounts in the hydraulic line to a
wheel motor, and controls only the flow to that motor
or axle in one direction of rotation. Free flow is
permitted in the opposite direction, and allows a
second regulator valve to separately control flow in 56061422
the opposite direction.
26
Flow Regulator, Normal Operation (flow below
regulated value)
The sliding spool (A) is used to control the oil flow 2
from the hydrostatic system to the wheel motor, and
contains a fixed reference orifice in the outer end. As A
oil flow increases through the flow regulator, the
pressure drop through that orifice will cause the
sliding spool to move into the regulator. The space
between the mating edges of the sliding spool and
the baffle (B) act as a variable orifice to balance the
movement of the sliding spool.
1
B
56061413
27
Forward Direction Operation
1. Oil Flow from Hydrostatic Pump
2. Oil Flow to Wheel Motor
Flow Regulator, Flow at Regulated Value

As flow rate through the valve approaches the B
controlled value, the spool (A) and baffle (B) 2 A
compress the spring reducing the flow path to control
the flow rate. The valve constantly modulates to
maintain constant flow at the design reference value.
1
56061414
28
Forward Direction Operation, Regulated
29-46
Flow Regulator, Flow in Return Direction
When flow returns in the reverse direction, the spool
(A) slides freely to the right. The spool will extend 1
past the end of the body and allows for additional A
orifices to open. This allows for free flow return
through the flow regulator.
2
56061415
29
Reverse Direction Operation
29-47
HYDRAULIC LINE -- PLUMBING SCHEMA PRA HOSES
5
1
4
2
7
6
86054620
30
Front Right View of PRA Selector Valve
1. Forward High Pressure from Hydrostatic System

2. Reverse High Pressure from Hydrostatic System
3. Forward High Pressure to Right Wheel Motor
4. Reverse High Pressure to Right Wheel Motor
5. Left Wheel Motor Case Drain
6. Right Wheel Motor Case Drain
7. Case Drain from Selector Valve
29-48
86054622
31
Left Side View of PRA Selector Valve
1. Forward High Pressure to Left Wheel Motor

2. Reverse High Pressure to Left Wheel Motor
3. Case Drain from Selector Valve
Hose routing from the powered rear axle selector

valve to the wheel motors is dependent on the tread
width setting of the rear axle.
29-49
2
4
4 3
2 4
56061420
32
Hose Routing, Tread Width Position 1, 2, 3, 4
1. Hose support loops

2. Forward high pressure lines
3. Reverse high pressure lines
4. Wheel motor case drain lines
Tread Width Positions 1, 2, 3, 4 1, must be mounted on the rear of the axle. The hose
With the rear axle tread width set in one of the first bundle from the wheel motors loops to the rear of the
four positions, the hose fittings at the wheel motors axle, then passes forward through the loop support
need to be angled to the rear, and the loop support, and across the front of the axle to the selector valve.
29-50
2
4
4 3
2 4
53061421
33
Hose Routing, Tread Width Position 5, 6, 7
1. Hose support loops

2. Forward high pressure lines
3. Reverse high pressure lines
4. Wheel motor case drain lines
Tread Width Positions 5, 6, 7 steering cylinder mounts. The hose bundle from the
With the rear axle tread width set to the three widest wheel motors is routed across the front of the axle,
positions, the hose fittings at the wheel motors must through the loop support, and then to the selector
be angled to the front, and the loop support is valve.
positioned on the front of the rear axle, inside of the
29-51
Wheel Motor Connections
Three hoses are connected to each wheel motor for
2
3
forward and reverse high pressure, and for case 1
drain. On the left wheel motor, the forward-most port,
1, is for the forward high pressure hose, the middle
port, 2, is for case drain, and the rearward-most port,
3, is for the reverse high pressure hose.
53031264
34
On the right wheel motor, the hose connections are
opposite of the left wheel motor. The forward-most 1 2 3
port, 1, is for the reverse high pressure hose, the
middle port, 2, is for case drain, and the
rearward-most port, 3, is for the forward high
pressure hose.
53031265
35
29-52
TESTING
SELECTOR VALVE
WARNING
Hydraulic oil leaking under pressure can
penetrate the skin and cause infection or other
injury. To Prevent Personal Injury: Relieve all
pressure, before disconnecting fluid lines.
Before applying pressure, make sure all connec-
tions are tight and components are in good
condition. Never use your hand to check for
suspected leaks under pressure. Use a piece of
cardboard or wood for this purpose. If injured by
leaking fluid, see your doctor immediately.
Make sure that the outside of the selector valve is

free from any dirt or grease. Dirt must NOT be
allowed to enter the valve when removing any of the
valve components.
1. Install 700 bar (10000 psi) pressure gauges in
both the forward, 1, and reverse, 2, inlet hoses to 1
the valve.
2
86054620
36
2. Install 70 bar (1000 psi) pressure gauges in one
of the charge pressure test ports, 1, and drain 2
test port, 2.
1
3. With the powered rear axle “ON”, record pressure
readings with machine moving in forward and
then reverse, while applying the service brakes
to load the system. Sluggish (poor) performance
of machine may be caused when charge
pressure drops below 7 bar (100 psi), indicating
excessive internal leakage somewhere in the
hydrostatic system. Loss of adequate charge
pressure can prevent the hydrostatic system
from reaching maximum system pressure. 56061416
37
29-53
4. Leakage from the selector valve should not
exceed 7.5 L/min (2 US gpm) with the machine
operating at system pressure. To check the
selector valve leakage, disconnect the drain
hose, 1, from bottom fitting on valve and plug the
hose end.
5. Suspend a large pail or container under the
valve, and operate the vehicle under load by
applying the service brakes while timing the flow
from the selector valve drain port into the
container. After 1 or 2 minutes of operation,
measure the volume of oil in the container to 1
calculate the flow rate. If the flow rate exceeds 56061416
7.5 L/min (2 US gpm), disassemble the selector 38
valve to determine the source of excessive
leakage. Replace the valve if necessary.
NOTE: The flow rate may pulse when shifting the
valve.
6. Leakage from the wheel motors will vary

depending on the size and type of motor. In 1
general, leakage should not exceed 7.5 L/min (2
US gpm) from each wheel motor. To test the case
drain flow from the wheel motors, disconnect the
left wheel motor hose, 1, or right wheel motor
hose, 2, from the tee assembly beside the
selector valve, and cap the port on the tee
assembly.
7. Suspend a large pail or container under the valve 86054620
2
to catch oil flow from the wheel motor hose.
Operate the vehicle with the powered rear axle 39
engaged and under load by applying the service
brakes while timing the flow into the container.
After 1 or 2 minutes of operation, measure the
volume of oil in the container to calculate the flow
rate. Repeat the test for the opposite wheel
motor.
NOTE: The flow rate may pulse when shifting the
valve.
8. If excessive leakage exists, the wheel motor is

worn internally and requires service. Refer to
Section 41, Chapter 2, “Hydrostatic Motor --
Disassembly” for repair information. If leakage is
within specification, then components with the
hydrostatic transmission of the combine may
have excessive leakage; refer to Section 29,
Chapter 1, “Hydrostatic Transmission” for
additional information on the hydrostatic system
components.
29-54
Test Selector Spool
WARNING

valve components.
the valve, as well as in one of the forward, 3, and
reverse, 4, outlet hoses from the selector valve
to the wheel motors. 3
4 2
86054620
40
2. Install a 70 bar (1000 psi) pressure gauge in one
of the charge pressure test ports, 1, in the 2
selector valve.
1
56061416
41
29-55
3. Operate the combine while monitoring the
pressure readings as follows:
• With the powered rear axle “ON”, record pressure
readings with combine moving in forward and
then reverse while applying some load with the
service brakes.
• With the powered rear axle “OFF”, record
pressure readings with combine moving in
forward and then reverse while applying some
load with the service brakes.
• The charge pressure should be approximately
22 bar (320 psi) with the powered rear axle “ON”,
and less than 1 bar (15 psi) with the powered rear
axle “OFF”.
• The forward and reverse pressures should be
greater than 35 bar (500 psi) in the line related to
the direction of travel, and approximately 22 bar
(320 psi) (charge pressure) in the return line.
4. If charge pressure reading in the sector valve is
not correct with the powered rear axle “ON”, then
the solenoid valve should be checked to be sure
that the valve is shifting properly. Refer to
“Troubleshooting -- Selector Valve -- Electrical
Circuit” for testing information.
5. If charge pressure reading is correct, but the
forward and reverse line pressures to the wheel
motors are less than 1 bar (15 psi) with the
powered rear axle “ON”, then the control spool in
the selector valve is not shifting. Forward and
reverse pressures should be the same as the
combine system pressure and charge pressure.
6. Loosen and remove the drain hose connec-
tion(1) from the bottom of the valve. Plug the
hose to prevent draining the reservoir.
1
56061416
42
29-56
7. Remove bottom fitting, 1, from the selector valve.
Check for free movement of the selector spool,
2, in the bore. If spool does not move freely,
remove spool from bore and check for excessive
wear on the spool and the bore.
8. Reinstall spool in bore and check again for free
movement. If spool continues to stick, replace-
ment of the complete selector valve is necessary.
56061419
43
29-57
Test Flow Regulators
WARNING

valve components.
the valve, as well as in one of the forward, 3, and
reverse, 4, outlet hoses from the selector valve
to the wheel motors. 3
NOTE: Optional flow regulators not shown. Install
gauges between flow regulators and hoses to wheel
motors.
4 2
83054620
44
29-58
2. Install a 70 bar (1000 psi) pressure gauge in one
of the charge pressure test ports, 1, in the 2
selector valve.
1
3. Operate the combine while monitoring the
pressure readings as follows:
• With the powered rear axle “ON”, record pressure
readings with combine moving in forward and
then reverse while applying some load with the
service brakes.
• With the powered rear axle “OFF”, record
pressure readings with combine moving in
forward and then reverse while applying some 56061416
load with the service brakes.
45
• The charge pressure should be approximately
22 bar (320 psi) with the powered rear axle “ON”,
and less than 1 bar (15 psi) with the powered rear
axle “OFF”.
• The forward and reverse pressures should be
greater than 35 bar (500 psi) in the line related to
the direction of travel, and approximately 22 bar
(320 psi) (charge pressure) in the return line.
4. If charge pressure reading in the selector valve
is not correct with the powered rear axle “ON”,
then the solenoid valve should be checked to be
sure that the valve is shifting properly. Refer to
“Troubleshooting -- Selector Valve -- Electrical
Circuit” for testing information.
5. If charge pressure reading is correct, but the
forward and reverse line pressures to the wheel
motors are less than 1 bar (15 psi) with the
powered rear axle “ON”, then the selector spool
in the selector valve is not shifting. Forward and
reverse pressures should be the same as the
combine system pressure and charge pressure.
Refer to “Testing -- Selector Valve” for additional
information.
6. If the solenoid valve and the selector spool are
shifting properly, the optional flow regulators may
not be functioning properly.
Loosen and remove the drain hose connection,
1, from the bottom of the valve. Plug the hose to
prevent draining the PTO gearbox through the
control valve when the flow regulators are
removed.
7. Remove the hoses from the flow regulators and
the flow regulators from the selector valve.
1
56061416
46
29-59
8. Check for free movement of piston, 1, in the bore
of each flow regulator. If a piston does not move 4
freely, remove piston, 1, washer, 2, spring, 3, and
baffle, 4, from the suspect flow regulator by
removing hydraulic adapter. Check all parts and
1
bore for excessive wear. Reinstall spool in bore
and check again for free movement. If spool
continues to stick, replacement of the flow
3
regulator is necessary.
2
56061403
47
29-60
TROUBLESHOOTING
2WD-4WD HYDRAULIC SYSTEM • Check the quality of the oil; change if milky, dirty
or discolored. Also smell the oil. A burned odor
Operation indicates excessive heat that can destroy the
If an operator reports problems with the powered rear lubricating qualities of the oil. Again, the oil
axle, detailed information of the concern should be should be changed if this condition is found.
gathered before attempting service of the axle Determine the cause of the excessive heat and
components. Use the chart below for reference when correct it.
investigating the concern. • Determine if the hydrostatic filter is plugged or
damaged. A filter that has failed will permit oil to
Troubleshooting bypass the system, affecting system operation
• With the engine of the combine shut off, check for and tests.
evidence of external oil leakage around seals, • Check the maintenance records with the
housing or hose connections. Also check for machine to determine if the recommended
pinched or kinked hoses that could restrict oil service procedures have been made at the
flow and cause excessive heat build-up in the proper intervals. Check for previous reports of
hydraulic oil. unusual, frequent or similar failures.
• Check hydraulic oil level in the hydraulic fluid
reservoir and add the correct amount and type of
hydraulic oil, if necessary.
Problem Possible Cause Correction

Performance of powered rear Operating with transmission gear- System is more effective in higher
axle is sluggish (poor). ing too low. gear.
Incorrectly plumbed main high Verify lines are installed correctly.
pressure lines (forward and re- Refer to Hydraulic line -- Plumbing
verse). schema for proper hose routing
information.
Weak high pressure relief valve in Refer to Section 29, Chapter 1,
the hydrostatic pump. “Testing -- Multifunction Valve” for
testing information.
Excessive case leakage from the Refer to “Testing -- Selector Valve”
powered rear axle wheel motors for testing information.
or selector valve.
Inadequate charge pressure. Refer to “Testing -- Selector Valve”
for testing information.
Optional flow regulators are stick- Refer to “Testing -- Selector Valve”
ing internally. for testing information.
Powered rear axle operates in Excessive case leakage. Refer to “Testing -- Selector Valve”
only one direction (either Forward for testing information.
or Reverse).
Electrical circuit malfunction. Refer to “Troubleshooting --
Selector Valve -- Electrical Circuit”
Stuck selector spool in control Disassemble valve and clean
valve. spool. If spool is damaged,
replace the valve.
29-61

One wheel of powered rear axle Incorrectly mounted high pressure Refer to Hydraulic line -- Plumbing
is dragging or locked up. hoses on hydraulic wheel motors. schema for proper hose routing
and connections.
Hydraulic wheel motor is locked With the combine OFF and wheels
up due to internal component properly blocked, raise the af-
failure. fected wheel off the ground, and
attempt to rotate the wheel by
hand. If the wheel will not rotate,
the wheel motor has failed. Ser-
vice or replace the wheel motor;
refer to Section 41, Chapter 2,
“Hydrostatic Motor -- Removal”
and “Hydrostatic Motor -- Disas-
sembly” for additional information.
Powered rear axle is not function- Low hydrostatic system fluid level. Check the PTO gearbox oil level,
ing. and correct if necessary. Purge
any air from the powered rear axle
system; refer to “Hydrostatic Motor
-- Bleed” for instructions.
Electrical circuit to selector valve Refer to “Troubleshooting -- Selec-
is not functioning. tor Valve -- Electrical Circuit” for
testing information.
Stuck selector spool in selector Disassemble valve and clean
valve. spool. If spool is damaged, re-
place the valve.
Excessive wheel motor leakage. Refer to “Testing -- Selector Valve”
2 Speed powered rear axle oper- Electrical circuit to 2 speed valve Refer to Selector valve Two speed
ates in one speed only (either is not functioning properly. valve -- Testing for testing informa-
low or high). tion.
2 speed spool sticking in wheel Carefully remove and inspect the
motor. 2 speed spool. If scoring or other
damage is found, replace the
wheel motor.
29-62
SELECTOR VALVE -- ELECTRICAL
Other Result
No Test Point Expected Result (Possible Cause)
1 Key on. Enter the InfoView™ If this fault code is not present, If fault is present, refer to diag-
“DIAG” screen, and select “HIS- Go to test 2 nostic procedure at Section 55,
TORY”. Chapter 14 -- “CCM1 Fault
Check for the following fault Codes -- Fault Code E0066-11”
code: E0066-11 - 2-Speed Pow-
ered Rear Axle Valve.
2 Key on. Enter the InfoView™ If voltage increases to approxi- If there is not a voltage increase
“DIAG” screen. Select the mately 12 volts, the electrical when the switch is depressed,
“GROUND DRIVE” sort menu, circuits test okay. Check the se- Go to test 3
and select “2-Spd PRA SW”. lector valve solenoid cartridge
Depress the rear wheel assist and valve spool for sticking.
switch S-10 on the right hand
console. The “DIAG” screen
should change to indicate a
voltage increase.
3 Key on. Enter the InfoView™ If there is 12 volts, Go to test 4 If there is not 12 volts, a power
“DIAG” screen. Select the supply circuit to the right hand
“VOLTAGE” sort menu, and se- console has failed.
lect “RHM Key SW”. Go to test 6
The “DIAG” screen should indi-
cate approximately 12 volts.
4 Key on. Open the right hand If there is 12 volts, Go to test 5 If there is not 12 volts, there is
console. an open circuit in the right con-
Use a multimeter to check for sole (RC) harness between
voltage at switch connector connector X501 and connector
X051 pin 2. There should be 12 fuse F-48 wire 366 orange or
volts. 287 orange.
Locate the open and repair.
5 Key on. Open the right hand If there is 12 volts, there is an If there is not 12 volts, the rear
console. open circuit in the right console switch panel has failed.
Use a multimeter to check for (RC) harness between connec- Replace the rear switch panel.
voltage at the switch panel con- tor X051 pin 3 and the RHM
nector X051 pin 3 while de- connector X029 pin 17 wire 336
pressing the rear wheel assist yellow.
switch S-10. There should be Locate the open and repair.
12 volts.
29-63
Other Result
6 Key off. If fuse F-48 is good, Go to test If fuse F-48 has failed, replace
Check fuse F-48. 7 the fuse. If the fuse immediately
fails again, there is a short to
ground in the cab main (CM)
harness or right console (RC)
harness that is causing the fuse
to fail.
Refer to Section 55, Chapter 3,
“Electrical schematic frame 25”
for information on the circuits
that are connected to fuse F-48.
Locate the short and repair.
7 Key on. Disconnect connector If there is 12 volts, there is an If there is not 12 volts, there is
X001 from the bottom of the open circuit in the right console an open circuit in the cab main
right console. (RC) harness wire 108 orange, (CM) harness between fuse
Use a multimeter to check for or at the harness splice. Refer F-48 and connector X001 wire
voltage at the cab main (CM) to Section 55, Chapter 3, 108 orange.
harness end of connector X001 “Electrical schematic frame 25” Locate the open and repair.
pin 3. There should be 12 volts. for information on the right
console circuits powered by
fuse F-48.
29-64
TWO-SPEED VALVE -- ELECTRICAL
Other Result
1 Key on. Enter the InfoView™ If this fault code is not present, If fault is present, refer to
“DIAG” screen, and select Go to test 2 diagnostic procedure in
“HISTORY”. “Section 55, Chapter 14 --
Check for the following fault “CCM1 Fault Codes --Fault
code: E0059-11 -- 2-Speed Code E0059-11.”
Front Hydro Valve.
2 Key on. Enter the InfoView™ If voltage increases to If there is not a voltage increase
“DIAG” screen. Select the approximately 12 volts, the when the switch is depressed,
“GROUND DRIVE” sort menu, electrical circuits test okay. Go to test 3
and select “2-Spd F Hydro SW”. Check the two speed valve
Depress the rear wheel assist solenoid cartridge and valve
HI/LOW switch S-11 on the right spool for sticking.
hand console. The “DIAG”
screen should change to
indicate a voltage increase.
3 Key on. Enter the InfoView™ If there is 12 volts, Go to test 4 If there is not 12 volts, a power
“DIAG” screen. Select the supply circuit to the right hand
“VOLTAGE” sort menu, and console has failed.
select “RHM Key SW”. Go to test 6
The “DIAG” screen should
indicate approximately 12 volts.
4 Key on. Open the right hand If there is 12 volts, Go to test 5 If there is not 12 volts, there is
console. an open circuit in the right
Use a multimeter to check for console (RC) harness between
voltage at switch connector connector X050 and Fuse F-48
X050 pin 2. There should be 12 X001 wire 367 orange or 287
volts. orange.
5 Key on. Open the right hand If there is 12 volts, there is an If there is not 12 volts, the rear
console. open circuit in the right console switch panel has failed.
Use a multimeter to check for (RC) harness between Replace the rear switch panel.
voltage at switch connector connector X050 pin 3 and the
X050 pin 3 while depressing the RHM connector X029 pin 6 wire
rear wheel assist HI/LOW 337 yellow.
switch S-11. There should be Locate the open and repair.
12 volts.
29-65
Other Result
6 Key off. If fuse F-48 is good, Go to test If fuse F-48 has failed, replace
Check fuse F-48. 7 the fuse. If the fuse immediately
fails again, there is a short to
ground in the cab main (CM)
harness or right console (RC)
harness that is causing the fuse
to fail.
Refer to Section 55, Chapter 3,
“Electrical schematic frame 25”
for information on the circuits
that are connected to fuse F-48.
7 Key on. Disconnect connector If there is 12 volts, there is an If there is not 12 volts, there is
X001 from the bottom of the open circuit in the right console an open circuit in the cab main
right console. (RC) harness wire 108 orange, (CM) harness between fuse
Use a multimeter to check for or at the harness splice. Refer F-48 and connector X001 wire
voltage at the cab main (CM) to Section 55, Chapter 3, 108 orange.
harness end of connector X001 “Electrical schematic frame 25” Locate the open and repair.
pin 3. There should be 12 volts. for information on the right
console circuits powered by
fuse F-48.
29-66
REPAIR
20042887
48
CONTROL VALVE 6. Remove the four M6 capscrews, 3.
Replacement 7. Remove the valve assembly, 4.
1. To remove and install the Single Speed and Two 8. Remove and discard the four O-rings, 5.
Speed control valve from the machine it can be 9. Make sure the valve and motor mounting
done without removing the motor from the surfaces are clean. Install new O-rings, 5.
C-frame.
10. Install the new valve assembly, 4.
CAUTION
11. Torque four capscrews, 3, to 12.5 -- 15.5 N⋅m (9.3
Before you do service under the machine, put the -- 11.3 ft-lb).
machine on a level surface, engage the parking
brake and stop the engine. Put blocks at the front 12. Reconnect the drain line and pressurize the
and rear of the tires. Failure to follow these supply system.
instructions can cause injury. 13. Bleed air from system by loosening bleed screw,
6, approximately one turn. Re-tighten after all air
2. Turn the wheel to the steering stop to gain access is bled from the system.
to the valve. 14. Re-connect the electrical connection. Add cover,
3. Release the pressure in the supply circuit. 1, and two capscrews, 2. Torque capscrews to
22.5 -- 27.5 N⋅m (16.6 -- 20.2 ft-lb) (Two Speed
4. Disconnect the drain line at the tank level to avoid Valve Only).
siphoning.
5. Remove two cap screws, 2, and cover, 1.
Disconnect the electrical connection (Two Speed
Valve Only).
29-67
20042888
49
Overhaul 6. Remove the Hex nut, 5, magnetic winding, 4, and
cartridge valve, 3.
NOTE: The solenoid valve can be replaced without
removing the motor from the C-frame. 7. Make sure new cartridge valve is clean.
Lubricate O-rings with hydraulic fluid. Install new
1. Turn the wheel to the steering stop to gain access cartridge valve, 3, and torque to 24-- 30 N⋅m (17.8
to the valve. -- 22.2 ft-lb).
CAUTION 8. Install new magnetic winding, 4, and Hex nut, 5.
Before you do service under the machine, put the Torque nut to 2.7 -- 3.3 N⋅m (2.0 -- 2.4 ft-lb).
machine on a level surface, engage the parking 9. Re-clamp electrical leads and reconnect the
brake and stop the engine. Put blocks at the front electrical connection.
and rear of the tires. Failure to follow these
instructions can cause injury. 10. Reconnect the drain line and pressurize the
supply line.
2. Release the pressure in the supply circuit. 11. Bleed air from system by loosening bleed screw,
6, approximately one turn. Tighten after all air is
3. Disconnect the drain line at the tank level to avoid bled from the system.
siphoning.
12. Re-install cover, 1, with capscrews, 2. Torque the
4. Disconnect the electrical connection. capscrews, 2, to 22.5 -- 27.5 N⋅m (16.6 -- 20.2
5. Remove the two capscrews, 2, and cover, 1. ft-lb).
29-68
20042886
50
Single Speed Valve Replacement
1. Bleed Screw 6. Spring Seat

2. Bleed Screw Seal 7. Valve Block
3. Spool Cap 8. Metered Set Screw
4. Wheel motor case drain lines 9. M14 Plug
5. Spool Spring 10. M18 Plug
20042889
51
Two Speed Valve Replacement
1. Bleed Screw 8. Metered Set Screw

2. Bleed Screw Seal 9. M18 Plug
3. Spool Cap 10. Solenoid Hex Pug
4. Cartridge Valve 11. Solenoid Magnetic Winding
5. Spool Spring 12. Solenoid Valve
6. Spring Seat 13. Small Metered Set Screw
7. Valve Block
29-69
20042890
52
TWO-SPEED VALVE 6. Remove the spring, 5, washer, 4, and snap ring,
2, from spool, 3.
Replacement
7. Install the snap ring, 2, washer, 4, and spring, 5,
NOTE: The two-speed spool can be replaced without onto the new spool, 3.
removing the motor from the C-frame
8. Oil, then install new spool assembly.
1. Turn the wheel to the steering stop to gain access
to the spool. 9. Re-install plug, 1. Torque to 285 -- 380 N⋅m (210
-- 280 ft-lb).
2. Release the pressure in the supply circuit.
10. Reconnect the drain line and pressurize the
3. Disconnect the drain line at the tank level to avoid supply system.
siphoning.
11. Bleed air from system by loosening bleed screw,
4. Remove the plug, 1. 6, approximately one turn. Re-tighten after all air
5. Extract the spool, 3, with snap ring, 2, washer, 4, is bled from the system.
and spring, 5.
29-70
Chapter 5 - Pressure Testing and Troubleshooting
CONTENTS

29 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Hydrostatic System, Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Servo Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
29-1
SPECIFICATIONS
Charge Relief, Pump . . . . . . . . . . . . . . . . . . . . . . . 38 bar (550 PSI)
Pressure Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 bar (6090 PSI)
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 bar (6525 PSI)
Approximate system pressures expected during testing:
Charge Pressure Servo Pressure

Low Idle High Idle Forward Reverse
Neutral 36 bar 40.8 bar Servo Servo
522 PSI 592 PSI Neutral 10 bar 10 bar
Forward 28.3 bar 32.9 bar 145 PSI 145 PSI
410 PSI 477 PSI Forward 14 bar 5 bar
Reverse 29.5 bar 33.4 bar 203 PSI 73 PSI
428 PSI 484 PSI Reverse 7 bar 10.5 bar
Forward Brakes On 26 bar 31 bar 102 PSI 152 PSI
377 PSI 450 PSI
Forward Pressure Reverse Pressure

Low Idle High Idle Low Idle High Idle
Neutral 35 bar 38 bar Neutral 35 bar 35 bar
508 PSI 551 PSI 508 PSI 508 PSI
Forward 65 bar 90 bar Forward 20 bar 20 bar
943 PSI 1305 PSI 290 PSI 290 PSI
Reverse 25 bar 30 bar Reverse 65 bar 80 bar
363 PSI 435 PSI 943 PSI 1160 PSI
Forward Brakes On 450 bar 456 bar Reverse Brakes On 450 bar 456 bar
6525 PSI 6612 PSI 6525 PSI 6612 PSI
29-2
SPECIAL TOOLS
NEW HOLLAND NEW HOLLAND

PART NUMBER PART NUMBER
DESCRIPTION
(North America Only) (All Markets Except
North America)
Universal Pressure Test Kit FNH02003 292870

Quad Gauge OEM1212 -
Hydrostatic Test Set FNH03132 -
Pressure gauge 0-40 bar (0 - 600 PSI) OEM 1459 293242#
Pressure gauge 0 - 60 bar (0 - 1000 PSI) OEM 1460 -
Pressure gauge 0 - 150 bar (0 - 2500 PSI) - 293243#
Pressure gauge 0 - 600 bar (0 - 9000 PSI) OEM1465 293246#
Pressure gauge hose - 292246#
1/8″ NPT fitting to attach hose 292246 to gauge - 291927#
Adaptor M10 x 1.0p x 7/16″ JIC male (enables use of gauges with - 297417
7/16″ JIC hoses if used)
Minimess connector size EMA3 - 9/16″-18 UNF - 84021707
Minimess connector (tube side) M16 x 2 - Procure Locally
Quick release (female) FNH00535 291924
Adaptor, quick release FNH00035 -
#Part of Kit 292870
PARKER HANNIFIN
FITTINGS
PART NUMBER
Coupler, male (9/16″-18 UNF) [NH Part #86596853] PD361
29-3
MAIN HYDROSTATIC SYSTEM, PRESSURE TESTING

Various pressure and vacuum gauge readings are WARNING
necessary for troubleshooting problems with the
Gauges, gauge fittings and hoses MUST have op-
main hydrostatic drive system.
erating pressure ratings of at least 25 per cent
To check the high pressure settings of the multi higher than the highest pressure of the circuit be-
function valves it will be necessary to connect high ing tested.
pressure gauges to the system.
Measuring the charge pump inlet vacuum assist in CAUTION
locating restrictions in the suction lines and filter Block the front and rear wheels with suitable
screen. blocks so the machine cannot move. Make sure
everyone is clear of the machine before starting
Case pressure readings will assist in locating
the engine.
restrictions in the return lines, oil cooler and filter.
The pump and motor charge pressure must be CAUTION
checked and recorded during pressure testing.
To make sure accurate pressure readings are Proper ventilation is required under all circum-
obtained, the system must be at normal operating stances.
temperature and at full rated engine speed.
IMPORTANT: The interior of all test equipment must
be exceptionally clean before being used to test the
hydrostatic drive system. Make sure the test equip-
ment is purged of all oil and foreign material to avoid
contamination of the hydrostatic drive system.
29-4
CHARGE PRESSURE

SPECIAL TOOLS
North America)
Pressure gauge 0 - 60 bar (0 - 1000 PSI) OEM 1460 -

(or) Quad Gauge OEM1212 -
(or) Hydrostatic Test Set FNH03132 -
PARKER HANNIFIN
FITTINGS
PART NUMBER
The minimum allowable charge pressure for the

pump is 24 bar (350 PSI) above the case drain
pressure. To determine the actual charge pressure, 1
subtract the case drain pressure from the charge
pressure reading.
Check the charge pressure at test port located at the

charge pressure filter housing, 1. Remove the plug and
install the male quick coupler. Use a minimum 60 bar
(1000 PSI) pressure gauge. The measured pressure at
this test point is charge pressure plus case drain
pressure.
1
The charge pressure can also be measured at the
drive motor,1, at test port, M8.
To find the actual charge pressure, check the case
pressure and subtract the case pressure reading
from the charge pressure reading.
Charge Pressure
Low Idle High Idle
Neutral 36 bar 40.8 bar
522 PSI 592 PSI M8
Forward 28.3 bar 32.9 bar
410 PSI 477 PSI
Reverse 29.5 bar 33.4 bar 2
428 PSI 484 PSI
Forward Brakes On 26 bar 31 bar
377 PSI 450 PSI
29-5
SERVO PRESSURE

SPECIAL TOOLS
North America)
Pressure gauge 0 - 40 bar (0 - 600 PSI) OEM 1459 293242

(or) Quad Gauge OEM1212 -
PARKER HANNIFIN
FITTINGS
PART NUMBER
Gauges should be installed into the X1, 1, and X2, 2,

ports of the control unit, located at the top of the pump. 1
Remove the plugs and install the male quick coupler.
In neutral the pressure should be equal. As the

forward or reverse is activated a pressure rise on one
gauge should be countered with a corresponding
pressure drop on the other gauge.
This test may determine the reason for a unit that

creeps whilst the lever is in neutral. Joining the ports
together should stop the creeping, if this is the case 2
adjust the neutral position within the control unit. If the
unit still creeps when the ports are joined the pump 3
will require replacement.
Servo Pressure
Forward Reverse
Servo Servo
Neutral 10 bar 10 bar
145 PSI 145 PSI
Forward 14 bar 5 bar
203 PSI 73 PSI
Reverse 7 bar 10.5 bar
102 PSI 152 PSI
29-6
HIGH PRESSURE

SPECIAL TOOLS
North America)
Pressure gauge 0 - 600 bar (0 - 9000 PSI) OEM 1465 293246

PARKER HANNIFIN
FITTINGS
PART NUMBER
The high pressure is determined by the two multi

function valves, 1. The relief valve setting is 450 bar
(6525 PSI). The pressure limiter will start to destroke
the pump servo cylinders at 420 bar (6090 PSI).
M1
The high pressure can be checked at pump test ports
M1 for forward, Figure 4, and test port M2 for reverse,
Figure 5. A test coupler is installed in Port M1 from the
factory. To test reverse pressure, remove the plug and
install the male quick coupler.
The pressure can also be checked at the drive motor.
Forward high pressure at test port M1 and reverse
high pressure at test port M2.
CAUTION 4
Block the front and rear wheels with suitable
blocks so the machine cannot move. Make sure
everyone is clear of the machine before starting
the engine.
29-7
With the gauges installed put the transmission in 4th
gear, start and run the engine at high idle, hold the
brake pedals down and move the hydrostatic control
lever forward, then rearward. Record the pressure M2
gauge readings. Only hold the system in the
overpressure situation for a few seconds and return
to neutral as soon as possible.
CAUTION
proper ventilation is required under all circum-
stances.
Forward Pressure Reverse Pressure

Low Idle High Idle Low Idle High Idle
Neutral 35 bar 38 bar Neutral 35 bar 35 bar
508 PSI 551 PSI 508 PSI 508 PSI
Forward 65 bar 90 bar Forward 20 bar 20 bar
943 PSI 1035 PSI 290 PSI 290 PSI
Reverse 25 bar 30 bar Reverse 65 bar 80 bar
363 PSI 435 PSI 943 PSI 1160 PSI
Forward Brakes On 450 bar 456 bar Reverse Brakes On 450 bar 456 bar
6525 PSI 6612 PSI 6525 PSI 6612 PSI
29-8
TROUBLESHOOTING

Machine will not operate 1. Low hydrostatic oil. 1. Check and fill the reservoir to the
in either direction. correct oil level. Use specified oil
only.
2. Blocked hydrostatic filter. 2. Replace filter.
3. Air in system. 3. Locate and repair leak.
4. Exceeding relief valve pressure. 4. Shift to lower gear.
5. Transmission gear not selected or 5. Check transmission for correct
inoperative. gear selection and engagement.
6. Servo valve not operating. 6. Check for displayed error code.
Carry out electrical repairs as per
error code.
Check for sticking solenoid valve
and servo spool linkage.
7. Drive system unable to build up 7. Air in system. Air will also cause
pressure. the system to be noisy. Check all
fittings, especially around the filter,
in the suction line and locate the
point or points where air is being
drawn into the system. Tighten
fittings and joints where air leaks
exist. Replace seal where
necessary.
8. Charge pressure relief valve is 8. Repair charge pressure relief
stuck open. valve.
Combine does not move 1. Transmission gear selector in 1. Select required gear.
when hydrostatic control neutral.
lever is moved
moved.
2. Selected transmission gear too 2. Change to lower gear.
high to move combine activating
pressure override.
3. Reservoir oil level very low. 3. Check and fill the reservoir to the
correct oil level. Used specified oil
only.
4. Air in system (may be due to low oil 4. Purge air from system. Refer to
level). Section 29, Chapter 3.
5. Hydrostatic lines leaking. 5. Check, tighten or replace as
necessary.
6. Blocked hydrostatic filter. 6. Check and replace filter element
as necessary.
7. Servo solenoid not operating. 7. Check for displayed error code.
Carry out electrical repairs as per
error code.
Check for sticking solenoid valve
and servo spool linkage.
Hard to select a 1. Hydrostatic pump not in neutral 1. Calibrate hydrostatic lever.
transmission gear, or will though hydrostatic control lever is
not go into gear. in neutral.
29-9
Neutral is difficult or 1. Hydrostatic lever out of calibration. 1. Calibrate hydrostatic lever.
impossible to find.
Ground travel speed 1. Oil level low. 1. Check for leaks and repair as
erratic. necessary.
2. Blocked oil filter element. 2. Change filter element.
Repair or replace relief valve.
4. Unable to maintain charge 4. The charge pressure relief valve is
pressure. damaged or stuck open.
Internal damage to pump or motor.
5. Cold or low oil supply. 5. Check oil levels. Allow oil to warm.
Ground speed or 1. Reservoir oil level low. 1. Check and fill the reservoir to the
combine erratic and correct oil level. Used specified oil
loses power. Also seems only.
to lack power.
power
2. Hydraulic lines leaking. 2. Check level, fill as necessary.
as necessary.
4. Internal leaks or malfunction in 4. Pressure test system, repair or
pump or motor. replace motor or pump as
required.
Oil temperature too high. 1. Low oil level. 1. Fill to correct level and check for
leaks.
2. Blocked oil cooler. 2. Clean / replace as required.
3. Blocked inlet filter. 3. Replace filter.
4. System pressure too high, relief 4. Pressure test system, inspect
valve continually blowing. multi function valves.
5. Brake flow control valve setting too 5. Replace brake flow control valves
low. in brake block.
System noisy. 1. Air in system. 1. Check and fill the reservoir to the
correct oil level. Use specified oil
only.
2. Suction line between reservoir and 2. Repair leaks.
charge pump, including suction
filter, leaking and allowing air to be
drawn into the system, indicated
by considerable amount of foam in
the reservoir.
3. End of return line within the 3. Check and fill the reservoir to the
reservoir not below the oil level. correct oil level. Used specified oil
only.
4. Hose or tubing not properly 4. Make sure all hoses and tubes are
insulated. correctly routed and secured.
Make sure the hoses and tubes
are clear of any metal that will act
as a sound board for normal
hydraulic hum.
Insulate hose and tube clamps
with rubber to absorb sound.
29-10
Acceleration and 1. Filter or suction line from reservoir 1. Replace filter element and check
deceleration sluggish. to charge pump is blocked. and remove obstructions from
suction line.
2. Control orifice plug is partially 2. Inspect and clean /replace as
blocked. required.
as necessary.
4. Air in system. 4. Check fittings for air leaks.
Repair as necessary.
5. Low charge pressure. 5. Inspect filter and hoses.
Inspect charge pump relief valve.
Inspect the charge pump.
Unit surges. 1. Air in system. 1. Check fittings for air leaks between
reservoir and charge pump.
Repair as necessary.
2. Low hydrostatic oil. 2. Check and fill the reservoir to the
correct oil level. Used specified oil
only.
as necessary.
5. Unable to maintain charge 5. Repair or replace charge pressure
pressure. relief valve.
6. System contaminated. 6. Flush system.
7. Faulty pump. 7. Repair or replace pump.
Combine engine over 1. Brake flow control valve setting too 1. Replace brake flow control valves
revs when braking or high. in brake block.
driving downhill.
29-11
29-12
Chapter 6 - Hydrostatic Pump and Motor Repair
CONTENTS

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
29 212 Main Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
29 218 Shaft Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
29 218 Shaft Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
29 218 Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
29 218 Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
29 212 Charge Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
29 212 Charge Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Major Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electric Displacement Control (EDC) Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
29 218 Multi-Function Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
29 218 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
29 218 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pump Charge Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
29 212 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Major Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
29 218 Motor Charge Relief Valve -- Style 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
29 218 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
29-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Motor Pressure Relief Valve - Style 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Pressure Release Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pressure Release Valve Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
29-2
REPAIR
Op. 29 212
1
MAIN HYDROSTATIC PUMP
Removal 2
NOTE: Most minor repairs can be performed with the 3
pump still attached to the combine. The pump must
be removed for major repairs.
Drain the hydraulic reservoir.

suitable container readily available to capture any 10012187 4
1
Disconnect and cap hydraulic lines, 1, from the main
hydrostatic pump. Turn four cap screws out from
each fitting, 2, to disconnect the hydraulic lines from
the pump. Cap the lines just removed.
Disconnect and cap hydraulic line, 3, from the main

hydrostatic pump.
Disconnect and cap hydraulic line, 4, from the valve

body.
Disconnect and cap hydraulic line, 1, from the main
hydrostatic pump. Detach the connector, 2, from the 3
oil pressure switch. Unplug the connector, 3, from the
Electronic Displacement Control (EDC) valve.
1
2
10012188
2
Disconnect and cap hydraulic line, 1, at both ends
and remove from the combine. Store the line in a 2 1
suitable location.
Turn off oil filter, 2.
Loosen but do not remove the four hydrostatic pump

mounting nuts and washers.
10012189
29-3
Securely attach the main hydrostatic pump to a tow

motor or other suitable lifting device with a lifting
strap, 1, or chain. Remove the mounting nuts and
washers, lift the pump from the combine. 1
10012190
4
Op. 29 212
Installation
Securely attach the main hydrostatic pump to a tow

motor or other suitable lifting device with a lifting 1
strap, 1, or chain. Lubricate and install a new O ring
onto the mounting flange of the pump. Raise the
pump to the mounting flange on the gearbox and turn
on the four mounting nuts and washers. Tighten the
nuts to standard torque. 10012190
5
Attach hydraulic line, 1, to the main hydrostatic pump
at 2 and 3, to the valve block. 1
4 2
Turn on a new oil filter, 4. 3
10012189
29-4
Connect the electrical sensing line to the oil pressure
switch at 1. Plug in the EDC valve connector at 2. 2
Attach hydraulic line, 3, to the main hydrostatic
pump. Torque the fitting to 110 - 120 N⋅m (81 - 89
ft-lbs).
3
1
10012188
7
Attach hydraulic line, 1, to the main hydrostatic
pump. Torque the fitting to 110 - 120 N⋅m (81 - 89
ft-lbs).
Attach hydraulic line, 2, to the valve body. Torque the 3

fitting to 255 - 325 N⋅m (188 - 240 ft-lbs). 1
Lubricate and install new O rings into the flat fittings
of lines, 3. Secure the hydraulic lines to the valve
body with four cap screws for each fitting. Torque the
cap screws to 159 N⋅m (117 ft-lbs).
2
Prepare the system for operation in accordance with
10012187
Section 29, Chapter 3 “Filling the Hydrostatic System
and Start-Up Procedure”. 8
29-5
Op. 29 218
Shaft Seal Removal
2
NOTE: The same procedures for the replacement of

the shaft seal apply to the pump and the motor (pump
shown). 1
1. Remove the pump/motor in accordance with 1

their appropriate sections.
2. Remove cap screws, 1, holding the seal cover
and the seal retainer, 2.
19992161
9
3. After removal of the cap screws, the seal cover
may move out of its bore by approximately 6 mm
(0.25″). An outward spring force on the shaft will
tend to overcome the friction from the O ring on
the seal cover outside diameter. If the seal cover
does not move from its bore upon removal of the
cap screws, then gently pry it from the bore as
shown.
40013267
10
CAUTION
After the seal cover is removed, the shaft is free
and can be removed or may fall out of the unit. Do
not remove shaft.
4. Place the seal cover and seal in an arbor press

and remove the old seal.
5. Inspect the seal cover, the new seal, and the O
ring for any damage or nicks.
19988777
11
29-6
Op. 29 218
Shaft Seal Installation
1. Using an arbor press, install the new seal into the
cover, being careful not to damage the seal.
2. Inspect the sealing area on the shaft for rust,
wear, or contamination.
19988778
12
3. Prior to assembly, lubricate the O ring on the
outside diameter of the seal cover and the inside
diameter of the seal with petroleum jelly.
19988779
13
4. Wrap the spline or key end of the shaft with
plastic film to prevent damage to the sealing lip
on the seal during installation.
5. Assemble the seal cover and seal, 1, over the
shaft, 2, and into the seal cover cavity. 1
40013268
14
29-7
6. Install the cap screws, 1, and torque to 10 N⋅m (7
ft-lbs) on motors and torque to 13.5 N⋅m (10
ft-lbs) on pumps.
7. Install the pump/motor in accordance with their
appropriate sections. 1
40013269 1
15
Op. 29 218
Shaft Removal
NOTE: The pump and motor must be removed to
replace the shaft.
NOTE: The same procedures for replacement of the
shaft apply to the pump and motor (pump shown).
1. Drain the oil from the reservoir.
2. Remove the pump/motor in accordance with
2
their appropriate sections.
3. Remove the cap screws holding the seal cover
and seal retainer, 1. 1
1
19992161
16
4. After removal of the cap screws, the seal cover
may move out of its bore by approximately 6 mm
(0.25″). An outward spring force on the shaft will
tend to overcome the friction from the O ring on
the seal cover outside diameter. If the seal cover
does not move from its bore upon removal of the
cap screws, then pry it from the bore, and/or
lightly tap the end of the shaft with soft mallet.
40013267
17
29-8
NOTE: The inside diameter of the bearing is a press
fit on the shaft and the outside diameter of the
bearing is a slip fit in the housing.
5. Place the unit on the end cap and remove the

shaft bearing assembly, 1. With the seal
removed, the shaft assembly is free to be pulled
from the housing.
19992167
1
18
6. The motor shaft is shown removed.
7. Inspect the sealing area on the shaft for rust,
wear, or contamination.
19988780
19
8. Remove snap ring, 1, and press the bearing off
the shaft.
1
Op. 29 218
Shaft Installation
NOTE: Installation of both the pump and motor shaft
are similar (pump shown).
1. Press the bearing on the shaft and install snap

ring, 1. Use caution to prevent damage to the
sealing surface on the bearing. 19988780
20
29-9
2. Install the shaft and bearing assembly through
the front of the housing, aligning the shaft spline
with the cylinder block spline.
Continue to lower the shaft into the unit and
carefully align the end of the shaft with the end
cap journal bearing. Then lower the shaft and
bearing assembly into position.
Rotate the shaft by hand. The assembly should
rotate freely. If it does not, correct the problem
before proceeding.
The torque required to turn the shaft (after break
away) is: 19992167
Pump - 10 -17.6 N⋅m (7.5 - 13 ft-lbs) 21

Motor - 11.5 -19 N⋅m (8.5 - 14 ft-lbs)
3. Wrap the end of shaft with plastic film to prevent
damage to the sealing lip on the seal during
installation.
4. Prior to assembly, lubricate O ring on the outside
diameter of the seal cover and the inside
diameter of the seal with petroleum jelly.
5. Assemble the seal cover and seal over the shaft
and into the seal cover cavity.
40013268
22
6. Install the cap screws, 1, and torque to 9.5 N⋅m
(7 ft-lbs) on motors and torque to 13.5 N⋅m (10
ft-lbs) on pumps.
7. Install the pump/motor in accordance with their
appropriate sections. 1
8. Shut the drain valve and screw on the dust cap.

and Start-Up Procedure”.
40013269 1
23
29-10
Op. 29 212
1
Charge Pump Removal
1. Using a hex wrench, remove the six screws, 1,
holding the charge pump cover retainer. Mark the
cover orientation before disassembly.
2. Remove the retainer, 2.
40013246 1 2
24
3. Remove the charge pump cover, 1.
40013260
25
4. Remove the charge pump shaft, 1, and charge
pump drive key. Note location of key to aid
assembly.
40013261
26
29-11
5. Remove the charge pump gerotor assembly, 1.
1
40013262
27
6. Remove the inner port plates, 1, and alignment
pin, 2.
7. Inspect the port plates, gerotor assembly,
bushings, and charge pump shaft for abnormal 2
wear, damage, or foreign material.
40013263 1
28
Op. 29 212
Charge Pump Installation
1. Prior to installation, apply a small quantity of
petroleum jelly to the ID, OD and side faces of the
gerotor assembly.
NOTE: The charge pump rotation is determined by
the orientation of the gerotor assembly outer
eccentric ring and the location of the alignment pin in
the end cap. The combine uses counterclockwise
rotation.
29
29-12
2. Install the inner port plate and outer ring, 1. Use
the alignment pin, 2, to achieve the correct
orientation.
40013263 1
30
3. Install the gerotor assembly, 1.
40013264
31
4. Install the charge pump drive key, 1, into the
charge pump shaft, 2.
5. Install the charge pump shaft. The internally-
splined end of the shaft is inserted first into the 1
cavity.
40013262
2
32
29-13
6. Carefully remove the alignment pin from the
cavity without disturbing the aligned parts. Using
petroleum jelly place the pin, 1, in the charge
pump cover, 2.
7. Install the charge pump cover, 1, with the aligning
pin, 2, into the aligned parts in the cavity, taking
caution not to damage the cover O ring during
assembly.
1
40013265
2
33
8. Install the charge pump cover retainer and the six
hex screws.
NOTE: Shown is the proper torquing sequence.
Improper installation can cause charge pump failure.
9. Tighten bolt 2-finger tight. Torque bolts 1 through 3 2
6 to 13.5 N⋅m (10 ft-lbs) in proper sequence.

4 5
1 6
40013246
34
Major Repairs
Major repairs are those which require the removal of
the end cap or side cover. Repairs of this type are to
be performed only by Sauer-Sundstrand Authorized
Service Centers and/or original equipment manufac-
turers who have personnel adequately trained to
perform these repairs. Performing major repairs on
the Sauer Series 90, 100 cc and 130 cc Hydrostatic
Transmissions may affect the unit warranty status.
29-14
ELECTRIC DISPLACEMENT CONTROL

(EDC) VALVE
1
Removal
1. Thoroughly clean external surfaces prior to
removal of the control valve. Disconnect the
connector from, 1.
40013255
35
2. Using a hex wrench, remove six cap screws from
the control valve, 1. 1
40013256
36
3. Lift the valve, 1, away from the housing.
40013257
37
29-15
Op. 29 218
Inspection
CAUTION
Protect exposed surfaces and cavities from
damage and foreign material.
1. Check the surface for nicks or damage. Look for

any cracks in the surface.
2. Check that the orifice, 1, is in position.
40013258 1
38
3. To check for a plugged orifice, remove the spring
retainer, 1, spring, 2, and orifice, 3. Clean any
foreign material from the orifice.
2 1
3
19988754
39
4. Install the orifice, spring and retainer, 1.
40013258 1
40
29-16
Op. 29 218
Installation
1. In preparation for installing the control valve,
place a new gasket on the housing. Inspect to
assure that the control orifice and spring are in
the proper position in the control valve.
2. Engage the pin, 1, on the control linkage in the
mating hole, 2, in the link attached to the swash
plate.
3. Set control valve into place.
40013259
41
4. Move the control valve, 1, into place against the
pump housing, align the gasket and install the 1
cap screws.
5. Torque the cap screws, 1, to 16 N⋅m (12 ft-lbs).
40013256
42
6. Attach the connector at 1.
40013255
43
29-17
Op. 29 218
MULTI-FUNCTION VALVE
Adjustment
NOTE: Although the pump is shown removed for
clarity, most repairs and adjustments can be made
without removing the hydrostat.
WARNING
The machine must be operating to check system
pressures. Make certain that everyone is clear of
the machine and all gauges are secured.
CAUTION
Raise the combine drive wheels off the ground to
prevent the combine from traveling uncontrolled
when making adjustments. Be sure to use
suitable blocking or jack stands to support the
weight of the combine.
CAUTION
If equipped with powered rear axle make certain
the switch is off.
1. In order to set the pressure on the limiter or relief

valves, the motor output shaft must be locked so
it does not rotate. This may be accomplished by
locking the brakes.
WARNING
Take necessary precautions that the motor shaft
remains locked during the adjusting procedure.
2. Install two 690 bar (10,000 psi) pressure gauges

in the high pressure gauge ports, 1 and 2.
3. Start the combine and operate at normal speeds.
1
40013246
44
29-18
4. Loosen locking nut (smallest hex on multi-func-
tion valve), 1.
40013247
45
5. Insert a hex wrench into the pressure adjusting
screw, 1.
NOTE: A plastic dust cap may be used in the
adjusting screw.
6. Move the control lever so that pressure increases
in the high pressure closed circuit to the pressure 1
limiter setting. The limiter setting is reached
when the pressure stops increasing and remains
steady at a given level as shown on the gauges.
CAUTION
Keep clear of all drives. Rotating elements may
40013248
cause serious bodily injury.
46
7. Rotate the pressure adjusting screw with the hex
wrench until the desired pressure level is
established as shown on the gauges.
NOTE: Clockwise rotation of the adjustment screw
will increase the pressure setting, and counterclock-
wise rotation will decrease the pressure setting.
Each complete rotation of the adjusting screw
changes the pressure setting by 93 bar (1350 psi).
8. While holding the hex wrench and pressure
adjusting screw in the same position, tighten the
adjusting screw locknut, 1, to 27 N⋅m (20 ft-lbs) 1
(5 mm wrench). Do not over-torque.
9. Move the control lever so the pump returns to
neutral position. The pressure in the high
pressure circuit should return to the charge
pressure setting. To verify the actual pressure
setting, repeat step #6.
10. Shut down the combine and remove the two 690
bar (10,000 psi) gauges and install the gauge
port plugs. 40013249
11. The same procedure is used for setting the 47
pressure on the other multi-function valves, but
the control lever must be activated or moved in
the opposite direction so that the pressure
develops in the opposite high pressure side of
the closed circuit.
29-19
Op. 29 218
Removal
1. Turn the desired multi-function valve, 1, from the
pump port.
1
40013250
48
2. Inspect cartridge, 1, for damage to parts and O
rings.
1
40013251
49
Show below are the components of the multi-function
cartridge.
19988743
50
29-20
Op. 29 218
Installation
1. Install the cartridge, 1, in the multi-function valve
cavity.
1
40013251
51
2. Torque to 89 N⋅m (66 ft-lbs).
CAUTION
Do not over torque the multi-function valve
cartridge.
1
40013250
52
PUMP CHARGE PRESSURE RELIEF VALVE
3
Adjustment
To measure the pump charge pressure relief valve
2
setting, install a 35 bar (500 psi) gauge in port 1. Start
the combine and, with the hydrostatic transmission in
1
neutral, record the pressure.
CAUTION
Block the wheels so the machine cannot move.
make certain that everyone is clear of the machine.
The charge pump pressure reading should be 20.1 40013246

- 21.2 bar (291 - 308 psi). The gauge will read 22 - 23
bar (320 - 340 psi). This includes case pressure. 53
If the pump charge pressure is not within
specifications, adjust the relief valve as follows:
1. Loosen the jam nut, 2.
2. Turn the adjusting screw, 3, clockwise to
increase the pressure and counterclockwise to
decrease the pressure.
3. When the charge pump relief valve setting is
within specifications, tighten the jam nut to 52
N⋅m (38 ft-lbs) and remove the gauge.
NOTE: The pressure will change at a rate of
approximately 3.4 bar (50 psi) per turn.
29-21
Removal
1
NOTE: Before removing the screw-adjustable relief
valve plug, mark the plug, locknut, and housing to
approximately maintain the original adjustment when
assembling.
1. Remove the screw-adjustable charge relief valve

plug by loosening the locknut with a 1-1/16″
wrench and unscrewing the plug, 1, with a large
screwdriver.
40013252
54
2. Remove the spring, 1, and relief valve poppet, 2.
2 1
40013253
55
3. Inspect the poppet and mating seat in the end
cap for damage or foreign material.
40013254
56
29-22
Op. 29 218
1 2
Installation
1. Install the poppet, 1, and spring, 2.
40013253
57
2. Install the plug with its locknut, aligning the marks
made at disassembly, and torque the locknut, 1, 1
to 52 N⋅m (38 ft-lbs). The shim adjustable relief
valves are torqued to 68 N⋅m (50 ft-lbs).
3. Check and adjust the charge pressure if
necessary.
40013252
58
Op. 29 212
DRIVE MOTOR 1
Removal
Drain the hydraulic reservoir.
NOTE: During removal of the three hydraulic lines,

up to five additional gallons of fluid can be expected.
A suitable container must be positioned under the
lines to capture the residual hydraulic fluid.
Remove the two main hydraulic lines, 1, by turning

10013278
out eight cap screws.
59
29-23
Unplug electrical connector, 1. Turn out the screw
from the top of electrical connector, 2. Unplug 1
electrical connector, 2, from the solenoid.
2
10013279
60
Disconnect the case drain line, 1, at the upper elbow
union. Loosen the lower elbow union, 2, and rotate 2 1
the elbow 90 degrees.
10013280
61
Support the weight of the motor with a floor jack. Turn
off the four mounting nuts, 1, (two shown).
1
1
10013281
62
29-24
Move the motor away from the transmission until the
spline shaft is disengaged. Lower the motor from the
combine.
10013282
63
Op. 29 212
Installation
Support the weight of the motor with a floor jack.
Raise the motor into position on the transmission.
Engage the spline shaft of the motor and push it into
the female spline until the mounting flange is against
the transmission.
10013282
64
Turn on the four mounting nuts, 1, (two shown).
Torque the nuts to standard torque.
1
1
10013281
65
29-25
NOTE: The case drain line may have sprung. Use a
crowbar or other prying device to line the pipe up 1 2
enough to engage the threads of the fitting to prevent
galling.
Line the case drain elbow, 1, up with the case drain

line, 2. Engage the line into the elbow and tighten the
fitting. Tighten the lower elbow fitting. Torque both
ends of the elbow to 110 - 120 N⋅m (81 - 89 ft-lbs).
10013280
66
Plug electrical connector, 1, into the case drain line
elbow. Plug in the solenoid connector, 2. Turn in the 1
screw at the top of the connector to secure it in place.
2
10013279
67
Lubricate and install O rings into the ends of the main
hydraulic lines, 1. Attach the lines to the motor using
four cap screws for each fitting. Torque the cap 1
screws to 104 N⋅m (77 ft-lbs).

and Start-Up Procedure”.
10013278
68
Major Repairs
Major repairs are those repairs which require the
removal of the end cap or side cover. Repairs of this
type are to be performed only by Sauer-Sundstrand
Authorized Service Centers and/or original equip-
ment manufacturers who have personnel adequately
trained to perform these repairs. Performing major
repairs on the Sauer Series 90 Hydrostatic
Transmission may affect the unit warranty status,
thus the branch service manager should be
consulted prior to such an undertaking.
29-26
Cleanliness is a primary means of assuring
satisfactory hydraulic motor life, on either new or
repaired units. Cleaning parts by using a clean
solvent wash and air drying is usually adequate. As
with any precision equipment, all parts must be kept
free of foreign materials and chemicals. Protect all
exposed sealing surfaces and open cavities from
damage and foreign material.
During the assembly of the Sauer Series 90 variable

motor, all surfaces, which have relative motion
between two parts, should be coated with a film of
clean hydraulic oil. This will assure that these
surfaces will be lubricated during start-up.
Replace all O rings and gaskets. Lightly lubricate all

O rings with clean petroleum jelly prior to assembly.
All gasket sealing surfaces must be cleaned prior to
installing new gaskets.
Op. 29 218
MOTOR CHARGE RELIEF VALVE -- STYLE 1

Check
NOTE: The motor charge pump relief valve is not
adjustable.
To measure the motor charge pressure relief valve,
1, setting, install a 35 bar (500 psi) gauge in gauge
port 2. Start the combine. Engage the parking brake, 2
put transmission in fourth gear and the engine at high
idle. Apply pressure to the foot brake and stroke the
hydrostat lever. 10013271 1
CAUTION 69
Block the wheels so the machine cannot move.
Make certain that everyone is clear of the
machine.
The motor charge pressure reading must be 18.1 ±

1.4 bar (262 ± 20 psi). The gauge will read 21 ± 1.4
bar (302 ± 20 psi). This includes case pressure.
If the motor charge pressure is not within
specification, check the pump charge pressure and
adjust as previously described. Recheck the motor
charge pressure, and if it is still out of specification,
replace the relief valve.
29-27
Op. 29 218
Replace
1. Drain the hydraulic reservoir.
2. Remove the motor charge pressure relief valve, 1.
NOTE: Motor shown removed for clarity.
1
10013271
70
3. Turn in the new relief valve, 1. Torque the valve
to 52 N⋅m (38 ft-lbs). 1
10013272
71
29-28
Op. 29 218
2
SHUTTLE SPOOL VALVE -- STYLE 1
Removal
NOTE: The motor is shown removed for clarity.

2. Remove the cartridges, 1 and 2, from both sides 1
of the valve.
10013273
72
3. Push the spool, 1, out of the motor.
10013274
73
4. Inspect parts for damage or foreign material.
20015831
74
29-29
Op. 29 218
Installation
1. Install the flushing valve spool, 1. 1
10013276
75
2. Install the cartridges, 1, on each end of the spool
and torque them to 41 N⋅m (30 ft-lbs). 1
20015831
76
29-30
MOTOR CHARGE RELIEF VALVE -- STYLE 2

1
Replacement
CAUTION
Before you do service under the machine, put the
brake and stop the engine. Put blocks at the front
instructions can cause injury.
Replacing the Charge Pressure Relief Valve -

Motor 83054875
1. Drain the PTO gearbox reservoir. 77
2. Using a 22 mm wrench, remove the threaded
plug, 1, that holds the charge pressure relief
valve.
NOTE: Motor shown removed for clarity.
3. Remove the plug, 1, spring, 2, and valve, 3.
3 1
2
83054877
78
4. Place the new relief valve, 1, in the relief valve
cavity. Put the spring, 2, in after it, then the 1
threaded plug, 3. Finger tighten the threaded
plug.
2 3
83054876
79
29-31
5. Torque the threaded plug to 52 N⋅m (38 ft-lb).
6. Refill the hydrostatic transmission as described
in Section 29, Chapter 3.
63054878
80
29-32
SHUTTLE SPOOL VALVE -- STYLE 2

1 1
Removal
CAUTION
1. Drain the PTO gearbox reservoir.

2. Using a 26 mm wrench, remove the hex plugs, 1, 83054884
from both sides of the valve. 81
3. Remove the plugs, 1, O rings, 2, springs, 3, and
retaining sleeves, 4, from both sides of the 5
shuttle spool, 5.
4
3
1 2
63054886
82
4. Push the spool, 1, out of the motor.
1
83054885
83
29-33
5. Inspect parts for damage or foreign material.
83054887
84
Installation
CAUTION
Before you do service under the machine, put the 1
1. Insert the shuttle spool, 1, fully into the loop

flushing valve cavity in the motor end cap.
NOTE: Motor shown removed for clarity. 83054888
85
2. Insert each spring, 1, in its retainer sleeve, 2, and
install the springs and sleeves in each end of the
loop flushing valve cavity. Screw in the hex plugs,
3, with O rings, 4, and finger tighten. 2
1
3 4
63054886
86
29-34
3. Torque the hex plugs to 68 N⋅m (50 ft-lb).
83054883
87
29-35
PRESSURE RELEASE VALVE SOLENOID

1
Removal
1. Using a 19 mm wrench, remove the nut, 1, that 2
holds the solenoid coil, 2, in place.
83054894
88
2. Remove the coil, 1, from the solenoid valve stem.
1
83054895
89
3. Using a 22 mm box-end wrench, remove the nut,
1, that holds the solenoid pressure relief valve in 1
place.
83054896
90
29-36
4. Remove the solenoid pressure release valve, 1,
from its cavity. 1
83054897
91
Installation
1
CAUTION
1. Install the solenoid pressure release valve, 1, in

its cavity, using care to prevent damaging the
seals.
83054897
92
2. Replace the nut, 1, that holds the valve in place.
Snug firmly with a 22 mm wrench.
1
83054896
93
29-37
3. Replace the coil, 1, on the solenoid valve stem.
1
83054895
94
4. Replace the nut, 1, that holds the solenoid coil,
2, in place. Tighten with a 19 mm wrench. 1
83054894
95
29-38
PRESSURE RELEASE VALVE SPOOL

Removal
CAUTION

2. Using a 22 mm socket wrench, remove the bolt, 2

1, from the lower right-hand corner of the motor
faceplate. This will provide access to the
pressure release spool retaining plug.
1
83054890
96
3. The pressure release spool retaining plug is
accessible through the hole, 1, in the lower right
side of the motor faceplate. Use an 8 mm hex
wrench to unscrew the plug.
1
83054891
97
4. Remove the retaining plug, 1, and pressure
release spool, 2.
1
2
83054892
98
29-39
5. Remove the spring, 1, from the rear of the
pressure release spool cavity.
83054893
99
Installation
6. Inspect the spring, 1, and the pressure release
valve spool, 2, for damage or dirt before 1 2
replacing them in the pressure release valve
cavity.
83054893
100
7. Insert the spring first, then the spool, 1, in the
pressure release valve cavity.
83054892
101
29-40
8. Place the retaining plug in the threaded end of
the cavity and tighten securely, using an 8 mm
hex wrench.
NOTE: The threaded plug will need to overcome the
pressure of the spring to mesh with the cavity
threads. Use the hex wrench to push the plug in far
enough for the threads to catch.
83054891
102
9. Replace the lower right-hand faceplate bolt.
Using a 22 mm socket wrench, tighten the bolt
securely.
83054890
103
29-41
29-42
SECTION 33 -- BRAKES AND CONTROLS -- CHAPTER 1
SECTION 33 -- BRAKES AND CONTROLS
Chapter 1 -- Brakes and Controls
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Minimum Hardware Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bleeding the Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake Caliper and Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Parking Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Park Brake Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Parking Brake Piston Travel and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Parking Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Bleeding the Hydraulic Parking Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Parking Brake Caliper -- Cross Section View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
33-1
SPECIFICATIONS
Service brake disc diameter CR920, 940, 960: . . . . . . . . . 330 mm (13.0 in)
CR970, 980: . . . . . . . . . . . . . . 400 mm (15.75 in)
Service brake fluid SAE DOT 3 (Factory fill fluid)
SAE DOT 4 (High temperature stability)
Parking brake piston travel 3 -- 5 mm (0.12 -- 0.20 in)
Parking brake disc diameter 224 mm (8.82 in)
TIGHTENING TORQUES
Hex Socket Head Bolts, Brake Caliper 260 -- 270 N⋅m (192 -- 200 ft-lb)
Bleeder Screws, Service Brake 25 -- 35 N⋅m (19 -- 26 ft-lb)
Banjo Bolts, Service Brake Line 25 -- 35 N⋅m (19 -- 26 ft-lb)
End Fittings, Service Brake Line 13 -- 15 N⋅m (10 -- 11 ft-lb)
Bolts, Parking Brake Caliper Mounting 190 -- 210 N⋅m (140 -- 155 ft-lb)
Bolts, Parking Brake housing 127 N⋅m (94 ft-lb)
Bleed Screw, Parking Brake 15 -- 18 N⋅m (11 -- 13 ft-lb)
90° Elbow, Hydraulic (Hydraulic supply fitting into parking 45 -- 50 N⋅m (34 -- 36 ft-lb)
brake housing)
Fitting, Hydraulic Hose End (Hydraulic supply hose end fitting 43 -- 47 N⋅m (32 -- 34 ft-lb)
into 90° Elbow at the parking brake.)
33-2

METRIC NON-FLANGED HARDWARE AND LOCKNUTS

CLASS 5.8 CLASS 8.8 CLASS 10.9 LOCKNUT
NOMINAL CL.8
SIZE UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED W/CL8.8
W/ZnCr W/ZnCr W/ZnCr BOLT
M4 1.7 (15)* 2.2 (19)* 2.6 (23)* 3.4 (30)* 3.7 (33)* 4.8 (42)* 2.3 (20)*
M6 5.8 (51)* 7.6 (67)* 8.9 (79)* 12 (102)* 13 (115)* 17 (150)* 7.8 (69)*
M8 14 (124)* 18 (159)* 22 (195)* 28 (248)* 31 (274)* 40 (354)* 19 (169)*
M10 28 (21) 36 (27) 43 (32) 56 (41) 61 (45) 79 (58) 38 (28)
M12 49 (36) 63 (46) 75 (55) 97 (72) 107 (79) 138 (102) 66 (49)
M16 121 (89) 158 (117) 186 (137) 240 (177) 266 (196) 344 (254) 164 (121)
M20 237 (175) 307 (226) 375 (277) 485 (358) 519 (383) 671 (495) 330 (243)
M24 411 (303) 531 (392) 648 (478) 839 (619) 897 (662) 1160 (855) 572 (422)

IDENTIFICATION
HEX CAP SCREW AND CARRIAGE BOLTS
CLASSES 5.6 AND UP
PROPERTY CLASS
HEX NUTS AND LOCKNUTS

CLASSES 05 AND UP
86529681 REV F 5.1 PROPERTY CLASS CLOCK MARKING
33-3

INCH NON-FLANGED HARDWARE AND LOCKNUTS

SAE GRADE 2 SAE GRADE 5 SAE GRADE 8 LOCKNUTS
NOMINAL UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED GR.B GR.C NOMINAL
SIZE or W/ZnCr or W/ZnCr or W/ZnCr w/GR5 w/GR8 SIZE
PLATED PLATED PLATED BOLT BOLT
SILVER GOLD SILVER GOLD SILVER GOLD
1/4 6.2 (55)* 8.1 (72)* 9.7 (86)* 13 (112)* 14 (121)* 18 (157)* 8.5 (75)* 12.2 (109)* 1/4
5/16 13 (115)* 17 (149)* 20 (178)* 26 (229)* 28 (250)* 37 (324)* 17.5 (155)* 25 (220)* 5/16
3/8 23 (17) 30 (22) 35 (26) 46 (34) 50 (37) 65 (48) 31 (23) 44 (33) 3/8
7/16 37 (27) 47 (35) 57 (42) 73 (54) 80 (59) 104 (77) 50 (37) 71 (53) 7/16
1/2 57 (42) 73 (54) 87 (64) 113 (83) 123 (91) 159 (117) 76 (56) 108 (80) 1/2
9/16 81 (60) 104 (77) 125 (92) 163 (120) 176 (130) 229 (169) 111 (82) 156 (115) 9/16
5/8 112 (83) 145 (107) 174 (128) 224 (165) 244 (180) 316 (233) 153 (113) 215 (159) 5/8
3/4 198 (146) 256 (189) 306 (226) 397 (293) 432 (319) 560 (413) 271 (200) 383 (282) 3/4
7/8 193 (142) 248 (183) 495 (365) 641 (473) 698 (515) 904 (667) 437 (323) 617 (455) 7/8
1 289 (213) 373 (275) 742 (547) 960 (708) 1048 (773) 1356 (1000) 654 (483) 924 (681) 1

IDENTIFICATION
CAP SCREWS AND CARRIAGE BOLTS
SAE GRADE 2 SAE GRADE 5 SAE GRADE 8
REGULAR NUTS SAE GRADE 5 SAE GRADE 8

HEX NUTS HEX NUTS
LOCKNUTS
GRADE IDENTIFICATION GRADE IDENTIFICATION
GRADE A NO NOTCHES GRADE A NO MARKS

GRADE B ONE CIRCUMFERENTIAL NOTCH GRADE B THREE MARKS
GRADE C TWO CIRCUMFERENTIAL NOTCHES GRADE C SIX MARKS

MARKS NEED NOT BE LOCATED
AT CORNERS
GRADE A NO MARK
GRADE B LETTER B
GRADE C LETTER C
86529681 REV F 5.2
GRADE IDENTIFICATION
33-4
OVERHAUL
BRAKE PADS
Replacement
IMPORTANT: Always replace the upper and lower
brake pads at the same time. Use genuine CNH
brake pads, as they will provide the best
performance.
To replace the upper right-hand side or left-hand side
brake pads, proceed as follows:
1
1. Block the wheels adequately to prevent runaway
of the combine.
2. Raise the feeder and lower the header safety 50030333
stop, 1, onto the cylinder. Stop the engine. 1
3. On the upper brake caliper, remove two bolts, 1,
and cover, 2.
2
4. Disconnect the electric wires at 1.
1
NOTE: Only the upper brake caliper pads have
electrical connectors.
33-5
5. Remove pins, 1, out of the brake caliper and take
out the brake pads, 2. 1 2
4
NOTE: If the piston seals are replaced, then the
brakes must be bled. Reference: Bleeding the Brake 1
System, in this chapter.
6. Check the condition of the piston seals, 1. If
necessary, replace them.
7. Push the brake pistons, 2, into their housing to
allow the installation of new brake pads.
5
8. Install new CNH brake pads.
1 2
9. Secure the brake pads, 2, with pins, 1.
33-6
10. Connect electric wires at, 1.
1
7
To replace the lower brake pads on both sides:
1
NOTE: There is no cover installed on the lower brake
caliper.
11. On the lower brake caliper, remove pins, 1, out of
the brake caliper and take out the brake pads, 2.
NOTE: If the piston seals are replaced, then the
brakes must be bled. Reference: Bleeding the Brake
System, in this chapter.
1
12. Check the condition of the seals. If necessary, 2
replace them.
13. Push the brake pistons into their housing to allow 8
the installation of new brake pads.
14. Install new CNH brake pads.
15. Secure the brake pads, 2, with pins, 1, Figure 8.
16. Use the same procedure to replace the brake
pads on the opposite side of the combine.
17. Bleed the brake system if brake piston seals were
replaced.
18. At the brake fluid reservoir, 1, check the fluid
level, 2. Add or remove fluid as required to adjust
fluid level to mark on reservoir. Use only SAE
DOT 3 brake fluid, or SAE DOT 4 fluid for higher
temperature stability.
NOTE: SAE DOT 3 (factory installed grade) and SAE
DOT 4 (higher temperature stability grade) are
mutually compatible if mixed, but the higher stability
temperature provided by the DOT 4 fluid will be
lowered.
19. Check the brakes for proper operation.
33-7
BRAKE CYLINDERS
The two main cylinders, 1, are mutually connected
with connectors, 2 and 3, and further with pipe, 4, to 9 12 11 8
the fluid reservoir, 13, and with pipes, 5, to the brake
cylinders.
Fluid from the fluid reservoir, 13, follows pipe, 4, and

is distributed at connector, 3. The fluid enters the
brake main cylinder through port, 6, (pedal not
engaged).
When both brake pedals are engaged, port, 6, is shut 6

off by seal, 7, and fluid is pressed through port, 8, and 10 1 7
pipes, 5, to the brake cylinder. Ball, 9, is lifted up in
10
both main cylinders, 1, by plunger, 10.
When only one brake pedal is engaged, port, 6, is

also shut off by seal, 7, and fluid is pressed through
port, 8, and pipe, 5, to the brake cylinder.
In the other main cylinder, ball, 9, is pressed down by

the fluid pressure coming from the first cylinder
through connector, 2, and seat, 11. The fluid flow is
stopped by seal, 12.
13
11
33-8
BLEEDING THE BRAKE SYSTEM

NOTE: As the brake pedals must be depressed
several times while bleeding, this job requires two
people.
To bleed the brake system, proceed as follows:

of the combine.
Raise the feeder and lower the header safety 1
stop, 1, onto the cylinder.
Stop the engine. 50030333
12
The bleed procedures described below are
performed in the following order:
1. Check the brake fluid level, 2, at the brake fluid
reservoir, 1. Add or remove brake fluid as
required. Use only SAE DOT 3 or SAE DOT 4.
2. Bleed the left-hand side circuit.
3. Bleed the connection pipe between the two main
cylinders
4. Bleed the right-hand side circuit.
NOTE: Catch bleed brake fluid in a container.
Dispose of used fluid per local regulations. Do not
reuse. 13
NOTE: SAE DOT 3 (factory installed grade) and SAE
DOT 4 (higher temperature stability grade) are
mutually compatible if mixed, but the higher stability
temperature provided by the DOT 4 fluid will be
lowered.
33-9
Bleed the left-hand side circuit as follows:
3 1
1. Ensure the brake fluid reservoir is filled to the
maximum fluid indicator mark on the reservoir.
2. Remove rubber caps from left-hand side bleed
screws, 1, 2 and 3.
3. Slide a transparent hose over bleed screw, 1, to
direct bleed brake fluid into a catch container.
4. Open bleed screw, 1.
5. Depress and hold the left-hand side brake pedal
until fluid escapes. Do not release pedal. 2
6. Close bleed screw, 1.
14
7. Release and depress the left-hand side brake
pedal several times to build up a pressure.
8. Depress and hold left-hand side brake pedal
depressed under pressure.
9. Open bleed screw, 1, slightly to allow air and fluid
to escape.
10. Close bleed screw, 1, and release the brake
pedal.
11. Repeat steps seven to ten until fluid, free of air
bubbles, escapes through bleed screw, 1.
12. Remove the transparent hose from bleed screw,
1, and install the rubber cap.
13. Repeat steps one through twelve for each
remaining bleed screw; the lower caliper bleed
screw, 2, and then the upper caliper inner bleed
screw, 3.
14. Bleed the connection pipe between the two main
cylinders, as described in the following proce-
dure.
33-10
Bleed the connection pipe between the two main
cylinders as follows:
maximum fluid indicator mark on reservoir.
2. Remove rubber caps from right-hand side bleed
screws, 1, 2 and 3.
3. Slide a transparent hose over outside bleed
screw, 1, to direct bleed brake fluid into a catch
container.
4. Open outside bleed screw, 1.
5. Depress and hold the right-hand side brake pedal
until fluid escapes. Do not release pedal. 15
6. Depress the left-hand side brake pedal once,
holding the pedal depressed. Do not release
pedal.
7. Close bleed screw, 1
8. Release the right-hand side brake pedal and then
the left-hand side brake pedal.
9. Repeat steps four to eight until brake fluid, free of
air bubbles, escapes from bleed screw, 1.
10. Bleed the right-hand side circuit.
Bleed the right-hand side circuit as follows:

maximum fluid indicator mark on reservoir.
2. Depress the right-hand side brake pedal several
times to build up a pressure.
3. Keep the pedal depressed.
4. Open bleed screw, 1, slightly to allow air and fluid
to escape.
5. Close bleed screw, 1, and release the brake
pedal.
6. Repeat steps two to four until fluid, free of air
bubbles, escapes through bleed screw, 1. 16
7. Remove the transparent hose from bleed
screw, 1, and install the rubber cap.
8. Repeat steps one through six for each remaining
bleed screw; the lower caliper bleed screw, 2, and
then the upper caliper inner bleed screw, 3.
9. Ensure all bleed screw rubber caps are installed.
10. Torque all bleed screws to 25 -- 35 N⋅m (19 -- 26
ft-lb).
11. Check and adjust the brake fluid level as
described in primary step 2.
12. Check the brakes for proper operation.
33-11
BRAKE CALIPER AND BRAKE DISC

Removal
NOTE: Catch bleed brake fluid in a container. Dispose
of used fluid per local regulations. Do not reuse.
NOTE: Cap or plug open brake lines to prevent dirt
ingress.
IMPORTANT: Ensure the brake lines are not crimped
or damaged when handling.
To remove the brake caliper and brake discs on both
sides of the transmission, proceed as follows:
Remove the half-shafts. Reference Section 25,
Chapter 1, “Half-shaft -- Removal.”
1. Disconnect the banjo bolts, 1, on brake line, 2,
from the upper and lower brake calipers.
2. Disconnect brake line banjo bolt from the lower
caliper feeding port, 3.
1 2
17
3. Turn disc, 1, until the holes in the disc aligns with
hex socket head screws, 2 and 3.
4. Remove two hex socket head screws, 2 and 3.
5. Remove upper brake caliper, 4.
18
6. Remove bolt, 2, to free the lower caliper bleed
line, 1.
7. If required, disconnect bleed line, 1, from the
lower caliper at the banjo bolt, after the caliper is
removed.
19
33-12
8. Remove two hex socket head screws, 1 and 2.
9. Remove lower brake caliper, 3.
20
21
11. Remove brake disc, 1.
12. Repeat the procedure for the opposite side.
22
33-13
Installation
To install the brake calipers and brake discs on both
sides of the transmission, proceed as follows:
1. Lubricate the output shaft splines with Molykote

G-n paste.
2. Install brake disc, 1, on the output shaft of the
transmission.
23
3. Secure the brake disc on the output shaft with
retaining ring, 1.
24
4. If removed, connect the lower caliper bleed line
to the lower caliper prior to installing the caliper as
described below.
5. Tighten and torque the banjo bolt to 25 -- 35 N⋅m
(19 -- 26 ft-lb).
6. Apply Loctite 242/243 on Hex Socket Head
Screws, 1 and 2.
7. Install lower brake caliper, 3, and then tighten and
torque the Hex Socket Head Screws, 1 and 2, to
260 -- 270 N⋅m (192 -- 200 ft-lb).
25
33-14
8. Secure the bleed line, 1, to the transmission with
bolt, 2. Torque to 45 -- 55 N⋅m (33 -- 40 ft-lb.). If
bleed line fittings were loosened, torque to 13 --
15 N⋅m (10 -- 11 ft-lb).
26
9. Rotate the brake disc, 1, to align the hardware
access holes to the caliper mounting holes in the
transmission housing.
10. Apply Loctite 242/243, on Hex Socket Head
Screws, 2 and 3.
11. Install upper brake caliper, 4, with the Hex Socket
Head Screws.
12. Tighten and torque screws, 2 and 3, to 260 -- 270
N⋅m (192 -- 200 ft-lb).
27
13. Connect the banjo bolts, 1, of brake line, 2, to the
upper and lower brake calipers.
14. Tighten and torque the banjo bolts to 25 -- 35 N⋅m
(19 -- 26 ft-lb).
15. If the brake line, 1, fittings were loosened, torque
the fitting to 13 -- 15 N⋅m (10 -- 11 ft-lb).
1
16. Connect the supply brake line banjo bolt to the 2
supply port, 3, of the lower caliper.
17. Tighten and torque the banjo bolt to 25 -- 35 N⋅m
(19 -- 26 ft-lb). 2
3
18. If the supply brake line fitting was loosened from
the banjo bolt at the supply port, 3, torque the 28
fitting to 13 -- 15 N⋅m (10 -- 11 ft-lb).
19. Repeat the procedure for the opposite side.
Install the half-shafts. Reference Section 25, Chapter

1, “Half-shaft -- Installation.”
33-15
PARKING BRAKE CALIPER

Removal
NOTE: The parking brake caliper can be removed
without removal of the service brake calipers and
disc.
To remove the parking brake caliper and parking
brake disc, proceed as follows:
1. Disconnect the hydraulic oil supply line 90° elbow
fitting, 1, from the parking brake caliper housing.
29
2. Remove two bolts, 1, and the parking brake
caliper assembly.
3. Remove the four bushings, at 2, from the
housing. 2
30
33-16
Installation
To install the parking brake caliper, proceed as
follows:
2
1. Apply grease to the bushings and fill the cavity of
the two guides with NH AMBRA GR75 MD
grease.
2. Install the bushings into the guides of the parking
brake housing, at 2.
NOTE: Ensure the grease seals, on OD of bushing,
are properly installed and in good condition. Replace
if needed.
3. Apply Loctite 242/243, to bolts, 1. 31
4. Install the parking brake caliper and tighten bolts,

1, to a torque of 190 -- 210 N⋅m (140 -- 155 ft-lb).
NOTE: Ensure the parking brake caliper slides freely
on the bushings.
5. Connect the 90° elbow fitting, 1, of the parking
brake hydraulic supply line to the parking brake.
6. Torque the fitting to 45 -- 50 N⋅m (34 -- 37 ft-lb).
7. If the hydraulic supply hose end fitting was
loosened, torque to 43 -- 47 N⋅m (32-- 34 ft-lb).
8. Bleed the parking brake cylinder as described in
this chapter; “Bleeding the Hydraulic Parking
Brake Caliper”.
32
PARKING BRAKE DISC
Removal
To remove the parking brake disc, proceed as
follows:
NOTE: To remove the parking brake disc, the brake

calipers and the brake disc need to be removed.
33
33-17
2. Remove parking brake disc, 1.
34
35
Installation
To install the parking brake disc, proceed as follows:

2. Apply Molykote G-n paste to the shaft splines.
36
33-18
3. Install parking brake disc, 1.
37
38
33-19
PARK BRAKE OVERRIDE

WARNING 1
If machine is on a slope and the above procedure
is performed, the machine will roll. Perform the
above procedure only when machine is on a flat
surface or completely restrained by blocking the
wheels.
If it is not possible to release the parking brake

electrically, it can be released hydraulically. To
release the parking brake hydraulically, proceed as 2
follows.
39
NOTE: The hydraulic override is the preferred
method to safely override the parking brake. If the
hydraulic method fails, the brakes can be released
manually using great care.
1. Raise the feeder and lower the header safety stop
onto the cylinder. Stop the engine.
of the combine.
3. A tow valve is located behind the trim panel
between the front ladder deck and the grain tank.
This valve allows manual release of the park
brake using hydraulics.
• Block the combine front to rear.
• Turn key switch to on position.
• Turn park brake to off position. Alarm will
come on indicating park brake is not
engaging.
• To operate, turn knob, 1, to the detent
position. Use hand pump, 2, to release park
brake (approximately 60 pumps).
• Return valve, 1, to the detent position to set
park brake and for normal operation. Park
brake is fully released when park brake lamp
on shaft speed monitor goes off.
33-20
To release the park brake manually if the
hydraulic method fails proceed as follows:
DANGER
Be aware that the emergency brake does not
operate when the brake is manually disengaged.
1. Raise the feeder and lower the safety stop onto

the cylinder. Stop the engine.
of the combine.
3. Remove safety plate, 2, and rubber boot, 1.
40
4. Remove cotter pin, 1, and turn nut, 2, clockwise
until the parking brake piston is completely pulled
backwards to release the pressure on the parking
brake disc. 2
41
33-21
PARKING BRAKE PISTON TRAVEL AND

ADJUSTMENT
WARNING
wheels.
To maintain a correct and constant braking force as

brake pads wear or are replaced, a clearance check
and possible adjustment of the parking brake has to
be carried out every 600 operating hours or annually.
This procedure will disengage parking brake,
adequately block the wheels to prevent combine from
moving.
Proceed as follows:
1. Park the combine on level ground and block the
wheels adequately to prevent the combine from
moving.
2. Raise the feeder house and lower the header
safety stop, 1, onto the cylinder. Stop the engine.
50030333
42
43
33-22
4. Measure distance X mm (X in).
44
5. Remove cotter pin, 2.
6. Turn nut, 1, clockwise until the parking brake
piston is completely pulled backwards.
1
45
7. Measure distance Y mm (Y in).
8. The difference X -- Y mm (X -- Y in) is the piston
travel and should be 3 -- 5 mm (0.12 -- 0.20 in).
9. If the piston travel exceeds 5 mm (0.20 in), the
piston travel has to be adjusted by removing one
or more sets of half-shims.
10. If piston travel is less than 3 mm (0.12 in) the
piston travel must be adjusted by adding one or
more sets of half-shims stored between the cover
bolts and the housing.
46
33-23
11. Loosen housing cover bolts, 1, and remove or
add as many half-shims sets as necessary.
12. Install any removed half-shim sets between the
cover bolts and the housing, 3, to prevent loss of
the shims. The removed shims will be reinstalled
when the parking brake pads are replaced as part
of the adjustment procedure.
13. It is not necessary to remove the bolts completely
to remove or add a half-shim sets, 2.
14. Removing or adding one set of half-shims will
reduce or increase the piston travel by 2 mm
(0.078 in).
15. Tighten and torque the housing cover bolts, 1,
127 N⋅m (94 ft-lb).
16. Check piston travel. Readjust if necessary.
17. Unscrew nut, 4, to the cotter pin hole at the end
of the shaft.
18. Turn nut, 1, counterclockwise to align with hole at
the end of the central rod, and then secure nut, 1,
with cotter pin, 2.
1
47
19. Re-install rubber boot, 1, and safety plate, 2.
This procedure does not cover checking of the
parking brake pad wear. It is the operator’s
responsibility to check this on a regular basis. The
brake pads must be replaced if the remaining
thickness is less than 1 mm (0.039 in).
48
33-24
PARKING BRAKE PADS

DANGER
Shut down the machine, remove key, be sure all
moving parts have stopped and all pressure in
the systems is relieved before cleaning, adjust-
ing or lubricating the equipment.
WARNING
wheels.
Replacement
The parking brake pads must be replaced if the
remaining thickness is less than 1 mm (0.039 in).
IMPORTANT: Use genuine CNH brake pads as they

will give the best performance
1. Override the parking brake (refer to the “Park

Brake Override ” portion of this chapter).
2. Remove cotter pin, 1, and shaft, 2, together with
washers, 3, and spring, 4, on both sides of the
parking brake caliper.
3. Remove the brake pads.
49
4. Install a new set of pads, 5.
5. Re-install washers, 3, spring, 4, and shaft, 2. 5
Secure with cotter pin, 1.
6. Check for correct piston travel and adjustment.
(Refer to the “Parking Brake Piston Travel and
Adjustment” portion of this chapter.
50
33-25
BLEEDING THE HYDRAULIC PARKING

BRAKE CALIPER
WARNING
wheels.
NOTE: Catch bleed hydraulic fluid in a container.

Dispose of used hydraulic fluid per local regulations.
Do not reuse.
As a safety precaution, this bleed operation is
performed with the combine engine stopped, and unit
blocked to prevent rolling. This bleed procedure used
only the hydraulic head pressure created by the
elevated location of the hydraulic reservoir.
1. To bleed the hydraulic parking brake caliper,
proceed as follows:
1. Park the combine on level ground and block
the wheels adequately to prevent the
combine from moving.
2. Remove rubber cap, 2, from bleed screw, 1.
3. Slide a transparent hose over the bleed
screw, 1, to direct bleed hydraulic fluid into a
catch container.
4. Open the bleed screw until the oil, free of air
bubbles, escapes through the bleed screw.
5. Close the bleed screw. Torque bleed screw to 51
15 -- 18 N⋅m (11 -- 13 ft-lb).
6. Remove transparent hose and reinstall
rubber cap, 1.
7. Exit from underneath the combine to check
the parking brake operation.
8. Ensure no one is under the combine. Start the
combine engine.
9. From the cab, electrically disengage and
engage the parking brake a few times to
verify operation.
10. Engage the parking brake and stop the
engine.
11. If parking brake is not properly disengaging,
repeat the bleed procedure.
12. Check the Hydraulic Reservoir for correct oil
level. Add NH AMBRA MASTERTRAN as
needed.
33-26
PARKING BRAKE CALIPER

Parking Brake Caliper -- Cross Section view
52
1. Housing 10. Cotter pin
2. Shaft 11. Rubber cap
3. Seal 12. Seal reinforcement
4. O-ring 13. O-ring
5. Piston 14. O-ring
6. O-ring 15. Shims
7. Retaining ring 16. Spring
8. Washer 17. Spring guide
9. Nut 18. Lever
33-27
Disassembly
To disassemble the parking brake caliper, proceed as
follows:
WARNING
wheels.

53
2. Remove cotter pin, 2, and turn on nut, 1, until the
parking brake piston is completely pulled
backwards.
1
54
3. Loosen the cover bolts, 1, and remove all the
half-shims, 2, between the cover and housing, 1
and also, any shims stored between the cover
bolts, 1, and the cover, 3.
4. Completely remove cover bolts, 1, with washers
and the cover housing, 3.
3 2
55
33-28
5. Remove springs, 1.
56
6. Remove piston, 1.
57
7. Replace O-ring, 1, and seal reinforcement, 2.
Apply lubricant when installing new O-ring. 3
8. Remove piston from rod and replace seal, 3.
58
33-29
9. In the housing, replace seal, 1, and O-ring, 2.
NOTE: For better access to the seal, remove the 1
housing from the transmission as described
previously in this chapter.
59
Assembly
To assemble the parking brake caliper, proceed as
follows:
1. Place piston, 1, as shown.
60
2. Install springs, 1.
61
33-30
3. Install housing, 1, and washer, 2.
2
62
4. Screw on nut, 2, and tighten it until the piston is
against housing, 1. 2
NOTE: Be careful not to damage the seal and the
reinforcement in the piston.
63
5. Apply a cable tie, 2, around the seal and the seal
reinforcement and position the piston in 2
housing, 1. 1
64
33-31
6. Insert four bolts, 2, and screw them simulta-
neously until the seals are in housing, 1. 1
7. Remove the cable tie.
2
65
8. Install all half-shim sets, 2, between the housing
cover, 3, and the inner housing. 1
9. Tighten and torque the four housing cover bolts,
1, to 127 N⋅m (94 ft-lb).
10. Unscrew the castle nut, 4, until the slots align with
the cotter pin hole in the shaft.
4
NOTE: It is not necessary to install the cotter pin
when the nut, 4, is aligned to the cotter pin hole as it
is removed in the next operation of travel adjustment.
11. Check for correct piston travel and adjustment. 3 2
(Refer to the “Parking Brake Piston Travel and
Adjustment” portion of this chapter).
66
12. Bleed the parking brake as described in the
“Bleeding the Hydraulic Parking Brake Caliper”
portion of this chapter.
33-32
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
Chapter 1 - Introduction
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
High Pressure System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Low Pressure System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Low Pressure Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
High Pressure Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
High Pressure System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
High Pressure Circuit Diagram, Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
High Pressure Circuit Diagram, Main (with Hydraulic Cleaning Fan) . . . . . . . . . . . 10
Main Frame Stack Valve (NA Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Feeder Stack Valve (NA Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Main Frame Stack Valve (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Feeder Stack Valve (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Low Pressure System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Low Pressure System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Low Pressure System with Positive Straw Discharge . . . . . . . . . . . . . . . . . . . . . . . 32
-- Model Year 2004 and Earlier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
-- Model Year 2005 and Later . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
35-1
SPECIFICATIONS
HIGH PRESSURE SYSTEM

Main Hydraulic Pump
Type Variable Flow Closed Center Load Sensing Piston Pump
Displacement 45 cc/rev (2.75 cu. in/rev)
Minimum Output @ engine rated speed 114 l/min (30 US gpm)
Standby Pressure 19 bar (275 psi)
Maximum System Pressure 210 bar (3046 psi)
Inline Pressure Filter

Type Inline, serviceable
Nominal Rating (approx.) 100 micron
Return Filter
Type Cartridge, spin-on
Nominal Rating 10 micron
Priority Valve
Priority flow to Steering 35 l/min (9 US gpm)
Maximum Steering Pressure 185 bar (2683 psi)
Steering Motor, NA
Type Load Sensing, Dynamic signal non-reactive neutral logic for
cylinder workports
Steering Motor, Europe (HD Adjustable or PRA Axle)

cylinder workports
Displacement 160cc/320cc per rev variable (9.6 cu. in/19 cu. in per rev)
Shock Relief Valves 235--255 bar (3410--3700 psi)
Steering Motor, Europe (HD Fixed Axle)

cylinder workports
Displacement 125cc/250cc per rev variable (7.5 cu. in/14.8 cu. in per rev)
Shock Relief Valves 235--255 bar (3410--3700 psi)
35-2
Accumulator Valve
Header Shock Relief Valve 210 bar (3046 psi)
Header Accumulator
Precharge Pressure 70 bar (1015 psi)
Volume 0.5 L (17 oz)
Lateral Float Accumulators

Precharge Pressure, rod end accumulator 80 bar (1160 psi)
Precharge Pressure, base end accumulator 100 bar (1450 psi)
Volume 0.5 L (17 oz)
Rotor/Feeder Variator Circuits

Pressure--compensated flow control valve 0.16 liters/min (5.4 fl oz/min)
Hydraulic Cleaning Fan Drive

Relief valve 315 bar (4500 psi)
LOW PRESSURE SYSTEM

Low Pressure Pump
Type Gear Type Pump
Minimum Output @ engine rated speed 43 l/min (11.4 US gpm)
Chaff Spreader Valve

Chaff Spreader Motor Relief Valve 200 bar (2900 psi)
Chaff Spreader/PSD Valve

Chaff Spreader/PSD Motor Relief Valve 190 bar (2750 psi)
Differential Pressure Sensing Valve 11 bar (160 psi)
Chopper Infeed Roll Motor Valve

Type Bypass, manual rotary
Pressure Filter
Type Cartridge, spin-on
Nominal Rating 10 micron
Low Pressure Valve Block

Regulated System Pressure 25 bar (363 psi)
Cooler Bypass Valve 3.5 bar (50 psi)
Lubrication Pressure 2.75 bar (40 psi)
35-3
INTRODUCTION
The hydraulic system on CR combines contains two
separate circuits: 1
LOW PRESSURE CIRCUIT

The low pressure circuit operates the main, unload
and feeder engagement clutches, parking brake and
optional chaff spreader.
The circuit is fed by a gear pump, 1, mounted on and
driven through the high pressure closed center load
sensing (CCLS) variable displacement pump, used
for the high pressure circuit. 1
The low pressure circuit uses the main gearbox oil for
its reservoir. The oil is drawn from the gearbox and
pumped through the chaff spreader motor valve
block, 1, (if equipped) and the pressure filter, 2. A 1
relief valve, 3, in the chaff spreader motor valve block,
protects the chaff spreader motors and, if present, the
positive straw discharge (PSD) motor or the chopper
infeed roll motor. The relief valve is set at 200 bar
(2900 psi).
2
3
10020028
2
Oil then flows to the low pressure valve block, 1,
which is located on the left hand side of the combine
on top of the engine gearbox. This valve block directs
the oil, via solenoid valves, to the clutches and park
brake. The low pressure valve block contains a relief
valve, 2, which regulates the low pressure at 25 bar
(363 psi). Excess oil from the relief valve passes
through an oil cooler and is then directed to the lu- 3
brication circuits for the main and unloading clutches
in the gearbox. The lubrication pressure is regulated
by a check valve, 3, set at 2.75 bar (40 psi). Excess
oil from the lube check valve is returned to the gear-
box.
2 1
10004669
35-4
HIGH PRESSURE CIRCUIT

The high pressure circuit operates all of the work hy- 1
draulics and steering. The circuit is fed by a closed
center load sensing (CCLS) variable displacement
pump, 1, mounted on the engine gearbox. The pump
draws oil from a cross that connects the main reser-
voir, cooler return and hydraulic return lines with the
CCLS pump suction line. The CCLS pump pumps the
oil through an inline pressure filter to the main frame
valve stack.
4
The oil enters the main frame valve stack at the prior-
ity valve section, 1; this valve provides priority oil flow
up to 35 l/min (9 US gpm) to the steering circuit, and
also contains the steering circuit relief valve.
The secondary hydraulic functions in the main frame
1
valve stack include the header height control valve, a
header accumulator control valve, unloading auger
swing, rotor variator valve, and feeder variator valve
(if equipped).
10020031
5
The steering motor, 1, is mounted directly under the
cab, and is connected to the bottom of the steering 1
column. A fixed displacement steering motor is used
for the North American market, while a variable dis-
placement steering motor with shock relief valves is
used in all other markets.
35-5
The feeder stack valve is an extension of the main
frame stack valve, and is connected with pressure,
return and load sensing lines from the main frame
stack valve. The feeder stack valve contains the
feeder reverser valve, lateral flotation valve, reel lift,
fore/aft and drive valves and stone trap valve sec-
tions.
The bottom section of the feeder stack valve is a flush
valve. This valve allows a small amount of oil flow
through the stack valves, when no services are being
operated, allowing warm oil to bring the stack valve
assembly gradually up to operating temperature.
10020032
7
The circuit return oil flows through the return filter, 1,
and then back to the pump or to the reservoir.
1
10020028
8
While the hydraulic cleaning fan drive is not
technically part of the high pressure hydraulic circuit, 1 3
it draws its supply oil from the hydraulic reservoir. If
the combine is so equipped, the fan drive pump, 1, is
mounted on, and driven by, the hydrostatic drive
pump, 2. The pump draws oil from the hydraulic 2
reservoir at inlet port, 3, and directs the oil to fan drive
valve, 4, at inlet port P, 5. Oil flow to the hydraulic
cleaning fan motor is controlled by a pulse 7
width-modulated (PWM) solenoid valve, 6, to 5
maintain a constant fan speed regardless of engine 6
speed. Oil flow is directed to the fan motor from port
A on the rear of the valve block. Return oil from the 4
10051771
motor re-enters the valve at Port B, also on the rear
of the valve block, and exits the valve at port T, 7, from 9
which it returns to the reservoir.
35-6
HYDRAULIC SYMBOLS
Engine Gearbox
Hydraulic pump, single

direction with variable Hydraulic pump single
displacement direction fixed displacement
Hydraulic pump, bi-- Steering motor

directional with variable (bi--directional)
displacement
Motor
Motor, single direction bi--directional
fixed displacement fixed displacement
2 position valve 3 position valve
Proportional (PWM) valve Pressure relief valve
Proportional solenoid
Solenoid controlled movement
movement (Pulse Width Modulation)
Movement by or against Movement by or against

spring tension adjustable spring tension
Movement by or against
oil pressure Lock out valve
Non return valve Non return valve,

pressure controlled
Quick coupler with non
return valve Flexible hose
Restrictor Thermostat
Hydropneumatic Cylinder
accumulator
Filter Filler opening
Shuttle valve Reservoir
Pressure sensor Temperature sender
Oil to air cooler

Electrical indicator
35-7
HIGH PRESSURE SYSTEM DESCRIPTION

SCHEMATIC DIAGRAMS
High Pressure Circuit Diagram, Main
CR 920/940/960/970/980
1. Engine (min: 1300, max: 2100 rev/min) 14. Feeder variator valve (if equipped)
2. Gearbox 15. Top plate
3. Hydrostatic pump 16. Feeder stack valve top plate
4. CCLS pump 17. Feeder and header reversing valve
(114 l/min [30 gal/min])
18. Lateral flotation control valve
5. Low pressure gear pump
19. Reel horizontal adjustment valve
(43 l/min [11.4 gal/min])
6. Load sensing valve 20. Reel vertical adjustment valve
7. High pressure relief valve -- 210 bar (3046 psi) 21. Reel drive / speed adjustment valve (if equipped)
8. In--line high pressure filter 22. Stone trap valve
9. Priority valve 23. Flush valve
10. Header height control valve 24. Thermostat valve
11. Accumulator lock out valve 25. Cooler
12. Rotor variator valve 26. Return filter with by--pass
13. Unloading auger swing valve 27. Reservoir
35-8
16
17
18
15
19
14
20
13
21
12
9
22
11
23
10
1
2 3
24
4
8
25
26
7 5 27
10
35-9
High Pressure Circuit Diagram, Main
(with Hydraulic Cleaning Fan)
CR 920/940/960/970/980
1. Engine (min: 1300, max: 2100 rev/min) 15. Top plate
2. Gearbox 16. Feeder stack valve top plate
3. Hydrostatic pump 17. Feeder and header reversing valve
4. CCLS pump 18. Lateral flotation control valve
(114 l/min [30 gal/min]) 19. Reel horizontal adjustment valve
5. Low pressure gear pump 20. Reel vertical adjustment valve
(43 l/min [11.4 gal/min]) 21. Reel drive / speed adjustment valve (if equipped)
6. Load sensing valve 22. Stone trap valve
7. High pressure relief valve -- 210 bar (3046 psi) 23. Flush valve
8. In--line high pressure filter 24. Thermostat valve
9. Priority valve 25. Cooler
10. Header height control valve 26. Return filter with bypass
11. Accumulator lock out valve 27. Reservoir
12. Rotor variator valve 28. Hydraulic cleaning fan drive pump
13. Unloading auger swing valve 29. Hydraulic cleaning fan valve block
14. Feeder variator valve (if equipped) 30. Hydraulic cleaning fan motor
35-10
16
17
18
15
19
14
20
13
12 21
9 30 22
11 23
10
1
2 3 29
24
4
8
25
28
26
7 5 27
66060556
11
35-11
Main Frame Stack Valve (NA Only)
CR 920/940/960/970
1. Priority valve 13. Header lower valve
2. Steering relief valve - 185 bar (2683 psi) 14. Header lift cylinders
3. Priority flow divider valve 15. Electronic control unit
4. Steering motor - 315 cc/rev (18.9 cu. in./rev) fixed 16. Rotor variator valve
5. Steering cylinders 17. Flow control valve - 0.16 L/min. (5.4 oz./min.)
6. Header height control valve
18. Rotor variator adjustment plunger
7. Accumulator lock out valve
19. Unloading auger swing valve
8. Header shock relief valve -- 220 bar (3190 psi)
20. Unloading auger cylinder lock out
9. Header suspension accumulator
(pressure:70bar [1015 psi], vol:0.5L [17 oz]) 21. Unloading auger cylinder
10. Pressure sensor 22. Feeder variator valve
11. Header lift pressure compensator valve 23. Feeder variator adjustment plunger
12. Header raise valve 24. Top plate
35-12
24
17
22 23 20
21
19
17
16 18
4
5
2
3
1 9
8
11 10
7 14
6
15
12 13
12
35-13
Feeder Stack Valve (NA Only)
CR 920/940/960/970
1. Feeder stack valve top plate 10. Reel horizontal adjustment cylinders
2. Feeder and header reversing valve 11. Reel vertical adjustment valve
3. Feeder and header reversing motor 12. Reel vertical adjustment cylinders
4. Lateral flotation control valve 13. Reel drive / speed adjustment valve
5. Lateral float pressure compensation valve 14. Reel pressure compensation valve
6. Lateral flotation cylinder 15. Reel drive motor
7. Lateral float accumulator
16. Multi--line quick coupler
(pressure: 80 bar [1160 psi], vol: 0.5L [17 oz])
8. Lateral float accumulator 17. Stone trap valve
(pressure: 100 bar [1450 psi], vol: 0.5L [17 oz]) 18. Stone trap cylinder
9. Reel horizontal adjustment valve 19. Flush valve
35-14
3 1
12 10
7 2
6
15
4
8 5
9
11
16 13
14
17
18
19
20020029
13
35-15
Main Frame Stack Valve (Europe Only)
CR 960/980
1. Priority valve 12. Header raise valve
2. Steering relief valve - 185 bar (2683 psi) 13. Header lower valve
3. Priority flow divider valve 14. Header lift cylinders
4. Steering motor - 160/320 cc/rev 15. Electronic control unit
(9.6/19 cu. in./rev) variable 16. Rotor variator valve
5. Steering cylinders 17. Flow control valve - 0.16 L/min. (5.4 oz./min.)
6. Header height control valve 18. Rotor variator adjustment plunger
7. Accumulator lock out valve 19. Unloading auger swing valve
8. Header shock relief valve -- 220 bar (3190 psi) 20. Unloading auger cylinder lock out
9. Header suspension accumulator 21. Unloading auger cylinder
(pressure:70bar [1015 psi], vol:0.5L [17 oz]) 22. Feeder variator valve
10. Pressure sensor 23. Feeder variator adjustment plunger
11. Header lift pressure compensator valve 24. Top plate
35-16
24
17
22 23
20
21
19
17
16 18
4
2 5
1 3
9
11 10
7
6
14
12 13 15
14
35-17
Feeder Stack Valve (Europe Only)
CR 960/980
1. Feeder stack valve top plate 9. Lateral float minimum pressure valve
2. Feeder and header reversing valve 10. Reel horizontal adjustment valve
3. Feeder and header reversing motor 11. Reel horizontal adjustment cylinders
4. Lateral flotation control valve 12. Reel vertical adjustment valve
5. Lateral float pressure compensation valve 13. Reel vertical adjustment cylinders
6. Lateral flotation cylinder
14. Multi-line quick coupler
7. Lateral float accumulator
15. Stone trap valve
(pressure: 80 bar [1160 psi], vol: 0.5L [17 oz])
8. Lateral float accumulator 16. Stone trap cylinder
(pressure: 100 bar [1450 psi], vol: 0.5L [17 oz]) 17. Flush valve
35-18
3 1
13 11 7
6 2
8 9 5
10
12
14
15
16
17
20020022
15
35-19
COMPONENT LOCATIONS
3
4
66060559
16
1. Reservoir 5. Steering motor
2. Closed center load sensing (CCLS) pump 6. Feeder stack valve
3. High pressure filter 7. Return filter
4. Main stack valve
35-20
COMPONENT DESCRIPTIONS
3 1
Hydrostatic Pump, 1 2
Although not part of the high pressure system, the re-
turn oil from the hydrostatic system is used as charge
pressure oil for the high pressure CCLS pump.
Closed Center Load Sensing (CCLS) Pump, 2
Provides the oil for the high pressure system. Will
supply the pressure as demanded by the services in
use due to its load sensing and variable displacement
capability. Has the advantage over a fixed pump in
that it reduces the engine power absorbed when
maximum pump flow is not required. 17
Low Pressure Gear Pump, 3
Totally separate from the high pressure system.
Mounted on the CCLS pump from where it takes its
drive.
Load Sensing Valve (mounted on CCLS pump), 1

High Pressure Relief Valve (mounted on CCLS
pump), 2
Output from the CCLS pump is determined by adjust-
ing the angle of the swash plate. The load sensing
valve senses the circuit operating pressure and ad-
justs the swash plate angle to control pump output. If
pump output rises to 210 bar (3046 psi) the high pres-
sure relief valve over rides the load sensing valve and
adjusts the swash plate angle to limit maximum sys-
tem pressure.
1 2
18
In Line High Pressure Filter, 1

A replaceable filter located between the CCLS pump
output and the high pressure system priority valve.
10020033
19
35-21
10020031
20
Main Frame Stack Valve Assembly
Priority Valve, 1 Rotor Variator Control Valve, 4
Controls the plunger within the rotor variator drive unit
Located in the main frame stack valve, receives the
to provide adjustable variator speed. Solenoid oper-
output oil from the CCLS pump and will provide steer-
ated valves either allow pressure oil to provide a
ing with the priority for oil. Balance of oil supply is al-
speed increase or release oil pressure to decrease
lowed to flow into main gallery for remaining valves in
speed.
stack. Also contains the steering circuit relief valve.
Unloading Auger Swing Valve, 5
Accumulator Lock Out Valve, 2 Controls the unloading auger swing cylinder. Con-
sists of two electrically operated solenoid valves.
Controls the pressure within the header height cylin-
ders. Feeder Variator Control Valve (not shown)
Controls the plunger within the feeder variator drive
Contains the header shock relief valve, accumulator unit to provide adjustable variator speed. Solenoid
lock out valve and pressure sensor. operated valves either allow pressure oil to provide a
speed increase or release oil pressure to decrease
Header Height Control Valve, 3 speed.
Controls the raising and lowering of the header. Con- Top Plate, 6
tains the PWM raise and lower valves and compensa- Provides pressure and load sense connections to
tion valve. feeder stack valve.
35-22
Main Stack Plumbing
6 7
1 -- Flow from CCLS pump
8
2 – Return from feeder stack valve 1
3 – Return flow (combined) to filter and reservoir
4 – Steering load sense 5
2
5 – Steering return flow
6 – Feeder stack valve load sense 4
7 – Flow to Feeder stack valve
10020031 3
8 -- Pressure--compensated flow control valve [0.16
liters/min (5.4 fl oz/min)] 21
Back of Main Stack

1 – Tubing to header lift cylinders 6
2 – Tubing to header accumulator
3 – Header shock relief valve 5
4 – Flow to steering motor
5 -- Rotor Increase solenoid 3
6 – Unload auger swing in solenoid
4
2
1
10020035
22
Front of Main Stack
1 – HHC Module
Controls the header height via the head raise and 8
lower solenoids, based on the signal sent by the oper- 6
ator cab controls, the feeder angle sensor and pres- 7
sure sensor.
2 – Head Lower solenoid
4
3 – Head Raise solenoid
4 – Pressure sensor 5
Measures the pressure in the header lift cylinders. 2
Signal is supplied to the HHC module.
5 – Accumulator solenoid 3 1
10020036
Disconnects the accumulator when raising the
header to prevent delay in raise response. 23
6 – Steering relief valve
7 – Rotor Decrease solenoid
8 – Unload Auger Swing Out solenoid
35-23
Header Suspension Accumulator, 1
Absorbs the slight movement to the header encoun-
tered during normal operating. The accumulator is
rated at 70bar (1015 psi) pressure with a volume of
0.5L (17 oz.).
1
10020034
24
Steering Motor, 1
Supplied oil via the priority valve in the main frame 1
stack. The steering motor directs and controls oil to
the steering cylinders, based on input via movement
of the steering wheel.
There are 2 different motors available. An OSPF
315cc (18.9 cu. in./rev) load sensing fixed capacity
unit for North America only and an OSPQ160/320cc
(9.6/19 cu. in./rev) load sensing variable capacity unit
for all other locations.
25
Steering Cylinders, 1
Two steering cylinders are used on both the heavy 1 1
duty adjustable axle and power rear axle (PRA).
26
35-24
Header Lift Cylinders, 1
Stone Trap Door Latch Cylinder, 2 2
1
10020042
27
Rotor Variator Adjustment Plunger, 1
Operated via the rotor variator valve, the plunger is a 1
hydraulic cylinder that operates a floating disc within
the variator assembly to alter variator speed.
The pressure-compensated flow control valve, 2,
controls the flow to ensure smooth consistent speed
changes.
2
10020038
28
Unloading Auger Lockout Valve, 1
Isolates the unloading auger cylinder from the control 2
valve and pipework. Ensures that the unload auger
will remain in the required position until the control
valve is activated. When pressure oil is applied to the
lock out valve, a bleed line is supplied to the opposite
side which releases the lock valve and allows oil to es-
cape. When the pressure oil is removed the lock out
valves close and prevent cylinder movement.
Unloading Auger Cylinder, 2
Moves the unloading auger, controlled by the unload- 1
ing auger swing valve and lock out valve.
29
35-25
Feeder Variator Adjustment Plunger, 1
Operated via the feeder variator valve, the plunger is
a hydraulic cylinder that operates a floating disc with-
in the variator assembly to alter variator speed. 1
10020039
30
35-26
10020032
31
Feeder Valve Stack
Top Plate, 1 Reel Horizontal Adjustment Valve, 4
Provides the connection point for the pressure, return Controls the horizontal position of the reel. The valve
and load sense lines. consists of two electrically operated solenoids and a
lock out valve.
Feeder and Header Reversing Valve, 2 Reel Vertical Adjustment Valve, 5
Controls the motor for the feeder and header rev- Controls the vertical adjustment cylinders. Consists
erser. Contains two electrically controlled solenoids of two electrically operated solenoids and a lock out
which move a spool to obtain forward, reverse or a valve.
float position on the motor. Reel Drive Valve, 6
Lateral Flotation Control Valve, 3 Provides flow to the hydraulic reel drive motor used
on North American headers. Consists of a single
Controls the lateral flotation cylinder. Consists of two PWM solenoid and a pressure compensation valve.
electrically controlled solenoids, a pressure com-
Stone Trap Valve, 7
pensation valve and a lock out valve.
Controls the stone trap cylinder to open the stone
Lateral Float Minimum Pressure Valve (not shown) trap.
This is a resistant valve which mounts in the “A” port, Flush Valve, 8
and prevents the header from jerky counterclockwise When there are no services in use, charge pressure
movement and jerky operation when the cylinder is oil is allowed to join the return circuit through the flush
retracted. This is necessary because of the European valve. This function allows a constant flow of oil
header being heavier on the left hand side. The valve through the header stack valve thereby circulating
is set at approximately 60 bar (870 psi). warm oil through the valves.
35-27
Feeder and Header Reversing Motor, 1
10020041
32
Lateral Flotation Cylinder, 1
2
Adjusts header angle in relation to the combine.
Lateral Float Accumulator -- Rod End, 2 1
[80 bar 1160 psi]
Lateral Float Accumulator -- Base End, 3
[100 bar 1450 psi] 3
Header Hoses Quick Release Coupling, 4
4
10020040
33
Return Filter with Bypass, 1
1
10020028
34
35-28
PAGE INTENTIONALLY LEFT BLANK
35-29
LOW PRESSURE SYSTEM DESCRIPTION

SCHEMATIC DIAGRAMS
Low Pressure System
CR 920/940/960/970/980 8. Park brake cylinder
1. Engine gearbox 9. Oil to air cooler
2. Low pressure gear pump 10. Feeder clutch
(43 l/min. [11.4 US GPM])
11. Unloading clutch
3. Suction filter, 100 micron
12. Main clutch
4. Chaff spreader valve*
13. Engine
5. Chaff spreader motors*
14. Pressure sensor
6. High pressure filter with bypass and a blocked
filter switch 15. Temperature sensor
7. Low pressure valve block *Chaff spreader and valve are optional
35-30
9
10
8
6
14 4
5
12
13
11
15
3
1
20020027
35
35-31
Low Pressure System with Positive Straw Discharge
CR 920/940/960/970/980
1. Engine gearbox 9. Oil to air cooler
2. Low pressure gear pump 10. Feeder clutch
(43 l/min. [11.4 US GPM]) 11. Unloading clutch
3. Suction filter, 100 micron 12. Main clutch
4. Chaff spreader/PSD valve* 13. Engine
5. Chaff spreader motors* 14. Pressure sensor
6. High pressure filter with bypass and a blocked 15. Temperature sensor
filter switch 16. Positive straw discharge (PSD) motor*
7. Low pressure valve block 17. Hydraulic cleaning fan drive pump
8. Park brake cylinder *Chaff spreader/PSD and valve are optional
35-32
10
8
6
7
4
14
16
5
12
13
11
17
15
3
1
66060555
36
35-33
Low Pressure System with Chopper Infeed Roll
Motor with Valve -- Model Year 2004 and Earlier
CR 920/940/960/970/980
1. Engine gearbox 10. Park brake cylinder
2. Low pressure gear pump 11. Oil to air cooler
(43 l/min. [11.4 US GPM]) 12. Feeder clutch
3. Suction filter, 100 micron 13. Unloading clutch
4. Chaff spreader valve* 14. Main clutch
5. Chaff spreader motors* 15. Engine
6. High pressure filter with bypass and a blocked 16. Pressure sensor
filter switch 17. Temperature sensor
7. Chopper infeed roll motor valve* 18. Hydraulic cleaning fan drive pump
8. Chopper infeed roll motor* *Chaff spreader and valve are optional
9. Low pressure valve block Chopper infeed roll motor and valve are optional
35-34
11
8 7
6
12
10
16 4
14 15
13
18
17
3
1
56060562
37
35-35
Low Pressure System with Chopper Infeed Roll
Motor with Valve -- Model Year 2005 and Later
CR 920/940/960/970/980
1. Engine gearbox 10. Feeder clutch
2. Low pressure gear pump 11. Unloading clutch
(43 l/min. [11.4 US GPM])
12. Main clutch
3. Suction filter, 100 micron
13. Engine
4. Chaff spreader valve*
14. Pressure sensor
5. Chaff spreader motors*
6. High pressure filter with bypass and a blocked 15. Temperature sensor
filter switch 16. Chopper infeed roll motor*
7. Low pressure valve block 17. Hydraulic cleaning fan drive pump
8. Park brake cylinder *Chaff spreader and valve are optional
9. Oil to air cooler Chopper infeed roll motor is optional
35-36
9 16
10
8
6
14 4
12
11 13
17
15
3
1
56060563
38
35-37
COMPONENT LOCATION
3
4
66060559
39
1. Engine gearbox 4. High pressure filter
2. Low pressure gear pump 5. Low pressure valve block
3. Chaff spreader valve 6. Oil cooler
35-38
COMPONENT DESCRIPTIONS
Engine Gearbox, 1 1
Mounted onto the rear of the engine on the left hand
side of the vehicle. Output from the engine directly
drives the gearbox with subsequent drives to the Hy-
drostatic pump, CCLS and low pressure pump, main
clutch and unloading mechanism clutch.
40
Low Pressure Gear Pump, 1
Mounted on the CCLS pump from where it takes its
drive. Draws oil from the engine gearbox via a suction
1
filter located in the bottom of the gearbox. The pump
output is directed to the chaff spreader valve, if fitted,
then through the pressure filter and onto the low pres-
sure valve block.
Suction Filter, 2
Located in the gearbox, filters the oil being drawn into
the low pressure pump. 3 2
Gearbox Oil Temperature Sensor, 3
10020033
41
Chaff Spreader Valve, 1
Located at the rear of the vehicle on the left hand side.
This is an optional item, fitted first in line in the low
pressure circuit. The valve assembly incorporates an
electrically actuated solenoid, to direct oil to the mo-
tors, and a relief valve for the chaff motor circuit.
High Pressure Filter with Bypass and a Blocked Filter
Switch, 2 1
A replaceable filter located between the pump output
(and chaff spreader valve if fitted) and the low pres-
sure system valve block.
10020028 2
42
35-39
Chaff Spreader/PSD Valve

If the combine is equipped with the positive straw
discharge (PSD) system, the chaff spreader valve, 1,
has additional ports for feeding the PSD motor. This
motor is in series with the chaff spreader motors.
1
66060557
43
Chaff Spreader Motors
Located at the rear of the vehicle, one on each side.
Controlled by the chaff spreader valve, they provide
drive to the spreader rotors.
Positive Straw Discharge (PSD) Motor
Located just forward of the chopper, this motor drives
the PSD conveyor to positively discharge residue into
the chopper. It is in series with the spreader motors
and is controlled by the chaff spreader/PSD valve.
66060558
44
Chopper Infeed Roll Motor
If the combine is equipped with a chopper infeed roll,
its drive motor is located at the rear of the combine on 1
the right-hand side of the straw chopper. The roller
motor is in series with the chaff spreader motors.
Model year 2004 and earlier combines had a
manually operated bypass valve, 1, for turning off the
roller motor.
NOTE: Combines equipped with a chopper infeed roll
do not have positive straw discharge (PSD) and
vice-versa.
20032047
45
35-40
In model year 2005 and later combines, the hydraulic
hoses are connected directly to the chopper infeed
roll motor.
56060564
46
35-41
2 3 4 5 8
6 1 7
47
Low Pressure Valve Block
Low Pressure Valve Block, 1 Solenoid Valve -- Park Brake, 4
Located on the engine gearbox. Houses the solenoid Solenoid Valve -- Main Clutch, 5
valves for the unloading clutch, feeder clutch, hand- Low Pressure Relief/Control Valve, 6
brake and main clutch. Also houses the low pressure
relief/control valve, lube pressure check valve, oil Pressure Sensor, 7
cooler bypass and oil pressure sensor. Reservoir Filler cap, 8
Solenoid Valve -- Unloading Clutch, 2
Solenoid Valve -- Feeder Clutch, 3
35-42
Park Brake Cylinder, 1
Solenoid is normally on when running allowing hy- 1
draulic pressure to disengage the brake. When the
park brake is applied or the ignition is off, the park
brake is engaged under spring pressure.
48
Feeder Clutch, 1
20016286
49
Oil Cooler, 1
Hydraulic oil cooler, mounted with the engine cooler 1
on the right hand side of the vehicle.
50
35-43
35-44
Chapter 2 - Description of Operation
CONTENTS

Closed Center Load Sensing (CCLS) Variable Displacement Pump . . . . . . . . . . . . . . . . 2
Principal of Pump Operation -- Fixed Vs. Variable Displacement . . . . . . . . . . . . . . . . 3
Flow and Pressure Compensating Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Low Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
High Pressure Circuit High Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
High Pressure Circuit Low Demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Controlling Maximum System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Main Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Feeder Valve Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Stack Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Header Height Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Accumulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Function Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Rotor Variator/Feeder Variator/Reel Raise--lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Unloading Auger Swing/Feeder Reverser Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Lateral Float Valve/Reel Fore--Aft Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Reel Drive Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Stone Trap Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Hydraulic Cleaning Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Low Pressure System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Chaff Spreader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Chaff Spreader/PSD Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Chopper Infeed Roll Motor Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Low Pressure Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
35-1
CLOSED CENTER LOAD SENSING (CCLS)

VARIABLE DISPLACEMENT PUMP
The closed center load sensing pump assembly is
mounted directly onto the engine driven gearbox lo-
cated high on the left hand side of the combine.
1
The assembly consists of 2 pumps, the load sensing
piston pump, providing oil to the high pressure hy-
draulic system and a fixed displacement gear pump,
providing oil to the low pressure hydraulic system.
The pump drive shafts are linked by a coupler and lu-
bricated by the case drain oil of the load sensing
pump.
2
The pump is controlled by the flow, 6, and pressure,
7, compensating valves located on the pump casing.
35-2
1 2 3 4
11
10
8 7 6 5
TIA35042
4
Variable Displacement Piston Pump--Sectional Drawing
1. Pump End Plate 7. Slipper (9 off)
2. Swash Plate Servo Piston 8. Piston and Barrel
3. Swash Plate
9. Inlet Port
4. Swash Plate Return Spring
5. Driveshaft Gear 10. Pumping Head Pre--load Spring
6. Driveshaft 11. Outlet Port
Principal of Pump Operation -- Fixed vs. Variable systems therefore has distinct power loss
Displacement advantages over fixed displacement gear type
The operating principal of the fixed displacement pumps, which continually provide oil flow and absorb
gear pump is to provide a constant oil flow directly engine power even when the hydraulic circuits do not
related to the rotation speed of the pump. require the total pump output.
The feed oil for the variable displacement piston
The operating principal of a variable displacement pump is called the charge oil. The charge oil is
piston pump is to provide oil flow on demand and supplied by the return flow of the hydrostatic drive
minimises the engine power absorbed in driving the system. This supplies 60 l/min (16 gal/min) of oil via
hydraulic pump when the hydraulic circuits do not the oil cooler. Only under high demand situations,
require maximum pump flow. 60--114 l/min (16--30 gal/min), does an under
The variable displacement piston pump in hydraulic pressure develop in the charge supply line.
35-3
Variable Displacement Piston Pump following the contour of the swash plate. For every
The major components of the variable flow piston revolution of the drive shaft each piston completes
pump with closed centre load sensing are:-- one pumping cycle.
The swash plate, which does not rotate but pivots
1. A nine element pumping head. about the front of the pumping head, is the control
2. A plate mechanism (swash plate) to adjust piston mechanism that limits the stroke of each piston and
stroke and corresponding pump output. works in conjunction with the pressure and flow
compensating valves in the load sensing line.
3. A load sensing valve which monitors the
requirements of the hydraulic circuits and signals As the pumping head rotates each barrel passes over
the pump to increase or decrease hydraulic oil the inlet and then the outlet ports of the pump. During
flow accordingly. the inlet cycle for each piston and barrel, oil is pumped
into the barrel pushing the piston forward so that it
The nine element pumping head is cylindrical in always remains in contact with the swash plate. The
shape and has nine barrels, into each of which, is stroke of each piston and volume of oil charged into
installed a piston. On the end of each piston is its barrel is therefore dependent on the angle of the
pressed a slipper which always remains in contact swash plate.
with the face of the swash plate located at the front of After a piston and barrel has completed the inlet
the pumping head. stroke, further rotation of the head aligns the barrel
The drive shaft, which is driven by the pump drive with the outlet port. Oil within the barrel is then forcibly
gear, rotates the pumping head. As the pumping head ejected by the piston through the exhaust port to the
rotates, the pistons move in and out of their barrels, hydraulic circuits.
35-4
1 2 3 4 5 6 7
16
8
15
14 13 12 11 10 9
TIA35165
5
Flow and Pressure Compensating Valves
1. Plug and ‘O’ Ring 9. Tamperproof Cap
2. Housing 10. Locknut
3. Flow Compensating Spool 11. Adjuster and ‘O’ Ring Seal
4. Seat 12. Spring
5. Spring 13. Seat
6. Adjuster and ‘O’ Ring Seal 14. Pressure Compensator Spool
7. Locknut 15. ‘O’ Ring Seals
8. Tamperproof Cap 16. Plug and ‘O’ Ring
Flow and Pressure Compensating Valves

(CCLS Pump Load Sensing Valve)
Output from the variable flow piston pump is If pump output and circuit pressure rises to 210 bar
determined by adjusting the angle of the swash plate (3046 psi) the pressure compensating valve
in the pump. The flow compensating valves senses overrides the flow compensating valve and adjusts
the circuit operating pressure and adjusts the swash the swash plate angle to limit maximum system
plate angle to control pump output. pressure.
35-5
HYDRAULIC CIRCUIT OPERATION consequently remains in the maximum flow position

The variable flow closed center load sensing (CCLS) until the pump has developed sufficient flow to
hydraulic pump operates progressively in 4 modes:-- produce pressure at low pressure standby.
Low Pressure Standby As pump output pressure increases to 19 bar (275
psi), this pressure is sensed in gallery, E, and applied
to the flow compensating spool. The spool gradually
High Pressure Circuit Maximum Demand moves against the spring allowing oil flow from
gallery, E, to gallery, D.
High Pressure Circuit Low Demand The controlled pressure rise in gallery, D, operates
the swash plate servo piston, changing the angle of
Maximum System Pressure the swash plate in relation to the pumping head. The
(High Pressure Standby) change in angle reduces the operating stroke of the
pistons and output of the pump.
Low Pressure Standby As pump output decreases and the pressure in
gallery, D, reduces to less than 19 bar (275 psi), the
With Reference to Fig. 6
flow compensating valve gradually moves under
Low pressure standby is the system pressure 19 bar spring pressure to the left bleeding gallery, D, to sump
(275 psi) maintained by the hydraulic pump when through gallery, C. This reduces the control pressure
high pressure hydraulic circuits are not being applied to the servo piston, allowing the servo piston
operated. to retract at a controlled rate under pressure from the
During engine start up, standby pressure has not swash plate return spring and re--adjust the angle of
been generated and both the flow and pressure the swash plate to increase pump output.
compensating valves are held to the left by spring This control process continues maintaining pump
pressure. output pressure at 19 bar (275 psi) (low pressure
While the spools are held to the left oil pressure standby) until a high pressure circuit is operated and
generated by the pump cannot be applied to the pump system pressure needs to be increased to
swash plate servo piston. The swash plate operate the service.
35-6
E B B
4
5
D
1 2
6
BSC1301A
Low Pressure Standby 6
Standby Pressure @ 19 bar Return to Reservoir

(275 psi)
Control Pressure Charge Pressure
1. Straw elevator stack valve (In Neutral) 4. Flow Compensating Valve

2. Main frame stack valve (in neutral) 5. Swash Plate
3. Pressure Compensating Valve 6. Return from Hydrostatic motors
35-7
High Pressure Circuit High Demand
E B B
4
5
D
1 2
6
BSC1301B
High Pressure Circuit High Demand 7
Standby Pressure @ 190bar (2755 psi) Charge Pressure
Return to Reservoir
1. Straw elevator stack valve 4. Flow Compensating Valve

2. Main frame stack valve 5. Swash Plate
3. Pressure Compensating Valve 6. Return from hydrostatic motors
When a high pressure service is operated the pressure in gallery, E, preventing the flow of oil to the
pressure rise in the hydraulic circuit is sensed by the swash plate servo piston through gallery, C.
load sensing line, B. The pressure in the sensing line The movement of the spool opens gallery, D, to the
is now applied to the spring loaded end of the flow return to sump gallery, C, allowing the servo piston to
compensating valve. retract under pressure from the swash plate return
The combined pressure from the pilot line and flow spring and adjust the angle of the swash plate to
compensating valve return spring causes the flow increase pump output.
compensating spool to move against the standby
35-8
High Pressure Circuit Low Demand
E B B
4
5
D
1 2
6
BSC1301C
High Pressure Circuit Low Demand 8
Standby Pressure @ 210 bar (3046 psi) Return to Reservoir

3. Pressure Compensating Valve 6. Return oil from hydrostatic motors
When output from the pump is meeting the demand servo piston and changes the swash plate angle to
of the hydraulic circuit the output pressure of the reduce pump output according to demand.
hydraulic pump in gallery, E, will continue to rise
unless the flow from the pump is controlled. It can now be seen that whenever the differential
pressure between system and load sensed
As pump pressure increases the differential between pressures approaches 19 bar (275 psi) the flow
system pressure, E, and load sensed pressure, B, will compensator valve will operate to control the angle of
similarly increase. When this differential rises the swash plate and consequently pump flow
towards 19 bar (275 psi) the pressure in gallery, E, (output).
causes the flow compensator spool to move back
against the spring and load sense pressure in Gallery, The load sensing shuttle valves will always allow the
B, to open gallery, E, to gallery, D. The controlled service requiring the highest pressure to pass that
pressure rise in gallery, D, operates the swash plate pressure onto the flow compensating valve.
35-9
Controlling Maximum System Pressure
Controlling Maximum System Pressure 9
Standby Pressure @ 190bar (2755 psi) Return to Reservoir

3. Pressure Compensating Valve 6. Return oil from hydrostatic motors
To limit the maximum output pressure of the piston now applied to the servo piston which changes the
pump and prevent consequential damage that may swash plate angle to reduce pump output to minimum
occur due to excessive pressures, a pressure flow. This operating mode is referred to as high
compensating valve, located adjacent to the flow pressure standby.
compensator valve, is incorporated in the swash Functions requiring sensitive control, like the header
plate control circuit. This valve limits the pressure to height, lateral flotation and hydraulic reel drive have
210 bar (3046 psi) and operates as follows:-- an additional pressure compensation valve in their
As the pressure in gallery, E, increases to 210 bar circuit to ensure that the operational speed is
(3046 psi) the pressure compensator valve spool, 2, constant what ever the pump pressure is (see high
moves against the valve return spring and opens pressure circuit diagram).
gallery, E, to gallery, D. The pressure in gallery, D, is
35-10
MAIN STACK
Priority Valve, 1
Accumulator Lockout Valve, 2
Header Height Control Valve, 3
Rotor Variator Control Valve, 4 6
Unloading Auger Swing Valve, 5
Feeder Variator Control Valve (not shown) 5
Top Plate, 6
4
1
10020031
10
FEEDER VALVE STACK
Top Plate, 1
Feeder and Header Reversing Valve, 2 1
Lateral Flotation Control Valve, 3
Reel Horizontal Adjustment Valve, 4
Reel Vertical Adjustment Valve, 5
Reel Drive Valve, 6 (NA only) 2
Stone Trap Valve, 7 3
Flush Valve, 8
4
5
6
8 7
10020032
11
35-11
STACK VALVES
2
3 1
50020011
12
PRIORITY VALVE
The priority flow divider assembly is comprised of a
metering spool, 1, spring, 2, and relief valve assem-
bly, 3. The spool is held shifted to the right by the
spring when the system is at rest. The inlet port, 4, of
the flow divider is open to the steering priority port, 5,
in this position.
35-12
5 2
4
50020043
13
Steering Neutral
When the steering valve is in neutral, the inlet to the
steering valve is blocked and the pressure will in-
crease in the priority port. The pressure is felt on the
right end of the spool through an internal passage, 1.
The pressure at the end of the spool will overcome the
spring and shift the spool to the left and close the path
from the inlet, 2, to the priority port, 3, and open the
path from the inlet to the main pressure gallery, 4, in
the main stack valve. The signal from the steering
valve, 5, which is open to the spool spring chamber,
will be near 0 bar (0 psi) and therefore will not assist
the spring in opposing the spool. Because the steer-
ing system does not require any flow, all flow is avail-
able to the main and feeder stack valves.
The steering system uses a dynamic signal non--re-
active neutral logic steering motor; this motor allows
a small amount of oil to “leak” through the motor from
the priority port to the load sense port. As a result,
there is typically always a 7 – 10 bar (100 – 145 psi)
pressure in the load sense line, even when all circuits
are in neutral. This flow accomplishes two things: it
provides some flow of oil through the motor at all
times to warm up the components, and it provides im-
proved steering system response.
35-13
50020052
14
Steering Priority
When steering is used, a passage in the steering
valve opens. The pressure in the steering priority
port, 1, and the cavity on the right end of the spool
drops. The spring, 2, will shift the spool, 3, to the right
and meter oil to the priority port.
The load sense line from the steering valve is con-
nected to the load sense port, 4, on the flow divider.
This will determine the exact positioning of the spool
to achieve a pressure balance between the inlet port
and load sense port from steering, plus the 14 bar
(203 psi) spring. In addition, the load sense pressure
is directed through the load check poppets, 5, to the
flow compensator on the CCLS pump to ensure the
pump responds to the steering system demand.
The pressure in the priority port will drop when the de-
mand for steering increases. The load sense pres-
sure will then shift the spool further to the right and
allow more oil to the priority port. This will occur up to
the maximum system requirement of 35 l/min (9 US
gpm).
35-14
4 2
3
50020044
15
Inlet Flow Dividing
In the flow dividing mode, the control spool, 1, will give
the priority to the steering circuit. When another stack
valve function is activated, the pressure at the inlet,
2, will decrease. This decrease will allow the pressure
in the spring chamber (steering load sense plus the
spring) to shift the spool further to the right, to return
the steering flow back up to the level required (priority
to the steering). When the steering flow requirements
are met, any additional flow available will be allowed
to pass through the valve to the main stack pressure
gallery, 3. The load sense signal, 4, from the steering
valve will continuously adjust the position on the con-
trol spool to maintain the flow required by the steering.
35-15
1 3
50020045
16
Steering Relief Valve Activated
The maximum pressure in the steering circuit is li-
mited by the relief valve, 1. The relief valve monitors
the load sense pressure from the steering valve. If the
pressure in the load sense circuit increases above
185 bar (2683 psi), the poppet will unseat and direct
the load sense pressure, 2, to the return port, 3. The
priority pressure will then shift the spool to the left
against the spring and limit the oil flow from the inlet
to the priority port. System flow is available to the
main stack pressure gallery even when the steering
system is at relief pressure. The pump compensator
is set at 210 bar (3046 psi), 25 bar (363 psi) above
steering relief pressure.
35-16
2
1
50020010
17
HEADER HEIGHT CONTROL VALVE
The header height control valve consists of two dis-
tinct grouping of components, one set for controlling
header raising, the other for controlling header lower-
ing. Either set of components is controlled by a pulse
width modulated (PWM) solenoid, which can accu-
rately position the components to provide a specific
raise or lower rate.
The head raise component group consists of a
header lift pressure compensator, 1, header lift flow
control, 2, and a load check valve, 3.
The head lower component group consists of a pilot
operated header lower flow control spool, 4.
35-17
3
6
1
2
50020046
18
Header Raise
To raise the head, the Head Raise PWM solenoid, 1, far the solenoid has moved the flow control spool. The
is powered, and shifts the header lift flow control amount of this restriction will cause a pressure drop
spool, 2, to the right. This allows oil to flow from the between the main stack pressure gallery and the
main stack pressure gallery, 3, past the flow control header lift supply gallery. A greater restriction (due to
spool into the supply gallery. The load sense circuit, little spool movement) will result in a greater pressure
4, is connected to the supply gallery, so this pressure drop across the flow control spool, and reduced flow
is also fed back to the pump compensator to put the to the header lift cylinders for a slow raise. Less re-
pump into stroke. striction (due to greater spool movement) will result in
a small pressure drop across the flow control spool,
The supply gallery is blocked by the load check valve, and higher flow to the header lift cylinders for a fast
5, which is used to trap oil in the header lift cylinders. raise.
Once system pressure exceeds the header lift cylin-
der pressure, the load check valve opens and oil flows When the header lift control spool is returned to the
to the header lift cylinders. neutral position, the header supply gallery is con-
nected to the return gallery, 6; this dumps the pres-
The header lift flow control spool land is tapered, so sure in the supply gallery to destroke the pump and
the oil flow from the pump is restricted based on how allow the load check valve to close positively.
35-18
3
1
50020047
19
Pressure Compensation
The header lift pressure compensator, 1, is fitted in
the header valve to ensure that the header raise rate
remains constant irregardless of pressure in the main
stack gallery, 2, due to other circuit demands. If
another valve is activated which has a higher pres-
sure requirement (such as header tilt or unload auger
swing) than the header raise, the higher pressure
could result in a higher flow rate across the header lift
flow control spool, resulting in the header lift speed
varying with the pressure in the main or feeder stacks.
The lift pressure compensator is balanced with main
system pressure on one end acting against a spring,
3, plus header supply gallery pressure on the other
end. If system pressure increases, that higher pres-
sure will shift the lift pressure compensator spool
against the combined spring and supply gallery pres-
sure to restrict oil flowing from the main stack gallery
into the header lift valve. As the main stack pressure
drops, the spring and header supply gallery pressure
can shift the compensator spool to allow more flow
into the valve. This ensures a consistent flow rate into
the valve irregardless of the system pressure.
35-19
3
4
1
50020048
20
Header Lower
In the neutral position, the head lower flow control The header lower rate is directly controlled by how far
spool is held against its seat by a combination of the the Head Lower PWM solenoid moves the pilot spool.
spring loaded pilot spool, 1, and lift cylinder pressure, If the pilot spool is moved a small amount to the right,
which acts through an orifice and drilling, 2, to the as the flow control spool lifts off its seat, it will start to
right side of the spool. close the pilot valve. This causes oil to once again be
To lower the head, the Head Lower PWM solenoid, 3, trapped behind the spool, and try to close it. The spool
is powered, and pushes the pilot spool, 1, to the right, will balance itself in a position that only allows a small
lifting it off of its seat in the lower flow control spool, amount of oil to escape from the header lift cylinders
4. This allows oil to be released from behind the flow to return, causing the head to drop slowly. If the pilot
control spool faster than oil can be replenished spool is moved a large amount to the right, the flow
through the orifice. The resulting pressure drop be- control spool can open a much larger distance before
hind the flow control spool allows the spool to be lifted it starts to close the pilot valve, resulting in much
off its seat allowing oil to flow to return, 5. higher flow to return for a fast header drop.
35-20
1 2
50020012
21
ACCUMULATOR VALVE ways exposed to lift cylinder pressure, while the pres-
sure transducer is connected to the outlet port, 6, to
The accumulator valve is used to hold header height
the accumulator. The pressure transducer provides
components that are not fitted in the header height
feedback to the header height control module on the
valve, such as the pressure transducer, 1, header
actual lift cylinder pressure, while the header shock
shock relief valve, 2, and the accumulator control
relief valve protects the cylinders against pressure
spool, 3, and solenoid, 4.
spikes that may occur, such as when carrying a heavy
The header shock relief valve is connected directly to header over rough ground, irregardless of the operat-
the outlet port, 5, to the header lift cylinders, so it is al- ing position of the header height control valve.
35-21
50020049
22
The accumulator control spool, 1, and solenoid, 2, are noid, and shift the spool to the left whenever the sole-
used to connect and disconnect the header accumu- noid is deenergized.
lator from the header lift cylinder circuit when raising During normal operation, the solenoid is energized to
the header, to ensure quick response. The center gal- shift the spool to the right. This connects the lift cylin-
lery of the spool is exposed to the header lift cylinder der outlet port, 4, to the accumulator, 5, so that the
outlet port, and the spool is drilled such that cylinder accumulator can provide some cushioning or flotation
pressure is exposed to both ends of the spool. A effort to the cylinders during field operation.
spring, 3, is used to bias the spool against the sole-
35-22
5 4
50020012
23
When the header is raised, the accumulator solenoid, A small orifice drilling, 5, in the spool is used to pro-
1, is deenergized, and the accumulator spool, 2, is vide some “equalization” to the accumulator during
shifted to the left by the spring, blocking off the accu- the raising cycle to ensure that the accumulator is
mulator, 3, from the lift cylinders, 4. This allows all charged up when the header raise is stopped. This
pump flow to go to the header lift cylinders for raising, prevents the header from dropping slightly when the
rather than some oil being used to charge or fill the accumulator is reconnected to the lift cylinders after
accumulator, resulting in a delayed header response. the raise is completed.
35-23
5 6
1 4 2
3 1
10020019
24
FUNCTION CONTROL VALVES end of the spool, with just the centering spring assem-
Each control valve in the stack valve has its own bly located on the right end.
unique configuration, however, they all function in es- With the valve in the neutral position, the flow control
sentially the same way. land, 4, seals the pressure gallery, 5, in the stack from
Double acting valves have a solenoid, 1, on either end the supply gallery, 6, in the valve. At the same time,
of the valve spool, 2, along with a centering spring as- the main control lands, 7, on the spool trap the oil in
sembly, 3, on the right end of the spool. Single acting either work port to hold the circuit stationary.
valves have a single solenoid positioned on the left
35-24
2 3
4
1
50020050
25
When a solenoid, 1, is energized to move the valve, other work port is connected to the return gallery to
the spool is shifted sideways by the solenoid. This al- allow oil to flow through the circuit.
lows oil flow from the stack pressure gallery, 2, across The flow control land, 6, in each valve is machined to
the flow control land into the supply gallery, 3. The oil provide a specific amount of flow for that valve, to en-
flow, and resulting pressure, is picked up through the sure consistent operation of each circuit. If the pump
load sense gallery, 4, and fed back to the pump com- tries to provide too much oil to the valve, the resulting
pensator through the load check circuit to put the pressure drop across the flow control land is fed back
pump into stroke. through the load check circuit to the pump causing it
As the spool is shifting, the main control lands, 5, will to destroke to provide less oil.
connect one work port to the supply gallery, while the
35-25
50020037
26
Load Check Poppet Function it exits the valve stack and is connected to the pump
When a valve spool is shifted and pressure is fed into compensator.
the load sense gallery, the pressure pushes that If more than one valve section is activated at once
valve’s load check poppet against the opposite valve with differing pressure requirements, the highest
section, sealing the load sense gallery from those pressure requirement will be fed to the pump com-
valve sections. Pressure is then fed to the next valve pensator, as the higher pressure signal overcomes
section, pushing that load check poppet into that the others via the load check poppets. This ensures
valve section, which seals that valve section from the that the pump compensator always reacts to the
load sense gallery. Pressure continues in this manner highest demand.
until it reaches the accumulator valve section, where
35-26
1 1
5 2 5
4 3 3 4
50020053
27
Load Check Valves in the circuit. Once system pressure exceeds the cir-
Several valves are equipped with load check valves, cuit pressure, the load check valve opens and oil
1, to positively trap oil in the circuit to prevent the cir- flows to the circuit.
cuit from “drifting” when the valve is in neutral. When The load check valves consist of many smaller com-
the valve is activated, oil pressure will build in the sup- ponents, including the unload spool, 2, pilot pins, 3,
ply gallery until it can overcome the trapped pressure balls, 4, and springs, 5.
35-27
4 1
2
3
50020054
28
On double--acting valves with two load check valves from the back side of the valve faster than it can be
(one on each work port), the oil pressure in the supply replenished through the orifice drilling, 5, in the side
gallery not only lifts the load check valve, 1, off its of the valve. The pressure drops behind the spool, al-
seat, but also shifts the unload spool, 2, against the lowing the return pressure to push the load check
pilot pin, 3, in the opposite load check valve. This ac- valve open on the return side of the circuit.
tion lifts the ball, 4, off of its seat, allowing oil to drain
35-28
1
3
50020051
29
Pressure Compensator Spool The pressure compensator spool is balanced with
Some valves are equipped with a pressure compen- main system pressure on one end acting against a
sator spool, 1, to ensure that the flow rate through the spring, 3, plus supply gallery pressure on the other
valve remains constant irregardless of pressure in the end. If system pressure increases, that higher pres-
main gallery, due to other circuit demands. If another sure will shift the pressure compensator spool
valve is activated which has a higher pressure re- against the combined spring and supply gallery pres-
quirement (such as header raise or unload auger sure to restrict oil flowing from the main gallery into
swing), the higher pressure could result in a higher the valve. As the main pressure drops, the spring and
flow rate across the valve flow control land, 2, result- supply gallery pressure can shift the compensator
ing in the circuit operation varying with the pressure spool to allow more flow into the valve. This ensures
in the main or feeder stacks. a consistent flow rate into the valve irregardless of the
system pressure.
35-29
ROTOR VARIATOR/FEEDER
VARIATOR/REEL RAISE--LOWER
The rotor variator, feeder variator and reel lift valves
are all similar in specification, varying only in the spe-
cific flow rate setting. In order to provide precise flow
control on both variator circuits, two pressure--com-
pensated flow control valves are used in the external
circuits to limit the flow rate to and from the variator
cylinders to 0.16 liters/min (5.4 fl oz/min). This ensur-
es a consistent change of speed (20 seconds to move
from one end of the speed range to the other) for pre-
cise speed setting.
10020016
These are double acting valves, equipped with a load
check valve on the single work port. When lowering 30
the reel, or reducing variator speed, pump flow is re-
quired to pressurize the valve in order to shift the un-
load spool to open the load check valve in the work
port.
UNLOADING AUGER SWING/FEEDER

REVERSER VALVE
The unloading auger swing and feeder reverser
valves are very similar in operation, with one excep-
tion being the rated flow through the valve; the un-
loading auger has a set flow rate of 7.5 liters/min (2
US gpm), while the feeder reverser valve has a set
flow rate of 38 liters/min (10 US gpm). The other sig-
nificant difference is that the feeder reverser valve
connects both work ports to the return gallery when
the valve is in neutral, rather than trapping the oil in
the circuit as the unloading auger swing valve does.
This ensures that the reverser motor can coast to a 10020019
stop, rather than be stopped suddenly, which may
31
cause damage to the rotating components, or pres-
sure spikes within the hydraulics.
These valves are not equipped with load check
valves; they are not desired on a hydraulic motor cir-
cuit, such as the feeder reverser circuit. The unload-
ing auger swing circuit has the load check valves inte-
grated into a manifold block on the unloading swing
cylinder itself.
LATERAL FLOAT VALVE/REEL FORE--AFT

VALVE 1
The lateral float and reel fore/aft valves are both
double acting valves equipped with load check
valves. The main difference is that the lateral float
valve is equipped with a pressure compensator, 1, to
ensure smooth, consistent header tilting at all times
for reliable header height control (HHC) operation.
10020018
32
35-30
REEL DRIVE VALVE

The reel drive valve is a single acting valve that is
used to drive the reel on North American headers.
When the valve returns to neutral, both motor work
ports are connected to the return gallery to allow the
reel to coast to a stop to prevent damage due to forc-
ing a sudden stop. There are no load check valves re-
quired.
The reel drive valve is equipped with a pressure com-
pensator to prevent the reel speed from surging or
changing due to other functions being activated while
the reel drive is in operation.
10020015
33
STONE TRAP VALVE
The stone trap valve is a single acting valve that is
used to control the latching cylinder for the feeder
stone trap system. When the valve goes to neutral,
both ends of the cylinder are connected to return. The
back pressure in the return gallery is enough to en-
sure that the cylinder is held in the extended position,
due to the differences in area between the rod end v.
the base end of the cylinder. This keeps the stone
door latched.
When the stone trap valve solenoid is energized, the
valve directs oil from the main gallery to the rod end
to retract the cylinder and open the stone trap; the
base end of the cylinder remains connected to return.
HYDRAULIC CLEANING FAN DRIVE

1
While the hydraulic cleaning fan drive is not
technically part of the high pressure hydraulic circuit,
it draws its supply oil from the hydraulic reservoir. If
the combine is so equipped, the fan drive pump, 1, is
mounted on, and driven by, the hydrostatic drive
pump. The pump draws oil from the hydraulic
reservoir and directs the oil to fan drive valve at inlet
port P, 2.
2
10051771
34
35-31
Oil flow to the fan motor is modulated by a solenoid
valve, 1, operated by a pulse width-modulated 1
(PWM) signal from controller CCM1, and working in 4
conjunction with a proportional valve, to maintain a
5
constant fan speed regardless of engine speed. Oil
flow is directed to the fan motor from port A, 2. Return
oil from the motor re-enters the valve at port B, 3, and
exits the valve at port T, 4, and returns to the reservoir.
The proportional valve also serves as a bypass valve
in a condition where the thresher is not turned on, but
the cleaning fan pump, driven by the hydrostatic
pump, continues to supply oil to the valve through port 3 2
P, 5. Under this condition, the solenoid valve is closed 66060560
and oil is routed around it to the proportional valve. 35
The pressure of the incoming oil acts on the pilot input
of the proportional valve, causing its spool to shift,
routing the oil flow to the T, 4, port and back to the
reservoir.
35-32
LOW PRESSURE SYSTEM

CHAFF SPREADER VALVE
The chaff spreader valve consists of three main com- 1 2
ponents; the solenoid valve, 1, the adjustable flow
control valve, 2, and the relief valve, 3. 5
4
Oil from the low pressure gear pump enters the valve 6
at 4. If the solenoid is not activated, oil exits the valve
at 5, and flows through the filter, 6, before travelling
to the low pressure valve on the engine gearbox.
3
10020028
36
NOTE: If the solenoid valve, 1, is activated, oil is di-
rected to the adjustable flow control valve, 2. Oil that 2
1
can flow through the flow control valve exits the valve
at 3 where it travels through a quick coupler to the two 4
chaff spreader motors (connected in series). Oil re- 6
turning from the chaff spreader motors enters the
valve, joins bypass oil from the flow control valve, and
exits the valve at 4. 3
In the event that the chaff spreader becomes blocked,
the relief valve, 5, will open, directing oil from the
valve inlet, 6, to the valve outlet, 4. A diagnostic port
7
is fitted to the valve at 7 to allow testing. 5
10020028
37
CHAFF SPREADER/PSD VALVE
The chaff spreader/positive straw discharge (PSD)
valve consists of three main components: the 1
solenoid valve, 1, the adjustable flow control valve, 2, 4
and the relief valve, 3.
Oil from the low pressure gear pump enters the valve
at port IN, 4. If the solenoid is not activated, oil exits
the valve at port T1, 5, and flows through the pressure 2
filter, 6, before traveling to the low pressure valve on
the engine gearbox.
6 5
3
66060557
38
35-33
If the solenoid valve, 1, is activated, oil is directed to
port C OUT, 2, from which it flows to the positive straw 10 1 3
discharge (PSD) motor. Oil returning from the PSD 11
motor re-enters the valve at port C IN, 3, and is 2
8
directed to the adjustable flow control valve, 4. Oil that
can flow through the flow control valve exits the valve
at port S OUT, 5, from which it flows through a quick
coupler to the two chaff spreader motors (connected
in series). Oil returning from the chaff spreader
motors enters the valve through a quick coupler at 9
port T2, 6. 5
4
If the chaff spreader becomes blocked, the relief
valve, 7, will open, directing oil from the valve input 7 6
66060557
port IN, 8, to the outlet port, T1, 9. A diagnostic port
D1, 10, permits testing at the valve input. Diagnostic 39
port D2, 11, permits testing at the output of the PSD
motor.
CHOPPER INFEED ROLL MOTOR VALVE

Combines that are equipped with a chopper infeed
roll have a small hydraulic motor, 1, to drive the roller. 1
This motor is in series with the spreader motors and
is controlled by the spreader motor valve.
NOTE: Combines that are equipped with the chopper
infeed roll do not have positive straw discharge and
vice versa. Combines of model year 2004 and earlier,
a hydraulic bypass valve, 2, is piggybacked onto the
motor. This valve is manually operated via a knob, 3.
Depending upon the position of the knob, oil from the 2 3
low-pressure hydraulic pump is routed to the motor,
which turns the roller, or bypasses the motor, in which 20032047
case the roller is inoperative. In later models, this
valve was eliminated and the hoses go directly to the
motor. 40
35-34
LOW PRESSURE VALVE

2 3 1 4 5
The low pressure valve controls several functions
that do not require the high pressures generated by
the high pressure hydraulic systems, such as clutch 7
engagement and park brake disengage. The low
pressure valve also provides pressure lubrication for
several areas in the engine gearbox.
Oil from the low pressure pump enters the low pres-
sure valve at 1. The low pressure valve contains the
unload clutch solenoid valve, 2, feeder clutch sole- 8
noid valve, 3, park brake solenoid valve, 4, and the
thresher clutch solenoid valve, 5. Pressure for the en- 6
gagement circuits is regulated at 25 bar (363 psi) by 10004669
the relief valve, 6, and monitored by the electrical sys-
41
tem using the pressure sensor, 7. An external lube oil
line, 8, connects to the engine gearbox filler neck to
directly lube the hydrostatic pump drive gear in the
gearbox.
There are several hose and tubing connections to the

back of the low pressure valve. They are used for flow
out to the cooler, 1, return from the cooler, 2, supply 1 5
to the park brake release cylinder, 3, and supply to the
feeder clutch, 4. Supply oil for the thresher and unload
clutches travel from the valve down into the engine
3
gearbox through internal drillings.
Note that the oil cooler for the low pressure circuit is
contained in the same cooler assembly, but is separ-
4
ate from the oil cooler for the hydrostatic and hy-
draulic system.
50020055
2 6
42
35-35
50020056
43
Oil flows into the valve from the low pressure pump, flow directly to the lube oil gallery.
and is supplied to all solenoid valves through a central The lube oil gallery directs oil to the engine gearbox
gallery. The pressure in this gallery is regulated by the components for cooling and lubrication. Two drillings
relief valve at the bottom of the inlet port. The pres- directly off of the lube oil gallery supply oil directly to
sure sensor is mounted on one end of the gallery to the unload and thresher clutches, while an external oil
monitor the pressure, while a cross drilling directs line carries oil to the filler neck and down to lubricate
pressure oil to the diagnostic coupler. the hydrostatic pump drive gear. The pressure in the
Once all circuit requirements are met, the relief valve lube oil gallery is regulated by the lube pressure relief
will open and direct oil out of the low pressure valve valve. If the lube oil gallery pressure exceeds 2.75 bar
to the oil cooler. Return oil from the cooler enters the (40 psi), the lube pressure relief valve will open and
low pressure valve to supply the lube oil gallery. In allow oil to dump directly into the engine gearbox
the event of excessive restriction in the oil cooler cir- sump.
cuit, the cooler relief valve will open and allow oil to
35-36
The park brake circuit in the low pressure valve is
equipped with two extra components; a 0.5 mm 2
(0.020″) orifice, 1, and a check valve, 2. The check 3
valve allows rapid flow of oil through the solenoid
1
valve for releasing the park brake. However, in the
event that pump flow is lost while the park brake sole-
noid is energized, the check valve will close, forcing 5
oil to escape through the orifice. This provides for a
6
slow, progressive re--engagement of the park brake
and prevents a sudden, unexpected stop.
The low pressure valve is fitted with several diagnos- 4
tic ports to allow for troubleshooting. A coupler, 3, is
connected to the high pressure gallery for quick test- 50020057
ing, while plugs are installed in the following test
ports: 44
Unload clutch pressure, 4
Thresher clutch pressure, 5
Lube pressure, 6, Figure 42
If necessary, the cooler relief valve may be removed
from the valve block for inspection by removing plug,
5, Figure 42, while the lube pressure relief valve may
be removed by removing plug, 6.
35-37
35-38
Chapter 3 - Pressure Testing and Fault Finding

The High and Low Pressure Hydraulic Systems
CONTENTS

Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools ................................................................ 3
Specifications -- Closed Center Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Low Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CCLS Pump Pressure and Flow Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CCLS Pump Low Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CCLS Pump High Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CCLS Pump Load Sensing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CCLS Pump Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Steering Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Steering Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Steering Relief Valve Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic Cleaning Fan Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Low Pressure System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Low Pressure System – Chaff Spreader Pressure Test . . . . . . . . . . . . . . . . . . . . . 18
Chaff Spreader/PSD Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Low Pressure System – Regulated Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Low Pressure System – Individual Circuit Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Low Pressure System – Pump Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
35-1

This chapter describes the procedure for fault finding The hydraulic pump is the heart of the hydraulic sys-
the high and low pressure hydraulic systems and per- tem and the chapter describes in detail the tests
forming pressure tests. necessary to confirm that pump output is to specifica-
Before commencing hydraulic pressure testing per- tion. Once specified pump output has been confirmed
form the fault finding checks on Page 4 followed by attention can be focused on the appropriate pressure
the fault finding procedure for the type of concern testing of individual components in the hydraulic cir-
identified. Following these checks may identify an cuit.
obvious cause for the concern and prevent unnec-
essary component disassembly.
35-2
SPECIAL TOOLS
DESCRIPTION NEW HOLLAND NEW HOLLAND

(North America only) (All Markets Except
North America)
Blanking Cap 9/16″--18 ORFS -- 297604
Pressure Gauge 0--40 bar (0--600 psi) OEM1459 293242*
Quad Gauge OEM1212 --
Universal Pressure Test Kit FNH02003 292870
Remote valve coupling -- 5101741 or 293449
Quick release (Female) FNH00535 291924
Adaptor, Quick Release FNH00035 --
Pressure gauge hose -- 292246*
1/ NPT fitting to attach hose 292246 to gauge -- 291927*
8
7
Adaptor M10 x 1.0p x /16 JIC male (enables use of gauges with 7/16 JIC hoses if used) 297417
MiniMess (M16x2) Quick attach fitting -- (procure locally)
Flow Meter 120 ltr/min (0--50 gal/min) minimum FNH02760 (procure locally)
* Part of hydraulic pressure test kit 292870
O--RING FACE SEAL FITTINGS PARKER HANNIFIN

PART NUMBER
Blanking Cap (9/16″--18 ORFS) -- CCLS Pump Low Pressure Standby . . . . . . . . . . . . 4FNL
Plug (9/16″--18 ORFS) -- CCLS Pump Low Pressure Standby . . . . . . . . . . . . . . . . . . . . 4PNLO or 4PNMLO
Tee Piece (9/16″--18 ORFS swivel run) -- CCLS Pump Load Sensing . . . . . . . . . . . . . . 4R6LOS or 4R6MLOS
Tee Piece (13/16 UNF fittings) -- Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R6LOS or 8R6MLOS
Elbow (13/16 UNF fittings) -- Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8ELOS or 8EMLOS
Quick Release Fitting (9/16 UNF Female) -- CCLS Pump Load Sensing . . . . . . . . . . . . PD34BTL
Quick Release Fitting (13/16 UNF Female) -- Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . PD38BTL
Coupler, Male (M14x1.5) [NH Part #84320565] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PD367A
CCLS Pump Flow -- need Fittings to go from 13/16″--16 ORFS (--8 Size) to your Flow Meter for Pressure
Hose, and 1″--14 ORFS (--10 Size) to your Flow Meter for Return Hose.
Low Pressure Pump Flow -- Use 1/2″ ISO Couplers (1 Male, 1 Female) to attach Flow Meter to Chaff Spreader
Couplers. For units not equipped with Chaff Spreader, need Fittings to go from 1″--14 ORFS (--10 Size) to your
Flow Meter.
35-3
SPECIFICATIONS -- CLOSED CENTER SYSTEMS

MAIN HYDRAULIC PUMP
Type Variable Flow Closed Center
Load Sensing Piston Pump
Minimum Output @ engine rated speed 114 Ltr/min (30 US gal/min)
Standby Pressure 19 bar (275 psi)
Maximum System Pressure 210 bar (3046 psi)
Flow to Steering Motor 35 Ltr/min (9 US gal/min)
Steering Pressure 185 bar (2683 psi)
LOW PRESSURE PUMP

Type Gear Type Pump
Minimum Output @ engine rated speed 43 Ltr/min (11.4 US gal/min)
Chaff Spreader Motor relief valve 200 bar (2900 psi)
Regulated System Pressure 25 bar (363 psi)
Cooler Bypass Valve 3.5 bar (50 psi)
Lubrication Pressure 2.75 bar (40 psi)
1
High Pressure CCLS Hydraulic Pump and Low pressure Gear Pump Installation
1. Flow and pressure compensating valves 6. Low pressure pump output tube
2. Load sensing line 7. Low pressure gear pump
3. CCLS pump casing 8. Low pressure pump inlet
4. Pump case lubrication drain 9. CCLS pump high pressure output
5. CCLS pump inlet
35-4
GENERAL FAULT FINDING
Is the reservoir oil at the

correct level ? NO Add oil to reservoir
YES
Is oil contaminated with dirt, YES Investigate cause of contamination.

water or anti--freeze? Drain and replace oil
NO
Have oil filters been replaced NO Replace all filters in system

at correct service interval?
YES
Is the low pressure system YES Refer to Low Pressure system Warning
warning light ON Light ‘On’ fault finding chart
NO
Identify functions not operating

correctly and refer to appropriate
fault finding Chart
35-5
Low Pressure Warning ‘ON’

Alarm “A0012 Control Pressure LOW”
2 3
Suspect a faulty pressure

Perform the low pressure circuit regulated pressure test. YES sensor. Replace and
Is the pressure 25 bar (362 psi)? check operation.
NO
Suspect the drive link between the
Was the pressure measured 0 Bar (0 psi)? YES CCLS and low pressure pumps.
Remove the low pressure pump
NO and inspect. Is the drive link okay?
YES
Suspect a leak within the low
pressure block. Perform individual Remove and Inspect the relief
low pressure circuit tests. Clean or valve in the low pressure block.
replace solenoid valves as The valve may be stuck open.
required. Check the operation. Is Clean or replace as required, and
the pressure to the specification? recheck the operation. Is the
pressure to the specification?
NO NO
Suspect a faulty pump. Perform the Low Pressure Pump Flow

Test. Repair or replace the pump as required and recheck.
35-6
10020028
4 5
Low Pressure Filter Restriction Warning

Alarm “A0010 Gearbox Filter BLOCKED”
Is the gearbox oil at correct NO Add oil to engine gearbox.

level on sight glass?
YES
Disconnect wiring to filter restriction
Replace filter, 1. NO warning light switch
Fault cleared? warning is extinguished?
NO YES
Locate and repair short

circuit to chassis in Replace
intake filter restriction intake filter
switch wiring restriction
switch
Engine Gearbox Oil Overheating

Alarm “A0006 Gearbox Temperature HIGH”
Is the gearbox oil at correct NO Add oil to engine gearbox.

level on sight glass?
YES
Is oil cooler free of dirt and NO Clean oil cooler.

chaff build--up?
YES
Suspect a faulty pump. Perform the Low

Pressure Pump Flow Test. Repair or
replace the pump as required.
35-7
6 7
Power Steering Not Working or Working Incorrectly
Do the other high Pressure test at steering motor, 1. Fault lies in steering
pressure functions YES Is approximately 200 bar (2900 psi) YES
motor. Perform
operate? measured at motor ’P’ port when steering motor tests
steering wheel rotated? (gauge and refer to Section
NO tee’d into line) 41 steering systems
Fault in the CCLS pump circuit. NO
Perform Load sense circuit test,
Low pressure standby test and Suspect a fault within the Priority
high pressure standby test valve. Inspect the priority valve
spool for sticking
General Faults
No Steering and No Other High Pressure System Functions
Fault in CCLS pump circuit. Perform tests for CCLS pump
Steering Working Okay but No Other High Pressure System Functions
Fault in priority valve. Inspect spool for jamming in the valve housing.
35-8
All high pressure system functions affected
A fault common to all functions, possibly the CCLS pump is faulty, the
system relief valve is stuck open or a blocked pressure filter.
Both the high and low pressure systems are affected
A common fault affecting the pumps, possibly a pump drive fault or a

fault in the gearbox
Only one function affected, other functions operating normally
Fault specific to that function.

Is an error code displayed on the Infoview™ Monitor? If an error code
is displayed, investigate the error code and eliminate before
proceeding.
Determine if fault is electrical or hydraulic. If the solenoid has a
manual push button, activate; if function operates okay, the fault is
electrical.
If the function does not operate with the manual button check the
hydraulic circuit.
If possible install a pressure gauge to the component being operated.
If pressure is indicated this may suggest a seized or non--functioning
component. If there is no output pressure from the valve then there
may be a fault within that valve slice. Remove the valve and inspect
for sticking spools, broken springs or dirt ingress in galleries.
A function will only operate in one direction
Is an error code displayed on the Infoview™ Monitor? If an error code

is displayed investigate the error code and eliminate before
proceeding.
Determine if fault is electrical or hydraulic. If the solenoid has a
manual push button, activate, if function operates okay, the fault is
electrical.
If the function does not operate with the manual button check the
hydraulic circuit.
If possible install a pressure gauge to the component being operated.
If pressure is indicated this may suggest a seized or non--functioning
component. If there is no output pressure from the valve then there
may be a fault within that valve slice. Remove the valve and inspect
for sticking spools, broken springs or dirt ingress in galleries.
35-9
Oil overheating (high pressure system)
Relief valve continually blowing, check for broken spring or dirt ingress
and reset.
Oil cooler blocked or thermostatic bypass valve faulty not allowing oil
to circulate around the cooler.
If hydrostatic temperature control system (TCS) is limiting hydrostat
operation, hydrostatic system overload is causing oil overheat. Shift
transmission to lower gear to reduce load on hydrostatic system.
Jerky or inconsistent Operation
On functions requiring consistent and fine control, the system

pressure is maintained by a pressure compensation valve located
within the valve slices. If these stick and fail to operate, jerky or
inconsistent operation may result.
Components may drop gradually or Move gradually out of position without being operated
Functions that contain lock--out valves may drop or move if the seals
within that function are slightly worn and the lock out valve is not
functioning. This may be due to dirt ingress or the valve sticking open.
If the lock out valve sticks closed this may lead to a function not
operating or operating very slowly.
Accumulator faults
An accumulator is installed into a circuit to absorb spikes created in

the hydraulic system, ie, generated by forces acting on a raise/lower
cylinder. If an accumulator fails, the system will become rigid and the
component will have no damping.
35-10
CCLS PUMP PRESSURE AND FLOW TEST-

ING
IMPORTANT: Before performing any pressure or
flow testing operate the combine until the oil is at nor-
mal operating temperature, 65--70°C (150--160°F).
The following tests check operation of the hydraulic
pump and associated high pressure circuits.
CCLS Pump Low Pressure Standby

Special Tools North America All Markets Except NA
Blanking Cap (9/16″--18 ORFS) N/A 297604
Pressure Gauge 0 – 40 bar (0 -- 600 psi) OEM1459 293242
(or) Quad Gauge OEM1212 N/A
MiniMess Quick Attach fitting (M16x2) N/A (procure locally)
Quick release (Female) FNH00535 N/A
Adaptor, Quick Release FNH00035 N/A
Fittings Required Parker Hannifin #

Blanking Cap (9/16″--18 ORFS) 4FNL
Plug (9/16″--18 ORFS) 4PNLO or 4PNMLO
1. Attach the pressure gauge to the coupling, 1, in

the priority valve slice in the main stack valve. 1
IMPORTANT: If a 0 – 40 bar (0 – 600 psi) pressure
gauge is used, ensure that no hydraulic functions, in-
cluding steering, are activated while testing low pres-
sure standby, or the pressure gauge will be damaged.
2. Have an operator start the engine and set engine
speed to maximum. Record the value on the
pressure gauge. The reading should be approxi-
mately 28 bar (408 psi). Note that the low pres-
sure standby is actually higher than that listed in
the specifications, due to the dynamic bleed that
occurs in the steering motor. If the pressure
gauge reading is significantly higher or lower than 8
28 bar (408 psi), continue the test with steps 3
through 7 to confirm the fault.
3. Disconnect the load sense line, 2, from the fitting

on the main stack valve. Install the blanking cap
onto the fitting on the stack valve, and the plug in
the load sense line.
1
the priority valve slice in the main stack valve.
speed to maximum. Record the value on the
pressure gauge. The pressure reading should be
approximately 19 bar (275 psi). 2
10020036
35-11
6. If the pressure reading is marginally away from
specification, adjust the flow compensating
valve, 1, on the CCLS pump. If the reading is ex-
cessively high, examine the flow compensating
valve spool, 1, for sticking.
7. Remove the blanking cap and plug, and reinstall
the load sense line to the main stack valve.
10
CCLS Pump High Pressure Standby
(or) Pressure Gauge 0 – 400 bar (0 – 6000 psi) OEM1464 293245
NOTE: The load sense line must be connected for

this test. 1
the priority valve slice in the main stack valve.
speed to maximum.
3. Operate either the reel horizontal adjustment
valve or reel vertical adjustment valve to the
maximum travel of the cylinders and hold to read
the pressure obtained in the system.
4. The pressure reading should rise to 210 bar
(3046 psi), and is the ‘High Pressure Standby’. 11
5. If reading is not to specification adjust pressure

compensating valve, 2.
If the pressure reading is low, and cannot be ad-
justed to specification with the pressure compen-
sating valve, 2, there may be a fault in the load
sense circuit. Perform the “Load Sensing Circuit
Test”.
12
35-12
CCLS Pump Load Sensing Circuit
Quick release (Female) FNH00535 291924
Tee, Swivel Run (9/16″--18 ORFS) 4R6LOS or 4R6MLOS
Quick release fitting (9/16″--18 ORFS Female) PD34BTL
The load sensing circuit test checks the load sense

pressure that is fed back to the CCLS pump to put it
into stroke. If a circuit is not operating correctly, or if
it is not possible to set the high pressure standby on
the pump with the high pressure compensator, there
may be excessive leakage in the load sense circuit,
which is preventing the signal from reaching the
pump.
1. Remove the load sense line from the fitting on the

CCLS pump compensator valve. Install the
swivel run tee, 3, between the line and fitting in
compensator. Install the quick release fitting, 2, to
the tee, and attach the pressure gauge, 1, to the
quick release fitting.
speed to maximum.
3. With no functions being operated, there should
be approximately 7 -- 10 bar (101 – 145 psi) pres-
sure in the load sense line; this is the pressure
from the dynamic bleed in the steering motor.
Operate each of the functions of the high pres-
sure system one at a time. As each valve is oper- 13
ated, the pressure should rise to the maximum re-
quired by the function being operated, and will
rise to approximately 210 bar (3046 psi) when the
circuit stalls (cylinder hits end of stroke, etc).
NOTE: Some circuits, such as reel drive or feeder
reverser, will not stall unless overloaded, or if the lines
to the appropriate motor are uncoupled, or removed
and capped.
If a circuit does not generate relief pressure in the
sense line when stalled, this is an indication of leak-
age in the load sense circuit. Determining which cir-
cuits are affected by this leakage should help deter-
mine which load check poppet is leaking.
35-13
CCLS Pump Flow Test

If the CCLS pump is capable of developing the proper
high standby pressure, but several circuits operate
very slowly when loaded heavily (such as slow
header raise with large headers), the CCLS pump
may be worn internally, and be incapable of develop-
ing sufficient flow rate under high pressure. To flow
test the CCLS pump, it is recommended that the out-
put is checked at the hoses to the header stack valve.

Flow meter, 120 L/min (0--50 gpm) minimum FNH02760 (procure locally)
Fittings
Fittings are required to go from 13/16″ – 16 ORFS (--8 size) to your flow meter for the pressure hose, and
1″ – 14 ORFS (--10 size) to your flow meter for the return hose.
1. Note: A reverse flow check valve in the return

filter head will prevent the reservoir from draining
when the return line is removed, however, some
oil in the lines will be lost. Have a catch pan ready
when removing the lines to catch any oil loss.
Remove the pressure line from the elbow on top
side of the feeder stack. Install the appropriate
adapter fitting, and attach the line to the inlet hose
of the flowmeter.
Remove the return line from the top rear of the
feeder stack. Install the appropriate adapter fit-
ting, and attach the line to the outlet hose of the
flowmeter.
2. Ensure that the load valve on the flowmeter is 14
fully “Open”. Start the engine, and run the engine
at high idle for several minutes. Shut off the en-
gine.
Check the hydraulic reservoir for proper fluid
level, and top off as required.
3. Have an operator start the engine and run at high
idle. Engage and hold the unload auger swing in;
this will force pump oil through the system.
Gradually adjust the load valve on the flowmeter
to a pressure reading of approximately 35 bar
(507 psi). Record the oil flow through the flow-
meter; it should be approximately 114 L/min (30
US gpm).
If the flow is significantly less, the suction lines
may be restricted to the CCLS pump, or the pump
may be damaged internally.
4. Gradually adjust the load valve on the flowmeter
(2756 psi) while monitoring the oil flow through 15
the flowmeter. The flow rate should remain rela-
tively stable at approximately 114 L/min (30 US
gpm), and should not fall off significantly.
If the flowrate does drop significantly [23 L/min (6
US gpm) or more], this is an indication of a worn
or damaged CCLS pump.
35-14
STEERING TESTING
The following practical test will determine if steering
pump output is sufficient to allow satisfactory oper-
ation of the steering system.
Steering Test
1. Start the engine, and set engine speed to high
idle.
2. Turn steering quickly from lock to lock.
If steering is operating correctly the reaction
should be immediate with no time delay between
turning the steering wheel and movement of the
wheels.
3. At full lock the relief valve in the main frame valve
stack should be heard to blow. The steering
wheel should not continue to turn at full lock; if the
steering can be rotated somewhat, this is an in-
dication of possible steering cylinder leakage
across the piston seals. 16
Steering Relief Valve Pressure Test


the priority valve slice in the main stack valve. 1
17
35-15
2. Start the engine, and set engine speed to maxi-
mum. Rotate the steering wheel in one direction
to full lock, and hold in position. The reading on
the pressure gauge should be approximately 185 1
bar (2683 psi).
If the reading is significantly higher or lower than
specification, adjust the steering pressure by ad-
justing the relief valve, 1, on the priority valve
slice.
10020036
18
Hydraulic Cleaning Fan Flow Test

This test is used to determine the efficiency of the
cleaning fan hydraulic drive pump. The pump will
wear internally over time, causing the fan speed to
decrease.
1. Disconnect the hose from the input (top)
connector of the cleaning fan motor. This is the
motor input hose from the cleaning fan valve.
Connect the hose to the input of the flow meter.
Disconnect the hose from the output (bottom)
connector of the motor. This is the output hose
back to the return port of the cleaning fan valve.
Connect this hose to the output connector of the
flow meter.
NOTE: If the flow meter does not include a pressure
gauge, a separate pressure gauge may be connected
to diagnostic port M on the cleaning fan valve block.
This port is located on the inboard side of the valve
block.
2. Open the restriction valve on the flow meter
completely.
3. Start the engine and engage the combine’s
separator. Using the cleaning fan speed rocker
switch on the right--hand console, set the fan
speed to the minimum setting and run the engine
at high idle.
4. While monitoring the flow meter, gradually 56060566
increase the fan speed to maximum. This will
verify correct operation of the solenoid valve and
software operation. The cleaning fan pump’s
output flow should reach approximately 77 l/min
(20 gal/min), which is the pump’s maximum
theoretical flow rate for this application. 19
35-16
5. Slowly turn in the flow meter’s restriction control to replace the valve block assembly with a known
to increase the system pressure and verify that good assembly.
the system’s relief valve is working correctly. The
5. The pump could be worn excessively.
valve should open at 210 bar (3000 psi).
6. Slowly reopen the restriction valve until the
pressure drops to approximately 21 bar (300 psi) NOTE: If the flow is below specifications, the output
below the relief valve setting: 210 – 21 = 189 bar of the pump alone can be checked by connecting the
(3000 – 300 = 2700 psi). The flow rate should be flow meter directly to the pump. However, the
greater than 65 l/min (17 gal/min), which is the following CAUTION should be strictly observed.
minimum flow specification. CAUTION
If Flow is Below Minimum Specifications
Use extreme caution if this procedure is used.
1. Check the oil level in the hydraulic systems There is no relief valve in the system when
reservoir. A low oil level can starve the system testing in this manner. The pump could be
during peak demands by other systems. damaged and flying pieces could cause injury.
2. Inspect the suction (input) hose of the cleaning Be absolutely sure the flow meter restrictor is
fan hydraulic motor. An aging hose can tend to open when starting the combine engine. Once
buckle when the motor draws oil, restricting the oil the machine is started, increase to full throttle
flow. and very slowly turn in the restrictor. DO NOT let
3. Check for worn relief valve and solenoid valve the pressure exceed 200 bar (2900 psi).
o--rings.
4. There could be a problem with the control If the flow rate is less than 65 l/min (17 gal/min), the
solenoid valve. The only sure way to test this is pump is worn excessively and must be replaced.
35-17
LOW PRESSURE SYSTEM TESTING for the chaff spreader, it provides oil pressure for
The low pressure system provides oil flow and pres- clutch engagement, and it provides flow through the
sure for three important functions; it provides power cooler for cooling the engine gearbox.
Low Pressure System – Chaff Spreader Pressure

Test
1. Attach the pressure gauge to the test fitting, 1, lo-

cated on the side of the chaff spreader valve. Un- 1
couple one of the quick couplers, 2, that connect
the chaff spreader motors to the valve.
2. Start the engine, and engage the thresher. Mo-
mentarily set the engine to high idle until a pres-
sure gauge reading is obtained, then reduce en-
gine speed and disengage the thresher.
3
IMPORTANT: As soon as the thresher is engaged,
the low pressure system is pushing all oil flow over the
relief valve in the chaff spreader valve. Do not run the
2
thresher for any longer than is required to obtain a
10020028
stable gauge reading, or pump damage may occur.
3. The reading on the pressure gauge should be ap- 20
proximately 200 bar (2900 psi). If the pressure
gauge reading is not correct, replace the relief
valve, 3.
Chaff Spreader/PSD Pressure Test

If the combine is equipped with the positive straw
discharge (PSD) system, a different chaff spreader
valve is used. In this case, attach the pressure gauge
to test fitting D1, 1, located on the front face of the 1
valve block, above the manual rotary valve knob.
Follow the steps above to perform the pressure test.
66060557
21
35-18
Low Pressure System – Regulated Pressure Test
1. Attach the pressure gauge to the test fitting, 1, lo-
cated on the low pressure valve. Start the engine,
and check the pressure gauge reading at low en-
gine idle. The reading on the pressure gauge
should be approximately 25 bar (363 psi).
If the pressure reading is low, this is a possible in-
dication of excessive leakage in one of the clutch
engagement circuits, a faulty relief valve, or a
worn or damaged pump.
2. Increase the engine speed to high idle, and check
the pressure gauge reading. The reading on the 1
pressure gauge should be approximately 25 bar
(363 psi).
If the reading is still low, this is a possible indica- 22
tion of a faulty relief valve or a worn or damaged
pump. Replace the relief valve and retest the cir-
cuit. If the pressure reading is still low, the pump
must be removed for inspection and repair.
Low Pressure System – Individual Circuit Testing

If a particular circuit is not operating correctly, it is
possible to test it individually from the other circuits.
Quick release fitting (M14 x 1.5) [NH part# 84320565] PD367A
(or) Quick release fitting (13/16″--16) PD38BTL
1. Install a quick release fitting into the appropriate

port for the circuit to be tested, as follows:
3
Unload clutch pressure, 1 (M14 x 1.5 ORB port)
Thresher clutch, 2 (M14 x 1.5 ORB port)
Remove the plug, and install a quick release fitting
[NH part # 84320565 (Parker #PD367A)], or remove
the regulated pressure test fitting, 3, and switch posi-
tions with the plug. 2
50020057
23
35-19
Park brake pressure, 1
Feeder clutch pressure, 2
These two ports are both M14 x 1.5 ORB, but have
a nipple installed to 13/16″ – 16 ORFS (--8 size) for 1
the hoses. Remove the hose from the fitting, and in-
stall a quick release fitting (Parker #PD38BTL). Alter-
natively, remove the hose and nipple, and install a
quick release fitting [NH part # 84320565 (Parker 2
#PD367A)] directly into the valve.
2. Start the engine, and run at low idle. Engage the
circuit to be tested, and check the pressure gauge
reading. The reading on the pressure gauge
should be approximately 25 bar (363 psi). 50020055
If the pressure reading is low, this is a possible in- 24

dication of excessive leakage in the clutch en-
gagement circuits, due to damaged seals in the
solenoid valve. On the unload and thresher clutch
circuits, this could also indicate a leak at the seal
rings on the clutch shaft in the engine gearbox.
3. Increase the engine speed to high idle, and check
the pressure gauge reading. The reading on the
pressure gauge should be approximately 25 bar
(363 psi).
If the reading is still low, this is a possible indica-
tion of a faulty relief valve or a worn or damaged
pump. Replace the relief valve and retest the cir-
cuit, If the pressure reading is still low, the pump
must be removed for inspection and repair.
Low Pressure System – Pump Flow Test

Consistently low pressures in the low pressure valve,
even after the relief valve has been replaced, may
indicate a worn or damaged low pressure pump. In
addition, the reduced flow from a worn pump may re-
sult in insufficient flow through the oil cooler, causing
engine gearbox oil overheating. If engine gearbox oil
overheating is a consistent problem, the low pressure
pump flow rate should be tested.
Flow meter, 120 L/min (0--50 gpm) minimum FNH02760 (procure locally)
Fittings
If unit is equipped with chaff spreader option, use standard ISO couplers (1 male, 1 female) to connect the
flowmeter to the couplers on the chaff spreader valve.
If unit is not equipped with chaff spreader option, fittings are required to go from 1″ – 14 ORFS (--10 size)
to your flow meter for both hoses.
35-20
1. Note: Some oil in the lines will be lost. Have a
catch pan ready when removing the lines to catch
any oil loss.
If equipped with chaff spreader:
Disconnect the chaff spreader quick couplers, 1. 2
Connect the flowmeter inlet hose to the female
coupler on the chaff spreader valve, and the flow-
meter outlet hose to the male coupler on the chaff
spreader valve.
If not equipped with a chaff spreader:
Remove the pressure line, 2, from the side of the 1
filter. Install the appropriate adapter fitting, and
10020028
attach the line to the inlet hose of the flowmeter.
Install the appropriate adapter fitting to the fitting 25
in the filter head, and attach the outlet hose of the
flowmeter.
2. Ensure that the load valve on the flowmeter is
fully “Open”. Start the engine, and run the engine
at high idle for several minutes. Shut off the en-
gine.
Check the engine gearbox for proper fluid level,
and top off as required.
IMPORTANT: On units not equipped with a chaff
spreader, use caution when adjusting the flowmeter
load valve, as there is no relief protection between the
pump and flowmeter. Excessive pressure buildup will
result in pump failure.
3. Have an operator start the engine and run at high
idle.
Gradually adjust the load valve on the flowmeter
(507 psi). Record the oil flow through the flow-
meter; it should be approximately 43 L/min (11.4
US gpm).
If the flow is significantly less [11 L/min (3 US
gpm) or more], the suction line to the pump may
be restricted, or the pump may be damaged inter-
nally.
4. Gradually adjust the load valve on the flowmeter
(2756 psi) while monitoring the oil flow through
the flowmeter. The flow rate should remain rela-
tively stable, or may drop slightly to approximate-
ly 36 L/min (9.5 US gpm), but should not fall off
significantly.
If the flowrate does drop significantly to 32 L/min
(8.5 US gpm) or less, this is an indication of a
worn or damaged pump.
35-21
35-22
Chapter 4 - Hydraulic Pump
CONTENTS

Special Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure and Flow Compensating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
High Pressure Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
35-1
SPECIAL TORQUE
Component Torque
Low Pressure to high pressure hydraulic pump attaching cap screws 58 -- 63 N⋅m (43 -- 47 ft-lbs)
Pressure and flow compensating valve plugs 25 -- 30 N⋅m (18.5 -- 22 ft-lbs)
Valve block to pump casing cap screws 50 -- 62 N⋅m (37 -- 46 ft-lbs)
35-2
REPAIR
LOW PRESSURE PUMP
The low pressure hydraulic pump is not serviceable. 2
3
If the pump is worn or damaged, it must be replaced.
3
Removal
Disconnect and cap hydraulic lines, 1, from the low

pressure pump, 2.
1
10012183
Turn out the two cap screws, 3, and remove the low
pressure pump from the high pressure pump. 1
NOTE: The other two cap screws hold the low

pressure pump together.
Installation
Set the low pressure pump, 1, into position on the 2 1
high pressure pump with the larger fitting toward the
front of the combine. 2
Turn in the two cap screws, 2, to secure the pump.

Torque the cap screws to 58 -- 63 N⋅m (43 -- 47 ft-lbs).

Connect the hydraulic lines, 3.

10012183
3
2
PRESSURE AND FLOW COMPENSATING
VALVE 2
Disassembly
Remove the four cap screws, 1, securing the flow 1
compensating valve assembly, 2, to the pump.
1
20013880
35-3
To ensure correct re-assembly, keep the component Remove the springs, 5 and 12 spring seats, 4 and 13,
parts for each valve separate. the flow compensating spool, 3, and the pressure
compensating spool, 14, from the valve body, 2.
CAUTION Remove the plugs and O rings, 1, 15 and 16, from the
Due to extreme spring pressure within the valve, housing.
DO NOT remove the rear plugs, 1 and 16, until the
adjusters, 6 and 11, have been removed. Inspection
Thoroughly clean all components in a suitable
IMPORTANT: Do not mix the parts from the flow and solvent.
pressure compensator assemblies.
Examine the springs for cracks or distortion. Replace
NOTE: The stem on the flow compensating valve if defective.
spool is longer than that on the pressure
compensating valve spool. Examine the spools for signs of wear and pitting.
Remove the tamper-proof caps, 8 and 9, from the Examine the lands in the valve body for signs of wear
adjuster locknuts. and pitting.
Loosen the adjuster lock nuts, 7 and 10, and remove

the adjusters and O rings, 6 and 11.
8-094
4
1. Plug 9. Cap
2. Valve body 10. Lock nut
3. Flow compensating spool 11. Adjuster (pressure)
4. Spring seat 12. Spring
5. Spring 13. Spring seat
6. Adjuster (flow) 14. Pressure compensating spool
7. Lock nut 15. O Ring
8. Cap 16. Plug
35-4
Assembly Insert the flow compensating spool, 3, and the
pressure compensating spool, 14, in their respective
NOTE: Replace all O rings during assembly.
bores through the rear of the valve body, 2.
Lubricate all parts with clean hydraulic fluid.
Insert the spring seats, 4 and 13, springs, 5 and 12,
Install the plugs and O rings, 1 and 16, and torque to and install the adjuster and O rings, 6 and 11, with
25 - 30 N⋅m (18.5 - 22 ft-lbs). lock nuts, 7 and 10.
Install the O rings, 15.
8-094
5
1. Plug 9. Cap
2. Valve body 10. Lock nut
3. Flow compensating spool 11. Adjuster (pressure)
4. Spring seat 12. Spring
5. Spring 13. Spring seat
6. Adjuster (flow) 14. Pressure compensating spool
7. Lock nut 15. O Ring
8. Cap 16. Plug
35-5
Secure the assembly, 1 to the pump with four cap
screws, 2. 1
NOTE: Do not install the tamperproof caps until the

valves have been adjusted. 2
Pressure test the pump and adjust the pressure and 2

flow compensating valves as described in the
“Pressure Testing” portion of this section.
20013880
6
HIGH PRESSURE HYDRAULIC PUMP
Removal 1
Disconnect and cap hydraulic lines, 1, from the low

pressure pump, 2.
10012183
7
Disconnect and cap the four hydraulic lines, 1, from
the high pressure pump, 2. 2
1
1
10012184
35-6
Loosen but do not remove the mounting nuts, 1,
holding the pump assembly to the combine gearbox. 1
10012185
9
Securely attach the high pressure pump to a tow

motor or other suitable lifting device. Remove the
mounting nuts and lift the pump from the combine.
10012186
10
Disassembly
Turn out two cap screws, 1, and remove the low
pressure pump from the high pressure pump.

1
20013879
11
35-7
Slide the pump coupling, 1, from the cavity. Remove
O ring, 2. Turn out four cap screws, 3. 3
20013864
1 2
12
Separate the two sections of the pump, 1. Remove
and discard the O ring.
1
20013865
13
Grasp the rotating group assembly, 1, and slide it
from the shaft.
1
20013866
14
35-8
Using a suitable marker, identify each piston and
slipper in the corresponding barrel in the cylinder
block.
8-075
15
Remove the pistons and slippers from the cylinder
block.
20013867
16
Lift the cone, 1, from the cylinder block. Do not
remove the pins, 2. 1
2
20013868
17
35-9
Pull the swash plate, 1, from the pump cavity.
Remove the swash plate return spring assembly, 2, 1 2
from the pump cavity.
20013869
18
Remove the retaining ring, 1, holding the shaft
assembly in place. Rotate the casing over so the
inside of the cavity is facing down. Use a mallet and
gently tap the shaft assembly from the pump casing.
1
20013870
19
Remove the retaining ring, 1, holding the shaft seal
in place. 1
20013871
20
35-10
Rotate the casing over so the inside of the cavity is
facing up. Use a long punch and remove the shaft
seal, 1.
20013872
21
Remove the retaining ring, 1, from the shaft
assembly. 1
20013873
22
Set the shaft assembly in a press with the short end
up. Push the shaft from the bearing.
20013874
23
35-11
Inspection
Remove the swash plate servo piston, 1. 1
Inspect the valve plate, 2, for damage but do not

remove the valve plate unless replacement is
necessary.
Wash all components in a suitable solvent and dry

thoroughly.
Examine the drive shaft locating bushings located in

the pump cover. If the bushings are worn or 2
damaged, the cover and bushings must be replaced 20013881
as an assembly.
24
Check that the drive shaft bearing rotates freely by
hand without roughness. Replace if found defective.
Inspect all parts for distortion or wear. Replace any

damaged part.
Assembly
Set the assembly in a press and slide the shaft, 1, into 1
the bearing, 2, until the bearing is seated against the
shaft shoulder.
20013875 2
25
Install the retaining ring, 1, on the shaft to secure the
bearing in place. 1
20013873
26
35-12
Press the shaft seal, 1, into the cavity of the pump
casing. Secure the seal in place with retaining ring, 2.
2 1
20013871
27
Set the casing on wood blocks with the pump cavity
facing up. Using a mallet, tap the shaft assembly, 1, 1
into place until the bearing is seated against the 4
shoulder. Secure the shaft using a retaining ring, 2.
Place the double spring assembly, 3, inside the

pump. Set the swash plate pivot, 4, onto the spring
assembly.
20013876 2
28
Position the swash plate, 1, as shown. Press down
on the needle bearings, 2, until they click into place.
1
2
20013877
29
35-13
Set the cone, 1, on the pins, 2, of the cylinder block
with the flat side down. 1
2
20013868
30
Referencing the identification marks previously
made, slide the pistons, 1, into the corresponding
barrels of the cylinder block, 2.
2
20013867
31
Slide the rotating group assembly, 1, onto the shaft.
Rotate the pumping head until the splines line up.
Continue pushing the head onto the shaft until the 1
slippers, 2, are resting against the swash plate.
2
20013878
32
35-14
Lubricate the casing O ring with petroleum jelly and
install it into the grove of the pump casing, 1. 1
20013866
33
IMPORTANT: Use care when assembling the two
sections of the pump. Pay special attention to the
1
position of the O ring. The O ring may shift during
assembly and cause the pump to leak. Petroleum
jelly may be used to hold the O ring in place.
Carefully push the two sections of the pump, 1,

together.
20013865
34
Turn in the four cap screws, 1, 1/2 turns at a time and
secure the two sections together. Torque the cap 1
screws to 50 -- 62 N⋅m (37 -- 46 ft-lbs). Insert the high
to low pressure pump coupling, 2. Lubricate the O
ring, 3, with petroleum jelly and install it into place.
20013864
2 3
35
35-15
Attach the low pressure pump to the high pressure
pump with two cap screws, 1. Torque the cap screws
to 58 -- 63 N⋅m (43 -- 47 ft-lbs).

1
20013879
36
Installation
Securely attach the high pressure pump to a tow

motor. Lubricate and install a new O ring onto the
mounting flange of the pump. Lift the pump assembly
up to the mounting flange of the gearbox with the
larger fitting of the low pressure pump toward the
front of the combine.
10012186
37
Secure the pump assembly to the combine with two
mounting nuts, 1. 1
10012185
38
35-16
Attach the four hydraulic lines, 1, to the high pressure
pump, 2. 2
1
1
10012184
39
Attach the two hydraulic lines, 1, to the low pressure
pump, 2. 2
10012183 1
40
35-17
35-18
Chapter 5 - Stack Valves Overhaul
CONTENTS

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Main Stack Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Feeder Stack Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Low Pressure Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
35-1
REPAIR
MAIN STACK VALVE
Removal
IMPORTANT: Be sure the area around the stack
valves is clean before removing them. Dirt
contamination will cause hydraulic component
damage and/or failure. Use caution while washing to
keep electrical components as dry as possible.
1. Open the hydraulic system drain valve, 1, and
drain the hydraulic oil into clean suitable
containers.
10013107
1
IMPORTANT: Lines and fittings must be capped and
plugged when disconnected to avoid contamination.
Dirt contamination will cause hydraulic component
damage and/or failure.
2. Loosen and disconnect the hydraulic line fittings

from the stack valve. Cap and plug all lines and
fittings.
10020036
2
NOTE: Mark all electrical connector locations for
proper connection during assembly. 2
3. Disconnect all electrical connectors from the

valve solenoids, 2, and valve stack.
4. Disconnect the main electrical connector, 1, from
the ECU.
1
10020036
35-2
5. Loosen and remove the four cap screws, 1,
securing the stack valve to the support brackets, 1 2
2. (only two screws are shown)
6. Remove the stack valve from the support
bracket.
50021213
4
Installation
2 1
1. Install the stack valve onto the support brackets,
1.
2. Install the four cap screws, 2, securing the stack
valve to the support brackets, 1.
3. Tighten the cap screws securely.
1
50021213
5
4. Connect the main electrical connector, 1, to the
ECU. 2
5. Connect the electrical connectors to the valve
solenoids, 2.
1
10020036
35-3
6. Remove all caps and plugs from the hydraulic
lines and fittings.
7. Connect the hydraulic line fittings to the stack
valve. Tighten the fittings securely.
10020036
7
8. Close the hydraulic system drain valve, 1.
9. Fill the hydraulic reservoir with the proper type
and amount of hydraulic fluid.
10. Start the engine and cycle the appropriate
features controlled by the main stack valve.
1
11. Check for proper operation of all functions of the
main stack valve.
12. Check all connections for leaks.
10013107
8
Disassembly
NOTE: Illustrations do not show optional feeder
variator valve.
1. Loosen and remove the three nuts, 1, from the tie

rods.
1
20015980
35-4
2. Carefully lift the base plate, 1, from the unloading
auger valve, 2. 1
20015981
10
3. Carefully lift the unloading auger valve, 1, from
the rotor variator valve, 2.
1
2
20015982
11
4. Carefully lift the rotor variator valve, 1, from the
priority valve, 2.
2
1
20015983
12
35-5
5. Carefully lift the priority valve, 1, from the
accumulator valve, 2.
1
20015986
13
6. Lay the remaining parts of the stack valve
assembly on the workbench.
7. Remove the three socket head cap screws, 1,
from the header lift valve, 2. 1
20015984 2
14
8. Carefully lift the accumulator valve, 1, from the
header lift valve, 2.
1
20015985
15
Inspection
1. Check all O rings for cuts, nicks or deformity.
2. Check mating surface of valve sections for nicks,
burrs, or other damage. Repair or replace as
necessary.
3. Inspect tie rods for straightness. Replace as
necessary.
35-6
Assembly
NOTE: Illustrations do not show optional feeder
variator valve. 2
1. Lubricate O rings with NH 134 hydraulic oil and

install onto the header lift valve, 1.
2. Assemble the accumulator valve, 2, to the
header lift valve, 1. 1
20015985
16
3. Install the three socket head cap screws, 1,
through the header lift valve, 2, into the
accumulator valve.
4. Tighten the cap screws securely. 1
20015984 2
17
install onto the connecting plate, 2.
1
6. Carefully install the priority valve, 1, onto the
20015986
18
35-7
install onto the priority valve, 2.
8. Carefully install the priority valve, 1, onto the rotor
variator valve, 2.
2
1
20015983
19
install onto the rotor variator valve, 2.
10. Carefully install the unloading auger valve, 1,
onto the rotor variator valve, 2.
1
2
20015982
20
35-8
install onto the unloading auger valve, 2. 1
12. Carefully install the base plate, 1, onto the 2
unloading auger valve, 2.
20015981
21
13. Install the three nuts, 1, onto the tie rods.
14. Tighten and torque the nuts to 25 N⋅m (18.5 ft-lb).
20015980
22
35-9
FEEDER STACK VALVE

Removal
IMPORTANT: Be sure the area around the stack
valves is clean before removing them. Dirt
contamination will cause hydraulic component
damage and/or failure. Use caution while washing to
keep electrical components as dry as possible.
1. Disconnect the hydraulic supply and return lines,
1. 1
2. Cap and plug all fittings to avoid dirt contamina-
tion of the hydraulic system.
10021116
23
IMPORTANT: Lines and fittings must be capped and
plugged when disconnected to avoid contamination.
Dirt contamination will cause hydraulic component
damage and/or failure.
IMPORTANT: Mark all lines for proper connection

during installation.
3. Loosen and disconnect the hydraulic line fittings

from the feeder stack valve. Cap and plug all
lines and fittings
10020032
24
IMPORTANT: Mark all electrical connector locations
for proper connection during assembly.
1
4. Disconnect the electrical connectors, 1, from the 2
front side of the valve solenoids.
5. Disconnect the electrical connectors, 2, from the
rear of the valve solenoids.
10020032
25
35-10
6. Loosen and remove the four cap screws, 1,
securing the stack valve to the feeder, 2. (only
two screws are shown)
7. Remove the stack valve from the support
brackets. 1
20015990
26
Installation
1. Install the stack valve onto the feeder, 1.
2. Install the four cap screws, 2, securing the stack
valve to the support bracket. (only two screws are
shown) 2
3. Tighten the cap screws securely.
20015990
27
4. Connect the electrical connectors, 2, to the valve
solenoids at the rear of the stack valve assembly.
5. Connect the electrical connectors, 1, to the valve 1
2
solenoids at the front of the stack valve
assembly.
10020032
28
35-11
6. Remove all caps and plugs from the hydraulic
lines and fittings.
7. Connect the hydraulic line fittings to the stack
valve. Be sure all lines are attached to their
proper locations. Tighten the fittings securely.
10020032
29
8. Remove the caps and plugs from coupler fittings.
1
9. Connect the hydraulic supply and return lines, 1,
to the feeder stack valve.
features controlled by the feeder stack valve.
feeder stack valve.
10021116
30
Disassembly
1
NOTE: Illustrations do not show stone ejection valve.
1. Loosen and remove the three nuts, 1, from the tie

rods.
20015991
31
35-12
2. Carefully lift the end plate, 1, from the reel drive
valve, 2. 1
20015992
32
3. Carefully lift the reel drive valve, 1, from the reel
up\down valve, 2. 1
20015993
33
4. Carefully lift the reel up\down valve, 1, from the
reel fore/aft valve, 2. 1
20015994
34
35-13
5. Carefully lift the reel fore/aft valve, 1, from the
lateral tilt valve, 2.
1
20015995
35
6. Carefully lift the lateral float valve, 1, from the
reverser valve, 2.
1
20015996
36
7. Carefully lift the reverser valve, 1, from the
2
20015997
37
Inspection
1. Check all O rings for cuts, nicks or deformity.
2. Check mating surface of valve sections for nicks,
burrs, or other damage. Repair or replace as
necessary.
3. Inspect tie rods for straightness. Replace as
necessary.
35-14
Assembly
NOTE: Illustrations do not show stone ejection valve.

install onto the accumulator valve, 2.
2. Assemble the reverser valve, 1, onto the
1
2
20015997
38
install onto the reverser valve, 2.
4. Assemble the lateral float valve, 1, onto the 1
reverser valve, 2.
20015996
39
install onto the lateral float valve, 2.
6. Assemble the reel fore\aft valve, 1, onto the 1
lateral float valve, 2.
20015995
40
35-15
install onto the reel fore\aft valve, 2. 1
8. Assemble the reel up\down valve, 1, onto the reel
fore\aft valve, 2.
20015994
41
install onto the reel up\down valve, 2. 1
10. Assemble the reel drive valve, 1, onto the reel
up\down valve, 2.
20015993
42
35-16
install onto the reel drive valve, 2. 1
12. Assemble the end plate, 1, onto the reel drive
valve, 2.
2
20015992
43
13. Install the three nuts, 1, onto the tie rods.
1
14. Tighten and torque the nuts to 25 N⋅m (18.5 ft-lb).
20015991
44
35-17
LOW PRESSURE VALVE BLOCK

Removal
IMPORTANT: Be sure the area around the
low-pressure manifold is clean before disconnecting
lines or removing from the gearbox. Dirt contamina-
tion will cause hydraulic component damage and/or
failure. Use caution while washing to keep electrical
components as dry as possible.
1. Open the hydraulic system drain valve, 1, and
drain the hydraulic oil into clean suitable
containers.
10013107
45
2. Disconnect the solenoid wire connector plug, 1.
3. Loosen the fittings, 2, and remove the hydraulic 1
lines from the sides and top of the manifold block.
2
50020055
46
4. Disconnect the wire connector, 3, to the pressure
sensor, 2.
5. Loosen and remove the four cap screws, 1. 3
Remove the low-pressure manifold from the top
of the gearbox (only two are shown).
6. Remove the O rings between the gearbox and
manifold block mating surfaces.
1 2
50023224
47
35-18
Installation
1. Install the O rings between the gearbox and
manifold block mating surfaces. 3
2. Install the low-pressure manifold onto the top of
the gearbox. Install and tighten the four cap
screws, 1 (only two are shown).
3. Torque the cap screws to 28 N⋅m (21 ft-lb).
4. Connect the wire connector, 3, to the pressure 1 2
sensor, 2.
50023224
48
5. Connect the solenoid wire connector plug, 1.
6. Connect the hydraulic lines on the sides and top 1
of the manifold block and tighten the fittings, 2.
2
50020055
49
7. Close the hydraulic system drain valve, 1.
8. Fill the hydraulic reservoir with the proper type
and amount of hydraulic fluid.
features controlled by the low--pressure manifold
block. 1
low-pressure manifold.
10013107
50
35-19
35-20
SECTION 41 -- STEERING AXLE -- CHAPTER 1
Chapter 1 - Axle, General
CONTENTS

Axle Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Heavy Duty Adjustable Steering Axle (HDASA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Powered Rear Axle (PRA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Height Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Track Width Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Toe In Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Axle Front/Rear Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
41-1
AXLE TYPES
The combine steering axle is available in two
configurations, Heavy Duty Adjustable Steering Axle
and Powered Rear Axle. Both units can be adjusted
to allow the installation of a wide range of tire sizes.
Heavy Duty Adjustable Steering Axle (HDASA)
1 2
The Heavy Duty Adjustable Steering Axle is designed
to support the weight of the combine and provide
directional control to the operator. The center section, 1,
is attached to the combine frame with the axle pivot rod,
4
2. Two wear bushings, 3, are installed in the center
section to minimize the wear of the pivot rod. Some tire
sizes require the center section to be in the “Front” or 3
“Rear” position. A split collar, 4, is clamped onto the pivot
rod to hold the center section in the proper location. 3
Use the following charts to determine the correct
vertical and horizontal position of the axle. Reference 10010483
the charts according to the model of combine and
extensions on which the adjustments are to be made. 1
Find the Traction and Steering Tire Size from those
listed. Follow the row of the Traction Tire Size
horizontally until the intersection of the Steering Tire
Size. The upper number in the box specifies the height.
The lower number in the box specifies the track width.
Fill in the table below with the values found.
Powered Rear Axle (PRA)

The Powered Rear Axle is designed to support the
weight of the combine, provide directional control to
the operator and increase traction by the addition of
two more drive wheels. The axle is constructed using
parts identical to the standard axle.
The Powered Rear Axle adjustment is performed in

the same manner as that for the standard axle. Only
one procedure is provided.
10010483
41-2
NOTE: Use the following chart to record what type of rear axle the combine is equipped with and height and track
width settings for the size being used.
Combine Model: Extension Type:

Steering Tire Size
Traction Tire Size Height

Value
Track Width
Value
NOTE: The height adjustment is the same whether

American or European extensions are used.
NOTE: If using Traction Tire Size,

68-50.00x32-16PR-STG-XT, refer to “Center Sec-
tion Adjustment/Repair”, Chapter 4 to position the
center section before adjusting the axle.
Raise the combine with the proper sized jack.
Support the weight of the combine with jack stands 2
positioned under the center axle section. Remove
both tires from the combine. Detach the tire rod, 1,
and steering cylinders, 2, from both sides.
10010489 1
41-3
Tire Selection Chart CR970 Allowed Recommended
Tire Width Max Inf Dished In Dished Axle Ex- Duals/Rows Treadwidth
Drive Tires *1 mm (in) Press mm (in) Out tension mm (in) Center/Center
Bar (psi) mm (in) mm (in) mm (in)
800/65R32 172A8 R1W 796 (31.3) 2.5 (36) 100 (3.9) 3048 (120.0)
115(4.5) 3478 (136.9)
100 (3.9) 316 (12.4) 3680 (144.9)
900/60R32
/ 176A8 R1W 921 (36.3) 2.6 (38)
( ) 100 (3.9) 3048 (120.0)
andd
115(4.5) 3478 (136.9)
900/60R32 176A8 R1
100 (3.9) 316 (12.4) 3680 (144.9)
900/65R32 172A8 R2 921 (36.3) 2.0 (29) 100 (3.9) 3048 (120.0)
115(4.5) 3478 (136.9)
100 (3.9) 316 (12.4) 3680 (144.9)
76x50.00--32 16 PR HF3 1234 (48.6) 1.2 (18) 100 (3.9) 316 (12.4) 3680 (144.9)
18.4R42 153A8 R1W 486 (19.1) 2.5 (36) 365 (14.4) 265 (10.4) Inner/762 (30) 3048 (120.0)
381 (15.0) 265 (10.4) Outer/762 (30) 4572 (180.0)
20.8R42 155A8 R1W 571 (22.5) 2.0 (29) 365 (14.4) 265 (10.4) Inner/762 (30) 3048 (120.0)
381 (15.0) 265 (10.4) Outer/762 (30) 4572 (180.0)
20.8R42 155A8 R2 551 (21.7) 2.0 (29) 365 (14.4) 265 (10.4) Inner/762 (30) 3048 (120.0)
381 (15.0) 265 (10.4) Outer/762 (30) 4572 (180.0)
420/80R46 159A8 R1 436 (17.2) 3.3 (48) 252 (9.9) 138 (5.4) Inner/508 (20) 3020 (118.9)
267 (10.5) 138 (5.4) Outer/508 (20) 4090 (161.0)
252 (9.9) 316 (12.4) Inner/559 (22) 3376 (132.9)
41--4
267 (10.5) 316 (12.4) Outer/559 (22) 4446 (175.0)
A B C D E F G H I J K L M N O P Q R S T
Tire Width Max Inf Axle Type Dished In Dished Axle Height Stop bolt Treadwidth Turn Ra-
Steering Tires *1 mm (in) Press mm (in) Out Width Position Length Center/Center dius m
Bar (psi) mm (in) Position mm (in) *2 mm (in) (ft) *3
480/70R30 152A8 R1W 499 (19.6) 3.3 (48) HDASA 50 (2.0) 3 3 51 (2.0) 3034 (119.4) 5.7 (18.7)
HDASA 50 (2.0) 3 4 34 (1.3) 3034 (119.4) 4.8 (15.7)
HDASA 50 (2.0) 4 2 29 (1.1) 3184 (125.4) 4.6 (15.1)
HDASA 50 (2.0) 5 3 18 (0.7) 3334 (131.3) 4.2 (13.8)
HDASA 50 (2.0) 6 2 18 (0.7) 3484 (137.2) 4.2 (13.8)
HDASA 50 (2.0) 6 3 18 (0.7) 3484 (137.2) 4.2 (13.8)

HDASA 50 (2.0) 7 2 18 (0.7) 3634 (143.1) 4.3 (14.1)
HDASA 50 (2.0) 7 3 18 (0.7) 3634 (143.1) 4.3 (14.1)
HDASA 50 (2.0) 7 4 18 (0.7) 3634 (143.1) 4.3 (14.1)
PRA 34 (1.3) 3 2 45 (1.8) 3150 (124.0) 5.9 (19.4)
PRA 34 (1.3) 3 3 37 (1.5) 3150 (124.0) 5.3 (17.4)
*1 -- Tire Restrictions: 800/65R32 172A8 R1W -- restricted to 30’ grain heads and 8R30 corn head 420/80R46 159A8 R1 -- recommended for 20″ and 22″ rows only; not approved for 36′, 39′ or 42′ draper headers
900/60R32 176A8 R1W -- increase inflation pressure to 2.8 bar (41 psi) for 36′, 39′ and 42′ draper headers
900/65R32 172A8 R2 -- not approved for 36′, 39′ and 42′ draper headers
76x50.00--32 16 PR HF3 -- increase inflation pressure to 1.4 bar (21 psi) for 36′, 39′ and 42′ draper headers
18.4R42 153A8 R1W -- not approved for 36′, 39′ and 42′ draper headers
*2 -- Stop bolt length measured at side of socket set screw from cast surface. On PRA axle measure on stop screw side closest to steer cylinder.
*3 -- Turn radius is measured to center of front axle.
Tire Selection Chart CR970 -- Cont’d. Allowed Recommended
A B C D E F G H I J K L M N O P Q R S T
480/70R30 152A8 R1W 499 (19.6) 3.3 (48) PRA 34 (1.3) 3 4 26 (1.0) 3150 (124.0) 4.7 (15.4)
PRA 50 (2.0) 3 3 16 (0.6) 3322 (130.8) 4.1 (13.5)
PRA 34 (1.3) 5 2 13 (0.5) 3450 (135.8) 4.2 (13.8)
PRA 34 (1.3) 5 3 13 (0.5) 3450 (135.8) 4.2 (13.8)
PRA 50 (2.0) 5 2 13 (0.5) 3622 (142.6) 4.2 (13.8)
PRA 50 (2.0) 5 3 13 (0.5) 3622 (142.6) 4.2 (13.8)
PRA 50 (2.0) 5 4 13 (0.5) 3622 (142.6) 4.2 (13.8)
540/65R30 150A8 R1W 552 (21.7) 2.8 (41) HDASA 50 (2.0) 3 4 46 (1.8) 3035 (119.5) 5.4 (17.7)
HDASA 50 (2.0) 4 2 38 (1.5) 3185 (125.4) 5.1 (16.7)
HDASA 50 (2.0) 4 3 25 (1.0) 3185 (125.4) 4.4 (14.4)
HDASA 50 (2.0) 5 3 18 (0.7) 3335 (131.3) 4.2 (13.8)
HDASA 50 (2.0) 6 2 18 (0.7) 3485 (137.2) 4.2 (13.8)
HDASA 50 (2.0) 6 3 18 (0.7) 3485 (137.2) 4.2 (13.8)
HDASA 50 (2.0) 6 4 18 (0.7) 3485 (137.2) 4.2 (13.8)
HDASA 50 (2.0) 7 2 18 (0.7) 3635 (143.1) 4.3 (14.1)
HDASA 50 (2.0) 7 4 18 (0.7) 3635 (143.1) 4.3 (14.1)
PRA 34 (1.3) 3 3 43 (1.7) 3154 (124.2) 5.7 (18.7)
41--5
PRA 34 (1.3) 3 4 33 (1.3) 3154 (124.2) 5.0 (16.4)
PRA 50 (2.0) 3 3 24 (0.9) 3325 (130.9) 4.5 (14.8)
PRA 50 (2.0) 4 2 13 (0.5) 3475 (136.8) 4.1 (13.5)
PRA 50 (2.0) 4 3 13 (0.5) 3475 (136.8) 4.1 (13.5)
PRA 50 (2.0) 4 4 13 (0.5) 3475 (136.8) 4.1 (13.5)
PRA 50 (2.0) 5 2 13 (0.5) 3625 (142.7) 4.2 (13.8)
PRA 50 (2.0) 5 4 13 (0.5) 3625 (142.7) 4.2 (13.8)
600/65R28 147A8 R1W 639 (25.2) 2.0 (29) HDASA 65 (2.6) 4 3 53 (2.1) 3213 (126.5) 5.9 (19.4)
HDASA 65 (2.6) 4 4 43 (1.7) 3213 (126.5) 5.4 (17.7)
HDASA 65 (2.6) 6 2 18 (0.7) 3513 (138.3) 4.3 (14.1)
HDASA 65 (2.6) 6 3 18 (0.7) 3513 (138.3) 4.3 (14.1)

HDASA 65 (2.6) 7 2 18 (0.7) 3663 (144.2) 4.3 (14.1)
HDASA 65 (2.6) 7 3 18 (0.7) 3663 (144.2) 4.3 (14.1)
HDASA 65 (2.6) 7 4 18 (0.7) 3663 (144.2) 4.3 (14.1)
PRA 49 (1.9) 4 3 47 (1.9) 3267 (128.6) 6.0 (19.7)
PRA 49 (1.9) 4 4 41 (1.6) 3267 (128.6) 5.6 (18.4)
Tire Selection Chart CR970 -- Cont’d. Allowed Recommended
A B C D E F G H I J K L M N O P Q R S T U
600/65R28 147A8 R1W 639 (25.2) 2.0 (29) PRA 49 (1.9) 5 2 33 (1.3) 3417 (134.5) 5.2 (17.1)
PRA 49 (1.9) 5 3 24 (0.9) 3417 (134.5) 4.7 (15.4)
PRA 49 (1.9) 7 2 13 (0.5) 3717 (146.3) 4.3 (14.1)
PRA 49 (1.9) 7 3 13 (0.5) 3717 (146.3) 4.3 (14.1)
PRA 49 (1.9) 7 4 13 (0.5) 3717 (146.3) 4.3 (14.1)
23.1--26 10 PR R2 635 (25.0) 1.8 (26) HDASA 80 (3.1) 5 1 53 (2.1) 3389 (133.4) 6.0 (19.7)
HDASA 80 (3.1) 5 2 53 (2.1) 3389 (133.4) 6.0 (19.7)
HDASA 80 (3.1) 5 3 51 (2.0) 3389 (133.4) 5.9 (19.4)
HDASA 80 (3.1) 6 1 36 (1.4) 3539 (139.3) 5.1 (16.7)
HDASA 80 (3.1) 6 2 36 (1.4) 3539 (139.3) 5.1 (16.7)
HDASA 80 (3.1) 7 1 18 (0.7) 3689 (145.2) 4.3 (14.1)
HDASA 80 (3.1) 7 2 18 (0.7) 3689 (145.2) 4.3 (14.1)
HDASA 80 (3.1) 7 3 18 (0.7) 3689 (145.2) 4.3 (14.1)
PRA 80 (3.1) 5 1 45 (1.8) 3679 (144.8) 6.0 (19.7)
PRA 80 (3.1) 5 2 41 (1.6) 3679 (144.8) 5.7 (18.7)
PRA 80 (3.1) 5 3 39 (1.5) 3679 (144.8) 5.6 (18.4)
41--6
28L--26 12 PR R1 753 (29.6) 1.5 (22) HDASA 140 (5.5) 5 1 46 (1.8) 3510 (138.2) 5.6 (18.4)
HDASA 140 (5.5) 5 2 46 (1.8) 3510 (138.2) 5.6 (18.4)
HDASA 140 (5.5) 5 3 43 (1.7) 3510 (138.2) 5.4 (17.7)
HDASA 140 (5.5) 6 1 25 (1.0) 3660 (144.1) 4.6 (15.1)
HDASA 140 (5.5) 6 2 25 (1.0) 3660 (144.1) 4.6 (15.1)
HDASA 140 (5.5) 6 3 25 (1.0) 3660 (144.1) 4.6 (15.1)
PRA 140 (5.5) 4 2 45 (1.8) 3650 (143.7) 6.0 (19.7)
PRA 140 (5.5) 4 3 45 (1.8) 3650 (143.7) 6.0 (19.7)
28L--26 12 PR R2 768 (30.2) 1.5 (22) HDASA 140 (5.5) 5 3 53 (2.1) 3509 (138.1) 6.0 (19.7)
HDASA 140 (5.5) 6 1 41 (1.6) 3659 (144.1) 5.4 (17.7)

HDASA 140 (5.5) 6 2 38 (1.5) 3659 (144.1) 5.3 (17.4)
HDASA 140 (5.5) 6 3 38 (1.5) 3659 (144.1) 5.3 (17.4)
PRA 140 (5.5) 5 1 43 (1.7) 3798 (149.5) 5.9 (19.4)
PRA 140 (5.5) 5 2 43 (1.7) 3798 (149.5) 5.9 (19.4)
PRA 140 (5.5) 5 3 41 (1.6) 3798 (149.5) 5.7 (18.7)
Tire Selection Chart CR940 and CR960 Allowed Recommended
Tire Width Max Inf Dished Dished Axle Ex- Duals/ Treadwidth
Drive Tires *1 mm (in) Press In mm Out tension Rows mm Center/Cen-
Bar (psi) (in) mm (in) mm (in) (in) ter mm (in)
30.5L--32 16 PR LS2 783 (30.8) 2.3 (34) 115(4.5) 3478 (136.9)
800/65R32 172A8 R1W 796 (31.3) 2.6 (38) 100 (3.9) 3048 (120.0)
115(4.5) 3478 (136.9)
100 (3.9) 316 (12.4) 3680 (144.9)
900/60R32 176A8 R1W 921 (36.3) 2.7 (39) 100 (3.9) 3048 (120.0)
and
d
115(4.5) 3478 (136.9)
900/60R32 176A8 R1
100 (3.9) 316 (12.4) 3680 (144.9)
900/65R32 172A8 R2 921 (36.3) 2.0 (29) 100 (3.9) 3048 (120.0)
115(4.5) 3478 (136.9)
100 (3.9) 316 (12.4) 3680 (144.9)
76x50.00--32 16 PR HF3 1234 (48.6) 1.2 (18) 100 (3.9) 316 (12.4) 3680 (144.9)
18.4R42 153A8 R1W 486 (19.1) 2.5 (36) 365 (14.4) 265 (10.4) Inner/762 (30) 3048 (120.0)
381 (15.0) 265 (10.4) Outer/762 (30) 4572 (180.0)
20.8R42 155A8 R1W 571 (22.5) 2.0 (29) 365 (14.4) 265 (10.4) Inner/762 (30) 3048 (120.0)
381 (15.0) 265 (10.4) Outer/762 (30) 4572 (180.0)
20.8R42 155A8 R2 551 (21.7) 2.0 (29) 365 (14.4) 265 (10.4) Inner/762 (30) 3048 (120.0)
381 (15.0) 265 (10.4) Outer/762 (30) 4572 (180.0)
420/80R46 159A8 R1 436 (17.2) 3.3 (48) 252 (9.9) 138 (5.4) Inner/508 (20) 3020 (118.9)
267 (10.5) 138 (5.4) Outer/508 (20) 4090 (161.0)
252 (9.9) 316 (12.4) Inner/559 (22) 3376 (132.9)
267 (10.5) 316 (12.4) Outer/559 (22) 4446 (175.0)
41--7
Tire Width Max Inf Axle Dished Dished Axle Width Height Stop bolt Treadwidth Turn Ra-
Steering Tires *1 mm (in) Press Type In mm Out Position Position Length Center/Cen- dius
Bar (psi) (in) mm (in) mm (in) *2 ter mm (in) m (ft) *3
18.4--26 12 PR R1 502 (19.8) 2.9 (42) HDASA 50 (2.0) 3 2 18 (0.7) 3034 (119.4) 4.0 (13.1)
HDASA 50 (2.0) 3 3 18 (0.7) 3034 (119.4) 4.0 (13.1)
HDASA 50 (2.0) 3 4 18 (0.7) 3034 (119.4) 4.0 (13.1)
HDASA 50 (2.0) 5 3 18 (0.7) 3334 (131.6) 4.2 (13.8)
HDASA 50 (2.0) 6 2 18 (0.7) 3484 (137.2) 4.3 (14.1)
HDASA 50 (2.0) 6 3 18 (0.7) 3484 (137.2) 4.3 (14.1)
HDASA 50 (2.0) 7 2 18 (0.7) 3634 (143.1) 4.3 (14.1)
HDASA 50 (2.0) 7 3 18 (0.7) 3634 (143.1) 4.3 (14.1)

PRA 39 (1.5) 2 2 22 (0.9) 2992 (117.8) 4.4 (14.4)
*1 -- Tire Restrictions: 800/65R32 172A8 R1W -- restricted to 30′ grain heads and 8R30 corn head 420/80R46 159A8 R1 -- recommended for 20″ and 22″ rows only

Tire Selection Chart CR940 and CR960 -- Cont’d. Allowed Recommended
Tire Width Max Inf Axle Type Dished In Dished Out Axle Width Height Stop bolt Treadwidth Turn Ra-
Steering Tires *1 mm (in) Press Bar mm (in) mm (in) Position Position Length mm Center/Center dius m
(psi) (in) *2 mm (in) (ft) *3
18.4--26 12 PR R1 502 (19.8) 2.9 (42) PRA 39 (1.5) 2 3 13 (0.5) 2992 (117.8) 4.0 (13.1)
PRA 39 (1.5) 2 4 13 (0.5) 2992 (117.8) 4.0 (13.1)
PRA 50 (2.0) 3 3 13 (0.5) 3321 (130.7) 4.0 (13.1)
PRA 39 (1.5) 5 2 13 (0.5) 3442 (135.5) 4.2 (13.8)
PRA 39 (1.5) 5 3 13 (0.5) 3442 (135.5) 4.2 (13.8)
PRA 50 (2.0) 5 2 13 (0.5) 3621 (142.6) 4.2 (13.8)
PRA 50 (2.0) 5 3 13 (0.5) 3621 (142.6) 4.2 (13.8)
480/70R30 152A8 R1W 499 (19.6) 3.0 (44) HDASA 50 (2.0) 3 2 18 (0.7) 3034 (119.4) 4.0 (13.1)
HDASA 50 (2.0) 3 3 18 (0.7) 3034 (119.4) 4.0 (13.1)
HDASA 50 (2.0) 3 4 18 (0.7) 3034 (119.4) 4.0 (13.1)
HDASA 50 (2.0) 5 3 18 (0.7) 3334 (131.3) 4.2 (13.8)
HDASA 50 (2.0) 6 2 18 (0.7) 3484 (137.2) 4.3 (14.1)
HDASA 50 (2.0) 6 3 18 (0.7) 3484 (137.2) 4.3 (14.1)
HDASA 50 (2.0) 7 2 18 (0.7) 3634 (143.1) 4.3 (14.1)
HDASA 50 (2.0) 7 3 18 (0.7) 3634 (143.1) 4.3 (14.1)
HDASA 50 (2.0) 7 4 18 (0.7) 3634 (143.1) 4.3 (14.1)
PRA 34 (1.3) 2 2 31 (1.2) 3000 (118.1) 4.8 (15.7)
PRA 34 (1.3) 2 3 20 (0.8) 3000 (118.1) 4.3 (14.1)
PRA 34 (1.3) 2 4 13 (0.5) 3000 (118.1) 4.0 (13.1)
41--8
PRA 50 (2.0) 3 3 22 (0.9) 3322 (130.8) 4.4 (14.4)
PRA 34 (1.3) 5 2 13 (0.5) 3450 (135.8) 4.2 (13.8)
PRA 34 (1.3) 5 3 13 (0.5) 3450 (135.8) 4.2 (13.8)
PRA 50 (2.0) 5 2 13 (0.5) 3622 (142.6) 4.2 (13.8)
PRA 50 (2.0) 5 3 13 (0.5) 3622 (142.6) 4.2 (13.8)
PRA 50 (2.0) 5 4 13 (0.5) 3622 (142.6) 4.2 (13.8)
540/65R30 150A8 R1W 552 (21.7) 2.6 (38) HDASA 50 (2.0) 3 2 18 (0.7) 3035 (119.5) 4.0 (13.1)
HDASA 50 (2.0) 3 3 18 (0.7) 3035 (119.5) 4.0 (13.1)
HDASA 50 (2.0) 3 4 18 (0.7) 3035 (119.5) 4.0 (13.1)
HDASA 50 (2.0) 5 3 18 (0.7) 3335 (131.3) 4.2 (13.8)
HDASA 50 (2.0) 6 2 18 (0.7) 3485 (137.2) 4.3 (14.1)
HDASA 50 (2.0) 6 3 18 (0.7) 3485 (137.2) 4.3 (14.1)

HDASA 50 (2.0) 6 4 18 (0.7) 3485 (137.2) 4.3 (14.1)
HDASA 50 (2.0) 7 2 18 (0.7) 3635 (143.1) 4.3 (14.1)
HDASA 50 (2.0) 7 4 18 (0.7) 3635 (143.1) 4.3 (14.1)

Steering Tires *1 mm (in) Press Bar mm (in) mm (in) Position Position Length Center/Center dius m
(psi) mm (in) *2 mm (in) (ft) *3
540/65R30 150A8 R1W 552 (21.7) 2.6 (38) PRA 34 (1.3) 2 2 35 (1.4) 3004 (118.3) 5.1 (16.7)
PRA 34 (1.3) 2 3 13 (0.5) 3004 (118.3) 4.0 (13.1)
PRA 34 (1.3) 2 4 13 (0.5) 3004 (118.3) 4.0 (13.1)
PRA 50 (2.0) 3 3 13 (0.5) 3325 (130.9) 4.0 (13.1)
PRA 50 (2.0) 4 2 13 (0.5) 3475 (136.8) 4.1 (13.5)
PRA 50 (2.0) 4 3 13 (0.5) 3475 (136.8) 4.1 (13.5)
PRA 50 (2.0) 4 4 13 (0.5) 3475 (136.8) 4.1 (13.5)
PRA 50 (2.0) 5 2 13 (0.5) 3625 (142.7) 4.2 (13.8)
PRA 50 (2.0) 5 4 13 (0.5) 3625 (142.7) 4.2 (13.8)
600/65R28 147A8 R1W 639 (25.2) 2.0 (29) HDASA 65 (2.6) 3 2 48 (1.9) 3063 (120.6) 5.6 (18.4)
HDASA 65 (2.6) 3 3 36 (1.4) 3063 (120.6) 4.9 (16.1)
HDASA 65 (2.6) 3 4 27 (1.1) 3063 (120.6) 4.4 (14.4)
HDASA 65 (2.6) 6 2 18 (0.7) 3513 (138.3) 4.3 (14.1)
HDASA 65 (2.6) 6 3 18 (0.7) 3513 (138.3) 4.3 (14.1)
HDASA 65 (2.6) 7 2 18 (0.7) 3663 (144.2) 4.3 (14.1)
HDASA 65 (2.6) 7 3 18 (0.7) 3663 (144.2) 4.3 (14.1)
HDASA 65 (2.6) 7 4 18 (0.7) 3663 (144.2) 4.3 (14.1)
PRA 49 (1.9) 3 2 41 (1.6) 3117 (122.7) 5.6 (18.4)
PRA 49 (1.9) 3 3 35 (1.4) 3117 (122.7) 5.2 (17.1)
41--9
PRA 49 (1.9) 3 4 24 (0.9) 3117 (122.7) 4.6 (15.1)
PRA 49 (1.9) 5 2 13 (0.5) 3417 (134.5) 4.2 (13.8)
PRA 49 (1.9) 5 3 13 (0.5) 3417 (134.5) 4.2 (13.8)
PRA 49 (1.9) 7 2 13 (0.5) 3717 (146.3) 4.3 (14.1)
PRA 49 (1.9) 7 3 13 (0.5) 3717 (146.3) 4.3 (14.1)
PRA 49 (1.9) 7 4 13 (0.5) 3717 (146.3) 4.3 (14.1)
23.1--26 10 PR R2 635 (25.0) 1.7 (25) HDASA 80 (3.1) 4 2 38 (1.5) 3239 (127.5) 5.1 (16.7)
HDASA 80 (3.1) 4 3 36 (1.4) 3239 (127.5) 5.1 (16.7)
HDASA 80 (3.1) 5 2 18 (0.7) 3389 (133.4) 4.2 (13.8)
HDASA 80 (3.1) 6 2 18 (0.7) 3539 (139.3) 4.3 (14.1)
HDASA 80 (3.1) 7 1 41 (1.6) 3689 (145.2) 5.5 (18.0)
HDASA 80 (3.1) 7 2 18 (0.7) 3689 (145.2) 4.3 (14.1)

HDASA 80 (3.1) 7 3 18 (0.7) 3689 (145.2) 4.3 (14.1)
PRA 80 (3.1) 3 3 41 (1.6) 3379 (133.0) 5.6 (18.4)
PRA 80 (3.1) 4 2 41 (1.6) 3529 (138.9) 5.7 (18.7)

Steering Tires *1 mm (in) Press Bar mm (in) mm (in) Position Position Length Center/Center dius m
(psi) mm (in) *2 mm (in) (ft) *3
23.1--26 10 PR R2 635 (25.0) 1.7 (25) PRA 80 (3.1) 5 2 28 (1.1) 3679 (144.8) 4.9 (16.1)
PRA 80 (3.1) 5 3 16 (0.6) 3679 (144.8) 4.3 (14.1)
28L--26 12 PR R1 753 (29.6) 1.4 (20) HDASA 140 (5.5) 3 2 48 (1.9) 3210 (126.4) 5.6 (18.4)
HDASA 140 (5.5) 3 3 48 (1.9) 3210 (126.4) 5.6 (18.4)
HDASA 140 (5.5) 5 1 43 (1.7) 3510 (138.2) 5.5 (18.0)
HDASA 140 (5.5) 5 2 18 (0.7) 3510 (138.2) 4.2 (13.8)
HDASA 140 (5.5) 6 1 25 (1.0) 3660 (144.1) 4.6 (15.1)
HDASA 140 (5.5) 6 2 18 (0.7) 3660 (144.1) 4.2 (13.8)
HDASA 140 (5.5) 6 3 18 (0.7) 3660 (144.1) 4.2 (13.8)
PRA 140 (5.5) 3 2 37 (1.5) 3500 (137.8) 5.3 (17.4)
PRA 140 (5.5) 3 3 37 (1.5) 3500 (137.8) 5.3 (17.4)
PRA 140 (5.5) 4 2 26 (1.0) 3650 (143.7) 4.7 (15.4)
PRA 140 (5.5) 4 3 26 (1.0) 3650 (143.7) 4.7 (15.4)
28L--26 12 PR R2 768 (30.2) 1.4 (20) HDASA 140 (5.5) 4 2 46 (1.8) 3359 (132.2) 5.5 (18.0)
HDASA 140 (5.5) 4 3 43 (1.7) 3359 (132.2) 5.4 (17.7)
HDASA 140 (5.5) 5 2 29 (1.1) 3509 (138.1) 4.7 (15.4)
HDASA 140 (5.5) 6 2 18 (0.7) 3659 (144.1) 4.3 (14.1)
HDASA 140 (5.5) 6 3 18 (0.7) 3659 (144.1) 4.3 (14.1)
HDASA 140 (5.5) 7 1 34 (1.3) 3809 (150.0) 5.1 (16.7)
41--10
PRA 140 (5.5) 3 3 45 (1.8) 3498 (137.7) 5.9 (19.4)
PRA 140 (5.5) 4 2 45 (1.8) 3648 (143.6) 6.0 (19.7)
PRA 140 (5.5) 4 3 33 (1.3) 3648 (143.6) 5.1 (16.7)

Tire / Operator Platform Extension Combinations
Drive Tire Size
ance
of Ladder
of LH Tire
of RH Tire
Axle Offset
Treadwidth
of Platform
CL to Inside
CL to Outside
CL to Outside
CL to Outside
Required Base
Required Base
Axle Extension
150mm (5.9 in)
250mm (9.8 in)
Over Tire Width
Wheel Dish
Width -- Transport
Minimum Machine
Platform Extension
Tire / Ladder Clear-
Platform Extensions
Machine Model
mm in mm in mm in mm in mm in mm in mm in mm in mm in
CR940,960 In 0 0 3048 120.0 3844 151.3 0 1922 75.7 1922 75.7 1 1 2169 85.4 247 9.7 1888 74.3 3844 151.3
CR940,960 Out 0 0 3478 136.9 4274 168.3 0 2137 84.1 2137 84.1 1 2 2419 95.2 282 11.1 2138 84.2 4275 168.3
CR940,960 In 316 12.4 3680 144.9 4476 176.2 0 2238 88.1 2238 88.1 1 2 2419 95.2 181 7.1 2138 84.2 4476 176.2
800/65R32 172A8 R1W
CR970 In 0 0 3048 120.0 3844 151.3 0 1922 75.7 1922 75.7 1 1 2169 85.4 247 9.7 1888 74.3 3844 151.3
CR970 Out 0 0 3478 136.9 4274 168.3 0 2137 84.1 2137 84.1 1 2 2419 95.2 282 11.1 2138 84.2 4275 168.3
CR970 In 316 12.4 3680 144.9 4476 176.2 0 2238 88.1 2238 88.1 1 2 2419 95.2 181 7.1 2138 84.2 4476 176.2
CR940,960 In 0 0.0 3048 120.0 3969 156.3 0 1985 78.1 1985 78.1 1 1 2169 85.4 185 7.3 1888 74.3 3969 156.3
CR940,960 Out 0 0.0 3478 136.9 4399 173.2 0 2200 86.6 2200 86.6 1 2 2419 95.2 220 8.6 2138 84.2 4399 173.2
900/60R32 176A8 R1W CR940,960 In 316 12.4 3680 144.9 4601 181.1 0 2301 90.6 2301 90.6 1 2 2419 95.2 119 4.7 2138 84.2 4601 181.1
&
900/60R32 176A8 R1 CR970 In 0 0 3048 120.0 3969 156.3 0 1985 78.1 1985 78.1 1 1 2169 85.4 185 7.3 1888 74.3 3969 156.3
CR970 Out 0 0 3478 136.9 4399 173.2 0 2200 86.6 2200 86.6 1 2 2419 95.2 220 8.6 2138 84.2 4399 173.2
CR970 In 316 12.4 3680 144.9 4601 181.1 0 2301 90.6 2301 90.6 1 2 2419 95.2 119 4.7 2138 84.2 4601 181.1
CR940,960 In 0 0 3048 120.0 3970 156.3 0 1985 78.1 1985 78.1 1 1 2169 85.4 184 7.2 1888 74.3 3970 156.3
41--11
CR940,960 Out 0 0 3478 136.9 4400 173.2 0 2200 86.6 2200 86.6 1 2 2419 95.2 219 8.6 2138 84.2 4400 173.2
CR940,960 In 316 12.4 3680 144.9 4602 181.2 0 2301 90.6 2301 90.6 1 2 2419 95.2 118 4.6 2138 84.2 4602 181.2
900/65R32 172A8 R2
CR970 In 0 0 3048 120.0 3970 156.3 0 1985 78.1 1985 78.1 1 1 2169 85.4 184 7.2 1888 74.3 3970 156.3
CR970 Out 0 0 3478 136.9 4400 173.2 0 2200 86.6 2200 86.6 1 2 2419 95.2 219 8.6 2138 84.2 4400 173.2
CR970 In 316 12.4 3680 144.9 4602 181.2 0 2301 90.6 2301 90.6 1 2 2419 95.2 118 4.6 2138 84.2 4602 181.2
CR940,960 In 316 12.4 3680 144.9 4964 195.4 0 2482 97.7 2482 97.7 1 3 2669 105.1 187 7.4 2388 94.0 4964 195.4
76X50.00-
6X 0 00 -32
32 16PR HF3
CR970 In 316 12.4 3680 144.9 4964 195.4 0 2482 97.7 2482 97.7 1 3 2669 105.1 187 7.4 2388 94.0 4964 195.4
CR940,960 Out 265 10.4 4572 180.0 5058 199.1 0 2529 99.6 2529 99.6 1 3 2669 105.1 140 5.5 2388 94.0 5058 199.1
18 R 2 1
18.4R42 153A8
3A8 R1W Duals
D l
CR970 Out 265 10.4 4572 180.0 5058 199.1 0 2529 99.6 2529 99.6 1 3 2669 105.1 140 5.5 2388 94.0 5058 199.1
CR940,960 Out 265 10.4 4572 180.0 5143 202.5 0 2572 101.2 2572 101.2 1 3 2669 105.1 98 3.8 2388 94.0 5143 202.5
20 8R 2 1
20.8R42 155A8
A8 R1W Duals
D l
CR970 Out 265 10.4 4572 180.0 5143 202.5 0 2572 101.2 2572 101.2 1 3 2669 105.1 98 3.8 2388 94.0 5143 202.5
CR940,960 Out 265 10.4 4572 180.0 5123 201.7 0 2562 100.8 2562 100.8 1 3 2669 105.1 108 4.2 2388 94.0 5123 201.7
20 8R 2 155A8
20.8R42 1 A8 R2 Duals
D l
CR970 Out 265 10.4 4572 180.0 5123 201.7 0 2562 100.8 2562 100.8 1 3 2669 105.1 108 4.2 2388 94.0 5123 201.7
CR940,960 Out 138 5.4 4090 161.0 4526 178.2 0 2263 89.1 2263 89.1 1 2 2419 95.2 156 6.1 2138 84.2 4526 178.2
420/80R46 159A8 R1W Duals CR940,960 Out 316 12.4 4446 175.0 4882 192.2 0 2441 96.1 2441 96.1 1 3 2669 105.1 228 9.0 2388 94.0 4882 192.2
CR970 Out 138 5.4 4090 161.0 4526 178.2 0 2263 89.1 2263 89.1 1 2 2419 95.2 156 6.1 2138 84.2 4526 178.2
CR970 Out 316 12.4 4446 175.0 4882 192.2 0 2441 96.1 2441 96.1 1 3 2669 105.1 228 9.0 2388 94.0 4882 192.2
OVERHAUL
HEIGHT POSITION
HEIGHT POSITION HDASA HEIGHT POSITION PRA
1 1
2 2
3 3
4 4
10010484 20016102
4
Turn out cap screws, 1. The cap screws are torqued
to 780 -- 800 N⋅m (576 -- 590 ft-lb). Raise or lower the 1
wheel hub casting as required. Turn in the cap
screws, 1, to secure the casting in place.
Torque the cap screws at 1 to 780 -- 800 N⋅m (576 --

590 ft-lb).
1
10010485
41-12
TRACK WIDTH POSITION

The Track Width number designation to the left of designations under each axle arrangement Figure
each axle arrangement Figure determines the determines the Fastener Installation Detail. Circle
position of the axle extension, steering cylinder the correct arrangement for easy reference.
mount and bolt pattern to be used. The letter
TRACK WIDTH POSITION HDASA WITH AMERICAN EXTENSIONS
BB B C C
C B B B C
C B BA D
D B AA D
D A A BB
D C AB B
CC B BB
10010486
41-13
TRACK WIDTH POSITION HDASA WITH EUROPEAN EXTENSIONS
BB B C C
BB B C C
C BB B C
C BB A D
D BA A D
D A A BD
10010491 D C AB B
41-14
TRACK WIDTH POSITION PRA WITH AMERICAN EXTENSIONS
D B B B C D
D B BA C D
D B A A D D
D D AA B D
D C AB B D
DC BBB D
20016100 DC BBB D
41-15
TRACK WIDTH POSITION PRA WITH EUROPEAN EXTENSIONS
D B B B C D
D B B B C D
D B BA C D
D BA A D D
D D AA B D
D C AB B D
20016099 DC BBB D
41-16
Remove all bolts, nuts, spacers and washers
securing the axle extension to the center section.
The hardware is torqued to 470 -- 490 N⋅m (347 -- 361
ft-lb). Adjust the extensions to the position
determined for the specific size tires being used.
10010490
10
NOTE: This Figure is meant to show only the four FASTENER INSTALLATION DETAIL - HDASA
different hardware arrangements and does not
reflect their prescribed positions in the axle. 1
2
Install the hardware to secure the extensions in the
center section as determined by the previous
Figures.
IMPORTANT: Spacers at 1, must be installed

correctly. These spacer washers are used to ensure
the steering cylinder mount is installed flat against
the axle. Extra spacer washers not used are stored C A B B D
as shown at 2. Improper installation of the spacer 10010487
washers will cause fracture of the steering cylinder
mount when full torque is applied to the cap screws 11
and nuts.
FASTENER INSTALLATION DETAIL - PRA
D C D
A B B
20016101
12
41-17
Torque the cap screws, 1, to 470 -- 490 N⋅m (347 --
361 ft-lb).
1
1
10010488
13
TOE IN ADJUSTMENT
Attach one end of the tie rod, 1, to the hub casting
with the threaded portion of the ball joint pointing up.
Torque the castellated nut to 105 -- 125 N⋅m (78 -- 92 2
ft-lb). Remove the cap screws and nuts from the
telescoping section of the tie rod, 2. Expand or
contract the rod as required so that the wheel hubs
will be nearly parallel with each other. Insert the cap
screws and nuts into the nearest holes and tighten to
standard torque.
1
10010498
14
Insert the opposite end into the hub casting with the
threaded portion of the ball joint pointing up. Tighten
the castellated nut with a wrench not to exceed the final
torque. Measure the distance between the front of the TOE-IN 8 - 12 mm (5/16 - 15/32″)
hubs. Measure the distance between the back of the
hubs. The difference between the two measurements
must be 8 -- 12 mm (5/16 -- 15/32 in) with the front hub
measurement being the smaller of the two values.
Loosen the tie rod end lock nut on both sides.

Remove the end of the tie rod that does not have
torque applied, and perform the adjustment. If the
front of the hubs must be adjusted in, turn in both tie 10010494
rod ends equally. If the front of the hubs must be
adjusted out, turn out both tie rod ends equally. 15
NOTE: Both tie rod ends are threaded alike. To

adjust the toe-in, one end must be dropped from its
mount and turned independently of the other.
IMPORTANT: The tie rod ends must have a

minimum thread engagement of 1.5I into the tie rod.
41-18
When the adjustment is complete, torque the tie rod
end lock nut to 290 -- 310 N⋅m (214 -- 228 ft-lb).
Torque the loose tie rod end into the hub casting
to105 -- 125 N⋅m (78 -- 92 ft-lb). Install cotter pins to
secure the castellated nuts in place.
Loosen the barrel end hydraulic line, 1, and fully

collapse both steering cylinders.
NOTE: Since the barrel end hydraulic lines from both 1

cylinders are connected to a common tee, only one
line needs to be loose to collapse the cylinders.
10010490
16
Reference the previously determined Height Posi-
tion value.
HDASA COLLAPSED LENGTH
For a value of (1), adjust the collapsed length of both

steering cylinders to 728 mm (28.661 in). For values
of (2), (3), or (4), adjust the collapsed length of both
steering cylinders to 722 mm (28.425 in).
PRA
For a value of (1), adjust the collapsed length of both
steering cylinders to 748 mm (29.45 in). For positions
10010492
(2), (3), and (4), the collapsed length must be 742 mm
(29.21 in). 17
While adjusting the overall collapsed length of the
steering cylinders, the following criteria must also be B
met:
A
HDASA
Dimension “A” must be 50 - 80 mm (2 -- 3-5/32 in).
Dimension “B” must be 120 mm (4-23/32 in)
maximum, no minimum value is specified.
PRA
Dimension “A” must be between 70 -- 80 mm
(2.75 -- 3.15 in). The length of dimension “B” must
10010493
be no longer than 120 mm (4.72 in).
18
When the adjustments are complete, expand or
collapse the cylinders without changing the
adjustments made. Set the cylinders into place in the
hub castings with the threaded ends pointing down.
Turn on the castellated nuts and torque them to 105
-- 125 N⋅m (78 -- 92 ft-lb). Install cotter pins to secure
the castellated nuts in place. Tighten all hydraulic
lines that have been loosened.
Install the tires onto the combine noting the direction of

travel as marked on the tire. Torque the lug nuts to 406
-- 435 N⋅m (300 -- 321 ft-lb). Remove the jack stands
from under the combine and lower it to the ground.
41-19
AXLE FRONT/REAR ADJUSTMENT

The axle is to be positioned either to the front or rear
with the split spacer in position, 1, depending on the
Steering Tire size used. Use the following table to
determine the correct position of the axle. FWD FWD
AXLE FRONT AXLE REAR
10010495
1
19
Steering Tire Size

14.9x 17.5L 540/6 480/7 540/6 600/6 18.4 620/7 23.1x 750/6 20.8x
24 R24 5R24 0R30 5R30 5R28 R30 5R26 26 5R26 34
Position Front Front Front Front Front Front Front Rear Rear Rear Rear
Remove split spacer, 1, from the axle pivot rod. If the

spacer cannot be rotated to access the cap screw on
the other side, insert a small hydraulic jack between
the axle and mount to open the gap and rotate the
spacer. 1
10010496
20
Insert the small hydraulic jack, 1, between the axle
and mount on the side that is to have the split spacer
installed. Force the axle to the front or rear as
determined by the previous table. 1
Install the split spacer into position and remove the
hydraulic jack.
10010497
21
41-20
Chapter 2 - Wheel Bearings (HDASA)
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Repacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
41-1
The rear wheel bearings should be cleaned and
repacked with a good quality wheel bearing grease
every 500 hours of operation, or once each season.
NOTE: Prior to raising the combine, it is advisable to

pivot the wheels at least half way to the steering stop.
If raising the right wheel, turn to the right. If raising the
left wheel, turn to the left. This ensures ample
working area during assembly of the wheel bearing.
NOTE: A new outer bearing must be available when

replacing the grease seal. The bearing is pressed
onto the spindle and must be destroyed to be
removed.
41-2
OVERHAUL
WHEEL BEARING
Disassembly
Support the weight of the combine with a jack stand
positioned under the axle. Remove the tire from the
combine. 1
Pry off the dust cover, 1.
10010518
1
Remove the cotter pin, 1, and turn off the castellated
nut, 2. Slide the washer and inner bearing from the
spindle. 2
NOTE: The clearance between the spindle and inner

bearing race is very close.
1
10010519
2
Remove the spindle, outer bearing and grease seal
as an assembly. A small hydraulic jack may need to
be used.
3
Remove the outer bearing, 1, from the spindle, 2.
NOTE: The outer bearing has been press fit onto the
1
spindle. To remove the bearing from the spindle it will
have to be cut off. 2
Slide the grease seal, 3, from the spindle.
20013340
41-3
Using a punch, remove the outer bearing race, 1,
from the hub casting. Remove the inner bearing race, 1
2, from the casting if the inner bearing is to be
2
replaced.
20013340
4
Repacking
Clean all old grease out of the inner bearing. Clean
all old grease out of the hub casting.
Completely dry the bearing and casting. Applying

grease to a bearing that is still wet with solvent will
reduce the lubricating properties of the grease.
Pack the inner and outer wheel bearings with grease.

Apply a generous layer of grease to the outside of the
bearings.
Assembly
Install the inner and outer bearing races into the hub
casting with the cupped side facing away from the
casting.
NOTE: To make installation easier, set the races in

a freezer for approximately thirty minutes to reduce
the outer diameter. Remove the races from the
freezer and install immediately, minimizing the time
they are allowed to warm up.
Apply a generous layer of grease to the installed races.
41-4
Slide the grease seal, 1, onto the spindle, 2, with the
cupped side facing up.
Press the outer bearing, 3, onto the spindle with the 1

tapered side of the bearing facing up.
NOTE: When setting the spindle assembly into the 3

hub casting, the grease seal must line up properly
with the seal seating area in the hub. 2
20013340
5
Insert the spindle assembly into the hub casting.
10010519
6
While holding the assembly in position, set the inner
bearing, 1, onto the spindle with the tapered side in. 1
Slide the washer, 2, on behind the bearing and turn
on the castellated nut, 3. Tighten the nut to draw the 3
seal into place, do not exceed 60 N⋅m (44 ft-lb). Turn
the nut off and remove the washer. Give the spindle
assembly a slight tug to ensure that the seal is
properly seated in the hub. If the seal comes out of
the hub easily, repeat this step until the assembly will
remain in place. 2
Remove the inner bearing from the spindle. Fill the

bearing cavity with a good quality wheel bearing 20013340
grease.
7
Set the inner bearing onto the spindle with the
tapered side in. Slide the washer on behind the
bearing and turn on the castellated nut. Tighten the
nut to 60 N⋅m (44 ft-lb). Line up the nut with the cotter
pin hole in the spindle. If required, turn the nut in the
loosen direction.
Install the cotter pin. Tap on the dust cap.
Install the tires onto the combine noting the direction of

travel as marked on the tire. Torque the lug nut to 406
-- 435 N⋅m (300 -- 321 ft-lb). Remove the jack stands
from under the combine and lower it to the ground.
41-5
41-6
Chapter 3 - Steering Pivot (HDASA)
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hub Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
41-1
OVERHAUL
HUB CASTING
2
Disassembly
Support the weight of the combine with jack stands
positioned under the axle. Remove the tire from the
combine. Remove the tie rod, 1, and steering
cylinder, 2, from the hub casting.
10010489
1
Attach lifting gear to the casting and turn out cap
screws, 1. The cap screws are torqued to 780 -- 800 1
N⋅m (576-- 590 ft-lb).
1
10010485
2
Rotate the hub casting so that it is upside down.
Attach the casting to the axle extension with two cap
screws, 1. Turn out allen head cap screws, 2. The 3
allen head cap screws are torqued to 590 -- 610 N⋅m
(435 -- 450 ft-lb). Remove grease plugs, 3, at the top
and bottom. Pull off lower casting, 4. 4 2 2
3
10010499 1
3
41-2
Lift the hub, 1, from the upper casting.
1
10010500
4
Bushing Replacement
Pry the seal, 1, from the lower casting. Remove the 1
bushing, 2, from the casting.
2
NOTE: Installed is a split bushing and must be
collapsed at the joint for removal.
10010501
5
Remove the seal, 1, and split bushing, 2, from the
upper casting in the same manner as the lower
casting.
1
The inner diameter of the upper and lower castings 2
is 85 ± .2 mm (3.346 ± .008 in). The inner diameter
of the installed bushing is 82 ± .2 mm (3.228 ± .008
in). A tool can be fabricated to assist in installing the
new bushing.
10010502
41-3
Using the locally fabricated tool, insert the bushing,
1, and press into place until there is a maximum of 3
mm (0.118 in) gap at the bottom of the bore. Apply a
generous coating of grease to the bushing and fill the 2
area above with the same grease. Install the seal, 2, 1
with the cupped side up.
10010502
7
Using the locally fabricated tool, insert the bushing,
1, and press into place until there is a maximum of 3 2
mm (0.118 in) gap at the bottom of the bore. Apply a
generous coating of grease to the bushing and fill the 1
area above with the same grease. Install the seal, 2,
with the cupped side up.
10010501
8
Inspect the machined ends, 1, of the steering knuckle
for wear, scratches and gouges. If the knuckle 1
exhibits excessive play when assembled, replace
the knuckle.
10010503
41-4
Assembly
Apply a generous layer of grease to the machined
1
end of the knuckle. Set the steering knuckle, 1, into
place on the upper casting.
NOTE: The assembly is upside down. Insert the

knuckle into the upper casting with the tie rod and
steering cylinder connections toward the rear of the
combine.
10010500
10
Set the lower casting, 1, onto the steering knuckle.
Turn in the allen head cap screws, 2, and torque to
590 -- 610 N⋅m (435 -- 450 ft-lb). Install the grease
plugs, 3, into the top and bottom of the castings.
3
Support the assembled hub casting with lifting 1 2 2

equipment. Turn out the two cap screws, 4.
3
10010499 4
11
Rotate the hub casting so that it is right-side up. Verify
the vertical position of the casting and turn in cap 1
screws, 1. Torque the four cap screws to 780 -- 800
N⋅m (576 -- 590 ft-lb).
1
10010485
12
41-5
Set the steering rod, 1, and tie rod, 2, into place. Turn
on the castellated nuts, 3, and torque to 105 -- 125
N⋅m (78 -- 92 ft-lb). Install cotter pins, 4, to secure the 1 4
castellated nuts in place.
Install the wheel onto the combine and torque the 2

lugs nuts to 406 -- 435 N⋅m (300 -- 321 ft-lb).
Remove the jack stand from the combine.
10010504
13
41-6
Chapter 4 - Center Section
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Center Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
41-1
The purpose of the axle center section is to attach the
wheels to the combine and provide a center pivot
allowing the combine to run over rough terrain with
minimal movement of the machine. The center
section is also a mounting point for the two power
steering cylinders used for directional control.
The following steps are provided for removal of the

axle extensions, moving the axle mounting point, and
replacement of the bushings and seals. To complete
the maintenance action after adjustment or repair of
the center section is finished, proceed to install the
extensions, tie rod and steering cylinders in their
proper places.
If using traction tire size 68-50.00x32-16PR-STG-

XT, the axle center section must be mounted at the
bottom hole. All other tire sizes require the center
section to be mounted at the top hole.
41-2
OVERHAUL
CENTER SECTION
2
Removal
Support the weight of the combine with jack stands
positioned under the center axle section. Remove
both tires from the combine. Detach the tire rod, 1,
and steering cylinders, 2, from both sides.
10010489 1
1
If removing a powered wheel motor, label,
disconnect and plug the three hydraulic lines, 1, at 1
each element.
1
1
10010514
41-3
Remove all axle cap screws and nuts, 1, holding the
extensions, 2, into the center section. The hardware 2
is torqued to 470 -- 490 N⋅m (347 -- 361 ft-lb). Use the 1
appropriate lifting gear and remove the axle
extensions from the center section.
NOTE: The hub casting or powered rear axle

elements do not need to be removed, but appropriate
lifting gear must be used to support the weight.
10010490
WARNING
Raise and lower the combine evenly on both
sides. Because of the center pin axle mount, the
combine will shift toward the side that is lower.
Failure to keep the combine level may result in
the unit falling off a jack stand and could result
in death or serious injury.
Raise the combine as required and set jack stands

under the left and right sides of the main frame
directly forward of the axle stops as shown. Lower the
combine frame carefully onto the jack stands. 10010505
4
Remove the four cap screws and nuts, 1, from the
hitch mount.
1 1
10010506
41-4
Turn out the two cap screws at 1, from the upper
portion of the hitch. While turning out the final cap
screws, ensure the weight of the hitch is properly
supported.
10010507 1
6
Set a hydraulic floor jack under the center section.
Remove the cotter pin, 1, and castellated nut, 2, from 1
the center section pivot pin. Capture the washer and
shims.
10010508
7
Adjust the height of the jack as required and pull the
center section pivot pin, 1, from the axle mount.
1
Capture the split spacer and note the position it was
in (i.e. forward or behind the center section). Inspect
the pin for unusual wear characteristics, replace if
required.
Raise, lower or remove the center section as

required. If simply raising or lowering the center
section, line up the mounting holes for installation of
the pivot pin.
10010509
41-5
Installation
Inspect the seals and bushings at 1, for unusual wear
characteristics. Replace the seals and bushings as
required. Install the seals with the cupped side out.
Apply a generous layer of grease to the bushings and
seals. Position the center section under the combine
and raise it up to the appropriate mounting hole.
1
10010513
9
Apply a generous layer of grease to the pivot pin.
Adjust the height of the jack as required and insert the
center section pivot pin, 1, into the axle mount. Install 1
the split spacer into its original position.
10010510
10
Set the washer and shims into position onto the end
of the pivot pin. Turn on the castellated nut, 1, and
torque to 115 N⋅m (85 ft-lb). Install the cotter pin, 2,
to secure the nut into place.
2
10010511
11
41-6
Set the hitch into place and install the four cap screws
and nuts, 1. Do not tighten the hardware.
1 1
10010506
12
Turn in the two cap screws at 1, through the slotted
holes of the hitch mount. Do not tighten the
hardware.
Tighten to standard torque the four cap screws and

nuts attaching the hitch to the combine. Tighten to
standard torque the two upper cap screws through
the slotted holes of the hitch mount.
10010507 1
13
WARNING
Raise and lower the combine evenly on both
sides. Because of the center pin axle mount, the
combine will shift toward the side that is lower.
Failure to keep the combine level may result in
the unit falling off a jack stand and could result
in death or serious injury.
Raise the combine as required and set jack stands

under the center section. Lower the combine
carefully onto the jack stands. Remove the stands
used to hold up the frame. 10010505
14
41-7
Set the axle extensions into place. Do not install any
hardware. 1
If working with a powered rear axle, attach the three
hydraulic lines, 1, to each wheel motor in their original
locations.
Proceed to HDASA or PRA Adjustment section of

Chapter 1.
10010512
15
41-8
Chapter 5 - Powered Rear Steering Axle

BSN HAJ100101
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bolt Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction and General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Troubleshooting - Powered Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Powered Rear Axle Hydraulic Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Powered Rear Axle Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Powered Rear Axle Solenoid Valve Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Start-up Procedure for Powered Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Equa-Trac II Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Wheel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Steering Pin Bushing and Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
41-1
SPECIFICATIONS
Wheel Motor
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1560 cc
Number of pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Maximum operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 bar (6500 psi)
Minimum charge pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 bar (350 psi)
Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 rpm
Maximum speed (disengaged, depends on case pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 rpm
BOLT TORQUE SPECIFICATIONS

Steering pin retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 - 75 N⋅m (50 - 55 ft. lbs.)
Steering knuckle bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435 N⋅m (321 ft. lbs.)
C-frame attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1255 N⋅m (926 ft. lbs.)
Seal cover attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 19 N⋅m (12 - 14 ft. lbs.)
Cover plate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 N⋅m (111 ft. lbs.)
SPECIAL TOOLS
At the time of this manual’s publication, special tools were not available yet. The tools required to test the powered
rear axle and to service the wheel motors of the powered rear axle will need to be manufactured as per the list
below and the drawings on the following pages.
TOOL DESCRIPTION DIMENSIONS

Steel tube 105 mm ID x 110 mm OD x 350 mm length
Steel spacer 50 mm OD x 12 mm thick
All-thread* (2 pieces) and nuts (4) M14-1.5 x 200 mm*
All-thread (1 piece) and nut M20-2.5 x 165 mm
Inline flowmeter ** 0 - 1.9 lpm (0 - 5 gpm) **
* New Holland part number 79077022 may be used in place of all-thread.

** Item must be purchased locally.
41-2
Safety pin extract tool
Wheel motor press tool
41-3
Wheel motor bar tool
Bushing press guide
41-4
Bushing press tool
41-5
INTRODUCTION AND GENERAL INFORMATION

The powered rear axle on the CR Series Combine Using the rear axle provides several advantages:
utilizes a hydraulic motor on each end of the axle
beam and a centrally located valve. The motors are • Allows the combine hydrostatic system to
mounted in a “C-frame” on each end of the axle. This operate at a lower pressure, thus helping to
frame allows the motors to swivel, which will turn the extend the life of the hydrostatic transmission
combine. The motors are turned in the “C-frame” by and geartrain.
two hydraulic cylinders, one for each motor. An • Reduces the hydraulic fluid temperature be-
adjustable tie-rod connects both motors. cause of lower hydrostatic system pressure.
The motors are an extension of the combine’s • Powering the rear wheels provides improved
hydrostatic system. When the operator engages the steering response.
rear axle, the Equa-Trac II valve, which is mounted • Additional traction when operating in adverse/
on the rear axle beam, allows hydraulic fluid to flow rough field conditions.
from the hydrostatic pump to the motors on the rear The center section and the axle extensions for the
axle. The hydraulic fluid, in turn, powers the motors powered rear axle are the same as the non-powered
to rotate the rear wheels. The second valve assists rear steering axle. Adjustment, removal, and
the E-T II valve in draining hydraulic fluid from the installation are covered in Chapters 1 and 4 of this
motors. section.
This chapter covers removal, repair, and replace-

ment of the powered rear axle components. For more
information on theory of operation, refer to Section
29, Chapter 4 of the CR Combine Repair Manual.
41-6
5 6
7
4
8 1
20015297
4
1. Left wheel motor 6. Hydraulic fluid reservoir
2. Right wheel motor 7. Forward pressure supply line
3. E-T II Valve, main body 8. Reverse pressure supply line
4. E-T II Valve, drain body 9. Axle beam (includes extensions)
5. Hydrostatic pump
41-7
TROUBLESHOOTING - POWERED REAR AXLE
PROBLEM POSSIBLE CAUSE CORRECTION
Performance of RWD is sluggish or Transmission is in too high of a Switch transmission to a lower

poor gear. gear.
Air in system. Determine source of air intake and

repair as necessary, bleed air from
system.
Main high pressure lines connected Check routing of high pressure

incorrectly. lines. Correct as necessary.
Hydraulic lines/hoses pinched or Check all lines and hoses. Repair or

kinked, restricting oil flow. replace as necessary.
Weak hydrostatic system high Check hydrostatic system relief

pressure relief valve. valve. Replace or adjust as neces-
sary.
Excessive case leakage from RWD Inspect components for leakage.

system wheel motors or the E-T II Check forward and reverse system
valve. pressure and charge (pilot) pres-
sure to engage. Repair wheel
motor or replace valve as neces-
sary.
Inadequate charge pressure. Check forward and reverse system

pressure and charge (pilot) pres-
sure to engage. Repair valve or
hydrostatic system as necessary.
RWD system only operates in one Air in system. Determine source of air intake and
direction repair as necessary, bleed air from
system.
Hydraulic lines/hoses pinched or Check all lines and hoses. Repair or

kinked, restricting oil flow. replace as necessary.
Excessive case leakage. Inspect for leakage. Check forward

and reverse system pressure and
charge (pilot) pressure to engage.
Repair leakage as necessary.
Electrical circuit malfunction. Test electrical circuit for shorts or

open grounds. Test valve solenoid
for proper operation. Repair as
necessary.
Valve spool in E-T II valve stuck. Check forward and reverse system
pressure and charge (pilot) pres-
sure to engage. Inspect valve for
proper operation.
41-8
PROBLEM POSSIBLE CAUSE CORRECTION
One wheel is dragging or is locked Main high pressure lines connected Check routing of high pressure
up incorrectly. lines. Correct as necessary.
Wheel motor internal component Test by switching RWD system

failure. “OFF” to relieve hydrostatic pres-
sure. Lift the suspected wheel off
the ground and attempt to manually
rotate. Repair wheel motor as
necessary.
Drain valve portion of E-T II valve Check spool in drain valve for free
malfunctioning. movement. Replace valve as nec-
essary.
RWD system is not functioning Main hydrostatic system malfunc- Check main hydrostatic system.
tion.
Blown fuse. Check fuse. Replace as necessary.
Low hydrostatic fluid level. Check hydrostatic fluid level. Add

fluid as necessary.
Hydrostatic filter clogged or broken. Inspect hydrostatic filters, replace

as necessary.
RWD ON/OFF switch defective. Test switch for proper operation.
Open or broken electrical connec- Check circuit for open or broken

tion/wire in RWD circuit. wire/connection.
Malfunctioning E-T II valve sole- Test solenoid for proper operation.

noid. Replace as necessary.
Main spool in E-T II valve or spool Test E-T II valve spools for proper
in drain valve not shifting. movement. Replace valve as nec-
essary.
Excessive wheel motor leakage. Inspect wheel motors for leakage.

Repair or replace as necessary.
41-9
TESTING
POWERED REAR AXLE HYDRAULIC PRESSURE TEST
12 9 8
1 6
7
13
17
4
5 2
10
11 14
18
15
19
16
20016111
5
1. E-T II Valve block 11. Reverse system pressure test port
2. Drain valve block (part of E-T II valve) 12. Pilot pressure to disengage port
3. Solenoid valve 13. Forward system pressure test port
4. Forward pressure inlet 14. Valve selector spool location
5. Reverse pressure inlet 15. Drain valve selector spool location
6. Left wheel motor reverse pressure port 16. Left wheel motor drain port
7. Left wheel motor forward pressure port 17. Right wheel motor drain port
8. Right wheel motor reverse pressure port 18. Inlet drain port from reverse pressure port
9. Right wheel motor forward pressure port 19. Valve drain port to hydraulic fluid tank
10. Pilot pressure to engage port
Testing the hydraulic pressure of the powered rear WARNING

axle can help determine sluggish or poor perfor-
Pressurized hydraulic fluid can penetrate the
mance problems in the RWD system. These
skin and cause severe injuries. Tighten all of the
problems include excessive leakage in the hydro-
connectors before starting the engine. If
static system, a stuck spool in the E-T II valve,
hydraulic fluid has penetrated the skin, seek
inadequate charge pressure and malfunctions in the
medical assistance immediately.
RWD electrical circuit. Use the following procedure
to test the hydraulic pressure:
IMPORTANT: Do not allow grease or dirt to enter the
Equa-Trac II valve, otherwise damage to the valve or
WARNING
motor may result.
Use extreme caution when performing the
following test. Failure to use caution and follow 1. Clean all grease and dirt from the Equa-Trac II
the procedure properly can result in serious valve.
injury or death.
41-10
CAUTION
Route the hoses for the pressure gauge so they 4
will not contact the rear wheels. 3
1
NOTE: Label the pressure gauges according to
the pressure port which they are connected to on
the E-T II valve. This will avoid confusion when
taking pressure readings.
2. Using a hose long enough to exit the SIDE of the
combine, connect a 520 bar (7500 psi) pressure
gauge to the forward system pressure test port, 5
1, on the E-T II valve. The gauge hose will require 50016087 2
a male -4 JIC type fitting to attach to the forward
system pressure test port. 6
Right Side View
combine, connect a tee fitting and a 520 bar
(7500 psi) pressure gauge to the reverse, 4, and
forward, 5, pressure outlet on the E-T II valve.
The tee’s required are -10 JIC type fittings.
4. Remove the external line, 2, which runs from the
charge (pilot) pressure to disengage port, 3, to
the drain valve. Using a hose long enough to exit
the SIDE of the combine, connect a 70 bar (1000
psi) pressure gauge to the charge (pilot)
pressure to disengage port, 3, on the E-T II valve.
The gauge hose will require a female -4 JIC type
fitting to attach to the charge (pilot) pressure to
disengage port.
5. Place a cap on the drain valve port which the
external line was connected to on the E-T II
valve.
CAUTION
1 3
Route the hoses for the pressure gauge so they
will not contact the rear wheels.
NOTE: Label the pressure gauges according to the

pressure port which they are connected to on the E-T 2
II valve. This will avoid confusion when taking
pressure readings.
NOTE: If the required amount of gauges are

unavailable for system pressure readings and
forward/reverse pressure readings, the system 20016086
pressure tests and forward/reverse pressure tests
can be performed independently of each other. 7
Left Side View
combine, connect a 520 bar (7500 psi) pressure
gauge to the reverse system pressure test port,
1, on the E-T II valve. The gauge hose will require
a male -4 JIC type fitting to attach to the reverse
system pressure test port.
41-11
7. Remove the external line, 2, which runs from the
charge (pilot) pressure to engage port, 3, to the 1 3
drain valve. Using a hose long enough to exit the
SIDE of the combine, connect a 70 bar (1000 psi)
pressure gauge to the charge (pilot) pressure to
engage port, 3, on the E-T II valve. The gauge
hose will require a female -4 JIC type fitting to 2
attach to the charge (pilot) pressure to engage
port.
8. Place a - 4 JIC cap on the drain valve port which
the external line was connected to on the E-T II
valve.
20016086
IMPORTANT: The hydraulic oil in the combine must
be at operating temperature and the engine must be 8
at rated speed when performing hydraulic testing for Left Side View
accurate test results.
9. Start the combine engine and increase throttle

until the combine engine reaches rated speed.
Warm the hydraulic oil in the combine to normal
operating temperature by driving the combine
and operating the hydraulic system.
CAUTION
Be sure that the assistant has a clear line of
communication with the person testing the
hydraulic pressure to avoid any dangerous
situations that may occur.
10. Using the help of an assistant, switch the

gearshift selector to the neutral position. Record
the pressure readings on the test pressure
gauges with the hydrostatic lever in neutral.
11. Move the hydrostatic lever into the forward
position and record the pressure gauge
readings. Record the pressure gauge readings
with the hydrostatic lever in the reverse position.
DANGER
Make sure the area around the combine is clear
before performing the following steps. Remain
as far away from the combine as possible when
reading and recording test pressures.
12. Have the assistant switch the gear selector to

position “3” and engage the RWD switch. Record
the readings on the pressure test gauges with the
hydrostatic lever in neutral.
13. While applying full pressure to the combine
brakes, have the assistant engage the hydrostat-
ic lever in forward and then reverse. Record the
readings from the test pressure gauges for each
position of the hydrostatic lever.
41-12
14. Use the chart below to determine if the pressure NOTE: If low charge pressures or system pressures
readings are within specified ranges. If the are obtained, most likely a problem exists with the
readings are not within specifications, further main hydrostatic system, not the RWD system.
troubleshooting and/or testing will be necessary Performing hydraulic tests on the main hydraulic
to determine the cause of the problem. Sluggish system before checking the internals of the E-T II
or poor performance may occur when the valve is advisable. Refer to Section 29, chapter 5 of
hydrostatic system charge pressure drops below the combine repair manual for testing procedures.
24 bar (350 psi). When charge pressure drops
below 24 bar (350 psi), system pressure is not 15. If the RWD system is not engaging and the E-T
high enough to allow the machine to move or II valve spool solenoid is functioning properly, the
keep moving. The probable cause of low charge main valve spool in the valve may not be shifting.
pressure is most likely the result of excessive If charge (pilot) pressure readings are correct,
leakage in the hydrostatic system or the RWD but forward and reverse line pressure readings
system. The motor case/E-T II valve leak test can are NOT correct, the main spool in the E-T II
be used to determine if the fault lies within the valve is not shifting and is stuck in the “OFF”
drive motors or E-T II valve. position.
Test Pressures vs. Machine Operation Mode
TEST LOCATIONS
OPERATION FORWARD REVERSE FORWARD REVERSE PILOT PILOT PRES-

MODE PORT PORT LINE LINE PRESSURE SURE TO
TO ENGAGE DISENGAGE
RWD SYSTEM CHARGE SYSTEM CHARGE CHARGE CASE DRAIN

“ON” PRESSURE PRESSURE PRESSURE PRESSURE PRESSURE PRESSURE
FORWARD 414 bar 24 bar 414 bar 24 bar 24 bar 2.0 - 3.5 bar
(6000 psi) (350 psi) (6000 psi) (350 psi) (350 psi) (30 - 50 psi)
RWD CHARGE CHARGE CHARGE CHARGE CHARGE CASE DRAIN

24 bar 24 bar 24 bar 24 bar 24 bar 2.0 - 3.5 bar
NEUTRAL (350 psi) (350 psi) (350 psi) (350 psi) (350 psi) (30 - 50 psi)
RWD CHARGE SYSTEM CHARGE SYSTEM CHARGE CASE DRAIN

24 bar 414 bar 24 bar 414 bar 24 bar 2.0 - 3.5 bar
REVERSE (350 psi) (6000 psi) (350 psi) (6000 psi) (350 psi) (30 - 50 psi)
RWD SYSTEM CHARGE CASE DRAIN CASE DRAIN CASE DRAIN CHARGE
“OFF” PRESSURE PRESSURE PRESSURE PRESSURE PRESSURE PRESSURE
414 bar 24 bar 2.0 - 3.5 bar 2.0 - 3.5 bar 2.0 - 3.5 bar 24 bar
FORWARD (6000 psi) (350 psi) (30 - 50 psi) (30 - 50 psi) (30 - 50 psi) (350 psi)
RWD CHARGE CHARGE CASE DRAIN CASE DRAIN CASE DRAIN CHARGE
NEUTRAL (350 psi) (350 psi) (30 - 50 psi) (30 - 50 psi) (30 - 50 psi) (350 psi)
RWD CHARGE SYSTEM CASE DRAIN CASE DRAIN CASE DRAIN CHARGE
REVERSE (350 psi) (6000 psi) (30 - 50 psi) (30 - 50 psi) (30 - 50 psi) (350 psi)
41-13
1
2
20016111
9
16. Remove the large hex plugs, 2, from each side of 18. The small hex plugs, 1, that are used to check
the E-T II valve. The tubes and fittings connected system pressure can be removed to check
to the hex plugs will need to be removed. Note movement of the low pressure control valve rod
how each tube and fitting is installed prior to and check balls. If the valve rod does not move
removal. freely, is damaged, or the check balls are
damaged, replace the E-T II valve.
17. Check the movement of the valve spool in the
valve bore. If the spool does not move freely, 19. More information on the E-T II valve is described
remove the valve spool and inspect the bore of in Section 29, Chapter 4 of the combine repair
the valve and the spool for excessive wear. Install manual.
the spool back into the bore and check again for
free movement. If the valve spool continues to
stick, replace the E-T II valve.
41-14
POWERED REAR AXLE LEAK TEST

If an excessive amount of leakage in the RWD or
hydrostatic system is suspected, testing the RWD
system can help to isolate the problem. Testing the
RWD system will help determine whether the
problem is located in the RWD system or in the
hydrostatic system. Use the following procedure to
test leakage in the RWD system:
WARNING
Use extreme caution when performing the
following test. Failure to use caution and follow
the procedure properly can result in serious
injury or death.
WARNING
1. Warm the combine hydraulic fluid to normal

operating temperature before beginning pres-
sure tests. Park the combine on a level surface
and engage the parking brake.
2. Check the hydraulic fluid level in the reservoir.
Add hydraulic fluid if necessary.
Equa-Trac II valve or wheel motors, otherwise
damage to the valve or motor may result.
3. Clean all grease and dirt from the Equa-Trac II

valve and hose connections at the wheel motors.
4. Disconnect the case drain return-to-tank line, 1,
for the E-T II valve case drain at the valve. Plug
the return-to-tank drain line.
NOTE: The direction of hydraulic fluid flow will be
from the E-T II valve to the tank (hydraulic reservoir),
make sure the inline flow meter is installed correctly.
5. Using a line with a 0 - 19 lpm (0 - 5 gpm) inline flow

meter, connect the hose to the E-T II valve with
a female -8 JIC type fitting. Remove the plug in
the return-to-tank line and install the other end of
the flow meter line to the return-to-tank line using 1
50016087
a male -8 JIC type fitting. The flowmeter line must
be long enough to exit the side of the combine. 10
41-15
CAUTION
communication with the person testing the
hydraulic leakage to avoid any dangerous
situations that may occur. Make sure the area
around the combine is clear.
6. Have an assistant start the combine engine and

increase throttle until the engine reaches rated
speed. Have the assistant switch the combine
gear selector to position “3” and engage the
RWD switch. While applying full pressure to the
combine brakes, have the assistant engage the
hydrostatic lever to the forward position for thirty
(30) seconds. Observe and record the flow meter
reading while standing back away from the
combine. Have the assistant shut the combine
off immediately if any hazardous conditions
should occur.
7. Repeat step 6 with the hydrostatic lever in
reverse.
8. Have the assistant disengage the RWD system,
shut the combine engine down, and engage the
parking brake.
9. The volume of hydraulic fluid draining from the
E-T II valve should not exceed 3.6 lpm (1.0 gpm).
If the volume of flow exceeds this, the E-T II valve
is worn and needs replaced.
10. Disconnect the flow meter line and connect the
return-to-tank line back to the E-T II valve. Check
the hydraulic fluid level in the reservoir. Add
hydraulic fluid if necessary.
11. Disconnect the wheel motor case drain line, 1,
(center hose connection) from the left wheel 1
motor. Connect the flowmeter line used to test
the E-T II valve case drain flow volume to the
wheel motor and the drain line.
12. Attach the flowmeter to the side of the combine
in a position that the flowmeter will be easy to
read. Make sure the flowmeter line will not
come in contact with the combine tire.
20016093
11
41-16
CAUTION 14. Repeat step 14 with the combine traveling in

reverse.
communication with the person testing the 15. Park the combine on a level surface and engage
hydraulic leakage to avoid any dangerous the parking brake.
situations that may occur.
16. Have the assistant disengage the RWD system
and shut the combine down.
IMPORTANT: Make sure the hydrostatic fluid is at
17. The volume of hydraulic fluid draining from the
operating temperature before performing this test.
wheel motor should not exceed 5.5 lpm (1.5
gpm). If the volume of flow exceeds this, the
13. Have an assistant start the combine engine and
wheel motor is worn and needs overhauled or
increase throttle until the engine reaches rated
replaced.
speed. Have the assistant switch the combine
gear selector to position “3” and engage the 18. Disconnect the flow meter line and connect the
RWD switch. Have the assistant drive the drain line back to the wheel motor. Check the
combine in a straight line with the combine hydraulic fluid level in the reservoir. Add
brakes “loading” the hydrostatic system for thirty hydraulic fluid if necessary.
seconds. The combine must remain in motion. 19. Repeat steps 12 - 19 for the right wheel motor.
From a safe distance, observe and record the
flow meter reading while standing back away 20. If all test results are within specifications, there
from the combine. Have the assistant shut the may be a problem with the main hydrostatic
combine off immediately if any hazardous system. Refer to the Hydrostatic System, Section
conditions should occur. 29 of the repair manual, for further information.
41-17
POWERED REAR AXLE SOLENOID VALVE TESTING
20016111
12
If the RWD system is not engaging, the solenoid, 1, 3. Check that the solenoid is properly grounded by
on the E-T II valve may not be functioning properly the E-T II valve. The solenoid is internally
due to a faulty solenoid valve. Use the following grounded by the E-T II valve and can be tested
procedure to test the solenoid valve: by running a jumper wire between the nut on end
of the solenoid and the combine frame. Make
1. Engage the parking brake. Have an assistant sure the jumper wire is connected to bare metal.
turn the combine ignition switch to the “ON” With the jumper connected have the assistant
position (DO NOT start the combine) and move turn the ignition switch to the “ON” position (Do
the RWD system switch to the “ON” and “OFF” NOT start the combine) and move the RWD
position several times. Listen for an audible switch to the “ON” and “OFF” position several
“click”, indicating the solenoid is shifting the main times.
valve spool. 4. If the solenoid operates properly with the jumper
2. If the solenoid does not produce an audible wire, examine the mounting of the solenoid to
“click”, check for loose wire connections at the make sure that there is no dirt, grease, or paint
screw terminal or connector on the solenoid and that may prevent the solenoid from achieving a
at the RWD switch inside the cab. proper ground.
41-18
NOTE: E-T II valve is shown without drain valve
portion.
1
NOTE: Some coils may have a two terminal
connector. Resistance can be tested through the two
connector leads.
5. If the solenoid will still not work, test the

resistance of the solenoid valve coil using an
ohmmeter. Remove the nut, 1, which secures the
coil to the valve. Slide the coil off the valve.
20015299
13
6. Place an ohmmeter test lead on the coil stud, 1,
and the other test lead on the end contact, 2. The
resistance in the coil should be between 7 - 9
ohms. Replace the solenoid coil if resistance is
not as specified.
20015300
2 1
14
7. If the resistance of the solenoid coil is OK, the
valve is faulty and must be replaced. Remove the
valve, 1, from the E-T II valve body, 2. 2
1
20015301
15
41-19
OVERHAUL
START-UP PROCEDURE FOR POWERED
REAR AXLE
A specific start-up procedure must be performed WARNING
after servicing the RWD system. This ensures
adequate flushing or bleeding after a component of
the RWD system has been serviced or replaced. The
following procedure serves to bleed air out of the
RWD system and flush any contamination of the
system out. Air in the RWD system is pushed out of
the hydrostatic system through the hydrostatic fluid
reservoir. It is imperative to follow the exact WARNING
procedure described; otherwise, the purpose of the
Use care not to exceed the 13 mm (1/2 in.)
procedure will be defeated. Steps 1 through 7 of the
movement of the hydrostatic control lever in order
procedure are to be performed with the rear wheels
to avoid excessive oil flow from the RWD system.
off the ground and the front wheels of the machine
securely blocked.
CAUTION
WARNING Make sure the hydraulic fluid in the hydraulic
Use extreme caution when performing the fluid reservoir is at the proper level at all times.
following procedure. Failure to use caution and Failure to maintain proper fluid level may cause
follow the procedure properly can result in damage to the machine hydrostatic components.
serious injury or death. Be sure that there is
sufficient working space around the machine IMPORTANT: If air is introduced into the RWD
and any obstacles are removed from the area. system at any time during the following procedure,
restart the procedure at step one.
STEP ENGINE GEAR RWD HYDRO TIME COMMENTS

SPEED SELECTOR SWITCH LEVER
1 1/2 SPEED NEUTRAL ON NEUTRAL 3 MIN BLEED AIR ENTIRE
SYSTEM
2 HIGH IDLE NEUTRAL OFF 13 mm (1/2″) 2 MIN FLUSH FORWARD MAIN
FORWARD SYSTEM
3 HIGH IDLE NEUTRAL OFF 13 mm (1/2″) 2 MIN FLUSH REVERSE MAIN
REVERSE SYSTEM
4 HIGH IDLE NEUTRAL ON 13 mm (1/2″) 30 SEC CHECK CORRECT
REVERSE MAX ROTATION OF RWD
WHEELS
* SEE NOTE
NOTE: 1. If wheel(s) rotate reverse - go to STEP 6. REAR WHEELS
2. If no rotation - go to STEP 5 (DO NOT repeat - check valve) OFF THE
3. If wrong rotation - correct forward/reverse circuit - to to STEP 1. GROUND
5 LOW IDLE HIGH GEAR ON 13 mm (1/2″) 15 SEC CHECK CORRECT
HOLD REVERSE MAX ROTATION OF RWD
BRAKES MAXIMUM WHEELS
* SEE NOTE
6 HIGH IDLE HIGH GEAR ON 13 mm (1/2″) 4 MIN FLUSH FORWARD RWD
HOLD FORWARD SYSTEM
BRAKES
7 HIGH IDLE HIGH GEAR ON 13 mm (1/2″) 4 MIN FLUSH REVERSE RWD
HOLD REVERSE SYSTEM
BRAKES
8 1/2 SPEED HIGH GEAR ON 6 mm (1/4″) 15 SEC FORWARD PRESSURE
HOLD FORWARD MAX CHECK FOR LEAKS REAR WHEELS
BRAKES ON THE
9 1/2 SPEED HIGH GEAR ON 6 mm (1/4″) 15 SEC REVERSE PRESSURE GROUND
HOLD REVERSE MAX CHECK FOR LEAKS
BRAKES
41-20
EQUA-TRAC II VALVE
NOTE: The drain valve is included in the following
procedure and is considered a part of the E-II valve
NOTE: The E-T II valve is not serviceable except for

the electronic solenoid valve and the hydraulic line
fitting O-rings. If the valve is suspected to be
defective, refer to the “Testing” portion of Chapter 4,
Section 29 of the Combine Repair Manual to test the
E-T II valve.
NOTE: Hydraulic fluid will leak from hydraulic lines

when disconnected. Use a suitable container to
catch the hydraulic fluid that drains from the lines.
Removal
1. Park the combine on a level surface and remove
the key from the ignition switch. Engage the
parking brake. Disconnect the negative (--)
battery cable from the battery.
2. Thoroughly clean grease and dirt from the E-T II
valve and drain valve to avoid getting contami- 1 5
nants in the valves and the hydraulic system.
3. Disconnect the wiring harness electrical connec-
tion, 1, from the E-T II valve solenoid. 2
IMPORTANT: Identify hydraulic line connections
before disconnecting the lines to avoid confusion
upon installation of the E-T II valve. 3
4
4. Disconnect the forward, 2, and reverse, 3,
pressure supply lines from the E-T II valve.
7 6
20016086
5. Disconnect the forward, 4, and reverse, 5, hydraulic
lines for the left wheel motor from the E-T II valve. 16
6. Disconnect the left wheel motor case drain line,
6, and the drain line, 7, to the cooling circuit of the
hydrostatic system.
7. Disconnect the forward, 1, and reverse, 2,
hydraulic lines for the right wheel motor from the 2
E-T II valve.
8. Disconnect the right wheel motor case drain line,
3, and the valve drain return-to-reservoir line, 4,
from the E-T II valve.
9. Remove the bolts which secure the E-T II valve 4
and drain valve to the mounting bracket.
50016087
1 3
17
41-21
Inspection
20016106
18
The E-T II valve is not serviceable except for the
electronic solenoid valve, 1, and the O-rings for the
hydraulic line fittings. If the valve is malfunctioning or
faulty, it is necessary to replace the entire valve.
Refer to the “Testing” portion of Chapter 4, Section 29
of the Combine Repair Manual to test the E-T II valve.
Installation
2
IMPORTANT: When installing the E-T II valve, be
sure to connect the hydraulic lines to the proper
locations on the valve.
1. Install the E-T II valve and drain valve onto the

mounting bracket and use the bolts to secure the
4
valves to the bracket.
2. Connect the forward, 1, and reverse, 2, hydraulic
lines for the right wheel motor to the E-T II valve.
3. Connect the motor case drain line, 3, and the
50016087
1 3
valve drain return-to-reservoir line, 4, to the E-T
II valve. 19
41-22
4. Connect the left wheel motor case drain line, 6,
and the drain line, 7, to the cooling circuit of the 1 5
hydrostatic system.
5. Connect the forward, 4, and reverse, 5, hydraulic
lines for the left wheel motor to the E-T II valve. 2
6. Connect the forward, 2, and reverse, 3, pressure
supply lines to the E-T II valve.
3
7. Connect the wiring harness electrical connec- 4
tion, 1, to the E-T II valve solenoid.
8. Bleed the air out of the RWD hydrostatic system
using the procedure outlined in this chapter of the 7 6
20016086
repair manual.
20
41-23
WHEEL MOTOR
Maintenance Schedule
The wheel motor assemblies and steering knuckles
are designed for long service life, provided that the
assemblies are cleaned and greased regularly. If the
assemblies are maintained properly, the assemblies
should not need to be rebuilt or bushings and thrust
washers replaced until the machine has logged a
considerable amount of fluid hours. In extreme
conditions such as sandy, wet/muddy or dusty
environments, the assemblies may need to be rebuilt
sooner. Use the following guidelines for lubricating
and maintaining the powered rear axle wheel motor
and steering assemblies.
Every 100 Hours of Machine Operation:

1. Clean the wheel motors of grease, dirt, and
debris. Check for oil leaks.
2. Pump high quality bearing grease into the zerk
fittings, 1, on the steering pins. The grease will
lubricate the pin bushings and thrust washers.
20016093
21
3. Torque the steering pin, steering knuckle, and
C-frame bolts. The steering pin screws, 1, should 3
be torqued to 69 -- 75 N⋅m (50 -- 55 ft-lb). The 1
steering knuckle bolts, 2, should be torqued to
435 N⋅m (321 ft-lb). Torque the C-frame attaching
bolts (not shown) to 1255 N⋅m (926 ft-lb).
4. Check the hydraulic lines, 3, at the wheel motors
to ensure tightness.
2
10010514 1
22
41-24
Every 1500 Hours of Machine Operation:
1. Clean the wheel motors of grease, dirt, and
debris. Check for oil leaks.
2. Remove the steering pins from the top and
bottom of each wheel motor. Visually check the 1 2
condition of the steering pins, thrust washers,
bushings, and steel washers. Check the
condition of all mating surfaces for excess or
uneven wear.
3. Check the condition of the seals on the inner, 1,
and outer, 2, hydraulic fluid tubes. Replace the
tubes if worn or damaged. Use the procedure
described in the “Wheel Motor Assembly” portion
of this manual to assemble the steering pins back
onto the wheel motors. Use new seals when
20015312
performing this procedure.
4. Pump high quality bearing grease into the zerk 23
fittings on the steering pins. The grease will
lubricate the pin bushings and thrust washers.
5. Torque the steering pin, steering knuckle, and
C-frame bolts. The steering pin screws, 1, should 3
be torqued to 69 - 75 N⋅m (50 - 55 ft. lbs.). The 1
steering knuckle bolts, 2, should be torqued to
435 N⋅m (321 ft. lbs.). Torque the C-frame
attaching bolts (not shown) to 1255 N⋅m (926 ft.
lbs.).
6. Check the hydraulic lines, 3, at the wheel motors
to ensure tightness.
2
10010514 1
24
41-25
Steering Pin Bushing and Seal Replacement 1. Engage the parking brake. Block the front
combine wheels and raise the rear axle off the
CAUTION ground using a jack with a minimum capacity of
The wheel motor and components are very 10-tons. Place jack stands with a minimum
heavy. Use proper lifting equipment and capacity of 10-tons under the rear axle for
assistance to help prevent personal injury. support.
2. Remove the wheel from the wheel motor.
IMPORTANT: Cleanliness is extremely important
when servicing the wheel motors. Service the wheel
motors in a clean, dust-free environment and always
use clean tools. Clean the wheel motor components
in solvent and use compressed air to dry. DO NOT
3. Clean all grease and dirt from the hose
use rags or paper towels to dry the components.
connections at the wheel motors.
Wrap the cleaned parts in clean paper and store in a
clean environment prior to assembly. If more than IMPORTANT: Before disconnecting the hydraulic
one wheel motor is to be serviced, work on one motor line, identify the lines to avoid confusion upon
at a time. DO NOT mix parts. installation of the wheel motor.
41-26
4. Disconnect the hydraulic supply lines, 3, and
case drain line, 4, from the wheel motor. 3
Hydraulic fluid will drain from the lines.
5. Remove the four bolts, 1, which secure the 4
steering knuckle, 2, to the wheel motor. Pull the
steering linkage away from the axle.
1
2
10010514
25
6. Remove the bolt, 1, which retains the hydraulic
line hanger, 2, to the rear axle. Position the lines 1
out of the way.
20015304
26
7. Run a chain or lifting strap through the wheel
motor C-frame. Use a hoist or lift to support the
wheel motor while the C-frame is being unbolted.
8. Remove the four bolts, 1, which secure the
C-frame to the axle beam. The wheel motor will
be then be free from the axle beam.
1
20015305
27
41-27
CAUTION
The wheel motor is heavy and may move in the
C-frame when the lifting strap is disconnected
and the hoist no longer supports the weight of
the wheel motor.
9. Lower the wheel motor and C-frame to the

ground with the flat portion of the C-frame resting
on the ground.
10. Attach two bolts into each side of the wheel motor
and connect a chain or lifting strap to the bolts.
Support the wheel motor with a hoist or lift.
bottom pin to the C-frame. Remove the pin from
the frame. 1
1
20015307
28
12. Remove the 5 bolts, 1, which secure the top pin
to the C-frame. Remove the top pin from the
C-frame. Hydraulic fluid will drain from the motor.
1
20015308
29
13. Remove the inner, 1, and outer, 2, hydraulic fluid
tubes.
20015309
30
41-28
14. For wheel motors with the serial number 23327
or above, remove the four bolts, 1, which secure 1
each of the seal covers, 2, to the C-frame.
20016108
31
15. Carefully raise the wheel motor from the C-frame
and place the motor on a suitable working table.
20015310
32
IMPORTANT: Do not damage the motor housing
when removing the bushing. 2
1
16. Remove the worn bushing(s) from the motor
housing by peeling the bushing, 1, away from the
housing at the seam, 2.
20015316
33
41-29
17. Using the bushing installer special tool, 1, and
sleeve, 2, install the new bushing, 3, into the 1
motor housing. 2
3
20015317
34
NOTE: The plastic side of the thrust washer should
face the wheel motor environmental seal when
installed properly.
18. For wheel motors with the serial number 23326U

or below, replace the steering pin environmental
seal, 1, in the top and bottom of the steering
1
motor. Inspect the steel washer, 3, and thrust
2
washer, 2, in the C-frame. When installing the
thrust washer and steel washer, use a thin layer
of grease to hold the washers in place.
20016107
3
35
installed properly.

or above, replace the steering pin environmental
motor. Inspect the seal cover, 2, and the thrust 1
2
washer, 3. Place the environmental seal, 1, the
thrust washer, 3, and the seal cover, 2, over each
end of the wheel motor. 3
CAUTION 20016108
C-frame when the lifting strap is disconnected 36
the wheel motor.
NOTE: Be sure that the wheel motor is properly

oriented top-bottom in the C-frame.
20. Maneuver the wheel motor to the C-frame so that

the holes for the steering pins in the C-frame and
the wheel motor are aligned.
41-30
21. Install the inner, 1, and outer, 2, hydraulic fluid
tubes.
20015309
37
NOTE: Step 22 is for wheel motors with serial
numbers 23327 or above. 1
22. Align the bolt holes in each seal cover, 2, and install
the four bolts, 1, which secure the seal cover to the
C-frame. Torque the bolts to 16 - 19 N⋅m (12 - 14
ft. lbs.).
2
20016108
38
23. Grease and install the top pin into the C-frame and
wheel motor. Using LocTite 271 on the threads,
install the 5 bolts, 1, which secure the top pin to the
C-frame. Torque the bolts to 69 - 75 N⋅m (50 - 55
1
ft. lbs.).
20015308
39
41-31
24. Grease and install the bottom pin into the
C-frame and wheel motor. Using LocTite 271 on
the threads, install the four bolts, 1, which secure
the bottom pin to the C-frame. Torque the bolts to
69 -- 75 N⋅m (50 -- 55 ft-lb).
1
1
20015307
40
25. Remove the two lifting bolts from each side of the
wheel motor and run the chain or lifting strap
through the top if the wheel motor C-frame. Use
a hoist or lift to hold the C-frame.
NOTE: The correct position of the wheel motor(s)
can be referenced by using the charts in “Section 41,
Chapter 1” of this manual.
26. Position the wheel motor assembly up to the axle

beam. Be sure that the height of the wheel motor
is the same as the opposite side. Install the four
bolts, 1, which secure the C-frame to the axle 1
20015305
beam. Torque the mounting bolts to 1255 N⋅m
(925 ft-lb). 41
27. Position the hydraulic lines up to the axle beam.
Secure the hydraulic lines to the axle using the 1
hanger, 2, and hanger bolt, 1.
20015304
42
41-32
28. Place the steering knuckle, 2, up to the wheel
motor and install the four bolts, 1, which 3
secure the knuckle to the motor. Torque the
bolts to 435 N⋅m (320 ft-lb).
4
29. Connect the hydraulic supply lines, 3, and case
drain line, 4, to the wheel motor. Make sure the
1
hydraulic supply lines are installed correctly or
the motor will not function properly.
30. Install the wheel/tire onto the wheel motor.
2
10010514
43
31. Grease the steering pins using high quality
multipurpose grease. Grease fittings, 1, are
located at the top and bottom of wheel motor.
Stop when the grease protrudes from the seal
area.
1
20016093
44
41-33
Removal
1. Engage the parking brake. Block the front
combine wheels and raise the rear axle of the
ground using a jack with a minimum capacity of
10-tons. Place jack stands with a minimum
capacity of 10-tons under the rear axle for
support.
2. Remove the wheel from the wheel motor.
3. Clean all grease and dirt from the Equa-Trac II

valve and hose connections at the wheel motors.
IMPORTANT: Before disconnecting the hydraulic
line, identify the lines to avoid confusion upon
installation of the wheel motor.
4. Disconnect the hydraulic supply lines, 3, and
case drain line, 4, from the wheel motor. 3
Hydraulic fluid will drain from the lines.
steering knuckle, 2, to the wheel motor. Pull the
steering linkage away from the axle.
1
2
10010514
45
6. Remove the bolt, 1, which retains the hydraulic
line hanger, 2, to the rear axle. Position the lines 1
out of the way.
20015304
46
41-34
CAUTION
the wheel motor.
7. Run a chain or lifting strap through the wheel

motor C-frame. Use a hoist or lift to hold the
wheel motor once the C-frame has been
unbolted.
C-frame to the axle beam. The wheel motor will 20015305
be then be free from the axle beam. 47
9. Lower the wheel motor and C-frame to the
ground with the flat portion of the C-frame resting
on the ground.
bottom pin to the C-frame. Remove the pin from
the frame. 1
1
20015307
48
12. Remove the 5 bolts, 1, which secure the top pin
to the C-frame. Remove the top pin from the
C-frame. Hydraulic fluid will drain from the motor.
1
20015308
49
41-35
13. Remove the inner, 1, and outer, 2, hydraulic fluid
tubes.
20015309
50
or above, remove the four bolts, 1, which secure 1
each of the seal covers, 2, to the C-frame.
20016108
51
15. Carefully raise the wheel motor from the
C-frame.
20015310
52
41-36
Disassembly
20015321
53
1. Socket head cap screw 13. Environmental seal 25. Bearing inner 37. Shaft seal, inner #
2. Top pin 14. C-frame 26. Spacer 38. Shaft - wheel hub
3. Seal top pin 15. Bushing 27. O-ring (cam ring) 39. Stud M20
4. Inner tube 16. Snap ring 28. Plug 40. Deflector & grease seal
5. Seal backup ring, inner tube* 17. Cover plate 29. Cam ring 41. Bearing - outer
6. Seal, inner tube* 18. O-ring 30. Cylinder block assy. 42. Grease fitting
7. Outer tube 19. Retaining ring 31. Piston assy. 43. Front housing support
8. Seal, outer tube* 20. Ring 32. Piston retainer 44. Split pin
9. Seal backup ring, outer tube* 21. Split retaining ring 33. Distributor - valve block 45. Safety pin
10. Bottom pin 22. Shim pack 34. Distributor seals 46. Socket head cap screw
11. Seal cover 23. Socket head cap screw 35. Spring
12. Thrust washer 24. Back housing 36. Spacer (1 speed
motors only)
* Non serviceable items. # Two piece seal
41-37
CAUTION
The wheel motor and components are very
heavy. Use proper lifting equipment and
assistance to help prevent personal injury.
IMPORTANT: Cleanliness is extremely important

when servicing the wheel motors. Service the wheel
motors in a clean, dust-free environment and always
use clean tools. Clean the wheel motor components
in solvent and use compressed air to dry. DO NOT
use rags or paper towels to dry the components.
Wrap the cleaned parts in clean paper and store in a
clean environment prior to assembly. If more than
one wheel motor is to be serviced, work on one motor
at a time. DO NOT mix parts.
NOTE: Any remaining hydraulic oil in the wheel

motor can be drained by tilting the motor down on the
top opening.
1. Remove the snap ring, 1, which secures the
cover plate, 2, in the wheel motor. Remove the
O-ring, 3, from the wheel motor.
1
20015318
54
41-38
2. Remove the retaining ring, 1, and washer, 2, from
the wheel motor housing. 1
20015319
55
NOTE: Use an M20-2.5 x 150 mm bolt to secure
the bearing press tool to the wheel motor shaft.
3. Install the bearing press tool, 1, to the wheel hub
shaft. Using a hydraulic press, compress the
bearings using a minimum of 50,000 Newtons 1
(11,250 lb).
4. Once the bearings have been compressed, slide
the split ring halves from the groove on the wheel
hub shaft.
20016090
56
5. Relieve pressure on the bearings and remove
the tool, spilt ring halves, 1, and shim pack, 2, 1
from the motor housing.
20015320
57
41-39
6. Remove the two plugs, 1, from the rear cover and
install the cover removal tool, 2, to the wheel
motor housing. Place a spacer, 3, between the 2
tool and the wheel shaft. Use 2 lengths of
M14-1.5 x 200 mm all-thread in the outer holes
of the tool and a 165 mm length of M20-2.5 1
all-thread in the center hole of the tool. If M14-1.5
x 200 mm all-thread is not available, 2 bolts, part 3
number 79077022 can be used instead.
20015322
58
7. Mark the rear cover and housing inline with one
of the plug holes with a paint marker so that the
motor can be assembled in the same position.
Remove the 14 bolts, 1, which secure the rear 1
cover to the motor housing.
20015323
59
8. Remove the rear cover from the motor housing.
Remove the bearing, 2, from the cover, 1. 2
9. Remove the O-ring, 4, and spacer, 3, from the
motor. Discard the O-ring. 1
4 3
20015324
60
41-40
IMPORTANT: Use care not to damage the
mating surfaces of the cylinder block and the 1
distributor valve block.
10. Remove the cylinder block assembly, 1, from the
motor housing.
20015329
61
11. Remove the distributor valve block, 1, from the
wheel motor. Use care not to lose any springs
from the valve block.
1
20015330
62
12. Use a press to remove the wheel hub shaft, 1,
from the motor housing.
20016092
63
41-41
13. To remove the pistons from the cylinder block,
remove the retaining clips, 1.
1
20016088
64
14. Pull the retainers, 2, and piston assembly, 1, from
the cylinder block. Discard the retaining clips.
20016089 Piston Assembly
65
IMPORTANT: Use care not to damage the piston
roller or mating surfaces of the cam ring. 1 2
15. Use the safety pin extractor tool, 1, and a slide 3

hammer to remove the safety pins, 2, which
secure the piston cam ring, 3, to the motor
housing. Remove the O-ring, 4, from the 4
housing.
20016091
66
41-42
16. Remove the spacer, 1, from the motor housing.
Use a press to remove the shaft seal, 2, from the 1
housing.
17. Remove the distributor block seals and O-rings, 2
3, from the motor housing. Note the position of
the each O-ring and seal in the motor housing.
20015325
67
18. Use a puller to remove the wheel hub shaft
bearing, 1. If necessary, remove the outer race, 2
2, from the motor housing. Remove the lip seal, 1
3. 3
20016105
68
Inspection
1. Discard all O-rings and seals.
2. Inspect all bearings and races for signs of
damage or excess wear. Replace the bearings
and races as a set, if replacement is necessary.
3. Inspect the piston assemblies for any damage or
excess wear. Replace the entire piston assembly
if any damage or excess wear is found.
4. Inspect the distributor valve block, cylinder block
and cam ring for scoring, pitting, cracks or excess
wear. Inspect the splines on the cylinder block for
damage or excess wear. Replace components
as necessary.
5. Inspect the hub shaft and shaft splines for any
damage.
6. Inspect the motor housing and rear cover for
cracks, holes, or excess wear. Replace
components if any damage is found.
7. Inspect the steering pins for scoring, pitting,
excess wear or any other damage. Inspect the
seal in the top steering pin. Replace the seal if
damaged or worn.
41-43
Assembly
NOTE: When assembling the wheel motor, coat all
O-rings with petroleum jelly.
2
1. Press a new lip seal, 1, onto the wheel hub shaft
using a piece of metal tubing that has an inside
diameter of 105 mm, an outside diameter of 110 1
mm and a length of 350 mm.
2. Install the bearing, 2, onto the wheel hub shaft
using a piece of metal tubing that has an inside
diameter of 85 mm, an outside diameter of 90
mm and a length of 300 mm. Pack the wheel hub 20016094
shaft bearing with grease.
69
3. Coat the edges of a new shaft seal, 1, with
LocTite 454 or equivalent and press the seal into
the motor housing using a piece of metal tubing
that has an inside diameter of 78 mm, an outside
diameter of 84 mm and a length of 150 mm. 1
4. Carefully install the new O-rings and excluders
(seals), 2, for the distributor valve block into the
grooves of the motor housing. 2
20015326
70
NOTE: Use care not to damage the shaft seal when
installing the shaft into the motor housing. 1
5. Install the hub shaft, 1, into the motor housing.
20016095
71
41-44
6. Fill the spring holes in the distributor valve block,
1, with petroleum jelly and install the springs, 2, 2
into the valve block.
20016097
72
IMPORTANT: The distributor block will not seat
completely in the housing at this point. It is very 2 1 3
important that the locating tabs will engage the 3
housing, make sure they are aligned. Use a soft
mallet, if necessary, to engage the locating tabs.
7. Coat the surfaces of the distributor valve block,
1, with new hydraulic fluid and install the block
into the motor housing. Push the block into the
housing far enough to engage the locating tabs.
8. Install a new O-ring, 2, into the housing.
9. Install the locating pins, 3, into the motor housing.
20016096
73
10. Coat the piston assemblies, 1, with new hydraulic
fluid. While compressing the wiper ring, 2, install
the pistons into the cylinder block, 3. Secure the
piston assemblies in the block using new
retaining clips. 1
20016089 Piston Assembly
74
41-45
11. Coat the cylinder block and piston cam ring with
new hydraulic fluid. Install the cylinder block, 1, 1
onto the hub shaft with the pistons pushed into
the bores of the cylinder block. 2
12. Install the cam ring, 2, onto the housing. Make
sure the aligning marks, 3, made during 3
disassembly are aligned when installing the cam
ring.
20016103
75
13. Install the spacer, 2, onto the hub shaft. Install a
new O-ring, 1, on the rear cover, 3, and place the 4
cover onto the motor housing. Be sure to line up
the aligning marks made during disassembly. 3
14. Install the 14 bolts, 4, which secure the rear cover
to the motor housing finger tight.
2 1
20016113
76
15. Install the bearing onto the wheel hub shaft using
the press tool, 1. Seat the bearing on the shaft 1
and outer race. 4
16. Torque the 14 cover bolts, 2, to 150 N⋅m (111
3
ft-lb). Remove the press tool from the hub shaft.
17. Push and set the safety pins, 3, into the motor
housing and install the cover plugs, 4. A hammer 2
and punch can be used to set the safety pins.
20015327
77
41-46
18. Place the split retaining ring, 1, onto the hub
shaft.
1
20015328
78
19. Install the wheel motor press tool, 1, onto the hub
shaft and using a press, apply 40,000 Newtons
(9000 lb) of pressure to shaft bearings.
20. Use a feeler gauge, 2, to measure the clearance
between the split ring and the internal bearing
race. The amount of clearance measured is the
thickness of shims to be used between the split
ring and the bearing race. The tolerance for
shimming is + 0.0 / – 0.1 mm (0.004 in.).
2 1
20016104
79
NOTE: If two different shim thicknesses are
used, place the thinner shim(s) between the
thicker shims.
NOTE: When installing the split ring, make sure
that the groove in the split ring is positioned up. 1
This groove is for the retaining ring.
21. Relieve pressure on the bearings and remove
the press tool. Remove the split ring and place
the correct thickness of shim(s), 1, onto the
wheel hub shaft bearing race. Place both halves
of the split ring onto the hub shaft and install the
wheel motor press tool.
20016109
80
41-47
NOTE: DO NOT force the split ring into the
groove of the wheel motor. A brass drift and 2
hammer may be used to GENTLY tap the split
ring into the wheel shaft groove, if necessary.
NOTE: When installing the split ring, make sure
that the groove, 3, in the split ring is positioned
up. This groove is for the retaining ring.
22. Install the bearing press, 2. Apply 40,000
Newtons (9000 lb) of pressure to shaft bearings 1
and install the split ring, 1, into the groove on the
hub shaft. Make sure that the split ring is fully 3
seated in groove of the wheel shaft and there is
20016110
equal space between the both halves of the split
ring before relieving pressure on the bearing. 81
23. Remove the press tool and install the spacer, 1,
and retaining ring, 2, onto the hub shaft. 1
20015319
82
41-48
24. Install a new O-ring, 1, into the motor housing.
Install the cover plate, 2, into the motor housing
and secure the plate using the retaining ring, 3.
3
20015318
83
Installation
1. Before installing the wheel motor and C-frame
back onto the combine, check the bushing and
seals for the top and bottom steering pins. If the
bushings and/or seals are damaged or worn
excessively, refer to the “Steering Pin Bushing
and Seal Replacement” portion of this chapter.
NOTE: The plastic side of the thrust washer
should face the wheel motor environmental seal
when installed properly.
2. For wheel motors with the serial number 23326U
or below, replace the steering pin environmental
seal, 1, in the top and bottom of the steering 1
motor. Inspect the steel washer, 3, and thrust
washer, 2, in the C-frame. When installing the 2
thrust washer and steel washer, use a thin layer
of petroleum jelly to hold the washers in place.
20016107
3
84
41-49
installed properly.

or above, replace the steering pin environmental 1
motor. Inspect the seal cover, 2, and the thrust
2
washer, 3. Place the environmental seal, 1, the
thrust washer, 3, and the seal cover, 2, over each
end of the wheel motor. 3
20016108
85
NOTE: Be sure that the wheel motor is properly
oriented top-bottom.
5. Maneuver the wheel motor to the C-frame so that

the holes for the steering pins in the C-frame and
the wheel motor are aligned.
20015310
86
6. Install the inner, 1, and outer, 2, hydraulic fluid
tubes.
20015309
87
41-50
NOTE: Step 7 is for wheel motors with serial
numbers 23327 or above. 1
7. Align the bolt holes in each seal cover, 2, and

install the four bolts, 1, which secure the seal
cover to the C-frame. Torque the bolts to 16 -- 19
N⋅m (12 -- 14 ft-lb).
2
20016108
88
8. Grease and install the top pin into the C-frame
and wheel motor. Using LocTite 271 on the bolt
threads, install the 5 bolts, 1, which secure the
top pin to the C-frame. Torque the bolts to 69
1
-- 75 N⋅m (50 -- 55 ft-lb).
20015308
89
9. Grease and install the bottom pin into the
C-frame and wheel motor. Using LocTite 271 on
the bolt threads, install the four bolts, 1, which
secure the bottom pin to the C-frame. Torque the
bolts to 69 -- 75 N⋅m (50 -- 55 ft-lb).
1
1
20015307
90
41-51
CAUTION
the wheel motor.
10. Remove the two bolts in each side of the wheel

motor and run the chain or lifting strap through
the top if the wheel motor C-frame. Use a hoist or
lift to hold the C-frame.
11. Position the wheel motor assembly up to the axle 1
beam. Be sure that the height of the wheel motor 20015305
is the same as the opposite side. Install the four 91
bolts, 1, which secure the C-frame to the axle
beam. Torque the mounting bolts to 1255 N⋅m
(925 ft-lb).
12. Position the hydraulic lines up to the axle beam.
Secure the hydraulic lines to the axle using the 1
hanger, 2, and hanger bolt, 1.
20015304
92
13. Place the steering knuckle, 2, up to the wheel
motor and install the four bolts, 1, which 3
secure the knuckle to the motor. Torque the
bolts to 435 N⋅m (320 ft-lb).
4
14. Connect the hydraulic supply lines, 3, and case
drain line, 4, to the wheel motor. Make sure the
1
hydraulic supply lines are installed correctly or
the motor will not function properly.
2
10010514
93
41-52
15. Install the wheel onto the wheel motor. Grease
the steering pins using high quality multipurpose
grease. Grease fittings, 1, are located at the top
and bottom of wheel motor. Stop when the
grease protrudes from the seal area.
16. Refer to the powered rear axle “Start-Up
1
Procedure” described previously in this manual
to bleed air from the wheel motor.
20016093
94
41-53
41-54
SECTION 41 -- STEERING AXLE
Chapter 6 -- Hydrostatic Motor

ASN HAJ100101
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydrostatic Motor -- Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bleeding the Rear Axle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydrostatic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
41-1
SPECIFICATIONS
Displacement 2100 cc
Number of Pistons 10
Type of piston (Standard or Stepped) Standard
Rated Speed (rpm) 60 rpm
Maximum Operating Pressure 6500 psi (450 bar)
Maximum Disengaged Speed (rpm) [Dependent on drain pressure in motor] 195 rpm
TIGHTENING TORQUES
Item Specification Torque

Top and Bottom Pins to C-frame M10 75 -- 91 N⋅m (55 -- 67 ft-lb)
Top and Bottom Seal Cover to C-frame M6 9 -- 11 N⋅m (6.6 -- 8 ft-lb)
Valve (Single/Two Speed) Block Fasten Bolts M6 12.5 -- 15.5 N⋅m (9.3 -- 11.3 ft-lb)
Valve Cover capscrews M6 22.5 -- 27.5 N⋅m (16 -- 19 ft-lb)
Solenoid Valve Cartridge Valve Cartridge Valve lube 24 -- 30 N⋅m (18.8 -- 22.2 ft-lb)
with hydraulic oil.
Magnetic Winding Hex Nut Nut. 2.7 -- 3.3 N⋅m (2.0 -- 1.8 ft-lb)
Spool Valve Plug Plug. 285 -- 380 N⋅m (210 -- 280 ft-lb)
Motor Bolts M16 x 100mm 320 -- 390 N⋅m (236 -- 288 ft-lb)
Rotational Rolling Torque of the Bearing Sup- Use Special Tool. 49 -- 91 N⋅m (36 -- 67 ft-lb)
port Assembly
41-2

REAR AXLE
The powered rear axle is available as a factory hydrostatic system pressure. The higher the system
installed or field installed option. This system will pressure the greater the wheel torque will be.
provide additional traction when the machine is
operated in tough field conditions. The system can NOTE: It is not necessary to synchronize the front
be engaged or disengaged electronically by a switch wheels (transmission mounted pump driven) with the
in the operators cab. Both rear wheels are driven by rear wheels (wheel motor driven) as the system
hydraulic motors and the system receives its oil pressure and hydraulic fluid flow hydraulic will do this
supply directly from the hydrostatic pump. The high automatically.
pressure lines from the hydrostatic pump (brake
manifold) supply the wheel motors through a control It is very important to maintain traction to the front
valve mounted near the rear axle. The powered rear wheels. If a front wheel loses traction and begins to
axle system operates as a function of the main slip, the system pressure will lower. The spinning
hydrostatic drive system. A standard hydrostatic wheel requires less pressure to rotate. The oil in the
system utilizes one pump and one drive motor pressure lines will take the least path of resistance,
(transmission mounted), whereas the powered rear therefore the amount of power assistance from the
axle system utilizes one pump and three motors (one rear wheels will be reduced because of the lower
transmission mounted and two wheel mounted).The pressure. Shifting to a higher gear (if possible) will
wheel motors are cam lobe type units with a fixed reduce the amount of torque at the front wheels to
displacement. The amount of wheel torque obtained stop the wheel slippage. Also, lightly touching the
from the wheel motors is directly related to the brakes will help.
41-3
Hydrostatic Motor -- Exploded View
41-4
1. Cylinder Block Assembly 23. Bearing (inner)
2. Piston Kit (8) 24. Shaft Seal Kit
3. Piston Retainer Kit 25. Retainer Ring
4. Cam Ring Plus O-Rings 26. Split Ring
5. O-Ring -- Cam Ring (2) 27. Outer Shaft Seal
6. Valve Housing Cover (2) 28. Deflector
7. Socket Head Cap Screw, M16 x 100 (16) 29. Shaft
8. Distributor Valve 30. Pin (top)
9. Distributor Seal Kit 31. Pin (bottom)
10. Plug 32. Socket Head Cap Screw, M10 x 25
11. Spring (12) 33. Outer Pipe (with seals)
12. Spool, 2 Speed 34. Inner Pipe (with seals)
13. Washer 35. Bushing
14. Snap Ring 36. Thrust Washer
15. Spring 37. Seal Cover, Protector
16. Grease Zerk, 90 (2) 38. Socket Head Cap Screw, M6 x 35
17. Seal Washer (3) 39. Seal (Top Pin)
18. Socket Head Cap Screw, M8 x 10 (3) 40. Environmental Seal
19. Bearing Support Assembly 41. Valve Block Single Speed or Two Speed
20. Bearing Support 42. Socket Head Cap Screw, M6 x 40
21. Shaft Seal (inner) 43. O-Ring
22. Bearing (outer)
41-5
OVERHAUL
BLEEDING THE REAR AXLE SYSTEM WARNING
A specific start up procedure must be performed after Pressurized hydraulic fluid can penetrate the
servicing the powered rear axle system. This skin and cause severe injuries. Tighten all of the
ensures adequate flushing or bleeding after a connections before starting the engine. If
component of the powered rear axle system has hydraulic fluid has penetrated the skin, seek
been serviced or replaced. The following procedure medical assistance immediately.
serves to bleed air out of the powered rear axle
system and flush any contamination of the system
out. Air in the powered rear axle system is pushed out WARNING
of the hydrostatic system through the hydrostatic Use care not to exceed the 13 mm (1/2 inch)
fluid reservoir. It is imperative to follow the exact movement of the hydrostatic control lever in
procedure described; otherwise, the purpose of the order to avoid excessive oil flow from the
procedure will be defeated. Steps 1 through 7 of the Powered Rear Axle system.
procedure are to be performed with the rear wheels
off the ground and the front wheels of the machine
securely blocked. WARNING
Make sure the hydraulic fluid in the reservoir is at
IMPORTANT: If air is introduced into the powered the proper level at all times. Failure to maintain
rear axle system at any time during the following the proper fluid level may cause damage to the
procedure, restart the procedure at step one. machine hydrostatic components.
WARNING
IMPORTANT: If air is introduced into the system at
Unexpected machine motion or moving parts any time during the following procedure, restart the
can cut and crush. Apply parking brake and shut procedure at step 1.
used to support the machine are solid, one--piece
being raised to prevent movement of the
machine.
41-6
1. Raise the rear wheels from the ground and NOTE: If wrong rotation -- correct forward/reverse
support with jack stands. circuit -- go to Step 1.
2. Bleed air from entire system -- Raise the rear
wheels from the ground and support with jack 6. Check correct rotation of powered rear axle
stands. run the engine at half throttle. Select wheels (See Note) -- Run the engine at low idle.
neutral on the gear selector. Activate the Select high gear and hold brakes. Activate the
powered rear axle. Move the hydro control lever powered rear axle. Move the Hydro control lever
to neutral. run the combine for a duration of 3 13 mm (1/2 in) reverse maximum. Run the
minutes. combine for a maximum of 15 seconds.
3. Flush forward main system -- Run the engine at 7. Flush forward powered rear axle system -- Run
HIGH idle. Select neutral on the gear selector. the engine at high idle. Select high gear and hold
Deactivate the powered rear axle. Move the brakes. Activate the powered rear axle. Move the
Hydro control lever 13 mm (1/2 in) forward. Run Hydro control lever 13 mm (1/2 in) forward. Run
the combine for a duration of 2 minutes. the combine for 4 minutes.
4. Flush reverse main system -- Run the engine at 8. Flush reverse powered rear axle system -- Run
high idle. Select neutral on the gear selector. the engine at high idle. Select high gear and hold
Deactivate the powered rear axle. Move the brakes. Activate the powered rear axle. Move the
Hydro control lever 13 mm (1/2 in) reverse. Run Hydro control lever 13 mm (1/2 in) reverse. Run
the combine for a duration of 2 minutes. the combine for 4 minutes.
5. Check correct rotation of powered rear axle 9. Lower the rear wheels onto the ground.
wheels (See Note) -- Run the engine at high idle. 10. Forward pressure check for leaks -- Run the
Select neutral on the gear selector. Activate the engine at 1/2 throttle. Select high gear and hold
powered rear axle. Move the Hydro control lever brakes. Activate the powered rear axle. Move the
13 mm (1/2 in) reverse. Run the combine for a Hydro control lever 6 mm (1/4 in) forward. Run
maximum of 30 seconds. the combine for a maximum of 15 seconds.
NOTE: If wheel(s) rotate in reverse -- go to Step 6. 11. Reverse pressure check for leaks -- Run the
engine at 1/2 throttle. Select high gear and hold
NOTE: If no rotation -- go to Step 5 (Do NOT repeat brakes. Activate the powered rear axle. Move the
-- check valve) Hydro control lever 6 mm (1/4 in) reverse. Run
the combine for a maximum of 15 seconds.
41-7
HYDROSTATIC MOTOR
Removal
CAUTION
The steering C-frame is heavy. Use proper lifting
equipment to prevent injury.
NOTE: The motor can be removed from the axle with

or without the C-frame attached. It is recommended
that the C-frame be removed from the axle with the
motor for easier disassemble on a bench. The motor
can also be removed with or without the steering 20042919
knuckle.
2
1. To remove the motor and steering knuckle,
disconnect and cap the hydraulic lines, 1, leading
to the motor. Remove the steering cylinder, 2,
and the steering cross tube, 3, from the steering
knuckle on the motor. Remove the steering
knuckle from the wheel motor by removing the
four bolts, 4.
NOTE: Ensure to remember hose routing. Use a
marker or paint pen to label to hoses and ports.
2. Use a hoist and a chain, 1, to support the motor
from the C-frame, 2, when removing it. To
remove the motor from the axle remove the four
M24 bolts, 3, attaching it.
20015305
3
3. With the motor on a solid work surface, support
the C-frame with a chain hoist so that it cannot
drop or rollover when pins are removed. Remove
the M10 capscrews, 1, and grease zerks, 2.
4. Use M10 bolts in threaded hole to separate or
back away the pins from the C-frame.
20041977
4
41-8
5. Remove top pin and bottom pin from inner cover.
20041979
5
6. Remove the inner, 1, and outer pipes, 2, with
seals.
20041980
6
7. Remove four M6 capscrews, 1, from top and
bottom of C-frame, 2. Remove C-frame, 2, Seal
Cover, 3, environmental seal, 4, thrust washer, 5,
and bushing, 6.
IMPORTANT: Do not damage the bushing bores in

the housing
IMPORTANT: Do not damage the thrust washer

contact surface.
20041978
7
41-9
8. Remove the bushing, 1, from bore by peeling the
bushing at seam with chisel.
20041983
8
Disassembly
IMPORTANT: Cleanliness is most important when

servicing cam lobe motors. Always use clean tools
and work in a clean environment. Wash all internal
parts in clean solvent and dry thoroughly with
compressed air. Do not use rags or paper towels.
Wrap parts in clean paper and keep them in a clean
area prior to assembly. If more than one motor is
being serviced, work on each one separately. Do not
mix parts.
20042859
9
1. Remove the sixteen M16 x 100 mm socket head
cap screws, 4, from the motor. Remove the M8
cap screw and washer, 1, and install the valve
retainer tool, 2.
NOTE: Before separating the motor components

mark the outside of the components with an
alignment mark, 3, for re-assembly.
20042860
10
41-10
2. Remove the valve cover, 1, and O-ring, 2.
Remove the cam ring, 3. Lift the cylinder block,
5, from the bearing support shaft, 6, and remove
the O-ring, 4.
20042861
11
3. To disassemble the cylinder block first inspect
the splines, 1, in the cylinder block for excessive
wear or damage. Inspect lapped surface, 2, of
block for damage. Remove retaining clip, 5,
piston retainers, 3, and piston assembly, 4. In the
event that a retainer clip breaks while removing
it from the cylinder block use a 10-32 tap, small
ball peen hammer and adjustable wrench to
remove it.
IMPORTANT: Do not reuse piston retaining clip.

Inspect pistons for excessive wear pattern.
20042865
12
41-11
4. To disassemble the distributor valve first remove
the special tool, 2, (Valve retainer tool) and note
the position of the distributor valve in relation to
the valve cover.
NOTE: Ensure the reference marks, 3, correspond
with each other for both Left and Right wheel motors.
20042860
13
5. Remove the distributor valve by prying carefully
(to not damage mating surfaces or O-ring
grooves) at the locating tabs, 1.
20042862
14
6. Remove the distributor valve, 1, and springs, 2,
from the valve cover. Remove backup rings, 3,
and O-rings, 4, from the valve cover.
20042863
15
41-12
7. Remove the thrust washer, 1, by prying it up off
the split rings, 2.
20042868
16
8. Use the special tool (split ring assembly hood), 1,
to press down on the inner bearing and remove
the split rings, 2.
20042869
17
9. Use the special tool (shaft removal tool), 1, to
press the shaft and outer bearing out of the
bearing support.
20042870
18
41-13
10. After pressing out the shaft, 4, remove the
bearing, 1, and bearing race, 2, from the bearing
support, 3.
20042871
19
11. Press out the seal support, 1, and lip seal, 2, from
the bearing support, 3. Remove outer race, 4.
20042872
20
41-14
12. Cut bearing cage, 1, and, 2, separate and
remove from shaft. Do not cut into shaft or flange.
20042873
21
13. Pull the inner race, 1, off the shaft. Pull the seal,
2, and remove the deflector, 3. Check the contact
surface of the inner seal on the shaft, 6, and the
condition of the splines, 4.
20042874
22
Assembly
NOTE: Ensure all parts are clean before assembly.
1. Start with the pre-assemble of the bearing

support. Install the deflector, 1, onto the shaft.
20042875
23
41-15
2. Install seal, 1, into bearing support, 2.
20042876
24
3. Remove old backup ring and O-ring from seal
support, 3. Install new O-ring, 2, and backup ring,
1, into seal support, 3. Apply Loctite Brand 454
to surface indicated on seal support, 4.
20042877
25
4. Press seal support, 1, and inner bearing outer
race, 2, into bearing support.
20042878
26
41-16
5. Press outer race, 1, of outer bearing into bearing
support. Coat the bearing surface of the outer
race with grease. Pack the outer bearing with
grease and install in the outer race. Coat the
outer surface of the seal, 3, with grease and
press into the bearing support, 2. Coat the lips of
the seal, 3, with grease.
20042879
27
6. Install bearing support, 2, onto shaft, 3. Be
careful not to damage shaft seals. Install bearing
into outer race, 1.
20042879
28
41-17
7. Use the special tool (split ring assembly hood), 1,
and a press. Pre-load inner bearing to 170,000 N
(38,220 lb) of force. Reduce force to 20,000 N
(4,500 lb) of force. Check bearing position by
rotating bearing housing a minimum of 5
revolutions clockwise and 5 revolutions counter-
clockwise. While maintaining 20,000 N (4,500 lb)
of force, install the split rings, 2.
20042881
29
8. Increase force on bearing to 170,000 N (38,220
lb). Use a feeler gauge to measure the distance
between top of the split ring and the shaft spline.
Reduce force to 20,000 N (4,500 lb) and remove
split rings. Increase force to 170,000 N (38,220
lb). Install new split rings that are closest to the
measured distance. Release the force and
remove the split ring assembly hood tool, 1.
Insure the gaps between the split rings are the
same on each side of the shaft.
20042882
30
9. Install thrust washer, 1, over split rings, make
sure the thrust washer is pressed securely
against the bearing.
20042883
31
41-18
10. Use a torque wrench on nut, 2, of special tool
(Rotational torque tool), 1, to check the final
rotational torque of the bearing support assem-
bly. The torque should be within 49 -- 91 N⋅m (36
-- 67 ft-lbs). If the torque is correct then continue
assembly. If it is not correct then readjust the
bearing support to obtain correct torque.
20042884
32
11. Re-assemble the distributor valve, 1, and
springs, 2, by lubricating the grooves in the valve
cover. Install the O-rings, 4, in the valve cover.
Install the backup rings, 3, in the valve cover.
20042863
33
12. Fill the spring cavities in the distributor valve
cover with grease, 1, and install the springs.
20042864
34
41-19
13. Lubricate the distributor valve backup ring
contact surface.
14. Align locating tabs, 1, with slots in valve cover
and press distributor into valve cover.
20042862
35
15. Install special tool, 1, (Valve retainer tool) into
valve cover.
20041987
36
16. To install a piston, 1, back into the cylinder block
coat the piston with clean hydraulic oil before
installing into the bore. Compress wiper ring to be
able to insert piston assembly into cylinder bore.
20042866
37
41-20
17. Once piston is in the cylinder block with the
retaining assembly use special tool, 2, (Retain-
ing clip installation tool) to install the new
retaining clip, 1.
20042867
38
18. Install new O-ring, 2, coated with grease in
groove of valve cover, 1. Install the cylinder
block, 5, onto bearing support, 6. Install new
O-ring, 4, coated with grease into groove of
bearing support, 6.
20042861
39
19. Align marks, 3, made prior to disassembly and
install cam ring and valve cover onto the bearing
support. Install sixteen M16 x 100 mm socket
head capscrews, 4. Tighten but do not torque.
Remove valve retainer tool, 2. Replace and
torque M8 socket head capscrew and washer, 1.
Torque the M8 capscrew, 1, to 18 -- 25 N⋅m (13
-- 18 ft-lbs).
20042860
40
41-21
20. Torque the M16 x 100 mm socket head
capscrews, 1, to 320 -- 390 N⋅m (236 -- 288 ft-lbs).
20042859
41
21. Install the wheel motor to the C-frame as
described in “Hydrostatic Motor -- Installation.”
20041981
42
Installation
1. To install new pivot pin bushings, 1, in the motor
use special tool (Bushing Installer), 2 and 3, until
the bushing is pressed flush into the housing.
NOTE: Be sure the holes in the bushing align with the

holes in the housing.
IMPORTANT: Ensure not to damage the bushing

bores or the bushing when installing.
20041984
43
41-22
2. With the bushings installed place the C-frame, 2,
on a flat surface. Prepare the motor wheel flange,
1, in a sling using a hoist to lift the motor over the
C-frame.
20015310
44
3. Apply Loctite Brand 454 to smooth side of thrust
washer, 5, and install on motor. Install
environmental seal, 4, on motor housing with
seal lips toward motor. Coat the seals with
grease. Install seal covers, 3, over environmen-
tal seals. Apply Loctite Brand 515 around holes
and threads on top and bottom ears of C-frame.
Install C-frame, 2, onto motor. Install and torque
M6 capscrews, 1, to 9 -- 11 N⋅m (7 -- 14 ft-lbs) to
hold seal covers to top and bottom ears of
C-frame.
20041978
45
4. Install new inner rings and seals on inner pipe, 1,
and outer pipe, 2. Lubricate seals with petroleum
jelly. Install the outer tube, 2. Install the inner
tube, 1. Apply Loctite Brand 515 to top pin
mounting surface of C-frame, and lubricate the
seals on the top pin with petroleum jelly.
20041980
46
41-23
5. Install the top pin and bottom pin.
20041979
47
6. Apply Loctite Brand 271 to the M10 socket head
cap screws. Install and torque to 75 -- 91 N⋅m (55
-- 67 ft-lbs) With the C-frame mounted to the
motor use Multi-purpose grease to lubricate the
bushings through the grease zerks until grease
protrudes from the seal area.
20041977
48
7. Use a hoist and a chain, 1, to lift the motor to the
axle flange. Mount the motor and C-frame, 2, to
the axle with four M24 bolts, 3, and torque to 800
N⋅m (590 ft-lbs).
20015305
49
41-24
8. Attach the steering knuckle to the wheel motor
and torque bolts, 4, to 577 -- 678 N⋅m (426 -- 500
ft-lbs). Connect the hydraulic lines, 1, to the
wheel motor. Install the steering cylinder, 2, and
crossover tube, 3, if they were removed.
20042919
50
41-25
41-26
SECTION 50 -- CLIMATE CONTROL -- CHAPTER 1
SECTION 50 -- CLIMATE CONTROL
Chapter 1 - Heating, Ventilation and Air-Conditioning
CONTENTS

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A/C Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Climate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Automatic Temperature Control (ATC) Above PIN HAJ102270 . . . . . . . . . . . . . . . . . 5
Automatic Temperature Control (ATC) Below PIN HAJ103301 . . . . . . . . . . . . . . . . . 8
Manual Temperature Control (MTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Problem Solving Pressure Test Results and Temperature/Pressure Chart . . . . . . 14
Air-conditioning Temperature/Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Ventilation System Separator Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ventilation System Blower Motor (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Ventilation System Blower Motor (MTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electrical Control Temperature Control Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Electrical Control Blower Speed Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electrical Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Electronic HVAC Control -- Display Data Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Electronic HVAC Control -- ATC Control Switch and Mode Control Switch . . . . . . . . . 32
Electronic HVAC Control -- ATC Controller Power Supply . . . . . . . . . . . . . . . . . . . . . . . 33
Sensing System High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Sensing System Low Pressure Switch (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Sensing System Low Pressure Switch/Freeze Switch (MTC) . . . . . . . . . . . . . . . . . . . . 38
Sensing System Outlet Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Sensing System Cab Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Sensing System Evaporator Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Evacuating the Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
50-1
SPECIAL TOOLS
Part No. Description
FNH00855 Refrigerant Gas Leak Detector

OEM1598 R-134 Recovery/Recycle and Recharging Station
OEM1662 Thermometer
OEM1419 Service Gauge Set - 134A
FNH02343B Sanko/Sanden Compressor Tools
TIGHTENING TORQUES
Hose End Tubing O-Ring Connection Torque
Metal Tube Outside Diameter Thread and Fitting Size Torque

Condenser large hose, steel to brass 3/4-16 24 -- 30 N⋅m (32.5 -- 40.7 ft-lb)
Condenser small hose, steel to brass 5/8-18 18 -- 23 N⋅m (24.4 -- 31 ft-lb)
Receiver/dryer hoses, steel to steel, 5/8-18 31 -- 36 N⋅m (42 -- 48.8 ft-lb)
inlet and outlet
Cab TXV small hose, steel to aluminum 5/8-18 18 -- 23 N⋅m (24.4 -- 31 ft-lb)
Cab TXV large hose, steel to aluminum 7/8-14 30 -- 37 N⋅m (40.7 -- 50.2 ft-lb)
Compressor large hose, steel to aluminum 7/8-14 30 -- 37 N⋅m (40.7 -- 50.2 ft-lb)
Compressor small hose, steel to aluminum 3/4-16 24 -- 30 N⋅m (32.5 -- 40.7 ft-lb)
Compressor Tightening Torques
Torque
Screw securing air-conditioner compressor drive belt automatic 24 -- 28 N⋅m (212 -- 247 ft-lbs)
tightener to crankcase M8 x 1.25
Screw securing air-conditioner compressor mount to engine 22 -- 27 N⋅m (194 -- 238 ft-lbs)
block M8 x 1.25
Screws (4) securing air-conditioning compressor to mount 20 -- 26 N⋅m (177 -- 230 ft-lbs)
M8 x 100
50-2
INTRODUCTION
Prompted by environmental concerns, New Holland
North America is now producing equipment with
Non-chlorofluorocarbon (non-cfc) air-condition sys-
tems. The refrigerant used is R-134a, a hydrofluoro-
carbon that has no ozone consuming chlorine
molecule.
NOTE: Follow all local and governmental regulations

regarding the handling of HFC materials before
performing any work on systems using HFC
compounds.
CAUTION
This air-conditioning system uses R-134a
refrigerant. Use only R-134a refrigerant and
compatible lubricants in this system. Gases and
lubricants of R-134a and R-12 are not compatible
with each other, they must be handled separately
and not mixed.
Vehicles with R-134a system components are

distinguished from others that use R-12 by an ID tag
mounted on or near the compressor mounting
location.
The function of the climate control system is to
provide a comfortable environment for the operator 4
by raising or lowering the air temperature, reducing 3
the humidity level and removing dust and pollen
within the cab compartment. 1
Two types of control panels are available, Automatic
Temperature Control (ATC), and Manual Tempera-
ture Control (MTC). The ATC system manages the
operation of the compressor, blower fan, and heater
valve to maintain cab air temperature at the value set
by the operator. Using the MTC system, the operator
controls fan speed, heater valve position and
compressor operation by direct input. 2
The components of the climate control system are

located at various points on the combine. The control
panel (ATC or MTC) is in the headliner of the
operators’ cab at 1. Directly behind the cab is the
central air handling, 2, unit which houses the blower BSC1361
fan, heater core, evaporator core and water valve. A 1
separator fan, 3, is located behind the shielding
outside the left cab door. The compressor,
condenser and receiver/drier are mounted in and
around the engine compartment at 4.
50-3
A/C CYCLE
2
Air Conditioning Process liquid. Then, when it reaches the evaporator coils, it
Refrigerant is drawn into the compressor as a cool, begins to cool, absorbing heat from the air drawn
low-pressure vapor, compressed and then moves across the coils and fins by the blower. The
out as a hot, high-pressure vapor to the condenser. refrigerant now changes from a cold low-pressure
liquid to a cool low-pressure vapor and leaves the
As the hot, high-pressure vapor passes through the evaporator outlet moving to the suction (low-pres-
condenser core, it gives off heat to the cooler outside sure) side of the compressor to repeat the cycle.
air being drawn past the condenser cooling fins.
As the heat loss is taking place, moisture (humidity)
The vapor is condensed to a liquid by giving off heat in the air will condense on the outside of the
to the outside air. This liquid moves to the evaporator and drain off as water through the drain
receiver/dryer under high pressure. hoses attached to the evaporator drain pan, thereby
reducing the humidity level of the cab. Also, dust or
Hot, high-pressure liquid is stored in the receiver/ pollen not removed by the cab filters will collect on the
dryer until it is released to the evaporator by the wet evaporator fins and coils and may require
expansion valve. periodic cleaning depending on operating condi-
tions.
The liquid refrigerant passes through a metered
orifice in the expansion valve and into the evaporator In summary, the heat in the cab is removed by the
coil. As the refrigerant passes through the orifice in refrigerant in the evaporator and is transferred from
the expansion valve, the refrigerant changes from a the refrigerant to the outside air by the condenser
high-pressure liquid to a low-pressure atomized unit.
50-4
CLIMATE CONTROL
Automatic Temperature Control (ATC) 2 1
Above PIN HAJ102270
Temperature Control, 1
The temperature control gives the operator control
over the cab interior temperature. Turning the control
clockwise will increase the temperature of the air and
turning the control counter-clockwise will lower the
temperature of the air.
Display Unit, 2
50030142
The display provides the operator with information
about the systems performance. 3
• It provides the desired cab temperature reading

selected by the operator. The display reading
may be in Fahrenheit or Celsius. To make the
changed between reading there is a ground wire
located under the left rear corner of the cab at the
main ground boss. Attaching the wire to the
ground provides for Celsius readings.
• It illuminates an icon “A”, when the system is
operating in the automatic climate mode.
• When the “A” is not illuminated the blower motor
speed MUST be manually controlled and “Auto”
mode will only control the water valve and
compressor, while trying to maintain the set
temperature.
• It illuminates an icon of a windshield when
the system is in the Defog mode.
• It illuminates an icon of a book when the system
is not operating correctly. Along with the book
icon a fault code will also be displayed to assist
the technician making the correct repairs.
The range for ATC is from a setpoint of 16°C
(61°F) to 30°C (89°F). The setpoint of 16°C
(60°F) or 32°C (90°F) will be displayed and the
“A” icon on the display will be off when the system
is in maximum mode.
20030143
50-5
Blower Speed Control, 3
The blower speed control gives the operator control 3
over the speed of the blower motor. Turning the
blower control clockwise will increase the speed of
the blower, producing more airflow out of the cab
vents, turning the control counter clockwise will
reduce the air flow.
If the ATC control button has been pressed, the blower

speed control position will have NO effect over the
blower’s speed. The ATC controller will increase or
decrease the blower motor speed as needed to
maintain the desired cab temperature. If the blower
4
50030142
motor control is adjusted, the controller will release the
automatic control over the blower motor speed. The 5
blower motor will only operate in the manual mode if
the “A” is NOT displayed. The ATC control button must
be toggled OFF and back ON to reset the automatic
blower motor operating mode. The automatic
temperature control will always be operating whether
the “A” is displayed or not. The blower control is a
potentiometer rated at 10K 10% ohms.
When operating in the Auto Climate or Defog mode,

the blower will make a speed increase for every 2°F
difference there is between the temperature set point
and the actual cab temperature sensed by the cab
temperature sensor.
If the evaporator sensor senses that the evaporator

temperature is below 80°F (26°C), and system is
calling for heat the blower speed will not be increased
until the evaporator temperature has increase.
Mode Control, 4
Once the operator has activated the ATC control, the
mode button is pressed to toggle between AUTO and
DEFOG. The digital display window will be
illuminated with the symbol displayed. The
button toggles between two modes:
“A” = Auto, the system will warm or cool the air as

needed to maintain the cab temp and the display will
be illuminated.
= Defog, the system will run the A/C

compressor full time and warm the air to defog the
windows and the display will be illuminated.
50-6
ATC Control, 5
The operator selects ATC Control by pressing the left
hand button one time, the digital display window will
be illuminated. When illuminated the mode of
operation will be displayed along with the desired
temperature. The button toggles between two
modes:
• “O” = OFF, the cab blower motor may be run, but
the air will not be conditioned and the display will
NOT be illuminated.
• “A” = Auto, the system will warm or cool the air as
needed to maintain the cab temp and the display 50030142
5
will be illuminated.
6
Defog Control Operation
Defog is used to clear off the windows by using the
A/C to lower the humidity in the air and using the
heater to warm the air enough to dry the windows.
The ATC control button, 1, must be pressed to
activate the AUTO controls and the Mode button, 2,
toggled to DEFOG and the windshield icon will be
displayed in the digital display. The temperature
control knob may be adjusted to any setting. If the
cab vent temperature is too cold the temperature
control may be rotated clockwise to provide some
additional heating of the air. The cab temperature will
be monitored by the re-circulation air sensor, and be 50030142 1 2
maintained at the temperature control setting by
7
cycling the heater valve. While operating in the defog
operation the compressor will run continuously,
unless the evaporator sensor determines the
evaporator is too cold and could start to freeze up.
The ATC controller will automatically control the

blower motor speed as required to maintain the
temperature desired. It will be normal for the vent
temperature to be cold during early morning start up,
due to low engine temperature. If the operator
reduces the blower speed until the engine warms up,
the ATC controller will disengage the auto mode of
the blower speed. To re-activate the auto mode for
the blower motor speed, the ATC control button
MUST be toggled to reactivate the auto position.
50-7
Automatic Temperature Control (ATC)
Below PIN HAJ103301 5 2
The Automatic Temperature Control panel will
operate the compressor, water valve, and fan speed
to obtain the value that has been set by the operator.
There are four modes of operation for the ATC
system, AUTOMATIC, 1, DEFOG, 2, RECIRCU-
LATE, 3, and ECONOMY, 4. The POWER button, 5,
turns the system on and off.
The default startup mode for the system is 3

AUTOMATIC. In the automatic mode, the panel 4
1
receives input from the cab air temperature sensor, 20018375
which is located directly behind the recirculation filter.
To raise or lower the cab temperature, the panel 8
controls the compressor and water valve. With the cab
temperature equal to the set temperature, the fan will
be in low, the compressor will be off, and the water
valve will be shut. Fan speed will shift to medium if the
cab temperature raises by 4 degrees, and to high if a
rise of 9 degrees is detected. If the temperature in the
cab should decrease below the set temperature by 1
degree, fan speed will automatically shift to medium.
The shift to high speed will occur when cab
temperature is 5 degrees lower.
Fan speed can be controlled manually by simply
pressing the up, 1, or down, 2, buttons. Pressing the 1
AUTO button, 3, will return the fan speed to panel
control.
3 2
20018375
50-8
During certain conditions, the inside of the cab
windows can become fogged with moisture. A 2 1
DEFOG mode is provided to remove the condensed
moisture from the windows. When the operator
presses the DEFOG button, 1, the compressor will
engage to remove the excess moisture from the cab
air. Fan speed will be controlled manually by
pressing the up, 2, and down, 3, buttons. Fresh air
drawn into the cab will be minimized by stopping the
separator fan, this allows the system to dry the air
inside the cab without the added load of outside 3
humid air. The separator fan will be stopped for only 4
forty minutes. Cab air temperature will continue to be 20018375
controlled by positioning the water valve. To stop the
DEFOG mode, the AUTO button, 4, is pressed. 10
When the RECIRC button, 1, is pressed the

separator fan is stopped. The separator fan is used
to draw fresh air into the ventilation system 1
(approximately 80% recirculation / 20% fresh air
intake), and to obtain cab pressurization. The system
will maintain the separator fan stopped for a period
of forty minutes to minimize the time that cab
pressurization is reduced. To return to the
AUTOMATIC mode, press the RECIRC button a
second time.
20018375
11
ECONOMY button, 1, is pressed when heating or
cooling of the air is not desired. The operator
manually controls fan speed, and the separator fan
will run to pressurize the combine cab. To return to
the AUTOMATIC mode, press the AUTO button, 2.
2 1
20018375
12
50-9
Set temperature can be controlled by pressing either
the up, 1, or down, 2, button. In Celsius, each push
of the button will change set temperature by 1/2
degree, in Fahrenheit the change is 1 degree. The
operator can change the display format from Celsius
to Fahrenheit and back again by pressing the OUT
TEMP, 3, and TEMP RAISE, 1, buttons simulta-
neously. The outside temperature can be displayed
for five seconds by pressing the OUT TEMP, 3,
button alone. A diagnostic mode display can be
accessed by pressing the OUT TEMP button three
times within five seconds. 1
3 2
20018375
Troubleshooting of error codes displayed on the
Automatic Temperature Control Panel, is covered 13
later in this chapter.
Manual Temperature Control (MTC)
The Manual Temperature Control panel directly 4
2
operates the various modes of the cab climate
control system.
The fan switch, 1, is a four position switch used to

select Off (0), Low (1), Medium (2), and High (3) fan
speeds. No other speed control is provided.
The temperature control knob, 2, gives the operator

control over the amount of heated engine coolant 1
that will circulate through the heater core. If a warmer
air temperature is desired, rotate the knob clockwise.
3
20018374
With the control knob in the fully clockwise position,
the water valve is completely open allowing 14
maximum coolant flow through the core, and
maximum heating of the cab air.
The A/C switch, 3, when pressed, will energize the air

conditioning circuit causing the A/C compressor to
cycle according to its own control parameters. A light
above the switch illuminates to indicate the air
conditioning system is operating.
The recirculation switch, 4, reduces air flow from

outside the combine cab by stopping the separator
fan at the fresh air intake screen. Since minimal air
is drawn into the ventilation circuit by the separator
fan, cab pressurization is minimized.
The combine cab is normally pressurized to

approximately 5 - 20 mm H2O (3/16 - 3/4I H2O) to
help prevent the entry of dust and debris into the cab
during operation. Pressurization is accomplished by
the use of a separator fan on the fresh air intake to the
system. To minimize the amount of time cab
pressurization is stopped, a forty minute timer is
installed in the circuitry to shift the ventilation system
back to its normal mode, and draw in fresh air from
the outside. A light below the switch indicates if the
separator blower is on or off.
50-10
TROUBLESHOOTING
GENERAL
Fault Code indicated in System problem. Troubleshooting Fault Codes
display window.
No cooling. A/C Mode switch not on. Turn A/C Mode switch on.
Loss of refrigerant. Overhaul -- Pressure Test
Insufficient air flow through evaporator. Check air filter.
Check evaporator core and clean as
necessary.
Check blower motor operation. Refer to
“Blower Motor -- Testing”
Loose or broken compressor drive belt. Check belt and tension. Adjust or
replace as necessary.
Compressor clutch does not engage. Electrical Control Relay -- Testing
Faulty expansion valve. Expansion Valve -- Testing
Faulty compressor and/or compressor Compressor Magnetic Clutch -- Testing
clutch.
Insufficient cooling Defrost on. Press Mode Control Button to turn
defrost off.
Dirty evaporator coil and/or filter. Visually inspect. Clean as necessary.
Dirty condenser core. Visually inspect. Clean as necessary.
Compressor drive belt slipping. Visually inspect. Adjust as necessary.
Faulty cab temperature sensor. Sensing System Cab Temperature
Sensor -- Testing
Faulty expansion valve operation. Expansion Valve -- Testing
Evaporator icing up. Overhaul -- Pressure Test
Low refrigerant charge. Overhaul -- Pressure Test
Heater Valve leak through. Operate engine at 1500 rpm for 15
minutes to warm engine coolant.
Operate the A/C system at maximum
cooling.
Install stem thermometer in mid-cab
louver and record temperature.
Close heater core supply valve at
engine.
Wait a few minutes and check the
temperature. If the temperature drops,
valve leak through is the problem;
replace heater valve. Refer to “Heater
Valve -- Removal.”
50-11

No heat Heater core supply and return valves Open valves.
located at the engine closed.
Heater Control Valve malfunction. Heater Valve -- Testing
Defrost not working Heater valve problem. Heater Valve -- Testing
Mode Control Button faulty. ATC Control Switch and Mode Control
Switch -- Testing
No air flow/reduced air System in automatic temperature con- System operating properly.
flow. trol and cab temperature approximately
equal to temperature setpoint.
Cab air filter dirty. Clean cab air filter.
Blower motor inoperable. Ventilation System Motor -- Testing
Noisy system. Faulty compressor clutch. Compressor Magnetic Clutch -- Testing
Negative pressure in Separator fan not operating. Ventilation System Separator Fan --
cab (Air is entering cab Testing
through doors and oth-
er openings; cab air is
dirty)
50-12
FAULT CODES
Fault #1 -- High Pres- High Pressure in system. Overhaul -- Pressure Test
sure Switch
Faulty High Pressure Switch electrical Sensing System High Pressure Switch
circuit. -- Testing
Fault #2 -- Low Pres- Low Pressure in system. Overhaul -- Pressure Test
sure Switch
Faulty Low Pressure Switch electrical Sensing System Low Pressure Switch
circuit. -- Testing
Fault #3 -- Blower Faulty Blower Speed Select Pot electri- Electrical Control Blower Speed Poten-
Speed Select Poten- cal circuit. tiometer -- Testing
tiometer
Fault #4 -- Temperature Faulty Temperature Select Pot electri- Electrical Control Temperature Control
Select Potentiometer cal circuit. Potentiometer -- Testing
Fault #7 -- Cab Temper- Faulty Cab Temperature Sensor electri- Sensing System Cab Temperature
ature Sensor cal circuit. Sensor -- Testing
Fault #8 -- Evaporator Faulty Evaporator Temperature Sensor Sensing System Evaporator Tempera-
Temperature Sensor electrical circuit. ture Sensor -- Testing
Fault #9 -- Outlet Tem- Faulty Outlet Temperature Sensor elec- Sensing System Outlet Temperature
perature Sensor trical circuit. Sensor -- Testing
Fault #19 -- No data Faulty electrical circuit between Control Display Data Line Testing
from Control Module Module and Auto Operation Display
unit.
50-13
TESTING
Problem Solving Pressure Test Results and Temperature/Pressure Chart
Air-Conditioning Temperature/Pressure Chart
Ambient % Relative Louver Temps* Normal Low Side Normal High Side
Temperature Humidity °C (°F) Pressure kPa (psi) Pressure kPa (psi)
°C (°F)
Low High Low High Low High Low High
RH RH RH RH RH RH RH RH
21(70) 19 to 21 81 to 89 4 (40) 11(51) 62 to 62 83 to 97 779 to 862 807 to 889
(9 to 9) (12 to 14) (113 to 125) (117 to 129)
27(80) 18 to 20 69 to 77 8(46) 14 (57) 69 to 83 103 to 117 917 to 1014 993 to 1103

(10 to 12) (15 to 17) (133 to 147) (144 to 160)
32 (90) 16 to 18 58 to 64 12 (53) 18 (64) 90 to 103 131 to 145 1089 to 1200 1207 to 1331
(13 to15) (19 to 21) (158 to 174) (175 to 193)
38(100) 14 to 16 48 to 53 16(60) 21(70) 117 to 131 165 to 179 1276 to 1413 1427 to 1579
(17 to 19) (24 to 26) (185 to 205) (207 to 229)
43(110) 12 to 14 36 to 40 19(66) 25(77) 152 to 165 200 to 228 1510 to 1669 1662 to 1841
(22 to 24) (29 to 33) (219 to 242) (241 to 267)
49(120) 10 to 12 26 to 28 23(73) 28(83) 200 to 221 248 to 276 1779 to 1972 1910 to 2117
(29 to 32) (36 to 40) (258 to 286) (277 to 307)
Perform the Following:

1. If the pressures obtained in the pressure test fall within the range above, your system problem is not a
pressure related problem. Further electrical testing may be in order.
2. Compare gauge readings from the pressure test to the Air Conditioning Temperature/Pressure Chart above.

Low Side Pressure is Fault #4 -- Temperature Select Pot Electrical Control Temperature Control
low and High Side Potentiometer -- Testing
Pressure is normal
Fault #8 -- Evaporator Temperature Sensing System Evaporator Tempera-
Sensor ture Sensor -- Testing
Low Air Flow Check evaporator seals.
Air in System Overhaul -- Leakage test
Low Side Pressure is Refrigerant excessively low. Overhaul -- Leakage test
low and High Side
Pressure is low. Improper operation of expansion valve Expansion Valve -- Testing
(stuck closed).
Restrictions in the high side of the sys- Check for crimped hoses/tubes or other
tem. restrictions.
50-14

Low Side Pressure is Condenser not operating correctly. Check belt tension. Loose or worn drive
high and High Side belts could cause excessive pressures
Pressure is high. in the compressor head.
Check for air flow restrictions in con-
denser.
Possible air in system. Perform Leakage Test.
System overcharged. Recover and Recharge. Refer to “Over-
haul -- Evacuating the Refrigerant” and
“Overhaul -- Charging”
Possible clogged condenser. Check condenser for plugging.
Expansion valve malfunction (stuck Expansion Valve -- Testing
open).
Low Side Pressure is Compressor Malfunction. Repair/Replace compressor.
high and High Side
Pressure is low.
Compressor cycles on Evaporator Temperature sensor is de- Replace Evaporator Temperature Sen-
at 34 psi (2.3 bar) and fective. sor.
off at 28 psi (1.9 bar) Make sure temperature sensing line is
indicated pressure on installed in the same position and depth
the Low Side Pressure in the evaporator core as previous bulb.
gauge and High Side
Pressure is normal.
50-15
HEATER VALVE
NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for
these tests.
CAUTION
DO NOT use a self-powered test light for any of these tests. Use of a self-powered light can cause damage
to components in this system.
WARNING
Before performing any of the electrical tests, be sure all operating controls are in neutral or park lock
position. This will eliminate accidental movement of the machine or start-up of power driven equipment.
No Test Point Expected Result Other Result (Possible Cause)

1 Run engine at 1500 Warm air comes out ventilation lou- Go to test 2
rpm for 15 minutes to vers.
warm engine coolant. System operating properly.
Keyswitch ON and ATC
Switch in AUTO.
Turn Temperature Con-
trol to maximum heat
setting.
2 Keyswitch ON and ATC Slot on front of valve rotates Go to test 3
Switch in AUTO. Ob- clockwise.
serve slot on front of Check for obstructions in the cool-
valve. ant supply and return hoses.
Turn Temperature Con-
trol from max cool to
max heat setting.
3 Disconnect connector Less than 1 ohms. Valve motor open. Replace heater
X151 at heater valve. Go to test 4 control valve assembly.
Check continuity
through valve motor
from pin “A” to pin “C”.
4 Disconnect connector Control voltage varies from 11.5 -- Go to test 8
X151 at heater valve. 1.5 volts
Keyswitch ON and ATC Go to test 5
Switch in AUTO.
Test voltage from pin
“D” at X151 to chassis
ground while turning
Temperature Control
from max cool to max
heat setting.
5 Check voltage at pin 12 volts Go to test 6
“A” at connector X151. Go to test 7
50-16

6 Check voltage at Con- 12 volts Faulty ATC Control Module. Repair
nector X398 pin “L” at Open in voltage supply circuit or replace.
ATC Control Module. AC-956-OR between heater valve
and ATC Control Module. Repair or
replace.
7 Measure resistance be- Less than 1 ohms. Open in ground circuit AC-957-BK.
tween Connector X151 System operating properly. Retest. Repair or replace.
at Heater Control Valve
and ground.
8 Test voltage from Con- Control voltage varies from 11.5 -- Faulty ATC Control Module. Repair
nector X397 pin “2E” at 1.5 volts or replace.
ATC Control Module to Open in control circuit AC-955-YE
chassis ground while between heater valve and ATC
turning Temperature Control Module. Repair or replace.
Control from max cool
to max heat setting.
50-17
EXPANSION VALVE

1 Disconnect Low Pres- Low pressure gauge shows de- Expansion Valve defective. Replace
sure Switch. crease in pressure. as described in “Expansion Valve
Connect the pressure Go to test 2 --Removal” and “Expansion Valve --
test gauge manifold as Installation.”
described in “Overhaul
-- Pressure Test.”
Remove insulation ma-
terial from top of expan-
sion valve.
With engine running
and A/C on maximum
cooling, cool the top of
the expansion valve
with ice.
2 Allow the top of the ex- The valve opens and the pressure If there is little or no change in pres-
pansion valve to warm. rises on the low pressure gauge. sure, replace the expansion valve
as described in “Expansion Valve --
Removal” and “Expansion Valve --
Installation.”
50-18
VENTILATION SYSTEM SEPARATOR FAN

these tests.
CAUTION
WARNING

1 Keyswitch ON. Separator fan running. Go to test 2
If fan is running, but cab does not
have positive pressure, clean sepa-
rator fan intake filter. Retest.
2 Keyswitch OFF. Fuse good. Replace Fuse F-17.
Check condition of Go to test 3
Fuse F-17.
3 Disconnect connector Less than 1 ohms. If good reading, Separator Fan Motor faulty.
X470 at Separator Fan. Go to test 4 Replace.
Measure resistance
across Separator Fan
pins A and B.
4 Disconnect connector 12 volts. If good reading, Go to test 6
X470 at Separator Fan. Go to test 5
Keyswitch ON.
Measure voltage at
Separator Fan connec-
tor X470, pin A.
5 Disconnect connector Less than 1 ohms. If good reading, Open in ground circuit AC-933-BK
X470 at Separator Fan. Go to test 6 between Separator Fan connector
Measure resistance be- X470 and ground. Repair or
tween Separator Fan replace.
connector X470, pin B
and ground.
6 Remove Separator Fan 12 volts. If good reading, Go to test 7
Relay K-09. Go to test 9
Keyswitch ON.
Measure voltage at
Separator Fan Relay
K-09, pin 1.
7 Measure voltage at in- 12 volts. If good reading, open in Go to test 8
line connector X003, circuit CM-902-WH between Sepa-
pin 5. rator Fan Relay K-09 and in-line
connector X003. Repair or replace
circuit.
50-19

8 Measure voltage at 12 volts. If good reading, open in ATC Control Module A20 faulty. Re-
ATC Control Module circuit CM-902-WH between ATC place control module.
A20 connector X128, Control Module A20 connector
pin C-4. X128 and in-line connector X003.
Repair or replace circuit.
9 Separator Fan Relay 12 volts. If good reading, Go to test Open circuit in line CM--930--RD
K-09 removed. 10 between Fuse F--17 and Separator
Keyswitch OFF. Fan Relay K--09. Repair or replace.
Measure voltage at
Separator Fan Relay
K-09, pin 3.
10 Measure resistance be- Less than 1 ohms. If good reading, Open in ground circuit between
tween Separator Fan Go to test 11 Separator Fan relay K--09 and
relay K--09, pin 2 and ground.
ground. Repair or replace.
11 Measure resistance be- Less than 1 ohms. If good reading, Go to test 12
tween Separator Fan Replace Separator Fan Relay K-09.
relay K-09, pin 5 and
ground.
12 Measure resistance be- Less than 1 ohms. If good reading, Open in ground circuit AC-926-RD
tween in-line connector open in ground circuit CM-926-WH between Separator Fan connector
X006, pin B and between Separator Fan relay K-09 X470 and in-line connector X006.
ground. and in-line connector X006. Repair Repair or Replace.
or Replace.
50-20
VENTILATION SYSTEM BLOWER MOTOR (ATC)

these tests.
CAUTION
WARNING

1 Keyswitch ON. Blower Blower running. Go to test 3
speed set to any speed. Go to test 2
2 Keyswitch ON. ATC Con- Blower speed changes. Blower Speed Control inoperable.
trol Switch is OFF. Blower operating properly. Go to Electrical Control Blower
Rotate Blower Speed Con- Speed Potentiometer -- Testing.
trol knob.
3 Keyswitch OFF. Fuse good. Replace Fuse F-18.
Check condition of Fuse Go to test 4
F-18.
4 Measure resistance be- Less than 1 ohm. If good read- Open in ground circuit CM-942-BK
tween Blower Motor Relay, ing, Go to test 5 between Blower Motor Relay, pin 2
pin 2 and ground. and ground. Repair or replace.
5 Remove Blower Motor 12 volts. If good reading, Go to Open in B+ supply circuit
Relay. test 6 CM-938-RD to Blower Motor Relay.
Keyswitch ON. Repair or replace.
Measure voltage at A/C
Clutch Relay, pin 3.
6 Measure voltage at Blower 12 volts. If good reading, Go to Open in circuit CM-906 between
Motor Relay, pin 1. test 9 Blower Motor Relay and HVAC
Control Module.
Go to test 7
7 Measure voltage at in-line 12 volts. If good reading, Open in Open in circuit CM-906 between in-
connector X003 (pin 9). circuit CM-906-WH between line connector X003 and HVAC
Blower Motor Relay and in-line Control Module.
connector X003. Repair or re- Go to test 8
place circuit.
8 Measure voltage at in-line 12 volts. If good reading, Open in Replace HVAC Control Module.
connector X128 (pin C-9). circuit CM-906-WH between in-
line connector X003 and in-line
connector X128. Repair or re-
place circuit.
50-21

9 Disconnect Blower Motor 12 volts. If good reading, Go to Go to test 10
from harness. test 13
Measure voltage at Blower
Motor connector, pin A.
10 Measure voltage at in-line 12 volts. If good reading, Open in Go to test 11
connector X152 (pin 1). circuit BL-926 between in-line
connector X152 (pin 1) and
Blower Motor. Repair or replace
circuit.
11 Measure voltage at in-line 12 volts. If good reading, Open in Go to test 12
connector X006 (pin G). circuit AC-926 between in-line
connector X152 (pin 1) and in-
line connector X006 (pin G). Re-
pair or replace circuit.
12 Measure voltage at Blower 12 volts. If good reading, Open in Faulty Blower Motor Relay. Repair
Motor Relay pin 5. circuit CM-926 between in-line or replace Blower Motor Relay.
Blower Motor Relay pin 5. Repair
or replace circuit.
13 Measure resistance Less than 1 ohm. If good read- Blower Motor windings open. Re-
across Blower Motor ter- ing, Go to test 14 place Blower Motor.
minals A and B.
14 Measure resistance be- Less than 1 ohm. If good read- Open in ground circuit between
tween Blower Motor termi- ing, Blower Motor circuit operat- Blower Motor and ground. Repair or
nal B and ground. ing properly. replace circuit
50-22
VENTILATION SYSTEM BLOWER MOTOR (MTC)

these tests.
CAUTION
WARNING

1 Keyswitch ON. Check Blower runs in all speeds. Blower does not operate in any
blower operation in Low, Blower operating properly speed: Go to test 2.
Medium, and High speeds Blower does not operate in Low
speed: Go to test 6.
Blower does not operate in Medium
Blower does not operate in High
2 Keyswitch OFF. Fuse good. Replace Fuse F--18.

F--18.
3 Keyswitch ON. Remove 12 volts. If good reading, go to Open in circuit CM--938--RD be-
Blower Motor High Speed test 4. tween Fuse F--18 and Blower Motor
Relay K--13. Check volt- High Speed Relay K--13. repair or
age at Blower Motor High replace.
Speed Relay K--13., pin 3
4 Keyswitch OFF. Measure Less than 1 ohm. If good read- Faulty Blower Motor. Repair or re-
resistance across Blower ing, go to test 5. place.
Motor.
5 Keyswitch OFF. Measure Less than 1 ohm. If good read- Open in ground circuit AC--933--BK
resistance between Blow- ing, go to test 6. between blower motor and ground.
er Motor connector X155 Repair or replace.
and ground..
6 Keyswitch OFF. Remove Less than 1 ohm. If good read- Open in ground circuit AC--940--BK
Blower Motor Low Speed ing, go to test 7. between blower relay and ground.
Relay K--11. Measure re- Repair or replace.
sistance between Blower
Motor Low Speed Relay
K--11, pin 2 and ground
7 Keyswitch ON. Check volt- 12 volts. If good reading, go to Open in circuit CM--936--RD be-
age at Blower Motor Low test 8. tween blower relay and Fuse F--18.
Speed Relay K--11., pin 3.
50-23

8 Keyswitch ON 12 volts. If good reading, go to Open in relay control circuit. Go to
Blower Fan speed set to test 10. test 9.
LOW. Check voltage at
Blower Motor Low Speed
Relay K--11., pin 1.
9 Keyswitch ON 12 volts. If good reading, open HVAC Control Module (A--09) faulty.
Blower Fan speed set to circuit in CM--904--WH between Replace.
LOW. Check voltage at blower relay and HVAC Control
HVAC Control Module Module (A--09).
(A--09) connector X128,
pin C--7.
10 Keyswitch ON 12 volts. If good reading, go to Blower Motor Low Speed relay de-
Blower Fan speed set to test 11. fective. Replace.
LOW. Check voltage at
Blower Motor Low Speed
Relay pin 5.
11 Keyswitch ON 12 volts. If good reading, resistor Go to test 12.
Blower Fan speed set to at Blower Motor defective. Re-
LOW. Check voltage at pair.
Blower Motor connector
X158.
12 Keyswitch ON 12 volts. If good reading, open in Go to test 13.
Blower Fan speed set to Low Speed circuit AC--928--YE.
LOW. Check voltage at Repair or replace.
connector X152, pin 1.
13 Keyswitch ON 12 volts. If good reading, open in Open in Low Speed circuit
Blower Fan speed set to Low Speed circuit AC--928--WH CM--928--WH between connector
LOW. Check voltage at between connector X006 and X006 and Blower Motor Low Speed
connector X006, pin D. X152. Repair or replace. Relay K--11. Repair or replace.
Blower Motor Medium ing, go to test 15. between blower relay and ground.
Speed Relay K--12. Mea- Repair or replace.
sure resistance between
Blower Motor medium
Speed Relay K--12, pin 2
and ground.
age at Blower Motor Me- test 16. tween blower relay and Fuse F--18.
dium Speed Relay K--12.,
pin 3.
MEDIUM. Check voltage
at Blower Motor Medium
50-24

MEDIUM. Check voltage blower relay and HVAC Control
at HVAC Control Module Module (A--09).
pin C--8.
18 Keyswitch ON 12 volts. If good reading, go to Blower Motor Medium Speed relay
Blower Fan speed set to test 19. defective. Replace.
MEDIUM. Check voltage
at Blower Motor Medium
Speed Relay pin 5.
19 Keyswitch ON 12 volts. If good reading, resistor Go to test 20.
Blower Fan speed set to at Blower Motor defective. Re-
MEDIUM. Check voltage pair.
at Blower Motor connector
X157.
Blower Fan speed set to Medium Speed circuit
MEDIUM. Check voltage AC--929--OR. Repair or replace.
at connector X152, pin 2.
21 Keyswitch ON 12 volts. If good reading, open in Open in Medium Speed circuit
Blower Fan speed set to Medium Speed circuit CM--929--WH between connector
MEDIUM. Check voltage AC--929--WH between connector X006 and Blower Motor Medium
at connector X006, pin E. X006 and X152. Repair or re- Speed Relay K--12. Repair or re-
place. place.
Blower Motor High Speed ing, go to test 23. between blower relay and ground.
Relay K--13. Measure re- Repair or replace.
sistance between Blower
Motor High Speed Relay
K--13, pin 2 and ground
age at Blower Motor High test 24. tween blower relay and Fuse F--18.
HIGH. Check voltage at
Blower Motor High Speed
Relay K--13., pin 1.
HIGH. Check voltage at blower relay and HVAC Control
HVAC Control Module Module (A--09).
pin C--9.
50-25

26 Keyswitch ON 12 volts. If good reading, go to Blower Motor Low Speed relay de-
Blower Fan speed set to test 27. fective. Replace.
Blower Motor High Speed
Relay pin 5.
27 Keyswitch ON 12 volts. If good reading, Blower Go to test 28.
Blower Fan speed set to Motor defective. Repair.
Blower Motor connector
X156.
Blower Fan speed set to High Speed circuit AC--946--RD.
HIGH. Check voltage at Repair or replace.
connector X152, pin 3.
29 Keyswitch ON 12 volts. If good reading, open in Open in High Speed circuit
Blower Fan speed set to High Speed circuit AC--946--WH CM--946--WH between connector
HIGH. Check voltage at between connector X006 and X006 and Blower Motor High Speed
connector X006, pin G. X152. Repair or replace. Relay K--13. Repair or replace.
50-26
ELECTRICAL CONTROL TEMPERATURE CONTROL POTENTIOMETER

these tests.
CAUTION
WARNING

1 Keyswitch ON and ATC Fault Code #4 displays only in Go to test 3
switch in AUTO. Defrost certain locations.
OFF. Probable faulty Temperature
Turn Temperature Control Control Pot.
Pot while observing Auto Go to test 2
Operation Display.
2 Keyswitch OFF. ATC OFF. Resistance changes smoothly Replace the HVAC Control Module
Disconnect HVAC Control between 0 -- 10K ohms as the (A20).
Module (A20) connector pot is turned from full CCW to full
X128. CW.
Resistance check the tem- Go to test 3
perature control pot be-
tween pins C-16 and D1
on the HVAC Control Mod-
ule.
3 HVAC Control Module Voltage reading >3.0 volts. Problem in ATC Controller circuit.
(A20) connector X128 dis- Open in Temperature Control Pot
connected. Keyswitch ON. circuit. Replace HVAC Control
Check for voltage at con- Module.
nector X128, pin D1.
50-27
ELECTRICAL CONTROL BLOWER SPEED POTENTIOMETER

these tests.
CAUTION
WARNING

1 Keyswitch ON and ATC Fault Code #3 displays only in Go to test 2
switch in AUTO. Defrost certain locations.
OFF. Probable faulty Blower Speed
Turn Blower Speed Con- Control Pot.
trol Pot while observing Go to test 3
Auto Operation Display.
2 Keyswitch ON and ATC Temperature setpoint changes in Open in Blower Speed and Temper-
switch in AUTO. Defrost display as Temperature Control ature Control Pot ground circuit.
OFF. Pot is turned. Replace HVAC Control Module.
Check Temperature Con- Go to test 3
trol Pot for proper opera-
tion.
3 Keyswitch OFF. ATC OFF. Resistance changes smoothly Replace the HVAC Control Module
Disconnect HVAC Control between 0 -- 10K ohms as the (A20).
Module (A20) connector pot is turned from full CCW to full
X128. CW.
Resistance check the Go to test 4
blower speed control pot
between pins C15 and
C16 on the HVAC Control
Module.
4 Disconnect HVAC Control Voltage reading >3.0 volts. Problem in ATC Control Module cir-
Module (A20) connector Open in Blower Speed Control cuit.
X128. Keyswitch ON. Pot circuit. replace HVAC Control
Check for voltage at con- Module.
nector X128, pin C15.
50-28
ELECTRICAL CONTROL RELAY

these tests.
CAUTION
WARNING

1 Ignition switch in “IGN” Compressor clutch is heard en- Go to test 2
position. gaging and disengaging. If good
Blower speed set to any reading, A/C Clutch Control cir-
fan speed. cuits are operating properly.
Cycle Defrost Switch On
and Off.
2 Ignition switch in “OFF” Fuse good. Replace Fuse F-19.
F-19.
3 Measure resistance be- Less than 1 ohm. If good read- Open in ground circuit CM-945-BK
tween A/C Clutch Relay, ing, Go to test 4 between A/C Clutch Relay, pin 2
pin 2 and ground. and ground. Repair or replace.
4 Remove A/C Clutch Relay. 12 volts. If good reading, Go to Open in B+ supply circuit
Ignition Switch in “IGN” test 5 CM-087-RD to A/C Clutch Relay.
position. Blower speed set Repair or replace.
to any fan speed.
Measure voltage at A/C
Clutch Relay, pin 3.
5 Measure voltage at A/C 12 volts. If good reading, Go to Open in circuit CM-900 between
Clutch Relay, pin 1. test 8 A/C Clutch Relay and HVAC Con-
trol Module.
Go to test 6
6 Measure voltage at in-line 12 volts. If good reading, Open in Open in circuit CM-900 between in-
connector X003 (pin3). circuit CM-900-WH between A/C line connector X003 and HVAC
Clutch relay and in-line connec- Control Module.
tor X003. Repair or replace cir- Go to test 7
cuit.
7 Measure voltage at in-line 12 volts. If good reading, Open in Replace HVAC Control Module.
connector X128 (pin C-3). circuit CM-900-WH between in-
line connector X003 and and in-
line connector X128. Repair or
replace circuit.
50-29

8 Ignition switch in “OFF” Less than 1 ohm. If good read- Open in ground circuit between A/C
position. A/C system OFF. ing, Replace A/C Clutch Relay. Clutch Relay and Ground.
A/C Clutch Relay installed. Go to test 9
Measure resistance be-
tween A/C Clutch Relay,
pin 5 and ground.
9 Measure resistance be- Less than 1 ohm. If good read- Open in ground circuit between in-
tween in-line connector ing, Open in ground circuit line connector X005 (pin 9) and
X005 (pin 9) and ground. CM-178-WH between in-line con- Ground.
nector X005 (pin 9) and A/C Go to test 10
Clutch Relay. Repair or replace
circuit.
10 Measure resistance be- Less than 1 ohm. If good read- Open in ground circuit between in-
tween in-line connector ing, Open in ground circuit line connector X010 (pin 11) and
X010 (pin 11) and ground. MF-178-WH between in-line con- Ground.
nector X005 (pin 9) and in-line Go to test 11
connector X010 (pin 11). Repair
or replace circuit.
11 Measure resistance be- Less than 1 ohm. If good read- Open in ground circuit between A/C
tween A/C Clutch connec- ing, Open in ground circuit Clutch connector X215 (pin A) and
tor X215 (pin A) and EN-178-WH between in-line con- Ground.
ground. nector X010 (pin 11) and A/C Go to test 12
Clutch connector X215 (pin B).
Repair or replace circuit.
12 Measure resistance be- Less than 1 ohm. If good read- Open in ground circuit between A/C
tween A/C Clutch connec- ing, Open in A/C Clutch coil. Re- Clutch connector X215 (pin B) and
tor X215 (pin B) and pair or replace A/C Clutch. Ground. Repair or replace circuit
ground.
50-30
ELECTRONIC HVAC CONTROL -- DISPLAY DATA LINE

these tests.
CAUTION
WARNING

1 Engine stopped. A/C OFF. Less than 1 ohm. If good read- Open in data circuit between HVAC
Disconnect Auto Opera- ing, Go to test 2 Control Module (A20) connector
tion Display unit. Measure X128, pin D-10 and pin 3 at Auto
resistance between HVAC Operation Display unit. Repair cir-
Control Module (A20) con- cuit.
nector X128, pin D-10 and
pin 3 at Auto Operation
Display unit.
2 Measure resistance be- Less than 1 ohm. If good read- Open in data circuit between HVAC
tween HVAC Control Mod- ing, Go to test 3 Control Module (A20) connector
ule (A20) connector X128, X128, pin D-10 and in-line connec-
pin D-10 and in-line con- tor X003 pin 26. Repair circuit.
nector X003 pin 26.
3 Measure resistance be- Less than 1 ohm. If good read- Open in data circuit between in-line
tween in-line connector ing, Go to test 4 connector X003 pin 26 and in-line
X003 pin 26 and in-line connector X006 pin “T”. Repair cir-
connector X006 pin “T”. cuit.
4 Measure resistance be- Less than 1 ohm. If good read- Open in data circuit between in-line
tween in-line connector ing, ATC Control Module faulty. connector X006 pin “T” and ATC
X006 pin “T” and ATC Repair or replace. Control Module (A15) connector
Control Module (A15) con- X398 pin “G”. Repair circuit.
nector X398 pin “G”.
50-31
ELECTRONIC HVAC CONTROL -- ATC CONTROL SWITCH AND MODE CONTROL SWITCH
these tests.
CAUTION
WARNING

1 Keyswitch ON and ATC Auto Operation Display window Go to test 4
Control Switch in AUTO. illuminated.
Mode Control Switch in Go to test 2
AUTO.
Control Switch in AUTO. illuminated.
Mode Control Switch in Go to test 3
DEFOG.
Control Switch in OFF. not illuminated.
ATC Control Switch and Mode
Control Switch operating proper-
ly.
4 Keyswitch OFF. ATC Con- Less than 1 ohm. If good read- Replace HVAC Control Module.
trol Switch in AUTO. Mode ing, Go to test 5
Control Switch in AUTO.
Disconnect HVAC Control
Module (A20) connector
X128.
Measure resistance
across pins C16 and D5
on HVAC Control Module.
5 HVAC Control Module >3 volts. If good reading, Go to Problem in ATC Controller circuit.
(A20) connector X128 dis- test 6
connected. Keyswitch ON.
Measure voltage at HVAC
Control Module connector
X128 pin D5.
6 HVAC Control Module >3 volts. If good reading, Open in Problem in ATC Controller circuit.
(A20) connector X128 dis- B+ supply circuit to Mode Control
connected. Keyswitch ON. Switch. Replace HVAC Control
Measure voltage at HVAC Module.
Control Module connector
X128 pin D7.
50-32
ELECTRONIC HVAC CONTROL -- ATC CONTROLLER POWER SUPPLY

these tests.
CAUTION
WARNING

1 Keyswitch ON. 12 volts. If good reading, Go to Open in Switched Ignition Power
Measure voltage at HVAC test 2 Supply to HVAC Unit. Repair or re-
Control Module connector place circuit.
X128 pin C2.
2 Keyswitch OFF. Less than 1 ohm. If good read- Open in ground circuit to HVAC
Measure resistance being, Repair or replace HVAC Unit.
tween HVAC Control Mod- Control Module. Repair or replace circuit.
ule connector X128 pin
D14 and ground.
50-33
SENSING SYSTEM HIGH PRESSURE SWITCH

these tests.
CAUTION
WARNING

1 Engine stopped. Less than 1 ohm. If good read- Open in high pressure switch cir-
Disconnect HVAC Control ing, Go to test 12 cuit.
Module connector X128. Go to test 2
Measure resistance be-
tween connector X128, pin
D-3 and D-4.
2 Reconnect HVAC Control Less than 1 ohm. If good read- A/C High Pressure switch failed. Re
Module connector X128. ing, Go to test 3 place A/C High Pressure switch.
Disconnect connector
X216 from high pressure
switch.
Measure resistance
across switch terminals.
3 Measure resistance be- Less than 1 ohm. If good read- Open in high pressure ground cir-
tween A/C High Pressure ing, Go to test 4 cuit EN-916-BL. Repair or replace
Switch connector X216 this circuit.
(pin B) and in-line connec-
tor X010 (pin22).
tween in-line connector ing, Go to test 5 cuit MF-916-BL. Repair or replace
X010 (pin22) and in-line this circuit.
connector X005 (pin28).
tween in-line connector ing, Go to test 6 cuit CM-916-BL. Repair or replace
connector X003 (pin19).
tween in-line connector ing, Go to test 7 cuit CR-934-BL. Repair or replace
connector X128 (pin D-3).
50-34

7 Reconnect all connectors. 12 volts. If good reading, Open in B+ supply circuit to high
Start engine with A/C on. Electrical portion of High Pres- pressure switch.
Measure voltage at HVAC sure Switch circuit operating Go to test 8
High Pressure Switch con- properly.
nector X126 (pin A).
8 Measure voltage at in-line 12 volts. If good reading, Open in Open in B+ supply circuit to con-
connector X010 (pin25). B+ circuit EN-917-YE between nector X010.
high pressure switch connector Go to test 9
X216 (pin A) and in-line connec-
tor X010 (pin25). Repair or re-
place this circuit.
9 Measure voltage at in-line 12 volts. If good reading, Open in B+ supply circuit to con-
connector X005 (pin29). Open in B+ circuit MF-917-YE nector X005.
between in-line connector X010 Go to test 10
(pin25) and in-line connector
X005 (pin29).
Repair or replace this circuit.
connector X003 (pin20). Open in B+ circuit CM-917-YE nector X003.
X003 (pin20).
connector X128 (pin D-4). Open in B+ circuit CR-917-YE nector X128.
X128 (pin D-4).
12 Engine running and A/C 12 volts. If good reading, Go to Repair or replace HVAC Control
on. test 13 Module (A-20).
Disconnect HVAC Control
Module connector X128.
Measure voltage at HVAC
Control Module, pin D-4.
13 Engine off and A/C off. Less than 1 ohm. If good read- Repair or replace HVAC Control
Measure resistance being, Electrical portion of high Module (A-20).
tween HVAC Control Mod- pressure operating properly.
ule, pin D-3 and ground.
50-35
SENSING SYSTEM LOW PRESSURE SWITCH (ATC)

these tests.
CAUTION
WARNING

1 Engine stopped. Less than 1 ohm. If good read- Open in low pressure switch circuit.
Disconnect HVAC Control ing, Go to test 2 Go to test 3
Module (A-15) connector
X397. Disconnect HVAC
Control Module (A-20)
connector X128. Measure
resistance between con-
nector X397, pin 1C and
connector X128, pin C-16.
2 Engine off and A/C off. Less than 1 ohm. If good read- Open in ground circuit to HVAC
Measure resistance being, Go to test 9 Control Module (A-15), repair or re-
tween HVAC Control Mod- place.
ule (A-15), pin 1C and
ground.
3 Reconnect HVAC Control Less than 1 ohm. If good read- A/C Low Pressure switch failed. Re-
Module (A-15) connector ing, Go to test 4 place A/C Low Pressure switch.
X397 and HVAC Control
Module (A-20) connector
X128. Disconnect connec-
tor X217 from A/C Low
Pressure switch.
Measure resistance
across switch terminals.
4 Measure resistance be- Less than 1 ohm. If good read- Open in A/C Low Pressure ground
tween A/C Low Pressure ing, Go to test 6 circuit.
Switch connector X217 Go to test 5
(pin 2) and ground.
50-36

5 Engine off and A/C off. Less than 1 ohm. If good Open in ground circuit to HVAC
Measure resistance reading, Open in A/C Low Control Module (A-15), repair or
between HVAC Control Pressure ground circuit replace.
Module (A-15), pin 1C and AC-950-BL between connector
ground. X397, pin 1C and connector
X217, pin 2. Repair or replace
this circuit.
6 Reconnect all connectors. 12 volts. If good reading, Open in B+ supply circuit to low
Start engine with A/C on. Electrical portion of Low pressure switch.
Measure voltage at HVAC Pressure Switch circuit operating Go to test 7
Low Pressure Switch properly.
connector X127 (pin 1).
7 Measure voltage at in-line 12 volts. If good reading, Open in Open in B+ supply circuit to
connector X006 (pin L). B+ circuit AC-91 3-YE between connector X006.
Low Pressure switch connector Go to test 8
X217 (pin 1) and in-line
connector X006 (pin L). Repair or
replace this circuit.
connector X003 (pin 16). B+ circuit CM-913-YE between connector X003.
in-line connector X006 (pin L) Go to test 9
and in-line connector X003 (pin
16).
9 Measure voltage at HVAC 12 volts. If good reading, Open in Open in B+ supply circuit to HVAC
Control Panel (A-20) B+ circuit CR-913-YE between Control Panel (A-20), repair or
connector X128 (pin in-line connector X003 (pin 16) replace control panel.
C-16). and HVAC Control Panel (A-20)
connector X128 (pin C-16).
50-37
SENSING SYSTEM LOW PRESSURE SWITCH/FREEZE SWITCH (MTC)

these tests.
CAUTION
WARNING

1 Keyswitch OFF. Less than 1 ohm. If good read- Low Pressure Switch failed. Re-
Disconnect connector ing, go to test 2. place.
X451 from Low Pressure
Switch. Measure resist-
ance across switch termi-
nals.
2 Keyswitch OFF. Less than 1 ohm. If good read- Freeze Switch failed. Replace.
Disconnect connectors ing, go to test 3.
X452 and X453 from
Freeze Switch. Measure
resistance across switch
terminals.
3 Keyswitch OFF. Less than 1 ohm. If good read- Open in circuit between connector
Reconnect Freeze Switch ing, go to test 4. X006 and switches. Repair.
and Low Pressure Switch.
Disconnect connector
X006. Measure resistance
across pin A and pin C.
Reconnect connector ing, go to test 5. X006 and connector X003. Repair.
X006. Disconnect connec-
tor X003. Measure resist-
ance across pin 10 and
pin 11.
Reconnect connector ing, faulty HVAC Control Module. X003 and connector X128. Repair.
X003. Disconnect connec- Repair or replace.
tor X128 at HVAC Control
Module. Measure resist-
ance across pin C--10 and
pin C--11.
50-38
SENSING SYSTEM OUTLET TEMPERATURE SENSOR

these tests.
CAUTION
WARNING

1 Engine off and A/C off. 15K -- 30K ohms, with an Outlet Temperature Sensor faulty.
Disconnect connector from ambient temperature between 90 Repair or replace sensor.
Outlet Temperature -- 60 °F (31 -- 16 °C). If good
Sensor. reading, Go to test 2
Measure resistance
across sensor terminals.
2 Measure resistance Less than 1 ohm. If good Open in Outlet Temperature Sensor
between Outlet Tempera- reading, Go to test 4 ground circuit.
ture Sensor connector pin Go to test 3
1 and ground.
3 Measure resistance Less than 1 ohm. If good Open in ground circuit to ATC
between ATC Control reading, Open in Outlet Control Module (A-15), repair or
Module (A-15), and Temperature Sensor ground replace.
ground. circuit between sensor connector
and connector at ATC Control
Module (A-15). Repair or replace
this circuit.
4 Reconnect all connectors. 12 volts. If good reading, Open in B+ supply circuit to Outlet
Start engine with A/C on. Electrical portion of Outlet Temperature Sensor.
Measure voltage at Outlet Temperature Sensor circuit
Temperature Sensor operating properly.
connector pin 2.
50-39
SENSING SYSTEM CAB TEMPERATURE SENSOR

these tests.
CAUTION
WARNING

1 Engine off and A/C off. 15K -- 30K ohms, with an Cab Temperature Sensor faulty.
Disconnect connector ambient temperature between 90 Repair or replace sensor.
X149 from Cab Tempera- -- 60 °F (31 -- 16 °C). If good
ture Sensor. reading, Go to test 2
Measure resistance
2 Measure resistance Less than 1 ohm. If good Open in Cab Temperature Sensor
between Cab Temperature reading, Go to test 4 ground circuit.
Sensor connector X149 Go to test 3
(pin 1) and ground.
between ATC Control reading, Open in Cab Control Module (A-15), repair or
Module (A-15), pin 2C and Temperature Sensor ground replace.
ground. circuit AC-952-BL between
connector X149, pin 1 and
connector X397, pin 2C. Repair
or replace this circuit.
4 Reconnect all connectors. 12 volts. If good reading, Open in B+ supply circuit to Cab
Start engine with A/C on. Electrical portion of Cab Temperature Sensor.
Measure voltage at Cab Temperature Sensor circuit Go to test 5
Temperature Sensor operating properly.
connector B+ circuit AC-91 3-YE between connect tor X006.
X006 (pin L). Cab Temperature Sensor Go to test 6
in-line connector X006 (pin L).
50-40

connector X003 (pin 16). B+ circuit CM-913-YE between connector X003.
16).
50-41
SENSING SYSTEM EVAPORATOR TEMPERATURE SENSOR

these tests.
CAUTION
WARNING

1 Engine off and A/C off. 15K -- 30K ohms, with an Evaporator Temperature Sensor
Disconnect connector ambient temperature between 90 faulty. Repair or replace sensor.
X150 from Evaporator -- 60 °F (31 -- 16 °C). If good
Temperature Sensor. reading, Go to test 2
Measure resistance
2 Measure resistance Less than 1 ohm. If good Open in Evaporator Temperature
between Evaporator reading, Go to test 4 Sensor ground circuit.
Temperature Sensor Go to test 3
connector X150 (pin 1)
and ground.
between ATC Control reading, Open in Evaporator Control Module (A-15), repair or
Module (A-15), pin 1B and Temperature Sensor ground replace.
ground. circuit AC-951-BL between
connector X150, pin 1 and
connector X397, pin 1B. Repair
or replace this circuit.
4 Reconnect all connectors. 12 volts. If good reading, Open in B+ supply circuit to
Start engine with A/C on. Electrical portion of Evaporator Evaporator Temperature Sensor.
Measure voltage at Temperature Sensor circuit Go to test 5
Evaporator Temperature operating properly.
Sensor connector X150
(pin 2).
connector X006 (pin L). B+ circuit AC-91 3-YE between connector X006.
Evaporator Temperature Sensor Go to test 6
in-line connector X006 (pin L).
50-42

connector X003 (pin 16). B+ circuit CM-913-YE be tween connector X003.
16).
50-43
OVERHAUL
EVACUATING THE REFRIGERANT
1. Recovered refrigerant passes through an oil
separator and filter-drier before entering the
refrigerant tank. The moisture indicator will turn
green when dry refrigerant passes over it.
2. If possible, run the air conditioning system for ten

minutes before starting the recovery process.
Turn the system off before proceeding.
1
3. Clean the external surfaces of the compressor
and hoses. Remove the caps from the service
ports, 1, on the suction and pressure hoses.
83054617
15
4. Make sure the charging station manifold gauge

valves are in the closed position. Connect the
hose from the low pressure gauge to the port on
the suction hose. Connect the hose from the high
pressure gauge to the port on the discharge
hose. Turn in both thumbscrews to depress the
service valves.
5. Open the high and low valves.
83060848
16
6. Make certain the refrigerant tank gas and liquid

valves are open.
83060842
17
50-44
7. Connect the main power plug to a 115 volt AC
outlet. Move the main power switch to the ON
position and depress the recovery start switch.
The compressor will shut OFF automatically
when recovery is complete. Wait for five minutes
and observe the manifold pressure gauges for a
pressure rise. If pressure rises above zero PSI,
depress the hold/cont switch. Then wait for the
compressor to automatically shut OFF.
83060846
18
8. Drain the oil separator of the A/C system oil.

Open the air purge valve long enough to let some
of the compressor discharge pressure back into
the separator.
83060843
19
9. Slowly open the oil drain valve and drain the oil
into the reservoir. When the oil stops draining,
close the oil drain valve completely.
83060844
20
50-45
10. Fill the A/C compressor with fresh SP-20 PAG oil
equal to the amount in the reservoir.
83060845
21
11. Disconnect the hoses from the service ports, 1,

and install the caps.
12. Replace the receiver-drier if one or more of the

following conditions occurs before you remove
the air and moisture from the system:
• The system has been opened for service before.

• Receiver-drier has operated two or more years.
• Disassembly of compressor shows small 1
particles of moisture removing material (gold or
brown particles).
• Large system leak (broken hose, break in line). 83054617
• Too much air or moisture in system. 22

• Removal of compressor caused the system to be •
open (uncapped) longer than 5 minutes.
50-46
13. Make sure the charging station manifold gauge
valves are in the closed position. Connect the
hose from the low pressure gauge to the port on
the suction hose, 1. Connect the hose from the
high pressure gauge to the port on the discharge
hose, 2. Turn in both thumbscrews to depress the
service valves.
14. Removal of air and moisture from the system is 1

necessary after the refrigerant has been
removed from the system after the system has 2
been opened for maintenance. Air enters the
system when the system is opened. Air has
moisture that must be removed to prevent 83054617
damage to the system components. 23
15. Air and moisture are removed from the system by

a vacuum pump. A vacuum pump is on the only
equipment made that will lower the pressure in a
system enough to change the moisture to a vapor
so that the moisture can be removed.
NOTE: Refer to the vacuum pump manufacturer ’s

user manual for additional information.
16. Connect the main power plug to a 115 volt AC

outlet. Move the main power switch to the ON
position. If program and vacuum do not appear
at the top of the display press the vacuum key.
Program a minimum of 45 minutes and press the
Enter key. The display will flash once indicating
the programmed data has been accepted.
83060847
24
17. Press the Charge Key. Program and Charge will

appear on the display.
83060849
25
50-47
18. Program 1.6 kg (3.52 lb) and press the enter key.
The display will flash once indicating the
programmed data has been accepted.
83060847
26
19. Full open the low and high pressure valves.
83060848
27
20. Open the red (vapor) and blue (liquid) valves on

the tank.
21. Press the Vacuum key. Automatic will show on

the display and after a slight delay, the vacuum
pump will start. The display will show the amount
of time programmed and begin a countdown to
zero.
83060842
28
50-48
22. When the programmed time has elapsed, an
automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28
-- 29-1/2 in of mercury (Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 15 minutes. If the system will not
hold vacuum, a leak exists that must be corrected
before recharging can begin. See “Overhaul --
Leakage Test” for a leak test.
83060847
29
PRESSURE TEST
NOTE: The compressor end plate is stamped with a
“D” and “S” to indicate the discharge and suction
ports.
1. Connect the pressure test gauge manifold to the

test connections at the compressor. Connect the
high side hose to the discharge side, 1, and the 2
low side hose to the suction side, 2.
1
83054617
30
2. On the pressure test gauge manifold, close the

high side valve, 1, and the low side valve, 2.
3. Close the cab windows and doors, set the

parking brake.
4. Start the engine and run at fast idle speed

(approximately 1500 rpm).
5. Set A/C mode switch to “on.” 2 1
6. Operate the system at maximum cooling, with

the blower fan at high speed for 10 minutes to
stabilize all components. 23060841
31
7. Check the manifold high and low pressure
gauges and compare the reading to the pressure
indicated on the Air Conditioning Temperature/
Pressure Chart. Refer to “Problem Solving
Pressure Test Results and Temperature/Pres-
sure Chart.”
50-49
LEAKAGE TEST
1. Shut off the engine.
WARNING
When refrigerant comes in contact with an open
flame, it forms phosgene gas. Never breathe
these fumes.
2. Use electronic leak detector OEM1437 to inspect

all connections. Use instructions from manufac-
turer of leak finding tool.
NOTE: When checking compressor seal for a leak,

remove the dust cover and rotate the clutch shaft
clockwise.
NOTE: To properly check the expansion valve for

leaks, remove the insulation tape.
3. Check Compressor oil level. Refill as necessary.
4. Repair all leaks and recharge the system.
CHARGING
1. Press the charge key to begin refrigerant
charging. Automatic and Charge will appear on
the display. The display shows the programmed
amount and counts down to zero as charging
proceeds. When charging is completed, the
display shows CPL.
83060847
32
2. Completely close the high and low pressure

manifold valves.
3. Start the engine and run at 1500 rpm. Operate

the air conditioner system at maximum cooling
setting and blower speed with the doors and
windows open.
NOTE: The compressor will not operate if the system

pressure is too low or too high. If the compressor fails
to operate and the condenser blowers also fail to
operate when you actuate the A/C switch, check the
system pressure to determine if refrigerant is
83060848
present. Check for continuity at the pressure switch
located at the receiver-dryer and the temperature 33
switch located at the evaporator.
50-50
4. Observe the pressure gauge readings to
determine that the correct amount of refrigerant
has entered the system. See table on “Testing --
Problem Solving Pressure Test Results,” for
temperature and pressure variations.
IMPORTANT: Check the OEM equipment manual

before performing this step to avoid damaging
recovery unit. Pressure reading should be obtainable
with valves closed. Damage may occur if the
machine is started with the valves accidently open or
if either or both valves are opened while the A/C
system operating.
83060850
34
5. Stop the engine, close any open valves and

carefully remove the manifold gauge hoses.
6. Install the caps on the service ports, 1, on the

suction and discharge hoses.
83054617
35
50-51
50-52
Chapter 2 - Air Filters
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fresh Air Intake Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Recirculation Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Separator Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
50-1
The combine is provided with three mechanisms
(below PIN HAJ100801) or two mechanisms (above
PIN HAJ100800) for filtering the air entering and
circulating through the cab.
Below PIN HAJ100801, the Fresh Air Intake Grill, 1,
is located behind the left shield next to the left cab
door. The grill will filter out large pieces of foreign 1
material that would otherwise quickly clog the finer
downstream filters. The grill is not removable from
the housing.
Above PIN HAJ100800, intake air is drawn down the

left, rear cab frame post into the separator filter.
10010476
1
Particles that pass through the course mesh of the
intake grill, enter the Separator Filter, 1, located
above the Fresh Air Intake Grill. Outside air is drawn
through the intake grill and discharged to the
separator by the separator fan mounted directly
behind the grill. Air entering the separator is directed
into a circular path around the paper element filter.
Centrifugal force will cause the heavier material to
move toward the outside. An outlet port is provided
on the cap of the separator to allow continuous
removal of the material separated. The separating
action of the unit extends the life of the paper filter.
10008334
1
2
The Recirculation Air Filter, 1, located behind the
operators’ control console filters the air circulating
inside the cab. The paper element filter removes
small particles from the air to prevent clogging of the
air conditioning system evaporator located directly
behind the filter.
NOTE: Operating the combine with the cab door

open will cause premature filter plugging.
1
10008336
50-2
OVERHAUL
FRESH AIR INTAKE GRILL
Cleaning (Below PIN HAJ100801)
Access to the fresh air intake grill is provided over the
left front tire. Open the lower door, 1, and remove all
foreign material caught in the grill. 1
10008376
4
RECIRCULATION AIR FILTER
1
Removal
1
Locate the recirculation air filter inside the cab,
behind the operators console. Move the operators
seat all the way forward. Simultaneously push down
while pulling out on the locking tabs, 1. A prying
device may have to be used.
10008336
5
Pull the grate and filter from the cavity.
10008337
50-3
Installation
Clean the evaporator core of any accumulated dust.
Insert the filter into the grate with the gasket
positioned toward the cores.
10008337
7
Set the grate and filter into place in the cavity. Push
the grate until the locking tabs, 1, snap into place. 1
1
10008336
8
SEPARATOR FILTER
2 1
Removal
Locate the separator/air filter housing inside the
cavity next to the left cab door.
Release the housing end cap lock, 1, by pulling it

away from the filter. Rotate the housing end cap, 2,
counter-clockwise until it can be removed.
10008334
50-4
Pull the filter element, 1, out of the filter housing.
1
10008335
10
Installation
1
Clean the inside of the filter housing to prevent
foreign material from entering the clean air side of the
filter element. Insert the air filter, 1, into the housing
base.
10008335
11
Set the end cap, 1, onto the filter housing and rotate
clockwise until the two components are held tightly 1 2
together. Secure the end cap into place by pushing
in the lock, 2.
10008334
12
50-5
50-6
Chapter 3 - Blower Fans
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Circulation Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Separator Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
50-1
Two fans are installed to bring in and circulate the cab
air.
The recirculating fan, 1, mixes air from outside and

inside the cab. Air is discharged from the fan to the
outlet plenum and directed to various points within
the cab.
10008347
1
Near the bottom of the outlet plenum, a port, 1, is
installed to direct air under the operators’ seat. The
vents can direct air across the cab floor and towards 1
the windshield.
Climate control systems using the Automatic

Temperature Control Panel have connections, 2 and
3, to provide cool air to the right hand storage
2
container behind the operators’ chair. Articles that
require cooling can be placed in this container. 3
10008340
2
The outlet plenum runs vertically near the right rear
corner of the cab directing the airflow into the 3 FRONT 3
headliner distribution plenum, 1. Main directional
vents, 2, can be adjusted by the operator for 3
maximum comfort. Defrosting vents, 3, are adjusted 3
to clear the inside of the windows of condensation.
2 2
1
50010477
50-2
OVERHAUL
CIRCULATION FAN
1
Removal
Turn out the five cap screws, 1, holding the
ventilation system shield in place. Lift the shield from 1
the combine.
1
10008343
4
Remove the bench top behind the drivers seat at the
hinges. Turn out the eight machine screws, 1, holding 1
the right side storage compartment in place. Lift the
1
compartment and store in a suitable location.
1
10008339
5
Take off under seat ventilation duct at 1. Turn out cap
screws 2 and 3. Detach electrical connector, 4. 4 1
10008340
50-3
Turn out water valve mounting cap screws, 1.
Carefully move the water valve out of the way of the 1
blower housing.
10008341
7
Disconnect ventilation duct, 1. Turn out plenum cap
screw, 2. Detach electrical connector, 3. Remove the 1
four blower motor mounting cap screws, 4. 2 3
4
4
10008346
8
Carefully slide the blower motor assembly from the
ventilation housing.
10008347
50-4
Installation
Install new seals, and slide the blower motor
assembly into the ventilation housing.
10008347
10
Secure the blower using four cap screws, 1. Turn in
plenum cap screw, 2. Attach electrical connector, 3. 4
Install a new seal, and connect ventilation duct at 4. 2 3
1
1
10008346
11
Mount the water control valve using two cap screws,
1. 1
10008341
12
50-5
Turn in cap screws, 1 and 2. Connect ventilation duct
at 3. Attach electrical connector, 4. 4 3
10008340
13
Install new seals, and install the storage compart-
ment. Secure in place with eight machine screws, 1. 1
Secure the bench top behind the drivers seat at the 1
hinges.
1
10008339
14
Set the ventilation system shield into place and
secure using five cap screws, 1. 1
1
10008343
15
50-6
SEPARATOR FAN
1
Removal 3
Disconnect the power wires, 1, from the motor. Cover 3
the exposed electrical connectors with tape to
prevent shorting them out.
Loosen hose clamp, 2. Turn out the three cap

screws, 3, and remove the fan from the combine.
3 2
10008377
16
The separator fan can be removed from the
mounting frame by turning out the three screws, 1. 2
Remove the adaptor ring from the fan by turning out
the four screws, 2.
1
1
2
10008378
17
Inspect the gasket, 1, and hose, 2, for deterioration.
Replace if necessary.
2
10008379
18
50-7
Installation
If it had been removed, install the adaptor ring on the 1
fan using four screws, 1.
NOTE: The correct screws must be used to avoid

damaging the plastic fan housing.
2
2
If it had been removed, secure the fan into position
in the mounting frame using three screws, 2.
1
10008378
19
Set the fan, 1, into position and secure using three
cap screws, 2. Attach the hose to the fan outlet and 4
tighten clamp, 3. 2
2
Attach the power wires, 4. The white wire is to be
connected to the positive terminal, and the black wire
is to be connected to the negative terminal of the
motor. Only the positive terminal is marked.
2 1
3
10008377
20
50-8
Chapter 4 - Compressor
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
50-1
The compressor, mounted inside the engine
compartment, is driven by the crankshaft pulley.
Refrigerant and oil is moved through the air
conditioning system by the compressor, which
lubricates and cools the unit during operation.
An electromagnetic clutch is used to engage or

disengage the compressor as required when
operating the air conditioning system. The clutch is
of a stationary coil type and forms an integral part of
the compressor pulley assembly. When the coil is
energized, the clutch plate is pulled against the
rotating pulley. De-energizing the coil will allow the
plate to return to a standby position.
1
50-2
OVERHAUL
COMPRESSOR
Removal
NOTE: Shielding around engine removed for clarity.
NOTE: The CR920/940 is shown. Compressor

removal on the CR960/970/980 is similar.
Recover refrigerant in accordance with the Refriger-

ant Recovery Procedure in this section.
NOTE: A 1/2I drive cutout square is provided in the

arm of the idler pulley to be used to release tension
on the belt.
Use a 1/2″ drive long handle breaker bar, 1, to
release tension from the serpentine belt. Remove the
belt from the compressor pulley.
10008351
2
Detach the compressor clutch electrical connector,
1. Disconnect the suction and discharge lines, 2. Cap 3 4 4
the line side to prevent moisture or foreign material
from entering the system. Take off the hose clamp
mounting bolt, 3. Remove the compressor mounting
bolts, 4, and lift the compressor from the combine.
2
4 4
10008350
50-3
Installation
4 1 1
Set the compressor on its mount and secure into
place using four cap screws and nuts, 1. Replace the
O rings, and lubricate them with PAG oil. Connect the
refrigerant suction and discharge lines, 2, and tighten
to the correct torque. Attach the clutch electrical
connector, 3. Install the hose clamp mounting bolt, 4. 2
10008350
1 1
4
Insert a 1/2″ long handle breaker bar, 1, into the idler
pulley bracket and rotate it enough to route the
serpentine belt around the compressor pulley.
Recharge the refrigerant system in accordance with

the Recharge/Refilling procedure. 1
10008351
5
CLUTCH
Removal
NOTE: It is highly recommended to remove the
compressor from the system before replacing the
clutch.
Insert the two pins of the front plate spanner into any
two threaded holes of the clutch front plate. Hold the
clutch plate stationary. Remove the hex nut with a 19
mm socket.
20018359
50-4
Remove the clutch plate using a puller. Align the
puller center bolt to the compressor shaft. Thumb
tighten the three puller bolts into the threaded holes.
Turn the center bolt clockwise until the front plate is

loosened.
20018360
7
Remove the shaft key by lightly tapping it loose with
a slot screwdriver and hammer.
20018361
8
Remove the internal bearing snap ring.
20018362
50-5
Remove the front housing external snap ring.
20018363
10
Insert the lips of the jaws into the internal bearing
snap ring groove.
Place the rotor puller shaft protector over the

exposed shaft.
20018364
11
Align the thumb head bolts to the puller jaws and turn
till finger tight.
20018365
12
50-6
Turn the puller center bolt clockwise until the rotor
pulley is free.
20018366
13
Loosen the core lead wire from the clip on top of the
compressor front housing.
20018367
14
Remove the snap ring and the field coil.
20018368
15
50-7
Installation
Install the field coil. The coil flange protrusion must
match the hole in the front housing to prevent coil
movement and the lead wire must be correctly
located.
Replace the rotor pulley.
20018369
16
Support the compressor on the four mounting ears at
the compressor rear side. If using a vise, clamp only
the mounting ears, never the compressor body itself.
Align the rotor assembly squarely on the front

housing hub.
Using a hammer and a special tool, tap until the rotor

bottoms to the compressor front housing hub.
20018370
17
Reinstall the internal bearing snap ring.
Reinstall the front housing external snap ring.
20018371
18
50-8
Check that the original clutch shims are in place on
the compressor shaft.
Replace the compressor shaft key.
Align the front plate key way to the compressor shaft

key.
Using a shaft protector, tap the front plate to the shaft

until it has bottomed to the clutch shims.
20018372
19
Replace the shaft hex nut and torque to 35 - 40 N⋅m
(26 - 30 ft. lbs.).
Check the air gap with a feeler gauge 0.4 to 0.8 mm

(0.016 - 0.032I). If the air gap is not consistent
around the circumference, lightly pry up at the
minimum variations. Lightly tap down at points of
maximum variation.
If the compressor had been removed, install the

compressor in accordance with the Compressor
Installation procedure in this section.
20018373
20
50-9
50-10
Chapter 5 - Condenser
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
50-1
The condenser, 1, is located on the inside of the
screen cleaner swing out door. The condenser
consists of a number of turns of continuous coil
1
mounted in a series of thin cooling fins to provide
maximum heat transfer in a minimum amount of
space.
The condenser receives the hot, high-pressure

refrigerant vapor from the compressor. As the hot
vapor passes through the coils, outside air is drawn
around the coils by the engine fan. Heat is
transferred from the hot refrigerant vapor into the
cooler outside air flowing across the coils and fins. 10008353
The refrigerant condenses inside the unit and
becomes a high pressure liquid. 1
50-2
OVERHAUL
CONDENSER
1
Removal
Open the rotary screen cleaner door, 1, to gain

access to the air conditioning condenser.
10010479
2
Disconnect and cap the refrigerant lines, 1, from the
condenser. The fittings are different sizes, labeling
should not be required.
IMPORTANT: Use a wrench on the condenser tube

nut to prevent twisting the condenser tube. 2
Support the weight of the condenser with blocking or 1

some other method. Detach the condenser from the
inside mount by removing the three cap screws and
nuts, 2.
10010478
3
Detach the condenser from the outside mount by
removing the three cap screws and nuts, 1. Lift the
condenser from the combine.
10008353
50-3
Installation
Open the rotary screen cleaner door, 1, to gain
1
access to the mounting area for the air conditioning
condenser.
10010479
5
Set the condenser into place and support the weight
of the unit with blocking or some other method.
Secure the condenser to the outside mount using
three cap screws and nuts, 1.
10008353
6
Secure the condenser to the inside mount using
three cap screws and nuts, 1. Replace the O rings,
and lubricate them with PAG oil. Attach the hoses to
the condenser, and tighten to the proper torque.
IMPORTANT: Use a wrench on the condenser tube 1

nut to prevent twisting the condenser tube.
2
NOTE: The fittings are different sizes.

the Recharge/Refilling procedure.
10010478
50-4
Chapter 6 - Cool Box
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cool Box Damper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
50-1
Climate control systems using the Automatic
Temperature Control Panel have connections to
provide cool air to the right hand storage container
behind the operators’ chair. Articles that require
cooling can be placed in this Cool Box. When the cab
temperature is low enough to open the hot water
valve, the cool box damper is shut to keep heated air
from circulating through it.
50-2
OVERHAUL
COOL BOX DAMPER ACTUATOR
1
Removal 1
hinges. Turn out the eight machine screws, 1, holding
the right side storage compartment in place. Lift the
compartment and store in a suitable location.
1
10008339
1
Shown is an actuator that has been removed. Note
the location of the three mounting machine screws, 1
1.
1
1
10008380
2
Detach the electrical connector, 1, for the cool box
damper actuator. Turn out the three machine screws, 2
2, holding the actuator to the mount. Slide the
1
actuator off of the damper.
2
NOTE: There is a shaft coupler used between the
actuator and damper. Use caution to prevent loosing
this coupler.
10008340
50-3
Installation
Shown is an actuator that has been removed. Note 1
the location of the three mounting machine screws,
1. 1
1
10008380
4
NOTE: To aid in starting the machine screws,
petroleum jelly can be used. 1
Install the shaft coupler on the actuator shaft, and

slide the actuator onto the damper stem. Turn in the 2
three machine screws, 1, and secure the actuator
into place.
1
CAUTION
The actuator casing is made of plastic, do not
over torque the mounting screws.
10008340
Attach the actuator electrical connector, 2.
5
Install the storage compartment and secure in place
with eight machine screws, 1. Secure the bench top 1
behind the drivers seat at the hinges. 1
1
10008339
50-4
Chapter 7 - Evaporator
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Evaporator Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
50-1
The evaporator is located in the ventilation housing
behind the combine cab. Similar to the condenser,
the evaporator core consists of numerous tubes
mounted in a series of thin aluminum cooling fins.
The fins and tubing are designed to transfer heat
from the cab air to the cold refrigerant liquid as it
moves through the evaporator tubing.
The low-pressure liquid inside the tubes remove heat

from air passing around them. As the refrigerant
absorbs heat, it boils and flashes to a vapor. The
low-pressure vapor then flows to the compressor to
repeat the refrigerant cycle. 10008342
50-2
OVERHAUL
EVAPORATOR CORE
1
Removal
the combine.
1
10008343
2
Remove the recirculation filter by simultaneously
push down while pulling out on the locking tabs, 1. A 1
prying device may have to be used. Pull the grate and 1
filter from the cavity.
10008336
3
Turn out mounting cap screw, 1.
10008338
50-3
the right side storage compartment in place. Lift the 1
compartment away and store in a suitable location.
1
10008339
5
Lift the thermal sensing bulb, 1, from the evaporator
core.
If it is planned to completely remove the evaporator

core from the combine, recover refrigerant in
accordance with the Refrigerant Recovery Proce-
dure in this section.
NOTE: The evaporator core may be slid out of the 1

ventilation housing without disconnecting the
refrigerant hoses.
10008340
6
Disconnect the refrigerant lines, 1, from the
evaporator. Cap the ends to prevent foreign material
and moisture from entering the system.
Turn out the four cap screws, 2, holding the 2

evaporator to the ventilation system housing. 2
1
2
10008341 1 2
7
50-4
Carefully pull the evaporator core from the housing.
10008342
8
Installation
Install a new seal, and slide the evaporator core into
the ventilation housing with the ports of the thermal
expansion valve facing down.
10008342
9
Turn in four cap screws, 1, holding the core to the
housing. Lubricate the O rings with refrigerant oil and
connect the supply and return lines, 2, if they had
been previously removed. Tighten the lines to the
correct torque. 1 1
2
1
10008341 2 1
10
50-5
Carefully insert the thermal sensing probe, 1, into the
evaporator core. Attach the electrical connector if it
had been unplugged.
10008340
11
ment and secure in place with eight machine screws, 1
1. Secure the bench top behind the drivers seat at the 1
hinges.
1
10008339
12
Secure the core into position using cap screw, 1.
10008338
13
50-6
1
Charge the refrigerant system in accordance with the
Recharge/Refilling procedure in this section. If the
evaporator core had been completely removed from
the combine.
10008336
14
1
10008343
15
50-7
50-8
Chapter 8 - Heater Core
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Water Valve Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
50-1
The heater core, 1, is located in the ventilation
housing behind the combine cab. Similar to the
evaporator, the heater core consists of numerous
tubes mounted in a series of thin aluminum cooling
fins. The fins and tubing are designed to transfer heat
from the heated engine coolant to the cab air as it
moves across the tubing.
10010480
1
A water valve,1, is located in the ventilation housing
behind the combine cab. The valve is installed to
control the flow of hot engine coolant through the 1
core. Combines equipped with the Automatic
Temperature Control system operate the water valve
to satisfy the temperature as set by the operator.
Manual Temperature Control systems position the
water valve according to the setting of the
temperature knob.
10008341
50-2
OVERHAUL
HEATER CORE
Removal
It is possible to completely remove the heater core
from the ventilation housing without removing the
coolant and lines. If the heater core is to be removed
from the combine, shut the heater core supply and
return valves located at the engine.
NEW HOLLAND ENGINE (CR920/940)
Return from
cab
Supply to
cab
20018348
3
IVECO ENGINE (CR960/970/980)
Supply to
cab
Return from
cab
20018349
50-3
the combine.
1
10008343
5
Remove the recirculation filter by simultaneously
push down while pulling out on the locking tabs, 1. 1
Pull the grate and filter from the cavity. 1
10008336
6
Turn out mounting cap screw, 1, for the evaporator
core.
10008338
50-4
the right side storage compartment in place. Take out 1
the compartment and store in a suitable location.
1
10008339
8
Lift the thermal sensing bulb, 1, from the evaporator
core.
10008340
9
Turn out the four cap screws, 1, holding the
evaporator to the ventilation housing.
1 1
10008341 1
10
50-5
Carefully pull the evaporator core from the housing
with the refrigerant lines still attached.
10008342
11
Take out mounting cap screw, 1, for the heater core
from the inside of the ventilation housing.
1
10008345
12
NOTE: When removing heater hoses, residual
coolant will drain. 3
If the heater core is to be completely removed from

the combine, remove hoses, 1 and 2, from the heater
core. Turn out mounting cap screws, 3. Pull the core
from the housing. 2 1
3
10008344
13
50-6
Installation
Install new seals, and slide the heater core into place.
Orient the core so that the notched corner is on the
bottom. Turn in cap screws, 1. Attach hoses 2 and 3,
if they were previously removed.
3 2
1
10008344 1
14
Secure the core into place with cap screw, 1.
1
10008345
15
Install new seals, and slide the evaporator core into
the housing with the refrigerant supply and return
lines oriented down.
10008342
16
50-7
Turn in four cap screws, 1.
1
1
10008341 1
17
Secure the core into place with cap screw, 1.
10008338
18
Carefully insert the thermal sensing probe, 1, into the
evaporator core. Attach the electrical connector if it
had been unplugged.
10008340
19
50-8
1
10008336
20
ment and secure in place with eight machine screws, 1
1. Secure the bench top behind the drivers seat at the 1
hinges.
1
10008339
21
1
10008343
22
50-9
Open the water supply and return valves. Refill the
coolant reservoir as required.
NEW HOLLAND ENGINE
Return from
cab
Supply to
cab
20018348
23
IVECO ENGINE
Supply to
cab
Return from
cab
20018349
24
50-10
WATER VALVE
Removal
Shut the heater core supply and return valves
located at the engine.
NEW HOLLAND ENGINE
Return from
cab
Supply to
cab
20018348
25
IVECO ENGINE
Supply to
cab
Return from
cab
20018349
26
50-11
the combine.
1
10008343
27
NOTE: When removing heater hoses, residual
coolant will drain.
1
Detach electrical connector, 1. Disconnect hoses 2
and 3. Turn out mounting cap screws, 4. Lift the water
valve from the unit. 3
2
4
10008341
28
Installation
Mount the water valve to the housing using two cap 2
screws, 1. Attach electrical connector, 2. Connect
heater hoses 3 and 4.
4
3
1
10008341
29
50-12
1
10008343
30
50-13
Open the water supply and return valves. Refill the
coolant reservoir as required.
NEW HOLLAND ENGINE
Return from
cab
Supply to
cab
20018348
31
IVECO ENGINE
Supply to
cab
Return from
cab
20018349
32
50-14
WATER VALVE ACTUATOR

Removal
NOTE: The actuator can be removed without
removing the water valve.
the combine.
1
10008343
33
Detach the electrical connector at 1. Turn out the
three screws, 2, holding the actuator to the valve. Lift 2 1
the actuator from the valve. 2
Check the condition of the shaft coupler between the
actuator and water valve. Replace if cracked or worn.
10010481
34
Installation
1 2
Install the shaft coupler on the actuator shaft, and
slide the water valve actuator onto the water valve 1
stem. Turn in the three screws, 1. Attach the
electrical connector at 2.
10010481
35
50-15
1
10008343
36
50-16
Chapter 9 - High/Low Pressure Cutout Switch
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
50-1
The high pressure cutout switch, 1, monitors the
operating pressure on the high pressure side of the
2
A/C system. The function of this switch is to prevent
the compressor from operating when the pressure on
the high side exceeds the preset operating limits.
When actuated at 28.96 - 26.20 bars (420 - 380 psi)
increasing, the electrical contacts in the switch open
and secure power to the compressor clutch. The
pressure switch will reset at 20.69 - 17.93 bars (300
- 260 psi) decreasing. The set point is not adjustable.
The low pressure cutout switch, 2, monitors the

operating pressure on the low pressure side of the 10008350
1
A/C system. The function of this switch is to prevent
the compressor from operating when pressure on the 1
low side is less than the preset operating limits. When
actuated at .070 - .482 bars (1 - 7 psi) decreasing, the
electrical contacts in the switch open and stop power
to the compressor clutch. The pressure switch will
reset at 2.134 - 2.686 bars (31 - 39 psi) increasing.
The set point is not adjustable.
50-2
OVERHAUL
HIGH PRESSURE SWITCH
Removal 1
Remove the high pressure switch, 1, from the

system.
Installation
Install the high pressure switch, 1, into the system.
Recharge the refrigerant system in accordance with 10008350

the Recharge/Refilling procedure in this section.
2
LOW PRESSURE SWITCH
Removal
Remove the low pressure switch, 1, from the system.
Installation
Install the low pressure switch, 1, into the system.

the Recharge/Refilling procedure in this section. 10008350
1
50-3
50-4
Chapter 10 - Receiver/Dryer
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Receiver / Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
50-1
The receiver/dryer, located on the right side of the
engine compartment (units below SN HAJ100073) or
on the right side of the cab platform (units above SN
HAJ100073) is a storage tank that receives the
high-pressure liquid refrigerant from the condenser
through an inlet line.
40021747
1
On units below SN HAJ100073, a sight glass, 1, is
installed so that the general condition of the 1 2
refrigerant charge can be determined. The decision
to add refrigerant should not be based on the
indication of the sight glass alone. Perform the
appropriate steps of the Testing and Troubleshooting
section in Chapter 1.
On units below SN HAJ100073, a moisture indicator,

2, is also provided on the dryer. A blue color indicates
that the dryer is in satisfactory condition. When the
dryer is saturated with moisture, the indicator will be
pink. The dryer section contains a desiccant to 10008354
absorb moisture but can only absorb a limited
amount of moisture before reaching a saturation 2
point. The ability to retain moisture absorbed is
dependent upon temperature. As the outside
temperature increases, the ability to retain absorbed
moisture decreases. This is why an air conditioning
system with a saturated dryer may operate
satisfactorily when outside temperatures are low, but
stop cooling when the temperature increases.
The refrigerant exits the receiver/dryer through an

outlet connection and flows to the thermostatic
expansion valve.
NOTE: Any moisture in the air conditioning system is

extremely harmful. Moisture not absorbed by the
dryer will circulate with the refrigerant. Droplets may
collect and freeze in the thermostatic expansion
valve restricting refrigerant flow. The moisture
circulating in the system may also react with the
refrigerant to form hydrochloric acid.
NOTE: In general, the receiver/dryer should be

replaced any time the system is opened for service.
50-2
OVERHAUL
RECEIVER/DRYER
1 2
Troubleshooting
(units below SN HAJ100073 only)
10008354
IF THEN
The sight glass, 1, show’s refrigerant without bubbles The refrigerant is OK
The sight glass shows milky refrigerant OK in ambient temperature
The glass shows air bubbles Lack of refrigerant
The moisture indicator, 2, is blue Filter and refrigerant are OK
The moisture indicator is pink Too much moisture: Receiver/Dryer

has to be replaced
The moisture indicator is brown or black Too much contamination: Receiver/Dryer

has to be replaced
Removal
1
Recover the refrigerant in accordance with the 1
Refrigerant Recovery Procedure in this section.
Disconnect and cap the refrigerant lines, 1, from the

receiver/dryer. Loosen the clamp, 2, holding the unit
in place. Remove the unit from the combine.
2
40021747
50-3
Installation
2
Set the receiver/dryer in place and secure by 2
tightening clamp, 1. Inspect the O rings and replace
if necessary. Lubricate the O rings with PAG oil, and
uncap and connect refrigerant lines, 2. Tighten the
lines to the correct torque.

the Recharge/Refilling procedure. 1
40021747
50-4
Chapter 11 - Thermal Expansion Valve
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Thermal Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
50-1
The thermal expansion valve, 1, is on the pressure
line leading from the drier/receiver into the
evaporator. The valve changes the liquid refrigerant
from high to low pressure without a change from
liquid to vapor.
A thermostatically controlled valve within the

expansion valve body controls the volume of liquid 1
refrigerant passing through the orifice and makes
sure the refrigerant is fully vaporized within the
evaporator by sensing the amount of superheat of
the vapor leaving the evaporator. Liquid refrigerant
would damage the compressor. 10008352
The valve responds to changes in the cooling 1

requirements of the system. When increased cooling
is required, the valve opens to increase the
refrigerant flow. When less cooling is required, the
valve closes and decreases the refrigerant flow.
TEMPERATURE
SENSOR
FROM TO
EVAPORATOR COMPRESSOR
TO
EVAPORATOR
FROM
CONDENSER
BALL AND SPRING
2
All of the needed temperature and pressure sensing
functions are consolidated into this unit. No other
external tubes are required for its operation.
50-2
When the compressor is off, pressure, (system plus
spring pressure), below the actuating diaphragm, 1,
is greater than the pressure above it. The metering
ball, 2, is held tightly against the seat by the spring,
and no flow is present through the valve.
1
2
70-610-1172
3
Upon initial startup of the compressor, the pressure
drops rapidly in area 1. The pressure above the
diaphragm is now greater than that below. The
actuating rod pushes down, unseating the ball and
allowing refrigerant to flow to the evaporator. 1
During operation, the pressure below the diaphragm
will change and adjust valve position to maintain
eight degrees superheat of the refrigerant flowing
from the evaporator.
70-610-1173
50-3
OVERHAUL
THERMAL EXPANSION VALVE
1
Removal
the combine.

ant Recovery Procedure in this section. 1
1
10008343
5
Fold back the insulation from the thermal expansion
valve. Disconnect refrigerant lines, 1, and cap them 1
to prevent moisture or foreign material from entering
the system. Turn out cap screws, 2, and remove the
valve from the core.
1
10008352
50-4
Installation
Set the thermal expansion valve into position and 2
secure it with two cap screws, 1. Apply refrigerant oil
to the O rings and connect the four refrigerant lines,
2.
Wrap the valve and attached lines with insulation.

1
the Recharge/Refilling procedure in this section.
2
10008352
7
1
10008343
50-5
50-6
SECTION 55 -- ELECTRICAL SYSTEMS -- CHAPTER 1
CONTENTS

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction to Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault Codes and Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
The Digital Multi-Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Measuring Voltage (Volts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Measuring Current (Amps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Measuring Resistance (Ohms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Continuity (Buzzer) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical Test Procedure 1: Continuity Test - Short to Ground . . . . . . . . . . . . . . . . . . . 12
Electrical Test Procedure 2: Voltage Measurement or
Short to Positive Supply Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Test Procedure 3: Resistance Test for Electrical Parts . . . . . . . . . . . . . . . . . 13
Electrical Test Procedure 4: Continuity Test - Check for
Open Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Circuit Components - Basic Description and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Flashers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Resistance Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fluid Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Potentiometer Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electromagnetic Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PWM Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
55-1

Speed and Position Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electronic Modules (CCM’s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CCM Power and Ground Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CCM1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CCM2 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CCM3 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Combine Control Module (CCM) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 28
CCM Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Instructional Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal of CCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CCM Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Instructional Seat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Wiring Harness Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Temporary Wiring Harness Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Harness Wire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Cab Electrical Connectors X002 and X003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Removal of Rear Speaker Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation of Rear Speaker Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
55-2
OVERVIEW
BSC1362
1
The CR combines use the latest technology in All of the modules communicate information from the
electronics to provide excellent reliability and combine sensors, switches and operator controls to
serviceability, and to provide enhanced functionality. each other and to the Infoview display, and then drive
The system consists of several electronic modules, the appropriate outputs, such as solenoids and
along with conventional copper wiring to all devices actuators. The operator instructs the electronic
and sensors. The electronic modules are connected modules what to do, the modules interpret the
together using a special twisted copper wire pair, that commands, and direct the combine sub systems to
allows the modules to communicate with each other complete the functions as required. In addition, the
using Controller Area Network (CAN) technology. modules check for faults and display or store this
This technology allows the modules to perform many information as required for reference in servicing.
functions through the use of shared input and output The modules also provide built-in diagnostics,
resources, thus minimizing sensors and wiring allowing the technician to monitor activity, or test
components on the combine. devices directly through the modules.
55-3
10
4
5
4
7
6
50020058
2
The CR combine is equipped with a minimum of 7 combine and height sensors on the header, and
electronic modules, and may be equipped with as controls the accumulator, header raise/lower and
many as 11 modules, depending on the configuration header tilt solenoids.
and options installed. These modules are:
Advanced stone protection (ASP) module, 6, is
Main Display Module (MDM), 1, or InfoviewTM located on the left side of the feeder. It processes
monitor; provides the main display of information for signals from the ASP sensors, and opens the stone
the operator. door when necessary.
Shaft Speed Monitor (SSM), 2, provides the display Chassis Control Module 3 (CCM3), 7, [optional] is
for shaft speed alarms, and for fuel level and coolant installed and used to control certain options on the
temp gauges. combine, such as the precision farming devices.
Right Hand Module (RHM), 3; most operator inputs, Data Logger Unit (DLU), 8, [optional] is available with
including from the multi-function handle (MFH), are fed some precision farming systems, and records data
into this module, which then reports this information to provided by the precision farming sensors.
the other modules in the network for action.
Differential GPS module, 9, [optional] is available
Chassis Control Module 1 (CCM1) and 2 (CCM2), 4; with some precision farming systems, and provides
these modules drive most of the actuators and location data to be recorded with the harvest data for
solenoids, and monitor most of the sensors and mapping purposes.
switches on the combine.
Engine Control Unit (ECU), 10, [optional] is installed
Header Height Control (HHC), 5, module is located on certain engine models to provide enhanced
on the main stack valve assembly. It receives inputs engine control and performance.
from the feeder angle and lift pressure sensors on the
55-4
A Diagnostic and Maintenance (DAM) connector, 1,
allows the NH Special Service Tool to be connected
to the network, in order to load new operating
software into the modules, and to provide more
detailed testing and diagnostic abilities.
55-5
INTRODUCTION TO TROUBLESHOOTING
FAULT CODES AND FAULT FINDING
Troubleshooting and fault finding of the electrical
system should always be carried out in a logical and
planned sequence. Many apparent faults associated
with electronic components are often hastily
diagnosed and result in the replacement of
expensive components. An extra few minutes
confirming the apparent fault will result in a more
positive and cost effective repair.
The CR combines have a built in diagnostic
capabilities to assist the operator and service
technician to identify and locate the source of
electrical system concerns. The Infoviewt monitor
is used to indicate, in coded format, any malfunction
detected in the electrical and electronic systems.
Two different coded formats are used to indicate
concerns; alarms and errors.
An alarm is an indication of some mechanical
condition on the vehicle, and alerts the operator to
perform necessary maintenance, or to change
operating conditions to correct the alarm condition.
Examples of alarms would be to indicate an engine
overheat condition, blocked filters, or improper
control operation. Alarms are not used to indicate
faults with electrical circuits.
20062986
4
An error is an indication of a fault with an electrical
circuit or component, and alerts the operator that the
circuit or component is no longer functioning.
Examples of error messages include open circuits,
shorts to ground, or short to high voltage. These
errors are typically the result of wire harness
damage, or sensor misadjustment or failure.
When investigating an electrical concern, the first
step is to fully understand the problem. Get a clear
description of the concern from the operator, and if
possible, operate the vehicle to confirm the problem.
20013664
55-6
Once the problem is clearly identified, use the
“Service Info” screens of the Infoviewt monitor to
determine if any alarm or error messages exist that
relate to the problem. If related error messages are
found, diagnostic screens howing voltage, current or
frequencies for that specific circuit are available to
assist in pinpointing the source of the problem. In
most cases, circuit testing may be accomplished
using only the on-board diagnostic capabilities.
Diagnostic procedures for each error code are
detailed in this manual.
Where the fault finding procedure requires checks for
continuity, a visual inspection of the wiring should be 20013665
made prior to conducting any test to ensure that
obvious ‘mechanical’ damage has not occurred to 6
the harness or connectors.
In some cases, use of a multimeter will be necessary
to locate the source of the fault. A good quality
multimeter, capable of measuring voltage, current,
and resistance of at least 20,000 ohms, is an
essential item to perform fault finding.
IMPORTANT: Use of powered test lights or any 12
volt source to test or activate electrical circuits may
result in internal failure of the computer modules.
Never apply a 12 volt source directly to a solenoid or
other device to prevent damage to the combine
electrical system.
When using a multimeter, it is good practice to select
a high range and work downwards to avoid
damaging the instrument. Refer to the Operator’s
manual supplied with the meter, and to the ‘Basic
Multimeter Use” section of this chapter for further
details.
IMPORTANT: Care should be taken when using the
multimeter. Use the instrument only as instructed to
avoid damage to the internal elements of the
microprocessors on the combine. When checking
the continuity of wiring, sensors or switches, it is
necessary to isolate the combine modules and
ensure the key switch is turned off to prevent possible
further damage. The key switch should only be
switched on and the combine modules connected
where specifically instructed in the fault finding
procedure.
55-7
During fault finding, it will often be necessary to
uncouple connectors for inspection, or to provide
access for testing. When using the combine
on-board diagnostics, uncoupling connectors as
directed in the fault finding procedures will often be
necessary to locate the source of the fault. Unless
specifically noted, connectors should not be
back-probed using test spoons or other tools, to
prevent damage to the connector and wire seals.
50032238
CAUTION
Never couple or uncouple electrical connectors
while the engine is running, to prevent machine
damage and personal injury due to electrical
shock.
WARNING
To avoid personal injury, never attempt to access
electrical connectors under the cab while the
engine is running. Accidental contact with the
feeder angle sensor or inappropriate access to
the electrical circuits to the modules may cause
the feeder to move unexpectedly, resulting in
personal injury or death.
IMPORTANT: The under-cab connectors to the

chassis control modules (CCM’s) do not normally
need to be accessed for diagnostic purposes.
Repeated coupling and uncoupling of these
connectors will result in seal and connector damage,
causing electrical circuit failures.
If it is found necessary to clean the connectors a

contact spray should be used. DO NOT USE ANY
OTHER METHOD FOR CLEANING TERMINALS.
Do not use a cleaner that contains Trichloro-ethyl-
ene, this solvent will damage the plastic body of the
connector.
55-8
THE DIGITAL MULTI-METER

NOTE: This section is only intended as a general
guide to using a digital multimeter.
Always refer to the manufacturer’s operators manual
for correct operation.
A multimeter is an electronic measuring device. The

different types of measurement that can be made
depend upon the make and model of the multimeter.
Most types of multimeter have the capacity to
measure:
• Current (A) ac or dc
• Resistance (Ω)
• Voltage (V) ac or dc
• Continuity (Buzz test)
More expensive multimeters have other functions,

such as the capacity to measure frequency (Hz) and
test diodes.
8
General Operation
Before proceeding with a test, decide on what is
going to be measured (Voltage, Current etc.). Rotate
the dial until the pointer is within the relevant zone.
Within each zone there are different scales. The
scale that is selected will represent the maximum
value that the multimeter will read. Always select a
scale which is greater than the value that you intend
to measure. If you are unsure of the value to be
measured, always select the highest scale and then
reduce the scale once you have an idea of the
measured value.
9
The closer that the scale is to the measured value,
the more accurate the reading will be: e.g., if
measuring the voltage of a battery with the scale set
at 200V, the display may read 12V. However, if the
scale was set to 20V the display may read a more
accurate reading of 12.27V.
10
55-9
Measuring Voltage (Volts)
Set the range dial to either ac or dc volts. Connect the
Black test probe to the “COM” terminal and the Red
test probe to the “V/Ω” terminal. Place the test probes
across the component to be measured with the
circuit complete (closed). Read off the display value
11
Measuring Current (Amps)
Set the range dial to either ac or dc current. When
measuring current up to 2 amps, connect the Red
test probe to the “A” terminal. When measuring
current up to 10 amps, connect the Red test probe to
the 10 “A” terminal. Always connect the Black test
probe to the “COM” terminal. When taking
measurement of current, always break the circuit and
connect the multi meter in series with the circuit.
Read off the display value.
NOTE: For protection, multi meters are usually fused

at 10A.
12
Measuring Resistance (Ohms)
Set the range dial to the desired Q position. Connect
the Red test probe to the “V/Ω” terminal. Connect the
Black test probe to the “COM” terminal. If the
resistance being measured is connected in a circuit,
then turn off the power to the circuit. Connect the test
probes to the measuring point and read off the
display value.
13
55-10
Continuity (Buzzer) Test
Set the range dial to the “Buzz” position. Connect the
Red test probe to the “V/Ω” terminal. Connect the
Black test probe to the “COM” terminal. Connect the
test probes to the measuring point. In general, if the
resistance is less than 50Ω then the buzzer will
sound, indicating continuity.
14
NOTE: Buzzers on different multi meters will sound
at different ohmic values, depending on the quality of
the meter. This can often be misleading. For
example, when checking a corroded earth point, a
poor quality multi meter may buzz at 150Ω, indicating
continuity and no problem. When using a higher
quality multi meter for the same test, it would not buzz
due to the high resistance. When carrying out such
tests, we should always check the value of resistance
as well as listening out for the buzz.
A good connection gives low resistance.
A bad connection gives high resistance.

15
Summary
When measuring:
Voltage (V)
Connect across the component with the circuit
closed.
Current (A)
Connect in series with the circuit. Circuit closed.
Resistance (Ω)
Connect across the component with the circuit open.
Continuity (Buzz)
Connect the meter across the component with the
circuit open. (Always check the value of resistance as
well!!).
55-11
ELECTRICAL TEST PROCEDURES

Four electrical tests will be required to properly
troubleshoot electrical concerns on the combine.
Each test is described in detail. Ensure that all steps

are reviewed and followed when testing.
1. Continuity Test, Short to ground

2. Voltage measurement, short to 12 volts
3. Resistance test for components
4. Continuity test, Open circuits
ELECTRICAL TEST PROCEDURE 1:

CONTINUITY TEST - SHORT TO GROUND
1. Power OFF, Keyswitch OFF, (sometimes battery
disconnected or fuse pulled out if specified in
procedure).
2. Connectors at each end or ends of circuit
disconnected to prevent false readings.
3. Set meter to measure resistance or ohms, and
measure circuit resistance. Use black lead to
make contact with a plated metal part on the
chassis such as a jump start post if fitted. Make
sure the surface of the part is not corroded. Use
the red meter lead to touch the connector pins,
one pin at a time, and avoid contact with the case
of metal connectors. 16
4. Determine if measured resistance falls within
guidelines specified in the procedure. 3 to 4
ohms indicates a direct short to chassis ground
and must be located and repaired. Higher
resistances usually indicate circuit paths through
modules, and that an additional connector needs
to be disconnected to perform the test. More than
100K ohms indicates that the circuit is free of
shorts to ground.
55-12

VOLTAGE MEASUREMENT OR SHORT TO
POSITIVE SUPPLY VOLTS
1. Keyswitch ON (sometimes OFF, if specified in
procedure).
2. Connectors at sensor, switch or potentiometer
end disconnected. All other connectors must be
reconnected to perform test.
3. Set meter to measure DC VOLTS, and measure
circuit voltage as illustrated. Use the red meter
lead to touch the connector pins, one pin at a
time, and avoid contact with the case of metal
connectors. Use the black lead to make contact
with a plated metal part on the chassis such as
a jump start post if fitted. Make sure the surface
of the part is not corroded.
4. Determine if measured voltage falls within
guidelines specified in the procedure.
17
RESISTANCE TEST FOR ELECTRICAL
PARTS
1. Disconnect part by unplugging electrical
connectors to expose the part assembly
connector for testing.
2. Set electrical meter to measure resistance or
Ohms and insert test probes into connector
terminals specified in procedure. When checking
potentiometers, measure from wiper terminal to
each of the other terminals while TURNING THE
POT SHAFT. This will ensure no open spots
escape detection. When checking rocker or
rotary switches, actuate the switch while
measuring for opens and shorts.
3. Compare measured values to values specified in
the fault code procedures. Allow plus or minus 5
percent of range tolerance for all measurements.
18
55-13

CONTINUITY TEST - CHECK FOR OPEN
CIRCUITS
1. Keyswitch OFF (sometimes disconnect battery
or pull fuses).
2. Connectors at both ends of the circuit
disconnected. All other connectors must be
reconnected to perform test.
3. Set meter to measure resistance or ohms, and
measure circuit resistance as illustrated.
Use the red meter lead to touch the connector
pins, one pin at a time, and avoid contact with the
case of metal connectors.
Use the black lead to make contact with the
connector pin at the other end of the circuit. Avoid
contact with other pins in the connector and the
connector case, if it is metal.
4. Determine if measured resistance falls within
guidelines specified in the procedure. If the
resistance is no more than 3 to 4 ohms, the circuit
is continuous. More resistance usually indicates
dirty or corroded terminals in connectors, and
100K ohms or greater indicates an open circuit.
19
55-14
CIRCUIT COMPONENTS - BASIC DESCRIPTION AND TESTING

FUSES
Fuses protect circuits with thin pieces of metal and
wire which heat up and melt to open up the circuit
when too much current flows through them. The
combine fuse panel, 1, is located in the left rear
corner of the cab, behind a removable panel.
Fuses are used to protect the circuit from overload.

This can occur in the event of a short circuit or by
connecting equipment which demands a current
greater than the circuit is designed to carry.
There are several types of fuses, but they all consist

of a metal conductor which is capable of carrying a
limited current. If the specified current is exceeded
then the metal conductor will overheat, causing it to
melt and break. This will in turn cause an open circuit.
1
50020070
20
The rating of the fuse relates to the current that the

fuse can carry continuously.
If a fuse blows, it must be replaced with a fuse of the

correct rating, and if it blows again, then the cause
must be investigated.
A fuse may be tested by checking continuity across

the fuse on the two exposed terminals, 1.
1
50014700
21
55-15
SWITCHES
Switches are a vital part of an electric circuit,
providing a method of controlling the circuit itself.
One switch can control a number of different circuits
at the same time. This is achieved by having several
separate connections and/or multi-connector
switches (several switch positions’).
There are several types of switches, and they may

incorporate a warning light.
22
Switches can be as simple as that used to turn on an

implement lamp or as complex as the ones used to
operate the starting and lighting systems. Checking
the operation of switches is usually just a matter of
testing for power going into the switch and for power
leaving the switch at the appropriate contacts when
the switch is operated.
One of the most common type of switches is the

pressure switch, a switch opened or closed by a fluid
pressure. An example of this type of switch is the
charge pressure switch, a simple on/off device that
opens (or closes) when oil pressure rises or lowers
past a preset value.
23
FLASHERS
Flashers work automatically to interrupt and connect
the flow of current.
In the flasher, a heating element warms a bimetallic

strip. The strip bends, breaking contact with the
power source. When it cools, the bimetallic strip once
again makes contact and the process begins again.
24
55-16
RESISTANCE DEVICES
A number of electrical components alter or make use
of electricity through their resistance to current flow.
Resistors are components which are generally used
to regulate the supply of voltage and current to other
electrical components.
In some cases, the purpose of resistance in an

electrical circuit is to provide light or heat. Lamps and
cigar lighters are examples. Lamps convert
electricity into light, and cigar lighters convert it into
heat. Both lamps and lighters make use of the same
physical principle, that is Ohms Law.
The engine grid heater and heated cab mirrors are 25

other examples of resistance devices designed to
convert electricity into heat.
FLUID LEVEL SENDER

It operates by varying resistance through the
movement of a float. An example is the fuel level
sender.
26
POTENTIOMETERS
Potentiometers are variable resistors which are
dependant on mechanical movement, i.e. Lateral
float movement, to vary the resistance of the
component and therefore alter the output voltage.
In order to verify the correct operation of a

potentiometer, the resistance should be measured at
the minimum and maximum positions and a smooth
and continuous change of resistance should be
observed between. As the resistance varies with
temperature, the test specifications are usually given
at 20 °C.
27
55-17
POTENTIOMETER ADJUSTMENT
When installing potentiometers, it is important to
ensure that they do not bottom out in either direction,
to prevent damage. Most potentiometers have 1
slotted mounting holes to allow some adjustment.
Before tightening the mounting hardware, operate
the attaching linkage fully in both directions to
confirm proper potentiometer positioning.
The feeder angle sensor, 1, and optional header
stubble height potentiometers (not shown) require
further adjustment to provide proper HHC operation
as follows:
40025215
a. Enter the Infoviewt monitor Diagnostic
screen for the potentiometer. 28
b. Adjust the potentiometer so that the
indicated voltage on the screen stays within
a range of 2.5V to 7.5V throughout the
normal operating motion of the potentiome-
ter. In practice, this is most easily accom-
plished by raising the feeder fully, and adjust
the potentiometers so that the diagnostic
screen indicates less than 7.5V.
55-18
ELECTROMAGNETIC DEVICES
In general, they use the magnetic field created by
flowing current to move metal parts within the
components.
RELAYS
The relay is an electromagnetic switch that uses a
small amount of current to switch a larger amount on
and off.
When the operator closes a switch, current flows

through the relay’s control circuit. In this circuit there
are windings surrounding an iron core which is fixed
in place.
29
Current turns the iron core into an electromagnet.
The core then attracts an arm which has a contact
point on it. When the point on the arm contacts the
stationary point, current flows through the power
circuit.
Relays are basically electrically operated switches.

They are used to switch a circuit on/off in similar way
to a manual switch.
Two circuits are connected to the relay:

• A work circuit, which is switched on/off by the
relay, and provides the supply for the equipment
to be operated, i.e., bulbs, solenoids, etc.
• A control circuit, switched on/off by manual

switches, used to operate the relay.
The part of the relay which is connected to the control

circuit consists of the winding of an electro-magnet.
When the control circuit is switched off, the contacts
are kept apart by a return spring. When the control
circuit is switched on, a current flows through the coil
and a magnetic force is produced. This force, which
is stronger than the spring pressure, pulls the
contacts of the relay together, causing the work
circuit to operate.
55-19
A switch-relay system has two main advantages over
a simple switch:
• The current that flows through the switch is not

the same as all the current requested by the
equipment to be operated, but usually by a
smaller current: this allows the usage of smaller
and less expensive switches.
• The distance from the supply, to the equipment,

can be made as short as possible to minimize
voltage drop.
30
There are five styles of relays used on the CR
combine. The micro relay, 1, is the most commonly 3 4
used relay, and is used on all but two locations on the
fuse panel in the cab. One mini relay, 2, is used in the
top left position of the fuse panel in the cab, while a
time delay relay, 3, is used in the top right position of
the fuse panel for controlling the cab interior light and 2
side lights. The fourth style of relay is the start relay,
4, which is located in the engine compartment. The
fifth style of relay is the grid heater relay (not shown) 1
located on the engine.
On the relay cover there are 4 or 5 terminal markings: 50004701

• 3 or 30: input terminal direct from battery positive,
normally live. 31
• 2 or 85: winding output terminal, usually to
ground.
• 1 or 86: winding input terminal.
• 4 or 87: output terminal for normally closed
contact.
• 5 or 87a: output terminal for normally open
contact.
SOLENOIDS
Solenoids work in much the same way as relays,
except that the iron core is not fixed in place. As a
result, the windings in the control circuit cause the
iron core to move.
In the starting system, for example, the movement of

this core is used to send large amounts of current to
the starter motor.
A solenoid is basically a winding around an iron core.

In the centre of the core there is a plunger which is
free to move through the core. When an electrical
current passes through the winding an electro-mag-
netic force is produced which causes the plunger to 32
move through the core. If the current is switched off,
the magnetic force is stopped and the plunger is
returned by a spring.
55-20
The solenoid plunger may have different uses: the
most common are moving a hydraulic spool or a
mechanical lever.
The MOST COMMON FAULTS that can occur are:

• Short circuit winding: if a section of the winding
allows the current to pass directly from positive
(+) to negative (--) terminals without passing
through the winding, this will cause the relevant
circuit fuse to blow.
• Broken winding: causing an open circuit, it will
not allow the current to pass through the winding,
so the solenoid will not operate.
• Seized plunger (and/or connected components):
the solenoid will only move the plunger if all
components are free to move.
PWM SOLENOID VALVES

Whenever it is necessary to provide proportional
control to the solenoid valves, it is much better to use
a principle of operation called pulse width modulation
(PWM). PWM is a variable DC voltage signal that is
used to control the solenoid valves. The voltage
signal is pulsed on and off many times a second (at
a constant frequency of 500 Hz) at a constant supply
voltage of 12 V.
33
55-21
The CCM modules contain transistors that are
supplied with a constant input voltage which is
switched on and off to achieve the variable input
range. In this way the control module is able to limit
the armature movement, so the hydraulic output flow
of the solenoid is proportional to the average DC
voltage. The lower voltage also allows the solenoid
to operate with less residual magnetism and so the
entire circuit will operate smoother.
The variable DC voltage signal level is determined by

varying the duration of the ON pulse relative to the
OFF pulse. The ratio between the ON time and the
cycle time is called duty cycle and is stated as a
percentage of one complete cycle.
Diagrams, 1 to 3, show the normal operating range

of the PWM valve, and diagram 4, shows the initial
12V programming and fill time only. The diagrams in
column A show the voltage signal that is sent to the
valve, whereas column B shows the relevant spring
pressure and column C the reading on a voltmeter
connected to the solenoid valve.
Diagram, 1, shows the OFF position: no signal is

directed to the valve, which means no spring
pressure in the valve at all and results in a zero
voltage reading. Increasing the duty cycle causes
some pressure to be made on the circuit (Diagram 2),
which results in a voltmeter reading increase.
Diagram, 3, shows the maximum signal that is used 34
during the normal activity of the valve: its duty cycle
is around 0.5, which results in a spring pressure for
the half of its run and in an indication of a 6 volt
average DC current.
The electrical circuit to the solenoids can be checked

by using a digital or analogue DC voltmeter, which
will indicate the average voltage readings.
55-22
SENSORS
A sensor is the primary component of a measure-
ment chain that converts the input variable
(temperature, capacitance, reluctance) into a signal
suitable for measurement. The relationship between
the input variable and the measured signal is a
characteristic of the sensor.
In the above mentioned measurement chain the

signal is filtered and treated in order to adapt it to its
use. It consists of three elements: the sensor itself;
the converter, which converts the output signal from
the sensor (in most of the cases into an electric
signal); and the conditioner, which transforms the
output signal from the converter in the most suitable
form. Generally the term sensor indicates the entire
measurement chain.
TEMPERATURE SENSORS
Generally based on a simple circuit with a thermistor.
A thermistor is a resistor that changes its resistance
according to the temperature.
There are two groups of thermistors: NTC (Negative

Temperature Coefficient) and PTC (Positive Temper-
ature Coefficient). In the first case the higher the
temperature, the lower is the resistance, and for the
PTC the higher the temperature, the higher the
resistance. The NTC are often used as sensors to
indicate temperature change in fluids, such as the
engine coolant fluid.
An example of these type of senders is the coolant 35

temperature sender. The changes in its resistance
(which varies with temperature) are relayed to the
Infoviewt monitor, which operates the bargraph and
the warning indicators accordingly.
PRESSURE SENDER
A pressure sender receives a supply signal and it
varies it according to the (oil) pressure. An example
is the oil pressure sender, which receives a 5 volt
signal and varies it according to the oil pressure. The
appropriate module keeps track of these variations
and changes its readouts and warnings accordingly.
36
55-23
SPEED AND POSITION SENSORS

The speed and position sensors used on the CR
combine are a 2-wire sensing device designed to
work with a switching amplifier circuit in the module
the sensor is attached to. The operation of this
sensor is similar to that of a variable resistor, which
changes its impedance as metal approaches the
sensor. When no metal is being sensed, the sensor
is in a low impedance state. When metal approaches
the sensor, the impedance increases. The varying
impedance results in a current flow change that the
module detects, and converts into a frequency for
speed sensing or position monitoring. 40011026
37
Sensor Adjustment
When installing a new sensor, adjust the sensor to
obtain a clearance of 3 mm (1/8″) to the target metal.
55-24
ELECTRONIC MODULES (CCM’S)

OVERVIEW
The electronic modules are the “black boxes” that
provide control on many of the functions of the
combine. These functions may vary according to the
options that are fitted on the combine.
Inside these “black boxes” there is a processor, the

“thinking part” of the module, and inside some of
them there is one or more memories, which may
allow the module to store calibration values, the
configuration of the vehicle (which optional tools or
devices have been installed) and the error codes.
38
A processor has a series of pins, which are electrical
contacts. There are three main types of pins: for the
inputs of the signals, for the outputs and for the
processor supply.
The processor, the memories and the link between

them form the hardware of the module, its “physical”
part.
Then some software is needed, to handle the

communication between the processor and the
memories and to manage the various signals going
into and out of the processor. The software is
designed to operate in a different way for every
module, and is called functional code. 39
The electronic modules are often blamed as

responsible for most of the problems of the modern
vehicles, while they are for certain among the most
protected parts of the vehicle. In fact, the pins of the
module are protected against spikes (high pulses) of
current, and the signals are filtered by the hardware
and by the software in input and in output to give the
best handling of information.
55-25
CCM POWER AND GROUND SUPPLIES one or two of these ground wires are broken, but
Each CCM module has two main power supplies. sensor reading and other functions may become
Keep Alive power is supplied to the module at interior erratic.
connector pin 1, while the main power supply is Some circuits on the CCM’s provide their own power
provided from the key switch at the interior connector supply through the engaging switch. This ensures
pin 4. The module will shutdown if the voltage drops that if power is ever lost through the switch into the
below 9V or exceeds 18V on either of these two module, the output from the module is immediately
circuits. Key switch power is also used to supply the disengaged. These circuits are the ground speed
5V and 8V regulators for voltage outputs to sensors hydrostat circuit (power supplied through the S22
and potentiometers. Neutral switch), thresher engage and feeder engage
Each CCM module has three main ground wires to circuits.
provide a ground path for all sensors and most valve H-bridge circuits in the modules are used to power
outputs. These three ground wires are linked high current draw components, such as motors and
together internally, but provide a solid ground path for actuators, and have their own dedicated power
the module. The module may continue to function if supplies and grounds, as listed in the charts below.
CCM1 Module
Power Supply Ground Components Affected
X018 pin 1 (F39) Keep Alive power
X018 pin 4 (F38, key switch) Main power; all potentiometers, speed and
position sensors
X018 pin 8, X019 pins 12 & 18 Main module grounds
X020 pins 29 & 30 (F22) X020 pins 9 & 10 Shoe Leveling Actuator
X020 pin 7 (F24) X020 pin 16 Cleaning Fan Adjust motor
Feeder Reverser actuator
X019 pin 11 (F24) X019 pin 3 Concave Clearance actuator
Grain Bin Covers actuator
X019 pin 2 (F43) Chaff Spreader valve
X019 pin 9 (F43) Backup Alarm
Vertical Knives
Rear Wheel Assist valve
X020 pin 11 (F44) Feeder Jog Fwd valve
Feeder Jog Rev valve
Dual Range valve
55-26
CCM2 Module
position sensors
X017 pins 29 & 30 (F25) X017 pins 9 & 10 Transmission Shift motor
X017 pin 7 (F23) X017 pin 16 Reel Speed motor
X016 pin 11 (F23) X016 pin 3 Throttle actuator (Bas mech)
Rotary Screen Brush actuator
X016 pin 2 (F36) Unload Cross Auger valve
Fuel Shutoff / Terminal 15
Park Brake Disengage valve
X016 pin 9 (F37) Unload Tube In valve
Unload Tube Out valve
Drum Increase valve
Drum Decrease valve
X017 pin 11 (F36) Reel Fore valve
Reel Aft valve
Reel Up valve
Reel Down valve
Reel Drive valve
Foot and Inch valve
CCM3 Module
position sensors
X014 pins 29 & 30 (F25) X014 pins 9 & 10 Cross Auger Tent motor
X014 pin 7 (F23) X014 pin 16 Spreader Plates motor
X013 pin 11 (F23) X013 pin 3 Upper Sieve actuator
Lower Sieve actuator
X013 pins 2 & 9 (F36) Bypass Unit Engage output (PF moisture
sensor auger)
55-27
COMBINE CONTROL MODULE (CCM)

REMOVAL AND INSTALLATION
The CCM’s are located under the storage box of the
instructional seat. The instructional seat must be
removed to access the CCM’s. The CCM’s should be
disconnected from the harness before removing.
The harness connectors are located under the cab
floor.
CCM Identification
ITEM DESCRIPTION 2
1. CCM 1
2. CCM 2 1
3. CCM 3 (If equipped)
10004693
40
Instructional Seat Removal
1. Raise bottom cushion and attach strap 1.
2. Loosen two bolts, 2, at bottom of seat back.
3. Lift seat back assembly up and forward to 1
remove from rear of cab.
3
4. Remove storage box 3.
2
50021851
41
Removal of CCM
The connectors, 1, are located under the cab floor left
of the center line of the combine.
50032238
42
55-28
1. Peel back connector boots, 1.
IMPORTANT: Before removing, if connectors are not
marked, label the connections for proper installation.
2
2. Unthread the captured connector screws, 2, and
remove connectors.
3. Remove the two mounting nuts and lock
washers, 3. 3 3
1
50032237
43
4. To disconnect connector,1, unthread captured
screw, 2. t
5. Carefully remove module from combine.
NOTE: It may be necessary to remove the seven
screws, 3, from the base of the instructional seat to 3
provide clearance to remove the CCM.
10004693
2
44
55-29
CCM Installation
1. Inspect the gaskets that seal the connector slots
in the cab floor for signs of deterioration, replace t
as required.
2. Place the CCM mounting studs through the floor
of the cab. Connect the appropriate connector, 1, 3
to the CCM. Tighten captured screw, 2, to secure
connector to CCM.
1
10004693
2
45
3. Install lock washers and thread nuts, 1, onto
mounting studs of CCM. Tighten nuts to standard
torque.
2
4. Inspect the seals on the connectors, clean or
replace as required.
5. Install the connector with the corresponding
decal on the underside of the cab floor. Thread in
captured screw of connector, 2, and tighten to 1 1
standard torque.
6. Fold protective boots, 3, around connectors. 3
50032237
Software Installation 46
IMPORTANT: The CCM must be loaded with
software.
Refer to the Electronic Service Tool section of the
Repair manual for software download instructions.
Instructional Seat Installation

1. Tighten the seven screws that secure the base of
the instructional seat to the cab frame.
2. Insert the storage box, 3. 1
3. Slide seat onto the 4 bolts by pushing the seat
back and downward against the rear of the cab. 3
Make sure the top two bolts fit into the notches on
the seat back.
4. Tighten two bolts, 2, at the bottom of the seat
back.
2
5. Release the strap, 1, on the seat cushion. 50021851
47
55-30
WIRING HARNESS REPAIRS

SPECIAL TOOLS
Europe Only
Description Tool No.

Harness Repair Kit (Except North America) 294070
Test Probe Kit (Except North America) 297448
Pin Removal Tool, Bosch Module Connector 84021087
Deutsch Extraction Tool 84400044
Deutsch Contact Crimp Tool 84400045
Deutsch Retraction Tool, DT Series Wedge 84400046
Packard Contact Crimp Tool 84400047
Packard Terminal Removal Tool 84400048
North America Only

FNH01000 Electrical Repair Tool Kit
20013704
48
Digital Multimeter OEM 1428A.
49
55-31
TEMPORARY WIRING HARNESS REPAIR

The following method to repair wiring is a temporary
expedient only. Wiring should be replaced as soon as
possible. Do not attempt to repair the wire on any sys-
tem sensors as these are sealed and should only be
replaced with a new component.
NOTE: When conducting a cable repair it is import-
ant that only RESIN CORED SOLDER is used. Use
of other types of solder may result in further cable
damage.
To carry out a temporary repair, proceed as follows:
1. Locate damaged portion of cable then cut away
outer protective cover on both sides of the dam-
aged area.
50
2. Peel back the cable from both ends of the dam-
aged area and carefully cut away the inner cable
cover at the damaged area and strip about 13
mm (1/2″) of insulation from the wires. Do not cut
away any wire strands.
3. Using a suitable solvent, clean about 2 inches
(50 mm) from each cover end. Clean the grey
cable cover and the individual leads.
4. Twist two bare leads together for each damaged
lead, being careful to match wire colours, then
solder the leads using resin cored solder. Tape
each repaired lead with vinyl insulation tape.
51
55-32
5. Wind a layer of vinyl insulation tape up to the grey
cable cover at each end of the repair section.
Make a paper trough, then apply silicon rubber
compound (non hardening sealant) over the re-
paired section up to the cover ends. Sufficient
sealant must be used to fill the ends of the cut
away area.
52
6. Allow the compound to cure then cover the area
with insulating tape taking the tape well over
each end of the repair. An overlap of at least 2 in-
ches (50 mm) of tape at each end is necessary.
7. Check to ensure the repair is satisfactory and se-

cure the repaired cable so that repeat damage is
avoided.
NOTE: This is a temporary repair only. Ensure the

damaged cable is replaced as soon as possible to
prevent ingress of water or chemicals.
53
HARNESS WIRE REPLACEMENT
If a wire within the harness is found to be beyond
repair or is open circuit, a jumper wire may be
installed as a temporary repair until such time when
a new harness assembly can be installed. Use the
following procedure to install an additional wire:
1. Locate the faulty wire using the procedures

described in the fault code charts.
2. Disconnect the affected connectors.
3. If fitted carefully roll back the seal between the

connector and harness outer covering.
4. Remove the pins from the connector blocks of

the affected wire using the appropriate removal
tool found in the harness repair kit.
NOTE: Use the instructions supplied with the kit to

ensure correct pin removal.
54
55-33
5. From the harness repair kit select the correct pin
for the connectors. Obtain locally the correct
cross-sectional size wire and measure out the
length required by following the harness routing.
6. Join the new wire to the new pins as described in

the harness repair kit and install one of the pins
into its connector.
7. If possible attempt to run the new wire within the

existing harness outer covering, if this is not
possible run the wire along the harness, securing
regularly with suitable ties. With the wire correctly
routed install the second terminal into its
connector block. Replace the connector seal if
removed.
8. To ensure that the repair has been effective

check for continuity of the new wire using a
suitable multi-meter.
NOTE: This is a temporary repair only. Ensure the

damaged cable is replaced as soon as possible to
prevent ingress of water or chemicals.
55
55-34
CAB ELECTRICAL CONNECTORS X002

AND X003
Connectors X002 and X003 are the main connectors
from the Fuse Panel to the Upper Cab Roof harness
and the Outer Cab Roof Harness. The connectors
are located in the upper left rear corner of the cab
along with the Cab Roof Ground. Removal of the rear
speaker panel is required to gain access to the
connectors for troubleshooting and cab roof removal.
Removal of Rear Speaker Panel

1. The rear speaker panel, 1, is located at the upper
rear of the interior of the cab. Clothing hanger, 2,
is the first item to be removed.
2
1
40015780
56
2. Using a flat bladed screwdriver or knife, pry the
screw cover, 1, from the hanger. Turn out the two
screws holding the hanger in place. Store the
hanger and screws in a suitable location.
40015779
57
3. Turn out seven screws, 1, from panel, 2. Allow
the panel to hang inside the cab. 1
40015780
58
55-35
Connector Locations
1. Connector X002
2. Connector X003
3. Cab Roof Ground 3
2
1
50032236
59
Installation of Rear Speaker Panel
2
1. Set rear panel, 1, into place and secure to
the headliner and cab roof using the seven
screws, 2.
40015780
60
2. Install the hanger using two screws. Push the
cover, 1, into place.
40015779
61
55-36
Chapter 2 - Infoviewt Monitor Diagnostic Functions
CONTENTS

55 000 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Service Info Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Active Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Active Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Error History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Network Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Diagnose Info Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
55-1
INTRODUCTION
The CR combine electrical system provides two
different menu options in the Infoviewt monitor to
assist in troubleshooting electrical concerns. The
“Service Info” menu provides information regarding
Active Alarms, Active Errors and Error History for the
electrical system, while the “Diagnose Info” allows
independent monitoring, testing and control of
electrical circuits and devices.
To access these two screens, their icons must be
displayed in the main menu. Select either the “Road”
or “Work” screens, and depress the “Enter” key to
bring up the “Menu” dialog box. Use the arrow keys
to select “Show menu’s”, and press the “Enter” key.
20013655
1
Use the arrow keys to select “Service info”, and press
“Enter” to display that menu icon (open book with
wrench) in the main menu. The Menu dialog box will
automatically close when the selection is made.
20013656
2
To display the Diagnostic menu icon, select
“Diagnose info”, and press “Enter”; the “Diagnostic
info” menu icon (magnifying glass) will now be
displayed in the main menu.
20013657
55-2
To enter the Service info or Diagnose info menus, use
the arrow keys to select the appropriate icon; the
sub-menus for each menu will then be displayed.
20013658
4
SERVICE INFO MENU
When the Service info menu icon is selected, its
sub-menu will be displayed in the adjacent column.
The available sub-menu items, in order from top to
bottom, are:
Active Alarms
Active Errors
Error History (Highlighted)
Clock
Network
20013659
5
Active Alarms
To select the Active alarms list, use the arrow keys to
select the Active alarms icon (exclamation point). All
alarms that are currently active on the combine will
be displayed.
An alarm is an indication of some mechanical

condition on the vehicle, and alerts the operator to
perform necessary maintenance, or to change
operating conditions to correct the alarm condition.
Examples of alarms would be to indicate an engine
overheat condition, blocked filters, or improper
control operation. Alarms are not used to indicate 20013660
faults with electrical circuits.
6
55-3
The alarm message uses an icon and unique number
to identify each alarm, indicates the priority (low,
medium or high), and provides a brief text message
of the alarm condition. The alarm messages do not
indicate when they occurred, or how long they have
been active.
In the highlighted example, the gearbox filter icon is

displayed, the alarm message number is 0010, and
the alarm is a low priority. The alarm message
indicates that the gearbox filter is blocked, and
gearbox oil is now bypassing the filter, which may
result in gearbox damage if not corrected. The 20013661
gearbox filter should be replaced to correct this alarm
condition. 7
Active Errors
To select the Active errors list, use the arrow keys to
select the Active errors icon (caution symbol). All
errors that are currently active on the combine will be
displayed. If there are more active errors than can be
displayed on the screen, the scroll bar will appear on
the right side of the screen to indicate that additional
errors are available. When the error is corrected, it
will automatically disappear from the list.
Error messages are displayed on the screen in the

order that they occurred.
20013662
An error is an indication of a fault with an electrical
circuit or component, and alerts the operator that the 8
circuit or component is no longer functioning.
Examples of error messages include open circuits,
shorts to ground, or short to high voltage.
To review the active errors list, use the arrow keys to
enter the list, and scroll up or down (if scroll bar
appears). Each error message includes a unique
identifying number, and the priority of the error. A
brief text message indicates the circuit or component
affected, and the type of error detected.
In the highlighted example, error message 0130-04

is a medium priority error, and indicates that the
second gear shift sensor on the transmission is
shorted to a low source (ground).
20013663
55-4
Additional information may be displayed for each
error message. Select the desired error message
using the arrow keys, and press the “Enter” key. A
dialog box will be displayed with additional
information, and a menu list of options for that error.
The circuit or component name will be displayed at

the top of the box, while the error number, priority and
type of error is listed below. In addition, the module
that is reporting the error (module the component is
attached to) is displayed. The next line will either
indicate “Error checking” or “Error bypassed”, while
the last line indicates the component label (use to 20013664
locate the component on the electrical schematic),
the module connector and pin number, and the 10
module hardware type (for engineering use).
The menu provides three options, as follows:
Diagnose sensor - selecting this item will

immediately display the diagnose screen for this
circuit or component. In this example, a voltage
bar graph is displayed, and the voltage level
indicates that the sensor is shorted to ground.
Troubleshooting of this circuit may now be done
using this screen to help locate the source of the
fault (refer to “Diagnose Info Menu”, later in this
section, for more information).
20013665
11
Bypass error - selecting this item will result in
the software in the affected module using an
alternative path to handle this particular circuit in
order to get around this particular error condition.
In some cases, this may restore partial function
to the affected system this circuit or component
was used for.
Clear error bypass - will clear the bypass for this
error, if it was previously bypassed. All error
bypasses are automatically cleared whenever
the electrical system is powered on, in order to
ensure that active errors are displayed once
again to the operator. 20013666
12
55-5
After working in the Active errors screen for some
time, the screen may no longer accurately reflect all
active errors, possibly due to a module being
connected to the network after the other modules
had already powered up and reported their errors. In
order to ensure that all active errors are being
displayed, use the arrow keys to select the Active
errors icon on the sub-menu, and press the “Enter”
key. A menu box will be displayed, with a single menu
option of “Reload errors”. Pressing the “Enter” key
will synchronize the Infoviewt monitor and all
modules with respect to active errors.
20013667
13
Error History
To select the Error history list, use the arrow keys to
select the Error history icon (open book). All errors
that have been detected active on the combine in the
past will be displayed. If there are more errors than
can be displayed on the screen, the scroll bar will
appear on the right side of the screen to indicate that
additional errors are available. Errors will remain in
the history list until they are erased.
The Error history list is not a real-time list, and

displays only those errors recorded at the time the
screen is opened. The error history is updated each 20013659
time the screen is selected, or may be reloaded while
working in the screen in order to retrieve the latest 14
information from all modules.
The Error history is useful in recording the number of

times a particular error has occurred, or to review
intermittent errors that may not be currently active.
The Error history may be sorted in several different
ways to assist in locating specific errors. With the
Error history icon selected, press the “Enter” key to
display the menu box. The menu choices are:
Sort ascending
Sort descending
Erase history - erases all items out of the history.
Active errors will be reloaded into the history list
with the occurrence count set to 1.
Reload history - retrieves the latest error
information from all modules to update the error 20013668
history. This is done automatically whenever the
Error history icon is selected, but may be done 15
manually using this menu item if the screen has
been open for some time.
Clear all bypasses - clears all bypasses that
may have been previously enabled on errors.
55-6
When the “Sort” menu items are selected, a second
menu box is displayed, which lists the various sorting
options that are available. Use the arrow keys to
select the desired sorting criteria, and press the
“Enter” key to sort the error history. The sorting
criteria available are:
Default - the default sort order as established in

the combine module software. This is the order
that errors appear in the history as reported by
the various modules on the combine.
Date - sorts the errors by the date and time of last
occurrence. This sort order is best used when 20013669
trying to locate the oldest or most recent errors.
16
Occ. Count - sorts the errors based on the
number of times they have occurred. This sort
order quickly locates errors that have occurred
frequently from those that only occur occasionally.
Fault code - sorts the errors in numerical order,
using the specific identifying number for each
error. This sort order will group errors by module,
since each module has a specific “block” of error
numbers assigned to it.
Failure - sorts the errors by the failure type. This
sort order will group all shorts to ground, open
circuits or shorts to high voltage together, which
may be useful in trying to determine which errors
are a result of damage to a specific harness.
Priority - sorts the errors by low, medium and
high priority.
Node - sorts the errors by the specific module
that the affected circuits are attached to. This sort
procedure will group errors from a module
together, but they will not be in numerical order.
Once the error history is sorted as desired, use the
arrow keys to enter the error list, and scroll to the
review the errors. Each error message includes the
identifying number, while a brief text message
indicates the circuit or component affected, and the
type of error detected.
In the highlighted example, error message 0143-04

indicates that straw chopper speed sensor is shorted
to a low source (ground).
20013670
17
55-7
Additional information may be displayed for each
error message. Select the desired error message
using the arrow keys, and press the “Enter” key. A
dialog box will be displayed with additional
information, and a menu list of options for that error.
The circuit or component name will be displayed at

the top of the box, while the error number, priority and
type of error is listed below. In addition, the module
that is reporting the error (module the component is
attached to) is displayed.
The next line indicates the number of occurrences 20013671

(14 in this example), and will either indicate “Error
checking” or “Error bypassed”. The date and time of 18
the last occurrence are reported. The last two lines
indicate module the affected circuit is attached to, the
component label (use to locate the component on the
electrical schematic), the module connector and pin
number, and the module hardware type (for
engineering use).
The menu provides several options, as follows:
Erase error - erases this specific error from the

error history.
Reload error - retrieves the latest information on
the error from the reporting module, in order to
update the number of occurrences, and date and
time of the last occurrence.
Diagnose sensor - selecting this item will
immediately display the diagnose screen for this
circuit or component. Troubleshooting of the
circuit may now be done using this screen to help
locate the source of the fault (refer to “Diagnose
Info Menu”, later in this section, for more
information).
Bypass error - selecting this item will result in
the software in the affected module using an
alternative path to handle this particular circuit in
order to get around this particular error condition.
In some cases, this may restore partial function
to the affected system this circuit or component 20013672
was used for.
19
Clear error bypass - will clear the bypass for this
error, if it was previously bypassed. All error
bypasses are automatically cleared whenever
the electrical system is powered on, in order to
ensure that active errors are displayed once
again to the operator.
55-8
Service Menu
To select the Service menu, use the arrow keys to
select the Service icon (clock). This screen displays
the total engine hours and threshing hours recorded
for the combine, and also shows the date and time
set in the combine electrical system.
20013673
20
If the current time displayed is not correct, the time
may be adjusted to the correct setting. Use the arrow
keys to enter the list and select the Date & Time.
Press the “Enter” key to open the clock setting box.
20013674
21
Use the arrow keys to select the desired line, and to
make changes to the set values. Once all changes
are made, press the “Enter” key to save the
information and return to the previous screen.
20013675
22
55-9
Network Menu
To select the Network menu, use the arrow keys to
highlight the Network icon (lines and boxes). A list of
all modules on the combine will be displayed, along
with information on their hardware and software
revision level. If a module is not installed on the
combine, or is not reporting on the network for some
reason, its icon will be “greyed out”.
The Network menu is typically used to find the current

revision level of the modules and the software in the
electrical system. This information may be required
when reporting certain electrical errors to engineer- 20013676
ing, or to determine if software updates are required
or appropriate. 23
DIAGNOSE INFO MENU

When the Diagnose info menu icon is selected, its
sub-menu will be displayed in the adjacent column.
The sub-menu icons provide an easy way to locate
a particular circuit by locating either the “system” on
the combine that the circuit supports, or by locating
the circuit in the specific module that it is attached to.
The available sub-menu items, in order from top to
bottom, are:
Console
MFH 56060567
Supply (supply voltages)
Engine 24
Electric (power sockets, lighting, horn)
Hydraulics
Drive Line
Header
Feeder
Threshing
Cleaning
Grain Storage/Unloading
Residue (straw chopper, chaff blower)
Precision Farming
Spare (unused circuits on modules)
CCM1 (module)
CCM2 (module)
CCM3 (module)
55-10
Use the arrow keys to enter any particular list, and
scroll as required to select the circuit to be
investigated. Press the “Enter” key to enter the
diagnostics for that circuit.
The circuits in the Diagnose info screens can be

generally separated into two groups; inputs and
outputs.
Inputs
Inputs include supply voltages, switches (operator or
machine-controlled), sensors (position, loss or
speed) and senders (pressure, temperature or level). 20013678
On any of the input diagnostic screens, a simple
25
voltage bar graph is displayed, which may be used to
determine the condition of the circuit.
The bar graph also has several arrows positioned

along the left side to separate the graph into ranges;
each range is represented by a letter, such as “A”,
“B”, “C”, etc. These ranges each have a specific
meaning depending on the type of circuit that is being
monitored.
Proximity and Speed Sensors
Proximity and speed (RPM) sensors generally will
have five ranges, as follows:
A = 0 to 0.25v/0.5v (short to ground)

B = 0.25v/0.5v to 5.6v (normal operation, no
metal present)
C = 5.6v to 7.6v (normal operation, metal
present)
D = 7.6v to 9v (open circuit)
E = >9v (short to high voltage)
20013679
In the example shown, the Unload Tube sensor
circuit is currently displaying 7.9 volts, and is in the 26
“D” range, indicating an open circuit condition exists
with this circuit.
55-11
Temperature/Fuel Level Senders
Temperature and fuel level sensors will generally
have four ranges, as follows:

B = 0.25v/0.5v to 4.9v (normal operating range)
C = 4.9v to 5.2v (open circuit)
D = >5.2v (short to high voltage)
In the example shown, the Hydraulic Reservoir

Temperature sender circuit is currently displaying 3.4
volts, and is in the “B” range, indicating normal 20013680
operation.
27
Potentiometers/Pressure Senders/
Grain Bin Level
Potentiometers, pressure senders, such as engine
oil pressure, control pressure or air filter restriction,
and the grain bin level senders all operate on similar
circuits, however there are some minor variation in
the exact voltages between the ranges. Refer to the
troubleshooting charts for each item for specific
information on that component.

B = 0.1/0.2v to 4.7v/4.9v/5.2v (normal operation)
20013698
C = > 4.7v/4.9v/5.2v (short to high voltage)
28
Switches
Switches may be generally divided into two separate
groups, in terms of how they function. Operator-con-
trolled switches in the cab are typically switched to 12
volts when they are engaged, while switches on the
combine, such as filter bypass switches, are typically
switched to ground when they engage.
Operator switched circuits are normally open; when

the operator moves the switch, it passes a 12 volt
signal to the module. The various ranges for these
switches are:
20013697
A = <0v (short to ground)
29
B = 0v to 4v (normal, switch off/open)
C = >4v (normal, switch on)
55-12
External switches on the combine, such as the filter
bypass or brake pressure switches, are switched to
a ground when they are activated, so the module
sees the circuit change from an open circuit to a
ground. The ranges for these switches are:
A = <1.8v (normal, switch closed)

B = 1.8v to 10v (normal, switch open)
C = >10v (short to high voltage)
20013696
30
The Multi Function Handle (MFH) Position Input
diagnostic screens provide two different bar graphs
to test the MFH potentiometer; “Relative Position”
and “Voltage”. The Relative Position bar graph
provides a graphical representation of handle
movement. In the example shown, the handle is in
neutral, and the percentage at the bottom of the
graph indicates 0%.
20013699
31
Moving the MFH forward will cause the bar graph to
increase gradually, and the percentage will also
increase, as shown. If the handle is moved rearward,
the graph would decrease, and a negative
percentage would be indicated. This bar graph may
be used to verify a steady, linear signal is received
from the MFH potentiometer while it is moved,
without any hesitation or spikes. In addition, the bar
graph should not move beyond 100% in either
direction; if it does, this is an indication that the MFH
should be recalibrated. Refer to the “Calibration”
section of the Operator’s manual for more information.
20013700
32
55-13
The “Voltage” screen shows the voltage signal from
the MFH potentiometer when it is moved. The bar
graph should be in the “C” range when the handle is
moved forward, or in the “B” range when the handle
is moved in reverse.
A voltage reading in the “A” range would indicate a

short to ground, while a reading in the “D” range
would indicate a short to high voltage.
20013701
33
The Gear Select Input switch is unique in that it is a
five position, rotary switch. The first diagnostic
screen, “Gear”, gives an indication of the detected
switch position, either 1, 2, N, 3 or 4.
20013702
34
The voltage bar graph has several ranges to indicate
the various switch positions. In general, the different
switch positions relate to the middle five ranges, as
follows:
A range = <0.5 volts (short to ground)

B range = 1st gear position
C range = 2nd gear position
D range = neutral position
E range = 3rd gear position
F range = 4th gear position
20013703
G range = short to high voltage
35
55-14
Outputs
The modules on the combine take information from
the various sensors and operator controls (inputs),
and then turn on or engage outputs to perform the
desired functions on the combine. These outputs
include things such as engaging relays, solenoids
(12v or PWM), and driving motors and actuators. The
circuits in the modules are designed to handle
different types of outputs, so the diagnostic screens
for the outputs generally reflect the type of output.
NOTE: The output diagnostic screens may NOT be

accessed while the engine is running, in order to 20013681
prevent accidental engagement of outputs, resulting
36
in machine damage or personal safety concerns.
Relays and Solenoids
Relays and normal solenoids are driven by module
outputs that simply switch 12 volts on or off, and are
limited to 3 amps maximum current draw. Since
these outputs are grounded locally, and the ground
is not back through the module, there is a limitation
on the values that may actually be monitored.
All relay and normal solenoid diagnostic screens will

default to a “Digital” screen, but in some cases, an
additional “Status” screen is also available. Use the
arrow keys to select the desired screen.
20013682
37
On the “Digital” screen, an indication is given of the
actual condition of the output, either “Off” or “On”.
While in this screen, if the output is activated through
normal means, this will be visible when the output
condition changes.
The output may also be controlled directly from the

diagnostic screen, allowing the circuit to be activated
for testing purposes. To directly control the output,
press the “Enter” key; the switch icon on the bottom
right of the screen will change position as shown to
indicate that the circuit is now activated.
20013683
NOTE: When the circuit is manually activated, the
software control is automatically bypassed, and the 38
circuit will no longer be activated by normal means
until the diagnostic screen is closed.
55-15
The “Status” screen, if available, provides some
indication if the module detects an error on the circuit,
typically either a short to ground or open circuit.
Select the “Status” screen by pressing the down
arrow key to highlight “Status”.
The status of the circuit will be indicated as either

“Ok” or “Error”, depending on the detected condition.
As in the “Digital” screen, the output may be manually
controlled in the “Status” screen also, simply by
pressing the “Enter” key to change the position of the
switch icon on the bottom right of the screen.
20013684
39
PWM Solenoids
PWM solenoids are used where progressive
engagement of the solenoid is desired, such as for
the thresher, feeder and unload clutches, chaff
spreader valve and header controls. Most PWM
solenoids are grounded locally, but where precise
control of the solenoid is required, the solenoid is
grounded back through the module. This feedback
allows additional monitoring of the current flow
through the circuit. The PWM outputs are limited to
3 amps maximum current flow.
20013685
40
PWM outputs have two diagnostic screens available,
if grounded locally, or three, if the solenoid is
grounded back through the module.
The “PWM” screen contains a bar graph that

provides a reference of the amount of output that the
software is attempting to drive the solenoid at. When
monitoring the output, it is possible to see the
progressive engagement of the output on the bar
graph.
NOTE: If the circuit is shorted to ground, the bar

graph will continue to indicate a rise in output, even 20013686
though the module has shut off the output in order to
protect the output driver. 41
55-16
The output may also be controlled directly by
pressing the “+” or “--” keys to set the amount of
output desired, and pressing the “Enter” key. The
amount that the output will be driven is initially
displayed below the arrows beside the switch icon at
the bottom right of the screen.
20013687
42
When the “Enter” key is pressed, the software will
drive the output at the set value, and the switch icon
will change position to indicate that the module is
driving the output.
NOTE: If the circuit being manually controlled is

shorted to ground, the bar graph will continue to
indicate a rise in output, even though the module will
shut off the output in order to protect the output driver.
20013688
43
The “Current” screen, if available, measures the
current flow on the circuit. In general, a properly
functioning circuit should draw approximately 1 to 1.5
amps continuous when the solenoid is fully powered
(100% output). If the circuit is shorted to ground, the
bar graph should indicate high current flow until the
module shuts the circuit off to protect the output
driver. If the circuit is open, the bar graph will not
indicate any current flow even though the “PWM”
screen is indicating that the software is driving the
output.
20013689
44
55-17
H-Bridge Outputs
H-bridge outputs are used to control motors and
actuators, where the ability to drive the component in
both directions is required. H-bridge circuits have two
connector pins associated with them to control both
sides of the circuit, and function by connecting one
pin to ground when the opposite pin is connected to
power. To reverse direction of the output, the power
and ground connections are switched. This type of
output control allows the module to operate motors
and actuators in both directions.
H-bridge circuits are limited to 3 amps for low power 20013690

circuits, 20 amps for medium power circuits, and 30
amps for high power circuits. 45
Low Power H-bridge (3 amp max)

Ground Speed Hydrostat (EDC valve)
Medium Power H-bridge (20 amp max)

Fan Speed motor
Feeder Reverser motor
Concave Clearance motor
Grain Bin Covers motor
Header Reel Speed motor
Rotary Screen Brush motor
Engine Throttle motor (7.5L mechanical only)
Spreader Plates motor
Upper & Lower Sieve motors
High Power H-bridge (30 amp max)

Leveling Shoe motor
Transmission Shift motor
H-bridge circuits have three or four available
diagnostic screens. The “H-bridge” screen provides
a graphic representation of the state of the circuit. In
the example shown, the circuit is currently in the
“Brake” mode (both sides of circuit to ground). When
the circuit is activated by the software, the icon in the
top left corner of the screen will change to reflect the
current output state of the circuit.
20013691
46
55-18
The output may be manually controlled by pressing
and holding the “Enter” key and one of the arrow keys
simultaneously. In the example shown, the “Enter”
and right arrow keys are being depressed, as
indicated by the icon in the lower right corner of the
screen, in order to drive the motor in a clockwise
direction.
The icon at the bottom right of the screen indicates

the four possible states of the circuit; (from the top)
Coast, CW rotation, Brake, CCW rotation.
Once the output has been controlled manually, the 20013692

module software control has been bypassed, and the
circuit will no longer operate normally. When the 47
“Enter” and right arrow keys are released, the output
will return to the “Brake” mode, but the Brake icon on
the lower right of the screen will now be lit, indicating
the circuit is operating under manual control only.
Use the down arrow key to select the “Status” screen.
The status of the circuit will be indicated as either
“Ok” or “Error”, depending on the detected condition.
The output may be controlled manually, as described

above. In the example shown, the output is being
manually controlled in the CCW rotation (by
simultaneously pressing and holding the “Enter” and
left arrow keys), and the module is detecting an error
in that direction. The error may be the result of either
a short to ground or open circuit.
20013693
48
The “Current” screen measures the current flow on
the circuit. Refer to the chart above to determine the
maximum amperage for each motor. In general, a
circuit should not draw more than 30% to 50% of max
rated amperage during normal operation. Excessive
amp draw is generally an indication of short to ground
or excessive mechanical load, due to worn or binding
linkage, or lack of lubrication.
If the circuit is shorted to ground, the bar graph

should indicate high current flow until the module
shuts the circuit off to protect the output driver. If the
circuit is open, the bar graph will not indicate any 20013694
current flow even though the “H-bridge” icon is
indicating that the software is driving the output. 49
55-19
The “Voltage” screen is used to display the feedback
from the potentiometer that is built into some of the
actuators used, such as the leveling shoe or concave
clearance actuators. As the actuator is operated, the
voltage scale will change to reflect the changing
position of the actuator. This bar graph is essentially
a duplication of the input seen on each specific
position sensor diagnostic screens, and is provided
for reference (provides feedback that actuator is
actually moving).
20013695
50
55-20
Chapter 3 - Electrical Schematics
CONTENTS

55 000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Schematic Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Machine Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component Index, 2003 Production -- SN HAJ100101 to 800 . . . . . . . . . . . . . . . . . . . . 19
2003 Production -- SN HAJ100101 to 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Component Index, 2004 Production -- SN HAJ100801 to 1500 . . . . . . . . . . . . . . . . . . 71
2004 Production -- SN HAJ100801 to 1500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Component Index, 2005 Production -- SN HAJ101501 to 3300 . . . . . . . . . . . . . . . . . 123
2005 Production -- SN HAJ101501 to 3300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Component Index, 2006 Production -- SN HAJ103301 and ABOVE . . . . . . . . . . . . . 175
2006 Production -- SN HAJ103301 and Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
55-1
INTRODUCTION
The electrical schematic index is organized into
groupings of components. Each component on the
combine is assigned a unique alpha-numeric code
that is used in all documentation, and uniquely
identifies that component. To locate a specific
component in the schematic, use the chart below to
determine the label prefix for that component type,
and look in that component group in the index to
determine which frame the component is located on.
Label Prefix Component Type

A Modules 20010925
B Sensors 1
E Lights, Lamps
F Fuses
G Alternator, batteries
H Horns, speakers
J Power Outlets
K Relays
L Solenoids
M Motors, actuators
R Potentiometers
S Switches
W Splice blocks
Schematic Frames
The electrical schematic is divided into page-sized
frames, and are numbered sequentially. The
schematic frames are ordered by system, as follows:
Starting Fr 1 - 3
Engine Fr 4 - 6
Drives Fr 7 - 9
Hydraulic Fr 10
Header Fr 11 - 13
Feeder Fr 14, 15
Thresher Fr 16, 17 20020068
Cleaning Fr 19 - 21
2
Unload Fr 22
Trash Fr 23
Precision Fr 24
Distribution Fr 25 - 31
Lighting Fr 33 - 43
Accessory Fr 44 - 46
HVAC Fr 47, 48
55-2
To accurately determine the location of a particular
circuit, use the index to locate circuits by component
label.
A box at bottom of each frame lists all devices shown

on that frame, with their label. In most cases, circuits
are contained completely within the frame. However,
in some cases, wires can cross frame borders to the
previous or next frame.
20020068
3
Power runs across the top of each frame, while
grounds generally occur at the bottom. Labels are
used to identify the power supply on the power wires
at the top of the frame. The top wire label “B +12V”
indicates this wire is directly supplied by the
batteries, while the wires below are supplied by the
K26 and K24 relays respectively.
Grounds are identified with a circled number, 1,

Figure 2, which indicates a specific ground location
on the combine. An absence of this circled number
indicates that the device is grounded locally.
20013708
There are five grounding locations on the combine,
as listed. 4
A minimal number of jumpers, 1, are used to extend

circuits to other frames in the schematic. These 1
jumpers are shown as a wire terminating in a square
box, with a letter-identifier and a frame number that 2
the wire is jumping to. To continue following the
circuit, flip to the identified frame number, and look for
a jumper box with the same letter-identifier.
Connectors in the schematic are shown as a dotted

box around a component, or around connections in
a wire, in the case of an inline connector between
harnesses. The connector number will be identified
in one corner of the box. 200110927
55-3
If only part of the connector is shown, a wavy dotted
line, 1, will be shown at one or both ends of the box 1
to indicate that part of the connector is missing, and 2
located in another frame of the schematic. The
connectors will identify pins or sockets in each
connector.
Bolted connections, 2, such as to batteries or

alternators, will not have a dotted box surrounding
the connection.
In most cases, an entire component is shown on a

single frame of the schematic. In some cases,
however, the component (typically a computer 20010928
module), 2, Figure 5, may be shown on several 6
frames of the schematic. If only part of the
component is shown, a solid wavy line will be shown
at one, or both ends of the component to indicate part
of the component is missing, and is located in
another frame of the schematic.
Power Distribution
For layout purposes, all switch and sensor power and
ground sources are grouped in the schematic on
frames 25 -- 27. Common power and ground sources
are identified with a circled number for reference
purposes. When viewing a switch or sensor in the
schematic, this circled number provides a reference
back to the actual power or ground source on frames
25 -- 27. Note that the power wires are identified with
a flat bar on the end of the wire, and an indication of
the voltage level. A reference ground wire (ground
back through a module) will have a triangle on the
end of the wire. 20031021
7
Machine Options
In some cases, the wiring may have slight differences
from one machine to another, depending on the
specific options that are installed. In these cases, the
schematic will show a reverse arrow head on one
wire, with two or more arrow heads available to “plug
in”. These arrow heads have a number in them to
identify the specific option or configuration they
represent. The arrow head options are listed at the
bottom of the first Index frame for reference.
In the example shown, the engine control unit A-01

is used with the Iveco electronic engine, while base 20020069
units with Basildon mechanical engines have the fuel
solenoid L-02 connected to this wire instead. 8
The options used in the schematic are:

EUROPEAN MARKET ONLY
NORTH AMERICAN MARKET ONLY
55-4
Harnesses
A two digit alpha code is assigned to each harness
used on the combine (with the exception of two or
three wire jumper harnesses). This label is used on
each wire on the schematic to identify which harness
any given wire is located in. The harness codes are:
Code Harness
MF Main Frame
FF Front Frame
LF Lower Frame
20010929
CM Cab Main
9
RC Right Hand Console
SC Steering Column
CR Cab Roof
OR Outer Roof
AC HVAC
FE Feeder
FB Feeder Bottom
FT Feeder Top
FV Feeder Valves
MV Main Valve Stack
GT Grain Tank
GB Gearbox
EN Engine
EX Expansion
SW Straw Hood, Front
SH Straw Hood, Rear
LR Lower Frame Rear
HH Header
CH Chopper RPM and Returns
BC Bin Covers
JP Jumper
FC Flip-up Lighting
UL Undershield Lighting, Left
UR Undershield Lighting, Right
UE Undershield Lighting, Engine
TL Unload Tube Light
MR Marker Lights, Right
ML Marker Lights, Left
MT Tail Lights
MA Marker Lights, Austria
LP License Plates (EU)
55-5
All wires in the schematic are labeled to indicate the
specific harness they are in, the circuit number, the wire
color (see chart below), and the wire size, indicated in
square mm cross-section. On the combine, the
appropriate circuit number is printed on each wire
approximately every 50 mm (2″) to identify it.
Wire Size Chart

Square mm AWG
0.5 20
0.8 18
1.0 16 20010929
2.0 14 10
3.0 12
5.0 10
8.0 8
In addition, the wire colors used identify the function

of the wire, depending on the type of component that
the wire is connected to. The following wire colors are
used for the CR combine wiring harnesses:
Color
Color Code Function
Black BK Ground, Chassis
Blue BL Printed Circuit Ground
White WH Increasing Actuation
Gray GY Decreasing Actuation
Orange OR Power After Ignition
Yellow YE Signal Wires
Red RD Battery Voltage
Purple PU Lighting
Pink PK Reference Voltage
The following tables identify the specific wiring colors
and functions, as well as the standard connector
location for each wire type for each component
group.
Sensors
3 Wire Sensors
(eg. Potentiometers)
Harness
Signal Pin Wire Color
Power 1 or A Pink
Ground 2 or B Blue
20010930
Signal 3 or C Yellow
11
55-6
2 Wire Sensors
(eg. Speed Sensors)
Harness
Ground 1 or A Blue
Power 2 or B Yellow
20010931
12
Actuators
Linear Actuators
(eg. Shoe)
Harness
Increase 1 or A White
Decrease 2 or B Gray
20010932
13
Solenoids w/Current Sensing

(eg. Header Raise/Lower)
Harness
High Side 1 or A White
Current 2 or B Blue
Sense
Solenoids w/o Current Sensing

(eg. Reel Fore) 20010933
Harness 14
High Side 1 or A White
Low Side 2 or B Black
55-7
HARNESS ROUTING
5 1
3 2
50020058
15
Ground Locations
1. Rear Frame Ground

2. Front Frame Ground
3. Cab Floor Ground
4. Cab Roof Ground
5. Engine Frame Ground (left rear mount)
NOTE: Cab Floor Ground is shown as two locations.

Upper location on rear deck is main ground point.
Location at bottom attaches ground strap from cab to
front frame ground, 2.
55-8
9
10 11
6 12
5
4 8
2
1
50020066
16
Main Frame (MF) Wire Harness
1. Connector X016, CCM2 - J2

3. Connector X008 to Front Frame harness
4. Connector X004 to Cab Main harness
6. Connector X009 to Grain Tank harness
7. Connector X034, X219 to Expansion harness
8. Connector X022 to Main Stack Valves harness
9. Connector X195 to Tank Extensions jumper harness
10. Connector X010 to Engine harness
11. Connector X011 to Gearbox harness
12. Connector X024 to Straw Hood
55-9
2
1
4
5
7
6
8
12 11
9
10
50020062
17
Front Frame (FF), Lower Frame (LF) and Feeder (FE) Wire Harnesses

4. Connector X008 to Main Frame harness
5. Front Frame (FF) wire harness
6. Connector X023 to Lower Frame harness
7. Lower Frame (LF) wire harness
8. Connector X007 to Feeder harness
9. Connector X021 to Feeder Valves harness
10. Feeder (FE) wire harness
11. Connectors X082, X086 to ASD module
12. Connector X032 to Header harness
55-10
4 8
10
3
2 6 9
11
50020065
18
Main Stack Valves (MV), Engine (EN), Gearbox (GB) and Lower Frame Rear (LR) Wire Harnesses
1. Connector X281 to Bosch HHC module

2. Main Stack Valves (MV) wire harness
4. Connector X010 to Engine harness
5. Engine (EN) wire harness
6. Connector X011 to Gearbox harness
7. Gearbox (GB) wire harness
8. Connector X285 to Straw Hood Front harness
9. Trailer plug wire harness
11. Lower Frame Rear (LR) wire harness
55-11
5
4
6 7
1
50020064
19
Straw Hood Front (SW) and Straw Hood Rear (SH) Wire Harnesses

2. Connector X025 to Expansion harness
3. Straw Hood Front (SW) wire harness
4. Connector X071 to Straw Hood Rear harness
5. Straw Hood Rear (SH) wire harness
6. Connector X285 to Trailer harness
7. Connector X072 to Lower Frame Rear harness
55-12
8
7
6
3 5
2
1
4
50020063
20
Expansion (EX), Grain Tank (GT) and Unload Tube Light Wire Harnesses

3. Connectors X034, X219 to Main Frame harness
4. Expansion (EX) wire harness
7. Grain Tank (GT) wire harness
8. Connector X105 to Unload Tube Light harness
9. Unload Tube Light wire harness
55-13
15
13
14
1
12
2
6 3
11 7
8
4
10 5
50020059
21
Cab Main (CM) Wire Harness
1. Fuse Panel
3. Connector X031 to Front Frame harness
5. Connector X006 to HVAC harness
9. Connector X033 to Steering Column harness
10. Connector X256 to Road Light switch (S26)
11. To SSM and Infoview™ monitor
12. Connector X001 to RH Console
13. To Start Panel
14. Connector X002 to Cab Roof harness
55-14
4
1
50020060
22
HVAC (AC) Wire Harness

2. To separator blower fan
3. Cab Floor Ground (3), outside of cab
4. HVAC (AC) wire harness
5. To cab blower fan
55-15
9
8
7 1
10
4 2
50020061
23
Cab Roof (CR) Wire Harness
1. Cab Roof Ground (4)

4. Connector X128 to HVAC Control Panel
5. Door Switch (S40)
6. Connector X036 to Outer Roof harness
7. Connector X140 to FM Radio
8. Connector X159 to Data Logger
9. Connector X142 to GPS Receiver
10. Dome Light (E34)
55-16
50010892
24
Outer Roof (OR) Wire Harness
55-17
THIS PAGE LEFT BLANK
55-18
COMPONENT INDEX, 2003 PRODUCTION -- SN HAJ100101 TO 800

Code Name Frame Code Name Frame
Electronics B--36 FUEL TEMP (IVECO) FR--06
A--01 ENGINE CONTROL UNIT (ELEC) FR--02 B--37 TRANS SHIFT POSITION FR--09
A--01 ENGINE CONTROL UNIT (ELEC) FR--03 B--38 UNLOAD CRADDLE FR--22
A--01 ENGINE CONTROL UNIT (ELEC) FR--04 B--39 RIGHT RETURNS RPM FR--20
A--01 ENGINE CONTROL UNIT (ELEC) FR--31 B--40 FUEL TEMP FR--04
A--02 MAIN DISPLAY MODULE (MDM) FR--30 B--41 AIR TEMP / BOOST PRESS FR--04
A--03 SHAFT SPEED MONITOR (SSM) FR--30 B--42 COOLANT TEMP (ELECTR) FR--04
A--04 RADIO FR--46 B--43 FLYWHEEL RPM FR--04
A--05 FLASHER MODULE FR--33 B--44 COOLANT TEMP (IVECO) FR--06
A--05 FLASHER MODULE FR--36 B--45 GEARBOX CLUTCH TEMP FR--16
A--07 HHC MODULE (EMR--OBE) FR--13 B--46 HYDROSTAT MOTOR TEMP FR--08
A--07 HHC MODULE (EMR--OBE) FR--31 B--47 COVERS OPEN FR--22
A--08 ASP AMPLIFIER FR--14 B--48 RH BOTTOM ASP SENSOR FR--14
A--08 ASP AMPLIFIER FR--31 B--49 LH BOTTOM ASP SENSOR FR--14
A--09 HVAC CONTROL MODULE FR--47 B--50 RH TOP ASP SENSOR FR--14
A--09 HVAC CONTROL MODULE FR--48 B--51 LH TOP ASP SENSOR FR--14
A--10 DATA LOGGER (DLU) FR--30 B--52 ENGINE OIL PRESSURE (IVECO) FR--05
A--11 GPS MODULE (DGPS) FR--30 B--53 PARK BRAKE PRESSURE FR--09
Sensors B--54 AIR TEMP (IVECO) FR--06
B--01 ROTOR RPM FR--17 B--55 SPREADER RPM FR--23
B--02 LATERAL INCLINATION FR--20 Lights
B--03 ENGINE OIL TEMP (IVECO) FR--05 E--01 LH HEADER FLASHING LMP (NA) FR--33
B--04 -- -- E--02 RH HEADER FLASHING LMP (NA) FR--33
B--05 ENGINE FLYWHEEL RPM (IVECO) FR--06 E--03 LH FRONT HAZARD LAMP FR--34
B--06 LEFT RETURNS RPM FR--20 E--04 LH FRONT HAZARD LAMP FR--34
B--07 ENGINE CAMSHAFT RPM (IVECO) FR--06 E--05 LH REAR FLASHING LAMP FR--35
B--08 CLEAN GRAIN ELEVATOR RPM FR--20 E--06 RH REAR FLASHING LAMP FR--35
B--09 REVERSER DISENGAGED FR--15 E--07 LH NASO FLASHING LAMP FR--33
B--10 CHOPPER RPM FR--23 E--08 RH NASO FLASHING LAMP FR--33
B--11 -- -- E--09 TURN INDICATOR FR--33
B--12 MOISTURE SENSOR FR--24 E--10 HIGH BEAM INDICATOR FR--33
B--13 -- -- E--11 LH BRAKE / MARKER LAMP FR--35
B--14 FEEDER RPM FR--15 E--12 RH BRAKE / MARKER LAMP FR--35
B--15 REEL RPM FR--12 E--13 LH ROAD LIGHT FR--36
B--16 CLEANING FAN RPM FR--19 E--14 RH ROAD LIGHT FR--36
B--17 GROUND SPEED RPM FR--09 E--15 LH CAB OUTER WORK LIGHT FR--41
B--18 HYD OIL RESERVOIR TEMP FR--10 E--16 RH CAB OUTER WORK LIGHT FR--41
B--19 LEFT ROTOR LOSS FR--20 E--17 LH CAB INNER WORK LIGHT FR--41
B--20 RIGHT ROTOR LOSS FR--20 E--18 RH CAB INNER WORK LIGHT FR--41
B--21 SIEVES LOSS FR--19 E--19 LH CAB MID WORK LIGHT FR--41
B--22 REAR LADDER FR--05 E--20 RH CAB MID WORK LIGHT FR--41
B--23 BOOST PRESSURE (IVECO) FR--06 E--21 LH HEADER LIGHT FR--40
B--24 STONE DOOR CLOSED FR--15 E--22 RH HEADER LIGHT FR--40
B--25 AMBIENT TEMP SENSOR FR--47 E--23 LH LOWER WORK LIGHT FR--40
B--26 CAB TEMP SENSOR FR--47 E--24 RH LOWER WORK LIGHT FR--40
B--27 OUTLET TEMP SENSOR FR--47 E--25 LH SIDE WORK LIGHT FR--43
B--28 EVAPORATOR TEMP SENSOR FR--47 E--26 RH SIDE WORK LIGHT FR--43
B--29 HEADER LIFT PRESSURE FR--13 E--27 LH REAR WORK LIGHT FR--42
B--30 ENGINE OIL PRESSURE FR--05 E--28 RH REAR WORK LIGHT FR--42
B--31 COOLANT TEMP (MECHANICAL) FR--05 E--29 UNLOAD TUBE LIGHT FR--40
B--32 GEARBOX TEMPERATURE FR--10 E--30 GRAIN TANK LIGHT FR--40
B--33 -- -- E--31 LH FRONT BEACON FR--39
B--34 -- -- E--32 RH FRONT BEACON FR--39
B--35 LOW CONTROL PRESSURE FR--10 E--33 REAR BEACON FR--39
E--34 DOME LIGHT FR--38
55-19
E--35 CONSOLE LIGHT FR--38 F--32 HIGH BEAM FUSE FR--36
E--36 COLD START INDICATOR FR--03 F--33 LOW BEAM FUSE FR--36
E--37 SIEVE LIGHT FR--43 F--34 UNDER SHIELD LTS FR--38
E--38 CENTER WORK LIGHT FR--40 F--35 RADIO KAPWR FR--46
E--39 UNLOAD TUBE MARKER LMP (FR) FR--34 F--36 CCM--2A FUSE FR--28
E--40 HEADER LH MARKER LAMP (EU) FR--33 F--37 CCM--2B FUSE FR--28
E--41 HEADER RH MARKER LAMP (EU) FR--33 F--38 KEY SWITCH FUSE FR--29
E--42 LH FRONT SHIELD LT FR--38 F--39 MEMORY (KAPWR) FR--29
E--43 LH REAR SHIELD LT FR--38 F--40 CCM--1 POWER FUSE FR--28
E--44 RH FRONT SHIELD LT FR--38 F--41 CCM--2 POWER FUSE FR--28
E--45 RH REAR SHIELD LT FR--38 F--42 CCM--3 / CAB POWER FUSE FR--28
E--46 ENGINE LT FR--38 F--43 CCM--1A FUSE FR--26
E--47 LH FLIP UP ROAD LT FR--37 F--44 CCM--1B FUSE FR--26
E--48 RH FLIP UP ROAD LT FR--37 F--45 HHC MODULE FUSE FR--13
E--49 RH POSITION LT (EU) FR--34 F--46 ASP POWER FUSE FR--14
E--50 LH POSITION LT (EU) FR--34 F--47 CCM--3 FUSE FR--24
E--51 RH FLASHING LT (EU) FR--34 F--48 RH CONSOLE FUSE FR--25
E--52 LH FLASHING LT (EU) FR--34 F--49 CAB FUSE FR--27
E--53 RH FRONT AUSTRIA LT FR--34 F--50 SIDE LTS FUSE FR--40
E--54 LH FRONT AUSTRIA LT FR--34 F--51 HORN / MARKER LTS FUSE FR--36
E--55 RH REAR AUSTRIA LT FR--35 F--52 DOME / BRAKE LT FUSE FR--38
E--56 LH REAR AUSTRIA LT FR--35 F--53 BEACON LTS FUSE FR--39
E--57 RH LICENSE PLATE LT (EU) FR--35 F--54 LOWER WORK LTS FUSE FR--40
E--58 LH LICENSE PLATE LT (EU) FR--35 F--55 REAR WORK LTS FUSE FR--42
Fuses F--56 HAZARD LIGHTS FUSE FR--33
F--01 ECU POWER FUSE FR--02 F--64 SWITCH BYPASS FUSES FR--44
F--02 ACCESSORY 2 FUSE FR--46 Generators
F--03 ACCESSORY 1 FUSE FR--45 G--01 ALTERNATOR FR--02
F--04 WIPER FUSE FR--45 G--02 FRONT BATTERY FR--01
F--05 CIGAR LIGHTER FUSE FR--45 G--03 REAR BATTERY FR--01
F--06 LH CAB WORK LTS FUSE FR--41 Audio
F--07 RH CAB WORK LTS FUSE FR--41 H--01 AUDIO ALARM FR--25
F--08 ACCESSORY OUTLET FUSE FR--45 H--02 HORN FR--36
F--09 WASHER / MIRROR FUSE FR--45 H--04 REAR LEFT SPEAKER FR--46
F--10 COLD START FUSE (AF) FR--45 H--05 FRONT LEFT SPEAKER FR--46
F--11 RADIO FUSE FR--46 H--06 REAR RIGHT SPEAKER FR--46
F--12 GPS POWER FUSE FR--30 H--07 FRONT RIGHT SPEAKER FR--46
F--13 TRANSCEIVER POWER FUSE FR--46 H--08 BACK UP ALARM FR--08
F--14 SERVICE LTS FUSE FR--43 Outlets
F--15 SERVICE SOCKETS FUSE FR--39 J--01 RH FT SERVICE SOCKET FR--39
F--16 SEAT PUMP FUSE FR--46 J--02 LH FT SERVICE SOCKET FR--39
F--17 SEPARATOR BLOWER FUSE FR--48 J--03 RH SIDE SERVICE SOCKET FR--39
F--18 MAIN BLOWER FUSE FR--48 J--04 LH SIDE SERVICE SOCKET FR--39
F--19 A/C CLUTCH FUSE FR--48 J--05 ENGINE SERVICE SOCKET FR--39
F--20 LH MARKER LIGHTS FUSE FR--34 J--06 ACCESSORY SOCKET FR--45
F--21 RH MARKER LIGHTS FUSE FR--34 J--07 TRANSCEIVER POWER OUTLET FR--46
F--22 SHOE LEVELING MOTOR FUSE FR--19 J--08 ACCESSORY OUTLET FR--45
F--23 THROTTLE / BRUSH FUSE FR--04 J--09 TRAILER OUTLET FR--35
F--24 FAN / REVERSER FUSE FR--15 J--10 DIAGNOSTIC OUTLET FR--29
F--25 TRANSMISSION SHIFT FUSE FR--09 Relays
F--26 CROSS AUGER TENT FUSE FR--22 K--01 CAB ROOF WORK LTS RELAY FR--41
F--27 SIEVE / SPREADER FUSE FR--21 K--02 LIGHT CONTROL RELAY FR--36
F--28 FUEL PUMP FUSE FR--06 K--03 ACCESSORY 2 RELAY FR--46
F--29 DISTANCE WORK LTS FUSE FR--41 K--04 HIGH BEAM RELAY FR--36
F--30 HEADER WORK LTS FUSE FR--40 K--05 LOW BEAM RELAY FR--36
F--31 CAB ROOF WORK LTS FUSE FR--41 K--06 WIPER RELAY FR--45
55-20
K--07 FUEL PUMP RELAY FR--06 L--19 LATERAL FLOAT CCW FR--13
K--08 ACCESSORY 1 RELAY FR--45 L--20 FEEDER JOG FORWARD FR--15
K--09 SEPARATOR BLOWER RLAY FR--48 L--21 FEEDER JOG REVERSE FR--15
K--10 A/C CLUTCH RELAY FR--48 L--22 GEARBOX CLUTCH FR--17
K--11 MAIN BLOWER RELAY HIGH FR--48 L--23 GROUND SPEED HYDROSTAT FR--09
K--12 MAIN BLOWER RELAY MED FR--48 L--24 FEEDER CLUTCH FR--15
K--13 MAIN BLOWER RELAY LOW FR--48 L--25 -- --
K--14 ECU POWER RELAY FR--02 L--26 REAR WHEEL ASSIST FR--08
K--15 THROTTLE / BRUSH RELAY FR--04 L--27 DUAL RANGE FR--08
K--16 CONCAVE / COVERS RELAY FR--16 L--28 CHAFF SPREADER / BLOWER FR--23
K--17 FAN / REVERSER RELAY FR--15 L--29 ROTOR INCREASE FR--17
K--18 UPPER / LOWER SIEVE RELAY FR--21 L--30 ROTOR DECREASE FR--17
K--19 FEEDER DISENGAGE FR--15 L--31 STONE DOOR OPEN FR--14
K--20 TIME DELAY MODULE FR--38 L--32 BRAKE LIMITING FR--09
K--21 DISTANCE WORK LTS RELAY FR--41 L--33 ENGINE BRAKE (IVECO) FR--06
K--22 HEADER WORK LTS RELAY FR--40 L--34 FUEL ACTUATOR 1 (IVECO) FR--06
K--23 NEUTRAL START RELAY FR--02 L--35 FUEL ACTUATOR 2 (IVECO) FR--06
K--24 CCM--1 POWER RELAY FR--28 L--36 FUEL ACTUATOR 3 (IVECO) FR--06
K--25 CCM--2 POWER RELAY FR--28 L--37 FUEL ACTUATOR 4 (IVECO) FR--06
K--26 CCM--3 / CAB POWER RELAY FR--28 L--38 FUEL ACTUATOR 5 (IVECO) FR--06
K--27 ROAD LIGHTS RELAY (AF) FR--41 L--39 FUEL ACTUATOR 6 (IVECO) FR--06
K--28 THRESHING LATCHING FR--17 Motors
K--29 BEACON LIGHTS RELAY FR--39 M--01 12V STARTER (BASILDON) FR--01
K--30 LOWER WORK LTS RELAY FR--40 M--02 TRANSMISSION SHIFT MOTOR FR--09
K--31 REAR WORK LTS RELAY FR--42 M--03 SHOE LEVELLING ACTUATOR FR--19
K--32 UNLOAD TUBE LIGHT RELAY FR--40 M--04 CONCAVE CLEARANCE MOTOR FR--16
K--33 BRAKE LIGHTS RELAY FR--38 M--05 CLEANING FAN ADJUST MOTOR FR--15
K--34 TIMED SIDE WORK LIGHT RELAY FR--43 M--06 UPPER SIEVE ACTUATOR FR--21
K--35 SIDE WORK LIGHT RELAY FR--43 M--07 LOWER SIEVE ACTUATOR FR--21
K--36 START RELAY FR--02 M--08 -- --
K--37 GRID HEATER RELAY (BAS) FR--03 M--09 REEL SPEED MOTOR FR--12
K--38 24V START RELAY (IVECO) FR--01 M--10 FEEDER REVERSER ACTUATOR FR--15
K--39 GRID HEATER RELAY (IVECO) FR--02 M--11 SPREADER PLATE MOTOR FR--23
K--40 FLIP UP LOW BEAM RELAY FR--37 M--12 COVERS MOTOR FR--16
K--41 FLIP UP HIGH BEAM RELAY FR--37 M--13 THROTTLE ACTUATOR (MECH) FR--04
K--42 RH VERTICAL KNIFE RELAY (OP) FR--12 M--15 COLD BOX DOOR MOTOR FR--47
K--43 LH VERTICAL KNIFE RELAY (OP) FR--12 M--16 WATER VALVE MOTOR FR--47
Solenoids M--17 MAIN BLOWER MOTOR FR--48
L--01 NEUTRAL LOCK SOLENOID FR--07 M--18 SEPARATOR BLOWER MOTOR FR--48
L--02 FUEL SOLENOID (MECHANICAL) FR--02 M--19 RH MIRROR UP / DOWN FR--44
L--03 UNLOAD TUBE IN FR--22 M--20 RH MIRROR IN / OUT FR--44
L--04 UNLOAD TUBE OUT FR--22 M--21 LH MIRROR UP / DOWN FR--44
L--05 FOOT AND INCH FR--08 M--22 LH MIRROR IN / OUT FR--44
L--06 HDR HEIGHT ACCUMULATOR FR--13 M--23 FUEL PUMP FR--06
L--07 A/C CLUTCH FR--48 M--24 WIPER WASHER MOTOR FR--45
L--08 UNLOAD TUBE CLUTCH FR--22 M--25 WIPER MOTOR FR--45
L--09 FUEL INJECTION PUMP FR--04 M--26 SEAT PUMP MOTOR FR--46
L--10 PARK BRAKE DISENGAGE FR--09 M--27 ROTARY SCREEN BRUSH FR--04
L--11 FEEDER INCREASE FR--14 M--28 SAMPLE MOTOR FR--24
L--12 FEEDER DECREASE FR--14 M--29 24V STARTER (IVECO) FR--01
L--13 REEL DOWN FR--12 M--30 GERMAN MIRROR UP / DOWN FR--44
L--14 REEL UP FR--12 M--31 GERMAN MIRROR IN / OUT FR--44
L--15 REEL AFT FR--12 Resistive
L--16 REEL FORE FR--12 R--01 FUEL LEVEL FR--05
L--17 REEL DRIVE FR--12 R--02 LATERAL FLOAT POT FR--12
L--18 LATERAL FLOAT CW FR--13 R--03 FEEDER ANGLE POT FR--13
55-21
R--04 GROUND SPEED POT FR--07 S--32 RETURNS FILTER BYPASS FR--10
R--05 YIELD SENSOR FR--24 S--33 HYDRAULIC RESERVOIR LEVEL FR--10
R--06 CONCAVE POSITION FR--16 S--34 GEARBOX FILTER BYPASS FR--10
R--07 -- -- S--35 UPPER SIEVE REAR ADJUST FR--21
R--08 CIGAR LIGHTER FR--45 S--36 ENGINE THROTTLE FR--03
R--09 ENGINE GRID HEATER (IVECO) FR--02 S--37 CHARGE PRESSURE FR--09
R--10 RH MIRROR HEAT FR--44 S--38 WASHER SWITCH FR--45
R--11 LH MIRROR HEAT FR--44 S--39 BRAKE PRESSURE FR--09
R--12 LH STUBBLE HEIGHT FR--13 S--40 LH DOOR SWITCH FR--38
R--13 RH STUBBLE HEIGHT FR--13 S--41 BEACON LIGHT SWITCH FR--39
R--14 GERMAN MIRROR HEAT FR--44 S--42 TANK EXTENSIONS SWITCH FR--22
R--15 AIR FILTER SWITCH RESISTOR FR--05 S--43 WORK LIGHT SWITCH FR--42
Switches S--44 REAR WORK LIGHT SWITCH FR--42
S--01 -- -- S--45 SEAT ADJUST SWITCH FR--46
S--02 KEY SWITCH FR--29 S--46 LOWER SIEVE REAR ADJUST FR--21
S--03 MULTIFUNCTION HANDLE FR--11 S--47 A/C HIGH PRESSURE FR--48
S--04 HEADER HEIGHT MODE FR--11 S--48 A/C LOW PRESSURE FR--48
S--05 SEAT SWITCH FR--27 S--49 BRAKE FLUID LEVEL SWITCH FR--08
S--06 HHC FINE ADJUST FR--11 S--50 -- --
S--07 FEEDER REVERSER FR--14 S--51 VERTICAL KNIVES FR--11
S--08 REEL SPEED MODE FR--11 S--52 BATTERY SWITCH (EU) FR--01
S--09 PARK BRAKE FR--07 S--53 FREEZE SWITCH FR--47
S--10 REAR WHEEL ASSIST FR--07 S--54 SIEVE LIGHT SWITCH FR--43
S--11 DUAL RANGE FR--07 S--55 LH BRAKE WEAR SWITCH FR--08
S--12 ON THE ROAD SWITCH FR--07 S--56 RH BRAKE WEAR SWITCH FR--08
S--13 UPPER SIEVE FR--19 S--57 MIRROR SELECT SWITCH (DE) FR--44
S--14 LOWER SIEVE FR--19 S--58 ENGINE OIL TEMP SWITCH (BAS) FR--05
S--15 FAN SPEED FR--19 S--59 --
S--16 CONCAVE CLEARANCE FR--16 S--60 --
S--17 ROTOR SPEED FR--10 S--61 AIR FILTER SWITCH FR--05
S--18 FEEDER SPEED FR--10 S--62 FUEL FILTER SWITCH (IVECO) FR--05
S--19 MIRROR HEAT SWITCH FR--44
S--63 LEFT SHIELD LT SW FR--38
S--20 WIPER SWITCH FR--45
S--64 ENGINE LT SW FR--38
S--21 ALTERNATE SETTINGS FR--11
S--65 RIGHT SHIELD LT SW FR--38
S--22 NEUTRAL SWITCH FR--09
Splice Blocks
S--23 SPREADER PLATE FR--23
W--01 SPLICE BLOCK A FR--25
S--24 GEAR SELECT FR--07
W--02 SPLICE BLOCK B FR--25
S--25 HAZARD SWITCH FR--33
W--03 SPLICE BLOCK C FR--27
S--26 ROAD LIGHT SWITCH FR--36
W--06 SPLICE BLOCK F FR--25
S--27 MIRROR ADJUST SWITCH FR--44
1 REAR FRAME GROUND
S--28 GRAIN BIN 3/4 FULL FR--22
2 FRONT FRAME GROUND
S--29 GRAIN BIN FULL FR--22
3 CAB FLOOR GROUND
S--30 THRESHER ENGAGE FR--17
4 CAB ROOF GROUND
S--31 FEEDER ENGAGE FR--14
5 CAB ROOF GROUND
55-22
2003 PRODUCTION -- SN HAJ100101 to 800
55-23
55-24
55-25
55-26
55-27
55-28
55-29
55-30
55-31
55-32
55-33
55-34
55-35
55-36
55-37
55-38
55-39
55-40
55-41
55-42
55-43
55-44
55-45
55-46
55-47
55-48
55-49
55-50
55-51
55-52
55-53
55-54
55-55
55-56
55-57
55-58
55-59
55-60
55-61
55-62
55-63
55-64
55-65
55-66
55-67
55-68
55-69
55-70
COMPONENT INDEX, 2004 PRODUCTION -- SN HAJ100801 to 1500
Electronics B--41 AIR TEMP/ BOOST PRESS (7.5L) FR--04
A--01 ENGINE CONTROL UNIT FR--02 B--42 COOLANT TEMP (7.5L) FR--04
A--01 ENGINE CONTROL UNIT FR--04 B--43 FLYWHEEL RPM (7.5L) FR--04
A--01 ENGINE CONTROL UNIT FR--06 B--44 COOLANT TEMP (IVECO) FR--06
A--01 ENGINE CONTROL UNIT FR--31 B--45 GEARBOX CLUTCH TEMP FR--17
A--02 MAIN DISPLAY MODULE (MDM) FR--30 B--46 HYDROSTAT MOTOR TEMP FR--08
A--03 SHAFT SPEED MONITOR (SSM) FR--30 B--47 COVERS OPEN FR--22
A--04 RADIO FR--46 B--48 -- --
A--05 FLASHER MODULE FR--33 B--49 -- --
A--05 FLASHER MODULE FR--36 B--50 -- --
A--06 -- -- B--51 -- --
A--07 HHC MODULE (EMR--OBE) FR--14 B--52 ENGINE OIL PRESSURE (IVECO) FR--05
A--07 HHC MODULE (EMR--OBE) FR--31 B--53 PARK BRAKE PRESSURE FR--09
A--08 -- -- B--54 AIR TEMP (IVECO) FR--06
A--09 HVAC CONTROL MODULE FR--47 Lights
A--09 HVAC CONTROL MODULE FR--48 E--01 LH HEADER FLASHING LMP (NA) FR--33
A--10 DATA LOGGER (DLU) FR--30 E--02 RH HEADER FLASHING LMP (NA) FR--33
A--11 GPS MODULE FR--31 E--03 LH FRONT HAZARD LAMP FR--34
A--21 FUTURE OPTION FR--30 E--04 LH FRONT HAZARD LAMP FR--34
Sensors E--05 LH REAR FLASHING LAMP FR--35
B--01 DRUM RPM FR--18 E--06 RH REAR FLASHING LAMP FR--35
B--02 LATERAL INCLINATION FR--20 E--07 LH NASO FLASHING LAMP FR--33
B--03 ENGINE OIL TEMP (IVECO) FR--05 E--08 RH NASO FLASHING LAMP FR--33
B--04 ROTARY SEPARATOR RPM FR--20 E--09 TURN INDICATOR FR--33
B--05 ENGINE FLYWHEEL RPM (IVECO) FR--06 E--10 HIGH BEAM INDICATOR FR--33
B--06 LEFT RETURNS RPM FR--20 E--11 LH BRAKE / MARKER LAMP FR--35
B--07 ENGINE CAMSHAFT RPM (IVECO) FR--06 E--12 RH BRAKE / MARKER LAMP FR--35
B--08 CLEAN GRAIN ELEVATOR RPM FR--20 E--13 LH ROAD LIGHT FR--36
B--09 REVERSER DISENGAGED FR--16 E--14 RH ROAD LIGHT FR--36
B--10 CHOPPER RPM FR--23 E--15 LH CAB OUTER WORK LIGHT FR--41
B--11 SWATH PLATE POSITION FR--15 E--16 RH CAB OUTER WORK LIGHT FR--41
B--12 MOISTURE SENSOR FR--24 E--17 LH CAB INNER WORK LIGHT FR--41
B--13 STRAW WALKER RPM FR--20 E--18 RH CAB INNER WORK LIGHT FR--41
B--14 -- -- E--19 LH CAB MID WORK LIGHT FR--41
B--15 REEL RPM FR--13 E--20 RH CAB MID WORK LIGHT FR--41
B--16 CLEANING FAN RPM FR--19 E--21 LH HEADER LIGHT FR--40
B--17 GROUND SPEED RPM FR--09 E--22 RH HEADER LIGHT FR--40
B--18 HYD OIL RESERVOIR TEMP FR--10 E--23 LH LOWER WORK LIGHT FR--40
B--19 -- -- E--24 RH LOWER WORK LIGHT FR--40
B--20 -- -- E--25 LH SIDE WORK LIGHT FR--43
B--21 SIEVES LOSS FR--19 E--26 RH SIDE WORK LIGHT FR--43
B--22 REAR LADDER FR--05 E--27 LH REAR WORK LIGHT FR--42
B--23 BOOST PRESSURE (IVECO) FR--06 E--28 RH REAR WORK LIGHT FR--42
B--24 -- -- E--29 UNLOAD TUBE LIGHT FR--40
B--25 AMBIENT TEMP SENSOR FR--47 E--30 GRAIN TANK LIGHT FR--40
B--26 CAB TEMP SENSOR FR--47 E--31 LH FRONT BEACON FR--39
B--27 OUTLET TEMP SENSOR FR--47 E--32 RH FRONT BEACON FR--39
B--28 EVAPORATOR TEMP SENSOR FR--47 E--33 REAR BEACON FR--39
B--29 HEADER LIFT PRESSURE FR--14 E--34 DOME LIGHT FR--38
B--30 ENGINE OIL PRESSURE (7.5L) FR--05 E--35 CONSOLE LIGHT FR--38
B--31 -- -- E--36 COLD START INDICATOR FR--02
B--32 GEARBOX TEMPERATURE FR--10 E--37 SIEVE LIGHT FR--43
B--33 LEFT WALKER LOSS FR--20 E--38 CENTER WORK LIGHT FR--40
B--34 RIGHT WALKER LOSS FR--20 E--39 UNLOAD TUBE MARKER LMP (FR) FR--34
B--35 LOW CONTROL PRESSURE FR--10 E--40 HEADER LH MARKER LAMP (EU) FR--33
B--36 FUEL TEMP (IVECO) FR--06 E--41 HEADER RH MARKER LAMP (EU) FR--33
B--37 TRANS SHIFT POSITION FR--09 E--42 -- --
B--38 UNLOAD CRADLE FR--22 E--43 -- --
B--39 RIGHT RETURNS RPM FR--20 E--44 -- --
B--40 FUEL TEMP (7.5L) FR--04 E--45 -- --
55-71
E--46 -- -- F--49 CAB FUSE FR--27
E--47 LH FLIP UP ROAD LT FR--37 F--50 SIDE LTS FUSE FR--40
E--48 RH FLIP UP ROAD LT FR--37 F--51 HORN / MARKER LTS FUSE FR--36
E--49 RH POSITION LT (EU) FR--34 F--52 DOME / BRAKE LT FUSE FR--38
E--50 LH POSITION LT (EU) FR--34 F--53 BEACON LTS FUSE FR--39
E--51 RH FLASHING LT (EU) FR--34 F--54 LOWER WORK LTS FUSE FR--40
E--52 LH FLASHING LT (EU) FR--34 F--55 REAR WORK LTS FUSE FR--42
E--53 RH FRONT AUSTRIA LT FR--34 F--56 HAZARD LIGHTS FUSE FR--33
E--54 LH FRONT AUSTRIA LT FR--34 F--64 SWITCH BYPASS FUSES FR--44
E--55 RH REAR AUSTRIA LT FR--35 Generators
E--56 LH REAR AUSTRIA LT FR--35 G--01 ALTERNATOR FR--02
E--57 RH LICENSE PLATE LT (EU) FR--35 G--02 FRONT BATTERY FR--01
E--58 LH LICENSE PLATE LT (EU) FR--35 G--03 REAR BATTERY FR--01
Fuses Audio
F--01 ECU POWER FUSE FR--02 H--01 AUDIO ALARM FR--25
F--02 ACCESSORY 2 FUSE FR--46 H--02 HORN FR--36
F--03 ACCESSORY 1 FUSE FR--45 H--03 -- --
F--04 WIPER FUSE FR--45 H--04 REAR LEFT SPEAKER FR--46
F--05 CIGAR LIGHTER FUSE FR--45 H--05 FRONT LEFT SPEAKER FR--46
F--06 LH CAB WORK LTS FUSE FR--41 H--06 REAR RIGHT SPEAKER FR--46
F--07 RH CAB WORK LTS FUSE FR--41 H--07 FRONT RIGHT SPEAKER FR--46
F--08 ACCESSORY OUTLET FUSE FR--45 H--08 BACK UP ALARM FR--08
F--09 WASHER / MIRROR FUSE FR--45 Outlets
F--10 COLD START FUSE (AF) FR--45 J--01 RH FT SERVICE SOCKET FR--39
F--11 RADIO FUSE FR--46 J--02 LH FT SERVICE SOCKET FR--39
F--12 GPS POWER FUSE FR--30 J--03 RH SIDE SERVICE SOCKET FR--39
F--13 TRANSCEIVER POWER FUSE FR--46 J--04 LH SIDE SERVICE SOCKET FR--39
F--14 SERVICE LTS FUSE FR--43 J--05 ENGINE SERVICE SOCKET FR--39
F--15 SERVICE SOCKETS FUSE FR--39 J--06 ACCESSORY SOCKET FR--45
F--16 SEAT PUMP FUSE FR--46 J--07 TRANSCEIVER POWER OUTLET FR--46
F--17 SEPARATOR BLOWER FUSE FR--48 J--08 ACCESSORY OUTLET FR--45
F--18 MAIN BLOWER FUSE FR--48 J--09 TRAILER OUTLET FR--35
F--19 A/C CLUTCH FUSE FR--48 J--10 DIAGNOSTIC OUTLET FR--29
F--20 LH MARKER LIGHTS FUSE FR--34 J--10 DIAGNOSTIC OUTLET FR--30
F--21 RH MARKER LIGHTS FUSE FR--34 Relays
F--22 SHOE LEVELING MOTOR FUSE FR--19 K--01 CAB ROOF WORK LTS RELAY FR--41
F--23 THROTTLE / BRUSH FUSE FR--04 K--02 LIGHT CONTROL RELAY FR--36
F--24 FAN / REVERSER FUSE FR--16 K--03 ACCESSORY 2 RELAY FR--46
F--25 TRANSMISSION SHIFT FUSE FR--09 K--04 HIGH BEAM RELAY FR--36
F--26 CROSS AUGER TENT FUSE FR--22 K--05 LOW BEAM RELAY FR--36
F--27 SIEVE / SPREADER FUSE FR--21 K--06 WIPER RELAY FR--45
F--28 FUEL PUMP FUSE FR--06 K--07 FUEL PUMP RELAY FR--06
F--29 DISTANCE WORK LTS FUSE FR--41 K--08 ACCESSORY 1 RELAY FR--45
F--30 HEADER WORK LTS FUSE FR--40 K--09 SEPARATOR BLOWER RLAY FR--48
F--31 CAB ROOF WORK LTS FUSE FR--41 K--10 A/C CLUTCH RELAY FR--48
F--32 HIGH BEAM FUSE FR--36 K--11 MAIN BLOWER RELAY HIGH FR--48
F--33 LOW BEAM FUSE FR--36 K--12 MAIN BLOWER RELAY MED FR--48
F--34 NOT USED FR--38 K--13 MAIN BLOWER RELAY LOW FR--48
F--35 RADIO KAPWR FR--46 K--14 ECU POWER RELAY FR--02
F--36 CCM--2A FUSE FR--28 K--15 THROTTLE / BRUSH RELAY FR--04
F--37 CCM--2B FUSE FR--28 K--16 CONCAVE / COVERS RELAY FR--17
F--38 KEY SWITCH FUSE FR--29 K--17 FAN / REVERSER RELAY FR--16
F--39 MEMORY (KAPWR) FR--29 K--18 UPPER / LOWER SIEVE RELAY FR--21
F--40 CCM--1 POWER FUSE FR--28 K--19 FEEDER DISENGAGE FR--16
F--41 CCM--2 POWER FUSE FR--28 K--20 TIME DELAY MODULE FR--38
F--42 CCM--3 / CAB POWER FUSE FR--28 K--21 DISTANCE WORK LTS RELAY FR--41
F--43 CCM--1A FUSE FR--26 K--22 HEADER WORK LTS RELAY FR--40
F--44 CCM--1B FUSE FR--26 K--23 NEUTRAL START RELAY FR--02
F--45 HHC MODULE FUSE FR--31 K--24 CCM--1 POWER RELAY FR--28
F--46 NOT USED FR--28 K--25 CCM--2 POWER RELAY FR--28
F--47 CCM--3 FUSE FR--24 K--26 CCM--3 / CAB POWER RELAY FR--28
F--48 RH CONSOLE FUSE FR--25 K--27 ROAD LIGHTS RELAY (AF) FR--41
55-72
K--28 THRESHING LATCHING FR--18 M--08 -- --
K--29 BEACON LIGHTS RELAY FR--39 M--09 REEL SPEED MOTOR FR--12
K--30 LOWER WORK LTS RELAY FR--40 M--10 FEEDER REVERSER ACTUATOR FR--16
K--31 REAR WORK LTS RELAY FR--42 M--11 SPREADER PLATE MOTOR FR--23
K--32 UNLOAD TUBE LIGHT RELAY FR--40 M--12 COVERS MOTOR FR--17
K--33 BRAKE LIGHTS RELAY FR--38 M--13 -- --
K--34 TIMED SIDE WORK LIGHT RELAY FR--43 M--14 -- --
K--35 SIDE WORK LIGHT RELAY FR--43 M--15 COLD BOX DOOR MOTOR FR--47
K--36 START RELAY FR--02 M--16 WATER VALVE MOTOR FR--47
K--38 24V START RELAY (IVECO) FR--01 M--17 MAIN BLOWER MOTOR FR--48
K--39 GRID HEATER RELAY (IVECO) FR--02 M--18 SEPARATOR BLOWER MOTOR FR--48
K--40 FLIP UP LOW BEAM RELAY FR--37 M--19 RH MIRROR UP / DOWN FR--44
K--41 FLIP UP HIGH BEAM RELAY FR--37 M--20 RH MIRROR IN / OUT FR--44
K--42 RH VERTICAL KNIFE RELAY (OP) FR--12 M--21 LH MIRROR UP / DOWN FR--44
K--43 LH VERTICAL KNIFE RELAY (OP) FR--12 M--22 LH MIRROR IN / OUT FR--44
Solenoids M--23 FUEL PUMP FR--06
L--01 NEUTRAL LOCK SOLENOID FR--07 M--24 WIPER WASHER MOTOR FR--45
L--02 -- -- M--25 WIPER MOTOR FR--45
L--03 UNLOAD TUBE IN FR--22 M--26 SEAT PUMP MOTOR FR--46
L--04 UNLOAD TUBE OUT FR--22 M--27 ROTARY SCREEN BRUSH FR--04
L--05 PRESSURE RELEASE FR--08 M--28 SAMPLE MOTOR FR--24
L--06 HDR HEIGHT ACCUMULATOR FR--14 M--29 24V STARTER (IVECO) FR--01
L--07 A/C CLUTCH FR--48 M--30 GERMAN MIRROR UP / DOWN FR--44
L--08 UNLOAD TUBE CLUTCH FR--22 M--31 GERMAN MIRROR IN / OUT FR--44
L--09 FUEL INJECTION PUMP (7.5L) FR--04 Resistive
L--10 PARK BRAKE DISENGAGE FR--09 R--01 FUEL LEVEL FR--05
L--11 -- -- R--02 LATERAL FLOAT POT FR--14
L--12 -- -- R--03 FEEDER ANGLE POT FR--14
L--13 REEL DOWN FR--12 R--04 GROUND SPEED POT FR--07
L--14 REEL UP FR--12 R--05 YIELD SENSOR FR--24
L--15 REEL AFT FR--12 R--06 CONCAVE POSITION FR--17
L--16 REEL FORE FR--12 R--07 -- --
L--17 REEL DRIVE FR--12 R--08 CIGAR LIGHTER FR--45
L--18 LATERAL FLOAT CW FR--14 R--09 ENGINE GRID HEATER (IVECO) FR--02
L--19 LATERAL FLOAT CCW FR--14 R--10 RH MIRROR HEAT FR--44
L--20 FEEDER JOG FORWARD FR--16 R--11 LH MIRROR HEAT FR--44
L--21 FEEDER JOG REVERSE FR--16 R--12 LH STUBBLE HEIGHT FR--14
L--22 GEARBOX CLUTCH FR--18 R--13 RH STUBBLE HEIGHT FR--14
L--23 GROUND SPEED HYDROSTAT FR--09 R--14 GERMAN MIRROR HEAT FR--44
L--24 FEEDER CLUTCH FR--16 R--15 AIR FILTER SWITCH RESISTOR FR--05
L--26 REAR WHEEL ASSIST FR--08 R--16 -- --
L--27 DUAL RANGE FR--08 R--17 -- --
L--28 CHAFF SPREADER / BLOWER FR--23 R--18 -- --
L--29 DRUM INCREASE FR--18 R--19 -- --
L--30 DRUM DECREASE FR--18 R--20 HEADER TYPE MODULE FR--13
L--31 -- -- R--21 -- --
L--32 BRAKE LIMITING FR--09 R--22 -- --
L--33 ENGINE BRAKE (IVECO) FR--06 R--23 -- --
L--34 FUEL ACTUATOR 1 (IVECO) FR--06 R--24 REEL HORIZONTAL POSITION FR--13
L--35 FUEL ACTUATOR 2 (IVECO) FR--06 R--25 REEL VERTICAL POSITION FR--13
L--36 FUEL ACTUATOR 3 (IVECO) FR--06 Switches
L--37 FUEL ACTUATOR 4 (IVECO) FR--06 S--01 -- --
L--38 FUEL ACTUATOR 5 (IVECO) FR--06 S--02 KEY SWITCH FR--29
L--39 FUEL ACTUATOR 6 (IVECO) FR--06 S--03 MULTIFUNCTION HANDLE FR--11
Motors S--04 HEADER HEIGHT MODE FR--11
M--01 12V STARTER (7.5 L) FR--01 S--05 SEAT SWITCH FR--27
M--02 TRANSMISSION SHIFT MOTOR FR--09 S--06 HHC FINE ADJUST FR--11
M--03 SHOE LEVELLING ACTUATOR FR--19 S--07 FEEDER REVERSER FR--16
M--04 CONCAVE CLEARANCE MOTOR FR--17 S--08 REEL SPEED MODE FR--11
M--05 CLEANING FAN ADJUST MOTOR FR--16 S--09 PARK BRAKE FR--07
M--06 UPPER SIEVE ACTUATOR FR--21 S--10 REAR WHEEL ASSIST FR--07
M--07 LOWER SIEVE ACTUATOR FR--21 S--11 DUAL RANGE FR--07
55-73
S--12 ON THE ROAD SWITCH FR--07 Splice Blocks
S--13 UPPER SIEVE FR--19 W--01 SPLICE BLOCK A FR--25
S--14 LOWER SIEVE FR--19 W--02 SPLICE BLOCK B FR--25
S--15 FAN SPEED FR--19 W--03 SPLICE BLOCK C FR--27
S--16 CONCAVE CLEARANCE FR--17 W--04 -- --
S--17 ROTOR SPEED FR--10 W--05 -- --
S--18 FEEDER SPEED FR--10 W--06 SPLICE BLOCK F FR--25
S--20 WIPER SWITCH FR--45 REAR FRAME GROUND FR--48
1
S--22 NEUTRAL SWITCH FR--09 2 FRONT FRAME GROUND FR--48
S--24 GEAR SELECT FR--07 3 CAB FLOOR GROUND FR--48
S--26 ROAD LIGHT SWITCH FR--36 4 CAB ROOF GROUND FR--48
S--28 GRAIN BIN 3/4 FULL FR--22 5 ENGINE GROUND FR--48
S--30 THRESHER ENGAGE FR--18 6 -- --
S--32 RETURNS FILTER BYPASS FR--10 7 CCM--1 REFERENCE GROUND “A” FR--26
S--33 HYDRAULIC RESERVOIR LEVEL FR--10
S--34 GEARBOX FILTER BYPASS FR--10 8 CCM--1 REFERENCE GROUND “B” FR--26
S--35 UPPER SIEVE REAR ADJUST FR--21
9 CCM--1 REFERENCE VOLTAGE “A” FR--26
S--36 ENGINE THROTTLE FR--04
S--37 CHARGE PRESSURE FR--09
10 CCM--1 REFERENCE VOLTAGE “B” FR--26
S--38 WASHER SWITCH FR--45
S--39 BRAKE PRESSURE FR--09
11 CCM--2 REFERENCE GROUND “A” FR--27
S--40 LH DOOR SWITCH FR--38
S--41 BEACON LIGHT SWITCH FR--39 CCM--2 REFERENCE GROUND “B” FR--27
12
S--42 TANK EXTENSIONS SWITCH FR--22
S--43 WORK LIGHT SWITCH FR--42 CCM--2 REFERENCE VOLTAGE “A” FR--27
131
S--44 REAR WORK LIGHT SWITCH FR--42
S--45 SEAT ADJUST SWITCH FR--46 14 CCM--1 REFERENCE VOLTAGE “B” FR--27
S--46 LOWER SIEVE REAR ADJUST FR--21
S--47 A/C HIGH PRESSURE FR--48 CCM--3 REFERENCE GROUND FR--26
15
S--48 A/C LOW PRESSURE FR--48
S--49 BRAKE FLUID LEVEL SWITCH FR--08 16 CCM--3 REFERENCE VOLTAGE FR--26
S--50 -- --
S--51 VERTICAL KNIVES FR--11 17 BACK LIGHTING “A” FR--27
S--52 BATTERY SWITCH FR--01
S--53 FREEZE SWITCH FR--47 18 BACK LIGHTING “B” FR--25
S--54 SIEVE LIGHT SWITCH FR--43
S--55 LH BRAKE WEAR SWITCH FR--08 19 RH CONSOLE +12 VOLTS FR--25
S--56 RH BRAKE WEAR SWITCH FR--08
S--57 MIRROR SELECT SWITCH (D) FR--44 20 CAB +12 VOLTS FR--27
S--58 ENGINE OIL TEMP SWITCH (7.5L) FR--05
S--59 STRAW WALKER PROTECT FR--20
S--60 CHOPPER HOOD PROTECT FR--20
S--61 AIR FILTER SWITCH FR--05
S--62 FUEL FILTER SWITCH (IVECO) FR--05
55-74
G-02 = FRONT BATTERY M-29 = 24V STARTER (IVECO) (1) BASE MODEL WITH 7.5L BASILDON ENGINE
G-03 = REAR BATTERY S-52 = BATTERY SWITCH (EU) (2) BASE MODEL WITH IVECO ENGINE
K-38 = 24V START RELAY (IVECO) (7) BASE MODEL SOLD IN NORTH AMERICA STARTING
M-01 = 12V STARTER (7.5 L) (8) BASE MODEL SOLD IN EUROPE FRAME--1
55-75
A-01 = ENGINE CONTROL UNIT K-14 = ECU POWER RELAY R-09 = ENGINE GRID HEATER (IVECO)
E-36 = COLD START INDICATOR K-23 = NEUTRAL START RELAY
STARTING F-01 = ECU POWER FUSE K-36 = START RELAY
FRAME--2 G-01 = ALTERNATOR K-39 = GRID HEATER RELAY (IVECO)
55-76
BLANK
FRAME--3
55-77
A-01 = ENGINE CONTROL UNIT B-43 = FLYWHEEL RPM (7.5 L) M-27 = ROTARY SCREEN BRUSH
B-40 = FUEL TEMP (7.5 L) F-23 = THROTTLE/BRUSH FUSE S-36 = ENGINE THROTTLE
ENGINE B-41 = AIR TEMP/BOOST PRESS (7.5 L) K-15 = THROTTLE/BRUSH RELAY
FRAME--4 B-42 = COOLANT TEMP (7.5 L) L-09 = FUEL INJECTION PUMP (7.5 L)
55-78
B-03 = ENGINE OIL TEMP (IVECO) R-01 = FUEL LEVEL S-62 = FUEL FILTER SWITCH (IVECO)
B-22 = REAR LADDER R-15 = AIR FILTER RESISTOR
B-30 = ENGINE OIL PRESS (7.5 L) S-58 = ENGINE OIL TEMP SWITCH (7.5 L) ENGINE
B-52 = ENGINE OIL PRESS (IVECO) S-61 = AIR FILTER SWITCH FRAME--5
55-79
B-05 = ENGINE FLYWHEEL RPM (IVECO) B-44 = COOLANT TEMP (IVECO) L-33 = ENGINE BRAKE (IVECO) L-37 = FUEL ACTUATOR 4 (CYL 6)
B-07 = ENGINE CAMSHAFT RPM (IVECO) B-54 = AIR TEMP (IVECO) L-34 = FUEL ACTUATOR 1 (CYL 1) L-38 = FUEL ACTUATOR 5 (CYL 3)
ENGINE B-23 = BOOST PRESSURE (IVECO) F-28 = FUEL PUMP FUSE L-35 = FUEL ACTUATOR 2 (CYL 4) L-39 = FUEL ACTUATOR 6 (CYL 5)
FRAME--6 B-36 = FUEL TEMP (IVECO) K-07 = FUEL PUMP RELAY L-36 = FUEL ACTUATOR 3 (CYL 2) M-23 = FUEL PUMP
55-80
A C
L-01 = NEUTRAL LOCK SOLENOID S-11 = DUAL RANGE

R-04 = GROUND SPEED POT S-12 = ON THE ROAD SWITCH
S-09 = PARK BRAKE S-24 = GEAR SELECT DRIVES
S-10 = REAR WHEEL ASSIST FRAME--7
55-81
B-46 = HYDROSTAT MOTOR TEMP L-27 = DUAL RANGE

H-08 = BACK UP ALARM S-49 = BRAKE FLUID LEVEL SWITCH
DRIVES L-05 = PRESSURE RELEASE S-55 = LH BRAKE WEAR SWITCH
FRAME--8 L-26 = REAR WHEEL ASSIST S-56 = RH BRAKE WEAR SWITCH
55-82
B-17 = GROUND SPEED RPM L-10 = PARK BRAKE DISENGAGE S-22 = NEUTRAL
B-37 = TRANS SHIFT POSITION L-23 = GROUND SPEED HYDROSTAT S-37 = CHARGE PRESSURE
B-53 = PARK BRAKE PRESSURE L-32 = BRAKE LIMITING S-39 = BRAKE PRESSURE DRIVES
F-25 = TRANSMISSION SHIFT FUSE M-02 = TRANSMISSION SHIFT MOTOR FRAME--9
55-83
B-18 = HYD OIL RESERVOIR TEMP S-18 = FEEDER SPEED

B-32 = GEARBOX TEMPERATURE S-32 = RETURNS FILTER BYPASS
HYDRAULIC B-35 = LOW CONTROL PRESSURE S-33 = HYDRAULIC RESERVOIR LEVEL
FRAME--10 S-17 = ROTOR SPEED S-34 = GEARBOX FILTER BYPASS
55-84
S-03 = MULTIFUNCTION HANDLE S-21 = ALTERNATE SETTINGS

S-04 = HEADER HEIGHT MODE S-51 = VERTICAL KNIVES
S-06 = HHC FINE ADJUST HEADER
S-08 = REEL SPEED MODE FRAME--11
55-85
K-42 = RH VERTICAL KNIFE RELAY (OP) L-15 = REEL AFT

K-43 = LH VERTICAL KNIFE RELAY (OP) L-16 = REEL FORE
HEADER L-13 = REEL DOWN L-17 = REEL DRIVE
FRAME--12 L-14 = REEL UP M-09 = REEL SPEED MOTOR
55-86
B-15 = REEL RPM

R-20 = HEADER TYPE MODULE
R-24 = REEL HORIZONTAL POSITION HEADER
R-25 = REEL VERTICAL POSITION FRAME--13
55-87
A-07 = HHC MODULE L-19 = LATERAL FLOAT CCW R-13 = RIGHT STUBBLE HEIGHT
B-29 = HEADER LIFT PRESSURE R-02 = LATERAL FLOAT POT
HEADER L-06 = HEADER HEIGHT ACCUMULATOR R-03 = FEEDER ANGLE
FRAME--14 L-18 = LATERAL FLOAT CW R-12 = LEFT STUBBLE HEIGHT
55-88
A-08 = ASP AMPLIFIER B-51 = LH TOP ASP SENSOR L-31 = STONE DOOR OPEN
B-48 = RH BOTTOM ASP SENSOR F-46 = ASP POWER FUSE S-07 = FEEDER REVERSER
B-49 = LH BOTTOM ASP SENSOR L-11 = FEEDER INCREASE FEEDER
B-50 = RH TOP ASP SENSOR L-12 = FEEDER DECREASE FRAME--15
55-89
B-09 = REVERSER DISENGAGE K-17 = FAN/REVERSER RELAY L-24 = FEEDER CLUTCH

B-14 = FEEDER RPM K-19 = FEEDER DISENGAGE M-05 = CLEANING FAN ADJUST MOTOR
FEEDER B-24 = STONE DOOR CLOSED L-20 = FEEDER JOG FORWARD M-10 = FEEDER REVERSER ACTUATOR
FRAME--16 F-24 = FAN, REVERSER FUSE L-21 = FEEDER JOG REVERSE S-31 = FEEDER ENGAGE
55-90
B-45 = GEARBOX CLUTCH TEMP R-06 = CONCAVE POSITION

K-16 = CONCAVE/COVERS RELAY S-16 = CONCAVE CLEARANCE
M-04 = CONCAVE CLEARANCE MOTOR THRESHER
M-12 = COVERS MOTOR FRAME--17
55-91
B-01 = ROTOR RPM L-30 = ROTOR DECREASE

K-28 = THRESHER LATCHING S-30 = THRESHER ENGAGE
THRESHER L-22 = GEARBOX CLUTCH
FRAME--18 L-29 = ROTOR INCREASE
55-92
B-16 = CLEANING FAN RPM S-13 = UPPER SIEVE

B-21 = SIEVES LOSS S-14 = LOWER SIEVE
F-22 = SHOE LEVELING MOTOR FUSE S-15 = FAN SPEED CLEANING
M-03 = SHOE LEVELING ACTUATOR FRAME--19
55-93
B-02 = LATERAL INCLINATION B-20 = RIGHT ROTOR LOSS

B-06 = LEFT RETURNS RPM B-39 = RIGHT RETURNS RPM
CLEANING B-08 = CLEAN GRAIN ELEVATOR RPM
FRAME--20 B-19 = LEFT ROTOR LOSS
55-94
F-27 = SIEVE/SPREADER FUSE S-35 = UPPER SIEVE REAR ADJUST

K-18 = UPPER/LOWER SIEVE RELAY S-46 = LOWER SIEVE REAR ADJUST
M-06 = UPPER SIEVE ACTUATOR CLEANING
M-07 = LOWER SIEVE ACTUATOR FRAME--21
55-95
B-38 = UNLOAD CRADLE L-04 = UNLOAD TUBE OUT S-42 = TANK EXTENSIONS SWITCH
B-47 = COVERS CLOSED L-08 = UNLOAD TUBE CLUTCH
UNLOAD F-26 = CROSS AUGER TENT FUSE S-28 = GRAIN BIN 3/4 FULL
FRAME--22 L-03 = UNLOAD TUBE IN S-29 = GRAIN BIN FULL
55-96
B-10 = CHOPPER RPM S-23 = SPREADER PLATE

B-55 = SPREADER RPM
L-28 = CHAFF SPREADER TRASH
M-11 = SPREADER PLATE MOTOR FRAME--23
55-97
B-12 = MOISTURE SENSOR

F-47 = CCM-3 FUSE
PRECISION M-28 = SAMPLE MOTOR
FRAME--24 R-05 = YIELD SENSOR
55-98
F-48 = RH CONSOLE FUSE W-06 = SPLICE BLOCK F

H-01 = AUDIO ALARM
W-01 = SPLICE BLOCK A DISTRIBUTION
W-02 = SPLICE BLOCK B FRAME--25
55-99
F-43 = CCM-1A FUSE

F-44 = CCM-1B FUSE
DISTRIBUTION
FRAME--26
55-100
F-49 = CAB FUSE

S-05 = SEAT SWITCH
W-03 = SPLICE BLOCK C DISTRIBUTION
FRAME--27
55-101
F-36 = CCM-2A FUSE F-42 = CCM-3, CAB POWER FUSE

F-37 = CCM-2B FUSE K-24 = CCM-1 POWER RELAY
DISTRIBUTION F-40 = CCM-1 POWER FUSE K-25 = CCM-2 POWER RELAY
FRAME--28 F-41 = CCM-2 POWER FUSE K-26 = CCM-3, CAB POWER RELAY
55-102
F-38 = KEY SWITCH FUSE

F-39 = MEMORY (KAPWR)
J-10 = DIAGNOSTIC OUTLET DISTRIBUTION
S-02 = KEY SWITCH FRAME--29
55-103
A-02 = MAIN DISPLAY MODULE F-12 = GPS POWER FUSE

A-03 = SHAFT SPEED MONITOR J-10 = DIAGNOSTIC OUTLET
DISTRIBUTION A-10 = DATA LOGGER
FRAME--30 A-21 = FUTURE OPTION
55-104
A-01 = ENGINE CONTROL UNIT F-45 = HHC MODULE

A-07 = HHC MODULE
A-08 = ASP AMPLIFIER DISTRIBUTION
A-11 = GPS MODULE FRAME--31
55-105
BLANK
FRAME--32
55-106
A-05 = FLASHER MODULE E-08 = RH NASO FLASHING LAMP (NA) E-41 = HEADER RH MARKER LAMP (EU)
E-01 = LH HEADER FLASHING LAMP (NA) E-09 = TURN INDICATOR F-56 = HAZARD LIGHTS FUSE
E-02 = RH HEADER FLASHING LAMP (NA) E-10 = HIGH BEAM INDICATOR S-25 = HAZARD SWITCH LIGHTING
E-07 = LH NASO FLASHING LAMP (NA) E-40 = HEADER LH MARKER LAMP (EU) FRAME--33
55-107
E-03 = LH FRONT HAZARD LAMP E-50 = LH POSITION LAMP (EU) E-54 = LH FRONT AUSTRIA LAMP
E-04 = RH FRONT HAZARD LAMP E-51 = RH FLASHING LAMP (EU) F-20 = LH MARKER LIGHTS FUSE
LIGHTING E-39 = UNLOAD TUBE MARKER LMP (FR) E-52 = LH FLASHING LAMP (EU) F-21 = RH MARKER LIGHTS FUSE
FRAME--34 E-49 = RH POSITION LAMP (EU) E-53 = RH FRONT AUSTRIA LAMP
55-108
E-05 = LH REAR FLASHING LAMP E-55 = RH REAR AUSTRIA LAMP J-09 = TRAILER OUTLET
E-06 = RH REAR FLASHING LAMP E-56 = LH REAR AUSTRIA LAMP
E-11 = LH BRAKE/TAIL LAMP E-57 = RH LICENSE PLATE LAMP (EU) LIGHTING
E-12 = RH BRAKE/TAIL LAMP E-58 = LH LICENSE PLATE LAMP (EU) FRAME--35
55-109
A-05 = FLASHER MODULE F-33 = LOW BEAM FUSE K-04 = HIGH BEAM RELAY
E-13 = LH ROAD LIGHT F-51 = HORN, MARKER LTS FUSE K-05 = LOW BEAM RELAY
LIGHTING E-14 = RH ROAD LIGHT H-02 = HORN S-26 = ROAD LIGHT SWITCH
FRAME--36 F-32 = HIGH BEAM FUSE K-02 = LIGHT CONTROL RELAY
55-110
E-13 = LH ROAD LIGHT K-40 = FLIP UP LOW BEAM RELAY

E-14 = RH ROAD LIGHT K-41 = FLIP UP HIGH BEAM RELAY
E-47 = LH FLIP UP ROAD LIGHT LIGHTING
E-48 = RH FLIP UP ROAD LIGHT FRAME--37
55-111
E-34 = DOME LIGHT E-44 = RH FRONT SHIELD LT F-52 = DOME/BRAKE LT FUSE S-63 = LEFT SHIELD LT SW
E-35 = CONSOLE LIGHT E-45 = RH REAR SHIELD LT K-20 = TIME DELAY MODULE S-64 = ENGINE LT SW
LIGHTING E-42 = LH FRONT SHIELD LT E-46 = ENGINE LT K-33 = BRAKE LIGHTS RELAY S-65 = RIGHT SHIELD LT SW
FRAME--38 E-43 = LH REAR SHIELD LT F-34 = UNDERSHIELD LIGHTS S-40 = LH DOOR SWITCH
55-112
E-31 = LH FRONT BEACON LIGHT F-53 = BEACON LT FUSE J-04 = LH SIDE SERVICE SOCKET
E-32 = RH FRONT BEACON LIGHT J-01 = RH FT SERVICE SOCKET J-05 = ENGINE SERVICE SOCKET
E-33 = REAR BEACON LIGHT J-02 = LH FT SERVICE SOCKET K-29 = BEACON LIGHT RELAY LIGHTING
F-15 = SERVICE SOCKETS FUSE J-03 = RH SIDE SERVICE SOCKET S-41 = BEACON LIGHT SWITCH FRAME--39
55-113
E-21 = LH HEADER LIGHT E-29 = UNLOAD TUBE LIGHT F-50 = SIDE LTS FUSE K-32 = UNLOAD TUBE LIGHT RELAY
E-22 = RH HEADER LIGHT E-30 = GRAIN TANK LIGHT F-54 = LOWER WORK LTS FUSE
LIGHTING E-23 = LH LOWER WORK LIGHT E-38 = CENTER WORK LIGHT K-22 = HEADER WORK LTS RELAY
FRAME--40 E-24 = RH LOWER WORK LIGHT F-30 = HEADER WORK LTS FUSE K-30 = LOWER WORK LTS RELAY
55-114
E-15 = LH CAB OUTER WORK LIGHT E-19 = LH CAB MID WORK LIGHT F-29 = DISTANCE WORK LTS FUSE K-27 = ROAD LIGHTS RELAY
E-16 = RH CAB OUTER WORK LIGHT E-20 = RH CAB MID WORK LIGHT F-31 = CAB ROOF WORK LTS FUSE
E-17 = LH CAB INNER WORK LIGHT F-06 = LH CAB WORK LTS FUSE K-01 = CAB ROOF WORK LTS RELAY LIGHTING
E-18 = RH CAB INNER WORK LIGHT F-07 = RH CAB WORK LTS FUSE K-21 = DISTANCE WORK LTS RELAY FRAME--41
55-115
E-27 = LH REAR WORK LIGHT S-43 = WORK LIGHT SWITCH

E-28 = RH REAR WORK LIGHT S-44 = REAR WORK LIGHT SWITCH
LIGHTING F-55 = REAR WORK LTS FUSE
FRAME--42 K-31 = REAR WORK LTS RELAY
55-116
E-25 = LH SIDE WORK LIGHT K-34 = TIMED SIDE WORK LIGHT RELAY
E-26 = RH SIDE WORK LIGHT K-35 = SIDE WORK LIGHT RELAY
E-37 = SIEVE LIGHT S-54 = SIEVE LIGHT SWITCH LIGHTING
F-14 = SERVICE LTS FUSE FRAME--43
55-117
F-64 = SWITCH BYPASS FUSES M-22 = LH MIRROR IN/OUT R-11 = LH MIRROR HEAT S-57 = MIRROR SELECT SWITCH (D)
M-19 = RH MIRROR UP/DOWN M-30 = GERMAN MIRROR UP/DOWN R-14 = RH GERMAN MIRROR HEAT
ACCESSORY M-20 = RH MIRROR IN/OUT M-31 = GERMAN MIRROR IN/OUT S-19 = MIRROR HEAT SWITCH
FRAME--44 M-21 = LH MIRROR UP/DOWN R-10 = RH MIRROR HEAT S-27 = MIRROR ADJUST SWITCH
55-118
F-03 = ACCESSORY 1 FUSE F-09 = WASHER/MIRROR FUSE K-06 = WIPER RELAY R-08 = CIGAR LIGHTER
F-04 = WIPER FUSE F-10 = COLD START FUSE (AF) K-08 = ACCESSORY 1 RELAY S-20 = WIPER SWITCH
F-05 = CIGAR LIGHTER FUSE J-06 = ACCESSORY SOCKET M-24 = WIPER WASHER MOTOR S-38 = WASHER SWITCH ACCESSORY
F-08 = ACCESSORY OUTLET FUSE J-08 = ACCESSORY OUTLET M-25 = WIPER MOTOR FRAME--45
55-119
A-04 = RADIO F-16 = SEAT PUMP FUSE H-06 = REAR RIGHT SPEAKER M-26 = SEAT PUMP MOTOR
F-02 = ACCESSORY 2 FUSE F-35 = RADIO KAPWR FUSE H-07 = FRONT RIGHT SPEAKER S-45 = SEAT ADJUST SWITCH
ACCESSORY F-11 = RADIO FUSE H-04 = REAR LEFT SPEAKER J-07 = TRANSCEIVER OUTLET
FRAME--46 F-13 = TRANSCEIVER FUSE H-05 = FRONT LEFT SPEAKER K-03 = ACCESSORY 2 RELAY
55-120
A-09 = HVAC CONTROL MODULE B-28 = EVAPORATOR TEMP SENSOR (ATC)

B-25 = AMBIENT TEMP SENSOR (ATC) M-15 = COLD BOX DOOR (ATC)
B-26 = CAB TEMP SENSOR (ATC) M-16 = WATER VALVE HVAC
B-27 = OUTLET TEMP SENSOR (ATC) S-53 = FREEZE SWITCH (MANUAL A/C) FRAME--47
55-121
A-09 = HVAC CONTROL MODULE K-09 = SEPARATOR BLOWER RELAY K-13 = MAIN BLOWER RELAY HIGH S-47 = A/C HIGH PRESSURE
F-17 = SEPARATOR BLOWER FUSE K-10 = A/C CLUTCH RELAY L-07 = A/C CLUTCH S-48 = A/C LOW PRESSURE
HVAC F-18 = MAIN BLOWER FUSE K-11 = MAIN BLOWER RELAY LOW M-17 = MAIN BLOWER
FRAME--48 F-19 = A/C CLUTCH FUSE K-12 = MAIN BLOWER RELAY MED M-18 = SEPARATOR BLOWER
55-122
COMPONENT INDEX, 2005 PRODUCTION -- SN HAJ101501 to 3300
Electronics B--40 FUEL TEMP (7.5L) FR--04
A--01 ENGINE CONTROL UNIT FR--02 B--41 AIR TEMP/ BOOST PRESS (7.5L) FR--04
A--02 MAIN DISPLAY MODULE (MDM) FR--30 B--45 GEARBOX CLUTCH TEMP FR--17
A--03 SHAFT SPEED MONITOR (SSM) FR--30 B--46 HYDROSTAT MOTOR TEMP FR--08
A--04 RADIO FR--46 B--47 COVERS OPEN FR--22
A--05 FLASHER MODULE FR--33 B--48 RH BOTTOM ASP SENSOR FR--15
A--05 FLASHER MODULE FR--36 B--49 LH BOTTOM ASP SENSOR FR--15
A--07 HHC MODULE (EMR--OBE) FR--14 B--50 RH TOP ASP SENSOR FR--15
A--07 HHC MODULE (EMR--OBE) FR--31 B--51 LH TOP ASP SENSOR FR--15
A--08 ASP AMPLIFIER FR--15 B--52 ENGINE OIL PRESSURE (IVECO) FR--05
A--08 ASP AMPLIFIER FR--31 B--53 PARK BRAKE PRESSURE FR--09
A--09 HVAC CONTROL MODULE FR--47 B--54 AIR TEMP (IVECO) FR--06
A--09 HVAC CONTROL MODULE FR--48 B--55 SPREADER RPM FR--23
A--10 DATA LOGGER (DLU) FR--30 B--69 STEERING COLUMN SENSOR
A--11 GPS MODULE FR--31 Lights
A--19 IDM LASER SCANNER E--01 LH HEADER FLASHING LMP (NA) FR--33
A--21 FUTURE OPTION FR--30 E--02 RH HEADER FLASHING LMP (NA) FR--33
Sensors E--03 LH FRONT HAZARD LAMP FR--34
B--01 ROTOR RPM FR--18 E--04 LH FRONT HAZARD LAMP FR--34
B--02 LATERAL INCLINATION FR--20 E--05 LH REAR FLASHING LAMP (EU) FR--35
B--03 ENGINE OIL TEMP (IVECO) FR--05 E--06 RH REAR FLASHING LAMP (EU) FR--35
B--04 -- -- E--07 LH NASO FLASHING LAMP FR--33
B--05 ENGINE FLYWHEEL RPM (IVECO) FR--06 E--08 RH NASO FLASHING LAMP FR--33
B--06 LEFT RETURNS RPM FR--20 E--09 TURN INDICATOR FR--33
B--07 ENGINE CAMSHAFT RPM (IVECO) FR--06 E--10 HIGH BEAM INDICATOR FR--33
B--08 CLEAN GRAIN ELEVATOR RPM FR--20 E--11 LH BRAKE / MARKER LAMP FR--35
B--09 REVERSER DISENGAGED FR--16 E--12 RH BRAKE / MARKER LAMP FR--35
B--10 CHOPPER RPM FR--23 E--13 LH ROAD LIGHT FR--36
B--11 -- -- E--14 RH ROAD LIGHT FR--36
B--12 MOISTURE SENSOR FR--24 E--15 LH CAB OUTER WORK LIGHT FR--41
B--13 -- -- E--16 RH CAB OUTER WORK LIGHT FR--41
B--14 FEEDER RPM FR--16 E--17 LH CAB INNER WORK LIGHT FR--41
B--15 REEL RPM FR--13 E--18 RH CAB INNER WORK LIGHT FR--41
B--16 CLEANING FAN RPM FR--19 E--19 LH CAB MID WORK LIGHT FR--41
B--17 GROUND SPEED RPM FR--09 E--20 RH CAB MID WORK LIGHT FR--41
B--18 HYD OIL RESERVOIR TEMP FR--10 E--21 LH HEADER LIGHT FR--40
B--19 LEFT ROTOR LOSS FR--20 E--22 RH HEADER LIGHT FR--40
B--20 RIGHT ROTOR LOSS FR--20 E--23 LH LOWER WORK LIGHT FR--40
B--21 SIEVES LOSS FR--19 E--24 RH LOWER WORK LIGHT FR--40
B--22 REAR LADDER FR--05 E--25 LH SIDE WORK LIGHT FR--43
B--23 BOOST PRESSURE (IVECO) FR--06 E--26 RH SIDE WORK LIGHT FR--43
B--24 STONE DOOR CLOSED FR--16 E--27 LH REAR WORK LIGHT FR--42
B--25 AMBIENT TEMP SENSOR FR--47 E--28 RH REAR WORK LIGHT FR--42
B--26 CAB TEMP SENSOR FR--47 E--29 UNLOAD TUBE LIGHT FR--40
B--27 OUTLET TEMP SENSOR FR--47 E--30 GRAIN TANK LIGHT FR--40
B--28 EVAPORATOR TEMP SENSOR FR--47 E--31 LH FRONT BEACON FR--39
B--29 HEADER LIFT PRESSURE FR--14 E--32 RH FRONT BEACON FR--39
B--30 ENGINE OIL PRESSURE (7.5L) FR--05 E--33 REAR BEACON FR--39
B--31 -- -- E--34 DOME LIGHT FR--38
B--32 GEARBOX TEMPERATURE FR--10 E--35 CONSOLE LIGHT FR--38
B--33 -- -- E--36 COLD START INDICATOR FR--02
B--34 -- -- E--37 SIEVE LIGHT FR--43
B--35 LOW CONTROL PRESSURE FR--10 E--38 CENTER WORK LIGHT FR--40
B--36 FUEL TEMP (IVECO) FR--06 E--39 UNLOAD TUBE MARKER LMP (FR) FR--34
B--37 TRANS SHIFT POSITION FR--09 E--40 HEADER LH MARKER LAMP (EU) FR--33
B--38 UNLOAD CRADLE FR--22 E--41 HEADER RH MARKER LAMP (EU) FR--33
B--39 RIGHT RETURNS RPM FR--20 E--42 LH FRONT SHIELD LT FR--38
55-123
E--43 LH REAR SHIELD LT FR--38 F--46 ASP POWER FUSE FR--15
E--44 RH FRONT SHIELD LT FR--38 F--47 CCM--3 FUSE FR--24
E--45 RH REAR SHIELD LT FR--38 F--48 RH CONSOLE FUSE FR--25
E--46 ENGINE LT FR--38 F--49 CAB FUSE FR--27
E--49 RH POSITION LT (EU) FR--34 F--52 DOME / BRAKE LT FUSE FR--38
E--50 LH POSITION LT (EU) FR--34 F--53 BEACON LTS FUSE FR--39
E--53 RH FRONT AUSTRIA LT FR--34 F--56 HAZARD LIGHTS FUSE FR--33
E--54 LH FRONT AUSTRIA LT FR--34 F--64 SWITCH BYPASS FUSES FR--44
E--55 RH REAR AUSTRIA LT FR--35 Generators
E--56 LH REAR AUSTRIA LT FR--35 G--01 ALTERNATOR FR--02
Fuses Audio
F--10 COLD START FUSE (AF) FR--45 J--01 -- --
F--13 TRANSCEIVER POWER FUSE FR--46 J--04 -- --
F--23 ROTARY SCREEN BRUSH FUSE FR--04 K--02 LIGHT CONTROL RELAY FR--36
F--26 STARTING FUSE FR--03 K--05 LOW BEAM RELAY FR--36
F--32 HIGH BEAM FUSE FR--36 K--11 MAIN BLOWER RELAY LOW FR--48
F--34 UNDER SHIELD LTS FR--38 K--13 MAIN BLOWER RELAY HIGH FR--48
F--36 CCM--2A FUSE FR--28 K--15 STARTING RELAY FR--02
F--40 CCM--1 POWER FUSE FR--28 K--19 FEEDER DISENGAGE FR--16
55-124
K--25 CCM--2 POWER RELAY FR--28 Motors
K--26 CCM--3 / CAB POWER RELAY FR--28 M--01 12V STARTER (7.5 L) FR--01
K--27 ROAD LIGHTS RELAY (AF) FR--41 M--02 TRANSMISSION SHIFT MOTOR FR--09
K--28 THRESHING LATCHING FR--18 M--03 SHOE LEVELLING ACTUATOR FR--19
K--29 BEACON LIGHTS RELAY FR--39 M--04 CONCAVE CLEARANCE MOTOR FR--17
K--30 LOWER WORK LTS RELAY FR--40 M--05 CLEANING FAN ADJUST MOTOR FR--16
K--31 REAR WORK LTS RELAY FR--42 M--06 UPPER SIEVE ACTUATOR FR--21
K--32 UNLOAD TUBE LIGHT RELAY FR--40 M--07 LOWER SIEVE ACTUATOR FR--21
K--34 TIMED SIDE WORK LIGHT RELAY FR--43 M--09 REEL SPEED MOTOR FR--12
K--35 SIDE WORK LIGHT RELAY FR--43 M--10 FEEDER REVERSER ACTUATOR FR--16
K--36 START RELAY FR--02 M--11 SPREADER PLATE MOTOR FR--23
K--37 -- -- M--12 COVERS MOTOR FR--17
K--38 24V START RELAY (IVECO) FR--01 M--13 -- --
K--39 GRID HEATER RELAY (IVECO) FR--02 M--14 -- --
K--40 FLIP UP LOW BEAM RELAY FR--37 M--15 COLD BOX DOOR MOTOR FR--47
K--41 FLIP UP HIGH BEAM RELAY FR--37 M--16 WATER VALVE MOTOR FR--47
K--42 RH VERTICAL KNIFE RELAY (OP) FR--12 M--17 MAIN BLOWER MOTOR FR--48
K--43 LH VERTICAL KNIFE RELAY (OP) FR--12 M--18 SEPARATOR BLOWER MOTOR FR--48
Solenoids M--19 RH MIRROR UP / DOWN FR--44
L--01 NEUTRAL LOCK SOLENOID FR--07 M--20 RH MIRROR IN / OUT FR--44
L--02 -- -- M--21 LH MIRROR UP / DOWN FR--44
L--03 UNLOAD TUBE IN FR--22 M--22 LH MIRROR IN / OUT FR--44
L--04 UNLOAD TUBE OUT FR--22 M--23 FUEL PUMP FR--06
L--05 PRESSURE RELEASE FR--08 M--24 WIPER WASHER MOTOR FR--45
L--06 HDR HEIGHT ACCUMULATOR FR--14 M--25 WIPER MOTOR FR--45
L--07 A/C CLUTCH FR--48 M--26 SEAT PUMP MOTOR FR--46
L--08 UNLOAD TUBE CLUTCH FR--22 M--27 ROTARY SCREEN BRUSH FR--04
L--09 FUEL INJECTION PUMP (7.5L) FR--04 M--28 SAMPLE MOTOR FR--24
L--10 PARK BRAKE DISENGAGE FR--09 M--29 24V STARTER (IVECO) FR--01
L--11 FEEDER INCREASE FR--15 M--30 GERMAN MIRROR UP / DOWN FR--44
L--12 FEEDER DECREASE FR--15 M--31 GERMAN MIRROR IN / OUT FR--44
L--13 REEL DOWN FR--12 M--35 TURNTABLE ACTUATOR
L--14 REEL UP FR--12 Resistive
L--15 REEL AFT FR--12 R--01 FUEL LEVEL FR--05
L--16 REEL FORE FR--12 R--02 LATERAL FLOAT POT FR--14
L--17 REEL DRIVE FR--12 R--03 FEEDER ANGLE POT FR--14
L--18 LATERAL FLOAT CW FR--14 R--04 GROUND SPEED POT FR--07
L--19 LATERAL FLOAT CCW FR--14 R--05 YIELD SENSOR FR--24
L--20 FEEDER JOG FORWARD FR--16 R--06 CONCAVE POSITION FR--17
L--21 FEEDER JOG REVERSE FR--16 R--07 -- --
L--22 GEARBOX CLUTCH FR--18 R--08 CIGAR LIGHTER FR--45
L--23 GROUND SPEED HYDROSTAT FR--09 R--09 ENGINE GRID HEATER (IVECO) FR--02
L--24 FEEDER CLUTCH FR--16 R--10 RH MIRROR HEAT FR--44
L--25 -- -- R--11 LH MIRROR HEAT FR--44
L--26 REAR WHEEL ASSIST FR--08 R--12 LH STUBBLE HEIGHT FR--14
L--27 DUAL RANGE FR--08 R--13 RH STUBBLE HEIGHT FR--14
L--28 CHAFF SPREADER / BLOWER FR--23 R--14 GERMAN MIRROR HEAT FR--44
L--29 ROTOR INCREASE FR--18 R--15 AIR FILTER SWITCH RESISTOR FR--05
L--30 ROTOR DECREASE FR--18 R--16 -- --
L--31 STONE DOOR OPEN FR--15 R--17 -- --
L--34 FUEL ACTUATOR 1 (CYL 1) FR--06 R--20 HEADER TYPE MODULE FR--13
L--35 FUEL ACTUATOR 2 (CYL 4) FR--06 R--21 -- --
L--38 FUEL ACTUATOR 5 (CYL 3) FR--06 R--24 REEL HORIZONTAL POSITION FR--13
L--39 FUEL ACTUATOR 6 (CYL 5) FR--06 R--25 REEL VERTICAL POSITION FR--13
L--56 STEERING DUMP SOLENOID R--26 CORN ROW LEFT POSITION
L--57 STEER LEFT SOLENOID R--27 CORN ROW RIGHT POSITION
L--58 STEER RIGHT SOLENOID
55-125
Switches S--57 MIRROR SELECT SWITCH (DE) FR--44
S--01 -- -- S--58 ENGINE OIL TEMP SWITCH (7.5L) FR--05
S--02 KEY SWITCH FR--29 S--59 -- --
S--03 MULTIFUNCTION HANDLE FR--11 S--60 -- --
S--04 HEADER HEIGHT MODE FR--11 S--61 AIR FILTER SWITCH FR--05
S--05 SEAT SWITCH FR--27 S--62 -- --
S--06 HHC FINE ADJUST FR--11 S--63 LEFT SHIELD LT SW FR--38
S--07 FEEDER REVERSER FR--15 S--64 ENGINE LT SW FR--38
S--08 REEL SPEED MODE FR--11 S--65 RIGHT SHIELD LT SW FR--38
S--09 PARK BRAKE FR--07 Splice Blocks
S--10 REAR WHEEL ASSIST FR--07 W--01 SPLICE BLOCK A FR--25
S--11 DUAL RANGE FR--07 W--02 SPLICE BLOCK B FR--25
S--12 ROAD MODE SWITCH FR--07 W--03 SPLICE BLOCK C FR--27
S--13 UPPER SIEVE FR--19 W--06 SPLICE BLOCK F FR--25
S--14 LOWER SIEVE FR--19
S--15 FAN SPEED FR--19
S--16 CONCAVE CLEARANCE FR--17 REAR FRAME GROUND FR--48
1
S--17 ROTOR SPEED FR--10
S--18 FEEDER SPEED FR--10 2 FRONT FRAME GROUND FR--48
S--20 WIPER SWITCH FR--45 3 CAB FLOOR GROUND FR--48
S--22 NEUTRAL SWITCH FR--09 4 CAB ROOF GROUND FR--48
S--24 GEAR SELECT FR--07 5 ENGINE GROUND FR--48
S--26 ROAD LIGHT SWITCH FR--36 6 -- --
S--28 GRAIN BIN 3/4 FULL FR--22 7 CCM--1 REFERENCE GROUND “A” FR--26
S--30 THRESHER ENGAGE FR--18 8 CCM--1 REFERENCE GROUND “B” FR--26
S--32 RETURNS FILTER BYPASS FR--10
S--34 GEARBOX FILTER BYPASS FR--10
S--37 CHARGE PRESSURE FR--09 CCM--2 REFERENCE GROUND “B” FR--27
12
S--38 WASHER SWITCH FR--45
S--41 BEACON LIGHT SWITCH FR--39 14 CCM--2 REFERENCE VOLTAGE “B” FR--27
S--42 TANK EXTENSIONS SWITCH FR--22
S--43 WORK LIGHT SWITCH FR--42 CCM--3 REFERENCE GROUND FR--26
15
S--44 REAR WORK LIGHT SWITCH FR--42
S--45 SEAT ADJUST SWITCH FR--46 16 CCM--3 REFERENCE VOLTAGE FR--26
S--46 LOWER SIEVE REAR ADJUST FR--21
S--47 A/C HIGH PRESSURE FR--48 17 BACK LIGHTING “A” FR--27
S--48 A/C LOW PRESSURE FR--48
S--49 BRAKE FLUID LEVEL SWITCH FR--08 18 BACK LIGHTING “B” FR--25
S--50 -- --
S--51 VERTICAL KNIVES FR--11 19 RH CONSOLE +12 VOLTS FR--25
S--52 BATTERY SWITCH (EU) FR--01
S--53 FREEZE SWITCH FR--47 20 CAB +12 VOLTS FR--27
S--54 SIEVE LIGHT SWITCH FR--43
S--55 LH BRAKE WEAR SWITCH FR--08
55-126
55-127
A-01 = ENGINE CONTROL UNIT K-14 = ECU POWER RELAY K-39 = GRID HEATER RELAY (IVECO)
E-36 = COLD START INDICATOR K-15 = STARTING RELAY R-09 = ENGINE GRID HEATER (IVECO)
STARTING F-01 = ECU POWER FUSE K-23 = NEUTRAL START RELAY
FRAME--2 G-01 = ALTERNATOR K-36 = START RELAY
55-128
F-26 = STARTING FUSE
STARTING
FRAME--3
55-129
A-01 = ENGINE CONTROL UNIT B-43 = FLYWHEEL RPM (7.5 L) S-36 = ENGINE THROTTLE
B-40 = FUEL TEMP (7.5 L) F-23 = THROTTLE/BRUSH FUSE
ENGINE B-41 = AIR TEMP/BOOST PRESS (7.5 L) L-09 = FUEL INJECTION PUMP (7.5 L)
FRAME--4 B-42 = COOLANT TEMP (7.5 L) M-27 = ROTARY SCREEN BRUSH
55-130
B-03 = ENGINE OIL TEMP (IVECO) R-01 = FUEL LEVEL

55-131
55-132

R-04 = GROUND SPEED POT S-12 = ROAD MODE SWITCH
55-133

55-134
55-135

55-136

55-137

55-138
B-15 = REEL RPM

55-139
55-140
55-141

B-14 = FEEDER RPM K-19 = FEEDER DISENGAGE M-05 = CLEANING FAN ADJUST MOTOR
55-142

55-143

55-144
B-16 = CLEANING FAN RPM S-13 = UPPER SIEVE

B-21 = SIEVES LOSS S-14 = LOWER SIEVE
F-22 = SHOE LEVELING MOTOR FUSE S-15 = FAN SPEED CLEANING
M-03 = SHOE LEVELING ACTUATOR FRAME--19
55-145

55-146

55-147
B-38 = UNLOAD CRADLE L-08 = UNLOAD TUBE CLUTCH

B-47 = COVERS CLOSED S-28 = GRAIN BIN 3/4 FULL
UNLOAD L-03 = UNLOAD TUBE IN S-29 = GRAIN BIN FULL
FRAME--22 L-04 = UNLOAD TUBE OUT S-42 = TANK EXTENSIONS SWITCH
55-148

B-55 = SPREADER RPM
55-149

F-47 = CCM-3 FUSE
55-150

H-01 = AUDIO ALARM
55-151
F-43 = CCM-1A FUSE

F-44 = CCM-1B FUSE
DISTRIBUTION
FRAME--26
55-152
F-49 = CAB FUSE

S-05 = SEAT SWITCH
FRAME--27
55-153

55-154

55-155

55-156

A-07 = HHC MODULE
55-157
BLANK
FRAME--32
55-158
55-159
E-03 = LH FRONT HAZARD LAMP E-50 = LH POSITION MARKER LAMP (EU) E-54 = LH FRONT AUSTRIA MARKER LAMP
FRAME--34 E-49 = RH POSITION MARKER LAMP (EU) E-53 = RH FRONT AUSTRIA MARKER LAMP
55-160
E-05 = LH REAR FLASHING LAMP (EU) E-55 = RH REAR AUSTRIA MARKER LAMP J-09 = TRAILER OUTLET
E-06 = RH REAR FLASHING LAMP (EU) E-56 = LH REAR AUSTRIA MARKER LAMP
55-161
55-162

55-163
55-164
E-31 = LH FRONT BEACON LIGHT F-53 = BEACON LT FUSE K-29 = BEACON LIGHT RELAY
E-32 = RH FRONT BEACON LIGHT J-02 = LH FT SERVICE SOCKET S-41 = BEACON LIGHT SWITCH
E-33 = REAR BEACON LIGHT J-03 = RH SIDE SERVICE SOCKET LIGHTING
F-15 = SERVICE SOCKETS FUSE J-05 = ENGINE SERVICE SOCKET FRAME--39
55-165
55-166
55-167

55-168
55-169
55-170
55-171
55-172

55-173
55-174
COMPONENT INDEX, 2006 PRODUCTION -- SN HAJ103301 and ABOVE
Electronics B--40 FUEL TEMP (7.5L) FR--04
A--01 ENGINE CONTROL UNIT FR--02 B--41 AIR TEMP/ BOOST PRESS (7.5L) FR--04
A--02 MAIN DISPLAY MODULE (MDM) FR--30 B--45 GEARBOX CLUTCH TEMP FR--17
A--03 SHAFT SPEED MONITOR (SSM) FR--30 B--46 HYDROSTAT MOTOR TEMP FR--08
A--04 RADIO FR--46 B--47 COVERS OPEN FR--22
A--05 FLASHER MODULE FR--33 B--48 RH BOTTOM ASP SENSOR FR--15
A--05 FLASHER MODULE FR--36 B--49 LH BOTTOM ASP SENSOR FR--15
A--07 HHC MODULE (EMR--OBE) FR--14 B--50 RH TOP ASP SENSOR FR--15
A--07 HHC MODULE (EMR--OBE) FR--31 B--51 LH TOP ASP SENSOR FR--15
A--08 ASP AMPLIFIER FR--15 B--52 ENGINE OIL PRESSURE (IVECO) FR--05
A--08 ASP AMPLIFIER FR--31 B--53 PARK BRAKE PRESSURE FR--09
A--09 HVAC CONTROL MODULE FR--47 B--54 AIR TEMP (IVECO) FR--06
A--09 HVAC CONTROL MODULE FR--48
Lights
A--10 DATA LOGGER (DLU) FR--30
E--01 LH HEADER FLASHING LMP (NA) FR--33
A--11 GPS MODULE FR--31
E--02 RH HEADER FLASHING LMP (NA) FR--33
A--19 IDM LASER SCANNER
E--03 LH FRONT HAZARD LAMP FR--34
A--21 FUTURE OPTION FR--30
E--04 LH FRONT HAZARD LAMP FR--34
Sensors
E--05 LH REAR FLASHING LAMP (EU) FR--35
B--01 ROTOR RPM FR--18
E--06 RH REAR FLASHING LAMP (EU) FR--35
B--02 LATERAL INCLINATION FR--20
E--07 LH NASO FLASHING LAMP FR--33
B--03 ENGINE OIL TEMP (IVECO) FR--05
E--08 RH NASO FLASHING LAMP FR--33
B--04 -- --
E--09 TURN INDICATOR FR--33
B--05 ENGINE FLYWHEEL RPM (IVECO) FR--06
E--10 HIGH BEAM INDICATOR FR--33
B--06 LEFT RETURNS RPM FR--20
E--11 LH BRAKE / MARKER LAMP FR--35
B--07 ENGINE CAMSHAFT RPM (IVECO) FR--06
E--12 RH BRAKE / MARKER LAMP FR--35
B--08 CLEAN GRAIN ELEVATOR RPM FR--20
E--13 LH ROAD LIGHT FR--36
B--09 REVERSER DISENGAGED FR--16
E--14 RH ROAD LIGHT FR--36
B--10 CHOPPER RPM FR--23
E--15 LH CAB OUTER WORK LIGHT FR--41
B--11 -- --
E--16 RH CAB OUTER WORK LIGHT FR--41
B--12 MOISTURE SENSOR FR--24
E--17 LH CAB INNER WORK LIGHT FR--41
B--13 -- --
E--18 RH CAB INNER WORK LIGHT FR--41
B--14 FEEDER RPM FR--16
E--19 LH CAB MID WORK LIGHT FR--41
B--15 REEL RPM FR--13
E--20 RH CAB MID WORK LIGHT FR--41
B--16 CLEANING FAN RPM FR--19
E--21 LH HEADER LIGHT FR--40
B--17 GROUND SPEED RPM FR--09
E--22 RH HEADER LIGHT FR--40
B--18 HYD OIL RESERVOIR TEMP FR--10
E--23 LH LOWER WORK LIGHT FR--40
B--19 LEFT ROTOR LOSS FR--20
E--24 RH LOWER WORK LIGHT FR--40
B--20 RIGHT ROTOR LOSS FR--20
E--25 LH SIDE WORK LIGHT FR--43
B--21 SIEVES LOSS FR--19
E--26 RH SIDE WORK LIGHT FR--43
B--22 REAR LADDER FR--05
E--27 LH REAR WORK LIGHT FR--42
B--23 BOOST PRESSURE (IVECO) FR--06
E--28 RH REAR WORK LIGHT FR--42
B--24 STONE DOOR CLOSED FR--16
E--29 UNLOAD TUBE LIGHT FR--40
B--25 AMBIENT TEMP SENSOR FR--47
E--30 GRAIN TANK LIGHT FR--40
B--26 CAB TEMP SENSOR FR--47
E--31 LH FRONT BEACON FR--39
B--27 OUTLET TEMP SENSOR FR--47
E--32 RH FRONT BEACON FR--39
B--28 EVAPORATOR TEMP SENSOR FR--47
E--33 REAR BEACON FR--39
B--29 HEADER LIFT PRESSURE FR--14
E--34 DOME LIGHT FR--38
B--30 ENGINE OIL PRESSURE (7.5L) FR--05
E--35 CONSOLE LIGHT FR--38
B--31 -- --
E--36 COLD START INDICATOR FR--02
B--32 GEARBOX TEMPERATURE FR--10
E--37 SIEVE LIGHT FR--43
B--33 -- --
E--38 CENTER WORK LIGHT FR--40
B--34 -- --
E--39 UNLOAD TUBE MARKER LMP (FR) FR--34
B--35 LOW CONTROL PRESSURE FR--10
E--40 HEADER LH MARKER LAMP (EU) FR--33
B--36 FUEL TEMP (IVECO) FR--06
E--41 HEADER RH MARKER LAMP (EU) FR--33
B--37 TRANS SHIFT POSITION FR--09
E--42 LH FRONT SHIELD LT FR--38
B--38 UNLOAD CRADLE FR--22
B--39 RIGHT RETURNS RPM FR--20
55-175
E--43 LH REAR SHIELD LT FR--38 F--46 ASP POWER FUSE FR--15
E--44 RH FRONT SHIELD LT FR--38 F--47 CCM--3 FUSE FR--24
E--45 RH REAR SHIELD LT FR--38 F--48 RH CONSOLE FUSE FR--25
E--46 ENGINE LT FR--38 F--49 CAB FUSE FR--27
E--49 RH POSITION MARKER LT (EU) FR--34 F--52 DOME / BRAKE LT FUSE FR--38
E--50 LH POSITION MARKER LT (EU) FR--34 F--53 BEACON LTS FUSE FR--39
E--53 RH FRONT AUSTRIA MARKER LT FR--34 F--56 HAZARD LIGHTS FUSE FR--33
E--54 LH FRONT AUSTRIA MARKER LT FR--34 F--64 SWITCH BYPASS FUSES FR--44
E--55 RH REAR AUSTRIA MARKER LT FR--35 Generators
E--56 LH REAR AUSTRIA MARKER LT FR--35 G--01 ALTERNATOR FR--02
Fuses Audio
F--10 COLD START FUSE (AF) FR--45 J--01 -- --
F--13 TRANSCEIVER POWER FUSE FR--46 J--04 -- --
F--23 ROTARY SCREEN BRUSH FUSE FR--04 K--02 LIGHT CONTROL RELAY FR--36
F--26 STARTING FUSE FR--03 K--05 LOW BEAM RELAY FR--36
F--32 HIGH BEAM FUSE FR--36 K--11 MAIN BLOWER RELAY LOW FR--48
F--34 UNDER SHIELD LTS FR--38 K--13 MAIN BLOWER RELAY HIGH FR--48
F--36 CCM--2A FUSE FR--28 K--15 STARTING RELAY FR--02
F--40 CCM--1 POWER FUSE FR--28 K--19 NOT USED FR--16
55-176
K--25 CCM--2 POWER RELAY FR--28 Motors
K--26 CCM--3 / CAB POWER RELAY FR--28 M--01 12V STARTER (7.5 L) FR--01
K--27 ROAD LIGHTS RELAY (AF) FR--41 M--02 TRANSMISSION SHIFT MOTOR FR--09
K--28 THRESHING LATCHING FR--18 M--03 SHOE LEVELLING ACTUATOR FR--19
K--29 BEACON LIGHTS RELAY FR--39 M--04 CONCAVE CLEARANCE MOTOR FR--17
K--30 LOWER WORK LTS RELAY FR--40 M--05 CLEANING FAN ADJUST MOTOR FR--16
K--31 REAR WORK LTS RELAY FR--42 M--06 UPPER SIEVE ACTUATOR FR--21
K--32 UNLOAD TUBE LIGHT RELAY FR--40 M--07 LOWER SIEVE ACTUATOR FR--21
K--34 TIMED SIDE WORK LIGHT RELAY FR--43 M--09 REEL SPEED MOTOR FR--12
K--35 SIDE WORK LIGHT RELAY FR--43 M--10 FEEDER REVERSER ACTUATOR FR--16
K--36 START RELAY FR--02 M--11 SPREADER PLATE MOTOR FR--23
K--37 -- -- M--12 COVERS MOTOR FR--17
K--38 24V START RELAY (IVECO) FR--01 M--13 -- --
K--39 GRID HEATER RELAY (IVECO) FR--02 M--14 -- --
K--40 FLIP UP LOW BEAM RELAY FR--37 M--15 COLD BOX DOOR MOTOR FR--47
K--41 FLIP UP HIGH BEAM RELAY FR--37 M--16 WATER VALVE MOTOR FR--47
K--42 RH VERTICAL KNIFE RELAY (OP) FR--12 M--17 MAIN BLOWER MOTOR FR--48
K--43 LH VERTICAL KNIFE RELAY (OP) FR--12 M--18 SEPARATOR BLOWER MOTOR FR--48
Solenoids M--19 RH MIRROR UP / DOWN FR--44
L--01 NEUTRAL LOCK SOLENOID FR--07 M--20 RH MIRROR IN / OUT FR--44
L--02 -- -- M--21 LH MIRROR UP / DOWN FR--44
L--03 UNLOAD TUBE IN FR--22 M--22 LH MIRROR IN / OUT FR--44
L--04 UNLOAD TUBE OUT FR--22 M--23 FUEL PUMP FR--06
L--05 PRESSURE RELEASE FR--08 M--24 WIPER WASHER MOTOR FR--45
L--06 HDR HEIGHT ACCUMULATOR FR--14 M--25 WIPER MOTOR FR--45
L--07 A/C CLUTCH FR--48 M--26 SEAT PUMP MOTOR FR--46
L--08 UNLOAD TUBE CLUTCH FR--22 M--27 ROTARY SCREEN BRUSH FR--04
L--09 FUEL INJECTION PUMP (7.5L) FR--04 M--28 SAMPLE MOTOR FR--24
L--10 PARK BRAKE DISENGAGE FR--09 M--29 24V STARTER (IVECO) FR--01
L--11 FEEDER INCREASE FR--15 M--30 GERMAN MIRROR UP / DOWN FR--44
L--12 FEEDER DECREASE FR--15 M--31 GERMAN MIRROR IN / OUT FR--44
L--13 REEL DOWN FR--12 M--35 TURNTABLE ACTUATOR
L--14 REEL UP FR--12 Resistive
L--15 REEL AFT FR--12 R--01 FUEL LEVEL FR--05
L--16 REEL FORE FR--12 R--02 LATERAL FLOAT POT FR--14
L--17 REEL DRIVE FR--12 R--03 FEEDER ANGLE POT FR--14
L--18 LATERAL FLOAT CW FR--14 R--04 GROUND SPEED POT FR--07
L--19 LATERAL FLOAT CCW FR--14 R--05 YIELD SENSOR FR--24
L--20 FEEDER JOG FORWARD FR--16 R--06 CONCAVE POSITION FR--17
L--21 FEEDER JOG REVERSE FR--16 R--07 -- --
L--22 GEARBOX CLUTCH FR--18 R--08 CIGAR LIGHTER FR--45
L--23 GROUND SPEED HYDROSTAT FR--09 R--09 ENGINE GRID HEATER (IVECO) FR--02
L--24 FEEDER CLUTCH FR--16 R--10 RH MIRROR HEAT FR--44
L--25 -- -- R--11 LH MIRROR HEAT FR--44
L--26 REAR WHEEL ASSIST FR--08 R--12 LH STUBBLE HEIGHT FR--14
L--27 DUAL RANGE FR--08 R--13 RH STUBBLE HEIGHT FR--14
L--28 CHAFF SPREADER / BLOWER FR--23 R--14 GERMAN MIRROR HEAT FR--44
L--29 ROTOR INCREASE FR--18 R--15 AIR FILTER SWITCH RESISTOR FR--05
L--30 ROTOR DECREASE FR--18 R--16 -- --
L--31 STONE DOOR OPEN FR--15 R--17 -- --
L--34 FUEL ACTUATOR 1 (CYL 1) FR--06 R--20 HEADER TYPE MODULE FR--13
L--38 FUEL ACTUATOR 5 (CYL 3) FR--06 R--24 REEL HORIZONTAL POSITION FR--13
L--39 FUEL ACTUATOR 6 (CYL 5) FR--06 R--25 REEL VERTICAL POSITION FR--13
L--44 FAN DRIVE SOLENOID FR--19 R--26 CORN ROW LEFT POSITION
R--27 CORN ROW RIGHT POSITION
55-177
Switches S--57 MIRROR SELECT SWITCH (DE) FR--44
S--01 -- -- S--58 ENGINE OIL TEMP SWITCH (7.5L) FR--05
S--02 KEY SWITCH FR--29 S--59 -- --
S--03 MULTIFUNCTION HANDLE FR--11 S--60 -- --
S--04 HEADER HEIGHT MODE FR--11 S--61 AIR FILTER SWITCH FR--05
S--05 SEAT SWITCH FR--27 S--62 -- --
S--06 HHC FINE ADJUST FR--11 S--63 LEFT SHIELD LT SW FR--38
S--07 FEEDER REVERSER FR--15 S--64 ENGINE LT SW FR--38
S--08 REEL SPEED MODE FR--11 S--65 RIGHT SHIELD LT SW FR--38
S--09 PARK BRAKE FR--07 S--67 COOLANT LEVEL SW FR--04
S--10 REAR WHEEL ASSIST FR--07 Splice Blocks
S--11 DUAL RANGE FR--07 W--01 SPLICE BLOCK A FR--25
S--12 ROAD MODE SWITCH FR--07 W--02 SPLICE BLOCK B FR--25
S--13 UPPER SIEVE FR--19 W--03 SPLICE BLOCK C FR--27
S--14 LOWER SIEVE FR--19 W--06 SPLICE BLOCK F FR--25
S--15 FAN SPEED FR--19
S--16 CONCAVE CLEARANCE FR--17
S--17 ROTOR SPEED FR--10 REAR FRAME GROUND FR--48
1
S--18 FEEDER SPEED FR--10
S--19 MIRROR HEAT SWITCH FR--44 2 FRONT FRAME GROUND FR--48
S--20 WIPER SWITCH FR--45
S--21 ALTERNATE SETTINGS FR--11 3 CAB FLOOR GROUND FR--48
S--22 NEUTRAL SWITCH FR--09
S--23 SPREADER PLATE FR--23 4 CAB ROOF GROUND FR--48
S--24 GEAR SELECT FR--07
S--25 HAZARD SWITCH FR--33 5 ENGINE GROUND FR--48
S--26 ROAD LIGHT SWITCH FR--36
S--27 MIRROR ADJUST SWITCH FR--44 6 -- --
S--28 GRAIN BIN 3/4 FULL FR--22
S--29 GRAIN BIN FULL FR--22 7 CCM--1 REFERENCE GROUND “A” FR--26
S--30 THRESHER ENGAGE FR--18
S--31 FEEDER ENGAGE FR--16 8 CCM--1 REFERENCE GROUND “B” FR--26
S--32 RETURNS FILTER BYPASS FR--10
S--34 GEARBOX FILTER BYPASS FR--10
S--37 CHARGE PRESSURE FR--09
S--38 WASHER SWITCH FR--45 CCM--2 REFERENCE GROUND “B” FR--27
12
S--41 BEACON LIGHT SWITCH FR--39
S--42 TANK EXTENSIONS SWITCH FR--22 14 CCM--2 REFERENCE VOLTAGE “B” FR--27
S--43 WORK LIGHT SWITCH FR--42
S--44 REAR WORK LIGHT SWITCH FR--42 CCM--3 REFERENCE GROUND FR--26
15
S--45 SEAT ADJUST SWITCH FR--46
S--46 LOWER SIEVE REAR ADJUST FR--21 16 CCM--3 REFERENCE VOLTAGE FR--26
S--47 A/C HIGH PRESSURE FR--48
S--48 A/C LOW PRESSURE FR--48 17 BACK LIGHTING “A” FR--27
S--49 BRAKE FLUID LEVEL SWITCH FR--08
S--50 -- -- 18 BACK LIGHTING “B” FR--25
S--51 VERTICAL KNIVES FR--11
S--52 BATTERY SWITCH (EU) FR--01 19 RH CONSOLE +12 VOLTS FR--25
S--53 FREEZE SWITCH FR--47
S--54 SIEVE LIGHT SWITCH FR--43 20 CAB +12 VOLTS FR--27
S--55 LH BRAKE WEAR SWITCH FR--08
55-178
2006 PRODUCTION -- SN HAJ103301 and ABOVE
55-179
55-180
STARTING
FRAME--3
55-181
A-01 = ENGINE CONTROL UNIT B-43 = FLYWHEEL RPM (7.5 L) M-27 = ROTARY SCREEN BRUSH
B-40 = FUEL TEMP (7.5 L) B-59 = WATER IN FUEL S-36 = ENGINE THROTTLE
ENGINE B-41 = AIR TEMP/BOOST PRESS (7.5 L) F-23 = ROTARY SCREEN BRUSH FUSE S-67 = COOLANT LEVEL
FRAME--4 B-42 = COOLANT TEMP (7.5 L) L-09 = FUEL INJECTION PUMP (7.5 L)
55-182
B-03 = ENGINE OIL TEMP (IVECO) R-01 = FUEL LEVEL

55-183
55-184

55-185

55-186
B-53 = PARK BRAKE PRESSURE (FUTURE) L-32 = BRAKE LIMITING S-39 = BRAKE PRESSURE DRIVES
55-187

55-188

55-189

55-190
B-15 = REEL RPM

55-191
55-192
55-193

B-14 = FEEDER RPM K-19 = NOT USED M-05 = CLEANING FAN ADJUST MOTOR
55-194

55-195

55-196
B-16 = CLEANING FAN RPM M-03 = SHOE LEVELING ACTUATOR

B-21 = SIEVES LOSS S-13 = UPPER SIEVE
F-22 = SHOE LEVELING MOTOR FUSE S-14 = LOWER SIEVE CLEANING
L-44 = FAN DRIVE SOLENOID S-15 = FAN SPEED FRAME--19
55-197

55-198

55-199
B-38 = UNLOAD CRADLE L-08 = UNLOAD TUBE CLUTCH

B-47 = COVERS CLOSED S-28 = GRAIN BIN 3/4 FULL
UNLOAD L-03 = UNLOAD TUBE IN S-29 = GRAIN BIN FULL
FRAME--22 L-04 = UNLOAD TUBE OUT S-42 = TANK EXTENSIONS SWITCH
55-200
B-10 = CHOPPER RPM

L-28 = CHAFF SPREADER
M-11 = SPREADER PLATE MOTOR TRASH
S-23 = SPREADER PLATE FRAME--23
55-201

F-47 = CCM-3 FUSE
55-202

H-01 = AUDIO ALARM
55-203
F-43 = CCM-1A FUSE

F-44 = CCM-1B FUSE
DISTRIBUTION
FRAME--26
55-204
F-49 = CAB FUSE

S-05 = SEAT SWITCH
FRAME--27
55-205

55-206

55-207

55-208

A-07 = HHC MODULE
55-209
BLANK
FRAME--32
55-210
55-211
E-03 = LH FRONT HAZARD LAMP E-50 = LH POSITION MARKER LAMP (EU) E-54 = LH FRONT AUSTRIA MARKER LAMP
FRAME--34 E-49 = RH POSITION MARKER LAMP (EU) E-53 = RH FRONT AUSTRIA MARKER LAMP
55-212
E-05 = LH REAR FLASHING LAMP (EU) E-55 = RH REAR AUSTRIA MARKER LAMP J-09 = TRAILER OUTLET
E-06 = RH REAR FLASHING LAMP (EU) E-56 = LH REAR AUSTRIA MARKER LAMP
55-213
55-214

55-215
55-216
E-31 = LH FRONT BEACON LIGHT F-53 = BEACON LT FUSE K-29 = BEACON LIGHT RELAY
E-32 = RH FRONT BEACON LIGHT J-02 = LH FT SERVICE SOCKET S-41 = BEACON LIGHT SWITCH
E-33 = REAR BEACON LIGHT J-03 = RH SIDE SERVICE SOCKET LIGHTING
F-15 = SERVICE SOCKETS FUSE J-05 = ENGINE SERVICE SOCKET FRAME--39
55-217
55-218
55-219

55-220
55-221
55-222
55-223
55-224

55-225
55-226
Chapter 4 - CAN Data Bus Network
CONTENTS

CAN Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Troubleshooting a Module Offline Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Troubleshooting Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Troubleshooting “A2000 Communication Lost” Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Data Bus -- Short Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ECU Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HHC Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ASD Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Integrated GPS Receiver Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Front Frame Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Main Frame Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CCM3 Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CCM2 Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cab Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
GPS Receiver Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DLU Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PFD Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cab Roof Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CCM1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Data Bus -- Open Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CCM1 Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cab Roof Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CCM2 Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ECU Branch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CAN Data Bus Connector Locations -- SN HAJ100800 and Below . . . . . . . . . . . . . . . 16
CAN Data Bus Connector Locations -- SN HAJ100801 and Above . . . . . . . . . . . . . . . 19
55-1
50050022
1
CAN NETWORK Each control module “tees” into the network, and acts
The CAN network is a multiplex system which follows as a separate “node” on the network. As a control
the guidelines established in SAE J1939. Multiplexing module receives data from sensors, switches and
simply stated is linking two or more digital devices potentiometers, it broadcasts this information on the
through a network. In the past, if an RPM sensor’s network for other modules to pick up and use as
information was needed by a tachometer, an engine needed. Each module knows which information it
controller and a transmission, all three devices would needs through the software programmed into it.
need to be hard wired to the RPM sensor. Through the When the network is initially powered up (operator turns
CAN Data Bus only one wire is needed. The key on), each module on the network sends out a
information is then accessed through the network by message announcing its existence, and “looks” for
other systems that need it. Any other system on the messages from other modules on the network. After this
network that does not care about RPM data ignores the initial message, each control module sends out data
message on the network. On today’s high tech messages as necessary, and, if necessary, it will send
machinery, the complexity of wiring can be greatly out another broadcast message announcing its
reduced through the use of the CAN data bus network. existence if it has not sent any messages within the last
The network is made up of a twisted pair of wires, 5 seconds. This is done in order to monitor each
identified as CAN HI (yellow) and CAN LO (green). module’s status on the network; if a certain module has
These two wires are used to form a “linear bus” network, not transmitted any messages for more than 5 seconds,
in that the wires run in parallel from one end of the then the other modules on the network will generate an
vehicle to the other, and each module is connected to alarm message indicating that the module is “offline”.
both wires as a “node”. These two wires are connected NOTE: If a control module never powers up and
together at each end of the network using a 120 ohm broadcasts its initial message, the other modules will
resistor, which is known as a “termination” resistor. not be aware that it exists, and no “offline” alarm will
Because there is a 120 ohm resistor at each end of the be generated.
network, the resistance should always be 60 ohms
between the CAN HI and CAN LO wires. Optional control modules, such as the ECU (engine
control unit), CCM3 (installed for Precision Farming
On the CR combine, one of these termination and other options), DLU (data logger unit, used for
resistors is located in the Infoview™ monitor itself, Precision Farming) and DGPS (differential GPS
while the termination resistance on the other end of receiver), must be set to “ON” in the Configuration
the network is located in the ECU (engine control screens when installed in order for their alarm
unit) on combines equipped with an electronic messages to become active. In addition, like the
engine. On mechanical engine units, there is a other modules, they must be powered up at start-up
connector next to the starter relay in the engine and transmit a message in order to be recognized as
compartment that contains the necessary 120 ohm being on the network.
termination resistor.
55-2
ALARMS
The network is capable of diagnosing itself and
generating alarm messages to the operator when
problems are detected. The combine may continue
to function when a network alarm message appears,
but systems related to that module will no longer
function. The alarm messages that are related to the
CAN network are listed below.
20014717
2
Alarm message Priority Description/Symptom

A2000 Communication Lost High CAN Hi & CAN LO wires are shorted together; icons on the
Infoview™ monitor will be grayed out, and lights on SSM will
flash in rotating sequence. Combine engine will not start.
A2001 MDM Offline Med Infoview™ monitor is offline; icons on the Infoview™ monitor
will be grayed out, and will not respond to keypad on RHM.
A2002 CCM1 Offline Med CCM1 module is offline.
A2005 RHM Offline Med RHM module is offline.
A2006 SSM Offline Med SSM module is offline; lights on SSM will flash in rotating
sequence.
A2007 ECU Offline Med ECU module is offline.
A2008 HHC Offline Med HHC module is offline.
A2009 GPS Offline Med GPS module is offline.
A2010 DLU Offline Med DLU module is offline.
Whenever a network-related alarm message ap-

pears, verify the concern by navigating to the
“Service Info\Network” screen, as shown. If a module
is “offline”, its icon will be grayed out as shown.
20014718
3
55-3
TROUBLESHOOTING
TROUBLESHOOTING A MODULE OFFLINE
ALARM
There are two general conditions that may cause an
individual module may go “offline”; loss of module
power, or CAN-related faults.
Each module requires a power and ground supply to

provide main operating power for the module; if
either of these is lost, the module will power down
and will not be active on the network.
NOTE: If a control module never powers up and

broadcasts its initial message, the other modules will
not be aware that it exists, and no “offline” alarm will
be generated.
There are several possible CAN-related faults that

may cause a module to go offline. External problems
include bad or open connections to the CAN HI and
CAN LO network wires as a result of damaged wiring.
Internal problems may include a failure of the CAN
controller itself (the device that actually does the
“communicating” on the network), or the module may
be “bussing off” due to excessive error messages.
Whenever a module transmits or receives a faulty

message, it keeps a record of that error. After its error
history fills up, the CAN controller assumes that it is
faulty, and will stop transmitting on the network
(module has gone “Bus Off”); this will set the alarm
off. This error history is erased and reset at zero
when the module is powered down.
Troubleshooting Steps
1. Verify module is offline by navigating to the
“Service Info\Network” screen, and confirm that
module icon is grayed out.
20014718
4
55-4
NOTE: If the Infoview™ monitor module (MDM) is
offline, all icons will be grayed out on screen, and
monitor will be non-responsive to keypad on RHM.
2. Turn the key switch off, and back on again.
Immediately navigate back to the “Service
Info\Network” screen, and recheck the module
status.
A. If affected module is initially online, and then
goes offline after a short period of time, it is
bussing off due to excessive error messages.
The excessive number of error messages
could be due to bad electrical connections to
20014719
the network, or a problem with the CAN
controller in the module. Continue with step 5. 5
B. If the module is offline immediately after the
network is powered up, continue with step 3.
3. A quick way to verify if a module has a power and
ground connection is to activate a function within
that module that does not require other CAN
message information (function is controlled
entirely by affected module). If the function
operates, then the module is powered up, and
the alarm is due to a CAN fault. See available
functions by module below. If the module that is
offline is not listed below, continue with step 4.
RHM: Depress Multi Function Handle (MFH)
button to activate neutral lock solenoid.
If solenoid activates, the RHM module
is powered up and functioning.
CCM1: Turn on Road Lights or Work Lights. If
lights come on, CCM1 is powered up
and functioning.
CCM2: Turn on Beacon Lights (EU, ROW) or
depress brake pedal to activate brake
lights. If lights come on, CCM2 is
powered up and functioning.
CCM3: Use remote Sieve Adjust switches to
activate sieve actuators (if installed). If
sieves operate, CCM3 is powered up
and functioning.
NOTE: There are no quick tests available for CCM3
on Yield monitor-only units.
SSM: If it has power but no CAN, warning
lights will flash in rotating sequence.
MDM: Icons will be grayed out, and Infoview™
monitor is non-responsive to keypad on
RHM. See Figure 5 above for reference.
A. If the module function operates, the module
is powered up, and the fault is due to a CAN
problem. Continue with step 5.
B. If the module function does not operate, the
module may not be powered up. Continue
with step 4.
55-5
4. Testing indicates that module is not powering up. ground on the ground path, and for 12V power on
Refer to the power and ground chart below for the the supply wires. If the module power and ground
specific power and ground sources for each supplies are good, but the module is still offline,
module. Use a multimeter to test for continuity to continue with step 6.
Module Power Ground Comments

MDM Connector X064 pin C wire 097 Connector X064 pin F wire 145 • Power from fuse F38 through key
orange black switch
• May also test at white plastic
circuit board connector prior to
replacing module
SSM Connector X064 pin C wire 097 Connector X064 pin F wire 145 • Power from fuse F38 through key
orange black switch
• May also test at white plastic
circuit board connector prior to
replacing module
RHM • KAM* power @ connector Connector X026 pins 15 & 20 wires • Main power from fuse F42 through
X026 pin 13 wire 051 red 389 & 352 black Cab power relay K26 to fuse F48
• Main power @ connector X026 and through splice block B, W02
pins 4 & 5 wires 098 & 089 • Ground path though splice block
orange A, W01
• Refer to schematic frames 25 & 28
CCM1 • KAM* power @ connector • Connector X018 pin J1-8 wire • KAM power from fuse F39
X018 pin J1-1 wire 052 red 215 black • Main power from fuse F38 through
• Main power @ connector X018 • Connector X019 pin J2-12 & 18 key switch
pin J1-4 wire 099 red wires 686 & 687 black • Refer to schematic frame 29
ASD • Main power @ connector X082 • Connector X082 pin 1 wire 720 • Main power from fuse F41 through
pin 4 wire 580 white black CCM2 power relay K25 to Fuse
F46
• Refer to schematic frames 14 & 28
ECU Connector X193 pin 3 & 4 wires Connector X193 pins 1 & 2 wires Refer to Sect 55 Chapter 5 for more
810 & 811 white. 815 & 816 black information on ECU power supply
DLU • KAM* power @ connector X159 • Connector X159 pins 6 & 8 wires • KAM power from fuse F39
pin 1 wire 831 red 854 & 855 black • Main power from fuse F12
• Main power @ connector X159
pin 5 wire 805 orange
For precision farming display
option (2005 & later):
• KAM power @ display left • Display left connector pin 3 wire • KAM power from fuse F39 via X159
connector pin 2 wire 550 red 355 black • Main power from fuse F12 via X159
• Main power @ display left rear
connector pin 1 wire 650 orange
DGPS Connector X142 pin 1 wire 903 Connector X142 pin 3 wire 282 Power from fuse F12
orange black
For external GPS option (2004 &
later):
Connector X321 pin 1 wire 1238 Connector X321 pin 3 wire 1239 Power from fuse F45
orange black
NOTE: KAM* = Keep Alive Memory; constant, key-off power.
55-6
5. Testing has determined that the module is offline ohms, the external wiring is okay, and the
due to a CAN fault, either with the CAN controller fault is internal to the module. Continue with
inside the module, or with the physical wiring to step 6.
the network. Use a multimeter to check for B. If there is continuity between the two network
continuity between the two wires that connect the wires, but the resistance is very high (> 70
module to the network. ohms), there is a bad connection in the
NOTE: Several modules are connected to the external wiring to the network. Check the
network through internal solder paths on the circuit harness and connectors for damage and
boards, and cannot be tested as described. These repair as necessary.
modules include the Infoview™ monitor (MDM), RHM, C. If there is no continuity between the two
CCM1, CCM2, and the Engine Control Unit (ECU). If network wires, there is an open circuit in one
one of these modules are offline, continue with step 6. of the two wires. Locate the open and repair.
A. If there is continuity between the two network

wires, and the resistance measured is 60
Module Network Connection Comments

SSM Connector X320 pin 4 (CAN HI) and pin 3 (CAN LO) • Connects to splice in MDM harness just before
reaching connector X064
• Refer to schematic frame 30
DLU Connector X159 pin 2 wire 807 yellow (CAN HI) and • Connects to network at splice in cab roof (CR)
pin 7 wire 806 green (CAN LO) harness
For precision farming display option (2005 &
later):
Display left connector pin 8 wire 1250 yellow (CAN • Connects to network at connector X159, pin 2 (CAN
HI) and pin 7 wire 1249 green (CAN LO) HI) and pin 7 (CAN LO)
• Refer to schematic frame 30A
DGPS Connector X142 pin 2 wire 999 yellow (CAN HI) and • Connects to network at splice in cab roof (CR)
pin 4 wire 996 green (CAN LO) harness.
For external GPS option (2004 & later):
Connector X000 pin 4 black/white wire (CAN HI) and • Connects to network at X321 on grain bin front
pin 9 red/white wire (CAN LO) panel.
CCM3 Connector X012 pin J1-14 wire 133 yellow (CAN HI) • Connects to network at CCM2 connector X015 pins
and pin J1-13 wire 134 green (CAN LO) J1--20 (CAN HI) and J1--19 (CAN LO)
ASD Connector X082 pin 6 wire 729 yellow (CAN HI) and • Connects to network at splice in feeder (FE) harness
pin 7 wire 730 green (CAN LO) • Refer to schematic frame 31
HHC • 1st check -- Connector X281 pin 12 wire 544 • Connects to network through connector X022 to
yellow (CAN HI) and pin 6 wire 545 green (CAN splice in main frame (MF) harness.
LO) • If 1st check indicates high or infinite resistance, use
• 2nd check – Connector X022 pin S wire 544 yellow 2nd check to determine which harness fault is in.
(CAN HI) and pin T wire 545 green (CAN LO) • Refer to schematic frame 31
6. CAN fault is internal to the module. Use the B. If module still remains offline after software is
Electronic Service Tool to reload the correct reloaded, the module has failed internally,
version software in the module. and must be replaced to repair the fault.
A. If module now functions properly, fault was
due to corrupt software. Fault should be
resolved.
55-7
TROUBLESHOOTING “A2000
COMMUNICATION LOST” ALARM
The alarm message “A2000 Communication Lost”
indicates that the CAN HI and CAN LO network wires
are shorted together, or that there is an open in one
of the two wires.
To confirm whether CAN HI and CAN LO are shorted

or open, make the following check at the diagnostic 1
port connector X065 on the B-post console.
1. Use a multimeter to check the resistance

between pin D and pin C on connector X065, 1.
This will quickly verify whether there is a short or 6
open in the system.
A. A reading of 0 ohms confirms that CAN HI
(yellow wire) is shorted to CAN LO (green
wire). Continue with Step 2.
B. A reading of 120 ohms indicates an open in
either CAN HI or CAN LO. Continue with
Step 2.
C. A reading of 60 ohms indicates that the
network wiring is okay.
X065
DIAGNOSTICS AND MAINTENANCE
2. Open the service door on the right side of the cab.

Disconnect connector X001, 1. This essentially 1
splits the CAN system in half. Connector X001
pins 6 and 7 will be referred to as LEG 1 and
connector X001 pins 8 and 9 will be referred to as
LEG 2. Use a multimeter to check resistance
between pins 6 and 7 (LEG 1) on the harness end
of Connector X001.
A. A reading of 0 ohms indicates that CAN HI
and CAN LO are shorted together some-
where in LEG 1. Continue with “Trouble-
shooting LEG1” in this section.
10010921
B. A reading of Extreme high resistance OL
(Over load-open circuit) indicates an open, or 7
broken wire in CAN HI or CAN LO in LEG 1.
Continue with “Troubleshooting LEG1” in this
section.
C. A reading of 120 ohms indicates that LEG 1
is okay. Continue with Step 3.
X001
55-8
3. Probe Connector X001 pins 8 and 9 (LEG 2) and
check resistance.
where in LEG 2. Continue with “Trouble-
shooting LEG2” in this section.
B. A reading of Extreme high resistance OL
(Over load-open circuit) indicates an open, or
broken wire in CAN HI or CAN LO in LEG 2.
Continue with “Troubleshooting LEG2” in this
section.
C. A reading of 120 OHMS indicates that leg 2
is okay. Continue with Step 4.
4. Use a multimeter to check resistance between
pins 6 and 7 on the console end of connector X001
X001.

where inside the right console (RC) harness.
Remove the console and inspect the right
console (RC) harness for damage. Locate
the short and repair.
B. If a reading of OL (overload – open circuit) is
observed, continue with step 5.
pins 6 and 8 on the console end of connector
X001.
A. A reading of OL (overload – open circuit)
indicates that there is an open circuit in the
right console harness between connector
X001 pins 6 & 8 and connector X026 pins 2
and 11 wires 127 yellow and 129 yellow.
B. If a reading of 0 ohms is observed, continue
with step 6.
pins 7 and 9 on the console end of connector
X001.
A. A reading of OL (overload – open circuit)
indicates that there is an open circuit in the
right console harness between connector
X001 pins 7 & 9 and connector X026 pins 1
and 10 wires 128 green and 130 green.
B. If a reading of 0 ohms is observed, the
network wiring in the right console harness is
okay. Reattach all connectors and retest
system.
55-9
Troubleshooting Leg 1
(Refer to schematic Frames 30 and 31 in this
section)
• A 0 ohm reading indicates a short circuit between
CAN HI and CAN LO.
• An OL (Over load-open circuit ) indicates a
broken wire.
1. Disconnect connector X064 at the Infoview™
Monitor harness in the right front cab post. Use
a multimeter to check the resistance between
pins A and E on the monitor harness end of
connector X064.
A. A reading of 120 ohms indicates the circuit is
okay through connector X064 to the
Infoview™ Monitor. Continue with step 2.
B. A reading of OL (Over load-open circuit)
indicates an open wire between connector X064
X064 and Connector X319 in the monitor
harness. Locate open and repair.
C. A reading of 0 ohms indicates a short in CAN
HI and CAN LO between connector X064
and monitor Connector X319 or SSM
Connector X320. Examine harness for
damage. Replace /repair as necessary.
2. Use a multimeter to check the resistance
between Pins A and E on the cab main (CM)
harness end of Connector X064.
A. A reading of 0 ohms indicates a short exists
in the cab main (CM) harness between
connector X064, connector X065 and
connector X001. Locate the short and repair.
B. If an OL (Overload-Open circuit) reading is
observed, continue with step 3.
55-10
3. Check for continuity between connector X064 B. If continuity is found, continue with step 5.
pin E and DAM connector X065 pin D. 5. Check for continuity between connector X064
A. If no continuity is found, locate and repair pin A and DAM connector X065 pin C.
open in cab main harness wire 144GN and A. If no continuity is found, locate and repair
270GN between connector X064 pin E and open in cab main harness wire 143YE and
connector X065 pin D. 271YE between connector X064 pin A and
B. If continuity is found, continue with step 4. connector X065 pin C.
4. Check for continuity between DAM connector B. If continuity is found, locate and repair open
X065 pin D and connector X001 pin 7. in cab main harness wire 127YE between
splice and connector X001 pin 6.
A. If no continuity is found, locate and repair
open in cab main harness wire 128GN
between splice and connector X001 pin 7.
3
4
2
50020071
8
1. Connector X064 4. Connector X065
3. Connector X320
55-11
Troubleshooting Leg 2 A. If there is no continuity, there is a short in the
main valves (MV) harness between connector
(Refer to schematic Frames 30 and 31 in this
X281 and connector X022 wires 544 yellow
section) and 545 green. Locate the short and repair.
If a reading of 0 ohms was detected, there is a short B. If there is continuity, continue with step 5.
circuit between the CAN HI and LO wires somewhere
on the network. Begin troubleshooting at step 1. ASD Branch
If a reading of OL was detected, there is an open 5. Disconnect the feeder harness from the ASD
circuit in either the CAN HI or CAN LO wires module at connector X082. Use a multimeter to
somewhere on the main network trunk. Go to Data check for continuity between connector X001
Bus -- Open Circuit Troubleshooting. pins 8 and 9.
A. If there is no continuity, there is a fault in the
DATA BUS -- SHORT CIRCUIT ASD module. Replace the module.
TROUBLESHOOTING
B. If there is continuity, continue with step 6.
ECU Branch
6. Disconnect the feeder harness at connector
1. Disconnect connector X193 from the ECU
X007. Use a multimeter to check for continuity
(engine control unit) on units with electronically
between connector X001 pins 8 and 9.
controlled engines, or unplug the CAN node
connector X291 on units with mechanically A. If there is no continuity, there is a short in the
controlled engines. Use a multimeter to check for feeder (FE) harness between connector
continuity between connector X001 pins 8 and 9. X082 and connector X007 wires 729 yellow
and 730 green. Locate the short and repair.
ECU (electronic engine units) or the CAN B. If there is continuity, continue as follows: For
node connector X291 (mechanical engine 2004 and later production models with the
units). Replace the component. optional integrated GPS receiver mounted
on the grain tank, proceed with step 7. For
models with the GPS receiver mounted in the
cab roof, or for models with no GPS receiver,
2. Disconnect the engine harness at connector
proceed with step 9.
Integrated GPS Receiver Branch
A. If there is no continuity, there is a short in the
engine (EN) harness between connector 7. Refer to schematic Frame 31A. Disconnect the
X193 and connector X010 wires 819 yellow GPS receiver cable from the GPS receiver at
and 820 green. Locate the short and repair. connector X000. Use a multimeter to check for
continuity between connector X001 pins 8 & 9.
HHC Branch GPS receiver. Replace the receiver.
3. Disconnect the main valves harness from the
HHC module at connector X281. Use a
8. Disconnect the GPS receiver cable at connector
multimeter to check for continuity between
connector X001 pins 8 and 9.
between connector X001 pins 8 & 9.
HHC module. Replace the module.
GPS receiver cable between connector
B. If there is continuity, continue with step 4. X000 and X321 wires black/white and
red/white. Locate the short and repair.
4. Disconnect the main valves harness at connec-
tor X022. Use a multimeter to check for continuity
55-12
Front Frame Harness A. If there is no continuity, there is a fault in the
CCM3 module. Replace the module.
9. Disconnect the front frame harness from the
main frame harness at connector X008. Install B. If there is continuity, continue with step 13.
jumper wires on the main frame half of connector
X008 between pins 1 & 3 and between pins 2 & CCM2 Branch
4. Use a multimeter to check for continuity 13. Disconnect the cab main harness from the CCM2
between connector X001 pins 8 and 9. module at connector X015. Install jumper wires
A. If there is no continuity, there is a short in the on the cab main half of connector X015 between
front frame (FF) harness between connector pins J1--13 & J1--19 and between pins J1--14 &
X007 and connector X008 on one of the J1--20. Use a multimeter to check for continuity
following pairs of wires: between connector X001 pins 8 & 9.
Wires 729 yellow and 730 green from A. If there is no continuity, there is a fault in the
connector X007 pins 8 & 9 to FF harness splice. CCM2 module. Replace the module.
Wires 674 yellow and 675 green from B. If there is continuity, continue with step 14.
connector X008 pins 1 & 2 to FF harness splice.
Wires 744 yellow and 746 green from FF Cab Main Harness
harness splice to connector X008 pins 3 & 4.
14. Remove the jumper wires from the cab main half
Locate the short and repair. of connector X015. Use a multimeter to check for
B. If there is continuity, continue with step 10. continuity between connector X001 pins 8 & 9.
Main Frame Harness A. If there is no continuity, there is a short in the

cab main (CM) harness between connector
10. Remove the jumper wires from the main frame X012 and connector X015 wires 133 yellow
half of connector X008. Use a multimeter to check and 134 green. Locate the short and repair.
for continuity between connector X001 pins 8 & 9.
main frame (MF) harness between connector GPS Receiver Branch
X010, connector X022 and connector X008
15. Slide the GPS receiver out of its DIN slot in the
on one of the following pairs of wires:
cab roof. (If a GPS receiver is not installed,
Wires 819 yellow and 820 green from continue with step 16). Disconnect the cab roof
connector X010 pins 19 & 21 to MF harness harness from the GPS receiver at connector
splice. X142. Use a multimeter to check for continuity
Wires 544 yellow and 545 green from between connector X001 pins 8 & 9.
connector X022 pins S & T to MF harness
splice.
GPS receiver. Replace the receiver.
Wires 674 yellow and 675 green from MF
B. If there is continuity, continue as follows: For
harness splice to connector X008 pins 1 & 2.
production models with the data logger (DLU)
Locate the short and repair. mounted in the cab roof, proceed with step 16.
B. If there is continuity, continue with step 11. For models with the optional precision farming
11. Disconnect the main frame harness from the display (PFD), continue with step 17. For
CCM2 module at connector X016. Use a models with no DLU or precision farming
multimeter to check for continuity between display, continue with step 19.
connector X001 pins 8 & 9.
DLU Branch
main frame (MF) harness between connector 16. Slide the data logger (DLU) module out of its DIN
X008 and connector X016 wires 744 yellow slot in the cab roof. Disconnect the cab roof
and 746 green. Locate the short and repair. harness from the DLU module at connector X159.
Use a multimeter to check for continuity between
CCM3 Branch A. If there is no continuity, there is a fault in the
DLU module. Replace the module.
12. Disconnect the cab main harness from the CCM3
module at connector X012. (If a CCM3 module is B. If there is continuity, continue with step 19.
not installed, continue with step 13). Use a
multimeter to check for continuity between
55-13
PFD Branch A. If there is no continuity, there is a short in the
17. Refer to schematic Frame 31 A. Disconnect the
X015 and connector X003 wires 131 yellow
precision farming display (PFD) harness at the
two connectors at the bottom of the display. (The
connector housing the CAN bus wires is on the B. If there is continuity, continue with step 21.
left, facing the front of the display). Use a
multimeter to check for continuity between CCM1 Module
connector X001 pins 8 & 9. 21. Disconnect the cab main harness from the CCM1
A. If there is no continuity, there is a fault in the module at connector X018. Install jumper wires
PFD module. Replace the module. on the cab main end of connector X018 between
pins J1--13 & J1--19 and between pins J1--14 &
B. If there is continuity, continue with step 18. J1--20. Use a multimeter to check for continuity
between connector X001 pins 8 & 9.
18. Disconnect the precision farming display harness
at connector X159. Use a multimeter to check for A. If there is no continuity, there is a fault in the
continuity between connect X001 pins 8 & 9. CCM1 module. Replace the module.
A. If there is no continuity, there is a short in the B. If there is continuity, continue with step 22.
precision farming display harness between
the left display connector and connector X159 22. Remove the jumper wires from the cab main end
wires 1250 yellow and 1249 green. Locate the of connector X018. Use a multimeter to check for
short and repair. continuity between connector X001 pins 8 & 9.
B. If there is continuity, continue with step 19. A. If there is no continuity, there is a short in the
Cab Roof Harness X003 and connector X018 wires 137 yellow
19. Disconnect the cab roof harness from the cab
B. If there is continuity, there is a short in the cab
main harness at connector X003 (it will be
main (CM) harness between connector X018
necessary to remove the upper trim panel in the
and connector X001 wires 129 yellow and
cab to gain access to this connector). Install
130 green. Locate the short and repair.
jumper wires on the cab main end of connector
X003 between pins 1 & 4 and between pins 2 &
6. Use a multimeter to check for continuity DATA BUS -- OPEN CIRCUIT
between connector X001 pins 8 & 9. TROUBLESHOOTING
A. If there is no continuity, there is a short in the CCM1 Branch
cab roof (CR) harness between connector
1. Disconnect the cab main harness from the CCM1
X142, connector X159 and connector X003
on one of the following pairs of wires: module at connector X018. Install a jumper wire
on the cab main end of connector X018 between
Wires 999 yellow and 996 green from pins 19 & 20. Use a multimeter to check for
connector X142 pins 2 & 4 to CR harness continuity between connector X001 pins 8 & 9.
splice.
Wires 807 yellow and 806 green from A. If there is no continuity, there is an open
circuit in the cab main (CM) harness between
connector X159 pins 2 & 7 to CR harness
splice. connector X001 and connector X018 wires
129 yellow or 130 green. Locate the open
Wires 131 yellow and 132 green from circuit and repair.
connector X003 pins 1 & 2 to CR harness
splice.
Wires 137 yellow and 138 green from CR 2. Remove the jumper wire from the cab main end
harness splice to connector X003 pins 4 & 6. of connector X018. Use a multimeter to check for
Locate the short and repair. continuity between connector X018 pins J1--13
B. If there is continuity, continue with step 20. and J1--14.
A. If there is continuity (approx. 120 ohms),
20. Remove the jumper wires from the cab main half there is a fault in the CCM1 module. Replace
of connector X003. Use a multimeter to check for the module.
continuity between connector X001 pins 8 & 9. B. If there is no continuity, continue with step 3.
55-14
Cab Roof Harness 7. Install a jumper wire in the front frame harness
end of connector X008 between pins 3 & 4. Use
3. Disconnect the cab roof harness from the cab
a multimeter to check for continuity between
main harness at connector X003 (it will be
necessary to remove the upper trim panel in the
cab to gain access to this connector). Install a A. If there is no continuity, there is an open
jumper wire on the cab roof end of connector circuit in the front frame (FF) harness
X003 between pins 1 & 2. Use a multimeter to between connector X008 pins 1 & 3 wires
check for continuity between connector X003 744 yellow or 674 yellow or between
pins 4 & 6 (cab roof end). connector X008 pins 2 & 4 wires 746 green
or 675 green. Locate the open and repair.
A. If there is no continuity, there is an open
circuit in the cab roof (CR) harness between B. If there is continuity, continue with step 8.
connector X003 pins 1 & 4 wire 131 yellow
and 137 yellow or between connector X003 ECU Branch
pins 2 & 6 wires 132 green and 138 green. 8. Disconnect the main frame harness from the engine
Locate the open and repair. harness at connector X010. Use a multimeter to
B. If there is continuity, continue with step 4. check for continuity on the engine harness end of
connector X010 between pins 19 & 21.
CCM2 Branch
A. If there is continuity (approx. 120 ohms), there
4. Reattach connector X003, and disconnect the is an open circuit in the main frame (MF)
cab main harness from the CCM2 module at harness between connector X008 and connec-
connector X015. Install a jumper wire on the cab tor X010 wires 674 or 819 yellow and 675 or
main end of connector X015 pins J1--13 & J1--14. 820 green. Locate the open and repair.
Use a multimeter to check for continuity between B. If there is no continuity, continue with step 9.
connector X018 pins J1--13 & J1--14.
9. On electronic engine units, disconnect the
A. If there is no continuity, there is an open
engine harness from the ECU module at
circuit in the cab main (CM) harness between
connector X193 (for mechanical engine units,
connector X018 and connector X003 wires
continue with step 10). Use a multimeter to check
137 yellow and 138 green, or between
for continuity on the ECU module connector
connector X003 and connector X015 wires
X193 between pins 11 & 12.
131 yellow and 132 green. Locate the open
and repair. A. If there is continuity (approx. 120 ohms),
B. If there is continuity, continue with step 5. there is an open circuit in the engine (EN)
harness between connector X010 and
5. Disconnect the main frame harness from the connector X193 wires 819 yellow and 820
CCM2 module at connector X016. Use a green. Locate the open and repair.
multimeter to check for continuity between B. If there is no continuity, there is a fault in the
connector X016 pins J2--23 & J2--32. ECU module. Replace the module.
A. If there is continuity (approx. 120 ohms),
10. On mechanical engine units, unplug the CAN
there is a fault in the CCM2 module. Replace
node connector X291. Use a multimeter to check
the module.
for continuity on the CAN node plug between pins
B. If there is no continuity, continue with step 6. A & B.
6. Disconnect the front frame harness from the A. If there is continuity (approx. 120 ohms),
main frame harness at connector X008. Install a there is an open circuit in the engine (EN)
jumper wire in the main frame harness end of harness between connector X010 and
connector X008 between pins 3 & 4. Use a connector X291 wires 819 yellow and 820
multimeter to check for continuity between green. Locate the open and repair.
connector X016 pins J2--23 & J2--32. B. If there is no continuity, there is a fault in the
A. If there is no continuity, there is an open CAN node plug. Replace the plug.
circuit in the main frame (MF) harness
between connector X016 and connector
X008 wires 744 yellow and 746 green.
55-15
CAN DATA BUS CONNECTOR LOCATIONS -- SN HAJ100800 AND BELOW
2 3
1 4
1. Connector X001
2. Connector X003
6 3. Connector X022
4. Connector X193
5. Connector X010
6. Connector X008
9 8 7. Connector X007
11 10 8. Connector X018
9. Connector X015
10. Connector X012
11. Connector X082
50020072
55-16
SN HAJ100800 AND BELOW
10
55-17
SN HAJ100800 AND BELOW
11
55-18
CAN DATA BUS CONNECTOR LOCATIONS -- SN HAJ100801 AND ABOVE
3
12
2
9 8
10

11 2. Connector X003 9. Connector X015
12
55-19
SN HAJ100801 AND ABOVE

FRAME--30A A-21 = FUTURE OPTION
13
55-20
SN HAJ100801 AND ABOVE

A-07 = HHC MODULE A-00 = PRECISION FARMING DISPLAY (OPT)
A-11 = GPS MODULE FRAME--31A
14
55-21
55-22
Chapter 5 - Engine Systems
CONTENTS

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Engine Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7.5 Liter Basildon Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7.5 Liter Basildon Electronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
8 Liter Iveco & 10 L Iveco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2003 Production -- SN HAJ100101 and above (Frame 9) . . . . . . . . . . . . . . . . . . . . . . 9
2003 Production -- SN HAJ100101 and above (Frame 29) . . . . . . . . . . . . . . . . . . . 10
2004 Production -- SN HAJ100801 to 1500 (Frame 1A) . . . . . . . . . . . . . . . . . . . . . . 11
2004 Production -- SN HAJ100801 to 1500 (Frame 2A) . . . . . . . . . . . . . . . . . . . . . 12
Starting System -- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
A -- Key Switch Power Supply Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
B -- Key Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
C – Neutral Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
D – Neutral Start Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
E – 12 V Start Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F – 24 V Start Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
G – 12V Starter Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
H – 24V Starter Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
I -- Starting Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
55-1

Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Charging System -- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
A -- Charging System Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
B – RPM Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Alternator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Grid Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Grid Heater Circuit, Iveco Engines --
SN HAJ100800 and Below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Grid Heater Circuit, Iveco Engines --
SN HAJ100801 and Higher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Grid Heater Circuit, Iveco Engines, Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Grid Heater Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Grid Heater Circuit Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
CCM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Engine Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Right Hand Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
ECU Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
55-2

Engine-Related Error Codes -- Automatic Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ECU Related Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Basildon – Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Throttle Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Basildon – Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Air Temperature/ Boost Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Flywheel RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Engine Oil Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
IVECO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Engine Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Fuel Filter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Engine Camshaft RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Engine Flywheel RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Style I -- Boost Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Style II -- Boost Pressure/Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fuel Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
All Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Rotary Screen Brush Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Air Filter Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Fuel Pump Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
55-3
OVERVIEW
GENERAL ENGINE SYSTEMS
This section describes the electrical systems
specifically related to the engine:
There are three types of engines available for the CR

Series combine. The Iveco engines are identical
except for tuning configurations.
7.5 Liter Basildon Mechanical
The 7.5 l Basildon engine is equipped with an inline
Bosch fuel pump and a mechanical governor. When
the throttle position is changed, CCM2 controls a
solenoid that adjusts fuel flow. All engine sensors are
monitored by CCM2.
7.5 Liter Basildon Electronic

A high-pressure electric fuel pump delivers fuel to the
7.5l Basildon engine. The Electronic Control Unit
(ECU) provides throttle information. The ECU
monitors all engine sensors such as, oil pressure,
20030056
boost pressure, and engine temperature.
1
8 Liter Iveco & 10 L Iveco
The governor on the IVECO engine is electronically
controlled. A low-pressure pump controls fuel flow to
the engine. The two IVECO engine models are the
same except for tuning. All electrical engine
components are the same.
20030057
55-4
STARTING SYSTEM
The CR Series combines are equipped with either a
12 or 24 volt starting system.
DESCRIPTION OF OPERATION NOTE: For models SN HAJ101501 and above,

starting relay K-15 has been added to the start circuit
12V Starting Circuit (Frame 2B). Neutral start relay K-23 provides a path
Refer to schematic Frames 1, 2, 9 and 29. from the key switch to the coil of K-15, which
energizes, applying +12 volts from fuse F-26 (Frame
For engine starting, the key switch S-02 (Frame 29) 3B) to start relay K-38.
is moved to the START position. Assuming neutral
switch S-22 (Frame 9) is on (multifunction handle in When K-38 energizes, the normally closed contacts
NEUTRAL), neutral start relay K-23 (Frame 2) is now open, opening the connections between K-38
energized, providing a current path from the key pins 30A and 30, and 31A and 31. This removes the
switch to the coil of start relay K-36. K-36 energizes parallel con-nections between the two batteries.
and, through closed contacts 30 and 87, applies 12
volts to 12-volt starter M-01, terminal S. This Normally open contacts 31A and 30, and 30A and 50
energizes the start solenoid in M-01 and the engine are now closed. This places the two batteries in
cranks. series through the following path: G-03 negative
terminal remains grounded, either directly or through
24V Starting Circuit battery switch S-52; G-03 positive terminal connects
Refer to schematic Frames 1, 2, 3, 9 and 29. For to G-02 negative terminal through K-38 contacts 30
models SN HAJ100801 to 101500, refer to and 31A; G-02 positive terminal connects to B+
schematic frames 1A , 2A , 9 and 29. For models SN terminal of starter motor M-29. The voltage present
HAJ101501 and above, refer to schematic frames at this terminal is now 24 volts.
1B, 2B, 3B, 9 and 29.
At the same time, the 24 volts at M-29’s B+ terminal
For engine starting, the key switch S-02 (Frame 29) is applied to M-29’s S terminal via wire 832, K-38
is moved to the START position. Assuming neutral contacts 30A and 50, and wire 834. This energizes
switch S-22 (Frame 9) is on (multifunction handle in the start solenoid in M-29, and the engine cranks.
NEUTRAL), neutral start relay K-23 (Frame 2) is
energized, providing a current path from the key
switch to the coil of start relay K-36. K-36 energizes
and, in turn, energizes the 24-volt start relay K-38
(Frame 1).
55-5
ELECTRICAL SCHEMATICS
2003 Production -- SN HAJ100101 to 800 (Frame 1)
55-6
55-7
55-8
55-9

55-10
2004 Production -- SN HAJ100801 to 1500 (Frame 1A)
M-01 = 12V STARTER (7.5 L) (8) BASE MODEL SOLD IN EUROPE
FRAME--1A
8
55-11
2004 Production -- SN HAJ100801 to 1500 (Frame 2A)
FRAME--2A G-01 = ALTERNATOR K-39 = GRID HEATER RELAY (IVECO)
55-12
2005 Production -- SN HAJ101501 and Above (Frame 1B)
M-01 = 12V STARTER (7.5 L) (8) BASE MODEL SOLD IN EUROPE FRAME--1B
10
55-13
FRAME--2B G-01 = ALTERNATOR K-36 = START RELAY
11
55-14
STARTING
FRAME--3B
12
55-15
STARTING SYSTEM -- TROUBLESHOOTING

PRELIMINARY CHECKS
Before troubleshooting the starting system, make 3. Transmission in neutral, brake lock on.
sure that the following conditions are met:
4. Battery switch closed.
1. The batteries are fully charged and all the
connections are clean and tight. 5. For combines with 24V starting systems, check
the two 80A fusible links on 24V start relay K-38
2. Check fuses F-38 and F-48. For models SN (Figure 14).
HAJ101501 and above, also check fuse F-26.
55-16
SYMPTOM CHART
NOTE: The batteries must be fully charged and all the WARNING
connections clean and tight. Use a multimeter
Before performing any of the electrical tests, be
(DVOM) for these tests. For battery testing and
service, see the battery section in the service manual. sure all operating controls are in neutral or park
lock position. This will eliminate accidental
movement of the machine or start-up of power
CAUTION driven equipment.
DO NOT use a self-powered test light for any of
these tests. Use of a self-powered test light can
cause damage to components in this system.
Symptom Possible Cause Reference/Test

Engine
g y is Fuse #38
does not crank when key A -- Key Switch Power Supply Test, test point 1
t
turned
d tto start
t t
Key Switch A -- Key Switch Power Supply Test.
B – Key Switch Test, test points 1 and 2.
Neutral Switch C – Neutral Switch Test.
Refer to Transmission Section of Service Manual
and check neutral switch adjustment.
Neutral Start Relay D – Neutral Start Relay Test
Start Relay
y E – 12V Start Relay Test (12V system)
F – 24V Start Relay Test (24V system)
Starter Motor G-- 12V Starter Motor Test
H-- 24V Starter Motor Test
Click is heard when key y is turned Starter Motor G --12V Starter Motor Test
b t engine
but i does
d nott crank
k
H --24V Starter Motor Test
Start Relay
y E -- 12V Start Relay Test (12V System)
F -- 24V Start Relay Test (24V System)
Neutral Start Relay D --Neutral Start Relay Test
Engine
g cranks slowly
y Starter Motor G --12V Starter Motor Test, test points 4, 5 and 6.
H --24V Starter Motor Test, test points 1 -- 5, 8 and 9.
Engine mechanical problem Refer to Engine Section in Service Manual.
Starter motor continues to operate Key Switch B -- Key Switch Test, and Confirm that switch opens
when keyy is released from START to when key is released.
RUN position
iti
Start Relay E -- 12V Start Relay Test (12V System) test point 5,
and confirm that relay opens when key is released.
F -- 24V Start Relay Test (24V System), test point 5,
and confirm that relay opens when key is released.
Neutral Start Relay Test D – Neutral Start Relay Test, test point 5, and confirm
that relay opens when the key is released.
Starter Solenoid G – 12V Starter Motor Test, test point 2 and confirm
that 12 volts are not present at “S” terminal when the
key is released. If starter continues to run when 12
volts are removed, replace starter.
H – 24V Starter Motor Test, test point 2 and confirm
that 24 volts are not present at “S” terminal when the
key is released. If starter continues to run when 24
volts are removed, replace starter.
55-17
DIAGNOSTIC TESTS
NOTE: The batteries must be fully charged and all WARNING
sure all operating controls are in neutral or park
service, see the battery section in the service manual.
movement of the machine or start--up of power
CAUTION driven equipment.
A -- Key Switch Power Supply Test

Test Point Good Reading Possible Cause of Bad Reading
1 Measure for 12 volts at Key Switch 12 volts Open circuit 053 (RD) between fuse
Connector X068 (pin 1). #38 and Key Switch connector X068
(pin 1).
If good reading, go to the next test Go to the next test point.

point.
2 Key Switch in “IGN/ACC” position. 12 volts Key Switch
Measure for 12 volts at Key Switch If good reading, go to next test point.
connector X068 (pin 6 and 4).
3 Key Switch in “START” position. 12 volts Key Switch
Measure for 12 volts at Key Switch
connector X068 (pin 2). If good reading, Key Switch operating
normally.
B -- Key Switch Test

1 Remove electrical Connector from Continuity Key Switch
Key Switch.
While holding Key Switch in “START” If good reading, go to the next test
position, Check for continuity be- point.
tween (pin 1 and 2).
2 While holding Key Switch in “START” Continuity Key Switch
position, Check for continuity be-
tween (pin 1 and 6). If good reading, go to the next test
point.
3 Key Switch in “IGN/ACC” position, Continuity Key Switch
check for continuity between (pin 1
and 6). If good reading, go to the next test
point.
4 Key Switch in “IGN/ACC” position, Continuity Key Switch
check for continuity between (pin 1
and 4). If good reading, go to the next test
point.
5 Key Switch in “ACC” Position, check Continuity Key Switch
for Continuity between (pin 1 and 4).
If good reading, go to the next test
point.
6 Key Switch in “OFF” Position, check No continuity Key Switch
for Continuity between (pin 1) and
(pins 2, 4, 6). If good reading, Key Switch operating
properly.
55-18
C – Neutral Switch Test

1 Key Switch in “IGN” position. 12 volts Open circuit 300 (OR) or 108 (OR)
between Fuse #48 and Neutral
Measure for 12 volts at Neutral If good reading, go to the next test Switch connector X059 (pin 1).
Switch connector X059 (pin 1). point. Check in-line connector X001 (pin 3)
for connection.
Blown Fuse #48 (refer to Power

Distribution section for testing).
2 Place Neutral Switch in the “Closed” 12 volts Neutral Switch
position.
Measure for 12 volts at Neutral If good reading, go to the next test

Switch connector X059 (pin 3). point.
3 Place Neutral Switch in the “open“ 12 volts Neutral Switch
position.
Measure for 12 volts at Neutral If good reading, Neutral Switch okay.

Switch connector X059 (pin 2).
D – Neutral Start Relay Test

NOTE: Starting Relay, K-15, has been added to the start circuit in CR combine models SN HAJ101501 and
higher. It is interposed between Neutral Start Relay, K-23, and Start Relay, K-36. It may be necessary to test
Starting Relay, K-15. Table I, Starting Relay Test has been added for this purpose.

1 Key Switch in “START” position. 12 volts Neutral Start Relay
Measure for 12 volts at Neutral Start If good reading, Neutral Start Relay Go to next test point.
Relay (pin 5). operating properly.
2 Key switch in “START” position. 12 volts Open or short to ground in circuit 91
Remove the Neutral Start Relay. (OR) between Key Switch connector
X068 (pin 2) and Neutral Start Relay
Measure for 12 volts at Neutral Start If good reading, go to next test point. (pin 3). A short to ground will blow
Relay (pin 3). Fuse #38.
3 Key Switch in “ON” position. 12 volts Open circuit 93 (WH) between
Neutral Switch and Neutral Start
Measure for 12 volts at Neutral Start If good reading, go to the next test Relay.
Relay (pin 1). point.
Neutral Switch. Perform C -- Neutral
Switch Test
4 Key Switch in “OFF” position. Less than 1 ohm Open in circuit 094 (BK) between
Neutral Start Relay (pin 2) and
IMPORTANT: When performing con- If good reading, replace the Neutral ground.
tinuity test on this circuit, ensure that Start Relay.
the cable is disconnected from the
battery positive terminal. Failure to do
so can result in damage to the test
meter.
Measure resistance from Neutral

Start Relay (pin 2) to ground.
55-19
E – 12 V Start Relay Test

12V start relay K-36, 1, is mounted on the frame just
aft of the engine.
10010871
13

1 Key Switch in “START” position. 12 volts Start Relay or wiring.
Measure for 12 volts at Start Relay If good reading, Start Relay is Go to next test point.
K-36 (pin 87). operating properly.
2 Measure for 12 volts at Start Relay 12 volts [7.5L] Open circuit 801 (RD) from
K-36 (pin 30). Start Relay (pin 30) to 12V Starter B+
If good reading, go to next test point. terminal.
[IVECO] open circuit 801 (RD) from

Start Relay (pin 30) to 24V Start
Relay (pin 51).
3 Key Switch in “START” position. 12 volts Open circuit 092 (WH) between Start
Relay connector X199 (pin 86) and
Measure for 12 volts at Start Relay If good reading, go to the next test Neutral Start Relay (pin 5).
K-36 connector X199 (pin 86). point.
Check in-line connectors X005 (pin 6)
and X010 (pin 5) for connection.
4 Key Switch in “OFF” position. Less than 1 ohm Open circuit 800 (BK) from Start
Relay to ground.
IMPORTANT: When performing conti- If good reading, replace the Start
nuity test on this circuit, ensure that the Relay.
cable is disconnected from the battery
positive terminal. Failure to do so can
result in damage to the test meter.
Measure resistance from Start Relay

K-36 connector X199 (pin 85) to
ground.
55-20
F – 24 V Start Relay Test

The 24V start relay K-38, 1, is located on the left rear
of the combine, just aft of the batteries. It has two 80A 1
fusible links, 2.
56060574
14

1 Key Switch in “START” position. 24 volts 24V Start Relay K-38.
Measure for 24 volts at 24V Start If good reading, relay is operating Open fusible link at 30A on K-38.
Relay K-38 (pin 50). properly. Go to next test point.
2 Key Switch in “START” position. 12 volts Open circuit 804 (WH) between 24V
Start Relay (pin 50A) and Start Relay
Measure for 12 volts at 24V Start If good reading, go to next test point. (pin 87).
Relay K-38 (pin 50A).
3 Key Switch in “START” position. 24 volts Open circuit 832 (RD) between 24V
Starter and 24V Start Relay (pin
30A).
Measure for 24 volts at 24V Start If good reading, go to the next test
Relay K-38 (pin 30A). point.
4 Key Switch in “OFF” position. Less than 1 ohm Open in circuit 833 (BK) between
24V Start Relay and ground.
IMPORTANT: When performing If good reading, go to the next test
continuity test on this circuit, ensure point.
that the cable is disconnected from
the battery positive terminal. Failure
to do so can result in damage to the
test meter.
Measure resistance from 24V Start

Relay K-38 (pin 31) to ground.
5 Key Switch in “OFF” position. Less than 1 ohm. Open fusible link at terminal 31 on
K-38.
Measure resistance from 24V Start
Relay K-38 (pin 31A) to ground. If good reading, go to the next test
point.
6 Key Switch in “OFF” position. 12 volts Open circuit between Rear Battery,
G-03, and 24V Start Relay (pin 30).
Measure for 12 volts at 24V Start
Relay (pin 30). If good reading, go to the next test
point.
7 Key Switch in “START” position. 12 volts 24V Start Relay failed.
Replace 24V Start Relay.
Measure for 12 volts at 24V Start 24V Start Relay is operating properly.
Relay (pin 31A).
55-21
G – 12V Starter Motor Test

1 Measure for 12 volts at B+ terminal of 12 volts Open circuit between 12V Starter B+
12V Starter. terminal and 12V System Batteries
positive terminal.
If good reading, go to next test point.

2 Key Switch in “START” position. 12 volts Open circuit 804 (WH) between Start
Relay (pin 87) and 12V Starter (S
Measure for 12V at S terminal of 12V If good reading, go to next test point. terminal).
Starter.
3 Measure resistance from 12V Sys- Less than 1 ohm Open circuit between 12V System
tem Batteries B-- terminal to ground. Batteries and ground.
If good reading, go to the next test Check contact surface of 12V Starter
point. with the engine. Ensure 12V Starter is
mounted securely. Check ground
strap between engine and chassis.
4 Set DVOM to read voltage. If less than 0.4 volts shown, and 12V More than 0.4 volts showing on
Starter does not operate, replace 12V voltmeter, replace cable between
Attach positive lead of DVOM to Starter. battery positive terminal and 12V
battery positive terminal. Starter B+ terminal.
Attach negative lead of DVOM to B+

terminal of 12V Starter.
Turn key to “START” position.
Less than 0.4 volts should show on

voltmeter.
55-22
H – 24V Starter Motor Test

1 Battery switch, S-52, if present, in 24 volts Open between 24V Starter B+
ON position for these tests. terminal and Front Battery, G-02,
positive terminal.
Key Switch in START position. If good reading, go to test point 3.
24V Start Relay, K-38.
Measure voltage on B+ terminal of
24V Starter M-29. Go to next test point.
2 Key Switch in START position. 12 volts Open circuit between Front Battery,
G-02, negative terminal, and 24V
Measure voltage on Front Battery, If good reading, check that Front Start Relay, K-38, pin 31A.
G-02, negative terminal. Battery, G-02, terminals are clean
and tight. 24V Start Relay, K-38.
Perform 24V Start Relay Test.
3 Key Switch in START position. 24 volts Open circuit 834 (WH) between 24V
Start Relay, K-38, pin 50, and 24V
Measure voltage on 24V Starter, If good reading, go to test point 5. Starter, M-29, pin S.
M-29, terminal S.
Go to next test point.
4 Key Switch in START position. 24 volts 24V Start Relay, K-38. Perform 24V
Start Relay Test.
Measure voltage on 24V Start If good reading, repair open in cir-
Relay, K-38, pin 50. cuit 834 (WH) to 24V Starter, termi-
nal S.
5 Key Switch in OFF position. Less than 1 ohm. Check contact surface of 24V Start-
er, M-29, with engine. Assure that
IMPORTANT: When performing If good reading, go to next test starter is mounted securely. Check
continuity test on this circuit, ensure point. ground strap between engine and
that the cable is disconnected from chassis.
test meter.
Measure resistance from case of

24V Starter, M-29, to ground.
6 Set DVOM to read voltage. If less than 0.4 volts Shown, and 24V More than 0.4 volts showing on
Starter does not operate, replace 24V Voltmeter, replace cable between
Starter. battery positive terminal and 24V
Starter B+ terminal.
Attach positive lead of DVOM to
battery positive terminal.
Attach negative lead of DVOM to B+

terminal of 24V Starter.
Turn key to “START” position.
Less than 0.4 volts should show on

voltmeter.
55-23
I -- Starting Relay Test
NOTE: Starting Relay, K-15, has been added to the start circuit in CR combine models SN HAJ101501 and
higher. It is interposed between Neutral Start Relay, K-23, and Start Relay, K-36.

1 Battery switch, S-52, if present, in 12 volts Starting Relay, K-15.
ON position for these tests.
Key Switch in START position. If good reading, Starting Relay, Go to next test point.
K-15, is working correctly.
Measure voltage on Starting Relay,
K-15, pin 5
2 Key Switch in START position. 12 volts Open circuit between Starting
Relay, K-15, and fuse F-26.
Measure voltage on Starting Relay, If good reading, go to next test Fuse F-26 blown.
K-15, pin 3. point.
3 Key Switch in START position. 12 volts Open circuit 502 (WH) between
Starting Relay, K-15, pin 1, and
Neutral Start Relay, K-23, pin 5.
Measure voltage on Starting Relay, If good reading, go to next test Neutral Start Relay, K-23. Perform
K-15, pin 1. point. D - Neutral Start Relay Test.
4 Key Switch in OFF position. Less than 1 ohm. Open circuit 148 (BK) between
Starting Relay K-15, pin 2, and
IMPORTANT: When performing ground.
continuity test on this circuit, assure
that the cable is disconnected from
test meter.
Measure resistance from Starting

Relay, K-15, pin 2, to ground.
55-24
CHARGING SYSTEM
The Alternator (B+) connector X213A is connected to For vehicles equipped with a 7.5L engine w/ mech
the battery via terminal B+ on the Starter Motor and governor, the Alternator provides engine RPM
is grounded to the engine through connector X213B. information to CCM2 through circuit 421.
The Alternator is self exciting and does not require an Refer to schematic frames 1 and 2.
excitation circuit. Charging system output is
controlled by an integral voltage regulator/brush For models SN HAJ100801 and above, refer to
assembly. The regulator is set to 14.2 volt regulation. schematic frames 1A and 2A.
The Alternator is temperature compensated so that
output will drop as the Alternator warms up.
55-25
15
55-26
16
55-27
2004 Production -- SN HAJ100801 and Above (Frame 1A)
M-01 = 12V STARTER (7.5 L) (8) BASE MODEL SOLD IN EUROPE
FRAME--1A
17
55-28
2004 Production -- SN HAJ100801 and Above (Frame 2A)
FRAME--2A G-01 = ALTERNATOR K-39 = GRID HEATER RELAY (IVECO)
18
55-29
CHARGING SYSTEM -- TROUBLESHOOTING
PRELIMINARY CHECKS SYMPTOM CHART

Before troubleshooting the starting system make NOTE: The batteries must be fully charged and all
sure that the following operating conditions are met: connections clean and tight. Use a multimeter
A. The batteries are fully charged and all service, see the battery section in the service
connections are clean and tight. manual.
B. Transmission in neutral or park lock.
CAUTION
C. Check all connectors for full installation, as well
as loose, corroded, pushed out, or bent DO NOT use a self-powered test light for any of
terminals. these tests. Use of a self-powered test light can
WARNING
movement of the machine or start--up of power
driven equipment.

System not charging or Charging Alternator belt See engine repair section of Service
poorly. Battery goes dead. Manual to replace or Adjust
B+ circuit A -- Charging System Output Test, test
points 2--4
Alternator A -- Charging System Output Test, test
points 4--6.
System overcharging Alternator A -- Charging System Output Test, test
points 2--4.
55-30
DIAGNOSTIC TESTS WARNING

NOTE: The batteries must be fully charged and all Before performing any of the electrical tests, be
connections clean and tight. Use a multimeter sure all operating controls are in neutral or park
(DVOM) for these tests. For battery testing and lock position. This will eliminate accidental
service, see the battery section in the service manual. movement of the machine or start-up of power
driven equipment.
CAUTION
A -- Charging System Output Test

1 Place transmission in PARK. Measure voltage at battery, should be High resistance between Battery and
12.8--14.5 volts. B+ terminal at Alternator.
Start engine and set at 1200 rpm.
If good reading, charging system is
operating properly. Go to next test point.
2 Place negative lead of DVOM to Less than 0.4 volts. High resistance between Battery and
Battery positive terminal and positive starter B+ terminal.
lead to starter B+ terminal.
If good reading, circuit is good. Go to Repair/replace wiring as needed.
Read voltage. next test point.
3 Attach positive lead of DVOM to B+ Less than 0.4 volts High resistance in circuit 802 (RD).
terminal of Alternator and negative
lead to starter B+ terminal. If good reading, go to the next test Repair/replace wiring as needed.
point.
Read voltage.
4 Measure for 12 volts at the B+ Voltage varies between 12.8 and 14.5 Alternator
terminal of the Alternator, while volts in response to load applied.
turning various load on and off (lights, Go to next test point.
heater fans etc.) If good reading, charging system is
operating properly
5 Stop engine, Key Switch in “OFF” Less than 1 ohm High resistance on circuit 803 (BK)
position. from Alternator to engine ground.
Clean surfaces at Alternator and
engine block.
Measure resistance between Alter- If good reading, repair or replace Ensure that all mountings are clean
nator housing and engine ground. Alternator. and tight.
55-31
B – RPM Circuit Test

1 Key in “OFF” position. Less than 1 ohm Open circuit in Alternator RPM circuit
421 (YE).
Disconnect Alternator connector If good reading, go to the next test
(pin R) and connector X010. point. Check all connectors for full installa-
tion, loose corroded, pushed out, or
Measure resistance between bent terminals.
alternator connector (pin R)
and connector X010 (pin 9).
2 Check circuit 421 (YE) between If good reading, Alternator RPM Open 421(YE) circuit between in--
in--line connector X010 (pin 9) and circuit wiring okay. line connector X010 (pin 9) and
CCM2--J2 (pin 36). CCM2--J2 connector X017 (pin 36).
ALTERNATOR SPECIFICATIONS
Internal or External Regulator Internal
Excitation: Ignition/ Self Excite Self Excite
Remote Voltage Sense (Y/ N) N
Lamp Driver (Y/ N) Y
Smart Check System (Y/ N) Y
Regulator Voltage Adjust: Fixed
(Fixed, Adjustable/Range)
Grounding: Isolated
(Negative, Isolated, Case)
Mounting Requirements:
J--180, Spool (length/ hole size)
Other: Flange, Saddle etc.
Adjusting Ear: 1/2--13UNC--2A
Style/ Thread Size
Termination Requirements: B+ 7/16--14UNC preferred(5/16--24UNF sample),
(Size, SAE, Metric) Lamp 10--24 UNC , Neg 7/16--14UNC preferred
(1/4--28UNF sample)
Shaft Diameter (5/8, 7/8, 17mm) 5/8 with hex for pulley mounting
55-32
GRID HEATER
DESCRIPTION
1
The grid heater, 1, heats the air entering the intake
manifold for easier starting in cold climates. The
removal procedure may vary slightly for different 2
engine types. A grid heater is used on the Iveco
engines only.
Removal 3
1. Disconnect the battery.
2. Disconnect the temperature sensor, 2, by

carefully unthreading the locking ring. 10010905
3. Disconnect the boost pressure sensor connec- 19

tor, 3.
4. Remove the two power leads from the grid heater
unit. 3 2
NOTE: There is a dry gasket on either side of the grid

heater. Observe the proper orientation and position
of the grid gaskets for installation.
NOTE: During grid heater removal, make sure no dirt 1

and debris enter the engine head. Cover the engine
head whenever the grid heater is not in place.
5. Unthread the bolts, 2, to remove the air intake

manifold, 3, and the grid heater, 1, from the
20030059
engine head.
20
55-33
OPERATION
Refer to schematic frames 2 and 6.
The grid heater relay K39 receives power from fuse

F01 through an energized ECU Power relay K14,
which also provides power to the ECU. The ECU
activates the grid heater relay K39 by completing the
ground path for the relay, and sends a CAN message
to CCM2 whenever this occurs. The CCM2 module
then turns on the cold start indicator light E36 in the
cab.
When the key switch is first turned on and the ECU

powers up, it reads the temperatures from the fuel
temperature sensor B36, coolant temperature
sensor B44 and air temperature sensor B54. If the
one or more of these temperatures are less than
10°C (50°F), and the battery voltage is greater than
7 volts, the ECU will activate the grid heater relay.
The grid heater will remain engaged for between
approximately 8 to 16 seconds, depending on the
measured battery voltage, to preheat the air in the
intake manifold, and will then switch to ‘Stand-by’
mode.
In Stand-by mode, the grid heater will remain

engaged for an additional 15 seconds, and then shut
off. The grid heater will be re-engaged when the
operator starts cranking the engine, and will remain
on for a certain period of time after the engine starts.
The amount of time the grid heater remains on after
the engine is running is dependent on the specific
temperatures read from the fuel temperature sensor
B36, coolant temperature sensor B44 and air
temperature sensor B54, and may vary between 80
and 300 seconds.
55-34
Grid Heater Circuit, Iveco Engines -- SN HAJ100800 and Below
50014706
21
55-35
Grid Heater Circuit, Iveco Engines -- SN HAJ100801 and Higher
FRAME--2 G-01 = ALTERNATOR K-39 = GRID HEATER RELAY (IVECO)
22
55-36
Grid Heater Circuit, Iveco Engines, Sensors
23
55-37
GRID HEATER TROUBLESHOOTING

Test Points
Test Point Schematic Good Reading Possible Cause of Bad Reading
Reference
1 Cold Start Indicator E--36 The cold start indicator light is not If not functioning properly, the cold
Light serviceable. The cold start indicator start indicator light requires replace-
light has internal electrical compo- ment.
nents which cannot be tested.
2 Grid Heater Relay K--39 When energized, continuity to Defective relay.
ground at wire EN-822-BK-08.
3 Engine Grid Heater R--09 Ohms resistance between two termi- Defective Grid Heater requires re-
nals should be approximately .50 placement.
ohms.
1. Observe the grid heater for defective or

damaged components.
2. Use an ohmmeter to test the grid heater for

electrical continuity.
3. The resistance between the two grid heater

terminals should be approximately .50 Ohms.
If the resistance measured between the two grid

heater terminals is not as listed above, the grid
heater is defective and requires replacement.
Components
Component Schematic Connectors Input/Output Circuit Description
Reference
Grid Heater R--09 X211 841--WH--16.0 Receives current through the
X193 grid heater relay K39.
Grid Heater Indica- E--36 X066 J1--12 CCM2 CM--814--WH--0.8 CCM2 sends current to the grid
tor Light X004 MF--814--WH--0.8 heater indicator light. This
X010 EN--814--WH--0.8 causes the light to illuminate.
X005 MF--839--WH--0.8
X015 CM--839--WH--0.8
Grid Heater Relay K--39 X211 Fuse F01 EN--818--WH--0.8 Controls current flow to the
ECU Power EN--822--BK--0.8 engine grid heater R09.
Relay K14
ECU Connec-
tor B X193
--pin10
Grid Heater Circuit Fault Codes

NOTE: This fault code applies to the output from
CCM2 only.
InfoView Description
Fault Code
E0196--11 Grid Heater output Unidentified Failure
Code
55-38
CONTROL MODULES
LOCATION
Item Description
1 CCM1
2 CCM2
3 CCM3 (If Equipped) 1
3
2
10004693
24
Item Description
4 Engine Control Unit (Iveco)
10010909
25
Item Description
5 Engine Control Unit (NH7.5L)
10010870
26
55-39
Item Description
6 Right hand Control Module
40025230
27
DESCRIPTION
This section describes how the control modules relate to the engine components.
CCM2
Ref Component Connectors Input/ Circuit Description
Output
R--01 Fuel Level Sensor X184 J2--17 MF--427--YE--0.8 The fuel level sensor monitors the
X016 amount of fuel within the fuel tank and
delivers the information to CCM2.
B--03 Engine Oil Tempera- X311 J2--27 EN--860--YE--0.8 The engine oil temperature sensor
ture Sensor (Iveco X197 EN--420--YE--0.9 monitors the engine oil temperature.
Only) X016 MF--501--YE--0.8
S--61 Air Filter Sensor X202 J2--29 EN--864--YE--0.8 The air filter sensor monitors the amount
X010 EN--420--YE--0.8 of air flow through the engine air intake
X016 MF--420--YE--0.8 system.
B--30 Engine Oil Pressure X201 J2--33 EN--419--YE--0.8 Measures engine oil pressure. If the
Sensor (Mechanical X010 MF--419--YE--0.8 engine oil pressure drops to dangerously
Only) X016 low conditions, the switch closes to send
a signal to CCM2. CCM2 then warns the
operator of an engine problem.
B--52 Engine Oil Pressure X337 J2--33 OR--1.0 Measures engine oil pressure. If the
Sensor (Iveco) X197 EN--419--YE--0.8 engine oil pressure drops to dangerously
X010 MF--419--YE--0.8 low conditions, the switch closes to send
X016 a signal to CCM2. CCM2 then warns the
operator of an engine problem.
G--01 Engine RPM Sensor X010 J2--36 EN--421--YE--0.8 Alternator sends a signal to CCM2 which
(from alternator) X016 MF--421--YE--0.8 translates into engine rpm.
B--31 Engine Coolant Tem- X310 J2--24 EN--429--YE--0.8 The engine coolant temperature sensor
perature Sensor (Me- X010 MF--429--YE--0.8 sends coolant temperature information to
chanical) X016 CCM2.
M--13 Throttle Actuator (Me- X196 J2--1 EN--828--GY--2.0 CCM2 energizes and de--energizes the
chanical) X010 J2--21 EN--829--GY--2.0 throttle actuator to increase and de-
X004 J1--6 MF--829--WH--2.0 crease engine rpm.
X015 CM--829--WH--2.0
L--02 Fuel Hold In (Me- X290 J2--13 EN--571--WH--0.8 CCM2 controls current flow to the fuel
chanical) X010 MF--571--WH--0.8 shutoff solenoid within the injection
X016 pump. When the solenoid is energized,
the solenoid retracts and allows fuel to
flow into the engine.
S--58 Engine Oil Temp X209 J2--27 EN--504--YE--0.8 The engine oil temperature switch closes
Switch X010 MF--504--YE--0.8 when the temperature increases to
X016 unsafe levels.
55-40
Engine Control Unit (ECU)

IVECO
Component Connectors Input/ Circuit Description
Output
B--05 Engine Flywheel RPM X192 Pin 1 WH--1.0 Measures how fast the engine flywheel is
X369 Pin 13 BK--1.0 rotating for timing control.
B--07 Engine Camshaft RPM X192 Pin 2 WH--1.0 Measures how fast the engine camshaft
X370 Pin 14 BK--1.0 is rotating for timing purposes.
B--23 Boost Pressure Sensor X192 Pin 17 WH--1.0 Monitors boost pressure for fuel delivery
X371 Pin 12 GN--1.0 purposes. On later Tier 2 engines, this
sensor also monitors intake air tempera-
Pin 23 RD--1.0 ture.
B--36 Fuel Temperature Sensor X192 Pin 11 OR/BK--1.0 Monitors fuel temperature for engine
X372 Pin 6 WH/RD--1.0 timing control.
B--44 Coolant Temperature X192 Pin 5 PK--1.0 Measures coolant temperature for grid
Sensor X373 Pin 22 YE--1.0 heater actuation.
B--54 Air Temperature Sensor X192 Pin 4 BK--1.0 Measures air temperature for timing
X374 Pin 21 OR--1.0 control.
L--34 Fuel Actuator X192 Pin 24 RD--1.25 Each fuel actuator controls start and
X004 Pin 35 WH--1.25 duration of fuel delivery into an individual
combustion chamber.
X376
L--35 Fuel Actuator X192 Pin 26 BL--1.25
X004 Pin 25 BK--1.25
X377
L--36 Fuel Actuator X192 Pin 34 YE--1.25
X004 Pin 24 RD--1.25
X378
L--37 Fuel Actuator X192 Pin 27 GY--1.25
X004 Pin 25 BK--1.25
X379
L--38 Fuel Actuator X192 Pin 33 GN--1.25
X004 Pin 24 RD--1.25
X380
L--39 Fuel Actuator X192 Pin 28 PU--1.25
X004 Pin 25 BK--1.25
X381
If Electronic Control Unit failure is suspected, inspect

the ECU by using the Electronic Service Tool (EST).
Refer to the Electronic Service Tool User Guide for
more information on proper testing procedures.
55-41
NH 7.5 L
Component Connectors Input/ Circuit Description
Output
L--09 Fuel Injection Pump X192 Pin 2 EN--893--YE--0.8 Controls fuel delivery to the engine.
X203 Pin 33 EN--896--BL--0.8
Pin 35 EN--895--YE--0.8
Pin 34 EN--895--YE--0.8
Pin 26 EN--894--YE--0.8
Pin 25 EN--898--WH--2.0
Pin 27 EN--870--GY--2.0
Pin 28 EN--871--GY--2.0
Pin 14 EN--884--BL--0.8
B--40 Fuel Temp Sensor X192 Pin 11 EN--883--YE--0.8 The fuel temperature sensor monitors the
fuel temperature and sends the informa-
X212 Pin 6 EN--882--BL--0.8 tion to the ECU.
B--42 Coolant Temperature X192 Pin 22 EN--891--YE--0.8 Monitors coolant temperature for grid
Sensor heater actuation
X214 Pin 5 EN--892--BL--0.8
B--43 Flywheel RPM X192 Pin 1 EN--823--BL--0.8 Measures how fast the flywheel is
Sensor rotating.
X207 EN--824--BL--0.8
EN--825--BL--0.8
Right Hand Control Module

Ref Component Connectors Input/ Circuit Description
Output
S--36 Throttle Increase / X060 Pin 13 RC--318--YE--0.8 The engine throttle switch sends current
Decrease Switch X029 (high RC--369--OR--0.8 to either pin 13 (high idle) or pin 4 (low
idle) idle)) of the right--hand
g control module
(RHM)
(RHM).
Pin 4 (low RC--322--YE--0.8
idle) RC--369--OR--0.8
55-42
ECU POWER SUPPLY

When the key is first turned on, power from the key
switch S02 pin 5 travels through the wire harnesses
to the ECU connector X193 pin 15, signaling the ECU
to “wake-up”. The ECU then connects the ground
path for the coil of the ECU Power relay K14, causing
the relay to energize and provide main power for the
ECU at connector X193 pins 3 & 4, as well as for the
grid heater relay K39.
If the operator turns the key off, this cuts off the power
supply to the ECU connector X193 pin 15. When this
power supply is lost, the ECU starts its “shut down”
routine, including saving files and operating
information to memory, and shuts down the engine
fuelling system to stop the engine. After several
seconds, the ECU disconnects the ground path for
the ECU Power relay K14 coil, and the relay
unlatches, stopping main power supply to the ECU.
Engine shutdown in the event of machine problems,

or for an operator-signaled “kill-stall”, is handled by
sending a message to the ECU through CAN, and the
ECU shuts down the engine without powering itself
off in the process.
55-43
Electrical Schematic
A-01
50014703
28
55-44
ENGINE-RELATED ERROR CODES --

AUTOMATIC SHUTDOWN
Description
The following alarms/error codes cause the engine to
automatically shut down. An alarm message is
generated to the operator when each condition
occurs; at the same time, an unerasable error
message is recorded in the error history as a
permanent record.
Alarm Messages
Alarm Message Error Message Alarm Condition Engine Shutdown

E0135--01 <5 bar (73 psi) pressure (switch Will occur only if engine is
A0081
closes)
closes). running for at least 4 seconds;
Hydrostatic Charge will shut down after alarm is
Hydrostatic Charge
Pressure present for 2 seconds.
Pressure Low
Valid Below Normal
Pressure below 20 bar (290 Will occur only if the engine is

E0162--01 psi) for 2 seconds after engine running for 5 seconds; will shut
A0012
runs for 3 seconds. down after alarm is present for 2
Control Pressure
Control Pressure Low seconds.
Valid Below Normal
E0161--01 Pressure is below 1 bar (14 psi) Will shut down after alarm is
A0002
for 3 seconds after engine runs present for 7 seconds.
Engine Oil Pressure
Engine Oil Pressure Low for 10 seconds.
Valid Below Normal
A0001 E0153--00 Temperature greater than Will occur only if engine is

126°C (260°F) for 3 seconds. running for at least 3 seconds;
Engine Oil Temperature Engine Oil Temperature will shut down after alarm is
High Valid Above Normal present for 2 seconds.
Temperature is greater than Will occur only if engine is

E0152--00 110°C (230°F) for 2.0 seconds running for at least 3 seconds;
A0000
(mechanical engines). will shut down after alarm is
present for 2 seconds.
Engine Coolant
Engine Coolant Temperature is greater than
Temperature
Temperature High 106°C (223°F) for 2.0 seconds
Valid Above Normal
(electronic engines).
ECU Related Fault Codes

Infoview Fault Error String Effect On Engine
Code
E0385 ECU defect Engine disabled
55-45
ENGINE SENSORS
NOTE: Use this section in conjunction with the

Electronic Service Tool for information regarding the
engine components.
NOTE: Refer to section 55, chapter 21 for engine

sensor testing procedures.
Description: This section describes the sensors that

monitor the engine and engine-related components.
BASILDON – MECHANICAL
The 7.5l Basildon mechanical engine is equipped
with an inline Bosch fuel pump and a mechanical
governor.
All engine sensors are monitored by CCM2.
Throttle Actuator
Schematic Reference: M--13
Schematic Frame: 4
Connector: X196
When the throttle position is changed, the ECU

controls the throttle actuator, 1, which adjusts fuel
flowing into the engine.
Fault Code - Throttle Actuator
Fault Code
E0173--06 Curr Sense Eng Throttle Short Circuit
E0207--11 Engine Throttle Motor Unidentified Failure 1
Code
10004674
29
55-46
Coolant Temperature Sensor
Schematic Reference: B--31
Schematic Frame: 5
Connector: X310
The coolant temperature sensor, 1, monitors the

temperature of the engine coolant and sends the
information to pin J2--24 of CCM2.
Fault Code - Coolant Temperature Sensor
InfoView Error Text String Effect on Engine

Fault Code
E0399 Coolant Tempera- No restriction on
ture sens fuel or speed
E0448 Coolant Temp sens No restriction on
1
(Phy) fuel or speed
10010869
30
55-47
BASILDON – ELECTRICAL
A high--pressure electric fuel pump delivers fuel to
the 7.5L Basildon engine. The Electronic Control Unit
(ECU) provides throttle information. The ECU
monitors all engine sensors such as, oil pressure,
boost pressure, and engine temperature.
Fuel Injection Pump

Schematic Reference: L--09
Schematic Frame: 4
Connector: X203
The high pressure Electric Fuel Injection Pump, 1,
controls fuel delivery to the engine. The ECU controls
the fuel injection pump.
Fault Code – Fuel Injection Pump

Fault Code
E0477 Resist Gov Devi- Engine Disabled 1
ation
E0478 Stop Pos Control Engine Disable
Rack
10010867
E0479 Rack Travel Sens Engine Disable
Defect
31
E0480 Rack Sens Intermit Engine Disable
Cont.
Fuel Temperature Sensor

Schematic Frame: 4
Connector: X212
The fuel temperature sensor, 1, monitors the

temperature of the fuel and sends the information to
the ECU (Pins 11 and 6). This information is used for
fuel delivery adjustments.
Fault Code – Fuel Temperature Sensor

Fault Code
E0401 Fuel Temperature No Restriction on
Sensor fuel or speed
E0470 Fuel Temperature No Restriction on 1
(Phy) fuel or speed 10010867
32
55-48
Air Temperature/ Boost Pressure Sensor
Schematic Frame: 4
Connector: X210
The air temperature / boost pressure sensor, 1, is
located in between the turbo-charger and the inlet
manifold. The sensor sends information to the ECU
(pins 10, 23, and 12) to allow for fuel delivery
adjustments to account for boost pressure and intake
air temperature.
Fault Code – Air Temperature/ Boost Pressure

Sensor
1
Fault Code
E0400 Boost Air Tempera- No restriction on 10010868
ture fuel or speed
33
E0441 Boost Air (PHY) No restriction on
fuel or speed

Schematic Frame: 4
Connector: X214
The Coolant Temperature Sensor, 1, monitors the

engine coolant temperature and sends the informa-
tion to pins 22 and 5 of the ECU.
1
Fault Code – Coolant Temperature Sensor

Fault Code
E0399 Coolant Tempera- No reduction of fuel
ture Sens or speed
10010869
34
Alarm Code - Engine Coolant Temperature High
Alarm Code Description Priority Module Check Condition Activation Resetting
A0000 Engine Coolant Tempera- High CCM2 Engine Running 2 sec > 106° C 2 sec < 106° C
ture High and Electronic En-
gine
55-49
Flywheel RPM Sensor
Schematic Frame: 4
Connector: X207
The Engine Flywheel RPM Sensor monitors the

engine flywheel speed and sends the information to
pins 1 and 13 of the ECU. The ECU uses this
information for timing adjustments.
Fault Code – Flywheel RPM Sensor

1
Fault Code
E0449 Engine Speed Sen- Speed restricted to
sor 1800 rev/ min.
10010870
35
Engine Oil Pressure Sensor

Schematic Frame: 5
Connector: X201
The Engine Oil Pressure Sensor monitors the engine

oil pressure and sends the information to pin J2--23 of
CCM2. CCM2 monitors the engine oil pressure in an
effort to prevent major engine damage. CCM2 will
warn the operator of insufficient oil pressure. If the oil
pressure drops to harmful levels, the engine will shut
down automatically. Refer to Engine-related Error
Codes -- Automatic Shutdown for more information.
10004681
36
Alarm Code - Oil Pressure Sensor
A0002 Engine Oil Pressure High CCM2 Engine Running for 3 sec < 1 bar 0.5 sec < 1 bar
Low 10 Seconds
Fault Code - Oil Pressure Sensor

Fault Code
E0161--06 Engine Oil Pressure Sens Valid Below Normal
E0161--03 Engine Oil Pressure Sens Shorted to High Source
E0161--05 Engine Oil Pressure Sens Line Disconnected
55-50
Engine Oil Temperature Switch
Schematic Reference: S--58
Schematic Frame: 5
Connector: X209
The Engine Oil Temperature Switch, 1, measures the

engine oil temperature. When the engine oil
temperature exceeds safe levels, the switch closes
to complete the ground path to pin J2--27 of CCM2.
CCM2 will automatically shut down the engine if the
temperature approaches damaging levels. 1
10010863
37
Alarm Code - Engine Oil Temperature Switch
A0001 Engine Oil Temperature High CCM2 Engine Running 3 sec > 126°C 2 < 126°C
High
Fault Code - Oil Temperature Sensor

Fault Code
E0153--00 Engine Oil Temperature Valid Above Normal
E0153--03 Engine Oil Temperature Shorted to High Source
E0153--04 Engine Oil Temperature Shorted to Low Source
E0153--05 Engine Oil Temperature Line Disconnected
55-51
IVECO
Engine Oil Temperature Sensor
Schematic Frame: 5
Connector: X311
The Engine Oil Temperature Sensor monitors the oil
temperature and sends the information to pin J2--27
of CCM2. When the engine oil exceeds safe
operating temperatures, CCM2 prompts an alarm
code (See below).
1
10010907
38
Alarm Code - Engine Oil Temperature

A0001 Engine Oil Temperature High CCM2 Engine Running 3 sec > 110° C 2sec <110° C
High
Fuel Filter Switch

Schematic Frame: 5
Connector: X338
The Fuel Filter switch, 1, monitors the fuel flow
through the fuel filter. Should the fuel filter become
clogged, the fuel filter switch closes, applying ground
to pin J2--24 of CCM2. 1
10010904
39
55-52
Engine Oil Pressure Sensor
Schematic Frame: 5
Connector: X337
The Engine Oil Pressure Sensor, 1, monitors the
engine oil pressure and sends the information to pin
J2--33 of CCM2. CCM2 monitors the engine oil
pressure in an effort to prevent major engine
damage. CCM2 will warn the operator of insufficient
oil pressure. If the oil pressure drops to harmful
levels, the engine will shut down automatically. Refer
to Engine-related Error Codes -- Automatic
1
Shutdown for more information.
10010912
40
Alarm Code - Engine Oil Pressure
A0002 Engine Oil Pressure High CCM2 Engine Running for 3 sec < 1 bar .5 sec < 1 bar
Low 10 seconds.
Engine Camshaft RPM

Schematic Frame: 6
Connector: X370
The engine camshaft RPM sensor, 1, monitors the
camshaft speed for timing purposes. It is connected
to pins 2 and 14 of the ECU.
Fault Code – Camshaft RPM Sensor

Fault Code
E0413 SEG signal Engine may stop or
not start and re-
mains disabled 1
10010904
41
55-53
Engine Flywheel RPM
Schematic Frame: 6
Connector: X369
The engine flywheel RPM sensor, 1, monitors the
flywheel speed for timing purposes. The flywheel
sensor is connected to pins 1 and 13 of the ECU.
1
Fault Code – Flywheel RPM Sensor

Fault Code
E0412 INK signal Fuel Restricted and
speed restricted to
1500 rev/min
10010904
42
NOTE: There are two styles of boost pressure/air
temperature sensor configuration. Style I uses
separate sensors for the boost pressure and air
temperature sensor functions. Style II uses a single
sensor assembly for both functions.
Style I -- Boost Pressure Sensor

Schematic Frame: 6
Connector: X371
The Engine Boost Pressure sensor, 1, measures the
amount of air pressure in the inlet manifold. It is
connected to pins 23, 17, and 12 of the ECU.
Fault Code – Boost Pressure Sensor

Fault Code
E0402 Boost Pressure No restriction on
1
10010905
43
55-54
Air Temperature Sensor
Schematic Frame: 6
Connector: X374
The air temperature sensor, 1, monitors the
temperature of the air in the intake manifold. It is
connected to pins 4 and 21 of the ECU.
10010905 1
44
Style II -- Boost Pressure/Air Temperature
Sensor
Schematic Frame: 6
Connector: X371
The boost pressure/air temperature sensor, 1,
measures the pressure and temperature of the air in 1
the intake manifold. It is connected to pins 12, 17, 21
and 23 of the ECU.
Fault Code – Boost Pressure Sensor

Fault Code
E0402 Boost Pressure No restriction on
86054618
45
55-55
Schematic Frame: 6
Connector: X373
The coolant temperature sensor, 1, monitors the
temperature of the engine coolant. It is connected to
pins 5 and 22 of the ECU.
Fault Code - Coolant Temperature Sensor

Fault Code
E0399 Coolant Tempera- No restriction on
ture sens fuel or speed
1
10010907
46
Fuel Temperature Sensor
Schematic Frame: 6
Connector: X372
The fuel temperature sensor, 1, monitors the
temperature of the fuel. It is connected to pins 11 and
6 of the ECU.
Fault Code - Fuel Temperature Sensor

Fault Code
E0401 Fuel Temperature No restriction on fuel
Sensor or speed
1
10010904
47
Fuel Actuators
The fuel actuators, 1, are an integral fuel injector and 1
solenoid assembly mounted in the cylinder head.
The fuel injectors are operated by rocker arms and
the camshaft. The timing and duration of fuel delivery
is controlled by the solenoid.
MID0302A
48
55-56
Fuel Actuator 1 Fuel Actuator 4
Schematic Reference: L--34 Schematic Reference: L--35
Schematic Frame: 6 Schematic Frame: 6
Connector: X376 Connector: X377
Fault Code – Fuel Actuator 1 Fault Code – Fuel Actuator 4

InfoView Error Text String Effect on Engine InfoView Error Text String Effect on Engine
Fault Code Fault Code
E0414 Cylinder 1 Engine Speed Re- E0415 Cylinder 4 Engine Speed Re-
stricted and only op- stricted and only
erating on 5 cylin- operating on 5 cyl-
ders. inders.


stricted and only stricted and only
operating on 5 cyl- operating on 5 cyl-
inders. inders.


stricted and only stricted and only
operating on 5 cyl- operating on 5 cyl-
inders. inders.
55-57
ALL ENGINES
Rotary Screen Brush Actuator
Schematic Frame: 4
Connector: X206
The Rotary Screen Brush Actuator, 1, controls the
engagement of the brush to the rotary screen.
10004648
49
Starting at the top of the diagram, the Rotary Screen
Rotary Screen brush logic
brush is in the “Brush Off” state, which is defined in
the dotted box as being that the brush motor is off. In brush not installed
order to change to the next state, the unloading

system has to be engaged AND it has to have been
at least 10 minutes since the last time the rotary
screen brush was last engaged OR it is the first time Brush off Brush motor OFF
the unloading system has been engaged since the
combine was started up.
unload in progress AND
When those conditions occur, the module will After 10 minutes OR
activate the rotary screen brush (“Brush in” state), by first time after startup
powering the brush actuator motor in. After 7

seconds (the next condition to change states), the
module shuts off the power to the actuator motor, and
the system is now in the “Brush on” state. Brush in Brush motor IN
After 0.05 seconds, the system moves to the “Brush

out” state, and the module once again powers the
actuator, this time to retract the brush from the rotary After 7 seconds After 7 seconds
screen. After 7 seconds of powering the actuator, the
system moves back to the “brush off” state, and the
brush actuator motor is shut off. The system will now
wait at least 10 minutes for the next unloading system
cycle before re-engaging the brush circuit. Brush on Brush motor OFF
Fault Code - Rotary Screen Brush
InfoView Description After 0.05 seconds

Fault Code
after contact key on
E0172--06 Curr Sense Rot Scr Brush Short Circuit
E0206--11 Rotary Screen Brush Motor Unidentified
Failure Code Brush out Brush motor OUT
50
55-58
Fuel Level Sensor
Schematic Reference: R--01
Schematic Frame: 5
Connector: X184
The fuel level sensor, 1, monitors the amount of fuel

inside the fuel tank and sends the information to pin
J2--17 of CCM2. As the fuel level rises and lowers
inside the fuel tank, the variable resistance through
the sensor changes. CCM2 monitors this variable
resistance and sends the information to the fuel 1
gauge found in the cab.
10010875
51
Alarm Code - Fuel Level Sensor
A0004 Fuel Level Low CCM2 -- 4 sec < 20 bar 4 sec < 12%
Fault Code - Fuel Level Sensor

Fault Code
E0154--03 Fuel Level Sensor Shorted to High Source
E0154--04 Fuel Level Sensor Shorted to Low Source
E0154--05 Fuel Level Sensor Line Disconnected
55-59
Air Filter Pressure Switch
Schematic Frame: 5
Connector: X202
The air filter pressure switch monitors the air

pressure inside the intake manifold. When the
pressure drops below safe levels, the sensor sends
the information to pin J2--29 of CCM2.
40025218
52
Alarm Code - Air Filter Switch
A0005 Air Filter Blocked Low CCM2 -- 10 sec < 61 mbar 2 sec < 61 mbar
Fault Code - Air Filter Switch

Fault Code
E0163--03 Engine Air Filter Sensor Shorted to High Source
E0154--05 Engine Air Filter Sensor Line Disconnected
Fuel Pump Actuator

Schematic Frame: 6
Connector: X183
The fuel pump, 1, delivers fuel to the engine injection
pump. The fuel pump is powered from fuse F28
through the fuel pump relay K07 whenever the key
switch is in the “ON” position.
10010875
53
55-60
SECTION 55 - ELECTRICAL SYSTEMS - CHAPTER 6
Chapter 6 - Power Distribution and Lighting
CONTENTS

Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models 920 & 940 (12 Volt System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models 960, 970 & 980 (12/24-Volt System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuse/Relay Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuse/Circuit Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power Distribution: Unswitched and Switched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power Distribution Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power Distribution Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Lighting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Circuit/Fuse Lighting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CR NA Lighting -- Steering Column Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CR European Lighting -- Steering Column Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
CR NA Lighting -- Rocker Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CR European Lighting - Rocker Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Lighting Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Hazard Light Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Marker Light Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Road Lights – Low Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Road Lights – High Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Flip-up Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Brake Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Beacon Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Front Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Rear Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Side Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Stubble Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Grain Tank Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Unload Tube Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Header Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Center Work Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Service Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Backlighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Exterior Lighting System Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
55-1
POWER DISTRIBUTION
MODELS 920 & 940 (12 VOLT SYSTEM) The first path is via a heavy gauge wire (RD-50.0) to
the buss bar within the fuse/relay panel in the cab.
NOTE: The 12-volt power distribution system uses The 12-volt supply voltage is then made available to
two 12-volt batteries in parallel. the combine electrical/electronics systems through
fuses.
Refer to schematic Frames 1 and 2.
The second path is via wire EN-801 to pin 30 of
The front (G-02) and rear (G-03) batteries are wired
starter relay K-36.
in parallel. The positive terminals are connected to
the B+ terminal of the starter motor M-01. The The third path is via wire AL-802 to the B+ terminal
negative terminals are connected to the M-01 ground of alternator G-01.
terminal, which is connected to chassis ground at the
engine ground terminal (5). Throughout the power distribution network, ground
return wires are tied to the nearest ground terminal.
The B+ terminal of M-01 serves as the 12-volt supply
terminal for the combine power distribution network.
Supply voltage is made available through three
separate paths.
55-2
2005 PRODUCTION -- SN HAJ101501 and Above
55-3
55-4
MODELS 960, 970 & 980

(12/24-VOLT SYSTEM)
NOTE: The 12/24-volt power distribution system With the two batteries in parallel, 12-volt supply
uses two 12-volt batteries. These batteries normally voltage is made available to the power distribution
work in parallel to supply 12 volts to the power network at K-38 pin 30, via wire RD-50-0 to the buss
distribution network. However, during engine start, bar in the fuse/relay panel, and via wire AL-802 to the
they are reconfigured for series operation, to provide B+ terminal of alternator G-01 and pin 30 of start
24 volts for starter motor M-29. relay K-36. Connection is also made to the B+
terminal of grid heater relay K-39 via wire
EN-RD-16.0.
Description
Refer to schematic Frames 1, 2, 9 and 29. For
models SN HAJ101501 and above, refer to Start Mode
schematic Frames 1A , 2A , 3A, 9 and 29. For engine starting, the key switch S-02 (Frame 29)
is moved to the START position. Assuming neutral
See also Figure 1. switch S-22 (Frame 9) is on (multifunction handle in
NEUTRAL), neutral start relay K-23 (Frame 2) is
The 12/24-volt power distribution system works in energized, providing a current path from the key
two modes: run and start. The 24-volt start relay K-38 switch to the coil of start relay K-36. K-36 energizes
switches between the two modes. and, in turn, energizes the 24-volt start relay K-38.
Run mode is for normal operation, when the system
NOTE: For models SN HAJ101501 and above,
batteries are supplying 12 volts to the power
starting relay K-15 has been added to the start circuit
distribution network.
(Frame 2A). Neutral start relay K-23 provides a path
Start mode is for engine starting, when the batteries from the key switch to the coil of K-15, which
supply 24 volts to the starter motor. energizes, applying +12 volts from fuse F-26 (Frame
3A) to start relay K-38.
When K-38 energizes, the normally closed contacts

Run Mode now open, opening the connections between K-38
In normal operation, the front (G-02) and rear (G-03) pins 30A and 30, and 31A and 31. This removes the
batteries are wired in parallel. This requires that the parallel connections between the two batteries.
positive terminal of G-02 be connected to the positive
terminal of G-03. Likewise, the negative terminals of Normally open contacts 31A and 30, and 30A and 50
both batteries must be connected together. are now closed. This places the two batteries in
series through the following path: G-03 negative
When relay K-38 (Frame 1) is de-energized, the terminal remains grounded, either directly or through
positive terminal of G-02 connects to the positive battery switch S-52; G-03 positive terminal connects
terminal of G-03 through this path: G-02 positive to G-02 negative terminal through K-38 contacts 30
terminal to the B+ terminal of starter motor M-29 via and 31A; G-02 positive terminal connects to B+
wire RD-70-0; wire 832 from M-29 B+ to K-38 pin terminal of starter motor M-29. The voltage present
30A; through the normally closed contacts to pin 30, at this terminal is now 24 volts.
and wire RD/WH-70.0 to G-03 positive.
At the same time, the 24 volts at M-29’s B+ terminal
The negative terminals connect together through this is applied to M-29’s S terminal via wire 832, K-38
path: G-02 negative via wire BK-70.0 to K-38 pin 31A, contacts 30A and 50, and wire 834. This energizes
through normally closed contacts to pin 31, via wire the start solenoid in M-29, and the engine cranks.
833 to G-03 negative terminal, and to ground through
wire BK-70.0 (or through battery switch S-52 on The starter motor M-29 is the only component in the
European models). combine electrical system that uses 24 volts.
55-5
7 50024376
50020070
50024375
4 5
40020079 50031002
6
50031001
50024378
1
1. Starter Motor M01/M29 5. Rear Battery G03
2. Rear Frame Ground 6. Front Frame Ground
3. 24 V Start Relay K38 (Iveco engines only) 7. 12 V Connection to Fuse Panel
4. Front Battery G02
55-6
55-7
55-8
M-01 = 12V STARTER (7.5 L) (8) BASE MODEL SOLD IN EUROPE FRAME--1A
55-9
FRAME--2A G-01 = ALTERNATOR K-36 = START RELAY
55-10
STARTING
FRAME--3A
55-11
55-12

55-13
FUSE/RELAY PANEL
** 15A/20A
** 5A/7.5A
** 20A/25A
** 5A/10A
** 15A/10A
* 15A
* Fuse F26 not used prior to PIN

HAJ101407
** Fuse values changed due to
electrical system updates. Fuse
values are shown as “Prior to PIN
HAJ100801/Above PIN HAJ100801”.
55-14
FUSE/CIRCUIT CHART
Fuse # Power Circuit Number Circuit Energized
Type to power
1 Unswitched 016 (RD) ECU power relay (Electronic engine only), K-14
2 Unswitched 018 (RD) Accessory 2 relay, K-03
3 Unswitched 020 (RD) Accessory 1 relay, K-08
4 Unswitched 070 (RD) Wiper relay, K-06
5 Unswitched 085 (OR) Cigar lighter, R-08
6 Switched 058 (OR) LH cab outer work light, E-15; mid work light, E-19
7 Switched 059 (OR) RH cab outer work light, E-16; mid work light, E-20
8 Switched 084, 086 (OR) Accessory outlets, J-06, 08
9 Switched 079 (OR) Switches, washer, S-38; mirror heat, S-19; mirror
adjust, S-27
10 Switched 1002 (OR) Cold start indicator, E-36
11 Switched 081 (OR) Radio, A-04
12 Switched 082 (OR) Data logger, A-10, GPS module, A-11 (in SN HAJ100801
and above, A-11 replaced by future option A-22).
13 Switched 083 (OR) Auxiliary radio power connector, M-26
14 Switched 604 (OR) Sieve light switch, S-54
15 Unswitched 068 (RD) Service sockets, J-01 to J-05
16 Unswitched 080 (OR) Seat adjust switch, S-45
17 Unswitched 930 (RD) Separator blower relay, K-09
18 Unswitched 938 (RD) Main blower relays, K-11, K-12, K-13
19 Unswitched 087 (RD) A/C clutch relay, K-10
20 Switched 177 (PU) LH marker lights, E-03, 11, 39, 50, 54, 56, 57, 58
21 Switched 176 (PU) RH marker lights, E-07, 12, 40, 41, 47, 48, 49, 53, 55
22 Unswitched 024 (RD) CCM1. Shoe leveling actuator
23 Unswitched 025, 028 (RD) CCM2. Throttle/brush
24 Unswitched 026, 027 (RD) CCM1. Reverser/fan
25 Unswitched 029 (RD) CCM2. Transmission gearshift motor
26 Unswitched 030 (RD) (In PIN HAJ101407 and above, F-26 becomes starting
fuse)
27 Unswitched 031 (RD) CCM3. Sieve/spreader
28 Unswitched 205 (RD) Fuel pump relay, K-07
29 Unswitched 060 (RD) Distance work lights relay, K-21
30 Unswitched 062 (RD) Header work lights relay, K-22
31 Unswitched 022 (RD) Cab Roof work lights relay, K-01
32 Unswitched 185 (RD) High beam relay, K-04
33 Unswitched 236 (RD) Low beam relay, K-05
34 Unswitched 214, 215 (RD) Under shield lights switches, S-63, S-64, S-65
35 Unswitched 048 (RD) Radio KAPWR
36 Switched 037, 038 (OR) CCM2A
37 Switched 039 (OR) CCM2B
55-15
Fuse # Power Circuit Number Circuit Energized

Type to power
38 Unswitched 053 (RD) Key switch, S-02
39 Unswitched 047 (RD) Memory (KAPWR)
40 Unswitched 012 (RD) CCM1 power relay, K-24
41 Unswitched 014 (RD) CCM2 power relay, K-25
42 Unswitched 010 (RD) CCM3, cab power relay, K-26
43 Switched 032, 033 (OR) CCM1A
44 Switched 034 (OR) CCM1B
45 Switched 013 (OR) HHC module, A-07
46 Switched 580 (OR) ASP amplifier, A-08
47 Switched 035, 036 (OR) CCM3, moisture sensor, B-12; sample motor, M-28;
yield sensor, R-05
48 Switched 108 (OR) Splice block B, neutral switch, S-22; thresher engage
switch, S-30; latching relay, K-28
49 Switched 45 (OR) / 46 (OR) Work light switch, S-43, rear work light switch, S-44,
beacon light switch, S-41, HVAC control, A-09, tank
extensions switch, S-42, seat switch, S-05.
50 Unswitched 073, 074 (RD) Unload tube light relay, K-32; timed side work light
relay, K-34.
51 Unswitched 213, 214 (RD) Road light switch, S-26; horn, H-02
52 Unswitched 056 (RD) Brake lights relay, K-33, time delay module, K-20, dome
light, E-34.
53 Unswitched 069 (RD) Beacon light relay, K-29
54 Unswitched 064 (RD) Lower work lights relay, K-30
55 Unswitched 066 (RD) Rear work lights relay, K-31
56 Unswitched 054 (RD) Hazard switch, S-25
55-16
POWER DISTRIBUTION: UNSWITCHED AND SWITCHED

Power is supplied to the system in two modes: K-06, wiper relay, supplying power to wiper
unswitched and switched. switch S-20.
1. Unswitched power is that which is available to the K-08, accessory 1 relay, supplying power to
system at all times, regardless of the position of fuses F-08, F-09 and F-10.
the ignition switch. In this mode, the battery
voltage is applied directly to the power buss bar NOTE: K-03, K-06 and K-08 are energized in both
in the electrical system fuse/relay panel, located ACC and IGN positions of key switch S-02.
in the cab. Those circuits intended to be
energized at all times get their power from this K-24, CCM1 power relay, supplying power to
buss. fuses F-43, F-44 and F-45.
Unswitched power is supplied to these fuses: K-25, CCM2 power relay, supplying power to
fuses F-36, F-37 and F-46.
F-1 to F-5
F-15 to F-19 K-26 CCM3/cab power relay, supplying power to
F-22 to F-35 fuses F-47, F-48 and F-49.
F-38 to F-42 Other fuses receive switched power by way of
F-50 to F-56 the following relays switched from CCM1:
2. Switched power is supplied to the system only K-01, cab roof lights relay, supplying power to
when ignition switch S-02 is turned on. This F-06 and F-07.
switches battery power to the following relays,
K-02, light control relay, supplying power to F-20
which, when energized, supply battery power to
and F-21.
the fuses listed:
The Fuse/Circuit Chart lists the system fuses, their
K-03, accessory 2 relay, supplying power to
power feed mode (unswitched or switched) and the
fuses F-11, F-12, F-13, and F-14.
circuits they supply.
POWER DISTRIBUTION CIRCUIT TROUBLESHOOTING

When starting out to troubleshoot a problem in the 4. Check the fuse supplying the problem circuit. If
power distribution system, checking for obvious blown, replace. If the fuse blows again, further
things first can save time. troubleshooting is needed to find the cause of the
excessive current.
1. First of all, for safety purposes, make sure all
operating controls are in neutral or park lock 5. Check the electrical connectors supplying the
position. problem circuit for loose, corroded or pushed-out
terminals. Check also for pulled-out or broken
2. Make sure the batteries are fully charged and all wires. Make sure the connectors are fully seated.
connections are clean and tight.
3. If the problem circuit is a switched circuit, make

sure the key switch is on.
55-17
POWER DISTRIBUTION SYMPTOM CHART

these tests. For battery testing and service, see the battery section in the service manual.
CAUTION
DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can cause
damage to components in this system.
WARNING
DIAGNOSTIC TESTS

No power at one fuse. Power supply to fuse Go to fuse/circuit chart to
determine power supply circuit.
No power at switched fuses CCM3 A - CCM3
F-47, F-48, F-49. Cab Power Relay K-26 Cab Power Relay Test.
No power at switched fuses CCM2 Cab Power Relay K-25 B - CCM2 Power Relay Test.
F-36, F-37, F-46.
No power at switched fuses CCM1 Cab Power Relay K-24 C - CCM1 Power Relay Test.
F-43, F-44, F-45.
No power at switched fuses Accessory 1 Relay K-08 D - Accessory 3 Relay Test.
F-08, F-09, F-10.
No power at switched fuses Accessory 2 Relay K-03 E - Accessory 2 Relay Test.
F-11, F-12, F-13, F-14.
55-18
these tests.
CAUTION
WARNING
A - CCM3/CAB POWER RELAY TEST

1 Check for 12 volts at 12 volts Open circuit 10 (RD) between
CCM3/Cab power relay If good reading, continue CCM3/Cab power relay K-26 (pin 3) and
K-26 (pin 3). with next step. Fuse #42.
Blown Fuse #42.
2 Key Switch S-02 in the 12 volts Open circuit 104 (OR), 103 (OR), 95
“ON” position. If good reading, continue (OR) or 96 (OR) between Key Switch
Check for 12 volts at with next step. S-02 connector X068 (pin 6) and
CCM3/Cab power relay CCM3/Cab power relay K-26 (pin 1).
K-26 (pin 1). 12 volts not available from Key Switch
S-02 connector X068 (pin 6), refer to
Key Switch Test, Section 55, Chapter 5,
Table B.
3 At CCM3/Cab power relay, 12 volts Faulty CCM3/Cab power relay K-26.
K-26 ground (pin 2) and If good reading, CCM3/ Short to ground in circuit 7 (RD). A short
check for 12 volts at Cab power relay is to ground will blow Fuse #42.
CCM3/Cab power relay operating properly.
K-26 (pin 5).
If good reading continue
with next step.
4 At CCM1, ground (pin 12 volts Open circuit 107 (BK) between CCM1
J1-23) and check for 12 If good reading, see (pin J1-23) and CCM3/Cab power relay
volts at CCM3/Cab power Service Manual for testing K-26 (pin 2).
relay K-26 (pin 5). of CCM1.
55-19
B - CCM2 POWER RELAY TEST

1 Check for 12 volts at CCM2 12 volts Open circuit 14 (RD) between CCM2
power relay K-25 (pin 3). If good reading, continue power relay K-25 (pin 3) and Fuse #41.
with next step. Blown Fuse #41.
2 Key Switch S-02 ON. 12 volts Open circuit 103 (OR), 95 (OR) or 96
Check for 12 volts at CCM2 If good reading, continue (OR) between Key Switch S-02
power relay K-25 (pin 1). with next step. Connector X068 (pin 6) and CCM2
power relay K-25 (pin 1).
12 volts not available from Key Switch
S-02 Connector X068 (pin 6), refer to
Key Switch test, Section 55, Chapter 5,
Table B.
3 At CCM2 power relay K-25, 12 volts Faulty CCM2 power relay K-25.
ground (pin 2) and check If good reading, CCM2
for 12 volts at CCM2 power power relay K-25 is
relay K-25 (pin 5). operating properly.
Continue with next step.
4 Key Switch S-02 OFF. Less than 1 ohm Open circuit106 (BK) between CCM2
Check resistance of circuit resistance. power relay K-25 (pin 2) and CCM3/Cab
106 (BK) between CCM2 If good reading, relay is power relay K-26 (pin 2).
power relay K-25 (pin 2) operating properly. See
and CCM3/Cab power Service Manual for testing
relay K-26 (pin 2). of CCM1.
C - CCM1 POWER RELAY TEST

1 Check for 12 volts at 12 volts Open circuit 12 (RD) between CCM1
CCM1 Power Relay K-24 If good reading, continue Power Relay K-24 (pin 3) and Fuse #40.
(pin 3). with next step. Blown Fuse #40.
2 Key Switch S-02 ON. 12 volts Open circuit 95 (OR) or 96 (OR)
Check for 12 volts at If good reading, continue between Key Switch S-02 connector
CCM1 Power Relay K-24 with next step. X068 (pin 6) and CCM1 Power Relay
(pin 1). K-24 (pin 1).
12 volts not available from Key Switch
Table B.
3 At CCM1 Power Relay 12 volts Faulty CCM1 Power Relay K-24.
K-24, ground (pin 2) and If good reading, CCM1
check for 12 volts at CCM1 Power Relay K-24 is
Power Relay K-24 (pin 5). operating properly.
Continue with next step.
4 Key Switch S-02 OFF. Less than 1 ohm Open circuit 105 (BK) between CCM1
Check resistance of circuit resistance. Power Relay K-24 (pin 2) and CCM2
105 (BK) between CCM1 If good reading, relay is Power Relay K-25 (pin 2).
Power Relay K-24 (pin 2) operating properly.
and CCM2 Power Relay See Service Manual for
K-25 (pin 2). testing of CCM1.
55-20
D - ACCESSORY 1 RELAY TEST

1 Key Switch S-02 “ON” 12 volts Accessory 1 Relay K-08.
Measure for 12 volts at If good reading, relay is Adjacent circuits.
Accessory 1 Relay K-08 operating properly. Go to next test point.
(pin 5).

Accessory 1 Relay K-08 If good reading, continue Accessory 1 Relay K-08 (pin 3) and
(pin 3). with next step. Fuse #3.
Blown Fuse #3.
3 Key Switch S-02 “ON”. 12 volts Open circuit 241 (OR) between Key
Check for 12 volts at If good reading, continue Switch S-02 connector X068 (pin 6) and
Accessory 1 Relay K-08 with next step. Accessory 1 Relay K-08 (pin 1).
(pin 1). If 12 volts not available from Key Switch
Table B.
4 Check resistance of circuit Less than 1 ohm Open circuit 150 (BK) between
150 (BK) between resistance. Accessory 1 Relay K-08 and ground.
Accessory 1 Relay K-08 If good reading, Accessory
(pin 2) and ground. 1 Relay K-08 is operating
properly.
E - ACCESSORY 2 RELAY TEST

1 Key Switch S-02 “ON” 12 volts Accessory 2 Relay K-03.
Measure for 12 volts at If good reading, relay is Adjacent circuits.
Accessory 2 Relay K-03 operating properly. Go to next test point.
(pin 5).

Accessory 2 Relay K-03 If good reading, continue Accessory 2 Relay K-03 (pin 3) and
(pin 3). with next step. Fuse #2.
Blown Fuse #2.
3 Key Switch S-02 “ON”. 12 volts Open circuit 126 (OR), 241 (OR) or 123
Check for 12 volts at If good reading, continue (OR) between Key Switch S-02
Accessory 2 Relay K-03 with next step. connector X068 (pin 4) and Accessory 2
(pin 1). Relay K-03 (pin 1).
If 12 volts not available from Key Switch
Key Switch test.
4 Key Switch S-02 “OFF”. Less than 1 ohm Open circuit 149 (BK) between
Check resistance of circuit resistance. Accessory 2 Relay K-03 and ground.
149 (BK) between If good reading, Accessory
Accessory 2 Relay K-03 2 Relay K-03 is operating
(pin 2) and ground. properly.
55-21
LIGHTING SYSTEM
The CR Series combines are equipped with several Turn Signals
lighting circuits to provide illumination as required for Brake Lights
different operations. Lighting packages may vary
depending on country. The lighting circuits may be Beacon Lights
generally grouped as follows: Front Work Lights
Hazard Lights Rear Work Lights
Marker Lights Side Work Lights
Road Lights Under Shield/Service Lighting
Flip-up Lights Backlighting
E-32 E-20 E-18 E-38 E-17 E-19 E-31

E-16 E-15
E-25
E-26
E-21
E-22
E-03
E-04
E-23
E-14 E-13
E-24
50050027
2
North American – Front View
E-03 LH FRONT HAZARD LIGHT (NOTE 1) E-21 LH HEADER LIGHT

E-04 RH FRONT HAZARD LIGHT (NOTE 1) E-22 RH HEADER LIGHT
E-13 LH ROAD LIGHT E-23 LH STUBBLE LIGHT
E-14 RH ROAD LIGHT E-24 RH STUBBLE LIGHT
E-15 LH CAB OUTER WORK LIGHT E-25 LH SIDE WORK LIGHT
E-16 RH CAB OUTER WORK LIGHT E-26 RH SIDE WORK LIGHT
E-17 LH CAB INNER WORK LIGHT E-31 LH FRONT BEACON
E-18 RH CAB INNER WORK LIGHT E-32 RH FRONT BEACON
E-19 LH CAB MID WORK LIGHT E-38 CENTER WORK LIGHT
E-20 RH CAB MID WORK LIGHT
NOTE 1: E-03 and E-04 mounted on folding extension arms on SN HAJ101501 and above.
55-22
E-33
E-29
E-12
E-11
E-07 E-27 E-28 E-08
E-05
E-06
50031008
North American – Rear View
E-05 LH REAR FLASHING LIGHT (NOTE 2) E-12 RH BRAKE/TAIL LIGHT

E-06 RH REAR FLASHING LIGHT (NOTE 2) E-27 LH REAR WORK LIGHT
E-07 LH NASO FLASHING LIGHT E-28 RH REAR WORK LIGHT
E-08 RH NASO FLASHING LIGHT E-29 UNLOAD TUBE LIGHT
E-11 LH BRAKE/TAIL LIGHT E-33 REAR BEACON
NOTE 2: E-05 and E-06 and foldout mounting arms eliminated on SN HAJ101501 and above.
55-23
E-32 E-17 E-19 E-31

E-20 E-18 E-38
E-16 E-15
E-25
E-26
E-21
E-22 E-47
E-48 E-54
E-49
E-51 E-50
E-52
E-53
E-04
E-23
E-14 E-13
E-24 E-03
50050025
European – Front View
E-03 LH FRONT HAZARD LIGHT E-25 LH SIDE WORK LIGHT

E-04 RH FRONT HAZARD LIGHT E-26 RH SIDE WORK LIGHT
E-13 LH ROAD LIGHT E-31 LH FRONT BEACON
E-14 RH ROAD LIGHT E-32 RH FRONT BEACON
E-15 LH CAB OUTER WORK LIGHT E-38 CENTER WORK LIGHT
E-16 RH CAB OUTER WORK LIGHT E-47 LH FLIP-UP ROAD LIGHT (OPTIONAL)
E-17 LH CAB INNER WORK LIGHT E-48 RH FLIP-UP ROAD LIGHT (OPTIONAL)
E-18 RH CAB INNER WORK LIGHT E-49 RH POSITION LIGHT
E-19 LH CAB MID WORK LIGHT E-50 LH POSITION LIGHT
E-20 RH CAB MID WORK LIGHT E-51 RH FLASHING LIGHT
E-21 LH HEADER LIGHT E-52 LH FLASHING LIGHT
E-22 RH HEADER LIGHT E-53 RH FRONT AUSTRIA MARKER LIGHT
E-23 LH STUBBLE LIGHT E-54 LH FRONT AUSTRIA MARKER LIGHT
E-24 RH STUBBLE LIGHT
55-24
E-33
E-39
E-29
E-55
E-56
E-28
E-27
E-12
E-11
E-05 E-06
50050026
European – Rear View
E-05 LH REAR FLASHING LIGHT E-29 UNLOAD TUBE LIGHT

E-06 RH REAR FLASHING LIGHT E-33 REAR BEACON
E-11 LH BRAKE/TAIL LIGHT E-39 UNLOAD TUBE MARKER (FRANCE)
E-12 RH BRAKE/TAIL LIGHT E-55 RH REAR AUSTRIA MARKER LIGHT
E-27 LH REAR WORK LIGHT E-56 LH REAR AUSTRIA MARKER LIGHT
E-28 RH REAR WORK LIGHT
55-25
NOTE: The exact lighting configurations on the CR
combine are affected by the specific marker
configurations, refer to the following chart to identify
the lights installed by market:
LIGHTING CHART
NORTH EUROPEAN FRANCE AUSTRIA
AMERICA
LH HEADER FLASHING E-01
RH HEADER FLASHING E-02
LH FRONT HAZARD E-03 E-03 E-03 E-03
RH FRONT HAZARD E-04 E-04 E-04 E-04
LH REAR FLASHING E-05 E-05 E-05 E-05
RH REAR FLASHING E-06 E-06 E-06 E-06
LH NASO FLASHING E-07
RH NASO FLASHING E-08
TURN INDICATOR E-09 E-09 E-09 E-09
HIGH BEAM INDICATOR E-10 E-10 E-10 E-10
LH BRAKE/MARKER E-11 E-11 E-11 E-11
RH BRAKE/MARKER E-12 E-12 E-12 E-12
LH ROAD LIGHTS E-13 E-13 E-13 E-13
RH ROAD LIGHTS E-14 E-14 E-14 E-14
LH CAB OUTER WORK E-15 E-15 E-15 E-15
RH CAB OUTER WORK E-16 E-16 E-16 E-16
LH CAB INNER WORK E-17 E-17 E-17 E-17
RH CAB INNER WORK E-18 E-18 E-18 E-18
LH CAB MID WORK E-19 E-19 E-19 E-19
RH CAB MID WORK E-20 E-20 E-20 E-20
LH HEADER LIGHTS E-21 E-21 E-21 E-21
RH HEADER LIGHTS E-22 E-22 E-22 E-22
LH LOWER WORK E-23 E-23 E-23 E-23
RH LOWER WORK E-24 E-24 E-24 E-24
LH SIDE WORK E-25 E-25 E-25 E-25
RH SIDE WORK E-26 E-26 E-26 E-26
LH REAR WORK E-27 E-27 E-27 E-27
RH REAR WORK E-28 E-28 E-28 E-28
UNLOAD TUBE LIGHT E-29 E-29 E-29 E-29
GRAIN TANK LIGHT E-30 E-30 E-30 E-30
LH FRONT BEACON E-31 E-31 E-31 E-31
RH FRONT BEACON E-32 E-32 E-32 E-32
REAR BEACON E-33 E-33 E-33 E-33
DOME LIGHT E-34 E-34 E-34 E-34
CONSOLE LIGHT E-35 E-35 E-35 E-35
COLD START INDICATOR E-36 E-36 E-36 E-36
SIEVE LIGHT E-37 E-37 E-37 E-37
CENTER WORKLIGHT E-38 E-38 E-38 E-38
UNLOAD TUBE MARKER LAMP E-39
55-26
LIGHTING CHART
NORTH EUROPEAN FRANCE AUSTRIA
AMERICA
LH HEADER MARKER E-40 E-40 E-40
RH HEADER MARKER E-41 E-41 E-41
LH FRONT SHIELD E-42 E-42 E-42 E-42
LH REAR SHIELD E-43 E-43 E-43 E-43
RH FRONT SHIELD E-44 E-44 E-44 E-44
RH REAR SHIELD E-45 E-45 E-45 E-45
ENGINE LIGHT E-46 E-46 E-46 E-46
LH FLIP-UP ROAD E-47 E-47 E-47
RH FLIP-UP ROAD E-48 E-48 E-48
RH POSITION LAMP E-49 E-49 E-49
LH POSITION LAMP E-50 E-50 E-50
RH FLASHING LAMP E-51 E-51 E-51
LH FLASHING LAMP E-52 E-52 E-52
RH FRONT AUSTRIA E-53
LH FRONT AUSTRIA E-54
RH REAR AUSTRIA E-55
LH REAR AUSTRIA E-56
RH LICENSE PLATE E-57 E-57 E-57
LH LICENSE PLATE E-58 E-58 E-58
55-27
CIRCUIT/FUSE LIGHTING CHART

CIRCUIT FUSE #
LH Cab Outer Work Light (E-15) LH Cab Mid Work Light (E19) FUSE-06,31,49
RH Cab Outer Work Light (E-16) RH Cab Mid Work Light (E-20) FUSE-07,31,49
Sieve Light (E-37) FUSE–14
LH Front Hazard Lamp (E-03) Unload Tube Marker Light (E-39) FUSE-20,51
LH Position Lamp (E-50)
LH Front Austria Lamp (E-54)
LH Rear Austria Lamp (E-56) RH License Plate Lamp (E-57)
LH License Plate Lamp (E-58) LH Tail Light (E-11)
RH Front Hazard Lamp (E-04) LH Header Marker Light (E-40) FUSE-21,51
RH Header Marker Light (E-41) RH Position Lamp (E-49)
LH Flip-up Road Light (E-47)
RH Flip-up Road Light (E-48)
RH Front Austria Lamp (E-53)
RH Rear Austria Lamp (E-55)
RH Tail Light (E-12)
LH Cab Inner Work Light (E-17) RH Cab Inner Work Light (E-18) FUSE-29
LH Header Light (E-21) RH Header Light (E-22) FUSE-30
Center Work Light (E-38)
LH Cab Work Lights Fuse (F-06) FUSE-31
RH Cab Work Lights Fuse (F-07)
LH Cab Outer Work Light (E-15)
RH Cab Outer Work Light (E-16)
LH Cab Mid Work Light (E-19) RH Cab Mid Work Light (E-20)
RH Road Lights (E-13/14) High Beams FUSE-32,51
LH Road Lights (E-13/14) Low Beams FUSE-33
LH Front Shield Light (E-42) RH Front Shield Light (E-43) FUSE-34
RH Front Shield Light (E-44) RH Rear Shield Light (E-45)
Engine Light (E-46)
Side Work Light (E-25) Timed Side Work Light (E-26) FUSE-50,52
Unload Tube Light (E-29) FUSE-50
LH Brake Light (E-11) RH Brake Light (E-12) FUSE-52
Dome Light (E-34)
LH Front Beacon Light (E-31) RH Front Beacon Light (E-32) FUSE-53,49
Rear Beacon Light (E-33)
LH Stubble Light (E23) RH Stubble Light (E24) FUSE-54
Grain Tank Light (E-30)
LH Rear Work Light (E-27) RH Rear Work Light (E-28) FUSE-55,49
LH Header Flashing Lamp (E-01) RH Header Flashing Lamp (E-02) FUSE-56
LH NASO Flashing Lamp (E-07) RH NASO Flashing Lamp (E-08)
Turn Indicator (E-09) High Beam Indicator (E-10)
LH Rear Flashing Lamp (E-05) RH Rear Flashing Lamp (E-06)
LH Flashing Lamp (E-52) RH Flashing Lamp (E-51)
LH Front Hazard Lamp (E-03) RH Front Hazard Lamp (E-04)
55-28
LIGHTING CONTROLS
The following switches and controls are used by the
operator to select and control the lighting on the
combine:
a1
b1
a2 c1
b2
c2
ZDA3953B
6
CR NA LIGHTING -- STEERING COLUMN CONTROL
CONTROL STALK, 1, POSITION (Figure 6) ROAD MODE FIELD MODE
a1 – Lever up Right turn indicators flash. Side work lights turn on.
Left turn indicators illumi- NOTE: Front work lights
nated, but not flashing. must be on.
a2 – Lever down Left turn indicators flash. Side work lights turn on.
Right turn indicators illumi- NOTE: Front work lights
nated, but not flashing. must be on.
b1 – Twist to position 1 Marker lights on. Marker lights on.
b2 – Twist to position 2 Headlights and marker Headlights and marker
lights on. lights on.
c1 – Pull to rear Headlights on low beams Headlights on low beams
c2 – Push to front Headlights on high beams Headlights on high beams
HAZARD LIGHT SWITCH, 2, (Figure 6) ROAD MODE FIELD MODE
Press to turn on Hazard lights on Hazard lights on
NOTE: If hazard light switch
is on, the following lights are disabled:
Cab inner work lights Rear work lights
Stubble lights, Unload tube light
Grain tank light
Header lights
Center work light
55-29
CR EUROPEAN LIGHTING -- STEERING COLUMN CONTROL
CONTROL STALK, 1,
POSITION (Figure 7) ROAD MODE FIELD MODE
a1 – Lever up Right turn indicators flash. Side work lights turn on.
Left turn indicators not illuminated. NOTE: Front work lights must be on.
a2 – Lever down Left turn indicators flash. Side work lights turn on.
Right turn indicators not illumi- NOTE: Front work lights must be on.
nated
b1 – Twist to position 1 Marker lights on. Marker lights on.
b2 – Twist to position 2 Headlights and marker lights on. Headlights and marker lights on.
c1 – Pull to rear Headlights on low beams Headlights on low beams
c2 – Push to front Headlights on high beams Headlights on high beams
HAZARD LIGHT SWITCH, 2,

(Figure 7) ROAD MODE FIELD MODE
Press to turn on Hazard lights on Hazard lights on
NOTE: If hazard light switch

is on, the following lights are
disabled:
Cab inner work lights
Stubble lights
Grain tank light
Header lights
Center work light
Rear work light
Unload tube light
55-30
a1
b1
a2 c1
b2
c2
55-31
3 2 1
CR NA LIGHTING -- ROCKER SWITCHES

ROCKER SWITCH POSITION 1 POSITION 2
(Figure 8) LIGHTS ACTIVATED ROAD FIELD ROAD FIELD
1 Work lights Cab outer work lights ON ON ON ON
Cab mid work lights ON ON ON ON
Cab inner work lights OFF OFF OFF ON
Stubble lights OFF ON OFF ON
Header lights OFF ON OFF ON
Center work light OFF ON OFF ON
Grain tank light OFF ON OFF ON
ROAD FIELD
2 Rear work lights Rear work lights OFF ON
(Combine in reverse, front ON ON
work lights on)
3 Beacon lights Beacons ON ON
NOTE: Beacon lights also
come on at:
Initial startup ( 3 s)
Grain tank 3/4 full (10 s)
Grain tank full (10 s)
55-32
CR EUROPEAN LIGHTING - ROCKER SWITCHES
ROCKER SWITCH LIGHTS ACTIVATED POSITION 1 POSITION 2

(Figure 8) ROAD FIELD ROAD FIELD
1 Work lights Cab outer work lights ON ON ON ON

Cab mid work lights ON ON ON ON
Cab inner work lights OFF OFF OFF ON
Stubble lights OFF ON OFF ON
Header lights OFF ON OFF ON
Center work light OFF ON OFF ON
Grain tank light OFF ON OFF ON
ROAD FIELD
2 Rear work lights Rear work lights OFF ON

(Combine in reverse, front ON ON
work lights on)
3 Beacon lights Beacons ON ON

NOTE: Beacon lights also
come on at:
Initial startup (3 s)
Grain tank 3/4 full (10 s)
Grain tank full (10 s)
55-33
LIGHTING CIRCUITS
HAZARD LIGHT CIRCUITS Pin 3 supplies pulsing voltage to the hazard lights on
the left side of the combine:
NOTE: Failed bulbs, poor connections, or broken
circuitry may cause the flashers to flash on and off at LH front hazard light E-03
an irregular rate. If trailer lights are connected, the LH rear flashing light E-05
lighting system will function differently. For example, LH flashing light E-52 (EU models)
when trailer lights are connected to the lighting LF header flasher E-01
circuit, a bulb failure will have less effect on the
operation of the circuit. Voltage from pin 3 is also made available for a trailer
at trailer outlet J-09 pin L.
Circuit Operation Pin 4 supplies pulsing voltage to the hazard lights on

Refer to Hazard Light Circuits functional diagram the right side of the combine:
Figure 9. For detailed circuit tracing, refer to RH front hazard light E-04
schematic Frames 33, 34 and 35.
RH rear flashing light E-06
Closing hazard switch S-25 (“On” position) applies RH flashing light E-51 (EU models)
+12 volts to pin 2 of flasher module A-05. At the same RF header flasher E-02
time, S-25 applies voltage to its internal light-emitting
diode (LED) indicator, which illuminates. Voltage from pin 4 is also made available for a trailer
at trailer outlet J-09 pin R.
The voltage at pin 2 of A-05 activates the module,
and pulsing voltage appears at output pins 3 and 4. NOTE: Rear flashing lights E-05 and E-06 have been
These pulsing voltage signals cause the LED eliminated on North American models SN
indicators in turn indicator E-09 to flash on and off. HAJ101501 and above. With this change, front
hazard Lights E-03 and E-04 have been mounted on
At the same time, A-05 pins 3 and 4 supply pulsing extender arms and are visible from front and rear.
voltage to the combine’s hazard lights (Figs. 2, 3, 4,
5), causing them to flash.
NOTE: In Europe, it is illegal to use flashing lights
when roading. They are to be used when the unit is
parked on a public roadway. Marker lights are to be
used when roading.
55-34
60050029
55-35
MARKER LIGHT CIRCUITS Voltage from F-20 is also made available for a trailer
Refer to Marker Light Circuits functional diagram at trailer outlet J-09 pin 58L.
Figure 10. For detailed circuit tracing, refer to
Voltage from fuse F-21 illuminates these marker
schematic Frames 33, 34, 35, 36 and 37.
lights:
The operator activates the marker lights via road light
E-04 RH front hazard light
switch S-26, located in the control stalk on the left
side of the steering column. When the stalk is rotated E-12 RH brake/tail light
to the first position (Marker Lights), the internal E-40 Header LH marker (EU models)
contacts close, connecting S-26 pin 5 to pin 1, E-41 Header RH marker (EU models)
applying +12 volts to relay K-02. At the same time,
E-47 LF flip-up road light (EU option)
+12 volts is applied to CCM1, J1-21, causing CCM1
to activate the backlighting circuits. E-48 RH flip-up road light (EU option)
E-49 RH position light (EU models)
K-02 energizes, applying +12 volts to fuses F-20 and E-53 RH front Austria marker light
F-21. Voltage from fuse F-20 illuminates these
marker lights: E-55 RH rear Austria marker light
E-03 LH front hazard light Voltage from F-21 is also made available for a trailer
at trailer outlet J-09 pin 58R.
E-11 LH brake/tail light
E-39 Unload tube marker Light (France) NOTE: European marker lights indicate the
E-50 LH position light (EU models) extremities of the combine and are to be used in
E-54 LH front Austria marker light roading. It is illegal to use flashers when roading.
E-56 LH rear Austria marker light Flashers are only to be used while the unit is parked
on a public roadway.
E-57 RH license plate (EU models)
E-58 LH license plate (EU models)
55-36
60050030
10
55-37
ROAD LIGHTS – LOW BEAM

NOTE: When the road light circuit is active, power is
also applied to the marker lights and backlighting
circuits. Refer to the marker light and backlighting
circuit descriptions for additional information.
Refer to Road Lights – Low Beam functional diagram

Figure 11. For detailed circuit tracing, refer to
schematic Frame 36.
The operator rotates the control stalk, located on the

left side of the steering wheel, to the second position
to turn on the road lights. As long as the stalk is in the
rear position, the road lights will be on low beam.
Figure 11 shows the circuit configuration for this
mode.
Road light switch S-26 is switched through from pin

5 to pin 1, for marker lights and backlighting, and also
to pin 7, which applies 12 volts to low beam relay
K-05. Relay K-05 energizes, applying 12 volts to the
low-beam (terminal B) lamp of LH road light E-13 and
RH road light E-14.
55-38
60050031
11
55-39
ROAD LIGHTS – HIGH BEAM

NOTE: When the road light circuit is active, power is
also applied to the marker lights and backlighting
circuits. Refer to the marker light and backlighting
circuit descriptions for additional information.
Refer to the Road Lights – High Beam functional

diagram Figure 12. For detailed circuit tracing, refer
to schematic Frame 36.
The operator rotates the control stalk, located on the

left side of the steering wheel, to the second position
to turn on the road lights. As long as the stalk is in the
rear position, the road lights will be on low beam. To
turn on the high beams,
the operator pushes the stalk to the forward position.

Figure 12 shows the circuit configuration for this
mode.
Road light switch S-26 is switched through from pin

5 to pin 1, for marker lights and backlighting, and also
to pin 4, which applies 12 volts to high beam relay
K-04. Relay K-04 energizes, applying 12 volts to the
high-beam (terminal A) lamp of LH road lamp E-13
and RH road lamp E-14.
At the same time, voltage from S-26 pin 4 is applied

to high beam indicator E-10, which illuminates.
55-40
60050032
12
55-41
FLIP-UP LIGHTS This 2-pin connector provides power for E-47 and
Flip-up lights are optional for European models and E-48 marker lights and relays K-40 and K-41, and a
are designed to be used with flip-up headers, which ground return for these relays. The relays switch
tend to block the standard road lights. The flip-up between the standard road lights and the flip-up road
lights (E-47 and E-48) are mounted on the cab lights.
platform railings as shown in Figure 4. Each flip-up
DC power for the relays is present whenever road
light unit contains a marker lamp, a low-beam lamp
switch S-26 is in the marker lights or road lights
and a high-beam lamp.
position. However, the ground return for the relays is
Refer to Flip-up Lights functional diagram Figure 13. through the flip-up header, via header connector
For detailed circuit tracing, refer to schematic X032. This path to ground only exists in the flip-up
Frames 36 and 37. header harness. Relays K-40 and K-41 will not
energize unless a flip-up header is installed.
The flip-up lights option is supplied as a kit, which is
interposed between the existing road lights (E-13 With no flip-up header installed, relays K-40 and
and E-14) and their control circuitry. The kit wiring is K-41 are de-energized and DC paths to the standard
shown enclosed in dashed lines in Figure 13. Note road lights exist through closed contacts 30 and 87A.
that connectors X164 and X169 of the existing main The standard road lights are enabled and can be
frame wire harness are unplugged from E-13 and controlled in the usual manner. The flip-up lights are
E-14, respectively, and are plugged into X164 and disabled. K-40 provides a path for DC current from
X169 of the flip-up lights wire harness. Connectors low-beam relay K-05; K-41 provides a path for DC
X335 and X336 of the flip-up lights wire harness then current from high-beam relay K-04.
are connected to E-13 and E-14.
If a flip-up header is installed, the coils of relays K-40
The circuitry at the top of Figure 13, outside the and K-41 now have a return path to ground. When
dashed lines, is the control circuitry for the road switch S-26 is turned to the marker or road lights
lamps. Its operation is described in Road Lights – position, 12 volts DC is applied to the relay coils and
Low Beam and Road Lights – High Beam. As with the they energize. The DC paths are now through closed
standard road lights, the flip-up lights are controlled contacts 30 and 87. The flip-up lights are enabled
from the control stalk located on the left side of the and can be controlled the same as the standard road
steering column. Rotating the stalk to the first lights. The standard road lights are disabled.
position turns on the marker lights. Rotating the stalk
Note that the marker lamps of E-47 and E-48 are
to the second position turns on the marker lights and
enabled whenever the standard marker lamps are
the flip-up road lights.
turned on, even if no flip-up header is installed.
Connector X218 of the flip-up harness plugs into an
open connector on the main frame harness.
55-42
60050033
13
55-43
TURN SIGNALS NASO Mode

If a left turn is selected (+12 volts on A-05 pin 8), A-05
NOTE: Failed bulbs, poor connections, or broken puts out a pulsing voltage on pins 3 and 10. This
circuitry may cause the flashers to flash on and off at causes these lamps to flash on and off:
an irregular rate. If trailer lights are connected, the
lighting system will function differently. For example, E-01 LH Header Flashing Light
when trailer lights are connected to the lighting
E-03 LH Front Hazard Light
circuit, a bulb failure will have less effect on the
operation of the circuit. E-05 LH Rear Flashing Light
E-07 LH NASO Flashing Light
NOTE: If the road/field mode switch is in the FIELD
position and the work lights are switched on, At the same time, A-05 puts out a steady DC voltage
activating a turn signal turns on the side work lights, on pins 4 and 11. This causes these lamps to glow
illuminating the sides of the combine. This enhances steadily:
visibility when turning in low-light conditions.
E-02 RH Header Flashing Light
Refer to Turn Signals functional diagram Figure 14. E-04 RH Front Hazard Light
For detailed circuit tracing, refer to schematic E-06 RH Rear Flashing Light
Frames 36, 33, 34 and 35.
E-08 RH NASO Flashing Light
The turn signals are activated from the control stalk
located on the left side of the steering column. The signals from A-05 pins 3 and 4 also go to turn
Pushing the stalk down (toward the floor) activates indicator E-09. The light-emitting diodes (LEDs) in
the left turn signal; pushing the stalk up (toward the E-09 illuminate in accordance with the applied signal,
roof) activates the right turn signal. The turn signal whether flashing or steady.
contacts are part of road switch S-26.
The signal voltages are also made available for
When key switch S-02 is in the ignition (IGN) position, trailer lights at trailer jack J-09.
+12 volts is available at pin 6 of S-26. If a left turn
signal is selected, contacts 6 and 3 of S-26 close, If a right turn is selected (+12 volts on A-05 pin 7),
applying +12 volts to pin 8 of flasher module A-05. If A-05 puts out a pulsing voltage on pins 4 and 11, and
a right turn is selected, contacts 6 and 2 close, a steady voltage on pins 3 and 10. This reverses the
applying +12 volts to pin 7 of A-05. Pins 3 and 2 of light operation just described, causing the right-hand
S-26 are also tied to CCM1, pins J1-2 and 9, to inform lights to flash and the left-hand lights to glow steadily.
the system that a turn signal has been selected.
Flasher module A-05 produces the pulsing voltages ISO Mode

that are applied to the lights involved in indicating a If a left turn is selected (+12 volts on A-05 pin 8), A-05
turn. puts out a pulsing voltage on pin 3. This causes these
lights to flash on and off:
NOTE: The turn signal indications behave differently,
depending on whether the combine is configured for E-03 LH Front Hazard Light
North American (NASO) or Euro-pean (ISO) use. In E-05 LH Rear Flashing Light
NASO configuration, the lights on the side for which E-52 LH Flashing Light
the turn is indicated flash on and off, while the lights
on the opposite side glow steadily. In ISO A-05 puts out 0 volts on pin 4, and the right-hand
configuration, the lights on the side for which the turn signal lights are dark:
is indicated flash on and off, while the lights on the
opposite side are dark. A voltage from CCM2 J1-5, E-04 RH Front Hazard Light
applied to A-05 pin 9, determines whether A05 E-06 RH Rear Flashing Light
operates in NASO or ISO mode. E-51 RH Flashing Light
If a right turn is selected (+12 volts on A-05 pin 7),

A-05 puts out a pulsing voltage on pin 4 and 0 volts
on pin 3. The situation is now reversed, with the
right-hand lights flashing and the left-hand lights
dark.
55-44
60050034
14
55-45
BRAKE LIGHTS
The brake lights are activated by depressing the
brake pedal or pulling back quickly on the
multifunction control lever.
Refer to Brake Lights functional diagram Figure 15.

For detailed circuit tracing, refer to schematic
Frames 9, 7, 38 and 35.
The brake light in each of the brake/tail light

assemblies E-11 and E-12 illuminates in the
circumstances mentioned above. If the brake pedal
is depressed, brake pressure switch S-39 closes,
applying ground to pin J2-34 of combine control
module CCM2.
CCM2, in turn, applies +12 volts to the coil of brake

lights relay K-33. K-33 energizes, closing contacts 3
and 5, which switches +12 volts from fuse F-52 to the
brake lights (pin 1) in E-11 and E-12. This causes the
brake lights to illuminate.
Brake light voltage is also made available for a trailer

at trailer jack J-09, terminal 54.
Ground speed pot R-04 tracks the position of the

multifunction control lever, applying this information
to the right-hand module (RHM) at X027 pin 1 in the
form of a changing analog voltage.
If the operator pulls the multifunction control lever

back quickly, the RHM senses the sudden change in
voltage and reports it to CCM2 via the CAN bus.
CCM2 then activates the brake lights as described
above.
55-46
60050035
15
55-47
BEACON LIGHTS
The CR Combine is equipped with three beacon
lights. There are two beacon lights mounted on the
cab roof and one mounted at the rear railing of the
combine, on the engine platform.
Three things can cause the beacon lights to become

active:
• Beacon switch S-41 switched on.

• Initial startup – Beacon lights illuminate for about
three seconds when key switch S-02 is moved
from the OFF position.
• Grain tank filling up - The combine is equipped
with a lower (3/4) and upper (full) grain tank level
sensor. When the thresher is engaged and the
material in the tank reaches the lower sensor, the
beacons will flash. The flashing beacons inform
a grain truck operator to prepare for unloading
the grain bin.
If the work lights are on, the beacons will only
flash for about 10 seconds. They flash for 10
seconds again when the upper sensor detects
material.
Refer to Beacon Lights functional diagram Figure 16.

For detailed circuit tracing, refer to schematic Frame
39.
CCM2 activates the beacon lights in response to any

of the three conditions described above. Figure 13
shows the beacon light switch S-41 in the ON
position. CCM2 applies +12 volts to beacon light
relay K29, which energizes, closing contacts 3 and 5.
This switches +12 volts from fuse F-53 to beacon
lights E-31, E-32 and E-33.
55-48
60050036
16
55-49
FRONT WORK LIGHTS Position 2 - Selecting position 2 of S-43 closes the

The front work lights are mounted in the front of the circuit between pins 5 and 6, applying ground to the
cab roof (Figures 2 and 4). They are controlled by B terminals of inner work lights E-17 and E-18. At the
work light switch S-43. same time, +12 volts from F-29 is made available to
the A terminals of E-17 and E-18 through contacts 3
Refer to Front Work Lights functional diagram Figure and 5 of relay K-21 and contacts 3 and 5 of road lights
17. For detailed circuit tracing, refer to schematic relay K-27.
Frames 41 and 42.
Relay K-21 is energized whenever S-43 is in position
Work light switch S-43, located in the upper 1 or 2. However, relay K-27 is energized only under
right-hand switch panel, has three positions: these conditions:
• Road/Field switch S-12 switched to FIELD.
OFF – No work lights are illuminated.
• Hazard lights switch S-25 OFF.
Position 1 – When ignition switch S-02 is switched
to IGN, +12 volts is present at pin 2 of work light If these conditions are met, CCM1 places +12 volts
switch S-43. Selecting position 1 of S-43 switches on pin J1-5. This energizes K-27, which switches +12
this voltage to J1-3 of CCM1. Voltage applied to volts to the A terminals of E-17 and E-18. The
CCM1 at this point not only activates the front work following front work lights are now illuminated:
light circuits, it also activates the backlighting circuits.
See BACKLIGHTING for details. LH cab outer work light E-15
RH cab outer work light E-16
CCM1 applies +12 volts from J1-11 to the coil of cab
roof work lights relay K-01 (pin 86). K-01 energizes, LH cab inner work light E-17
closing the circuit between pins 30 and 87, and RH cab inner work light E-18
switching +12 volts from fuse F-31 to fuses F-06 and LF cab mid work light E-19
F-07. This voltage illuminates these work lights: RH cab mid work light E-20
LH cab outer work light E-15
RH cab outer work light E-16
LF cab mid work light E-19
RH cab mid work light E-20
At the same time, the voltage from CCM1 J1-11
energizes distance work lights relay K-21.
55-50
60050037
17
55-51
REAR WORK LIGHTS

The rear work lights illuminate the rear of the
combine for better visibility in low-light conditions.
They can be activated in either of two ways:
• Rear work light switch S-44 placed in ON
position.
• Combine in reverse, with front work lights on.
Rear work light switch S-44 is located in the upper

right-hand switch panel.
Refer to Rear Work Lights functional diagram, Figure

18. For detailed circuit tracing, refer to schematic
Frame 42.
When ignition switch S-02 is switched to IGN, +12

volts is present at pin 2 of switch S-44. Turning on
S-44 closes contacts 1 and 3, applying +12 volts to
pin J1-3 of CCM1.
CCM1 then energizes rear work lights relay K-31 via

pin J1-18. K-31’s contacts 3 and pin 5 close,
switching +12 volts from fuse F-55 to the A terminals
of LH rear work light E-27 and RH rear work light
E-28, causing them to illuminate.
NOTE: Rear work lights do not illuminate when

combine is in ROAD mode.
55-52
60050038
18
55-53
SIDE WORK LIGHTS If the key switch is off (no power to pin 30), time delay
The side work lights illuminate the sides of the relay K-20 will start its time cycle anytime door switch
combine for better visibility in low-light conditions. S-40 changes state (either opens or closes). This
change of state is applied to K-20 pin 86, which
The side work lights can be activated in three ways: initiates the time cycle. Pin 87 of K-20 goes positive,
energizing timed side work light relay K-34. Contacts
1. Door – The side work lights will turn on 3 and 5 of K-34 close, illuminating LH side work light
automatically if the key switch is off and the left E-25 and RH side work light E-26.
side door is opened or closed.
K-20’s time cycle is approximately 60 seconds,
2. Control Stalk – The control stalk can be used to during which time K-34 stays energized and E-25
turn on the side work lights if the key switch is on, and E-26 remain on. If the key switch is turned on
the combine is in field mode, and the front work during that time (+12 volts to K-20 pin 30), K-20’s time
lights are turned on. In this case, the operator cycle is interrupted and the voltage at pin 87 goes
moves the control stalk as if indicating a left or away. K-34 will drop out, causing E-25 and E-26 to
right turn. turn off. If the key switch is on, K-20 will not cycle
based on door switch S-40 changing state.
3. Header Height – The side work lights turn on if
the front work lights are on, the combine is in field
mode, the front work lights are on and the header Control Stalk Operation
is above the maximum stubble height. When the key switch is on, the combine is in field
Refer to Side Work Lights functional diagram Figure mode and the front work lights are turned on, moving
19. For detailed circuit tracing, refer to schematic the control stalk to either left or right turn signal
Frame 43. positions will cause the side work lights to turn on.
CCM1 controls this, applying +12 volts from pin

J1-24 to side work lights relay K-35, which energizes.
Door Operation
Contacts 3 and 5 close, applying +12 volts from fuse
Time delay relay K-20 is powered by +12 volts
F-50 to LH side work light E-25 and RH side work light
directly from the battery via fuse F-52. This voltage
E-26, which illuminate.
also powers dome light E-34. Pin 86 of K-20 is
connected to door switch S-40. Pin 2 of dome light
E-34 also connects to S-40 at this point. When the
Header Height
key switch S-02 is turned to IGN, +12 volts is
When the key switch is on, the combine is in field
available at pin 30 of K-20.
mode, the front work lights are turned on, and the
header is above the operator-set maximum stubble
height, CCM1 energizes K-35 via pin J1-24. This
illuminates E-25 and E-26, as described in Control
Stalk Operation.
55-54
60050039
19
55-55
STUBBLE LIGHTS HEADER LIGHTS

The stubble lights E-23 and E-24 are located on the Header lights E-21 and E-22 illuminate the header
lower portion of the front of the cab, just outboard of under low-light or after-dark conditions. They are
the road lights E-13 and E-14 (Figures 2 and 4). located under the front cab roof overhang, just below
the front work lights (Figures 2 and 4).
Refer to Work Lights functional diagram Figure 20.
For detailed circuit tracing, refer to schematic Refer to Work Lights functional diagram Figure 20.
Frames 40, 41 and 42. For detailed circuit tracing, refer to schematic
Frames 40, 41 and 42.
The stubble lights turn on whenever the front work
lights are on, providing these conditions exist: The header lights turn on whenever the front work
lights are on, providing these conditions exist:
When key switch S-02 is switched to IGN, work light
switch S-43 is turned on, and the above conditions When key switch S-02 is switched to IGN, work light
are met, CCM1 places +12 volts on pin J1-5. This switch S-43 is turned on, and the above conditions
energizes lower work lights relay K-30, which are met, CCM1 places +12 volts on pin J1-5. This
switches +12 volts from fuse F-54, via closed energizes header work lights relay K-22, which
contacts 3 and 5, to LH stubble light E-23 and RH switches +12 volts from fuse F-30, via closed
stubble light E-24. contacts 3 and 5, to LH header light E-21 and RH
header light E-22.
GRAIN TANK LIGHT
The grain tank light E-30 provides the operator with CENTER WORK LIGHT
visibility into the grain tank, through the rear window, Center work light E-38 is an optional additional work
in after-dark conditions. It is located on the front light. If present, it is located under the front cab roof
inside wall of the grain tank. overhang, just to the left of the windshield wiper arm
(Figures 2 and 4).
Refer to Work Lights functional diagram Figure 20.
For detailed circuit tracing, refer to schematic Refer to Work Lights functional diagram Figure 20.
Frames 40, 41 and 42. For detailed circuit tracing, refer to schematic
Frames 40, 41 and 42.
E-30 is wired in parallel with stubble lights E-23 and
E-24. The circuit description under STUBBLE Center work light E-38 is wired in parallel with header
LIGHTS applies to E-30 as well. lights E-21 and E-22. The circuit description in
HEADER LIGHTS applies to E-38 as well.
UNLOAD TUBE LIGHT
When the unload tube is swung out from its cradle,
sensor B-38 sends a signal to pin J3-36 of CCM1.
CCM1, in turn, places +12 volts on pin J1-12, which
energizes unload tube light relay K-32. This relay
switches +12 volts from fuse F-50, via closed
contacts 3 and 5, to unload tube light E-29, which
illuminates.
55-56
60050040
20
55-57
SERVICE LIGHTS
The optional under-shield service lights provide
illumination under the combine’s protective side
shields when the shields are raised for service or
maintenance of the mechanisms beneath.
There are two service lights under each panel, one

toward the front of the combine, the other toward the
rear.
In addition, a service light is provided for illumination

while servicing the engine under low-light conditions.
This light is located on the rear deck, just under the
rear beacon light E-33.
Refer to Service Lights functional diagram Figure 21.

For detailed circuit tracing, refer to schematic Frame
38. For location of service lights switches, refer to CR
Operator’s Manual, Section 2.
The service lights are powered by +12 volts directly

from the battery, through fuse F-34. Turning on left
shield light switch S-63 places +12 volts on the A
terminals of LH front shield light E-42 and LH rear
shield light E-43, causing them to illuminate.
Right shield light switch S-65, when turned on,

switches +12 volts to RH front shield light E-44 and
RH rear shield light E-45, which illuminate.
Engine light switch S-64 turns on engine light E-46.
55-58
60050041
21
55-59
BACKLIGHTING Two additional backlighting circuits come directly

from CCM2 J1-11 as follows:
Description
The backlighting circuit is controlled by the internal CCM 2 Direct Backlighting Feed
network on the CR Series combines. The backlight-
ing circuit is energized whenever the following Frame
circuits are activated (see the corresponding circuit Pin ID Circuit #
description for more information): J1-11 Accessory Outlet J-08 45
Marker Light Circuit J1-11 Cigar Lighter R-08 45
Road Light Circuit
Front Work Light Circuit NOTE: All of these components are grounded at the
Side Work Light Circuit cab roof location. To gain access to the cab roof
Rear Work Light Circuit wiring, remove the rear center speaker panel.
When these circuits are activated, information is sent RHM

through the network to switch on the backlighting
Frame #25
circuit. CCM2 and the RHM then provide power to the
backlighting circuit. The network also sends a signal When the backlighting circuit is activated, current is
to the Infoview monitor to cause it to dim. This gives sent from RHM pin 18 to splice block F (W-06). The
the operator better visibility in low light conditions. splice block distributes current to the RH control
cluster backlighting. This causes the backlighting on
Refer to schematic frames 27 and 25. the RH control cluster to illuminate.
CCM2 Use the chart below to identify the splice block F, W06
Frame #27 pins that provide power to the corresponding light in
the backlighting circuit.
When the backlighting circuit is activated, current is
sent from CCM2 pin J1-11 to splice block C (W-03).
This provides power to the following backlighting RHM Pin ID (Backlighting)
systems: Frame
The cab upper control console (left side of cab interior) Pin ID Circuit #
The center control console Pin A HHC Fine Adjust Sw. S-06 11
The console light Pin A Header Height Mode Sw.S-04 11
Use the chart below to identify the splice block C Pin A Engine Throttle Sw. S-36 4
(W03) pins that provide power to the corresponding Pin B Rear Wheel Assist Sw. S-10 7
light in the backlighting circuit. Pin C Dual Range Sw. S-11 7
CCM 2 Pin ID (Backlighting) Pin D Road Mode Sw. S-12 7
Frame Pin F Feeder Reverser Sw. S-07 15
Pin ID Circuit # Pin G Alternate Settings Sw. S-21 11
Pin A Console Light E-35 38 Pin H RHM X027-18 25
Pin B CCM2 J1-11 27 Pin J Reel Speed Sw. S-08 11
Pin C Rear Worklight Sw. S-44 42 Pin K Parking Brake Sw. S-09 7
Pin D Work Light Sw. S-43 42 Pin L Spreader Plate Sw. S-23 23
Pin E Wiper Sw. S-20 45
Pin F Beacon Light Sw. S-41 39
Pin G Tank Extensions Sw. S-42 22
Pin H Mirror Heat Sw. S-19 44
Pin J Washer Sw. S-38 45
Pin K * *
Pin L * *
Pin M HVAC Control Module A09 47
55-60
22
55-61
23
55-62
EXTERIOR LIGHTING SYSTEM CIRCUIT TROUBLESHOOTING

Before troubleshooting the Exterior Lighting system make sure that the following conditions are met:
A. The batteries are fully charged and all connections are clean and tight.
B. Check for applicable active fault codes.
C. Check all connectors for full installation, loose, corroded, pushed out, or bent terminals.
D. If one of the worklamp circuits is not working, try swapping a relay from a working system for a quick and easy
relay check. Otherwise, follow the circuit diagnostic tests to determine the fault.
E. If a bulb is not working, substitute with a known good bulb to verify circuit operation.
FUSE/CIRCUIT LIGHTING CHART

FUSE # CIRCUITS
FUSE-06 LH Cab Outer Work Light (E-15) LH Cab Mid Work Light (E19)
FUSE-07 RH Cab Outer Work Light (E-16) RH Cab Mid Work Light (E-20)
FUSE–14 Sieve Light (E-37)
FUSE-20 LH Front Marker Lamp (E-03) Unload Tube Marker Light (E-39) LH Position Lamp (E-50)
LH Flashing Lamp (E-52)
LH Front Austria Lamp (E-54) RH Rear Austria Lamp (E-55)
LH Rear Austria Lamp (E-56) RH License Plate Lamp (E-57)
LH License Plate Lamp (E-58)
FUSE-21 RH Front Marker Lamp (E-04) LH Header Marker Light (E-40)
RH Header Marker Light (E-41) RH Position Lamp (E-49)
RH Flashing Lamp (E-51) RH Front Austria Lamp (E-53)
FUSE-29 LH Cab Inner Work Light (E-17) RH Cab Inner Work Light (E-18)
FUSE-30 LH Header Light (E-21) RH Header Light (E-22)
Center Work Light (E-38)
FUSE-31 LH Cab Work Lights Fuse (F-06)
RH Cab Work Lights Fuse (F-07)
LH Cab Outer Work Light (E-15)
RH Cab Outer Work Light (E-16)
LH Cab Mid Work Light (E-19) RH Cab Mid Work Light (E-20)
FUSE-32 RH Road Light (E-14)
FUSE-33 LH Road Light (E-13)
FUSE-34 LH Front Shield Light (E-42) LH Rear Shield Light (E-43)
RH Front Shield Light (E-44) RH Rear Shield Light (E-45)
Engine Light (E-46)
FUSE-49 Console Light (E-35)
FUSE-50 Side Work Light (E-25) Timed Side Work Light (E-26)
Unload Tube Light (E-29)
FUSE-51 Road Light Switch (S-26) Horn (H-02)
FUSE-52 LH Brake/Tail Light (E-11) RH Brake/Tail Light (E-12)
Dome Light (E-34)
FUSE-53 LH Front Beacon Light (E-31) RH Front Beacon Light (E-32)
Rear Beacon Light (E-33)
FUSE-54 LH Lower Work Light (E23) RH Lower Work Light (E24)
Grain Tank Light (E-30)
FUSE-55 LH Rear Work Light (E-27) RH Rear Work Light (E-28)
FUSE-56 LH Header Flashing Lamp (E-01) RH Header Flashing Lamp (E-02)
LH NASO Flashing Lamp (E-07) RH NASO Flashing Lamp (E-08)
Turn Indicator (E-09) High Beam Indicator (E-10)
55-63
Lighting System Fault Codes
Before beginning to test an individual circuit for faults, check for fault codes using the Diagnostic menu to deter-
mine if there are any active fault codes that may affect the circuit being investigated. The following fault codes
apply to the lighting circuits:
Marker lights, road lights E0011-04 Road Lights signal Shorted to low source
Hazard lights E0008-04 Left Turn signal Shorted to low source
E0012-04 Right Turn signal Shorted to low source
E0201-11 Flasher System Selection Unidentified Failure Code
Side lights E0072-11 Side Work Lights relay Unidentified Failure Code
Front work lights E0009-04 Front Work Lights switch Shorted to low source
E0070-11 Front Work Lights relay Unidentified Failure Code
Rear work lights E0010-04 Rear Work Lights switch Shorted to low source
E0071-11 Rear Work Lights relay Unidentified Failure Code
Unload tube light E0068-11 Unload Tube Light relay Unidentified Failure Code
Beacon lights E0136-04 Beacon Lights switch Shorted to low source
E0200-11 Beacon Lights relay Unidentified Failure Code
Backlighting lamps E0198-11 Backlighting lamps Unidentified Failure Code
Brake lights E0199-11 Brake Lights relay Unidentified Failure Code
55-64
EXTERIOR LIGHTING SYSTEM SYMPTOM CHART

these tests.
CAUTION
WARNING

LH and RH NASO Flashing Bulbs C - LH NASO Flashing Lamp Test
Lamps do not operate. D - RH NASO Flashing Lamp Test
Flasher Module B - Flasher Module Test
Hazard Switch A - Hazard Switch Test
LH and RH Header Flashing Bulbs E - LH Header Flashing Lamp Test
Lamps do not operate. F - RH Header Flashing Lamp Test
LH and RH Front Hazard Bulbs G - LH Front Hazard Lamp Test
Lamps (Hazard Bulbs) do not H - RH Front Hazard Lamp Test
operate.
LH and RH Front Marker Bulbs I - LH Front Marker Lamp Test
Lamps (Marker Bulbs) do not (Marker Bulb)
operate. J - RH Front Marker Lamp Test
(Marker Bulb)
Road Light Switch Q - Road Light Switch Tests 1,2 and
10
LH and RH Rear Flashing Bulbs K - LH Rear Flashing Lamp Test
Lamps do not operate. L - RH Rear Flashing Lamp Test
LH and RH Brake/Tail Lamps Bulbs M - LH Brake/Tail Lamp Test
(Marker Bulbs) do not operate. (Marker Bulb)
N - RH Brake/Tail Lamp Test
(Marker Bulb)
Road Light Switch Q - Road Light Switch Tests 1, 2
and 10
55-65

LH and RH Brake/Tail Lamps Bulbs O - LH Brake/Tail Lamp Test (Brake
(Brake Bulbs) do not operate. Bulb)
P - RH Brake/Tail Lamp Test (Brake
Bulb)
Brake Lights Relay Y - Brake Lights Relay Test
LH and RH Road Lights (Low Bulbs T - LH Road Light Test (Low Beam
Beam Bulbs) do not operate. Bulb)
U - RH Road Light Test (Low Beam
Bulb)
Low Beam Relay R - Low Beam Relay Test
Road Light Switch Q - Road Light Switch Tests 1, 2
and 11
LH and RH Road Lights (High Bulbs V - LH Road Light Test (High Beam
Beam Bulbs) do not operate. Bulb)
X - RH Road Light Test (High Beam
Bulb)
High Beam Relay S - High Beam Relay Test
Road Light Switch Q - Road Light Switch Tests 3,4 and
9
LH and RH Rear Work Lights Bulbs AA - LH Rear Work Light Test
do not operate. BB - RH Rear Work Light Test
Rear Work Lights Relay Z - Rear Work Lights Relay Test
Rear Work Light Switch GGG - Rear Work Light Switch Test
Sieve Light does not operate. Bulbs HH - Sieve Light Test
Sieve Light Switch GG - Sieve Light Switch Test
Rear Beacon Light does not Bulbs DD - Rear Beacon Test
operate.
Beacon Light Relay CC - Beacon Light Relay Test
Beacon Light Switch HHH - Beacon Light Switch Test
LH and RH Front Beacons do Bulbs EE - LH Front Beacon Test
not operate. FF - RH Front Beacon Test
Beacon Light Relay CC - Beacon Light Relay Test
Beacon Light Switch HHH - Beacon Light Switch Test
Side Work Light does not Bulb LL - Side Work Light Test
operate.
Side Work Light Relay II - Side Work Light Relay Test
Work Light Switch FFF - Work Light Switch Test
Timed Side Work Light does Bulb MM - Timed Side Work Light Test
not operate.
Timed Side Work Light Relay JJ - Timed Side Work Light Relay
Test
Unload Tube Light does not Bulb NN - Unload Tube Light Test
operate.
Unload Tube Light Relay KK - Unload Tube Light Relay Test
55-66

Grain Tank Light does not Bulb PP - Grain Tank Light Test
operate.
Lower Work Lights Relay OO - Lower Work Lights Relay Test
LH and RH Lower Work Lights Bulbs QQ - LH Lower Work Light Test
do not operate. RR - RH Lower Work Light Test
Lower Work Light Relay OO - Lower Work Lights Relay Test
LH and RH Header Lights do Bulbs TT - LH Header Light Test
not operate. UU - RH Header Light Test
Header Work Lights Relay SS - Header Work Lights Relay Test
LH and RH Cab Outer Work Bulbs XX - LH Cab Outer Work Light Test
Lights do not operate. ZZ - RH Cab Outer Work Light Test
Cab Roof Work Lights Relay VV - Cab Roof Work Lights Relay
Test
LH and RH Cab Mid Work Bulbs YY - LH Cab Mid Work Light Test
Lights do not operate. AAA - RH Cab Mid Work Light
Relay Test
Cab Roof Work Lights Relay VV - Cab Roof Work Lights Relay
Test
LH and RH Cab Inner Work Bulbs DDD - LH Cab Inner Work Light
Lights do not operate. Test
EEE - RH Cab Inner Work Light
Test
Distance Work Lights Relay BBB - Distance Work Lights Relay
Test
55-67
EXTERIOR LIGHTING SYSTEM DIAGNOSTIC TESTS

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) or an
unpowered test light for these tests.
CAUTION
WARNING
A - HAZARD SWITCH TEST

1 Measure for 12V at Hazard 12 volts Open circuit 40 (RD) or 54 (RD)
Switch S-25 connector X259 If good reading, go to test between Hazard Switch S-25
(pin 2). point 3. connector X259 (pin 2) and Fuse
#56.
Short to ground between Hazard
Switch S-25 connector X259 (pin 2)
and Fuse #56. A short to ground will
blow Fuse #56.
2 Disconnect the Flasher 12 volts Short to ground in circuit 102 (RD)
Module. If good reading, check between Flasher Module A-05
Measure for 12V at Hazard Flasher Module. connector X255 (pin 1) and Fuse
Switch S-25 connector X259 #56.
(pin 2). A short to ground will blow Fuse
#56.
3 Place Hazard Switch S-25 in 12 volts Hazard Switch S-25.
the closed position. If good reading, go to next
Measure for 12V at Hazard test point.
Switch S-25 connector X259
(pin 3).
4 Measure for 12V at Hazard 12 volts Hazard Switch S-25.
Switch S-25 connector X259 If good reading, go to next
(pin 9). test point.
5 Place Hazard Switch S-25 in Less than 1 ohm. Open circuit 220 (BK) or 219 (BK)
the open position. between Hazard Switch S-25
Measure resistance from connector X259 (pin 9) and ground.
Hazard Switch S-25 connector
X259 (pin 9) to ground.
55-68
B - FLASHER MODULE TEST

1 Measure for 12 volts at 12 volts Open in power feed circuit between
Flasher Module A-05 If good reading, go to next Flasher Module A-05 connector X255
connector X255 (pin 1). test point. (pin 1) and Fuse #56. Short to ground
between Flasher Module A-05
connector X255 (pin 1) and Fuse #56
(see test A-Hazard Switch Test, steps
1-4). A short to ground will blow Fuse
#56.
2 Close the Hazard Switch 12 volts Open in circuit 207 (PU) or 179 (PU)
S-25. Measure for 12 volts If good reading, go to next between Flasher Module A-05
at Flasher Module A-05 test point. connector X255 (pin 2) and Hazard
connector X255 (pin 2). Switch S-25 (pin 3).
Perform Hazard Switch Test.
3 Place Road Light Switch in 12 volts Perform Road Light Switch Test.
“LEFT” turn position. If good reading, go to next
Measure for 12 volts at the test point.
Road Light Switch S-26
4 Measure for 12 volts at 12 volts Open in circuit 201 (PU) or 203 (PU)
Flasher Module A-05 If good reading, go to next between Flasher Module A-05
connector X255 (pin 7). test point. connector X255 (pin 7) and Road Light
Switch S-26 connector X256 (pin 2).
5 Place Road Light Switch in 12 volts Perform Road Light Switch Test.
“RIGHT” turn position. If good reading, go to next
Measure for 12 volts at the test point.
Road Light Switch S-26
6 Measure for 12 volts at 12 volts Open in circuit 197 (PU) or 202 (PU)
Flasher Module A-05 If good reading, go to next between Flasher Module A-05
connector X255 (pin 8). test point. connector X255 (pin 8) and Road Light
Switch S-26 connector X256 (pin 3).
7 Disconnect the Flasher Less than 1 ohm. Open in circuit 141 (BK) between the
Module A-05. Flasher Module A-05 connector X255
Measure resistance on (pin 6) and ground.
circuit 141 (BK) between
Flasher Module A-05
ground.
8 Reconnect the Flasher 0 to 12 volts Flasher Module A-05.
Module A-05. If good reading, go to test Short to ground on circuit 199 (PU), 200
Place Hazard Switch S-25 point 13. (PU), 195 (PU) or 196 (PU) between
in the “ON” position. Flasher Module A-05 connector X255
Measure for voltage at (pins 3 and 4) and Turn Indicator E-09
Flasher Module A-05 and flashing lamps.
connector X255 (pins 3 Go to next test point.
and 4).
55-69

9 Disconnect the Flasher LH flashing lamps Short to ground will blow Fuse #56.
Module A-05. illuminate. Repair short to ground.
Place a jumper wire across If good reading, go to next
pins 1 and 4 of the Flasher test point.
Module A-05 connector
X255.
10 Disconnect the Flasher RH flashing lamps Short to ground will blow Fuse #56.
Module A-05. illuminate. Repair short to ground.
Place a jumper wire across If good reading, go to next
pins 1 and 3 of the Flasher test point.
Module A-05 connector
X255.
11 Reconnect the Flasher 0 to 12 volts Open circuit 199 (PU) or 196 (PU)
Module A-05. If good reading, go to next between Flasher Module A-05
Place Hazard Switch S-25 test point. connector X255 (pins 3 and 4) and Turn
in the “ON” position. Indicator E-09 connector X257 (pins
7and 10).
Measure for voltage at Turn
Indicator E-09 connector
X257 (pins 7 and 10).
12 Measure resistance on Less than 1 ohm. Turn Indicator E-09
circuit 209 (BK) between Open in circuit 141 (BK) between the
Turn Indicator E-09 Flasher Module A-05 connector X255
connector X257 (pin 9) and If good reading, go to next (pin 6) and ground.
ground. test point.
13 Measure 12 volts at 12 volts Flasher Module A-05.
Flasher Module A-05 If good reading, go to text Short to ground on circuit 208 (PU)
connector X255 (pin 5). point 16. between Flasher Module A-05
connector X255 (pin 5) and High Beam
Indicator E-10 connector X258 (pin 7).
14 Disconnect the Flasher High Beam Indicator E-10 Short to ground on circuit 208 (PU) will
Module A-05. illuminates. blow Fuse #56.
Place a jumper wire across If good reading, go to next Repair short to ground between Flasher
pins 1 and 5 of the Flasher test point. Module A-05 connector X255 (pin 5)
Module A-05 connector and High Beam Indicator E-10
X255. connector X258 (pin 7).
15 Measure resistance on Less than 1 ohm Open circuit 221 (BK) between High
circuit 221 (BK) between If good reading, check High Beam Indicator E-10 connector X258
High Beam Indicator E-10 Beam Indicator E-10. (pin 9) and ground.
ground.
16 Place Hazard Switch S-25 0 to 12 volts Flasher Module A-05.
in the “ON” position. If good reading, go to test Short to ground on circuit 243 (PU)
Measure the voltage at point 17. between Flasher Module A-05
Flasher Module A-05 connector X255 (pin 10) and LH NASO
connector X255 (pin 10). Flashing Lamp E-07 connector X242
(pin A).
55-70

17 Disconnect the Flasher LH NASO Flashing Lamp Short to ground on circuit 243 (PU) will
Module A-05. E-07 illuminates. blow Fuse #56.
Place a jumper wire across If good reading, go to next Repair short to ground on circuit 243
pins 1 and 10 of the test point. (PU) between Flasher Module A-05
Flasher Module A-05 connector X255 (pin 10) and LH NASO
connector. Flashing Lamp E-07 connector X242
(pin A).
18 Measure the voltage at 0 to 12 volts Flasher Module A-05.
Flasher Module A-05 Short to ground on circuit 244 (PU)
connector X255 (pin 11). between Flasher Module A-05
connector X255 (pin 11) and RH NASO
Flashing Lamp E-08 connector X245
(pin A).
19 Disconnect the Flasher RH NASO Flashing Lamp Short to ground on circuit 244 (PU) will
Module A-05. E-09 illuminates. blow Fuse #56.
Place a jumper wire across If good reading, replace the Repair short to ground on circuit 244
pins 1 and 11 of the Flasher Module A-05. (PU) between Flasher Module A-05
Flasher Module A-05 connector X255 (pin 11) and RH NASO
connector X255. Flashing Lamp E-08 connector X245
(pin A).
C - LH NASO FLASHING LAMP TEST

1 Place Hazard Switch S-25 0 to 12 volts Open circuit 243 (PU) between Flasher
in the “ON” position. Module A-05 connector X255 (pin 10)
Measure the voltage at LH and LH NASO Flashing Lamp E-07
NASO Flashing Lamp If good reading, go to test connector X242 (pin A).
E-07, connector X242 point 2. Short to ground on circuit 243 (PU)
terminal A. between Flasher Module A-05
connector X255 (pin 10) and LH NASO
Flashing Lamp E-07 connector X242
(pin A).
See Test B- Flasher Module A-05 step
16.
2 Disconnect the LH NASO Less than 1 ohm. Open circuit 679 (BK) between LH
Flashing Lamp E-07. If good reading, replace NASO Flashing Lamp E-07 connector
Measure resistance on the bulb. X242 (pin B) and ground.
LH NASO Flashing Lamp
E-07 connector X242 (pin
B) and ground.
55-71
D - RH NASO FLASHING LAMP TEST

in the “ON” position. Module A-05 connector X255 (pin 11)
Measure the voltage at RH and RH NASO Flashing Lamp E-08
NASO Flashing Lamp If good reading, go to test connector X245 (pin A).
E-08, connector X245 point 2. Short to ground on circuit 244 (PU)
terminal A. between Flasher Module A-05 connector
X255 (pin 11) and RH NASO Flashing
Lamp E-08 connector X245 (pin A).
See Test B- Flasher Module A-05 step 18.
2 Disconnect the RH NASO Less than 1 ohm. Open circuit 680 (BK) between RH
Flashing Lamp E-08. If good reading, replace NASO Flashing Lamp E-08 connector
Measure resistance on the bulb. X245 (pin B) and ground.
RH NASO Flashing Lamp
E-08, connector X245 (pin
B) and ground.
E - LH HEADER FLASHING LAMP TEST

1 Place Hazard Switch S-25 0 to12 volts Open circuit 613 (PU) between Flasher
in the “ON” position. Module A-05 connector X255 (pin 3) and
LH Header Flashing Lamp E-01
If good reading, go to next connector X303 (pin A).
Measure the voltage at LH test point. Short to ground on circuit 613 (PU)
Header Flashing Lamp between Flasher Module A-05 connector
E-01 connector X303 (pin X255 (pin 3) and LH Header Flashing
A). Lamp E-01 connector X303 (pin A).
See text B-Flasher Module Test step 8.
2 Disconnect the LH Header Less than 1 ohm. Open in circuit 775 (BK) or 776 (BK)
Flashing Lamp E-01. If good reading, replace between LH Header Flashing Lamp E-01
Measure the resistance on the bulb. connector X303 (pin B) and ground.
circuit 775 (BK) and 776
(BK) between the LH
Header Flasher Lamp E-01
connector X303 (pin B) and
ground.
55-72
F - RH HEADER FLASHING LAMP TEST

1 Place Hazard Switch S-25 0 to12 volts Open circuit 618 (PU) between Flasher
RH Header Flashing Lamp E-02
If good reading, go to next connector X304 (pin A).
Measure the voltage at RH test point. Short to ground on circuit 613 (PU)
Header Flashing Lamp between Flasher Module A-05 connector
E-02 connector X304 (pin X255 (pin 4) and RH Header Flashing
A). Lamp E-02 connector X304 (pin A).
See text B-Flasher Module Test step 8.
2 Disconnect the RH Header Less than 1 ohm. Open in circuit 775 (BK) or 776 (BK)
Flashing Lamp E-02. If good reading, replace between RH Header Flashing Lamp
Measure the resistance on the bulb. E-02 connector X304 (pin B) and
circuit 775 (BK) and 776 ground.
(BK) between the RH
Header Flasher Lamp E-02
ground.
G - LH FRONT HAZARD LAMP TEST

Measure the voltage at LH LH Front Hazard Lamp E-03 connector
Front Hazard Lamp E-03 X357 (pin A).
connector X357 (pin A). If good reading, go to next Short to ground on circuit 615 (PU)
test point. between Flasher Module A-05 (pin 3)
and LH Front Hazard Lamp E-03 (pin A).
See Test B-Flasher Module Test step 8.
2 Disconnect the LH Front Less than 1 ohm. Open in circuit 620 (BK) between LH
Hazard Lamp E-03. Front Hazard Lamp E-03 connector
Measure the resistance on If good reading, replace X357 (pin C) and ground.
circuit 620 (BK) between the hazard bulb of the LH
LH Front Hazard Lamp Front Hazard Lamp E-03.
C) and ground.
55-73
H - RH FRONT HAZARD LAMP TEST

Measure the voltage at RH RH Hazard Lamp E-04 connector X356
Front Hazard Lamp E-04 (pin A).
connector X356 (pin A). If good reading, go to next Short to ground on circuit 616 (PU)
test point. between Flasher Module A-05 connector
X255 (pin 4) and
RH Front Hazard Lamp E-04 connector
X356 (pin A).
See Test B-Flasher Module Test step 8.
2 Disconnect the RH Front Less than 1 ohm. Open in circuit 621 (BK) between RH
circuit 621 (BK) between the hazard bulb of the RH
RH Front Hazard Lamp Front Hazard Lamp E-04.
E-04 connector X356
(pin C) and ground.
I - LH FRONT HAZARD LAMP (MARKER BULB)

1 Turn Road Light Switch 12 volts Perform Road Light Switch Test.
S-26 to Marker Lights If good reading, go to next
position. Measure for 12 test point.
volts at Fuse #20.
2 Measure for 12 volts at LH 12 volts Open circuit 624 (PU) between Fuse #20
Front Hazard Lamp E-03 and LH Front Hazard Lamp E-03
connector X357 (pin B). If good reading, go to next connector X357 (pin B).
test point. Short to ground on circuit 624 (PU) and
177 (PU) between Fuse #20 and LH
Front Hazard Lamp E-03 connector
X357 (pin B). Any short to ground will
blow the Fuse #20.
circuit 620 (BK) between the marker bulb of the LH
LH Front Hazard Lamp Front Hazard Lamp E-03.
E-03 connector X357
(pin C) and ground.
55-74
J - RH FRONT HAZARD LAMP (MARKER BULB)

position. Measure for 12 test point.
volts at Fuse #21.
2 Measure for 12 volts at RH 12 volts Open circuit 627 (PU) between Fuse #21
Front Hazard Lamp E-04 and RH Front Hazard Lamp E-04
connector X356 (pin B). If good reading, go to next connector X356 (pin B).
test point. Short to ground on circuit 627 (PU) and
176 (PU) between Fuse #21 and RH
Front Hazard Lamp E-04 connector
X356 (pin B). Any short to ground will
blow the Fuse #21.
circuit 621 (BK) between the marker bulb of the RH
RH Front Hazard Lamp Front Hazard Lamp E-04.
E-04 connector X356
(pin C) and ground.
K- LH REAR FLASHING LAMP TEST

LH Rear Flashing Lamp E-05 connector
X301 (pin 1).
Measure the voltage at LH If good reading, go to test Short to ground on circuit 619 (PU)
Rear Flashing Lamp E-05 point 2. between Flasher Module A-05 connector
connector X301 (pin 1). X255 (pin 3) and LH Rear Flashing
Lamp E-05 connector X301 (pin 1).
See test B-Flasher Module Test step 8.
2 Disconnect the LH Rear Less than 1 ohm. Open in circuit 634 (BK) between LH
Flashing Lamp E-05. Rear Flashing Lamp E-05 connector
Measure the resistance on If good reading, replace X301 (pin 2) and ground.
circuit 634 (BK) between the bulb.
LH Rear Flashing Lamp
E-05 connector X301
(pin 2) and ground.
55-75
L - RH REAR FLASHING LAMP TEST

in the “ON” position. Module A-05 (pin 3) and RH Rear Flashing
Lamp E-06 connector X302 (pin 1).
If good reading, go to test Short to ground on circuit 622 (PU)
Measure the voltage at RH point 2. between Flasher Module A-05 connector
Rear Flashing Lamp E-06 X255 (pin 3) and RH Rear Flashing
connector X302 (pin 1). Lamp E-06 connector X302 (pin 1).
See test B-Flasher Module Test step 8.
2 Disconnect the RH Rear Less than 1 ohm. Open in circuit 635 (BK) between RH
Flashing Lamp E-06. Rear Flashing Lamp E-06 connector
Measure the resistance on If good reading, replace X302 (pin 2) and ground.
circuit 635 (BK) between the bulb.
RH Rear Flashing Lamp
E-06 connector X302
(pin 2) and ground.
M - LH BRAKE/TAIL LAMP TEST (MARKER BULB)

position. test point.
Measure for 12 volts at
Fuse #20.
2 Measure for 12 volts at LH 12 volts Open circuit 412 (PU) between Fuse #20
Brake/Tail Lamp E-11 and LH Brake/Tail Lamp E-11 connector
connector X299 (pin 3). X299 (pin 3).
Short to ground in circuit 412 (PU), 625
If good reading, go to next (PU) and 177 (PU) between Fuse #20
test point. and LH Brake/Tail Lamp E-11 connector
X299 (pin 3). Any short to ground will
blow the Fuse #20.
3 Disconnect the LH Less than 1 ohm. Open circuit 634 (BK) between LH
Brake/Tail Lamp E-11. Brake/Tail Lamp E-11 connector X299
(pin 2) and ground.
Measure the resistance on If good reading, replace
circuit 634 (BK) between the marker bulb of the LH
LH Brake/Tail Lamp E-11 Brake/Tail Lamp E-11.
ground.
55-76
N - RH BRAKE/TAIL LAMP TEST (MARKER BULB)

position. test point.
Measure 12 volts at Fuse
#21.
2 Measure for 12 volts at RH 12 volts Open circuit 421 (PU) between Fuse #21
Brake/Tail Lamp E-12 and RH Brake/Tail Lamp E-12 connector
connector X300 (pin 3). X300 (pin 3).
If good reading, go to next Short to ground in circuit 421 (PU), 626
test point. (PU) and 176 (PU) between Fuse #21
and RH Brake/Tail Lamp E-12 connector
blow the Fuse #21.
3 Disconnect the RH Less than 1 ohm. Open in circuit 635 (BK) between RH
(pin 2) and ground.
circuit 635 (BK) between the marker bulb of the RH
RH Brake/Tail Lamp E-12 Brake/Tail Lamp.
ground.
O - LH BRAKE/TAIL LAMP TEST (BRAKE BULB)

1 Place Key Switch S-02 in 12 volts Perform Brake Light Relay Test.
“ON” position. If good reading, go to next
Depress brake pedal. test point.
Brake Light Relay K-33
(pin 5).
2 Depress brake pedal. 12 volts Open circuit 629 (PU) between Brake
Measure for 12 volts at LH Light Relay K-33 (pin 5) and LH
Brake/Tail Lamp E-11 Brake/Tail Lamp E-11 connector X299
connector X299 (pin 1). (pin 1).
If good reading, go to next Short to ground on circuit 629 (PU)
test point. between Brake Light Relay K-33 (pin 5)
and LH Brake/Tail Lamp E-11 connector
blow the Fuse #52.
3 Disconnect the LH Less than 1 ohm. Open in circuit 634 (BK) between LH
(pin 2) and ground.
circuit 634 (BK) between the brake bulb of the LH
LH Brake/Tail Lamp E-11 Brake/Tail Lamp E-12.
ground.
55-77
P - RH BRAKE/TAIL LAMP TEST (BRAKE BULB)

1 Place Key Switch S-02 in 12 volts Perform Brake Light Relay Test.
Depress brake pedal. test point.
Brake Light Relay K-33
(pin 5).
2 Depress brake pedal. 12 volts Open circuit 630 (PU) between Brake
Measure for 12 volts at RH Light Relay K-33 (pin 5) and RH
Brake/Tail Lamp E-12 Brake/Tail Lamp E-12 connector X300
test point. between Brake Light Relay K-33 (pin 5)
and RH Brake/Tail Lamp E-12 connector
blow the Fuse #52.
3 Disconnect the RH Less than 1 ohm. Open circuit 635 (BK) between RH
Measure the resistance on If good reading, replace (pin 2) and ground.
circuit 635 (BK) between the brake bulb of the RH
RH Brake/Tail Lamp E-12 Brake/Tail Lamp E-12.
ground.
55-78
Q - ROAD LIGHT SWITCH TEST

1 Measure for 12 volts at 12 volts Open or short to ground on circuit 213
Road Light Switch S-26 If good reading, go to test (RD) between Road Light Switch S-26
connector X256 (pin 5). point 3. connector X256 (pin 5) and Fuse #51.
A short to ground will blow Fuse #51.
2 Disconnect Road Light 12 volts Open or short to ground on circuit 213
Switch S-26. (RD) between Road Light Switch S-26
Measure for 12 volts at If good reading, replace connector X256 (pin 5) and Fuse #51.
Road Light Switch S-26 Road Light Switch. A short to ground will blow Fuse #51.
3 Reconnect Road Light 12 volts Open or short to ground on circuit 214
Switch S-26. If good reading, go to test (RD) between Road Light Switch S-26
Measure for 12 volts at point 5. connector X256 (pin 8) and Fuse #51.
Road Light Switch S-26 A short to ground will blow Fuse #51.
connector (pin 8).
Switch S-26. (RD) between Road Light Switch S-26
Measure for 12 volts at If good reading, replace connector X256 (pin 5) and Fuse #51.
Road Light Switch S-26 Road Light Switch. A short to ground will blow Fuse #51.
5 Place Key in “ON” position. 12 volts Open or short to ground on circuit 96
Measure for 12 volts at If good reading, go to test (OR) or 55 (OD) between Road Light
Road Light Switch S-26 point 7. Switch S-26 connector X256 (pin 6) and
connector X256 (pin 6). Key Switch S-02 connector X068 (pin 6).

Switch S-26. (OR) or 55 (OD) between Road Light
Measure for 12 volts at If good reading, replace Switch S-26 connector X256 (pin 6) and
Road Light Switch S-26 Road Light Switch. Key Switch S-02 connector X068 (pin 6).
7 Place Key in “ON” position 0 to 12 volts Road Light Switch S-26
and Road Light Switch If good reading, go to next Short to ground on circuit 197 (PU)
S-26 in the “RIGHT” turn test point. between Road Light Switch S-26
position. connector X256 and CCM1 (pin J1-2)
Measure for 12 volts at and Flasher Module A-05 connector
Road Light Switch S-26 X255 (pin 8).
8 Place Key in “ON” position 0 to 12 volts Road Light Switch S-26
and Road Light Switch If good reading, go to next Short to ground on circuit 201 (PU)
S-26 in the “LEFT” turn test point. between Road Light Switch S-26
position. connector X256 (pin 2) and CCM1 (pin
Measure for 12 volts at J1-9) and Flasher Module A-05
Road Light Switch S-26 connector X255 (pin 7).
55-79

9 Place Road Light Switch 12 volts Road Light Switch S-26.
S-26 in the “High Beam” If good reading, Road Short to ground on circuits 218 (YE), 43
position. Light Switch S-26 is (YE) and 191 (YE) between Road Light
Measure voltage at Road working properly. Switch S-26 connector X256 (pin 4) and
Light Switch S-26 Go to next text point. High Beam Relay K-04 (pin 1) or High
connector X256 (pin 4). Beam Indicator.

S-26 in the “Hazard” If good reading, Road Short to ground on circuit 173 (OR)
position. Light Switch S-26 is between Road Light Switch S-26
Measure voltage at Road working properly. connector X256 (pin 1) and K-02 Light
Light Switch S-26 Go to next text point. Control Relay (pin 5).
connector X256 (pin 1). A short to ground will blow Fuse #51.
S-26 in the “Low Beam” Short to ground on circuits 169 (YE)
position. If good reading, Road between Road Light Switch S-26
Measure voltage at Road Light Switch S-26 is connector X256 (pin 7) and Low Beam
Light Switch S-26 working properly. Relay K-05 (pin 1).
connector X256 (pin 7). A short to ground will blow Fuse #51.
R - LOW BEAM RELAY TEST

1 Turn Road Light Switch S-26 12 volts Low Beam Relay K-05.
to “Low Beam” position.
Measure for 12 volts at Low If good reading, relay is
Beam Relay K-05 (pin 5). functioning properly. Adjacent circuits.

2 Turn Road Light Switch S-26 12 volts Open or short to ground in circuit 169
to “Low Beam” position. (YE) between Low Beam Relay K-05
(pin 1) and Road Light Switch S-26
Measure for 12 volts at Low If good reading, go to next A short to ground will blow the Fuse
Beam Relay K-05 (pin 1). test point. #51.
Road Light Switch S-26.
3 Measure for 12 volts at Low 12 volts Open circuit 236 (RD) between Low
Beam Relay K-05 (pin 3). Beam Relay K-05 (pin 3) and Fuse
#33.
If good reading, go to next A short to ground will blow the Fuse
test point. #33.
4 Disconnect the Low Beam Less than 1ohm. Open in circuit 156 (BK) between Low
Relay K-05. Beam Relay K-05 (pin 2) and ground.
Measure resistance on If good reading, replace
circuit 156 (BK) between Low Beam Relay K-05.
Low Beam Relay K-05
(pin 2) and ground.
55-80
S - HIGH BEAM RELAY TEST

1 Turn Road Light Switch S-26 12 volts High Beam Relay K-04.
to “High Beam” position.
Measure for 12 volts at High If good reading, relay is Adjacent circuits.
Beam Relay K-04 (pin 5). functioning properly.
2 Turn Road Light Switch S-26 12 volts Open or short to ground in circuit 191
to “High Beam” position. (YE) or 218 (YE) between High Beam
Relay K-04 (pin 1) and Road Light
Switch S-26 connector X256 (pin 4). A
Measure for 12 volts at High If good reading, go to next short to ground will blow the Fuse #51.
Beam Relay K-04 (pin 1). test point. Road Light Switch S-26.
3 Measure for 12 volts at High 12 volts Open circuit 185 (RD) between High
Beam Relay K-04 (pin 3). Beam Relay K-04 (pin 3) and Fuse
#32.
If good reading, go to next A short to ground will blow the Fuse
test point. #32.
4 Disconnect the High Beam Less than 1ohm. Open in circuit 192 (BK) between High
Relay K-04. Beam Relay K-04 (pin 2) and ground.

circuit 192 (BK) between the High Beam Relay
High Beam Relay K-04 K-04.
(pin 2) and ground.
T - LH ROAD LIGHT TEST (LOW BEAM BULB)

1 Turn Road Light Switch 12 volts Perform Low Beam Relay Test.
S-26 to “Low Beam”
position.
Measure for 12 volts at If good reading, go to next

Low Beam Relay K-05 test point.
(pin 5).
2 Measure the voltage at LH 12 volts Open circuit 237 (PU) or 638 (PU)
Road Light E-13 connector between Low Beam Relay K-05 (pin 5)
X164 (pin B). If good reading, go to next and LH Road Light E-13 connector X164
test point. (pin B).
3 Disconnect the LH Road Less than 1 ohm. Open in circuit 642 (BK) between LH
Light E-13. Road Light E-13 connector X164 (pin C)
and ground.
circuit 642 (BK) between the low beam bulb of the
LH Road Light E-13 LH Road Light E-13.
connector X164 (pin C) and
ground.
55-81
U - RH ROAD LIGHT TEST (LOW BEAM BULB)

1 Turn Road Light Switch 12 volts Perform Low Beam Relay Test.
S-26 to “Low Beam”
position.

Low Beam Relay K-05 test point.
(pin 5).
2 Measure the for 12 volts at 12 volts Open circuit 237 (PU) or 639 (PU)
RH Road Light E-14 between Low Beam Relay K-05 (pin 5)
connector X169 (pin B). If good reading, go to next and RH Road Light E-14 connector X169
test point. (pin B).
3 Disconnect the RH Road Less than 1 ohm. Open in circuit 643 (BK) between RH
and ground.
circuit 643 (BK) between the low beam bulb of the
RH Road Light E-14 RH Road Light E-14.
connector X169 (pin C)
and ground.
V - LH ROAD LIGHT TEST (HIGH BEAM BULB)

1 Turn Road Light Switch 12 volts Perform High Beam Relay Test.
S-26 to “High Beam”
position.

High Beam Relay K-04 test point.
(pin 5).
Road Light E-13 connector between High Beam Relay K-04 (pin 5)
X164 (pin A). If good reading, go to next and LH Road Light E-13 connector X164
test point. (pin A).
3 Disconnect the LH Road Less than 1 ohm. Open in circuit 642 (BK) between LH
and ground.
circuit 642 (BK) between the High beam bulb of the
LH Road Light E-13 LH Road Light E-13.
and ground.
55-82
X - RH ROAD LIGHT TEST (HIGH BEAM BULB)

1 Turn Road Light Switch 12 volts Perform High Beam Relay Test.
S-26 to “High Beam”
position.

High Beam Relay K-04 test point.
(pin 5).
2 Measure the voltage at RH 12 volts Open circuit 186 (PU) or 641 (PU)
Road Light E-14 connector If good reading, go to next between High Beam Relay K-04 (pin 5)
X169 (pin A). test point. and RH Road Light E-14 connector X169
(pin “A).
3 Disconnect the RH Road Less than 1 ohm. Open in circuit 643 (BK) between RH
and ground.
circuit 643 (BK) between the High beam bulb of the
RH Road Light E-14 RH Road Light E-14.
and ground.
Y - BRAKE LIGHTS RELAY TEST

1 Depress brake pedal. 12 volts Brake Lights Relay K-33.
Measure for 12 volts at If good reading, the relay Adjacent circuits.
Brake Lights Relay K-33 is OK. Go to next test point.
(pin 5).
2 Depress brake pedal. 12 volts Open or short to ground in circuit 183

(WH) between Brake Lights Relay K-33
Measure for 12 volts at If good reading, go to next (pin 1) and CCM2 connector X015
Brake Lights Relay K-33 test point. (pin J1-18).
(pin 1). See Service manual for testing of CCM.
3 Measure for 12 volts at 12 volts Open circuit 56 (RD) between Brake
Brake Lights Relay K-33 If good reading, go to next Lights Relay K-33 (pin 3) and Fuse #52.
(pin 3). test point.
Short to ground on circuit 78 (PU)
between Brake Lights Relay K-33
(pin 5) and Brake Lamps.
A short will cause Fuse #52 to blow.
4 Disconnect the Brake Less than 1 ohm. Open circuit 159 (BK) between Brake
Lights Relay K-33. Lights Relay K-33 (pin 2) and ground.
Measure resistance on If good reading, go to next

circuit 159 (BK) between test point.
Brake Lights Relay K-33
(pin 2) and ground.
55-83
Z - REAR WORK LIGHTS RELAY TEST

1 Place Key Switch S-02 in 12 volts Rear Work Lights Relay K-31.
“ON” position.
Close Rear Work Light Switch Adjacent circuits.
S-44.
Measure for 12 volts at Rear If good reading, the relay Go to next test point.
Work Lights Relay K-31 (pin 5). is operating properly.
2 Measure for 12 volts at Rear 12 volts Open or short circuit 184 (WH)
Work Lights Relay K-31 (pin 1). between Rear Work Lights Relay K-31
If good reading, go to next (pin 1) and CCM1 connector X018
test point. (pin J1-18).
See Service Manual for testing of CCM.
3 Measure for 12 volts at Rear 12 volts Open in circuit 66 (RD) between Rear
Work Lights Relay K-31 Work Lights Relay K-31 (pin 3) and
(pin 3). If good reading, go to next Fuse #55.
test point. Short to ground on circuit 67 (PU)
between Rear Work Lights Relay K-31
(pin 5) and Rear Work Lights E-27
and E-28 connector X106 and X110
(pin A).
A short to ground will blow the Fuse
#55.
4 Disconnect the Rear Work Less than 1 ohm. Open circuit 158 (BK) between Rear
Lights Relay K-31. Work Lights Relay K-31 (pin 2) and
ground.
Measure resistance on circuit If good reading, go to next
158 (BK) between Rear Work test point.
Lights Relay K-31 (pin 2) and
ground.
AA - LH REAR WORK LIGHT TEST

1 Place Key Switch S-02 in 12 volts Perform Rear Work Lights Relay Test.
“ON” position.
Close Rear Work Light
Switch S-43.
Rear Work Lights Relay test point.
K-31 (pin 5).
Rear Work Light E-27 If good reading, go to next between Rear Work Lights Relay K-31
connector X106 (pin A). test point. (pin 5) and LH Rear Work Light E-27
connector X106 (pin A).
3 Disconnect the LH Rear Less than 1 ohm. Open in circuit 661 (BK) between LH
Work Light E-27. Rear Work Light E-27 connector X106
(pin B) and ground.
Measure the resistance of If good reading, replace
circuit 661 (BK) between the Rear Work Lights bulb
LH Rear Work Light E-27 of the LH Rear Work Light
connector X106 (pin B) and E-27.
ground.
55-84
BB - RH REAR WORK LIGHT TEST

1 Place Key Switch S-02 in 12 volts Perform Rear Work Lights Relay Test.
“ON” position.
Close Rear Work Light
Switch S-44.
Rear Work Lights Relay test point.
K-31 (pin 5).
2 Measure the voltage at RH 12 volts Open circuit 653 (PU) or 67 (PU)
Rear Work Light E-28 If good reading, go to next between Rear Work Lights Relay K-31
connector X110 (pin A). test point. (pin 5) and RH Rear Work Light E-28
3 Disconnect the RH Rear Less than 1 ohm. Open in circuit 662 (BK) between RH
Work Light E-28. Rear Work Light E-28 connector X110
(pin B) and ground.
Measure the resistance of If good reading, replace
circuit 662 (BK) between the Rear Work Lights bulb
RH Rear Work Light E-28 of the RH Rear Work Light
connector X110 (pin B) and E-28.
ground.
CC - BEACON LIGHT RELAY TEST

1 Place Key Switch S-02 in 12 volts Beacon Light Relay K-29.
“ON” position.
Close Beacon Light Switch If good reading, the relay Adjacent circuits.
S-41. is operating properly.
Measure for 12 volts at Go to next test point.
Beacon Light Relay K-29
(pin 5).
2 Measure for 12 volts at 12 volts Open or short to ground in circuit
Beacon Light Relay K-29 If good reading, go to next between Beacon Light Relay K-29 (pin 1)
(pin 1). test point. and CCM2 connector X015 (pin J1-24).
3 Measure for 12 volts at 12 volts Open in circuit 69 (RD) between Beacon
Beacon Light Relay K-29 If good reading, go to next Light Relay K-29 (pin 3) and Fuse #53.
(pin 3). test point. Short to ground on circuit 578 (PU)
between Beacon Light Relay K-29 (pin
5) and Rear Beacon Light E-33
4 Disconnect the Beacon Less than 1 ohm. Open circuit 160 (BK) between Beacon
Light Relay K-29. If good reading, go to next Light Relay K-29 (pin 2) and ground.
Measure resistance on test point.
(pin 2) and ground.
55-85
DD - REAR BEACON TEST

1 Place Key Switch S-02 in 12 volts Perform Beacon Light Relay Test.
“ON” position.
Close Beacon Light Switch If good reading, go to next
S-41. test point.
(pin 5).
2 Measure the voltage at 12 volts Open circuit 578 (PU) between Beacon
Rear Beacon Light E-33 If good reading, go to next Light Relay K-29 (pin 5) and Rear
connector X247 (pin A). test point. Beacon Light E-33 connector X247
(pin A).
3 Disconnect the Rear Less than 1 ohm. Open circuit 623 (BK) between Rear
Beacon. Beacon Light E-33 connector X247
Measure the resistance on If good reading, replace (pin B) and ground.
circuit 623 (BK) between the Beacon Light bulb of
Rear Beacon Light E-33 the Rear Beacon E-33.
ground.
EE - LH FRONT BEACON TEST

“ON” position.
S-41. test point.
(pin 5).
2 Measure for 12 volts at LH 12 volts Open in circuit 579 (PU) or 663 (PU)
Front Beacon Light E-31 If good reading, go to next between Beacon Light Relay K-29
connector X113 (pin A). test point. (pin 5) and LH Front Beacon Light E-31
Beacon E-31. Front Beacon Light E-31 connector X113
LH Front Beacon Light the LH Front Beacon
E-31 connector X113 E-31.
(pin B) and ground.
55-86
FF - RH FRONT BEACON TEST

“ON” position.
S-41. test point.
(pin 5).
2 Measure for 12 volts at RH 12 volts Open in circuit 579 (PU) or 664 (PU)
Front Beacon Light E-32 If good reading, go to next between Beacon Light Relay K-29
connector X119 (pin A). test point. (pin 5) and RH Front Beacon Light E-32
Beacon E-32. Front Beacon Light E-32 connector X119
RH Front Beacon Light the RH Front Beacon
E-32 connector X119 E-32.
(pin B) and ground.
GG - SIEVE LIGHT SWITCH TEST

1 Measure the voltage at 12 volts Blown Fuse #14
Sieve Light Switch S-54 If good reading, go to next Open circuit 604 (OR) between Sieve
connector X237 (pin 2). test point. Light Switch S-54 connector X237 (pin 2)
and Fuse #14.
Short to ground on circuit 604 (OR)
between Sieve Light Switch S-54
connector X237 (pin 2) and Fuse #14.
A short to ground will blow the Fuse #14.
2 Close Sieve Light Switch 12 volts Sieve Light Switch S-54
S-54. Short to ground in circuit 610 (PU
Measure for 12 volts at If good reading, switch is between Sieve Light Switch S-54
Sieve Light Switch S-54 working properly. connector X237 (pin 3) and Sieve Light
connector X237 (pin 3). E-37 connector X234 (pin A).
A short to ground will blow the Fuse #14.
55-87
HH - SIEVE LIGHT TEST

1 Close Sieve Light Switch 12 volts. Perform Sieve Light Switch Test.
S-54.
Sieve Light Switch S-54 test point.
connector X237 pin 3).
2 Measure for 12 volts at 12 volts Open circuit 610 (PU) between Sieve
Sieve Light E-37 connector If good reading, go to next Light Switch S-54 connector X237 (pin 3)
X234 (pin A). test point. and Sieve Light E-37 connector X234
(pin A).
3 Disconnect the Sieve Light Less than 1 ohm. Open circuit 611 (BK) between Sieve
E-37. Light E-37 connector X234 (pin B) and
Measure the resistance on If good reading, replace ground.
circuit 611 (BK) between the Sieve Light bulb.
Sieve Light E-37 connector
X234 (pin B) and ground.
II - TIMED SIDE WORK LIGHT RELAY TEST

1 Cycle LH Door Switch. 12 volts Timed Side Work Light Relay K-34.
Measure for 12 volts at If good reading, the relay Adjacent circuits.
Timed Side Work Light is operating properly. Go to next test point.
Relay K-34 (pin 5).
2 Cycle LH Door Switch. 12 volts Open or short to ground in circuit 969
Measure for 12 volts at If good reading, go to next (PU) between Time Delay Module K-20
Timed Side Work Light test point. (pin 87) and Timed Side Work Light
Relay K-34 (pin 1). Relay K-34 (pin 1).
Time Delay Module K-20.
See Interior Lights section for testing.
3 Measure for 12 volts at LH 12 volts Open in circuit 73 (RD) between Timed
Side Work Light Relay If good reading, go to next Side Work Light Relay K-34 (pin 3) and
(pin 3). test point. Fuse #50.
Short to ground on circuit 76 (PU) 165

(PU) or 72 (PU) between Timed Side
Work Light Relay K-34 (pin 5) and Side
Work Lights E-25 and E-26 connector
X297 and X298 (pin A).
4 Disconnect the Timed Side Less than 1 ohm. Open in circuit 161 (BK) between Timed
Work Light Relay K-34. Side Work Light Relay K-34 (pin 2) and
Measure the resistance on ground.
Timed Side Work Light
Relay K-34 (pin 2) and
ground.
55-88
JJ - SIDE WORK LIGHT RELAY TEST

1 Place Key Switch S-02 in 12 volts. Side Work Light Relay K-35.
“ON” position.
Close Work Light Switch If good reading, the relay Adjacent circuits.
Side Work Light Relay
K-35 (pin 5).
2 Partially remove Side Work 12 volts Open or short to ground in circuit 180
Light Relay K-35. If good reading, go to next (WH) between Side Work Light Relay
Measure for 12 volts at test point. K-35 (pin 1) and CCM1 connector X018
Side Work Light Relay (pin J1-24).
K-35 (pin 1). See Service Manual for testing of CCM.
3 Measure for 12 volts at 12 volts Open circuit 71 (RD) or 73 (RD) between
Side Work Light Relay If good reading, go to next Side Work Light Relay K-35 (pin 3) and
K-35 (pin 3). test point. Fuse #50.
Short to ground on circuit 72 (PU), 165

(PU) or 76 (PU) between Side Work
Light Relay K-35 (pin 5) and Side Work
Lights E-25 and E-26 connectors X297
and X298 (pin A).
4 Disconnect the Side Work Less than 1 ohm. Open in circuit 161 (BK) between Side
Light Relay K-35. Work Light Relay K-35 (pin 2) and
circuit 162 (BK) between Side Work Light Relay
Side Work Light Relay K-35.
K-35 (pin 2) and ground.
KK - UNLOAD TUBE LIGHT RELAY TEST

1 Place Key Switch S-02 in 12 volts. Unload Tube Light Relay K-32.
“ON” position.
Unload tube must be swung If good reading, the relay Adjacent circuits.
out from its cradle to is operating properly.
activate Unload Tube Light Go to next test point.
Relay K-32.
Unload Tube Light Relay
K-32 (pin 5).
2 Measure for 12 volts at 12 volts Open or short to ground in circuit
Unload Tube Light Relay If good reading, go to test between Unload Tube Light Relay K-32
K-32 (pin 1). point 4. (pin 1) and CCM1 (J1-12).
55-89

3 Ground CCM1 pin J3-36. 12 volts Unload cradle sensor B-38.
Measure for 12 volts at If good reading, go to next Open in circuit 485 (YE) between CCM1
Unload Tube Light Relay test point. (J3-36) and Unload Cradle Sensor B-38
K-03 (pin 1). or between B-38 and ground.
CCM1. See Service Manual for testing of
CCM1.
4 Measure for 12 volts at 12 volts Open in circuit 74 (RD) between Unload
Unload Tube Light Relay Tube Light Relay K-32 (pin 3) and Fuse
K-32 (pin 3). #50.
test point. between Unload Tube Light Relay K-32
(pin 5) and Unload Tube Light E-29
5 Disconnect the Unload Less than 1 ohm. Open in circuit 163 (BK) between Unload
Tube Light Relay K-32. Tube Light Relay K-32 (pin 2) and
circuit 163 (BK) between Unload Tube Light Relay
Unload Tube Light Relay K-32.
LL - TIMED SIDE WORK LIGHT TEST

1 Place Key Switch S-02 in 12 volts. Perform Timed Side Work Light Relay
“ON” position. Test K-34.
Close Work Light Switch If good reading, go to next
S-43. test point.
K-34 (pin 5).
2 Measure for 12 volts at 12 volts Open circuit 76 (PU) between Timed
Timed Side Work Light If good reading, go to next Side Work Lights Relay K-34 (pin 5) and
E-25 connector X297 test point. Timed Side Work Light E-25 connector
(pin A). X297 (pin A).
3 Disconnect the Timed Side Less Than 1 ohm. Open circuit 671 (BK) between Side
Work Light E-25. Work Light E-25 connector X297 (pin B)
Measure the resistance on If good reading, replace and ground.
circuit 671 (BK) between the Timed Side Work Light
Timed Side Work Light bulb.
E-25 connector X297
(pin B) and ground.
55-90
MM - SIDE WORK LIGHT TEST

1 Place Key Switch S-02 in 12 volts. Perform Side Work Light Relay Test
“ON” position. K-35.
S-43. test point.
K-35 (pin 5).
2 Measure for 12 volts at RH 12 volts Open circuit 72 (PU) between Side Work
Side Work Light E-26 If good reading, go to next Lights Relay K-35 (pin 5) and RH Side
connector X298 (pin A). test point. Work Light E-26 connector X298 (pin A).
3 Disconnect the RH Side Less Than 1 ohm. Open circuit 670 (BK) between RH Side
Work Light E-26. Work Light E-26 connector X299 (pin B)
circuit 670 (BK) between the RH Side Work Light
RH Side Work Light E-26 bulb.
ground.
NN - UNLOAD TUBE LIGHT TEST

1 Place Key Switch S-02 in 12 volts. Perform Unload Tube Light Relay Test.
“ON” position.
Unload tube must be If good reading, go to next
swung out of its cradle to test point.
activate Unload Tube Light
Relay K-32.
Unload Tube Relay K-32
(pin 5).
2 Measure for 12 volts at 12 volts Open circuit 77 (PU) between Unload
Unload Tube Light E-29 If good reading, go to next Tube Relay K-32 (pin 5) and Unload
connector X322 (pin A). test point. Tube Light E-29 connector X322 (pin A).
3 Disconnect the Unload Less Than 1 ohm. Open in circuit 669 (BK) between Unload
Tube Light E-29. Tube Light E-29 connector X322 (pin B)
circuit 669 (BK) between the Unload Tube Light
Unload Tube Light E-29 bulb.
ground.
55-91
OO - LOWER WORK LIGHTS RELAY TEST

1 Place Key Switch S-02 in 12 volts. Lower Work Lights Relay.
“ON” position.
Lower Work Lights Relay
K-30 (pin 5).
2 Measure for 12 volts at 12 volts Open or short to ground in circuit 187
Lower Work Lights Relay If good reading, go to next (WH), 188 (WH), 189 (WH) or 117 (WH)
K-30 (pin 1). test point. between Lower Work Lights Relay K-30
(pin 1) and CCM1 (J1-5).
3 Measure for 12 volts at 12 volts Open in circuit 64 (RD) between Lower
Lower Work Lights Relay Work Lights Relay K-30 (pin 3) and Fuse
K-30 (pin 3). #54.
If good reading, go to next Short to ground in circuit 65 (PU), 645
test point. (PU), 644 (PU) or 646 (PU) between
Lower Work Lights Relay K-30 (pin 3)
and Lower Work Lights E-23 and E-24 or
Grain Tank Light E-30.
A short will cause the Fuse #54 to blow.
4 Disconnect the Lower Work Less than 1 ohm. Open in circuit 157 (BK) to Lower Work
Lights Relay K-30. Lights Relay K-30 (pin 2) and ground.
circuit 157 (BK) to Lower Lower Work Lights Relay
Work Lights Relay K-30 K-30.
(pin 2) and ground.
PP - GRAIN TANK LIGHT TEST

1 Place Key Switch S-02 in 12 volts Open circuit 65 (PU) or 646 (PU)
“ON” position. between Lower Work Lights Relay K-30
Measure for 12 volts at If good reading, go to next (pin 5) and Grain Tank Light E-30
Grain Tank Light E-30 test point. connector X108 (pin A).
2 Disconnect the Grain Tank Less than 1 ohm. Open in circuit 681 (BK) or 688 (BK)
Light E-30. between Grain Tank Light E-30
Measure the resistance on If good reading, replace connector X108 (pin 2) and ground.
circuit 681 (BK) between the Grain Tank Light E-30
Grain Tank Light E-30 bulb.
ground.
55-92
QQ - LH LOWER WORK LIGHT TEST

1 Place Key Switch S-02 in 12 volts. Perform Lower Work Lights Relay Test.
“ON” position.
S-43. test point.
Lower Work Light Relay
K-30 (pin 5).
2 Measure for 12 volts at LH 12 volts Open circuit 65 (PU) or 644 (PU)

Lower Work Light E-23 If good reading, go to next between Lower Work Lights Relay K-30
connector X163 (pin A). test point. (pin 5) and LH Lower Work Light E-23
3 Disconnect the LH Lower Less than 1 ohm. Open in circuit 654 (BK) or 676 (BK)
Work Light E-23. between LH Lower Work Light E-23
Measure the resistance on If good reading, replace connector X163 (pin B) and ground.
circuit 654 (BK) between the LH Lower Work Light
LH Lower Work Light E-23 bulb.
ground.
RR - RH LOWER WORK LIGHT TEST

1 Place Key Switch S-02 in 12 volts. Perform Lower Work Lights Relay Test.
“ON” position.
S-43. test point.
Measure for 12 volts at RH
Lower Work Light Relay
K-30 (pin 5).
2 Measure for 12 volts at 12 volts Open circuit 65 (PU) or 645 (PU)
Lower Work Light E-24 If good reading, go to next between Lower Work Lights Relay K-30
connector X168 (pin A). test point. (pin 5) and RH Lower Work Light E-24
3 Disconnect the RH Lower Less than 1 ohm. Open in circuit 655 (BK) or 677 (BK)
Work Light E-24. between RH Lower Work Light E-24
Measure the resistance on If good reading, replace connector X168 (pin B) and ground.
circuit 655 (BK) between the RH Lower Work Light
RH Lower Work Light E-24 bulb.
ground.
55-93
SS - HEADER WORK LIGHTS RELAY TEST

1 Place Key Switch S-02 in 12 volts. Header Work Lights Relay Test.
“ON” position.
Header Work Lights Relay
K-22 (pin 5).
2 Measure for 12 volts at 12 volts Open or short on circuit 188 (WT) or 117
Header Work Lights Relay If good reading, go to next (WH) between Header Work Lights
K-22 (pin 1). test point. Relay K-22 (pin 1) and CCM1 (pin J1-5).
3 Measure for 12 volts at 12 volts Open in circuit 62 (RD) between Header
Header Work Lights Relay If good reading, go to next Work Lights Relay K-22 (pin 3) and Fuse
K-22 (pin 3). test point. #30.
Short to ground in circuit 63 (PU), 258
(PU) or 257 (PU) between Header Work
Lights Relay K-22 (pin 5) and Header
Lights E-21 and E-22 connectors X167
and X162 (pin A).
4 Disconnect the Header Less than 1 ohm. Open circuit 238 (BK) between Header
Work Lights Relay K-22. Work Lights Relay K-22 (pin 2) and
Measure resistance on If good reading, replace ground.
circuit 238 (BK) between Header Work Lights
Header Work Lights Relay Relay.
TT - LH HEADER LIGHT TEST

1 Place Key Switch S-02 in 12 volts. Perform Header Work Lights Relay Test.
“ON” position.
Close Work light Switch If good reading, go to next
S-43. test point.
K-22 (pin 5).
Header Light E-21 If good reading, go to next between Header Work Lights Relay K-22
connector X162 (pin A). test point. (pin 5) and LH Header Light E-21
3 Disconnect the LH Header Less than 1 ohm. Open circuit 267 (BK) between LH
Light E-21. Header Light E-21 connector X162 (pin
Measure the resistance on If good reading, replace B) and ground.
circuit 267 (BK) between the LH Header Light bulb.
LH Header Light E-21
ground.
55-94
UU - RH HEADER LIGHT TEST

1 Place Key Switch S-02 in 12 volts. Perform Header Work Lights Relay Test.
“ON” position.
Close Work light Switch If good reading, go to next
S-43. test point.
K-22 (pin 5).
2 Measure for 12 volts at RH 12 volts Open circuit 63 (PU) or 258 (PU)
Header Light E-22 If good reading, go to next between Header Work Lights Relay K-22
connector X167 (pin A). test point. (pin 5) and RH Header Light E-22
3 Disconnect the RH Header Less than 1 ohm. Open circuit 268 (BK) between RH
Light E-22. Header Light E-22 connector X167 (pin
Measure the resistance on If good reading, replace B) and ground.
circuit 268 (BK) between the RH Header Light bulb.
RH Header Light E-22
ground.
VV - CAB ROOF WORK LIGHTS RELAY TEST

1 Place Key Switch S-02 in 12 volts. Cab Work Lights Relay K-01.
“ON” position.
Cab Roof Work Lights
Relay K-01 (pin 87).
2 Measure for 12 volts at 12 volts Open or short circuit 190 (WH) between
Cab Roof Work Lights If good reading, go to next Cab Roof Work Lights Relay K-01 (pin
Relay K-01 (pin 86). test point. 86) and CCM1 (pin J1-11).
3 Measure for 12 volts at 12 volts Open circuit 22 (RD) between Cab Roof
Cab Roof Work Lights If good reading, go to next Work Lights Relay K-01 (pin 30) and
Relay K-01 (pin 30). test point. Fuse #31.
Short to ground in circuit 23 (OR) or 88
(OR) between Cab Roof Work Lights
Relay K-01 (pin 87) and Mid/Outer Work
Lights E-15, E-16, E-19 and E-20.
4 Disconnect the Cab Roof Less than 1 ohm. Open circuit 154 (BK) between Cab Roof
Work Lights Relay K-01. Work Lights Relay K-01 (pin 85) and
Measure resistance on If good reading, replace ground.
circuit 154 (BK) between Cab Roof Work Lights
Cab Roof Work Lights Relay K-01.
Relay K-01 (pin 85) and
ground.
55-95
XX - LH CAB OUTER WORK LIGHT TEST

1 Place Key Switch S-02 in 12 volts. Perform Cab Roof Work Lights Relay
“ON” position. Test.
S-43. test point.
2 Measure for 12 volts at 12 volts Open circuit 23 (OR) between Fuse #6
Fuse #6, circuit 23 (OR). If good reading, go to next and Cab Roof Work Lights Relay K-01
test point. (pin 87).
3 Measure for 12 volts at LH 12 volts Fuse #6
Cab Outer Work Light E-15 If good reading, go to next Open circuit 58 (PU) or 251 (PU)
connector X112 (pin A). test point. between Fuse #6 and LH Cab Outer
Work Light E-15 connector X112 (pin A).
4 Disconnect the LH Cab Less than 1 ohm. Open circuit 259 (BK) between LH Cab
Outer Work Light E-15. Outer Work Light E-15 connector X112
circuit 259 (BK) between the LH Cab Outer Work
LH Cab Outer Work Light Light bulb.
B) and ground.
YY - LH CAB MID WORK LIGHT TEST

S-43. test point.
3 Measure for 12 volts at LH 12 volts Fuse #6
Cab Mid Work Light E-19 If good reading, go to next Open circuit 58 (PU) or 252 (PU)
connector X114 (pin A). test point. between Fuse #6 and LH Cab Mid Work
Light E-19 connector X114 (pin A).
4 Disconnect the LH Cab Less than 1 ohm. Open circuit 260 (BK) between LH Cab
Mid Work Light E-19. Mid Work Light E-19 connector X114
circuit 260 (BK) between the LH Cab Mid Work Light
LH Cab Mid Work Light E-19 bulb.
E-19 connector X114
(pin B) and ground.
55-96
ZZ - RH CAB OUTER WORK LIGHT TEST

S-43. test point.
3 Measure for 12 volts at RH 12 volts Fuse #7
Cab Outer Work Light E-16 If good reading, go to next Open circuit 59 (PU) or 254 (PU)
connector X120 (pin A). test point. between Fuse #7 and RH Cab Outer
Work Light E-16 connector X120 (pin A).
4 Disconnect the RH Cab Less than 1 ohm. Open circuit 264 (BK) between RH Cab
Outer Work Light E-16. Outer Work Light E-16 connector X120
circuit 264 (BK) between the RH Cab Outer Work
RH Cab Outer Work Light Light E-16 bulb.
B) and ground.
AAA - RH CAB MID WORK LIGHT TEST

S-43. test point.
3 Measure for 12 volts at RH 12 volts Fuse #7
Cab Mid Work Light E-20 If good reading, go to next Open circuit 59 (PU) or 253 (PU)
connector X118 (pin A). test point. between Fuse #7 and RH Cab Mid Work
Light E-20 connector X118 (pin A).
4 Disconnect the RH Cab Less than 1 ohm. Open circuit 263 (BK) between RH Cab
Mid Work Light E-20. Mid Work Light E-20 connector X118
circuit 263 (BK) between the RH Cab Mid Work
RH Cab Mid Work Light Light bulb.
E-20 connector X118
(pin B) and ground.
55-97
BBB - DISTANCE WORK LIGHTS RELAY TEST

1 Place Key Switch S-02 in 12 volts Distance Work Lights Relay K-21.
“ON” position.
Adjacent circuits.
Close Work Light Switch If good reading, the relay is
S-43. operating properly. Go to next test point.

Distance Work Light Relay
K-21 (pin 5).
2 Measure the voltage at 12 volts Open or short circuit 189 (WH) or 190 (WH)
Distance Work Lights Relay between Distance Work Lights Relay K-21
K-21 (pin 1). (pin 1) and CCM1 (pin J1-11).
If good reading, go to next
test point. See Service Manual for testing of CCM.
3 Measure for 12 volts at 12 volts Open circuit 60 (RD) between Distance
Distance Work Lights Relay Work Lights Relay K-21 (pin 3) and Fuse
K-21 (pin 3). If good reading, go to next #29.
test point.
4 Disconnect the Distance Less than 1 ohm. Open circuit 155 (BK) between Distance
Work Lights Relay K-21. Work Lights Relay K-21 (pin 2) and ground.

circuit 155 (BK) between Distance Work Lights Relay
Distance Work Lights Relay K-21.
55-98
CCC - ROAD LIGHTS RELAY TEST

1 Place Key Switch S-02 in 12 volts Road lights Relay K-27.
“ON” position.
Adjacent circuits.
Road/Field Mode Switch If good reading, the relay is
S-12 in “Field” position. operating properly. Go to next test point.
Hazard Lights Switch in
“OFF” position.
Close Work Light Switch

S-43.
Measure for 12 volts at Road

Lights Relay K-27 (pin 5).
2 Measure the voltage at Road 12 volts Open or short circuit 117 between Road
Lights Relay K-27 (pin 1). Lights Relay K-27 (pin 1) and CCM1 (pin
J1-5).
If good reading, go to next See Service Manual for testing of CCM.
test point.
3 Measure for 12 volts at Road 12 volts Distance Work Lights Relay K-21. Perform
Lights Relay K-27 (pin 3). Distance Work Lights Relay Test.
If good reading, go to next
test point. Open circuit 60 (RD) between Distance
Work Lights Relay K-21 (pin 3) and Fuse
#29.
Open circuit on short to ground on circuit 21

(PU) between Distance Work Lights Relay
K-21 (pin 5) and Road Lights Relay K-27
(pin 3).

4 Disconnect the Road Lights Less than 1 ohm. Open circuit 518 (BK) between Road
Relay K-27. Lights Relay K-27 (pin 2) and ground.
Measure the resistance in

Road Lights Relay K-27
(pin 2) and ground.
55-99
NOTE: For CR combine models SN HAJ100800 and below, use troubleshooting table DDD. For models
SN HAJ100801and above, skip to table DDD-A.
DDD - LH CAB INNER WORK LIGHT TEST

1 Place Key Switch S-02 in 12 volts. Perform Distance Work Lights Relay
S-43. test point.
Distance Work Lights
Relay K-21 (pin 5).
Cab Inner Work Lights If good reading, go to next between Work Light Relay K-21 (pin 5)
E-17 (pin A). test point. and LH Cab Inner Work Light E-17
3 Disconnect the LH Cab Less than 1 ohm. Open circuit 261 (BK) or 245 (BK)
Inner Work Light E-17. between LH Cab Inner Work Light E-17
Measure the resistance on If good reading, replace connector X115 (pin B) and work light
circuit 261 (BK) between the LH Cab Inner Work switch S-43 (pin 5).
LH Cab Inner Work Light Light bulb. Open circuit 925 (BK) between S-43
E-17 connector X115 (pin (pin 6) and ground.
B) and ground. Perform Work Light Switch Test.
DDD-A – LH CAB INNER WORK LIGHT TEST
1 Place Key Switch S-02 in 12 volts Road Lights Relay K-27.

“ON” position.
Road/Field Mode Switch If good reading, Road Lights Perform Road Lights Relay Test.
S-12 in “Field” position. Haz- Relay K-27 and Distance
ard Lights switch S-25 in Work Lights Relay K-21 are
“OFF” position. operating properly.
Close Work Light Switch Go to test point 3. Distance Work Lights Relay K-21.
S-43.
Measure for 12 volts at Road Go to next test point.
2 Measure for 12 volts at 12 volts Distance Work Lights Relay K-21. Perform
Distance Road Lights Relay If good reading, Distance Distance Work Lights Relay Test.
K-21 (pin 5). Work Lights Relay K-21 is
operating properly.
3 Measure for 12 volts at LH 12 volts Open circuit 61 (PU) or 255 (PU) between
Cab Inner Work Light E-17 If good reading, go to next Road Lights Relay K-27 (pin 5) and LH
(pin A) test point. Cab Inner Work Light E-17 connector X115
(pin A).
4 Disconnect the LH Cab Inner Less than 1 ohm. Open circuit 261 (BK) or 245 (BK) between
Work Light E-17. Measure LH Cab Inner Work Light E-17 connector
the resistance on circuit 261 X115 (pin B) and Work Light Switch S-43
(BK) between LH Cab Inner (pin 5).
Work Light E-17 X115 (pin B) Open circuit 925 (BK) between S-43 (pin 6)
and ground. and ground.
Perform Work Light Switch Test
55-100
NOTE: For CR combine models SN HAJ100800 and below, use troubleshooting table EEE. For models
SN HAJ100801and above, skip to table EEE-A.
EEE - RH CAB INNER WORK LIGHT TEST

1 Place Key Switch S-02 in 12 volts. Perform Distance Work Light Relay Test.
Close Work Light Switch test point.
S-43.
Distance Work Lights
Relay K-21 (pin 5).
2 Measure for 12 volts at RH 12 volts Open circuit 61 (PU) or 256 (PU)
Cab Inner Work Lights If good reading, go to next between Work Light Relay K-21 (pin 5)
E-18 Relay (pin A). test point. and RH Cab Inner Work Light E-18
3 Disconnect the RH Cab Less than 1 ohm. Open circuit 265 (BK) or 245 (BK)
Inner Work Light E-18. between RH Cab Inner Work Light E-18
Measure the resistance on If good reading, replace connector X117 (pin B) and Work Light
circuit 265 (BK) between the RH Cab Inner Work Switch S-23 (pin 5).
RH Cab Inner Work Light Light bulb. Open circuit 925 (BK) between S-43
E-18 connector X117 (pin (pin 6) and ground.
B) and ground. Perform Work Light Switch Test.
EEE-A – RH CAB INNER WORK LIGHT TEST
1 Place Key Switch S-02 in 12 volts Road Lights Relay K-27.

“ON” position. If good reading, Road Lights Perform Road Lights Relay Test.
Road/Field Mode Switch Relay K-27 and Distance Distance Work Lights Relay K-21.
S-12 in “Field” position. Haz- Work Lights Relay K-21 are
ard Lights switch S-25 in operating properly.
“OFF” position. Go to test point 3.
Close Work Light Switch
S-43.
Measure for 12 volts at Road
2 Measure for 12 volts at Dis- 12 volts Distance Work Lights Relay K-21. Perform
tance Road Lights Relay If good reading, Distance Distance Work Lights Relay Test.
K-21 (pin 5). Work Lights Relay K-21 is
operating properly.
3 Measure for 12 volts at RH 12 volts Open circuit 61 (PU) or 256 (PU) between
Cab Inner Work Light E-18 If good reading, go to next Road Lights Relay K-27 (pin 5) and RH Cab
(pin A) test point. Inner Work Light E-18 connector X117 (pin
A).
4 Disconnect the RH Cab Inner Less than 1 ohm. Open circuit 265 (BK) or 245 (BK) between
Work Light E-18. Measure LH Cab Inner Work Light E-18 connector
the resistance on circuit 265 X117 (pin B) and Work Light Switch S-43
(BK) between RH Cab Inner (pin 5).
Work Light E-18 connector Open circuit 925 (BK) between S-43 (pin 6)
X117 (pin B) and ground. and ground.
Perform Work Light Switch Test
55-101
FFF - WORK LIGHT SWITCH TEST

1 Place Key Switch S-02 in 12 volts. Open or short circuit 240 (OR) or 45
“ON” position. (OR) between Work Light Switch S-43
Measure for 12 volts at If good reading, go to next connector X132 (pin 2) and Fuse #49.
Work Light Switch S-43 test point.
2 Close Work Light Switch. 12 volts. Work Light Switch S-43.
Use INFO Diagnostic If good reading, go to next Short to ground on circuit 171(YE)
Screen to check for voltage test point. between Work Light Switch S-43
at CCM1 (pin J1-3). connector X132 (pin 3) and CCM1 (pin
J1-3)
3 Turn Key Switch S-02 off. Less than 1 ohm. Work Light Switch S-43.
Using an ohmmeter, If good reading, go to next
measure between Work test point.
Light Switch S-43
and ground.
4 Measure for continuity at Less than 1 ohm. Open circuit 61 (PU) between Work Light
Work Light Switch S-43 Switch S-43 connector X132 (pin 6) and
connector X132 (pin 6) and cab roof ground.
cab roof ground.
GGG - REAR WORK LIGHT SWITCH TEST

1 Place Key Switch S-02 in 12 volts. Open circuit 239 (OR) or 45 (OR)
“ON” position. between Rear Work Light Switch S-44
Rear Work Light Switch test point.
S-44 connector X131
(pin 2).
2 Close Rear Work Light 12 volts Rear Work Light Switch S-44.
Switch. Short to ground on circuit 170 (YE)
Measure for 12 volts at If good reading, system between Rear Work Light Switch S-44
Rear Work Light Switch OK. connector X131 (pin 3) and CCM1
S-44 connector X131 (pin J1-15)
(pin 3). A short to ground will blow Fuse #49.
55-102
HHH - BEACON LIGHT SWITCH TEST

1 Place Key Switch S-02 in 12 volts. Open circuit 172 (OR) or 45 (OR)
“ON” position. between Beacon Light Switch S-41
Beacon Light Switch S-41 test point.
2 Close Beacon Light Switch 12 volts Beacon Light Switch.
S-41.
Measure for 12 volts at If good reading, system Short to ground on circuit 166 (YE)
Beacon Light Switch S-41 OK. between Beacon Light Switch S-41
connector X130 (pin 3). connector X130 (pin 3) and CCM2
(pin J1-2)
III - LH UNDERSHIELD LIGHT SWITCH TEST

1 Place LH Undershield Light 12 volts Open circuit 1214 (RD) between LH
Switch S-63 in “ON” position. Undershield Light Switch S-63 connector
X339 (pin 2) and Fuse #34.
Measure for 12 volts at LH If good reading, the wiring
Undershield Light Switch has good continuity, go to
S-63 connector X339 (pin 2). next test point.
2 Close LH Undershield Light 12 volts LH Undershield Light Switch S-63.
Switch S-63.
Measure for 12 volts at LH If good reading, system OK. Short to ground on circuit 2004 (PU), 2005
Undershield Light Switch (PU) or 2006 (PU) between LH Under-
S-63. connector X339 (pin 3) shield Light Switch S-63 connector X339
and ground. (pin 3) and ground.
JJJ - RH UNDERSHIELD LIGHT SWITCH TEST

1 Place RH Undershield Light 12 volts Open circuit 1215 (RD) or 2008 (RD)
Switch S-65 in “ON” position. between RH Undershield Light Switch
S-65 connector X341 (pin 2) and Fuse #34.
Measure for 12 volts at RH If good reading, the wiring
Undershield Light Switch has good continuity, go to
S-65 connector X341 (pin 2). next test point.
2 Close RH Undershield Light 12 volts RH Undershield Light Switch S-65.
Switch S-65.
Measure for 12 volts at RH If good reading, system OK. Short to ground on circuit 2010 (PU), 2011
Undershield Light Switch (PU) or 2012 (PU) between RH Under-
S-65 connector X341 (pin 3) shield Light Switch S-65 connector X341
and ground. (pin 3) and ground.
55-103
KKK - LICENSE PLATE LAMP TEST

1 Place Road Light Switch 12 volts Open circuit 213 (RD) between Road Light
S-26 in “ON” position. Switch S-26 connector X256 (pin 5) and
Fuse #51.
Measure for 12 volts at Road If good reading, the wiring
Light Switch S-26 connector has good continuity, go to
X256 (pin 5). next test point.
2 Remove the Light Control 12 volts Open in circuit 173 (RD) between Light
Relay K-02. Measure for 12 Control Relay K-02 (pin 5) and Road Light
volts at (pin 5). If good reading, the wiring Switch S-26 connector X256 (pin 1).
has good continuity, go to
next test point. A short will cause Fuse # 51 to blow.
3 Reinstall the Light Control 12 volts Open in circuit 121 (OR) between LH
Relay K-02. Measure for 12 Marker Light Fuse #20 and Light Control
volts at LH Marker Light Fuse If good reading, the wiring Relay K-02 (pin 3).
#20. has good continuity, go to
next test point. A short will cause Fuse # 51 to blow.
4 Measure for 12 volts at RH 12 volts Open in circuit 1571 (PU) or 1577 (PU) or
License Plate Lamp E-57 1578 (PU) between Fuse #20 and RH
connector X362 (pin 1) and If good reading, the wiring License Plate Lamp E-57 connector X362
LH License Plate Lamp E-58 has good continuity, go to (pin 1) and LH License Plate Lamp E-58
connector X363 (pin 1). next test point. connector X363 (pin 1).
5 Measure resistance at circuit 0-2 OHMS Open circuit 1580 (BK) or 1581 or 1574
1580 (BK), 1581 (BK) and (BK) between RH License Plate Lamp
1574 (BK) between RH If good reading, system OK. E-57 connector X362 (pin 2) and LH
License Plate Lamp E-57 License Plate Lamp E-58 connector X363
connector X362 (pin 2) and (pin 2) and ground.
LH License Plate Lamp E-58
ground.
55-104
Chapter 7 - Cab Systems
CONTENTS
Description and Operation of Cab Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Power Seat System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Seat Height Adjustment System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power Seat Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power Seat System Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Seat Suspension System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wiper Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cab Roof Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wiper Motor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wiper/Washer System Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wiper/Washer System Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wiper System Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wiper System Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wiper System Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Windowscreen Washer System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Washer System Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Power Mirror System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cab Roof Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Power Mirror Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Power Mirror Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Heated Mirror Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Power Mirror Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Mirror Fuse -- Power and Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Mirror Adjust Switch S-27 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Mirror Select Switch S-57 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Left Hand Mirror Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Right Hand Mirror Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Additional Mirror Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Mirror Heat Switch S-19 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Mirror Heat Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Horn System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Horn System Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Horn System Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Horn System Circuit Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Audio System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Audio System Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Audio System Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Audio System Diagnostic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
55-1
DESCRIPTION AND OPERATION OF CAB SYSTEMS

This section describes the following electrical
systems:
• Power Seat System

• Wiper Washer System
• Power Mirror System
• Horn System
• Audio System
These electrical systems are located in or near the

combine cab. This section explains the overall
description of the components, connectors, current
flow, and proper testing for each of the cab electrical
systems.
55-2
POWER SEAT SYSTEM

SEAT HEIGHT ADJUSTMENT SYSTEM
The seat system has a power seat adjustment that
uses air pressure to raise and lower the seat. A
switch controls the air pressure. An unswitched
battery circuit allows height adjustment at all times.
Cab Main Harness to Seat Pump
Connector X074 – Seat Pump, 1.
10010921
1
1. Fuse Panel
2. Main Cab Harness
3. Connector X074 1
2
50020059
2
POWER SEAT CIRCUIT
Current travels across the fuse panel system buss
bar to fuse F16.
Current passes through fuse F16 and connector

X074 pin A to connector X312 pin 1 of the seat
adjustment switch S45. When the seat adjustment
switch is moved to the “ON” position, current is sent
from pin 2 of connector X312 to connector X313 pin
A of the seat pump motor M26. The ground path to
the motor is completed through connector X074 pin
B to reach the cab floor ground location #3. This
causes the motor to energize and pump air into the
seat reservoir (raising the seat). Releasing a check
valve, which is controlled mechanically, lowers the
seat assembly.
55-3
55-4
POWER SEAT SYSTEM CIRCUIT TROUBLESHOOTING

Before troubleshooting the seat system make sure that the following operating conditions are met:
B. Transmission in neutral or park.
D. Check fuse F16.
CAUTION
WARNING

Height adjustment not Power and ground supply Seat Suspension System Test
operating
Seat Pump Motor
Seat Solenoid
Air system leaking Check air lines for leakage
55-5
SEAT SUSPENSION SYSTEM TEST
Other Result
No. Test Point Expected Result (Possible Cause)
1 Press Seat Adjust Switch S-45 Seat Pump Motor M-26 runs If the seat pump motor does not
to the “UP” position. and seat raises. run, there is a fault with the
If compressor runs but seat electrical circuit.
does not adjust, check for air Go to test 3
leakage.
Go to test 2
2 Press Seat Adjust Switch S-45 Air is released and seat lowers. If air is not released, there is a
to “Down” position. System is OK. fault with the mechanical link-
age to the release valve.
Inspect the linkage and repair.
3 Unplug connector X312 from 12 volts If no voltage, there is an open
the seat adjust switch S-45. If good reading, wiring has con- circuit in wire 80 (OR) between
Check for 12 volts at the Seat tinuity. fuse F-16 and Seat Adjust
Adjust switch S-45 connector switch S-45 connector X312 pin
Go to test 4
X312 pin 1. 1.
Locate the open circuit and re-
pair.
4 Unplug connector X312 from Less than 1 ohms. If high or infinite resistance,
the seat adjust switch S-45, and If good reading, wiring has con- there is an open circuit between
connector X313 from the seat tinuity. Seat Pump Motor M-26 connec-
pump motor M-26. tor X313 pin A and Seat Adjust
Go to test 5
Use a multimeter to check for Switch S-45 connector X312 pin
continuity between Seat Pump 2.
Motor M-26 connector X313 pin Locate the open circuit and re-
A and Seat Adjust Switch S-45 pair.
connector X312 pin 2.
5 Unplug connector X312 from Less than 1 ohms with switch in If there is no continuity with the
the seat adjust switch S-45. “UP” position. switch in the “UP” position, the
Use a multimeter to check for If good reading, switch has con- switch has failed.
continuity between Seat Adjust tinuity. Replace the switch.
Switch S-45 terminals 1 & 2. Go to test 6
Operate the switch in the “UP”
position while checking continu-
ity.
55-6
No. Test Point Expected Result Other Result

(Possible Cause)
6 Unplug connector X313 from Less than 1 ohms. If the resistance to ground is
the seat pump motor M-26. If good reading, the circuit has greater than 1 ohms, there is
Use a multimeter to check the continuity to ground. excessive resistance or an
resistance between connector open circuit in wire 164 BK to
Go to test 7
X313 and a known good cab ground 3.
ground. Locate the excessive resistance
or open circuit and repair.
7 Unplug connector X313 from Less than 5 ohms resistance. If the resistance is greater than
the seat pump motor M-26. Seat pump motor is good. 5 ohms, the motor has failed in-
Use a multimeter to check the ternally.
continuity of the seat pump mo- Replace the motor.
tor M-26.
55-7
WIPER WASHER SYSTEM

The wiper washer system consists of a two--stage
motor and a separate washer motor and reservoir.
The system is energized by switched power and will

operate in a continuous or fixed interval speeds.
CAB ROOF CONTROLS
1 2
1. Windscreen wiper tumbler switch 2. Windscreen washer rocker switch

• Wiper ON (continuous) • ON
• Wiper ON (intermittent) • OFF
• Wiper OFF
55-8
1. Fuse Panel
4. Cab Roof Ground 4
8 3
5. Connector X018, CCM1 -- J1
2
6. Connector X015, CCM2 -- J1
7. Connector X012, CCM3 -- J1 1
6 5
8. To Start Panel 7
50020059
4
3
2. Connector X003 to Cab Roof harness 2
5 4
3. Cab Roof Ground
1
4. Connector X135 Wiper Switch
5. Connector X134 Washer Switch
6
6. Connector X036 Outer Roof harness
50010891
55-9
CONNECTOR X002
CAB MAIN/ROOF
WIRE
CAV NUMBER CIRCUIT REFERENCE
1 045 (OR) CAB POWER FROM FUSE #49

2 058 (PU) LH CAB WORK LIGHTS FUSE #6
3 072 (PU) SIDE WORK LIGHT RELAY, K-35
4 059 (PU) RH CAB WORK LIGHTS FUSE #7
DISTANCE WORK LIGHTS RELAY,
5 061 (PU) K-21
FUSE #39, BATTERY POWER TO
6 048 (RD) MODULE MEMORY X002
POWER FROM RELAY K-22 TO LH, CAB MAIN
7 063 (PU) RH, AND CENTER HEADER LIGHTS
FUSE #9, POWER TO SWITCHES
8 079 (OR) S-19, S-27, AND S-38
9 081 (OR) FUSE #11, POWER TO RADIO
FUSE #12, POWER TO DATA
10 082 (OR) LOGGER AND GPS MODULE
FUSE #13, POWER TO AUX.
11 083 (OR) RADIO OUTLET
X015-CCM-2 J1-2, BEACON LIGHTS
12 166 (YE) SWITCH S41
X015-CCM-2 J1-3, OPEN COVERS
POWER TO WIPER SWITCH FROM
14 272 (OR) RELAY K-6
X002
X018-CCM-1 J1-15, REAR WORK
15 170 (YE) LIGHTS SWITCH S44 ROOF
X018-CCM-1 J1-3, FRONT WORK
16 171 (YE) LIGHTS SWITCH S43
17 278 (WH) X-005 PIN 14, WASHER MOTOR M24
3 2
18 232 (PU) X015-CCM-2 J1-11, BACKLIGHTING 1
POWER FROM TIME DELAY
19 965 (RD) MODULE, K-20
POWER FROM TIMED SIDE WORK
20 076 (PU) LIGHT RELAY, K-34
POWER FROM BEACON LIGHT
21 579 (PU) RELAY, K-29
22 210 (PU) CENTER WORK LIGHT E38
23 - -
24 - -
10010915
6
1. CONNECTOR X002 - CAB MAIN (CM) HARNESS
TO CAB ROOF (CR) HARNESS
2. CONNECTOR X003, CAB MAIN (CM) HARNESS
3. CAB ROOF GROUND
55-10
CONNECTOR X036
CAB ROOF/OUTER ROOF
WIRE
LH CAB OUTER & MID WORK

1 058 (PU) LIGHTS
RH CAB OUTER & MID WORK
2 059 (PU) LIGHTS
3 061 (PU) INNER WORK LIGHTS E17, E18
4 063 (PU) HEADER LIGHTS E21, E22
5 072 (PU) RH SIDE WORK LIGHT E26
6 076 (PU) LH SIDE WORK LIGHT E25
7 579 (PU) BEACON LIGHTS E31, E32
GROUND THROUGH WORK LIGHT
8 245 (BK) SWITCH S43
GROUND, HEADER & CENTER
9 246 (BK) WORK LIGHTS
GROUND, LH CAB OUTER & INNER
GROUND, RH CAB OUTER & INNER
GROUND, SIDE LIGHTS & MIRROR
12 295 (BK) HEAT
GROUND, BEACON LIGHTS E31,
13 665 (BK) E32
14 280 (BK) GROUND, WIPER MOTOR M25 X036
15 275 (WH) WIPER MOTOR M25 - PARK OUTER ROOF
16 276 (WH) WIPER MOTOR M25 - ON
WIPER MOTOR M25 -
17 277 (WH) INTERMITTENT
18 931 (OR) MIRROR HEAT SWITCH S19
19 955 (WH) RH MIRROR M19 - DOWN
20 963 (WH) RH GERMAN MIRROR M30 - DOWN 1
21 962 (WH) RH MIRROR M20 - IN
22 958 (WH) LH MIRROR M21 - DOWN
23 959 (WH) LH MIRROR M22 - OUT
24 964 (WH) RH GERMAN MIRROR M31 - IN
25 961 (GY) LH MIRROR ADJUST
26 954 (GY) RH MIRROR ADJUST
27 -
28 -
29 210 (PU) CENTER WORK LIGHT E38 10010916
30 -
31 -
7
1. CONNECTOR X036, CAB ROOF (CR) HARNESS
TO OUTER ROOF (OR) HARNESS
55-11
WIPER MOTOR CIRCUIT

Current travels across the fuse panel buss bar and
passes through fuse F38 to pin1 of the key switch
S02. When the key switch is in the ACC/Run position,
current travels from pin 4 of the key switch to pin 1 of
the wiper relay K06. The relay energizes and latches
pins 3 and 5. Current travels from the fuse panel buss
bar and passes through fuse F04 to pin 3 of the wiper
relay K--06. When the wiper relay is energized,
power crosses to pin 5. Current exits pin 5 and
passes through connector X002 pin 14 to the wiper
switch S20. The wiper switch controls current flow to
the wiper motor.
55-12

55-13
55-14
WIPER/WASHER SYSTEM CIRCUIT TROUBLESHOOTING

Before troubleshooting the Wiper/Washer system make sure that the following operating conditions are met:
B. Check all connectors for full installation, loose, corroded or pushed out terminals.
C. Check Fuses F03 and F09.
WIPER/WASHER SYSTEM SYMPTOM CHART

CAUTION
WARNING

Wiper
p Motor is inoperative
p Wiper Relay Wiper Relay Test
Wiper Switch Wiper Switch Test
Wiper Motor Wiper Motor Test
Wiper
p Motor works in low Wiper Switch Wiper Switch Test
speed only
Wiper Motor works in high Wiper Switch Wiper Switch Test
speed only

Wiper Motor does not park, Wiper Switch Wiper Switch Test
stops when switch is turned
OFF
Front washer inoperative
p Washer Switch Windscreen Washer Test
Washer Motor Washer Motor Test
Washer Fluid Supply Check reservoir and fluid lines.
55-15
WIPER SYSTEM RELAY TEST
Other Result
1 Remove wiper relay K-06. Key 12 volts Open circuit in wire 123 OR be-
Switch S-02 in the “ON” posi- Go to test 2 tween key switch S-02 connec-
tion. tor X068 pin 4 and wiper relay
Check for 12 volts at wiper K-06 pin 1.
relay K-06 pin 1. Locate the open circuit and re-
pair.
2 Remove wiper relay K-06. Key 12 volts Open circuit in wire 70 RD be-
Switch S-02 in the “OFF” posi- Go to test 3 tween fuse F-04 and wiper
tion. relay K-06 pin 3, or fuse F-04
Check for 12 volts at wiper has failed.
relay K-06 pin 3. Inspect fuse F-04, and replace
if necessary. Locate the open
circuit and repair.
3 Remove wiper relay K-06. Key Less than 1 ohms Open circuit in wire 242 BK be-
Switch S-02 in the “OFF” posi- Go to test 4 tween wiper relay K-06 pin 2
tion. and Cab ground #3.
Check for continuity to ground Locate the open circuit and re-
at wiper relay K-06 pin 2. pair.
4 Remove wiper relay K-06, and 12 volts Open or short circuit in wire 272
install a jumper wire between Go to test 5 OR from wiper relay K-06 pin 5
pins 3 & 5 on the fuse panel. through connector X002 pin 14
Remove wiper switch S-20. to wiper switch S-20 connector
X135 pin 2.
Check for 12 volts at wiper
switch S-20 connector X135 pin A short circuit will cause fuse
2. F-04 to blow, opening the cir-
cuit.
Inspect fuse F-04, and replace
if necessary. Locate the open or
short circuit and repair.
5 Remove jumper wire between 12 volts If there is no voltage, wiper
pins 3 & 5 on the fuse panel, Testing indicates relay is okay. relay K-06 has failed.
and install wiper relay K-06. Re- Replace relay.
move wiper switch S-20. Key
switch S-02 in the “ON” posi-
tion.
switch S-20 connector X135 pin
2.
55-16
WIPER SYSTEM SWITCH TEST
No. Test Point Expected Result Other Result (Possible

Cause)
1 Key switch S-02 in “ON” posi- 12 volts Open or short circuit in wire 272
tion. Go to test 2 OR from wiper relay K-06 pin 5
Wiper switch S-20 in “OFF” through connector X002 pin 14
position. to wiper switch S-20 connector
X135 pin 2.
switch S-20 connector X135 pin A short circuit will cause fuse
2. F-04 to blow, opening the cir-
cuit.
2 Key switch S-02 in “ON” posi- 12 volts If there is no voltage, switch
tion. Go to test 3 has failed internally.
Wiper switch S-20 in “RUN” Replace switch.
position (either intermittent or
continuous).
3.
3 Key switch S-02 in “ON” posi- 12 volts If there is no voltage, there is
tion. If good reading, power feed to an open circuit between wiper
Wiper switch S-20 in “RUN” illuminate lamp operating cor- switch S-20 and splice block C,
position (either intermittent or rectly. W-03, wire 273 purple.
continuous). Go to test 4 Locate the open circuit and re-
Front work light switch S-43 in pair.
“ON” position.

switch S-20 connector X135
(pin 7).
4 Key Switch S-02 “OFF”. Continuity Found. If there is no continuity, there is
Check for continuity to ground If good reading, and lamp does an open circuit 296 (BK) be-
on wiper switch S-20 connector not illuminate with wiper switch tween wiper switch S-20 con-
X135 pin 9. S-20 in “ON” position, or when nector X135 pin 9 and Cab
vehicle lighting is “ON”, illumina- Roof ground #4.
tion circuit in switch has failed. Locate the open circuit and re-
Replace wiper switch. pair.
55-17
WIPER SYSTEM MOTOR TEST
Other Result
1 Key switch S-02 in the “ON” 12 volts Open circuit in wire 275 white
position. Wiper switch S-20 in Go to test 2 between wiper switch S-20 con-
the “ON” position. nector X135 pin 3 through X036
Check for 12 volts at wiper mo- pin 15 to wiper motor M-25 con-
tor M-25 connector X116 pin 3. nector X116 pin 3.
pair.
2 Key switch in the “OFF” posi- Continuity found. Open circuit in wire 280 black
tion. If good reading, circuit wiring is between wiper motor M-25 con-
Wiper switch S-20 in “OFF” good, indicating a fault with the nector X116 pin 1 through X036
position. wiper motor. pin 14 to Cab Roof ground #4.
Check for continuity to ground Replace the wiper motor. Locate the open circuit and re-
at wiper motor M-25 connector pair.
X116 pin 4.
55-18
WINDSCREEN WASHER SYSTEM TEST
Other Result
1 Key Switch S-02 in “ON” posi- 12 volts If there is no voltage, Go to test
tion. Go to test 6 2
Check for 12 volts at fuse F-09.
2 Remove accessory 1 relay 12 volts Open circuit in wire 123 orange
K-08. Go to test 3 or 241 orange between key
Key switch S-02 in the “ON” switch S-02 connector X068 pin
position. 4 and accessory 1 relay K-08
pin 1.
Check for 12 volts at accessory
1 relay K-08 pin 1. Locate the open circuit and re-
pair.
3 Remove accessory 1 relay 12 volts Open circuit in wire 020 red be-
K-08. Go to test 4 tween fuse F-03 and accessory
Key switch S-02 in the “OFF” 1 relay K-08 pin 3, or fuse F-03
position. has failed.
Check for 12 volts at accessory Inspect fuse F-03, and replace
1 relay K-08 pin 3. if necessary. Locate the open
circuit and repair.
4 Remove accessory 1 relay Less than 1 ohms Open circuit in wire 150 BK be-
K-08. Go to test 5 tween accessory 1 relay K-08
Key switch S-02 in the “OFF” pin 2 and Cab ground #3.
position. Locate the open circuit and re-
Check for continuity to ground pair.
at accessory 1 relay K-08 pin 2.
5 Remove accessory 1 relay 12 volts Open or short circuit in wire 009
K-08, and install a jumper wire If there is voltage, accessory 1 orange from accessory 1 relay
between pins 3 & 5 on the fuse relay K-08 has failed. K-08 pin 5 to fuse F-09.
panel. A short circuit will cause fuse
Replace the relay.
Check for 12 volts at fuse F-09. F-03 to blow, opening the cir-
cuit.
6 Key Switch S-02 in “ON”. posi- 12 volts Open or short to ground in
tion. Go to test 7 wires 279 orange or 079 orange
Check for 12 volts at washer between washer switch S-20
switch S-38 connector X134 pin connector X134 pin 2 through
2. connector X002 pin 8 to fuse
F-09. A short to ground will
cause fuse F-09 to fail.
Locate the open or short circuit
and repair. Replace fuse F-09
as necessary.
55-19
Other Result
7 Key switch S-02 in “ON”. posi- 12 volts If there is no voltage, the switch
tion. Go to test 8 has failed.
Washer switch S-38 in “ON” Replace the switch.
position.
Check for 12 volts at washer
3.
8 Key switch S-02 in “ON”. posi- 12 volts Open or short to ground in wire
tion. Go to test 9 278 white between washer
Washer switch S-38 in “ON” switch S-38 connector X134 pin
position. 3 through connector X002 pin
17 and X005 pin 14 to washer
Check for 12 volts at washer
motor M-24 connector X171 pin
motor M-24 connector X171 pin
2. A short to ground will cause
2.
fuse F-09 to fail.
Locate the open or short circuit
and repair. Replace fuse F-09
as necessary.
9 Key switch S-02 in “OFF” posi- Continuity found. Open circuit in wire 449 black
tion. If continuity to ground is found, or 246 black between washer
Check for continuity to ground and the washer system still motor M-24 connector X171 pin
at washer motor M-24 connec- does not function, the washer 1 and main frame ground #2.
tor X171 pin 1. motor M-24 has failed.
Replace washer motor M-24.
55-20
WASHER SYSTEM MOTOR TEST
Other Result
1 Key switch S-02 in the “ON” 12 volts Open circuit in wire 278 white
position. Washer switch S-38 in Go to test 2 between washer switch S-38
the “ON” position. connector X134 pin 3 through
Check for 12 volts at wiper X002 pin 17 and X005 pin 14 to
washer motor M-24 connector wiper washer motor M-24 con-
X171 pin 2. nector X171 pin 2.
pair.
2 Key switch in the “OFF” posi- Continuity found. Open circuit in wire 449 or 246
tion. If good reading, circuit wiring is black between wiper washer
Washer switch S-38 in “OFF” good, indicating a fault with the motor M-24 connector X171 pin
position. wiper washer motor. 1 to Front Frame ground #2.
Check for continuity to ground Replace the wiper washer mo- Locate the open circuit and re-
at wiper washer motor M-24 tor. pair.
55-21
POWER MIRROR SYSTEM

There are three types of mirrors found on the
Combines: The LH, RH and German mirror (If
Equipped).
CAB ROOF CONTROLS
1 2
Power Mirror Circuit Operation

1. Mirror Adjustment Switch (if installed) 2. Mirror select tumbler switch (if installed)
• Arrow to the left: left-hand mirror • Main mirror adjustment
• Arrow to the right: right-hand mirror • Additional mirror adjustment (Germany)
Only one mirror can be operated at a time. therefore the motors can only be operated in one
There are two motors in each mirror assembly. mode at a time; up only, down only, in only, or out only.
Power and ground are supplied to the motors
through three wires for each mirror assembly, one A change in mirror motor direction is accomplished
wire for each motor and one wire in common, by reversing current flow through the motors.
55-22
POWER MIRROR CIRCUIT

Current travels across the fuse panel buss bar and
through fuse F38 to pin1 of the key switch S02.
When the key switch is in the ACC/Run position,

current travels from pin 4 of the key switch to pin 1 of
the wiper relay K06.
A jumper wire sends current from pin 1 of the wiper

relay to pin 1 of the Accessory 1 relay K08.
The Accessory 1 Relay energizes and latches pins 3

and 5. Current sent from pin 5 of the Accessory 1
relay passes through fuse F09 and connector X002
pin 8 to the mirror adjust switch S27. Depending on
the switch position, current is sent to the motors
within the mirror assemblies.
Use the chart below to determine current flow:
Switch Position Left Right Up Down

Mirror Select Left Hand Mirror Left Hand Mirror Left Hand Mirror Left Hand Mirror
Switch in the Moves left Moves Right Moves up Moves down
LH position
Mirror Select Right Hand Mirror Right Hand Mirror Right Hand Mirror Right Hand Mirror
Switch in the Moves left Moves Right Moves up Moves down
RH position
55-23

55-24
55-25
55-26
55-27
HEATED MIRROR CIRCUIT OPERATION
1. Mirror heating tumbler switch (if equipped)

• ON
• OFF
Switched power is supplied to the mirror heat switch the operator to determine the length of the heating
through fuse F09 from the Accessory 1 relay. cycle required to defrost the power mirrors.
Chassis ground is supplied to the LH, RH, and When the ignition switch is in the RUN position and
German Mirror heaters through connectors X111, the mirror heat switch is in the closed position,
X121, and X287. current flows through the heating elements, in each
mirror, to chassis ground.
The mirror heat switch controls the LH, RH, and
German Mirror Heaters simultaneously and allows
55-28
50020061
10
Cab Roof (CR) Wire Harness
1. Cab Roof Ground

2. Connector X002 to Cab Main Harness
3. Connector X036 to Outer Roof Harness
55-29
50010892
11
Outer Roof (OR) Wire Harness
1. Connector X036 to Cab Roof Harness
55-30
CONNECTOR X002
CAB MAIN/ROOF
WIRE

5 061 (PU) K-21
8 079 (OR) S-19, S-27, AND S-38
14 272 (OR) RELAY K-6
X002
17 278 (WH) X-005 PIN 14, WASHER MOTOR M24 3
18 232 (PU) X015-CCM-2 J1-11, BACKLIGHTING 2 1
19 965 (RD) MODULE, K-20
21 579 (PU) RELAY, K-29
23 - -
24 - -
10010915
12
2. CONNECTOR X003, CAB MAIN (CM) HARNESS
3. CAB ROOF GROUND
55-31
CONNECTOR X036
CAB ROOF/OUTER ROOF
WIRE

1 058 (PU) LIGHTS
2 059 (PU) LIGHTS
5 072 (PU) RH SIDE WORK LIGHT E26
GROUND THROUGH WORK LIGHT
12 295 (BK) HEAT
13 665 (BK) E32
14 280 (BK) GROUND, WIPER MOTOR M25 X036
15 275 (WH) WIPER MOTOR M25 - PARK outer roof
16 276 (WH) WIPER MOTOR M25 - ON
WIPER MOTOR M25 -
17 277 (WH) INTERMITTENT
20 963 (WH) RH GERMAN MIRROR M30 - DOWN 1
22 958 (WH) LH MIRROR M21 - DOWN
27 -
28 -
29 210 (PU) CENTER WORK LIGHT E38 10010916
30 -
31 -
13
55-32
CONNECTOR X178
MIRROR SELECT SWITCH (GERMAN)
WIRE
GERMAN MIRROR ADJUST -

1 963 (WH) UP/DOWN
MIRROR ADJUST SELECTOR -
2 957 (WH) GERMAN/RH
3 955 (WH) RH MIRROR ADJUST - UP/DOWN
4 964 (WH) GERMAN MIRROR - IN/OUT
MIRROR SELECTOR IN/OUT -
5 960 (WH) RH/GERMAN
6 962 (WH) RH MIRROR - IN/OUT
7 -
8 -
9 -
10 -
X178
MIRROR SELECT SWITCH
CONNECTOR X126
MIRROR ADJUST SWITCH S27
WIRE
A 949 (BK) GROUND

B 959 (WH) LEFT MIRROR IN/OUT ACTUATION
LEFT MIRROR DECREASING
C 961 (GY) ACTUATION
LEFT MIRROR UP/DOWN
D 958 (WH) ACTUATION
RIGHT MIRROR UP/DOWN
E 957 (WH) ACTUATION
RIGHT MIRROR DECREASING
F 954 (GY) ACTUATION
G 960 (WH) RIGHT MIRROR IN/OUT ACTUATION
H 274 (OR) SWITCHED B+
X126
MIRROR ADJUST SWITCH
55-33
CONNECTOR X127
MIRROR HEAT SWITCH S19
WIRE
1 -
2 953 (OR) IGNITION B(+)
4 -
5 -
6 -
7 285 (PU) BACK LIGHTING
8 -
9 950 (BK) GROUND
10 -
X127
MIRROR HEAT SWITCH
55-34
POWER MIRROR CIRCUIT TROUBLESHOOTING
56061448
14
Before troubleshooting the power mirror system CAUTION
make sure that the following operating conditions are
met:
these tests. Use of a self-powered light can cause
1. Check Fuses F-03 and F-09.
2. Check operation of the Accessory 1 Relay K-08.
WARNING
3. Check all connectors for complete installation, Before performing any of the electrical tests, be
loose, corroded, pushed out, or bent terminals. sure all operating controls are in neutral or park
NOTE: The batteries must be fully charged and all lock position. This will eliminate accidental
connections clean and tight. Use a multimeter for movement of the machine or start-up of power
these tests. For battery testing and service, see the driven equipment.
battery section in the service manual.
55-35

All Power Mirrors inoperable No power or ground to Mirror Ad- Refer to Mirror Fuse -- Testing
just Switch S-27. Power and Ground
Mirror Adjust Switch S-27 failed. Refer to Mirror Adjust Switch
S-27 -- Testing.
Only Left Power Mirror inoperable Mirror Adjust Switch S-27 failed. Refer to Mirror Adjust Switch
S-27 -- Testing.
Harness or Left Mirror Assembly Refer to Left Hand Mirror -- Tes-
failure. ting.
Only Right Power Mirror inoper- Mirror Adjust Switch S-27 failed. Refer to Mirror Adjust Switch
able S-27 -- Testing.
Bypass Fuses F-64/Mirror Select Refer to Mirror Select Switch
Switch S-57 failed. S-57 -- Testing.
Harness or Right Mirror Assembly Refer to Right Hand Mirror -- Test-
failure. ing.
Both RH and German Power Mir- Mirror Adjust Switch S-27 failed. Perform Mirror Adjust Switch
rors inoperable S-27 -- Testing.
Mirror Select Switch S-57 failed. Refer to Mirror Select Switch
S-57 -- Testing.
Only German Power Mirror inoper- Mirror Adjust Switch S-27 failed. Refer to Mirror Adjust Switch
able S-27 -- Testing.
Bypass Fuses F-64/Mirror Select Refer to Mirror Select Switch
Switch S-57 failed. S-57 -- Testing.
Harness or German Mirror As- Refer to Additional Mirror -- Test-
sembly failure. ing .
All Heated Mirrors inoperable No power or ground supply to Mir- Refer to Mirror Fuse -- Testing
ror Heat Switch S-19. Power and Ground.
Mirror Heat Switch S-19 failed. Perform Mirror Heat Switch S-19
-- Testing.
Only LH Heated Mirror inoperable Harness or LH Mirror Heating ele- Refer to Mirror Heat Circuits --
ment failure. Testing, steps 1 to 3.
Only RH Heated Mirror inoperable Harness or RH Mirror Heating ele- Refer to Mirror Heat Circuits --
ment failure. Testing, steps 4 to 6.
Only German Heated Harness or German Mirror Heat- Refer to Mirror Heat Circuits --
Mirror inoperable ing element failure. Testing, steps 7 to 9.
55-36
Mirror Fuse -- Power and Ground Test
Other Result
1 Key switch OFF. If fuse is good, Go to test 2 If fuse has failed, replace the
Check condition of fuse F-03. fuse.
If the fuse immediately fails,
there is a short to ground in
wire 020 red from fuse F-03 to
the accessory 1 relay K-08.
2 Key switch OFF. If there is 12 volts, Go to test 3 If there is no voltage, there is
Remove the accessory 1 relay an open circuit in wire 020 red
K-08. Use a multimeter to between fuse F-03 and the ac-
check for voltage at pin 3. cessory 1 relay K-08.
3 Turn key switch ON. If there is 12 volts, Go to test 4 If there is no voltage, there is
With the accessory 1 relay K-08 an open circuit in the cab main
removed, use a multimeter to (CM) harness between the key
check for voltage at pin 1. switch “Acc” terminal and the
accessory 1 relay K-08 wires
123 orange or 241 orange.
4 Install the accessory 1 relay If there is 12 volts, Go to test 5 If there is no voltage, recheck
K-08. the condition of fuse F-03. If
Turn key switch ON. fuse F-03 has failed, there is a
short to ground in wire 009
Use a multimeter to check for
orange between the accessory
voltage at fuse F-09.
1 relay K-08 and fuse F-09. If
fuse F-03 has not failed, there
is an open circuit in wire 009
orange between the accessory
1 relay K-08 and fuse F-09.
Locate the short or open and
repair.
5 Key switch OFF. If fuse is good, Go to test 6 If fuse has failed, replace the
Check condition of fuse F-09. fuse, and turn the key switch
ON. If the fuse immediately
fails, there is a short to ground
in the cab main (CM) or cab
roof (CR) harnesses wires 079
orange, 274 orange or 953
orange from fuse F-09 to the
mirror adjust switch S-27 and
mirror heat switch S-19.
55-37
Other Result
6 Carefully remove the mirror ad- If there is 12 volts, Go to test 7 If there is no voltage, there is
just switch S-27 from the upper an open circuit in the cab main
left console. Turn key switch (CM) or cab roof (CR) har-
ON. nesses wires 079 orange or
Use a multimeter to check for 274 orange.
voltage at connector X126 pin Locate the open and repair.
H.
7 Carefully remove the mirror If there is 12 volts, Go to test 8 If there is no voltage, there is
heat switch S-19 from the upper an open circuit in the cab roof
left console. Turn key switch (CR) harness wire 953 orange.
ON. Locate the open and repair.
voltage at connector X127 pin
2.
8 Turn key switch OFF. Carefully If there is continuity to ground, If there is no continuity, there is
remove the mirror adjust switch the mirror power supply and an open circuit in the cab roof
S-27 from the upper left con- ground circuits are functioning (CR) harness between connec-
sole. properly. tor X126 pin A and cab roof
Use a multimeter to check for ground 4.
continuity between connector Locate the open and repair.
X126 pin A and ground.
55-38
Mirror Adjust Switch S-27 Test
Other Result
1 Carefully remove the mirror ad- 12 volts. If there is no voltage, there is
just switch S-27 from the upper If good reading, Go to test 2 an open circuit inside the Mirror
left console, but leave it con- Adjust Switch.
nected to the cab roof (CR) har- Replace the mirror adjust
ness. Turn key switch ON. Set switch S-27.
Mirror Adjust Switch selector to
Left mirror.
Hold Mirror Adjust Switch in
RIGHT position.
Check the voltage at Mirror Ad-
just Switch connector X126 pin
C.
2 Hold Mirror Adjust Switch in 12 volts. If there is no voltage, there is
LEFT position. If good reading, Go to test 3 an open circuit inside the Mirror
Check the voltage at Mirror Ad- Adjust Switch.
just Switch connector X126 pin Replace the mirror adjust
B and pin G. switch S-27.
3 Hold Mirror Adjust Switch in 12 volts. If there is no voltage, there is
DOWN position. If good reading, Go to test 4 an open circuit inside the Mirror
D and pin E. switch S-27.
4 Hold Mirror Adjust Switch in UP 12 volts. If there is no voltage, there is
position. If good reading, Go to test 5 an open circuit inside the Mirror
C. switch S-27.
5 Set mirror selector to Right mir- If there is 12 volts, all voltage If there is no voltage, there is
ror. paths in the switch test okay. an open circuit inside the Mirror
Hold Mirror Adjust Switch in Go to test 6 Adjust Switch.
RIGHT position. Replace the mirror adjust
Check the voltage at Mirror Ad- switch S-27.
just Switch connector X126 pin
F.
6 Turn key switch OFF. Set Mirror Less than 1 ohm. If there is no continuity, there is
Adjust Switch selector to Left If good reading, Go to test 7 an open circuit inside the Mirror
mirror. Adjust Switch.
Hold Mirror Adjust Switch in Replace the mirror adjust
RIGHT position. switch S-27.
Check resistance between Mir-
ror Adjust Switch connector
X126 pin B and ground, and
then pin G and ground.
55-39
Other Result
7 Hold Mirror Adjust Switch in Less than 1 ohm. If there is no continuity, there is
LEFT position. If good reading, Go to test 8 an open circuit inside the Mirror
Check resistance between Mir- Adjust Switch.
ror Adjust Switch connector Replace the mirror adjust
X126 pin C and ground. switch S-27.
DOWN position. If good reading, Go to test 9 an open circuit inside the Mirror
X126 pin C and ground. switch S-27.
9 Hold Mirror Adjust Switch in UP Less than 1 ohm. If there is no continuity, there is
position. If good reading, Go to test 10 an open circuit inside the Mirror
X126 pin D and ground, and switch S-27.
then pin E and ground.
LEFT position. If good reading, the mirror ad- an open circuit inside the Mirror
Check resistance between Mir- just switch is functioning prop- Adjust Switch.
ror Adjust Switch connector erly. Replace the mirror adjust
X126 pin F and ground. switch S-27.
55-40
Mirror Select Switch S-57 Test All other markets will have two electrically adjusted
mirrors, and will have two 10 amps fuses plugged into
NOTE: Combines sold in certain markets may be
connector X178 between pins 2 and 3, and pins 5 and
equipped with a third electrically adjusted mirror, and
6 in order to bypass this connector.
will have a Mirror Select switch S-57 plugged into
connector X178 in the upper left console in the cab.
Other Result
1 Inspect the combine to deter- If there are two electrically ad- If there are three electrically ad-
mine if it has two or three elec- justed mirrors, Go to test 2 justed mirrors and a mirror se-
trically adjusted mirrors. lect switch, Go to test 3
2 Carefully remove the HVAC If the fuses are good, Go to test If one or both of the fuses have
controller from the upper left 5 failed, replace the fuses. Turn
console to gain access to con- the key switch ON, and operate
nector X178. the right mirror in all directions.
Remove and inspect the two If one or both fuses immediately
mini fuses that are installed in fail, there is a short to ground in
the connector. the cab roof (CR) or outer roof
(OR) harnesses.
Refer to Right Hand Mirror --
Testing to locate the fault.
3 Carefully remove the mirror se- If there is continuity between If there is no continuity between
lect switch S-57 from the upper both sets of pins, Go to test 4 one or both sets of pins, the
left console, and unplug it from switch has failed open.
the cab roof (CR) harness. Set Replace the mirror select switch
the switch to the right mirror S-57.
position (position 1).
Use a multimeter to check the
continuity between the switch
pins 2 and 3, and then between
pins 5 and 6.
4 Set the mirror select switch to If there is continuity between If there is no continuity between
the additional mirror position both sets of pins, Go to test 5 one or both sets of pins, the
(position 2). switch has failed open.
Use a multimeter to check the Replace the mirror select switch
continuity between the switch S-57.
pins 1 and 2, and then between
pins 4 and 5.
5 Carefully remove the mirror ad- If there is continuity, Go to test If there is no continuity, there is
just switch S-27 from the upper 6 an open circuit in the cab roof
left console, and unplug it from (CR) harness between connec-
the cab roof (CR) harness. tor X126 and connector X178
Use a multimeter to check from wire 957 white.
continuity between the mirror Locate the open and repair.
adjust switch connector X126
pin E and connector X178 pin
2.
6 Use a multimeter to check from If there is continuity, the mirror If there is no continuity, there is
continuity between the mirror select/bypass fuses circuit is an open circuit in the cab roof
adjust switch connector X126 functioning properly. (CR) harness between connec-
pin G and connector X178 pin tor X126 and connector X178
5. wire 960 white.
55-41
Left Hand Mirror Test (Deutsch part #0460-215-16141) on one end, and a
suitable socket on the other that can connect to the
NOTE: A long [2 m (6 ft)] test lead will be required for
multimeter test probe.
one person to be able to complete this test. Construct
the test lead using a Deutsch Size 16 Series 30 pin
Other Result
1 Unplug the small connector at If there is 12 volts in each posi- If there is no voltage, check the
the base of the mirror support tion, Go to test 2 condition of fuse F-09.
bracket. If fuse F-09 has failed, there is
Insert the pin of the test lead a short to ground in this circuit.
into socket 2 of this connector. If fuse F-09 has not failed, there
Turn key switch ON. is an open circuit.
Set Mirror Adjust Switch to Left This circuit is in the cab roof
mirror. (CR) or outer roof (OR) har-
Hold Mirror Adjust Switch in nesses between Mirror Adjust
RIGHT, and then UP positions. Switch connector X126 pin C,
Use a multimeter to check for through connector X036 pin 25
voltage at LH Mirror connector and connector X111 pin 2 to the
pin 2. mirror connector wire 961 gray.
repair.
2 Move the test lead pin to socket If there is 12 volts, Go to test 3 If there is no voltage, check the
4 of the mirror support bracket condition of fuse F-09. If fuse
connector. Hold Mirror Adjust F-09 has failed, there is a short
Switch in DOWN position. Use to ground in the circuit.
a multimeter to check for volt- If fuse F-09 has not failed, there
age at LH Mirror connector pin is an open circuit.
4. This circuit is in the cab roof
(CR) or outer roof (OR) har-
nesses between Mirror Adjust
Switch connector X126 pin D,
through connector X036 pin 22
and connector X111 pin 4 to the
mirror connector wire 958
white.
repair.
3 Move the test lead pin to socket If there is 12 volts, the circuits If there is no voltage, check the
1 of the mirror support bracket to the left mirror are functioning condition of fuse F-09.
connector. Hold Mirror Adjust properly. If fuse F-09 has failed, there is
Switch in LEFT position. Test the left mirror assembly. a short to ground in the circuit.
Use a multimeter to check for Go to test 4 If fuse F-09 has not failed, there
voltage at LH Mirror connector is an open circuit.
pin 1. This circuit is in the cab roof
nesses between Mirror Adjust
Switch connector X126 pin B,
through connector X036 pin 23
and connector X111 pin 1 to the
mirror connector wire 959
white.
repair.
55-42
Other Result (Possible

No. Test Point Expected Result Cause)
4 Key switch OFF. If there is 10 -- 40 ohms resist- If there is zero or infinite resist-
Use a multimeter to check re- ance, Go to test 5 ance, the LH mirror in/out motor
sistance through the mirror at M-22 has failed.
the small connector pins 1 and Repair or replace the mirror as-
2. sembly.
Use a multimeter to check re- ance, the mirror adjust motors ance, the LH mirror up/down
sistance through the mirror at should be functioning properly. motor M-21 has failed.
4. sembly.
55-43
Right Hand Mirror Test (Deutsch part #0460-215-16141) on one end, and a
Other Result
Set Mirror Adjust Switch to This circuit is in the cab roof
Right mirror. Set the mirror se- (CR) or outer roof (OR) har-
lect switch S-57 to position 1, if nesses between Mirror Adjust
equipped. Switch connector X126 pin F,
Hold Mirror Adjust Switch in through connector X036 pin 26
RIGHT, and then UP positions. and connector X121 pin 2 to the
Use a multimeter to check for mirror connector wire 954 gray
voltage at RH Mirror connector or 956 gray.
pin 2. Locate the short or open and
repair.
4 of the mirror support bracket condition of fuse F-09.
connector. Hold Mirror Adjust If fuse F-09 has failed, there is
Switch in DOWN position. a short to ground in the circuit.
Use a multimeter to check for If fuse F-09 has not failed, there
voltage at RH Mirror connector is an open circuit.
pin 4.
This circuit is in the cab roof
nesses between connector
X178 pin 3, through connector
X036 pin 19 and connector
X121 pin 4 to the mirror con-
nector wire 955 white.
repair.
Switch in LEFT position. Test the right mirror assembly. a short to ground in the circuit.
Use a multimeter to check for Go to test 4 If fuse F-09 has not failed, there
voltage at RH Mirror connector is an open circuit.
pin 1.
repair.
55-44
Other Result
Use a multimeter to check re- ance, Go to test 5 ance, the RH mirror in/out mo-
sistance through the mirror at tor M-20 has failed.
the small connector pins 1 and Repair or replace the mirror
2. assembly.
Use a multimeter to check re- ance, the mirror adjust motors ance, the RH mirror up/down
sistance through the mirror at should be functioning properly. motor M-19 has failed.
the small connector pins 2 and Repair or replace the mirror
4. assembly.
55-45
Additional Mirror Test (Deutsch part #0460-215-16141) on one end, and a
Other Result
Set Mirror Adjust Switch to This circuit is in the cab roof
Right mirror. Set the Mirror Se- (CR) or outer roof (OR) har-
lect switch S-57 to position 2. nesses between Mirror Adjust
Hold Mirror Adjust Switch in Switch connector X126 pin F,
RIGHT, and then UP positions. through connector X036 pin 26
Use a multimeter to check for and connector X287 pin 2 to the
voltage at German Mirror con- mirror connector wire 954 gray
nector pin 2. or 966 gray.
repair.
4 of the mirror support bracket condition of fuse F-09.
connector. Hold Mirror Adjust If fuse F-09 has failed, there is
Switch in DOWN position. a short to ground in the circuit.
Use a multimeter to check for If fuse F-09 has not failed, there
voltage at German Mirror con- is an open circuit.
nector pin 4.
repair.
Switch in LEFT position. Test the German mirror assem- a short to ground in the circuit.
Use a multimeter to check for bly. If fuse F-09 has not failed, there
voltage at German Mirror con- Go to test 4 is an open circuit.
nector pin 1.
repair.
55-46
Other Result
Use a multimeter to check re- ance, Go to test 5 ance, the German mirror in/out
sistance through the mirror at motor M-31 has failed.
2. sembly.
Use a multimeter to check re- ance, the mirror adjust motors ance, the German mirror up/
sistance through the mirror at should be functioning properly. down motor M-30 has failed.
4. sembly.
55-47
Mirror Heat Switch S-19 Test
No. Test Point Expected Result Other Result

(Possible Cause)
1 Carefully remove the mirror If there is no continuity, Go to If there is continuity, the mirror
heat switch S-19 from the upper test 2 heat switch is shorted internally.
left console, and unplug it from Replace the mirror heat switch
the cab roof (CR) harness. Set S-19.
the switch in the OFF position.
continuity between the Mirror
Heat Switch terminals 2 and 3.
2 Set the Mirror Heat Switch in If there is continuity, the mirror If there is no continuity, the
the ON position. heat switch is functioning prop- switch has failed open.
Use a multimeter to check for erly. Replace the mirror heat switch
continuity between Mirror Heat Go to test 3 S-19.
Switch terminals 2 and 3.
3 Use a multimeter to check re- If there is approximately 1 ohms If there is approximately 3 ohms
sistance between connector resistance, the circuit is func- resistance, there is an open cir-
X127 pin 3 and ground. tioning properly. cuit to one of the mirror heat
elements.
Continue the testing at Mirror
Heat Circuits -- Testing.
If there is infinite resistance,
there is an open circuit in the
cab roof (CR) or outer roof (OR)
harnesses between X127 pin 3
and the wire splice in the outer
roof (OR) harness wire 931
orange, or between the wire
splice in the outer roof (OR)
harness and cab roof ground 4
wire 295 black.
55-48
Mirror Heat Circuits Test If the right mirror heat circuit is not functioning, start
at test 4.
NOTE: Before starting any of these tests, the testing
procedures at Mirror Fuse -- Testing Power and
Ground and Mirror Heat Switch S-19 -- Testing If the German mirror heat circuit is not functioning,
should be completed first. If the left mirror heat circuit start at test 7.
is not functioning, start at test 1.
Other Result
1 Turn key switch ON. Activate If there is 12 volts, If there is no voltage, there is
the Mirror Heat circuit. Unplug Go to test 2 an
the small connector at the left open circuit in the outer roof
mirror support bracket. (OR) harness between the har-
Use a multimeter to check for ness splice and LH mirror con-
voltage at LH Mirror small connector wire 935 orange.
nector pin 3. Locate the open and repair.
2 Key switch OFF. If there is less than 1 ohm, Go If there is infinite resistance,
Use a multimeter to check the to test 3 there is an open circuit in the
resistance between LH Mirror outer roof (OR) harness be-
small connector pin 6 and tween the LH mirror small con-
ground. nector and the harness splice
wire 671 black.
3 Use a multimeter to test the re- If there is approximately 3 ohms If there is infinite resistance, the
sistance through the mirror at resistance, the LH mirror heat LH mirror heat coil R-11 has
connector pins 3 and 6. circuit is functioning properly. failed.
Go to test 4 Repair or replace the mirror as-
sembly.
4 Turn key switch ON. Activate If there is 12 volts, Go to test 5 If there is no voltage, there is
the Mirror Heat circuit. Unplug an open circuit in the outer roof
the small connector at the right (OR) harness between the har-
mirror support bracket. ness splice and RH mirror con-
Use a multimeter to check for nector wire 932 orange.
voltage at RH Mirror small con- Locate the open and repair.
nector pin 3.
resistance between RH Mirror outer roof (OR) harness be-
small connector pin 6 and tween the RH mirror small con-
ground. nector and the harness splice
wire 670 black.
sistance through the mirror at resistance, the RH mirror heat RH mirror heat coil R-10 has
connector pins 3 and 6. circuit is functioning properly. failed.
Go to test 7 Repair or replace the mirror as-
sembly.
55-49
Other Result
7 Turn key switch ON. Activate If there is 12 volts, Go to test 8 If there is no voltage, there is
the Mirror Heat circuit. Unplug an open circuit in the outer roof
the small connector at the Ger- (OR) harness between the har-
man mirror support bracket. ness splice and German mirror
Use a multimeter to check for connector wire 862 orange.
voltage at German Mirror small Locate the open and repair.
connector pin 3.
resistance between German outer roof (OR) harness be-
Mirror small connector pin 6 tween the German mirror small
and ground. connector and the harness
splice wire 863 black.
sistance through the mirror at resistance, the German mirror German mirror heat coil R-14
connector pins 3 and 6. heat circuit is functioning prop- has failed.
erly. Repair or replace the mirror as-
All mirror heat circuits and com- sembly.
ponents should be functioning
properly.
55-50
HORN SYSTEM
The horn circuit is shown with the horn activated Current travels across the fuse panel buss bar to fuse
(control stalk pushed inward, toward the steering F51.
column).
Current passes through fuse F51 to connector X256
Power is supplied to the Horn Switch at all times. The pin 8. When the horn portion of the road light switch
Horn Switch is integrated into the Road Light Switch. (S26) is pushed inward to the “ON” position, current
When the operator closes the Horn Switch contact, crosses from pin 8 to pin 9. Current exits pin 9 of
current flows through the Horn Switch to operate the connector X256 to connector X004 pin 18. Current
horn. passes through connector X004 to connector X172
pin 1. Current passes through the connector to the
Current flows from the positive (+) battery terminals, horn. The ground path to the horn travels from
and through the start relay (if equipped), to the fuse connector X172 to the front frame ground location
panel located inside the cab of the combine. #2. This causes the horn to operate.
55-51
HORN SYSTEM CIRCUIT
55-52
HORN SYSTEM CIRCUIT TROUBLESHOOTING
Before troubleshooting the Horn System, make sure B. Transmission is in neutral or park.
that the following operating conditions are met:
C. Check all connectors for full installation, loose,
A. The batteries are fully charged, and all corroded, pushed out or bent terminals.
connections are clean and tight.
D. Verify that fuse F51 is not blown.

Horn does not operate Horn Horn System Circuit Test
Circuit Horn System Circuit Test

Road Light Switch Horn System Circuit Test,
test points 1 thru 3.
these tests.
55-53
HORN SYSTEM DIAGNOSTIC TESTS

these tests.
CAUTION
WARNING
HORN SYSTEM CIRCUIT DIAGNOSTIC TEST

1 Close Horn Switch located 12 volts Open in B+ circuit 193 (WH) between
in the Road Light Switch. If good reading, go to test Road Light Switch connector X256 (pin
Check for 12 volts at horn point 5. 9) and Horn connector X172 (pin 1).
connector X172 (pin 1). Go to next test point.
2 Close Horn Switch located 12 volts Horn Switch.

in the Road Light Switch. If good reading, repair Go to next test point.
Check for 12 volts at Road open in circuit 193 (WH).
Light Switch connector
Check in-line connector
X256 (pin 9).
X004 (pin 18) for
connection.
3 Check for 12 volts at Road 12 volts Open B+ circuit 214 (RD) between Road
Light Switch connector If good reading, replace Light Switch connector X256 (pin 8) and
X256 (pin 8). Road Light Switch. Fuse F51.
4 Check for 12 volts at Fuse 12 volts Blown Fuse F51.

F51. If good reading, repair Open in B+ circuit. See Power
open in circuit 214 (RD). Distribution for testing.
5 Check resistance of circuit Less than 1 ohm Open circuit 631 (BK) between horn and
631 (BK) between horn If good reading, horn ground.
connector X172 (pin 2) and power and ground circuits
ground. okay. If horn does not
work, replace horn.
55-54
CONNECTOR X004
MAIN FRAME/CAB MAIN
WIRE
1 032 (OR) CCM-1, FUSE 43

2 033 (OR) CCM-1, FUSE 43
3 1159 (WH) COLD START INDICATOR, E-36
4 035 (OR) SAMPLE MOTOR, FUSE 47
5 036 (OR) CCM-3, FUSE 47
6 037 (OR) CCM-2, FUSE 36
7 1214 (RD) LIGHT SWITCH, FUSE F34
8 039 (OR) CCM-2, FUSE 37 X004
LOWER WORK LIGHTS RELAY, MAIN FRAME
9 065 (PU) K-30
10 067 (PU) REAR WORK LIGHTS RELAY, K-31
11 068 (RD) SERVICE SOCKETS FUSE, F-15
12 578 (PU) BEACON LIGHT RELAY, K-29
13 875 (BL) FEEDER DISENGAGE, RELAY K-19
14 1210 (BL) FEEDER DISENGAGE, RELAY K-19
15 077 (PU) UNLOAD TUBE LIGHT RELAY, K-32
16 078 (PU) BRAKE LIGHTS RELAY, K-33
17 827 (YE) DAM CONNECTOR X065
18 193 (WH) ROAD LIGHT SWITCH
19 856 (WH) FUEL PUMP RELAY, K-07
20 814 (WH) COLD START X004
21 604 (OR) SERVICE LIGHTS FUSE, F-14 cab main
X033 PIN 13 LH FLASHING LAMP
22 243 (PU) E07
X033 PIN 14 RH FLASHING LAMP
23 244 (PU) E08
24 808 (YE) ECU POWER RELAY, K-14
25 809 (WH) ECU POWER RELAY, K-14
26 525 (WH) THROTTLE/BRUSH RELAY, K-15
29 523 (WH) CONCAVE/COVERS RELAY, K-16
1
10010899
15
1. CONNECTOR X004, MAIN FRAME (MF)
HARNESS TO CAB MAIN (CM) HARNESS
55-55
CONNECTOR X256
ROAD LIGHTS SWITCH S26
WIRE
LIGHT CONTROL RELAY, K02,

1 173 (OR) MARKER LIGHTS
2 203 (PU) RIGHT TURN
3 202 (PU) LEFT TURN
4 218 (YE) HIGH BEAM RELAY K04
5 213 (OR) FUSE, F-51
6 055 (OR) KEY SWITCH S02, IGNITION
7 169 (YE) LOW BEAM RELAY, K05
8 214 (RD) FUSE, F51
9 193 (WH) HORN, H02
X256
ROAD LIGHTS SWITCH
55-56
AUDIO SYSTEM
The audio system is an AM/FM stereo with
weatherband and two rear speakers (if equipped) or
an AM/FM stereo with single--play Compact Disc
player and four--speakers (If equipped). The audio
system is energized by switched power and has a
Transceiver Power Outlet connector so that the
operator may add additional audio equipment.
Radio, 1, Location with:
• 12 Volts DC connection 1
• Loudspeaker connections
• Antenna connection: AM/FM Universal Mo-

torola 3/4″ NMO mount (cable pre
installed).
16
Connectors
Connector X314 and connector X315, 1, To AM/FM 1
Radio.
50020061
17
55-57
AUDIO SYSTEM CIRCUIT

55-58
55-59
55-60
CONNECTOR X002
CAB MAIN/ROOF
WIRE

5 061 (PU) K-21
8 079 (OR) S-19, S-27, AND S-38
14 272 (OR) RELAY K-6
X002
18 232 (PU) X015-CCM-2 J1-11, BACKLIGHTING
1
19 965 (RD) MODULE, K-20
21 579 (PU) RELAY, K-29
23 - -
24 - -
10010915
18
55-61
CONNECTOR X314
FM RADIO “B”
WIRE
1 -
2 -
3 -
4 830 RD KEEP ALIVE POWER, B+, FUSE F35
5 -
6 -
7 081 OR RADIO POWER, B+, FUSE F11
8 973 BK RADIO GROUND TO CAB ROOF #4 X314
FM RADIO “B”
CONNECTOR X315
FM RADIO “C”
WIRE
1 974 WH REAR RIGHT SPEAKER, SUPPLY

2 979 BL REAR RIGHT SPEAKER, GROUND
3 976 WH FRONT RIGHT SPEAKER, SUPPLY
4 980 BL FRONT RIGHT SPEAKER, GROUND
5 977 WH FRONT LEFT SPEAKER, SUPPLY
6 983 BL FRONT LEFT SPEAKER, GROUND
7 975 WH REAR LEFT SPEAKER, SUPPLY
8 982 BL REAR LEFT SPEAKER, GROUND X315
FM RADIO “C”
55-62
AUDIO SYSTEM CIRCUIT TROUBLESHOOTING

Before troubleshooting the Audio system make sure that the following operating conditions are met:
B. Transmission in neutral or park.
D. Check Fuses F02, F11, F13, F35.
CAUTION
WARNING

Audio unit or Transceiver Fuse/Power Supply A - Audio System Power and
Power Outlet is inoperative Ground Supply Test
Audio Unit If A - Audio System Power and
Ground Supply Test results are
good, Audio unit is bad.
Blank display, radio/tape Audio unit
player operates
Audio operates, tape player Audio unit
does not operate
Noisy reception Antenna F - Antenna Test
Audio Unit If F - Antenna Test is good, audio
unit is bad.
Noisy reception, FM only Antenna F - Antenna Test
Audio unit If F - Antenna Test is good, audio
unit is bad.
Poor reception area
Poor quality/distorted Audio speaker B, C, D, E - Speaker Resistance
sound-One or more speakers Test
Substitute known good
speaker(s).
Circuit Perform relevant speaker circuit
test(s).
Audio unit If speaker(s) and circuit(s) are
good, audio unit is bad.
55-63

Poor quality/distorted sound Audio speakers B, C, D, E - Speaker Resistance
from all speakers Test
speaker(s).
test(s).
No sound from speakers Speakers B, C, D, E - Speaker Resistance
Test
speaker(s).
test(s).
Transceiver Power Outlet not Circuit A - Audio system power and
operating ground supply test.
55-64
AUDIO SYSTEM DIAGNOSTIC TESTS

these tests.
CAUTION
WARNING
NOTE: Refer to Radio Owner’s Manual for operation and removal instructions.
A -- Audio System Power and Ground Supply Test

1 Key Switch S02, in Less than 1ohm Open circuit 973 (BK) between Radio
“OFF” position. connector X314 (pin 8) and ground.
Measure resistance If good reading, go to next test Continue to next test point.
between Radio con- point 2.
nector X314 (Pin 8)
and ground.
2 Key Switch S02, in 12 volts Blown Fuse F35
“OFF” position.
Measure 12 volts at If good reading, go to test point 5. Open circuit 830 (RD) or 048 (RD) between
Radio connector X314 Radio connector X314 (pin 4) and in--line
(pin 4, KAPWR). connector X002 (pin 6).
Continue to next test point.

3 Measure for 12 volts 12 volts Open circuit 048(RD) between In--line
at in-line connector connector X002 (Pin 6) and Fuse F35.
X002 (pin 6). If good reading, repair open circuit
in 830 (RD) or 048 (RD).
Go to test point 5.
4 Measure for 12 volts 12 volts Open circuit between Fuse F35 and
at Fuse F35. unswitched power.
If good reading, repair open circuit See Power Distribution for testing.
048 (RD).

5 Key Switch S02 in 12 volts Open circuit 081 (OR) between Radio
“IGN” or “ACC” posi- connector X314 (pin 7) and Fuse F11.
tion.
If good reading, power and Check for connection at in--line connector
Measure 12 volts at grounds to Audio System are X002 (Pin 9).
Radio connector X314 operating properly.
(pin7). Continue to next test point.
55-65

6 Measure for 12 volts at 12 volts Open circuit 081 (OR) between Fuse F11 and
Fuse F11. Accessory 2 Relay K03.
If good reading, repair open circuit Blown fuse F11 or Accessory 2 Relay K03.
081 (OR) between Radio connec-
tor X314 (Pin 7) and Fuse F11. Refer to Power Distribution for Accessory 2
Relay K03 testing.
7 Key Ignition Switch S02 12 volts Open 083 (RD) circuit between Transceiver
in “IGN” position. Mea- Outlet connector X141 (pin 2) and Fuse F13.
sure for 12 volts at
Transceiver Outlet con- If good reading, go to test point 9. Check for connection at in--line connector
nector X141 (pin 2). X002 (pin11).

8 Measure 12 volts at 12 volts Blown Fuse F13.
Fuse F13.
If good reading, repair open circuit Open circuit 008 (OR) between Accessory 2
083 (OR) between Transceiver Relay K03 (pin 5) and Fuse F13.
Outlet connector X141 (pin 2) and
Fuse F13. Refer to Power Distribution for Accessory 2
Relay K03 testing.
9 Measure resistance be- Less than 1 ohm Open circuit 281 (BK) between Transceiver
tween Transceiver Out- Outlet connector X141 (pin 1) and ground.
let connector X141 If good reading, power and ground
(pin 1). to Transceiver Outlet connector
X141 (pin 1) are working properly.
B -- Left Front Speaker Circuit Test

1 Disconnect connector Approximately 4 ohms. Open/short to ground in circuit 977 (WH)
X315 from Radio A04. between Left Front Speaker H05 connector
X136 (pin B) and Radio A04 connector X315
(pin 5).
Measure resistance be- If good reading, Left Front Open/short to ground in circuit 983 (BL)
tween Radio A04 connector Speaker H05 and wiring are between Left Front Speaker H05 connector
X315 (pin 6) and Radio A04 okay. X136 (pin A) and Radio A04 connector X315
2 Disconnect connector X136 Approximately 4 ohms. Broken wire from Speaker H05 to connector
from Left Front Speaker X136, either to Pin A or to Pin B.
H05.
Measure resistance be- If good reading, continue with Broken solder connection at Speaker H05.
tween Pin A and Pin B on the next step.
lead from the Speaker H05. Bad Speaker H05.
55-66

3 Disconnect connector X136 Less than 1 ohm Open/short to ground in circuit 977 (WH)
from Left Front Speaker between Left Front Speaker H05 connector
H05. X136 (pin B) and Radio A04 connector X315
(pin 5).
Measure resistance be- If good reading, continue with
tween Radio A04 connector next step.
X315 (pin 6) and Left Front
Speaker H05 connector
X136 (pin A).
4 Measure resistance be- Less than 1 ohm Open/short to ground in circuit 983 (BL)
tween Left front Speaker between Left Front Speaker H05 connector
H05 connector X136 (pin If good reading, Left Front X136 (pin A) and Radio A04 connector X315
A) and Radio A04 connec- Speaker H05 wiring is okay. (pin 6).
tor X315 (pin 6).
C -- Right Front Speaker Circuit Test

1 Disconnect connector X315 Approximately 4 ohms. Open/short to ground in circuit 976 (WH)
from Radio A04. between Right Front Speaker H07 connector
(pin 3).
Measure resistance be- If good reading, Right Front Open/short to ground in circuit 980 (BL)
tween Radio A04 connector Speaker H07 and wiring are between Right Front Speaker H07 connector
X315 (pin 3) and Radio okay. X139 (pin A) and Radio A04 connector X315
A04connector X315 (pin 4). (pin 4).
from Right Front Speaker X139, either to Pin A or to Pin B.
H07.
tween Pin A and Pin B on next step.
the lead from Speaker H07. Bad Speaker H07.
from Right Front Speaker between Right Front Speaker H07 connector
(pin 3).
X315 (pin 3) and Right Front
X139 (pin B).
tween Right front Speaker between Right Front Speaker H07 connector
H07 connector X139 (pin A) If good reading, Right Front X139 (pin A) and Radio A04 connector X315
and Radio A04 connector Speaker H07 wiring is okay. (pin 4).
X315 (pin 4).
55-67
D -- Right Rear Speaker Circuit Test
from Radio A04. between Right Rear Speaker H06 connector
(pin 1).
Measure resistance be- If good reading, Right Rear Open/short to ground in circuit 979 (BL)
tween Radio A04 connector Speaker H06 and wiring are between Right Rear Speaker H06 connector
from Right Rear Speaker X122, either to Pin A or to Pin B.
H06.
from Right Rear Speaker between Right Rear Speaker H06 connector
(pin 1).
X315 (pin 1) and Right Rear
X122 (pin B).
tween Right Rear Speaker between Right Rear Speaker H06 connector
H06 connector X122 (pin A) If good reading, Right Rear X122 (pin A) and Radio A04 connector X315
and Radio A04 connector Speaker H06 wiring is okay. (pin 2).
X315 (pin 2).
E -- Left Rear Speaker Circuit Test

from Radio A04. between Left Rear Speaker H04 connector
(pin 7).
Measure resistance be- If good reading, Left Rear Open/short to ground in circuit 982 (BL)
tween Radio A04 connector Speaker H04 and wiring are between Left Rear Speaker H04 connector
from Left Rear Speaker X123, either to Pin A or to Pin B.
H04.
55-68

from Left Rear Speaker between Left Rear Speaker H04 connector
(pin 7).
X315 (pin 7) and Left Rear
X123 (pin B).
tween Left Rear Speaker between Left Rear Speaker H04 connector
H04 connector X123 (pin If good reading, Left Rear X123 (pin A) and Radio A04 connector X315
A) and Radio A04 connec- Speaker H04 wiring is okay. (pin 8).
tor X315 (pin 8).
F -- Antenna Test
1 Disconnect Antenna from Less than 1 ohm Antenna.
Radio A04.
Measure resistance be- If good reading, go to next test

tween center terminal of point.
Antenna (radio end) and
Antenna Mast.
2 Measure resistance from Less than 1 ohm Open circuit between Antenna and chassis
Antenna ground wire to ground.
chassis ground. Antenna is good.
55-69
55-70
Chapter 8 - Hydraulic Systems
CONTENTS

55 000 Gearbox Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic Reservoir Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Reservoir Level Low Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Gearbox Filter Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Return Filter Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control Pressure Low Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
55-1
Hydraulic System
The hydraulic system on the CR combine has
several sensors that monitor the state of the system.
When an abnormal condition is detected by these
sensors an alarm and/or error message will be
displayed on the Infoview monitor.
GEARBOX TEMPERATURE SENSOR

The gearbox temperature sensor monitors the
temperature of the oil in the engine gearbox.
The gearbox temperature sensor, 1, is located on the

front lower left section of the gearbox above the
gearbox drain line.
40025222
1
Alarm Code for Gearbox Temperature Sensor
The combine will continue to operate when this alarm
code is active.
Alarm Code Description Priority Check Condition Activation Resetting

A0006 Gearbox Temp HIGH High Engine Running 2 sec> 90°C (194° F) 2 sec< 90°C (194° F)
Error Codes for Gearbox Temperature Sensor

Error Codes Description
E0025--03 Gearbox Temp sensor Shorted to high source
E0025--04 Gearbox Temp sensor Shorted to low source
E0025--05 Gearbox Temp sensor Line Disconnected
NOTE: Refer to the appropriate section of the repair

manual for troubleshooting.
55-2
HYDRAULIC RESERVOIR TEMPERATURE

SENSOR
The hydraulic reservoir temperature sensor monitors
the temperature of the oil in the hydraulic reservoir.
The hydraulic reservoir temperature sensor, 1, is

located on the front of the hydraulic reservoir.
1
50014693
Alarm Code for Hydraulic Reservoir Temperature Sensor.

code is active.

A0007 Hydraulic Reservoir High _ 10 sec> 90°C (194° F) 3 sec< 85°C (185° F)
Temp HIGH
Error Codes for Hydraulic Reservoir Temperature Sensor

E0024--03 Hydraulic Reservoir Temp Shorted to high source
E0024--04 Hydraulic Reservoir Temp Shorted to low source
E0024--05 Hydraulic Reservoir Temp Line Disconnected

55-3
HYDRAULIC RESERVOIR LEVEL LOW

SENSOR
The Hydraulic Reservoir Level Low Sensor detects
when the hydraulic oil in the reservoir falls below a
specific level.
The Hydraulic Reservoir Level Low Sensor, 1, is

located on the top of the Hydraulic Reservoir.
1
50014693
Alarm Code for Hydraulic Reservoir Level Low Sensor.

code is active.
A0011 Hydraulic Reservoir High _ 4 sec level low 0.5 sec level high
Level LOW
Error Code for Hydraulic Reservoir Level Low Sensor.

E0133--03 Hydraulic Reservoir Level Shorted to high source

55-4
GEARBOX FILTER BYPASS SWITCH

The Gearbox Filter Bypass Switch will be activated
when the gearbox filter becomes blocked from
contamination, and oil starts to bypass the filter.
The Gearbox Filter Bypass Switch, 1, is located on

the back side of the filter head.
The Gearbox Filter Bypass Switch is normally open;

1
when the filter becomes blocked, the switch closes,
connecting the circuit to ground.
10020028
Alarm Code for Gearbox Filter Bypass Switch.

code is active.
A0010 Gearbox Filter Blocked Low -- 10 sec < 2 Volt 2 sec > 2 Volt
If the alarm code is displayed after replacing the filter, the circuit is shorted to ground.
Troubleshooting
Step Test Point Good Reading Possible Cause of Bad Reading
1 Disconnect harness from switch If alarm is active; Go to step 2 No alarm; Bad switch. Replace switch
2 Key Switch in ”OFF” position. Unplug If you have continuity, inspect No continuity; Inspect for short to
connector X024. Check continuity to for short to ground in Main ground in straw walker harness, wire
ground on Main Frame end of Frame harness, wire 448 (Y) 448 (Y)
Error Code for Gearbox Filter Bypass Switch.

E0007--03 Gearbox Filter Bypass Shorted to high source

55-5
RETURN FILTER BYPASS SWITCH

The Return Filter Bypass Switch will be activated
when the return filter becomes blocked from
contamination and oil starts to bypass the filter.
The Return Filter Bypass Switch, 1, is located on the

back side of the filter head.
1
The Return Filter Bypass Switch is normally open;
when the filter becomes blocked, the switch closes,
connecting the circuit to ground.
10020028
Alarm Code for Return Filter Bypass Switch.

code is active.
A0009 Return Filter Blocked Low -- 10 sec < 2 Volt 2 sec > 2 Volt
If the alarm code is displayed after replacing the filter, the circuit is shorted to ground.
Troubleshooting
Step Test Point Good Reading Possible Cause of Bad Reading
1 Disconnect harness from switch If alarm is active; Go to step 2 No alarm; Bad switch. Replace switch
2 Key Switch in ”OFF” position. Unplug If you have continuity, inspect No continuity; Inspect for short to
connector X024. Check continuity to for short to ground in Main ground in Straw Walker harness, wire
ground on Main Frame end of Frame harness, wire 447 (Y) 447 (Y)
Error Code for Return Filter Bypass Switch.

E0006--03 Return Filter Bypass Shorted to high source

55-6
CONTROL PRESSURE LOW SENSOR

The Control Pressure Low Sensor monitors the
pressure of the Low--pressure hydraulic system.
The Control Pressure Low Sensor, 1, is located on

the rear of the low pressure valve block for the
clutches and park brake.
1
50020057
6
Alarm Code for Control Pressure Low Sensor.
The combine engine will shut down when this alarm
code is active.

A0012 Control Pressure LOW High Engine running for 3 sec 4 sec < 20 bar (290 psi) 0.5 sec > 20 bar
or engine shut down (290 psi)
Error Code for Control Pressure Low Sensor.

E0162--01 Control Pressure sensor Valid below normal
E0162--03 Control Pressure sensor Shorted to high source
E0162--05 Control Pressure sensor Line Disconnected

55-7
55-8
Chapter 9 - Driveline Systems
CONTENTS

Hydrostatic Ground Drive Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Temperature Control System (TCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydrostat Ground Drive Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydrostat Ground Drive Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Calibration of the Multifunction Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting Multifunction Handle (MFH) Components . . . . . . . . . . . . . . . . . . . . . 7
Ground Speed Potentiometer (R04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Audio Alarm (H01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Park Brake Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Park Brake Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Park Brake Electrical Component Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 13
Park Brake Switch S09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Service Brake Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Service Brake Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Gearshifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Gearshift Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gearshift Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gear Select Switch S24 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ground Speed RPM Sensor B17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ground Speed RPM Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Rear Wheel Assist (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Rear Wheel Assist Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Rear Wheel Assist Switch S10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
55-1
HYDROSTATIC GROUND DRIVE

ELECTRICAL 2
Overview 1
The hydrostatic ground drive system on the CR
combine uses several electrical components,
electronic controllers, and the CAN Bus to provide
control of the hydrostatic pump. In order to move the
combine in either forward or reverse, the operator
must release the park brake, shift the mechanical
transmission into the desired gear, and move the
multifunction handle (MFH), 1, in the desired
direction of travel.
ZDA2288A
NOTE: Depress the switch, 2, on the back of the MFH
1
to activate the neutral unlock solenoid.
Two electrical components are mounted to the MFH
assembly that are used for ground drive operation.
The neutral switch, 1, serves two functions; when the
MFH is in neutral, power from fuse F-48 flows
through the neutral switch S-22 normally closed
contacts (pins 1 and 2) to energize the neutral start 1
relay K-23, allowing the engine to be started. When
the MFH is moved out of the neutral position, power
from fuse F-48 flows through the neutral switch S-22 2
normally open contacts (pins 1 and 3) to CCM2
connector X015 pin J1-17. This power is used by
CCM2 to power the output to the ground drive
hydrostat L-23 EDC valve solenoids. This provides a
margin of safety by immediately disconnecting the 40025230
power supply to the EDC valve when the MFH is 2
returned to the neutral position.
The second component on the MFH assembly is the

ground speed potentiometer R-04, 2, which monitors
the position of the MFH. When the MFH moves out
of neutral, the ground speed potentiometer R-04
signal to the RHM module changes. The RHM
processes the signal against stored calibration
information, and sends this information across CAN
to CCM2.
CCM2 processes this information against its stored
calibration data for the EDC valve solenoids, and 1
activates the output to the ground drive hydrostat
L-23, 1, in proportion to the MFH movement.
10010872
55-2
Temperature Control System (TCS) CCM1 monitors the temperature of the case drain oil
The hydrostatic system also includes a high at 10-second intervals. If the temperature climbs to
temperature control. Hydrostat Motor Temperature 100°C (212°F), CCM2 begins to de-stroke the
Sender B46, which senses case drain oil tempera- hydrostatic pump. The hydrostatic pump will be
ture, sends a signal to CCM1. CCM1 relays the de-stroked at increments of 5 to 10 %, depending on
reading to CCM2 via CAN. CCM2 software regulates the level of cooling required, to reach the 95°C
the EDC valve L23 to lower the temperature of the oil (203°F) and remain there for a minimum of 10
when it reaches or exceeds the set point defined by seconds.
the software.
The original setting of the MFH is restored by CCM2
If the temperature exceeds 100°C (212°F), CCM2 after the temperature has stabilized. CCM2 will not
will automatically reduce the current to the EDC de-stroke the hydrostatic pump more than 50% of the
Valve L23, reducing the swash plate angle original MFH setting.
independent of the MFH position. In addition, an
alarm message (A0083) will be displayed on
Infoview.
Hydrostat Ground Drive Alarms
Alarm Description Priority Check Activation Resetting

Code Condition
A0008 Hydrostatic Motor High ____________ 10 sec> 105°C 3 sec< 100°C (212°F)
Temp HIGH (221°F)
A0033 Parking Brake On Med Park Brake On Multifunction Handle Multifunction Handle
& Engine not in neutral (output in neutral and
running to EDC is disabled) Release Park Brake
(output to EDC is
enabled)
A0081 Hydrostat Charge High Engine running 1 sec switch low 0.5 sec switch high
Pressure Low for 1 sec Engine will shut
down after 4 sec.
A0083 Hydro Speed Low ____________ 10 sec>100°C 3 sec< 95°C (203°F)
Limitation (212°F)
(Motor Temp)
55-3
Hydrostat Ground Drive Fault Codes
The following fault codes must be resolved before
proceeding to troubleshooting. In many cases, the
fault codes will direct you to the proper component for
repair and resolution.
Fault Code Description

E0023-03 Hydrostatic Motor Temp Shorted to high source
E0023-04 Hydrostatic Motor Temp Shorted to low source
E0023-05 Hydrostatic Motor Temp Line Disconnected
E0065-11 Back Up Alarm Unidentified Failure Code
E0135-01 Charge pressure switch Valid below normal (Engine Shutdown)
E0135-03 Charge pressure switch Shorted to high source
E0135-05 Charge pressure switch Line Disconnected (Can only check when engine is not running or
cranking)
E0164-03 V Supply Ground Spd Hydro Shorted to high source
E0164-04 V Supply Ground Spd Hydro Shorted to low source
E0179-03 LoP Isense Grnd Spd Hydro Shorted to high source
E0179-04 LoP Isense Grnd Spd Hydro Shorted to low source
E0179-05 LoP Isense Grnd Spd Hydro Line Disconnected
E0202-11 Ground Speed Hydrostat Unidentified Failure Code
E0643-03 MFH Position Shorted to high source
E0643-04 MFH Position Shorted to low source
E0643-13 MFH Position Needs Calibration
NOTE: Refer to the appropriate section of the repair manual for troubleshooting fault codes.
55-4
Calibration of the Multifunction Handle
IMPORTANT: When calibrating the MFH it is very
important to move the MFH slowly through the full
stroke fore and aft. The potentiometer reading at that
point is considered the “100% output” setting. If the
MFH is not fully at the end of the slot during
calibration, later movement of the MFH may result in
exceeding the “100% output” setting; at 110%, the
output is disabled.
To calibrate the multifunction handle, proceed with

the following steps:
1. Select the “Multifunction Handle” calibration
window.
Message: “Refer to manual before continuing”.
Message: “Then press ENTER”.
2. During this calibration, you will be asked to move
the multifunction handle fore and aft. To avoid
unexpected movement from the machine,
disengage engine & set gear to neutral.
4
3. Press “Enter” to continue or “Esc” to abort the
calibration.
Message: “Calibration initiated”.
Message: “Calibration Started”.
Message: “Move handle to locked Neutral
position”.
Message: “Then press ENTER ”.
55-5
4. Place the Multifunction handle in the lockedneu-
tral position and press “ENTER ”.
Message: “Move handle completely Forward”.
5. Place the Multifunction Handle in the most
forward position and press “ ENTER ”.
Message: “Move handle completely Reverse”.
6
6. Place the multifunction handle in the full rearward
position and press ENTER.
Message: “Calibration successful”.
Message: “Move handle to locked neutral
position”.
7
7. The calibration is successful. Place the Multi-
function Handle in the locked neutral position and
press ENTER or ESC to close the calibration
window.
55-6
8. Verification of MFH calibration.
• In the Diagnostics Info menu, select the
Multifunction Handle (MFH) submenu. Se-
lect the “MFH Position Input” and press
“ENTER”; Relative Pos. Move the MFH fully
front, the reading should be on the “D” and
have +100% for the percentage reading.
Return the MFH to neutral lock. Move the
MFH fully aft. The reading should be on the
“A” and the percentage at 100%. The MFH
calibration was successful.
20013700
9
Troubleshooting Multifunction Handle (MFH)
Components
NOTE: The batteries must be fully charged and all
service, see the battery section in the service
manual.
CAUTION
WARNING
driven equipment.
55-7
Right Hand Console - Hydrostat Control
2
1. Connector X059 - Neutral Switch 3
2. Neutral Switch - S22
5
3. Neutral Lock Solenoid - L01 1
4. Connector X041 - Neutral Lock
5. Audio Alarm - H01
4
40025230
10
Right Hand Console - Hydrostat Control
6. Connector X058 - Audio Alarm
7. Connector X057 - Ground Speed
8. Ground Speed Potentiometer - R04 6
9. Connector X028 - MFH 8
9
40025230
11
55-8
IMPORTANT: The MFH switches use a matrix-wiring
configuration. Diodes are in the circuitry and high
resistance readings are present. To test, use the
Negative (--) test probe on the common pin and the
Positive (+) on the variable.
Neutral Unlock Switch

The Neutral Unlock Switch controls the Neutral Lock
Solenoid L01.
Test Point Good Reading Possible Cause For Bad

Reading
1 Diagnostics Info screen, MFH Sub-- Switch operates properly. Bad Switch, Open Circuit or RHM
Menu select, “HSW ILM (Handle) Testing complete. failure. Proceed to next test point.
unlock”. Operate switch with Info-
view diagnostics.
2 Disconnect connector X028 from Continuity present. Switch and Faulty switch. Replace MFH.
RHM, check continuity between pin 1 circuit are OK.
(common) and pin 2. Manually
operate switch.
Neutral Unlock Solenoid (L01)

The Neutral Unlock/Lock Solenoid L01, locks the
MFH in the neutral position to facilitate starting of the
engine and shifting of the transmission.

Reading
1 Diagnostic Info screen, MFH Sub- Coil operates properly. Testing Failed coil, Open Circuit or RHM
Menu, select “ILM (Handle) unlock complete. failure. Proceed to next test point.
coil”. Operate coil with Infoview
diagnostics.
2 Key Switch S02, in “OFF” position. Continuity present. Coil is OK. Faulty coil. Replace assembly.
Disconnect connector X041 at coil Proceed to next test point.
(L01). Check for continuity between
pin1 and pin 2 on coil connector.
3 Key Switch S02, in “OFF” position. Less than 1ohm Open circuit 317 (BK) between
Measure resistance between con- connector X041 (pin B) and ground.
nector X041 (pin B) and ground If good reading, proceed to
circuit 317 (BK). next test point.
4 Key Switch S02, in “OFF” position. Less than 1ohm Open circuit between connector
Measure resistance between con- X041 (pin A) and connector X027
nector X041 (pin A) and connector If good reading, proceed to (pin 13) circuit 305 (WH).
X027 (pin 13) circuit 305 (WH). next test point.
5 Key Switch S02, in “OFF” position. Less than 1ohm Open circuit between connector
Measure resistance between con- X041 (pin A) and connector X027
nector X041 (pin A) and connector If good reading, proceed to (pin 12) circuit 301 (WH), or failed
X027 (pin 12) circuit 301 (WH). next test point. RHM.
55-9
Neutral Switch (S22)
Neutral Start Switch S22, Normally Closed (NC)
position, pin 1 and 2 supplies power to the engine
starter relay K17, and cuts off the power supply of the
Hydrostatic logic in CCM-2, when the MFH is in the
neutral position.

Reading
1 Ignition switch in “IGN” position. 12 volts Open circuit 300 (OR) or 108 (OR)
Measure 12 volts at Neutral Switch between Fuse F48 and Neutral
S22 connector X059 (pin 1) If good reading, proceed to Switch S22 connector X059 (pin 1).
next test point. Check in-line connector X001 (pin
3) for connection.
Blown Fuse F48 (refer to Power

Distribution section for testing).
2 Place Neutral Switch S22 in closed 12 volts Neutral Switch S22.
position. Measure 12 volts at Neutral
Switch S22 connector X059 (pin 2). If good reading, proceed to
next test point.
3 Place Neutral Switch S22 in open 12 volts Neutral Switch S22.
position. Measure 12 volts at Neutral
Switch S22 connector X059 (pin 3). If good reading, Neutral
Switch S22 is OK.
55-10
GROUND SPEED POTENTIOMETER (R04) • A signal to the Back-up Alarm H08 is sent when
The Ground Speed Potentiometer R04, on the the MFH is moved rearward.
rotation point of the MFH controls: • The Neutral Lock Solenoid L01 will be
disengaged when the MFH is moved forward or
• The signal to the forward or rearward solenoid on rearward 7°(degrees) from the neutral lock
the Hydrostat Pump L23. position. This is to prevent overheating of the
solenoid. The MFH will not be able to shift from
• The Transmission Shift Motor M02 and the Foot
forward to reverse and reverse to forward without
and Inch Solenoid L05. Gearshifting and power
locking in neutral.
to the Foot and Inch Solenoid L05 is not possible
when the MFH is not in Neutral.

Reading
1 Diagnostic Info screen, Multifunc- The Ground Speed Potentiom- Faulty Potentiometer or open
tion Handle (MFH) submenu, select eter circuit.
“MFH Position Input” and press ”
ENTER ”; Relative Pos. Move the R04 is OK. Re-calibration required for MFH.
MFH fully front, the reading should
be on the “D” and have +100% for Testing complete. Proceed to next test point.
the percentage reading. Return the
MFH to neutral lock. Move the MFH
fully aft. The reading should be on
the “A” and the percentage at
-100%.
2 Disconnect connector X057. Mea- Less than 1ohm. Faulty Potentiometer R04.
sure resistance between pin A (316
PK) and pin B (320 BL) Proceed to next test point.
3 Disconnect connectors X057 and Less than 1ohm. Open circuit 381 (YE) or short to
X027. Measure resistance between ground.
pin C on X057 and pin 1 on X027 Proceed to next test point.
4 Disconnect connectors X057 and Less than 1ohm. Open circuit 316 (PK) or short to
X026. Measure resistance between ground.
pin A on X057 and pin 16 on X027 Proceed to next test point.
5 Disconnect connectors X057 and Less than 1ohm. Open circuit 320 (BL).
X026. Measure resistance between
pin B on X057 and pin 6 on X027. Good continuity in harness.
55-11
AUDIO ALARM (H01)

The Audio Alarm H01 sounds every time an Alarm or
Error message is displayed on the Infoview.
Test Point Good Reading Possible Cause for Bad

Reading
1 Disconnect X057. Measure resist- Measurement of approximately Failure of the speaker.
ance between pin A and pin B. 7 ohms.
2 Disconnect connector X026. Mea- Less than 1ohm. Open circuit 388 (BK)
sure resistance between pin 18
(388 BK) and pin B on X058. Proceed to next test point.
3 Disconnect connector X026. Less than 1ohm. Open circuit 376 (WH)
Measure resistance between pin 19
(376 WH) and pin A on X058. Speaker circuit OK.
PARK BRAKE
The Park Brake is controlled manually with a switch
(S09) 1, on the Right Hand Console (RHC). The Park
Brake Switch S09 sends a signal to the RHM. The
RHM sends a signal to CCM2. CCM2 sends a signal
to the Park Brake Disengage Solenoid L10. When
switch S09 is “ON” the Hydrostatic Pump L23 is
disabled. The combine must be at a complete stop
and the MFH in Neutral for the Park Brake to engage.
CCM2 will engage the Park Brake automatically
when shifting gears. An indicator light will be
displayed on SSM when Park Brake is engaged. The
indicator will flash when conditions are not met for the
brake to engage. The Park Brake is spring-applied,
12
pressure release.
NOTE: An audible alarm will sound if the Park Brake
is not set when the operator gets out of the seat with
the engine running and the MFH in neutral.
Park Brake Alarms
Alarm Description Priority Check Condition Activation Resetting

Code
A0020 Set Parking Brake High Engine ON, MFH 2 sec after Operator 0.5 sec after Operator
in Neutral, Park out of seat. seated
Brake OFF
A0033 Parking Brake ON Med Park Brake ON, MFH not in Neutral MFH in Neutral
Engine running
High Park Brake Switch MFH not in Neutral MFH in Neutral
in Error, Engine
Running and Park
Brake Engaged
55-12
Park Brake Fault Codes
The following fault code must be resolved before
fault code will direct you to the proper component for
E0181-11 Park Brake Disengage Valve Unidentified Failure Code
E0668-04 CSW Park Brake On Shorted to Low Source
E0669-04 CSW Park Brake Off Shorted to Low Source

manual for troubleshooting fault codes.
Park Brake Electrical Component

Troubleshooting
manual.
CAUTION
WARNING
driven equipment.
Park Brake Switch S09

Park Brake Switch S09 is a rocker switch that applies
and releases the Park Brake.
55-13
Lamp in Park Brake Switch S09

Reading
1 Diagnostics Info screen RHC Lamp turns ON and OFF with Lamp failure. Possible open
Sub-Menu, select “Lamp Park- Diagnostics. Testing is complete. circuit to or from switch. Check for
ing Brake”, “Digital” Press blown fuse F48. Failed Park
ENTER to turn lamp ON or OFF Brake Switch S09.
2 Measure resistance between Less than 1 ohm. Open circuit or short to ground on
connector X052 pin 7 (397 PU) circuit (397 PU) or failed Park
and pin K on connector X198. Brake Switch S09.
Proceed to next test point.
3 Measure resistance between Less than 1 ohm. Open circuit (393 BK) or failed
connector X052 pin 9 (393 BK) Park Brake Switch S09.
and cab ground #3.
4 Measure resistance between Less than 1 ohm. Open circuit or short to ground on
connector X052 pin 10 (355 circuit (355 BK) or failed Park
PU) and pin 8 on connector Brake Switch S09.
X027. Lamp is functioning properly.
55-14
Park Brake Switch

Reading
1 Diagnostics Info screen, RHC ON, when switch is turned OFF Open circuit or short to ground.
Sub-Menu, select “CSW Park
Brake off”. “Switch”. Cycle OFF, when switch is turned ON. Check for blown fuse F48. Failed
switch. Park Brake Switch S09.
2 Diagnostics Info screen, RHC OFF, approximately 4.9 volts. Open circuit or short to ground.
Brake off”. “Voltage”. Cycle ON, approximately 1.5 volts. Check for blown fuse F48. Failed
3 Diagnostics Info screen RHC OFF, when switch is turned OFF Open circuit or short to ground.
Brake on”. “Switch”. Cycle ON, when switch is turned ON. Check for blown fuse F48. Failed
4 Diagnostics Info screen, RHC ON, approximately 4.9 volts. Open circuit or short to ground.
Brake on”. “Voltage”. Cycle OFF, approximately 1.5 volts. Check for blown fuse F48. Failed
5 Measure resistance between Less than 1 ohm. Open circuit or short to ground in
connector X052 pin 1 (335 YE) circuit 335 (YE)
and pin 1 on connector X029.
connector X052 pin 3 (334 YE) circuit 334 (YE)
connector X052 pin 2 (365 OR) circuit 365 (OR). Check for blown
and pin C on connector X054. fuse F48.
connector X054 pin M (287 OR) circuit 287 (OR). Check for blown
and pin 1 on connector X001. fuse F48.
Park Brake Switch S09 and circuits
are OK.
55-15
SERVICE BRAKES
Service Brake line pressure is sensed by Brake
Pressure Switch S39, 1. The signal is sent to CCM2
that activates the Brake Lights Relay K33, which
sends power to activate the brake lights.
10010876
13
The Service Brake pads monitor wear by using a
wire, 1, embedded in the pads that has voltage 1
applied to them. As the pads wear down, the wire
becomes exposed, and shorts to ground on the
brake rotor, activating an alarm on Infoview.
Because of the embedded wire in the upper Service

Brake pads, the pads are switches with the
designation of Left Hand Brake Wear Switch S55 and
the Right Hand Brake Wear Switch S56.
NOTE: Only the upper brake caliper pads have

electrical connectors.
14
Service Brake Alarm Codes
Alarm Description Priority Check Activation Resetting

Code Condition
A0047 Check Brakes Med ___________ Input voltage <0.69V Input voltage >0.69V for
for 5 seconds due to 10 seconds (circuit not
brake pad wear or grounded)
brake fluid low
Service Brake Fault Codes

E0134-03 Brake Pressure switch Shorted to high source
E0199-11 Brake Lights relay Unidentified Failure Code

55-16
GEARSHIFTING
The operator rotates the Gear Select Switch S24, 1,
on the RHC to the desired transmission gear, either
1- 2- N- 3- 4. This can be done at anytime whether in
motion or parked. The actual gear shifting will not
start until the MFH is locked in the neutral position,
which automatically disables the Hydrostatic Drive-
line, and the combine stops forward or rearward
travel.
15
The sequence of the transmission gear shift after the
combine travel stops:
• The Park Brake starts to be applied. The Park

Brake LED, on the SSM, will flash until the Park
Brake is applied. The Park Brake LED will remain
lit for the duration of the shift sequence.
• The Foot and Inch Solenoid L05, in the Hydrostat
Motor, is activated to equalize the hydraulic
pressure to allow the gears to shift.
• The Shifting Motor M02 begins to turn in the
appropriate direction.
• When the selected gear is engaged, as sensed
by Transmission Shift Position Sensor B37, the
Shift Motor M02 stops turning and the Foot and
Inch Solenoid L05 is deactivated.
• The Park Brake starts to release.
• The Hydrostatic Driveline is enabled and driving
can resume. The Park Brake LED going out
indicates this.
NOTE: When the Park Brake is engaged with the

Park Brake Switch S09 before shifting, the Park
Brake will remain on after shifting is completed. The
Park Brake is released with Park Brake Switch S09
manually.
The gear indicated on Infoview, in the upper left-hand
corner, represents the currently engaged gear. This
is detected by Transmission Shift Position Sensor
B37, 1.
When the gear can not be engaged because of either

mechanical reason or failure of the Transmission
Shift Position Sensor B37, the software in CCM2 will
allow another gear to be selected.
1
NOTE: Refer to the Operator’s Manual for manual
gear shifting procedure.
10004664
16
55-17
Special Conditions
CCM2 limits the reverse speed of the Hydrostatic
Pump L23 when Transmission Shift Position Sensor
B37 indicates 3rd or 4th gear.
Gearshift Alarms
Alarm Description Prior- Check Activation Resetting
Code ity Condition
A0080 Gearshift Not Suc- Low ___________ Not able to get to Selected Gear found
cessful shift to selected
Gear
Gearshift Fault Codes


E0128-03 Trans Shift Gear N sens Shorted to high source
E0128-04 Trans Shift Gear N sens Shorted to low source
E0128-05 Trans Shift Gear N sens Line Disconnected
E0129-03 Trans Shift Gear 3 sens Shorted to high source
E0129-04 Trans Shift Gear 3 sens Shorted to low source
E0129-05 Trans Shift Gear 3 sens Line Disconnected
E0171-06 Curr Sense Transm Shift Short Circuit
E0195-11 Foot and Inch valve Unidentified Failure Code
E0203-11 Transmission Shift Motor Unidentified Failure Code
E0645-03 Gear Select Input Shorted to High Source
E0645-04 Gear Select Input Line Disconnected
E0645-05 Gear Select Input Mechanical Out of Range

55-18
Gear Select Switch S24 Troubleshooting

Reading
1 Diagnostic Info screen, RHC Approximately 0.5 volts Open circuit or short to ground.
Sub-Menu, select “Gear Select
input switch”. Rotate Gear Proceed to next test point. Failed Gear Select Switch S24.
Select Switch S24 to gear 1.
2 Diagnostic Info screen, RHC Approximately 1.3 volts Open circuit or short to ground.
input switch”. Rotate Gear Failed Gear Select Switch S24.
Select Switch S24 to gear 2.
3 Diagnostics Info screen, RHC Approximately 2.3 volts Open circuit or short to ground.
input switch”. Rotate Gear Failed Gear Select Switch S24.
Select Switch S24 to N.
4 Diagnostics Info screen, RHC Approximately 3.1 volts Open circuit or short to ground.
Sub-Menu, select, “Gear Select
input”. Rotate Gear Select Failed Gear Select Switch S24.
Switch S24 to gear 3.
Diagnostics Info screen, RHC Approximately 4.1 volts Open circuit or short to ground.
input”. Rotate Gear Select Failed Gear Select Switch S24.
Switch S24 to gear 4.
Measure resistance between Less than 1 ohm. Open circuit in circuit 323 (BL)
connector X048 pin B (323 BL)

Measure resistance between Less than 1 ohm. Open circuit or short to ground in
connector X048 pin A (319 PK) circuit 319 (PK).

connector X048 pin C (391 YE) circuit 391 (YE)
Gear Select Switch S24 OK
55-19
GROUND SPEED RPM SENSOR B17

The Ground Speed RPM Sensor B17, 1, is located on
the top cover of the transmission and gives input for
the read out of the ground speed on Infoview.
The Ground Speed RPM Sensor B17 prevents the

activation of the Transmission Shift Motor M02 when
value from the sensor is above the threshold value.
This avoids gear shifting when the gearbox has
components that are in motion.
1
10004641
17
Ground Speed RPM Fault Codes

E0142-03 Groundspeed RPM sensor Shorted to high source
E0142-04 Groundspeed RPM sensor Shorted to low source
E0142-05 Groundspeed RPM sensor Line Disconnected

REAR WHEEL ASSIST (IF EQUIPPED)

Rear Wheel Assist (RWA) is the hydro-mechanical
system that applies power to the rear wheels
providing more traction for the combine. The motors
are an extension of the combine’s hydrostatic
system. When the operator engages the rear axle,
the Equa-Trac II valve, which is mounted on the rear
axle beam, allows hydraulic fluid to flow from the
hydrostatic pump to the motors on the rear axle. The
hydraulic fluid, in turn, powers the motors to rotate
the rear wheels. The second valve assists the E-T II
valve in draining hydraulic fluid from the motors.
10021843
18
55-20
Using the rear axle provides several advantages:
• Allows the combine hydrostatic system to

operate at a lower pressure, thus helping to
extend the life of the hydrostatic transmission
and geartrain.
• Reduces the hydraulic fluid temperature be-
cause of lower hydrostatic system pressure.
• Powering the rear wheels provides improved
steering response.
• Additional traction when operating in adverse/
rough field conditions.
Rear Wheel Assist (RWA) is activated with the rocker
switch, 1, on the RHC.
19
Special Conditions
• The Rear Wheel Assist (RWA) Solenoid L26 is
disabled when the Transmission Shift Position
Sensor B37 detects the transmission is in 4th
gear.
• The Road Mode Switch S12 disables the Rear
Wheel Assist Solenoid L26 in all transmission
gears to prevent the use of the RWA in Road
Mode.
20
Rear Wheel Assist Switch S10 (If Equipped)
S ON
S OFF
55-21
Rear Wheel Assist Fault Codes
The following fault code must be resolved before
fault code will direct you to the proper component for

E0066-11 Rear Wheel assist valve Unidentified Failure Code


manual.
CAUTION
WARNING
driven equipment.
55-22
Rear Wheel Assist Switch S10 Troubleshooting

Reading
1 Diagnostic Info, RHC sub- ON, when switch is turned ON Open circuit or short to ground.
menu, select “CSW Rear Wheel
Assist”. ”Switch”. Cycle switch. OFF, when switch is turned OFF. Check for blown fuse F48. Failed
Rear Wheel Assist Switch S10.
2 Diagnostic Info, RHC sub-- OFF, approximately 1.4 volts. Open circuit or short to ground.
menu select “CSW Rear Wheel
Assist”. ”Voltage”. Cycle switch. ON, approximately 5 volts. Check for blown fuse F48. Failed
Rear Wheel Assist Switch S10.
Switch is OK.
3 Disconnect Rear Wheel Assist Switch turned OFF, no reading. (OL) Failed Rear Wheel Assist Switch
Switch S10 from connector S10.
X051. Measure resistance be- Switch turned ON, Less then 1 ohm.
tween pin 2 and pin 3 of switch.
Switch is OK. Replace switch.
4 Measure resistance between Less then 1 ohm. Open in circuit 384 (BK)
connector X051 pin 9 (384 BK)
and Cab Ground #3.
5 Measure resistance between Less then 1 ohm. Open or short to ground in circuit
connector X051 pin 2 (366 OR) 366 (OR). Blown Fuse F48.
and connector X054 pin D
connector X054 pin M (287 OR) 287 (OR). Blown Fuse F48.
and connector X001 pin 3
connector X051 pin 3 (336 YE) 336 (YE).
and connector X029 pin 17.
connector X051 pin 7 (289 PU) 289 (PU).
and connector X198 pin B.
connector X198 pin H (329 PU) 329 (PU).
and connector X027 pin 18.
Circuits are OK.
55-23
55-24

55-25

55-26
55-27

55-28

H-01 = AUDIO ALARM
55-29
55-30
Chapter 10 - Header Systems
CONTENTS

Reel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Reel Speed Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reel Speed Cannot Be Changed in Manual Mode, or Reel Speed Offset
Cannot be Adjusted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reel Speed Synchronization Cannot Be Engaged, or Will Not Disengage . . . . . . . . . . . 7
Reel Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Reel Positioning Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reel Will Not Raise or Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reel Will Not Move Fore or Aft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Header Height Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Header Height Control Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Header Will Not Raise or Lower Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Head Will Not Tilt Left or Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
One or More of the Header Height Operating Modes Cannot Be
Engaged or Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
55-1
The combine electronics provide the operator with
complete control over all header systems in order to
maximize field performance. The header systems
can be broken down into three control groups; reel
speed, reel position (raise/lower and fore/aft), and
header height control.
REEL SPEED
The combine is capable of controlling reel speed on
headers with two different types of reel drives, either
mechanical (vari-speed sheaves) or hydraulic. On
headers with mechanical reel drive, the combine
controls an actuator that moves a variable sheave on
a belt drive to control reel speed. On headers with
hydraulic reel drive, the combine is equipped with a
hydraulic valve in the feeder stack that provides oil
flow to the header reel drive motor; the oil flow may
be regulated through the valve to control reel speed.
Operator Controls
There are several controls and settings that may be
made to control the operation of the header reel
speed. The reel speed may be controlled manually
by using the reel speed control switches on the
multifunction handle (MFH). In manual mode, the
operator adjusts the reel speed by depressing the
reel speed increase, 2, or decrease, 1, switches, and
CCM2 adjusts the output to the reel speed valve
(hydraulic) or motor (mechanical).
The reel may also be controlled automatically by

engaging the reel speed synchronization switch, 3,
on the console. In this operating mode, the reel
speed is synchronized with the ground speed, so that 1
the reel speed changes automatically as the operator
changes the operating ground speed of the combine.
NOTE: The reel synchronization switch, 3, has a

third, momentary contact position, however, this
position has no function at this time.
The operator can adjust the amount of ‘offset’

between the reel speed and the ground speed using
the reel speed control switches, 1 & 2, on the
multifunction handle while in the synchronization
mode. Generally, the reel speed would be set to run
slightly faster than ground speed in order to pull crop
into the header, but it may be desired to run the reel
speed significantly faster than ground speed if
operating in lodged crop conditions, or about the
same speed as ground speed in delicate or over-ripe
crop conditions.
55-2
Configuration Settings
The proper settings must be made in the
Configuration screen in order for the reel speed
synchronization mode to work properly. Select the
“Header” sub-menu, and adjust the following
parameters:
Minimum reel speed: a minimum reel speed may be

set for the reel speed, so that the reel is turning at a
certain speed even when the combine is stopped, or
moving very slowly. This may be desired when
working in lodged crop conditions. The value may be
set between 0 – 10 km/h (0--6 mph) in 0.1 increments.
Auto reel speed slope: is the relationship between 2

the reel speed and the ground speed, and must be
set to match the type of header installed. Select
“hydraulic reel” for headers with hydraulic reel drive,
“mechanical reel” for headers with mechanical
vari-speed drives, and “pick-up reel” for windrow
pick-up headers.
Auto reel speed offset: is the offset between the reel

speed and ground speed. This offset may be preset
during header configuration, but will change to match
the settings made by the operator using the reel
speed increase and decrease switches during
operation in synchronization mode.
Hydraulic Reel Drive: the proper entry must be made
in the Configuration screen to specify which type of
reel drive is being used. Select “Installed” (hydraulic
reel drive) or “Not Installed” (mechanical reel drive)
to indicate which type of reel drive is in use on the
combine and header.
Reel speed sensor: must be set as “Installed” if a

header with mechanical reel drive is installed, since
these headers are equipped with a reel speed sensor
for feedback. If a hydraulic reel drive header is being
used, set this value to “Not Installed”.
55-3
Fault Codes
If the reel drive system is not functioning properly, check for the following fault codes and correct the problem
prior to beginning any other troubleshooting.
For units with mechanical vari-speed for reel drive only. Auto reel speed synchronization will be disabled.
E0141--03 Header Reel RPM sensor Shorted to high source

E0141--04 Header Reel RPM sensor Shorted to low source
E0141--05 Header Reel RPM sensor Line Disconnected
If these faults appear, auto reel speed synchronization will be disabled.
E0142--03 Groundspeed RPM sensor Shorted to high source

E0142--04 Groundspeed RPM sensor Shorted to low source
E0142--05 Groundspeed RPM sensor Line Disconnected
For units with hydraulic reel drive only. Reel drive will not function.
E0186--11 Header Reel Drive valve Unidentified Failure Code
For units with mechanical vari-speed for reel drive only. Reel drive speed cannot be changed.
E0169--06 Current Sense Reel Speed Short circuit

E0204--11 Header Reel Speed motor Unidentified Failure Code
55-4
REEL SPEED TROUBLESHOOTING

Symptom: Reel speed cannot be changed in manual mode, or reel speed offset cannot be adjusted.
Cause: No signal from reel speed increase or decrease switches on MFH.
Possible Failure Modes:

1. Switch failed.
2. Open circuit on switch wiring in MFH.
3. RHM module failure.
Solution:
1. Enter the Infoview monitor -- Diagnose Info screen.
Select “MFH” sub menu.
Select “HSW Reel Speed Incr” and monitor the display while cycling the reel speed increase switch. The
“switch” screen should show “on” when the switch is depressed. If the “Voltage” screen is selected, there
should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed.
A. If the voltage does not change, continue with Step 2.
B. If the voltage reading is within the proper limits, continue the troubleshooting at step 5.
NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. Inspect
the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the
harnesses involved to reveal intermittent breaks or shorts in the wiring concerned.
2. The voltage reading on the Infoview monitor does not change. Disconnect connector X028 from the RHM
module. Use a multimeter to check resistance between the harness end of connector X028 pin 2 and pin
7, with the black (common) probe of the multimeter on pin 7. Depress the reel speed increase switch; the
resistance should change from infinite to approximately 1.6 – 1.8 M ohms resistance.
A. If there is no change in resistance, the switch or wiring in the MFH handle has failed. Replace the MFH.
B. If the resistance reading is correct, continue with Step 3.
Select “HSW Reel Speed Decr” and monitor the display while cycling the reel speed decrease switch. The
7, with the black (common) probe of the multimeter on pin 7. Depress the reel speed decrease switch; the
5. Use the electronic service tool (EST) to reload the software in the RHM module, and retest the system. If the
problem still exists, the RHM has failed. Replace the RHM.
55-5
55-6
Symptom: Reel speed synchronization cannot be engaged, or will not disengage.
Cause: Constant or no signal from reel speed synchronization switch on the right hand console.

1. Switch failed.
2. Open circuit on switch wiring in console.
3. Short to high voltage on switch signal wire.
Solution:
The reel synchronization switch S08 is a two position switch that connects power to the RHM when in the manual
position, and opens the signal wire when in the synchronization position. If the switch, signal or supply wiring fails
open, the unit will operate in synchronization mode continuously. If the signal wire is shorted to high voltage, the
unit will operate in manual mode continuously.

Select “RHM” sub menu.
Select “CSW Reel Speed Manual” and monitor the display while cycling the reel speed synchronization
switch. The “switch” screen should show “off” when the switch is in the synchronization position, and “on”
when the switch is in the manual position.
If the “Voltage” screen is selected, there should be approximately 5.0 volts with the switch in the manual
position, and 1.7 volts when the switch is in the synchronization position.
A. If the voltage is low (1.7 volts) and does not change, continue with Step 2.
B. If the voltage is high (5.0 volts) and does not change, continue with Step 9.
C. If the voltage reading is within the proper limits, continue the troubleshooting at step 10.
2. The voltage reading on the Infoview monitor is low (1.7 volts) and does not change. Inspect fuse F48.
A. If the fuse is okay, continue with Step 3.
B. If the fuse has failed, replace the fuse and repeat Step 1. If the fuse immediately fails, there is a short
to ground somewhere in the right console switch power circuit. Locate the short and repair.
3. The voltage reading on the Infoview monitor is low (1.7 volts) and does not change. Disconnect connector
X040 from the reel speed mode switch S08. Use a multimeter to check for voltage at connector X040 pin
2 wire 362 orange. There should be 12 volts.
A. If there is no voltage, continue with Step 4.
B. If there is 12 volts, continue with Step 7.
4. The voltage reading on the Infoview monitor is low (1.7 volts) and does not change. Locate the splice block
B, W02 in the right hand console. Use a multimeter to check for voltage at splice block B, W02 pin B. There
should be 12 volts.
A. If there is voltage, there is an open circuit in the right console (RC) harness between connector X040
pin 2 and splice block B, W02 pin B wire 321 orange or 362 orange. Locate the open and repair.
B. If there is no voltage, continue with Step 5.
55-7
B, W02 in the right hand console. Use a multimeter to check for voltage at splice block B, W02 pin M. There
should be 12 volts.
A. If there is voltage, there is an open circuit in the splice block B, W02. Locate the open and repair.
X001. Use a multimeter to check for voltage at connector X001 pin 3. There should be 12 volts.
A. If there is voltage, there is an open circuit in the right console (RC) harness between splice block B, W02
pin M and connector X001 pin 3 wire 287 orange or 108 orange. Locate the open and repair.
B. If there is no voltage, there is an open circuit in the cab main (CM) harness between fuse F48 and
connector X001 pin 3 wire 108 orange. Locate the open and repair.
7. The voltage reading on the Infoview monitor is low (1.7 volts) and does not change. Position the reel speed
mode switch S08 in the “Off” or “Manual” position. Disconnect connector X029 from the RHM module. Use
a multimeter to check for voltage at connector X029 pin 10 wire 333 yellow. There should be 12 volts.
X040 from the reel speed mode switch S08 and connector X029 from the RHM module. Use a multimeter
to check for continuity between connector X040 pin 1 and connector X029 pin 10 wire 333 yellow. There
should be continuity.
A. If there is no continuity, there is an open circuit in the right console (RC) harness between connector
X040 pin 1 and connector X029 pin 10 wire 333 yellow. Locate the open and repair.
B. If there is continuity, the reel speed mode switch S08 is not functioning. Replace the switch.
9. The voltage reading on the Infoview monitor is high (5.0 volts) and does not change. Key on. Disconnect
connector X040 from the reel speed mode switch S08. Use a multimeter to check for voltage on connector
X040 pin 1 wire 333 yellow. There should be approximately 1.7 volts.
A. If the voltage is high (>5.0 volts), there is an short circuit in the right console (RC) harness between
connector X040 pin 1 and connector X029 pin 10 wire 333 yellow. Locate the short and repair.
B. If there is approximately 1.7 volts, the circuit is functioning properly. Continue with Step 10.
55-8
55-9
55-10
REEL POSITION
The combine is equipped with control circuits to
control the reel height and fore/aft positioning on
headers equipped with reels, or to control the deck
plate opening on corn headers with hydraulic deck
plate adjustment.
Operator Controls
The operator may control the reel position using the 1
four way rocker pad, 1, on the multifunction handle
(MFH) that activates four different switches. The top
of the pad controls reel raise, the bottom controls reel 50031473
lower, the left controls reel fore, and the right controls 7
reel aft positioning.
When the operator depresses one of these switches,

a signal is transmitted to the RHM module in the right
hand console. The RHM module transmits this
information on the CAN network to the CCM2
module, which activates the appropriate solenoid on
the feeder valve stack.
Some headers may also be equipped with sensors

that monitor the vertical and horizontal positioning of
the reel. These sensors allow the CCM2 module to
directly control the reel positioning under some
circumstances without the direct involvement of the
operator. These sensors allow the CCM2 module to
automatically lower the reel, and move it rearward to
sweep the cutter bar clean of crop when the header
is raised at the headland of the field (header is raised
above the maximum stubble height defined in
calibration). In addition, these sensors allow the
operator to set the reel positioning as part of the
Automatic Crop Settings function on the combine.
Reel Fore-Back; must be set as “Installed” if header
installed on the combine is equipped with reel fore
and aft cylinders, or if it is a corn head with hydraulic
adjustable deck plates.
55-11
Fault Codes
If the reel positioning system is not functioning properly, check for the following fault codes and correct the
problem prior to beginning any other troubleshooting.
E0185--11 Header Reel Fore valve Unidentified Failure Code

E0189--11 Header Reel Back valve Unidentified Failure Code
E0187--11 Header Reel Up valve Unidentified Failure Code

E0188--11 Header Reel Down valve Unidentified Failure Code
55-12
REEL POSITIONING TROUBLESHOOTING

Symptom: Reel will not raise or lower.
Cause: No signal from reel raise or lower switches on MFH.

1. Switch failed.
Solution:
Select “HSW Reel Up” and monitor the display while cycling the reel raise switch. The “switch” screen should
show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts with
the switch open, and 1.8 volts when the switch is depressed.
7, with the black (common) probe of the multimeter on pin 7. Depress the reel raise switch; the resistance
should change from infinite to approximately 1.6 – 1.8 M ohms resistance.
Select “HSW Reel Down” and monitor the display while cycling the reel lower switch. The “switch” screen
should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts
with the switch open, and 1.8 volts when the switch is depressed.
7, with the black (common) probe of the multimeter on pin 7. Depress the reel lower switch; the resistance
55-13
55-14
Symptom: Reel will not move fore or aft.
Cause: No signal from reel fore or aft switches on MFH.

1. Switch failed.
Solution:
Select “HSW Reel Fore” and monitor the display while cycling the reel fore switch. The “switch” screen should
7, with the black (common) probe of the multimeter on pin 7. Depress the reel fore switch; the resistance
Select “HSW Reel Back” and monitor the display while cycling the reel aft switch. The “switch” screen should
7, with the black (common) probe of the multimeter on pin 7. Depress the reel aft switch; the resistance should
change from infinite to approximately 1.6 – 1.8 M ohms resistance.
55-15
10
55-16
HEADER HEIGHT CONTROL

The combine is equipped with control circuits to
control the header height and lateral tilt positioning.
Operator controls
The operator may control the header position using
the four way rocker pad, 1, on the multifunction
handle (MFH) that activates four different switches.
The top of the pad controls head raise, the bottom
controls head lower, the left controls head tilt CCW,
and the right controls head tilt CW positioning. The
header raise and lower switches are two position 1
switches, which offers two speeds of raise and lower.
When the switch is depressed to the first position, the
head will raise or lower slowly, and when depressed
further to the second position, the head will raise or
lower quickly. 50031473
11
NOTE: The slow raise rate and the fast lower rate
may be adjusted in the “Header” configuration
screen.
When the operator depresses one of these switches,

a signal is transmitted to the RHM module in the right
hand console. The RHM module transmits this
information on the CAN network to the HHC module,
which activates the appropriate solenoid on the main
valve stack (header lift) or feeder valve stack (header
tilt).
The Resume switch, 1, on the MFH is used by the
operator for enabling the automatic header height
modes. The automatic mode that is enabled must
first be set using the Head Height Mode switch, 2,
which is a three position switch. Positions 1 and 2 1
may be programmed for Stubble Height or Autofloat
operation, while the third position is intended to be
programmed for Pressure Compensation operation.
NOTE: The threshing and feeder systems must be

engaged in order for the automatic header height 2
systems to be engaged.
50031473
The operator engages the selected mode by
pressing the Resume switch on the MFH once; the 12
head will then lower to the pre-selected position
based on the setting of the Head Height Mode switch.
While in the automatic mode, the operator may
switch between the different modes simply by
switching the Head Height Mode switch. The
automatic modes are disengaged whenever the
operator manually raises the header above the
maximum stubble height that has been calibrated, or
when the operator double-presses the Resume
switch, which causes the header to automatically
raise to the maximum stubble height.
55-17
Header Height Sensors
Several sensors on the combine and header provide
information to the HHC module to provide for
automatic header height control functions, as
follows:
-- Feeder Angle sensor, 1; is a potentiometer
which provides information to the HHC module
regarding the precise position of the feeder
housing relative to the combine frame. This
information is used for determining minimum and 1
maximum stubble height.
40025215
13
-- Header Lift Pressure sensor, 1; is mounted in
the main valve stack, and monitors the pressure
in the lift cylinder supply line. This information is
used for the header compensation system.
10020031
14
-- Stubble Height (Autofloat) sensors, 1; are
mounted on the header, and are connected to the
sense bars on the flexible header, or to the
protection plates on rigid headers. These
sensors provide precise feedback about the
header clearance to the ground within a specific 1
operating range.
50023023
15
55-18
In addition, signals are used from other components
on the combine in order to control the header height
system.
Feeder Engage Switch; must be engaged, and

provide voltage to CCM1 before any of the automatic
header height modes may be engaged. Note that the
Threshing Engage switch must be engaged first to
provide voltage to the Feeder Engage switch.
Ground Speed sensor; is mounted in the combine

transmission, and provides a signal to CCM2 for
ground speed calculations. The ground speed
information is used when operating in a header height
mode in order to adjust the amount of header height
corrections, to preventing overcorrecting and “hunting”.
If the combine is equipped with lateral tilt, the

combine will be equipped with a Lateral Tilt sensor
to monitor the movement of the feeder faceplate.
This sensor provides a signal which is used for lateral
tilt position display on the Infoview monitor only; this
signal is not used by the header height control
system for header control.
Calibration
There are several calibrations that must be
completed each time a head is installed on the
combine in order to ensure proper operation of the
header height control systems.
Header: The ‘Header’ calibration needs to be

completed whenever a header is changed on the
combine, to ensure that the correct settings are
stored for the following values:
• Ground position; head must be manually
lowered to the ground, and the Resume and
Head Lower switches are then pressed for seven
seconds to set the ground level position. This
16
calibration stores the Feeder Angle sensor signal
at this position. If the head is equipped with
stubble height sensors, then the signals from
these sensors are recorded also.
55-19
• Pressure signal above soil: head is lowered to a
position just above the ground, but not touching it,
and the Resume button is then pressed for seven
seconds to record the cylinder pressure mea-
sured by the Header Lift Pressure sensor. This
calibration is essentially recording the “weight” of
the head so that the system can recognize when
the head makes contact with the ground.
• Maximum lift height: the header is raised to the
maximum possible lift height, and the Resume
and Head Raise switches are then held for seven
seconds to record the signal from the Feeder
Angle sensor. This records the maximum
possible lift height, and helps establish the
operating range of the Feeder Angle sensor.
Maximum Stubble Height: the header is raised to

an operator-selected height at which the area-count-
ing will be stopped, and above which the automatic
header height modes will not operate. This setting
would typically be the height the header would be
raised to when turning on the headland. The signal
from the Feeder Angle sensor, and the Stubble
Height sensors (if equipped) is recorded for this
setting.
17
55-20
There are a number of settings that need to be made
in the “Header” configuration menu to ensure proper
operation of the header height systems.
Header Raise Rate; the manual slow raise speed

may be set to the speed desired by the operator.
Header Lower Rate; the manual fast lower speed

may be set to the speed desired by the operator.
Header threshold pressure; this setting determines

when the header height control system should switch
into the compensation mode if the header contacts
the ground. In general, this setting is best left at the 18
factory setting.
Header Lateral Float; must be set as “Installed” if

header height control is installed on the combine.
Header Autofloat; must be set as “Installed” if

Autofloat sensors are installed on the header.
Maximum Stubble Height; displays a relative value to

indicate the maximum stubble height that has been
currently calibrated.
Header Lift Cylinders; is factory-set for the size of lift

cylinders installed, and may not be changed from the
operator interface.
Auto Header Lift; must be set as “Installed” if using a 19

header at low cutting heights or in Compensation
mode. When installed, the header will raise off the
ground automatically if the combine is driven in
reverse to protect header components.
Head Accumulator Operation

The combine is equipped with an accumulator, 1,
which is connected to the header lift cylinders
through an accumulator control valve. This valve is
1
used to ‘connect’ or ‘disconnect’ the accumulator
from the header lift circuit as required for proper
operation.
40025225
20
55-21
In most cases, the accumulator valve will be Header Operating Modes – Dynamic Ride
positioned to connect the accumulator to the Control
cylinders, however, the accumulator is disconnected Dynamic Ride Control is automatically engaged and
in the following conditions: disengaged by the HHC module whenever neces-
sary, and is not controlled by the operator. In this
• Head Raise switch depressed; the accumulator mode, the HHC module evaluates the signals from
is switched off for 2 seconds the header lift pressure sensor, and makes slight
• Head Lower switch depressed; the accumulator adjustments to header raise and lower as necessary
is switched off for 2.5 seconds to dampen any oscillations in header movement,
• Stubbleheight mode engaged; the accumulator such as when travelling over rough ground. By
is switched off for 2 seconds actively damping header oscillations, bouncing
• Autofloat mode engaged; the accumulator is oscillations are reduced, steering safety is improved,
switched off for 4 seconds operator comfort is improved, and stress loads on the
combine and header frames are reduced.
• Pressure Compensation mode engaged; the
accumulator is switched off for 2 seconds In order for Dynamic Ride Control to be engaged,
NOTE: During engagement of an automatic header several conditions must be met:
height mode, if the header reaches a position close • Accumulator must be switched on
to the ground, or contacts the ground, the
• Feeder Angle sensor must be functioning (no
accumulator is switched on immediately.
errors)
• If an automatic mode is not selected, and the • Header Lift Pressure sensor must be functioning
header lift pressure signal drops below half of the (no errors)
recorded pressure signal (header weight), the • If feeder is disengaged, Dynamic Ride Control is
accumulator stays switched off as long as the active irregardless of header position.
pressure is reduced. This would typically occur • If feeder is engaged, Dynamic Ride Control is
when a header is removed from the combine. active only when header is above Maximum
• If an automatic mode is not selected, and the Stubble Height (defined by operator in Calibra-
header lift pressure signal increases above 180 tion screen)
bar (2646 psi), the accumulator stays switched
off until the pressure drops below this level. This
would typically occur when the header is raised
to the maximum lift height.
55-22
Header Operating Modes -- Transport
The Transport mode is the default operating header
height control mode, and allows the operator to make
manual adjustments to the header position using the
control switches, 1. This mode is automatically
selected whenever the feeder drive is disengaged,
and remains active with the feeder drive engaged
until one of the automatic header height modes is 1
engaged. The accumulator is turned on in this mode.
The header position selected by the operator will be

maintained by the HHC module. If necessary, the
header raise valve will activate to make up for any 50031473
leakage in the header lift circuit, as monitored by the
feeder angle sensor. 21
Dynamic Ride Control is active in the Transport mode

in all header positions if the feeder drive is not
engaged, but if the feeder is engaged, it is active
above Maximum Stubble Height position only.
When the Road-Field mode switch on the RH

console is moved to the ‘Road’ position, and the
header raise switch is pressed, the header will
automatically raise to an appropriate height for road
transport. The header control switches are then
disabled until the ‘Field’ mode is selected.
Header Operating Modes – Stubble Height
NOTE: The feeder drive must be engaged in order
for Stubble Height operating mode to be selected.
3
The stubble height mode allows an operator to set a
specific operating height for the head, and return to 2
that height repeatedly. To engage the stubble height
mode, the operator positions the Header Height
Mode switch, 1, to the forward or mid position, and
presses the ‘Resume’ switch, 2, on the MFH once.
The header will automatically lower to the previously 1
set operating height. If the operator depresses the
‘Resume’ switch twice quickly, the header will raise 50031473
from the set operating height to just above the
Maximum Stubble Height position for turning on the 22
headland. Depressing the Resume switch once will
reposition the head back to the set operating height.
The operator may change the set height at any time

by depressing the head raise slow or head lower slow
switches, 3, to position the head at the desired
operating height, and then depress the Resume
switch for 2 seconds to ‘memorize’ the new operating
height.
NOTE: The effective operating range of the Stubble

Height mode is from 2% below the operator-specified
maximum stubble height to 2% below the calibrated
ground level.
55-23
If the header contacts the ground while in the Stubble
Height mode (determined based on a drop of header
pressure signal), the combine will automatically raise
the head as required to maintain minimum ground
pressure to avoid bulldozing and to prevent damage
to the head.
Dynamic Ride Control is not active when the Stubble

Height mode is engaged.
Header Operating Modes -- Autofloat

for the Autofloat operating mode to be selected.
If the header being used on the combine is equipped

with Autofloat sensors, the header height control
system on the combine may be operated in the
Autofloat mode. The Autofloat mode allows an
operator to set a specific operating height for the
head, and return to that height repeatedly. In
addition, the combine will automatically adjust the
header height based on feedback from the header
Autofloat sensors to maintain that specific operating
height relative to the ground surface.
To engage the Autofloat mode, the operator positions
the Header Height Mode switch, 1, to the forward or
mid position, and presses the ‘Resume’ switch, 2, on
the MFH once. The header will automatically lower 3
until the header sensors contact the ground, and the
previously set operating height is reached. If the 2
operator depresses the ‘Resume’ switch twice
quickly, the header will raise from the set operating
height to just above the Maximum Stubble Height
position for turning on the headland. Depressing the
Resume switch once will reposition the head back to 1
the set operating height.
50031473
The operator may change the set height at any time by
depressing the head raise slow or head lower slow 23
switches, 3, to position the head at the desired
operating height, and then depress the Resume switch
for 2 seconds to ‘memorize’ the new operating height.
If the combine is equipped with lateral tilt, the header

tilt will also be controlled automatically by adjusting
the header tilt to get the same distance to the ground
from both Autofloat sensors on the head. The
automatic lateral tilt control remains active during
changes in the operating height made by the operator.
The operator may also temporarily override the
automatic lateral tilt by depressing the head tilt left or
right switches, 3; the automatic lateral tilt control will
resume after the operator releases the switch.
NOTE: The operating height range in the Autofloat

mode is limited to the operational range of the header
sensors.
55-24
If the header contacts the ground while in the
Autofloat mode (determined based on a drop of
header pressure signal), the combine will automati-
cally raise the head as required to maintain minimum
ground pressure to avoid bulldozing and to prevent
damage to the head.
Dynamic Ride Control is not active when the

Autofloat mode is engaged.
Header Operating Modes – Pressure

Compensation
for the Pressure Compensation operating mode to
be selected.
The pressure compensation mode allows an

operator to operate a head in contact with the ground
surface at a specific surface pressure. As the
combine and head move through the field, the
combine monitors the hydraulic pressure in the
header lift cylinders, and raises or lowers the head as
required to maintain the pressure set by the operator.
To engage the pressure compensation mode, the
operator positions the Header Height Mode switch,
1, to the rearward position, and presses the
‘Resume’ switch, 2, on the MFH once. The header 3
will automatically lower to the ground until the
desired ground pressure is reached. If the operator 2
depresses the ‘Resume’ switch twice quickly, the
header will raise from the ground to just above the
Maximum Stubble Height position for turning on the
headland. Depressing the Resume switch once will
reposition the head back to the ground at the set 1
ground pressure.
50031473
The operator may change the ground pressure at
any time by depressing the head raise slow or head 24
lower slow switches, 3, to position the head at the
desired ground pressure, and then depress the
Resume switch for 2 seconds to ‘memorize’ the new
pressure value.
The operating range for the pressure compensation

is based on a percentage range of the calibrated
pressure signal above the soil for that head. The
range is set at 6% greater than to 75% less than the
calibrated pressure signal for that head. It is
important to understand that the friction in the feeder
pivot and lift cylinders must be overcome in order for
a pressure change to be detected in the header lift
circuit and the system to provide an adjustment – the
sensitivity of the Pressure Compensation system is
limited by this amount of friction.
55-25
If the combine is equipped with lateral tilt, and the
head is equipped with Autofloat sensors, the header
tilt will also be controlled automatically by adjusting
the header tilt to get the same distance to the ground
from both Autofloat sensors on the head. The
automatic lateral tilt control remains active during
changes in the head ground pressure made by the
operator. The operator may also temporarily override
the automatic lateral tilt by depressing the head tilt
left or right switches, 3; the automatic lateral tilt
control will resume after the operator releases the
switch.
If the header loses contacts with the ground while in

the Pressure Compensation mode (determined
based on a rise of header height above the ground
position as measured by the head Autofloat
sensors), the combine will automatically lower the
head as required to maintain the desired ground.
This will occur only if the head is equipped with
Autofloat sensors.
Dynamic Ride Control is not active when the

Pressure Compensation mode is engaged.
Fault Codes
If the header height control system is not functioning properly, check for the following fault codes and correct the
problem prior to beginning any other troubleshooting.
E0080--12 HHC Module Bad Intelligent Device
E0512--05 Feeder Angle sensor Line Disconnected
E0513--05 Header Lift Pressure sens Line Disconnected
E0514--05 R Stubble Height / Flex R Line Disconnected

E0515--05 L Stubble Height / Flex L Line Disconnected
E0516--11 Lateral Float CCW valve Unidentified Failure Code

E0517--11 Lateral Float CW valve Unidentified Failure Code
E0518--11 Header Up valve Unidentified Failure Code

E0519--11 Header Down valve Unidentified Failure Code
55-26
HEADER HEIGHT CONTROL TROUBLESHOOTING

Symptom: Header will not raise or lower manually.
Cause: No signal from head raise or lower switches on MFH.

1. Switch failed.
Solution:
Select “HSW Header Up Slow” and monitor the display while cycling the head raise switch. The “switch”
screen should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be
5.1 volts with the switch open, and 1.8 volts when the switch is depressed.
6, with the black (common) probe of the multimeter on pin 6. Depress the head raise slow switch; the
Select “HSW Header Up Fast” and monitor the display while cycling the head raise switch to the second
position. The “switch” screen should show “on” when the switch is fully depressed. If the “Voltage” screen
is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed.
6, with the black (common) probe of the multimeter on pin 6. Fully depress the head raise switch; the
55-27

Select “HSW Header Down Slow” and monitor the display while cycling the header lower switch. The “switch”
6, with the black (common) probe of the multimeter on pin 6. Depress the header down switch; the resistance
Select “HSW Header Down Fast” and monitor the display while cycling the header lower switch to the second
position. The “switch” screen should show “on” when the switch is fully depressed. If the “Voltage” screen
is selected, there should be 5.1 volts with the switch open, and 1.8 volts when the switch is depressed.
6, with the black (common) probe of the multimeter on pin 6. Fully depress the header down switch; the
55-28
25
55-29
Symptom: Head will not tilt left or right.
Cause: No signal from head tilt left or tilt right switches on MFH.

1. Switch failed.
Solution:
Select “HSW Head Tilt Left” and monitor the display while cycling the head tilt left switch. The “switch” screen
should show “on” when the switch is depressed. If the “Voltage” screen is selected, there should be 5.1 volts
with the switch open, and 1.8 volts when the switch is depressed.
6, with the black (common) probe of the multimeter on pin 6. Depress the head tilt left switch; the resistance
Select “HSW Head Tilt Right” and monitor the display while cycling the head tilt right switch. The “switch”
6, with the black (common) probe of the multimeter on pin 6. Depress the head tilt right switch; the resistance
55-30
26
55-31
Symptom: One or more of the header height operating modes cannot be engaged or disengaged.
Cause: Constant or no signal from header height mode switch on the right hand console.

1. Switch failed.
3. Short to high voltage on switch signal wires.
Solution:
The header height mode switch S04 is a three position switch that connects power to the RHM connector X029
pin 3 when in Stubble Height/Autofloat position 1, opens both signal wires when in Stubble Height/Autofloat
position 2, or connects power to the RHM connector X029 pin 11 when in Pressure Compensation position. If
the switch, signal or supply wiring fails open, the unit will operate in Stubble Height/Autofloat position 2 mode
continuously.

Select “CSW HHC Auto Height” and monitor the display while cycling the header height mode switch. The
“switch” screen should show “off” when the switch is in Stubble Height/Autofloat position 2 (mid position), and
“on” when the switch is in Stubble Height/Autofloat position 1 (forward position).
If the “Voltage” screen is selected, there should be approximately 5.0 volts with the switch in Stubble
Height/Autofloat position 1 (forward), and 1.7 volts when the switch is in Stubble Height/Autofloat position
2 (mid).

Select “CSW HHC Compensation” and monitor the display while cycling the header height mode switch. The
“switch” screen should show “off” when the switch is in Stubble Height/Autofloat position 2 (mid position), and
“on” when the switch is in Pressure Compensation (rearward position).
If the “Voltage” screen is selected, there should be approximately 5.0 volts with the switch in Pressure
Compensation (rearward position), and 1.7 volts when the switch is in Stubble Height/Autofloat position 2
(mid).
A. If the voltage is low (1.7 volts) and does not change for either or both signal wires, continue with Step
3.
C. If the voltage readings for both signal wires are within the proper limits, continue the troubleshooting
at step 14.
B. If the fuse has failed, replace the fuse and repeat Steps 1 & 2. If the fuse immediately fails, there is a
short to ground somewhere in the right console switch power circuit. Locate the short and repair.
55-32
X061 from the header height mode switch S04. Use a multimeter to check for voltage at connector X061
pin 2 wire 361 orange. There should be 12 volts.
B, W02 in the right hand console. Use a multimeter to check for voltage at splice block B, W02 pin H. There
should be 12 volts.
pin 2 and splice block B, W02 pin H wire 361 orange. Locate the open and repair.
should be 12 volts.
A. If there is voltage, there is an open circuit in the splice block B, W02. Locate the open and repair.
B. If there is no voltage, there is an open circuit in the cab main (CM) harness between fuse F48 and
connector X001 pin 3 wire 108 orange. Locate the open and repair.
8. The voltage reading on the Infoview monitor is low (1.7 volts) and does not change. Position the header height
mode switch S04 in Stubble Height/Autofloat position 1. Disconnect connector X029 from the RHM module.
Use a multimeter to check for voltage at connector X029 pin 3 wire 330 yellow. There should be 12 volts.
X061 from the header height mode switch S04 and connector X029 from the RHM module. Use a multimeter
B. If there is continuity, the header height mode switch S04 is not functioning. Replace the switch.
10. The voltage reading on the Infoview monitor is low (1.7 volts) and does not change. Position the header height
mode switch S04 in the Pressure Compensation position. Disconnect connector X029 from the RHM
module. Use a multimeter to check for voltage at connector X029 pin 11 wire 331 yellow. There should be
12 volts.
X061 from the header height mode switch S04 and connector X029 from the RHM module. Use a multimeter
B. If there is continuity, the header height mode switch S04 is not functioning. Replace the switch.
55-33
12. The voltage reading on the Infoview monitor is high (5.0 volts) when the header mode switch S04 is in Stubble
Height/Autofloat position 1, and does not change. Key on. Disconnect connector X061 from the header
height mode switch S04. Use a multimeter to check for voltage on connector X061 pin 3 wire 330 yellow.
There should be approximately 1.7 volts.
13. The voltage reading on the Infoview monitor is high (5.0 volts) when the header mode switch S04 is in the
Pressure Compensation position, and does not change. Key on. Disconnect connector X061 from the
header height mode switch S04. Use a multimeter to check for voltage on connector X061 pin 1 wire 331
yellow. There should be approximately 1.7 volts.
55-34
27
55-35
28
55-36
Chapter 11 - Feeder Systems
CONTENTS

Feeder Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Feeder Engagement Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Conditions that Prevent Feeder Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Feeder Engage - Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Feeder Engage - Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Feeder Engage Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Feeder Engage - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Feeder Speed (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Feeder Engagement Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Feeder Speed Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Feeder Speed Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Feeder Reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Feeder Reverser - Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Feeder Reverser - Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Feeder Reverser - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Advanced Stone Protection (ASP) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Stone Ejection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ASP System - Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ASP System - Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ASP System - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
55-1
The Feeder System consist of the following systems:
Feeder Engage
Feeder Variable Speed
Feeder Reverser
ASP (Advanced Stone Protection) System
FEEDER ENGAGE
The feeder uses logic to prevent damage to the
mechanical components of the system.
Operation of the feeder system is quite simple. With
the thresher engaged, the operator simply raises the 5 4
Feeder Engage Switch, 1, to activate the Feeder.
3
To deactivate the feeder, the operator can depress
1
the Engage switch, 1, or hold in the Emergency stop
button, 2. When the emergency stop button, 2, on
MFH is depressed for a few seconds the feeder will 2
stop and the stone door will kick open. Raise the
feeder to close the stone door. Once the sensor
senses that the door is closed, the cylinder will
release, latching the stone door.
Feeder Engagement Requirements 20030010
Although Feeder engagement is simple, there are 1

many conditions that must be met in order to activate
the feeder. These conditions are monitored by the
electrical system on the combine. It is important to
understand all of these conditions to troubleshoot
concerns with the Feeder System.
• The Thresher Switch, 3, must be in the “on”

position.
• The Reverser switch, 4, must be in the “off”
position. If the operator tries to engage the feeder
when the Reverser is engaged, an Alarm
message is generated.
• The engine must be running 500 rpm or more.
• The Road/Field Mode switch, 5, must be in the
“FIELD” position.
• The Feeder Engage Switch, 1, must be in the “on”
position. Power through the feeder engage
switch, 1, on the right console to CCM is also used
for output to the feeder engage solenoid (just like
thresher system). In the event that power through
the switch is lost, the output is also immediately
lost and power stops traveling to the feeder.
• The feeder drive ties into the Operator Presence
switch in the seat - if the operator gets out of the
seat for a brief period, the feeder drive is
disengaged. This generates an alarm message
within the Infoview monitor.
55-2
Conditions that Prevent Feeder Engagement
• Thresher not activated before attempting to
engage Feeder.
• Reverser switch in the “On” position.
• Field Switch in “Road” Mode.
• Feeder Engage Switch in the “On” position
during engine startup. Feeder Engage Switch
must be cycled to “Off” and then “On” for
activation.
• Engine speed below 500 rpm.
• Seat Switch “Open” (no operator in seat) for 5
Seconds or more.
• Emergency stop switch on MFH activated.
• Stone Trap Door Open
Feeder Engage - Alarms

Error Description
A0014 Feeder Reverser Engaged
A0015 Seat Switch Open
Feeder Engage - Error Codes

Error Code Description Result
E0004-03 Fdr Reverser Disengaged Shorted to high source Will not affect operation
E0004-04 Fdr Reverser Disengaged Shorted to low source Will not affect operation
E0004-05 Fdr Reverser Disengaged Line Disconnected Will not affect operation
E0047-03 V Supply Feeder Clutch Shorted to high source Feeder will not engage
E0047-04 V Supply Feeder Clutch Shorted to low source Feeder will not engage
E0050-03 Isense Feeder Clutch Shorted to high source Feeder will not engage
E0052-11 Feeder Clutch valve Unidentified Failure Code Feeder will not engage
Feeder Engage Circuit

Power to the feeder engage switch S-31 is supplied
from pin 5 of the Thresher switch S-30 whenever the
combine engine is running and the Thresher is
Engaged. Current flows to pin 5 of the Feeder engage
switch. When the Feeder engage switch S-31 is moved
to the “On” position, current flows from pin 5, through
connector X001 to reach pin 1 of the Feeder Disengage
Relay, K-19. Current reaching pin 1 of the Feeder
Disengage Relay energizes the relay and passes
through a jumper wire to reach pin J1-7 of CCM-1.
When the power from the feeder engage switch reaches
pin J1-7 of CCM-1, current is sent from pin J2-30 to
reach the Feeder Clutch (pin 1). The solenoid within the
Feeder Clutch L-24 begins to engage. CCM-1 monitors
current flowing from pin 2 of the feeder clutch to pin
J2-40. Refer to chapter 18 CCM1 “Fault Codes” for
more information on the feeder clutch.
55-3
55-4

55-5

55-6
Feeder Engage - Troubleshooting
Symptom: Feeder will not engage.
NOTE: Check for all active alarms and errors, and correct before following this troubleshooting procedure.
Solution:
1. Ensure that the “On-the-Road” switch S30 is in the ‘Field’ position.
A. If switch is in the ‘Road’ position, move it to the ‘Field’ position and retest for feeder engage. Continue
with step 2 if necessary.
B. If switch is in the ‘Field’ position, continue with step 2.
2. Enter the InfoViewt monitor - Diagnose Info screen.

Select “Console” sub menu.
Select “On-the-road switch” and cycle the On the Road switch S12 to check voltage range. The voltage
should be 0 when the switch is in the “Field” position, and 12 volts when in the “Road” position.
A. If the voltage reading is correct (0v = Field, 12v = Road), continue with Step 2.
B. If the voltage reading remains at 0 volts, there is an open circuit in the right console (RC) harness between
the On-the-Road switch S12 and the RHM connector X029 pin 16 wire 339 yellow. Locate the open and
repair.
C. If the voltage reading remains at 12 volts, there is a short circuit to high voltage in the right console (RC)
harness between the On-the-Road switch S12 and the RHM connector X029 pin 16 wire 339 yellow.
the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex the har-
nesses involved to reveal intermittent breaks or shorts in the wiring concerned.
3. Move the thresher engage switch S30 to the ‘engaged’ position. Enter the InfoViewt monitor - Diagnose
Info screen.
Select “Threshing” sub menu.
Select “V Supply Thresher Clutch” and check the voltage range. The voltage should be 0 when the switch
is in the “Off” position, and 12 volts when in the “engaged” position.
A. If the voltage reading is correct (0v = ‘Off’, 12v = ‘engaged’), continue with Step 4.
B. If the voltage reading remains at 0 volts, go to Chapter 12 - Threshing Systems to correct the problem
of thresher not engaging.
4. Move the feeder engage switch S31 to the ‘engaged’ position. Enter the InfoViewt monitor - Diagnose Info
screen.
Select “Feeder” sub menu.
Select “V Supply Feeder Clutch” and check the voltage range. The voltage should be 0 when the switch is
in the “Off” position, and 12 volts when in the “engaged” position.
A. If the voltage reading is correct (0v = ‘Off’, 12v = ‘engaged’), go to Step 10.
B. If the voltage reading remains at 0 volts, continue with step 5.
5. Key on, feeder engage switch S31 engaged. Use a multi-meter to carefully back-probe connector X018
pin J1-7 and measure the voltage; the voltage should be 12 volts.
A. Multimeter indicates 12 volts. Continue with step 10.
B. There is no voltage present. Continue with step 6.
55-7
6. Key on, feeder engage switch S31 engaged. Remove the feeder disengage relay K19 (if installed) from
the fuse panel. Use a multi-meter to test for voltage at pin 1 of the relay base in the fuse panel. There should
be 12 volts.
A. If there is voltage, there is an open circuit in the cab main (CM) harness between the feeder engage relay
K19 pin 1 and connector X018 pin J1-7 wire 1211 yellow. Locate the open and repair.
B. If there is no voltage, continue with step 7.
7. Key off. Disconnect connector X001. Use a multi-meter to check for continuity between connector X001
pin 15 and connector X015 pin J1-7. There should be continuity.
A. If there is continuity, continue with step 8.
B. If there is no continuity, there is an open circuit in the cab main (CM) harness between connector X001
pin 15 and feeder engage relay K19 pin 1 wire 112 yellow. Locate the open and repair.
8. Key off. Disconnect connector X001. Remove the top portion of the RH console, and unplug connector
X056 at the feeder engage switch S31. Use a multimeter to check for continuity between connector X001
pin 15 and connector X056 pin 5 on the RC harness end of the connectors.
B. If there is no continuity, there is an open circuit in the right console (RC) harness between connector
9. Key off, feeder engage switch S31 engaged. Remove the top portion of the RH console, and unplug
connector X056 at the feeder engage switch S31. Use a multi-meter to test for continuity between the switch
end of connector X056 pins 5 & 6.
A. If there is no continuity, the feeder engage switch S31 is defective. Replace the switch.
B. If there is continuity, there is an open circuit in the right console (RC) harness between connector X056
pin 6 and a RC harness splice wire 861 yellow. Locate the open and repair.
10. The electrical portion of the feeder engage system is functioning properly. Inspect the following areas of the
combine:
-- Damaged or restricted line from the low pressure valve block to the feeder clutch.
55-8
55-9
FEEDER SPEED (OPTIONAL) Feeder Speed Errors

Feeder speed is adjusted from the cab by the The combine electronic system monitors the Feeder
operator using a switch on the right console, and the speed sensor B14 and the outputs to the Feeder
Feeder RPM may be monitored using the Infoview increase and decrease solenoids L11/L12. In the
monitor. The Feeder speed is adjusted using event of any problems with these circuits, the
electrical control of a hydraulic valve assembly that appropriate fault code will be displayed to indicate
controls a hydraulic piston in the Feeder drive the specific fault with these components and the
variable sheave. circuits containing them.
Feeder Speed Adjust The following fault codes relate to the Feeder speed
sensor B14:
When the operator moves the Feeder speed switch
S18 on the right console, a 12 volt signal is sent to the E0014-03 Feeder RPM sensor Shorted
right hand module (RHM). To increase Feeder to High Source
speed, a 12v signal is sent to connector X030 pin 12
wire 351 yellow; to decrease Feeder speed, a 12v E0014-04 Feeder RPM sensor Shorted
signal is sent to connector X030 pin 5 wire 350 to Low Source
yellow.
E0014-05 Feeder RPM sensor Line
When the RHM receives a Feeder speed increase or Disconnected
decrease signal, it broadcasts a message over CAN
which is picked up by CCM1. CCM1 will then activate The following fault code relates to the Feeder
the appropriate output to change the Feeder speed. increase solenoid L11:
Power is sent to the Feeder increase solenoid L11 to
increase Feeder speed, while the Feeder decrease E0082-11 Feeder Speed Incr (1) Unidentified
solenoid L12 is powered to decrease Feeder speed. Failure Code
These solenoids are simply turned ‘on’ or ‘off’, so do
not need to be grounded back through CCM1 like a The following fault code related to the Feeder
PWM solenoid. Both solenoids are grounded at the decrease solenoid L12:
main frame ground #2, located behind the left rear
corner of the cab on the main frame. E0083-11 Feeder Speed Decr (1) Unidentified
Failure Code
The actual Feeder rpm is measured at the left end of
the top feeder shaft using the Feeder rpm sensor
B14.
55-10
50031005
55-11
Feeder Speed Troubleshooting
Symptom: Feeder speed will not increase or decrease.
Solution:
Select “CSW Feeder Speed Incr” or “CSW Feeder Speed Decr”, and cycle the Feeder speed switch S18
in both directions to check voltage range. The voltage should be approximately 1.5 volts when the switch is
in the “middle” position, and 5 volts when in the “Increase” or “Decrease” positions.
A. If the voltage readings are correct, continue with Step 9.
B. If there is no 5 volt reading in any switch position, continue with step 2.
C. If the voltage reading indicates 5 volts for “CSW Feeder Speed Incr” but 1.5 volts for “CSW Feeder Speed
Decr”, there is an open circuit in the right console (RC) harness between the Feeder speed switch S18
pin 1 and the RHM connector X030 pin 5 wire 350 yellow. Locate the open and repair.
D. If the voltage reading indicates 5 volts for “CSW Feeder Speed Decr” but 1.5 volts for “CSW Feeder
Speed Incr”, there is an open circuit in the right console (RC) harness between the Feeder speed switch
S18 pin 3 and the RHM connector X030 pin 12 wire 351 yellow. Locate the open and repair.
2. Key switch in “On” position. Check fuse F48.

A. If fuse F48 is okay, continue with step 4.
B. If the fuse is blown, go to step 3.
3. Replace the failed fuse F48.

A. If the fuse is okay, continue with step 4.
B. If the fuse immediately fails again, a short to ground exists in one of the following wires:
Wire 109 orange, fuse F48 to thresher latching relay K28, terminal 3
Wire 108 orange, fuse F48 to connector X001, pin 3
Wire 110 orange, RC harness splice to thresher engage switch S30 pin 3
Wire 300 orange, RC harness splice to neutral switch S22 pin 1
Switch power wires from splice block B, W02 in the RH console (refer to frame 17 of electrical schematic
for more information)
Locate the short to ground and repair.
4. Toggle the Feeder speed switch S18 in both directions, and observe the fuse F48.
B. If the fuse immediately fails in the ‘decrease’ direction, there is a short to ground in the right console (RC)
harness between the Feeder speed switch connector X047 pin 1 and connector X030 pin 5 wire 350
yellow. Locate the short and repair.
C. If the fuse immediately fails in the ‘increase’ direction, there is a short to ground in the right console (RC)
harness between the Feeder speed switch connector X047 pin 3 and connector X030 pin 12 wire 351
55-12
5. Unbolt the top half of the right console to gain access to the Feeder speed switch S18 connector X047. Turn
the key switch to the “On” position. Unplug connector X047, and use a multi-meter to measure the voltage
at right console (RC) harness end of connector X047 pin 2. There should be 12 volts.
A. If there is 12 volts, the Feeder speed switch S18 is defective. Replace the switch.
6. Key on. Use a multi-meter to measure the voltage at splice block A, W02, pin A. There should be 12 volts.
A. If there is no voltage, continue with step 7.
B. If there is 12 volts, there is an open circuit in the right console (RC) harness between splice block A,
W02, pin A and connector X047 pin 2 wire 327 orange or 375 orange. Locate the open and repair.
7. Key on. Use a multi-meter to measure the voltage at splice block A, W02, pin M. There should be 12 volts.
B. If there is 12 volts, there is an open circuit internally in the splice block due to loose wire connections,
or a corroded or damaged splice bar. Repair or replace the splice block as required to repair the open.
8. Key on. Disconnect connector X001. Use a multi-meter to measure the voltage at connector X001 pin 3.
There should be 12 volts.
A. If there is no voltage, there is an open circuit in the cab main (CM) harness between connector X001
pin 3 and fuse F48 wire 108 orange. Locate the open and repair.
B. If there is voltage, there is an open circuit in the right console (RC) harness between splice block A, W02,
9. Verify that the RHM and CCM2 modules are on-line on the network by entering the InfoViewt monitor -
Service Info screen.
Select “Network” sub menu.
Scroll through the screen as necessary to locate the RHM and CCM2 icons. If either of the icons are ‘grayed
out’, the indicated module is off-line and is not capable of transmitting on the network. Refer to Section 55
Electrical, Chapter 4 - ‘CAN Network’ in this manual for more information in troubleshooting this concern.
55-13
50031005
55-14
55-15
FEEDER REVERSER
1
Description
The combine is equipped with a system to reverse
the gathering chains (in case of a corn header), the
auger, and the feeder should a blockage occur. The 3
feeder reverser switch, 1, is located on the right hand
console. Use the reel speed buttons, 2, and 3, to 2
rotate the feeder forward or reverse.
20030010
4
1. Feeder Reverser Actuator
2. Feeder Reverser Disengage Sensor
The following conditions must be met to engage the
Feeder Reverser:
• Engine running
• Thresher switch in the “Off” position for a
minimum of one second.
• The Road/Field Mode switch must be in the 2
“field” position.
When the reverser switch is activated, the reverser

1
actuator moves the clutch pawl to engage the drive 10020041
gear. After approximately two seconds, the reverser
actuator is fully engaged, allowing the operator to 5
use the reel speed buttons to rotate the feeder
forward or backward.
The Feeder Reverser Disengage Sensor, 2, monitors
the position of the Feeder Reverser Clutch Pawl. The
purpose of this sensor is to prevent the Feeder from
being engaged while the Reverser is activated.
Feeder Reverser - Alarms
Alarm Description
A0014 Feeder Reverser Engaged
Feeder Reverser - Fault Codes

Error Code Description Result
E0004-03 Fdr Reverser Disengaged Shorted to high source Will not prevent engagement
E0004-04 Fdr Reverser Disengaged Shorted to low source Will not prevent engagement
E0004-05 Fdr Reverser Disengaged Line Disconnected Will not prevent engagement
E0042-06 Current Sense Reverser Short Circuit Reverser will not engage
E0061-11 Feeder Jog Forward valve Unidentified Failure Code Reverser will not engage
E0067-11 Feeder Jog Reverse valve Unidentified Failure Code Reverser will not engage
E0077-11 Reverser motor Unidentified Failure Code Reverser will not engage
55-16
Feeder Reverser -- Troubleshooting
Symptom: Feeder reverser will not engage, or will not disengage.
Cause: Constant or no signal from feeder reverser mode switch on the right hand console.
1. Switch failed.
3. Short to high voltage on switch signal wire.
Solution:
The feeder reverser mode switch S07 is a two position switch that opens the signal wire when in the ‘Off’ position,
and connects power to the RHM when in the ‘On’ position. If the switch, signal or supply wiring fails open, the
feeder reverser can not be engaged. If the signal wire is shorted to high voltage, the feeder reverser will be en-
gaged continuously.
1. Enter the Infoview monitor - Diagnose Info screen.

Select “Console” sub menu.
Select “CSW Feeder Reverser” and monitor the display while cycling the feeder reverser mode switch. The
“switch” screen should show “off” when the switch is in the off position, and “on” when the switch is in the on
position.
If the “Voltage” screen is selected, there should be approximately 1.5 volts with the switch in the off position,
and 5.0 volts when the switch is in the on position.
B. If the fuse has failed, replace the fuse and repeat Step 1. If the fuse immediately fails, there is a short
to ground somewhere in the right console switch power circuit. Locate the short and repair.
X039 from the feeder reverser mode switch S07. Use a multimeter to check for voltage at connector X039
pin 2 wire 358 orange. There should be 12 volts.
B, W02 in the right hand console. Use a multimeter to check for voltage at splice block B, W02 pin B. There
should be 12 volts.
pin 2 and splice block B, W02 pin B wire 321 orange or 358 orange. Locate the open and repair.
55-17
should be 12 volts.
A. If there is voltage, there is an open circuit in splice block B, W02 pin B. Locate the open and repair.
B. If there is no voltage, there is an open circuit in the cab main (CM) harness between fuse F48 and con-
nector X001 pin 3 wire 108 orange. Locate the open and repair.
7. The voltage reading on the Infoview monitor is low (1.5 volts) and does not change. Position the feeder
reverser mode switch S07 in the “On” position. Disconnect connector X029 from the RHM module. Use a
multimeter to check for voltage at connector X029 pin 5 wire 326 yellow. There should be 12 volts.
X039 from the feeder reverser mode switch S07 and connector X029 from the RHM module. Use a
multimeter to check for continuity between connector X039 pin 1 and connector X029 pin 5 wire 326
yellow. There should be continuity.
B. If there is continuity, the feeder reverser mode switch S07 is not functioning. Replace the switch.
9. The voltage reading on the Infoview monitor is high (5.0 volts) and does not change. Key on. Disconnect
connector X039 from the feeder reverser mode switch S07. Use a multimeter to check for voltage on
connector X039 pin 1 wire 326 yellow. There should be approximately 1.5 volts.
A. If the voltage is high (>5.0 volts), there is an short circuit in the right console (RC) harness between con-
nector X039 pin 1 and connector X029 pin 5 wire 326 yellow. Locate the short and repair.
55-18
Symptom: Feeder reverser will engage, but will not move forward or backward.
Cause: No signal from reverser (reel speed) increase or decrease switches on MFH.

1. Switch failed.
Solution:
NOTE: The reel speed increase and decrease switches on the MFH are also used to move the feeder reverser
forward and backwards when the reverser is engaged.

Select “HSW Reel Speed Incr” and monitor the display while cycling the reel speed increase switch. The
7, with the black (common) probe of the multimeter on pin 7. Depress the reel speed increase switch; the
resistance should change from infinite to approximately 1.6 - 1.8 M ohms resistance.

Select “HSW Reel Speed Decr” and monitor the display while cycling the reel speed decrease switch. The
7, with the black (common) probe of the multimeter on pin 7. Depress the reel speed decrease switch; the
resistance should change from infinite to approximately 1.6 - 1.8 M ohms resistance.
55-19
ADVANCED STONE PROTECTION (ASP) SYSTEM
3 7
5
6
2
1
50021832
6
Stone Ejection System
The advanced stone protection (ASP) system impact has occurred. Upon detection, the ASP
guards against stone intrusion by a) detecting when controller activates a solenoid-controlled hydraulic
a stone enters the feeder and b) ejecting the stone valve, located in the feeder valve stack. This valve
from the combine. Stone detection is achieved directs oil to the hydraulic cylinder, 4, which
through the use of piezo-electric sensors and unlatches the bottom to swing down, deflecting the
electronic circuitry which distinguishes the acoustic stone out the open door.
signatures of stones or other hard objects impacting
on a metal plate. When an impact is detected, the After stone detection and ejection, the feeder bottom
system then ejects the stone from the feeder. door is re-latched by a two-step process: a) reversing
the feeder to clear the door opening and b) raising the
The first step, detection, is accomplished by having feeder to its highest position. (This procedure is
all the material entering the feeder pass over a metal spelled out in detail in the feeder operating
plate, 1, mounted just below the infeed roller. The instructions). Proximity sensor, 7, senses when the
plate is mounted with rubber pads to reduce the door is in the closed position, at which time the stone
pickup of acoustic hits from elsewhere in the trap solenoid valve is deactivated and the hydraulic
combine. An automotive knock sensor is mounted on cylinder, 4, releases the door latch mechanism.
each end of the plate. These sensors are
piezo-electric microphones (hardened for heavy- The stone trap door can also be opened by direct
duty applications) which relay acoustical information action by the operator if he or she observes foreign
in the form of electrical signals to the ASP controller, material entering the feeder. This is accomplished by
3, mounted on the left-hand side of the feeder. pressing the emergency stop button and holding it
down for 3 seconds.
The ASP controller electronically analyzes the
signals from the sensors and determines if stone
55-20
There are two styles of ASP system:
Style I -- Uses two sets of sensors, lower, 1, and

upper, 2, Figure 6, to detect stone impacts.
Style II -- This is a newer configuration, in which the

upper sensors are no longer used.
NOTE: If in doubt about which system is being used,
bring up the Service Info Menu on the InfoView™
monitor and scroll to the Network sub-menu, 1. Style
II uses ASP hardware version 2.00 (Figure 8) and
CCM1 software version 31.1.5.0 (Figure 7). The
CCM1 software for Style II is back-compatible with
Style I.
56060568
7
Schematic Frame 15 shows the wiring of the sensing
and control components. Each sensor set has its
own wire harness, FB for bottom sensors B-48 and
B-49 and FT for top sensors B-50 and B-51 (used in
Style I only). FB harness connects to the feeder
harness (FE) at X260, FT, at X261. Both branches
then connect to the ASP controller A-08 through
connector X086. Hydraulic control valve solenoid
L-31 connects to the ASP controller at X082. A
description of the hydraulic control valve can be
found in Section 35 Hydraulic Systems -- Chapter 3.
Schematic Frame 16 shows the wiring of the stone

56060569
trap door sensor B-24. A branch of feeder (FE)
harness connects to the sensor at X083. The sensor 8
signal is routed to combine controller module CCM1
through connector X007, pin 11, and through the
front frame (FF) harness to CCM1 connector X020,
pin J3-28.
The ASP controller communicates with controller

CCM1 via the CAN bus. Schematic Frame 31 shows
the CAN bus connection through A-08 connector
X082, pins 6 and 7, through FE harness to connector
X007, pins 8 and 9. The ASP controller a) signals the
CCM1 regarding detection and activation status and
b) receives operating parameters from CCM1.
CCM1 directs display information to the InfoViewTM
monitor.
55-21
55-22

55-23

A-07 = HHC MODULE
55-24
ASP System - Alarms
Alarm Description
A0031 Stonetrap Open
A0068 Stone Detected on Top Sensor (Style I only)
A0069 Stone Detected on Bottom Sensor
A0070 Electronic Stone Trap Disabled
A0071 Attempt Stone Door Re-Latch
A0072 Stone Door Failed to Open
A0073 Reverse Feeder Five Seconds
ASP System - Error Codes

Error Code Description
E0000-03 Stone Trap Closed sensor Shorted to high source
E0000-04 Stone Trap Closed sensor Shorted to low source
E0000-05 Stone Trap Closed sensor Line Disconnected
E1280-05 ASD Top Sensor Line Disconnected (Style I only)
E1281-05 ASD Bottom Sensor Line Disconnected
E1282-03 ASD Top Sensor Shorted to high source (Style I only)
E1282-05 ASD Top Sensor Line Disconnected (Style I only)
E1283-03 ASD Bottom Sensor Shorted to high source
E1283-05 ASD Bottom Sensor Line Disconnected
E1284-11 ASD Stonedoor Output Unidentified Failure Code
ASP System - Troubleshooting

The ASP system goes through a self-diagnostic
process during certain periods of operation. The ASP
does these checks at the following times:
• Directly following engine startup.

• Shortly after the feeder is disengaged
• Once a minute during times when the feeder is
NOT engaged.
The ASP self-diagnostics process measures voltage
to assess the condition of the system. When a
component is damaged or offline, the amount of
voltage will fall out of the desired parameters. This
allows the system to detect a failure.
55-25
55-26
Chapter 12 - Threshing Systems
CONTENTS

55 000 Thresher System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Thresher Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Thresher Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Thresher Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
“Thresher Will Not Engage” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
“Thresher Disengages During Operation” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rotor Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rotor Speed Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rotor Speed Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rotor Speed Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
“Rotor Speed Will Not Increase or Decrease” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Concave Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Concave Clearance Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Concave Clearance Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Concave Clearance Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
“Concave Clearance Will Not Increase or Decrease” . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
55-1
Thresher System
The threshing system operation is quite simple from 1
an operator’s perspective; he simply raises the
thresher engage switch S30, 1, to engage the
threshing system, and depresses it to shut the
threshing system off. However, there are many
conditions that have to be met in order for the
threshing system to operate that are controlled and
monitored by the electronic system on the combine.
It is important to understand all of these conditions in
order to troubleshoot concerns with the threshing
system.
50031473
Thresher Engage 1
Power to the thresher engage switch S30 pin 3 is
supplied from fuse F48 whenever the key is in the
“On” position. When the top part of the thresher
switch is depressed to unlock the switch, momentary
contact is made between pins 3 and 2. Power then
flows to terminals 5 and 1 of the thresher latching
relay K28, causing the relay to become energized.
Once the relay latches, power coming from fuse F48
to terminal 3 of the relay will ensure that the relay
remains latched, even after the top part of the
thresher switch is released.
As the thresher switch S30 is pulled upward, contact

is made between pins 5 and 6. Since the thresher
latching relay is energized, power flows from fuse
F48 through the thresher latching relay K28 back to
the switch, and flows through the switch where it is
supplied to all three CCM’s, and to the feeder engage
switch S31.
NOTE: Power is supplied to all three CCM’s to allow

for optional features and different machine configu-
rations. On the CR combine, the threshing system is
engaged through CCM2.
When the power from the thresher engage switch

S30 reaches CCM2 pin J1-7, the CCM may begin to
activate the output to the gearbox clutch solenoid
L22 to begin the threshing engage process. The
CCM2 uses the actual power supply coming from the
thresher engage switch to power the gearbox clutch
solenoid, so that if power supply through the switch
is ever interrupted, power to the L22 solenoid will
automatically be disconnected for safety reasons.
55-2
55-3
20032194
55-4
Before CCM2 actually directs the power from the Once the appropriate parameters are met, CCM2 will
thresher switch S30 to the gearbox clutch solenoid set the engine RPM, and begin engaging the
L22, several things happen in software, as follows: gearbox clutch using the appropriate engagement
curve. There are two different engagement curves
• Road/Field mode switch must be in the ‘Field’ that may be selected; normal and aggressive. The
position – thresher will not be engaged if in aggressive curve engages the clutch much quicker,
“Road” position putting more stress on driveline components, but
• Engine must be running – must be engine rpm preventing heat build-up and wear in the gearbox
sensor information clutch itself, while the normal curve allows for less
stress on the driveline components, but generates
• Rear ladder is in the ‘raised’ position – thresher more heat and wear in the gearbox clutch due to the
will not engage if ladder is down increased amount of slippage required for a smooth
• Status of engine throttle switch is determined start-up. The curve that is selected depends on
(depressed v. not depressed) – affects clutch several factors, as follows:
engagement of normal v. aggressive
• Status of gearbox clutch temperature sensor is
determined (OK v. error) – affects clutch
engagement of normal v. aggressive
Throttle switch status Gearbox clutch Engine RPM Gearbox clutch

temperature sensor status engagement curve
Not depressed OK 1500 Normal
Not depressed Error 1500 Aggressive
Depressed OK 2100 Aggressive
Depressed Error 1500 Aggressive
NOTE: The combination of the first two items in the

table determine the settings that the CCM2 will make
(the last two items in the table).
Once the appropriate engagement curve is selected,
the CCM2 starts modulating the gearbox clutch 1
solenoid L22, 1, to engage the threshing system.
While engaging the clutch, CCM2 monitors the rotor
RPM sensor B01 to confirm that the rotors are 2
beginning to rotate, OR the left returns sensor B06
for returns movement. If there is no rotor RPM
increase (or returns rotation) during the start of
gearbox clutch engagement, CCM2 will disengage
the gearbox clutch fully. If rotor RPM is sensed (or
returns rotation) during engagement, CCM2 will
maintain clutch engagement.
BSC1322
NOTE: Left returns sensor B06 is used as a back-up
RPM source, so that the threshing system may be 3
engaged with the rotor gearboxes in neutral, to allow
for rotor RPM changes for better belt tension when
unplugging the machine.
If, during gearbox clutch engagement, the gearbox

clutch temperature increases by more than 60
degrees C (140 degrees F) from the temperature
measured at the start of clutch engagement, the
gearbox clutch will be fully disengaged.
55-5
Thresher Disengage
The thresher system may be disengaged by the
operator, or could be disengaged by CCM2,
depending on a number of different conditions. If
necessary, CCM2 will disengage the threshing
system to prevent damage to machine components
and to ensure operator safety.
The operator may disengage the threshing system

by pushing the thresher engagement switch S30
downwards; this will disconnect the contact between
pins 5 and 6 of the thresher engage switch S30, and
power will no longer flow to CCM2 pin J1-7. Since this
is the power supply that is used to power the gearbox
clutch solenoid L22, the solenoid will de-energize,
and the threshing system will be disengaged.
CCM2 will disengage the threshing system if any of

the following conditions are met:
• Rear ladder is lowered

• Gearbox clutch temperature sensor B45, 2,
indicates temperature >130 degrees C (266
degrees F) for more than 0.1 seconds.
Thresher Alarms
The following alarms may be observed with the
resulting actions while operating with the threshing
system engaged:
A0006 Gearbox Temperature High –

Alert operator, no other action taken.
A0010 Gearbox Filter Plugged –

A0012 Control Pressure Low –

Alert operator, engine will shut-down.
20031003
A0013 Gearbox Clutch Temperature HIGH – 4
gearbox clutch will be disengaged.
A0016 Engine RPM Low –

A0021 Engine Ladder Down –

gearbox clutch will be disengaged.
A0039 Beater RPM Low –

A0051 Road mode selected –

gearbox clutch cannot be engaged.
55-6
Thresher Errors
The following error messages are related to the
threshing system, and should be corrected immedi-
ately when they occur, to allow for proper threshing
system operation.
E0015-03 Left Returns RPM sensor Shorted

to High Source
E0015-05 Left Returns RPM sensor Line

Disconnected
NOTE: The error E0015 will not cause the threshing

system to be disengaged, but will prevent startup of 20031006
the threshing system if the rotor gearboxes are in 5
neutral, or if the rotor RPM sensor is also failed.
E0026-03 Rear Ladder sensor Shorted

to High Source
E0026-04 Rear Ladder sensor Shorted

to Low Source
E0026-05 Rear Ladder sensor Line

Disconnected
NOTE: If the rear ladder sensor is disabled, the

threshing system will continue to operate if the ladder
is lowered.
E0145-03 Engine RPM sensor Shorted

to High Source
E0145-04 Engine RPM sensor Shorted

to Low Source
E0145-05 Engine RPM sensor Line

Disconnected
NOTE: Mech. 7.5L engine only: Engine RPM signal

is required for thresher engage.
E0146-03 Rotor RPM sensor Shorted

to High Source
E0146-04 Rotor RPM sensor Shorted

to Low Source
E0146-05 Rotor RPM sensor Line Disconnected
NOTE: Thresher engagement will not occur if the

rotor RPM sensor B01 and Left returns sensor B06
are both failed.
55-7
E0151-03 Thresher Clutch Temp Shorted
to High Source
E0151-04 Thresher Clutch Temp Shorted

to Low Source
E0151-05 Thresher Clutch Temp Line

Disconnected
NOTE: The threshing system can be engaged, but

will engage only with aggressive engagement at
1500 engine RPM.
E0175-03 V Supply Thresher Clutch Shorted

to High Source
E0178-03 Isense Thresher Clutch Shorted

to High Source
E0180-11 Thresher Clutch valve

Unidentified Failure Code
NOTE: A fault exists on the output circuit from CCM2

to the gearbox clutch solenoid L22, preventing the
threshing system from being engaged.
55-8
Troubleshooting Thresher System

Symptom: Thresher will not engage.
Solution:
1. Ensure that the “On-the-Road” switch S12 is in the ‘Field’ position.
A. If switch is in the ‘Road’ position, move it to the ‘Field’ position and retest for thresher engage. Continue
with step 2 if necessary.
B. If switch is in the ‘Field’ position, continue with step 2.
Select “CSW Road Mode” and cycle the On the Road switch S12 to check voltage range. The voltage should
be 1.5 volts when the switch is in the “Road” position, and 5 volts when in the “Field” position.
A. If the voltage reading is correct (1.5v = Road, 5v = Field), continue with Step 2.
B. If the voltage reading remains at 1.5 volts, there is an open circuit in the right console (RC) harness
between the On-the-Road switch S12 and the RHM connector X029 pin 16 wire 339 yellow. Locate the
open and repair.
C. If the voltage reading remains at 5 volts, there is a short circuit to high voltage in the right console (RC)
harness between the On-the-Road switch S12 and the RHM connector X029 pin 16 wire 339 yellow.
3. Move the thresher engage switch S30 to the ‘engaged’ position. Enter the InfoViewt monitor - Diagnose
Info screen.
Select “V Supply Thresher Clutch” and check the voltage range. The voltage should be 0 when the switch
is in the “Off” position, and 12 volts when in the “engaged” position.
A. If the voltage reading is correct (0v = ‘Off’, 12v = ‘engaged’), continue with Step19.
B. If the voltage reading remains at 0 volts, continue with step 4.
wire 109 orange, fuse F48 to thresher latching relay K28, terminal 3
wire 108 orange, fuse F48 to connector X001, pin 3
wire 110 orange, RC harness splice to thresher engage switch S30 pin 3
wire 300 orange, RC harness splice to neutral switch S22 pin 1
switch power wires from splice block B, W02 in the RH console (refer to frame 17 of electrical schematic
55-9
6. Depress the top cap of the thresher engage switch S30 without lifting the switch, and observe the fuse F48.
B. If the fuse immediately fails, a short to ground exists in one of the following wires:
Wire 858 yellow, thresher engage switch S30 pin 2 to RC harness splice
Wire 857 yellow, RC harness splice to thresher engage switch S30 pin 6
Wire 118 yellow, RC harness splice through connector X001 pin 14 to thresher latching relay K28 pin 5
Wire 115 yellow, thresher latching relay K28 pin 5 to relay pin 1
7. Lift the thresher engage switch S30 upwards, and observe the fuse F48.
Wire 861 yellow, RC harness splice to feeder engage switch S31 pin 6
Wire 147 yellow, RC harness splice through connector X001 pin 13 to CM harness splice
Wire 225 yellow, CM harness splice to CCM1 connector X018 pin J1-17
8. Key on, thresher engage switch S30 engaged. Use a multi-meter to carefully back-probe connector X015
pin J1-7 and measure the voltage; the voltage should be 12 volts.
A. Multimeter indicates 12 volts. Continue with step 19.
B. There is no voltage present. Continue with step 9.
9. Key off. Disconnect connector X001. Use a multi-meter to check for continuity between connector X001
pin 13 and connector X015 pin J1-7. There should be continuity.
B. If there is no continuity, there is an open circuit in the cab main (CM) harness between connector X001
pin 13 and connector X015 pin J1-7 wire 147 yellow or wire 111 yellow. Locate the open and repair.
10. Key off, thresher engage switch S30 engaged. Disconnect connector X001, and use a multimeter to check
for continuity between connector X001 pins 13 and 14 on the RC harness end of the connector.
B. If there is no continuity, continue with step 11.
11. Key off, thresher engage switch S30 engaged. Remove the top portion of the RH console, and unplug
connector X055 at the thresher engage switch S30. Use a multi-meter to test for continuity between the
switch end of connector X055 pins 5 & 6.
A. If there is no continuity, the thresher engage switch S30 is defective. Replace the switch.
pins 13 and 14 on one of the following wires:
Wire 118 yellow, connector X001 pin 14 to RC harness splice
Wire 147 yellow, RC harness splice to connector X001 pin 13
12. Key on. Disconnect connector X001, and use a multi-meter to check for voltage at the cab main (CM)
harness end of connector X001 pin 3. There should be 12 volts present.
A. If there is 12 volts, continue with step 13.
B. If there is no voltage, there is an open circuit in the cab main (CM) harness between connector X001
pin 3 and fuse F48 in wire 108 orange. Locate the open and repair.
55-10
13. Key on, connector X001 connected. Remove the top portion of the RH console, and unplug connector X055
at the thresher engage switch S30. Use a multi-meter to test for voltage at the RC harness end of
A. If there is 12 volts, continue with step 14.
B. If there is no voltage, there is an open circuit in the right console (RC) harness between connector X001
pin 3 and connector X055 pin 3 wire 108 orange or wire 110 orange. Locate open and repair.
14. Key off, RH console opened. Disconnect connector X001. Use a multi-meter to test for continuity between
the right console (RC) harness end of connector X001 pins 3 and 14 while depressing the top cap of the
thresher engage switch S30. There should be continuity.
15. Key off, RH console opened. Disconnect connector X055 at the thresher engage switch S30. Use a
multi-meter to test for continuity between the switch end of connector X055 pins 2 and 3 while depressing
the top cap of the switch. There should be continuity.
A. If there is no continuity, the thresher engage switch S30 is defective. Replace the switch.
and the RC harness splice in wire 858 yellow. Locate the open and repair.
16. Key on, all harness connectors should be connected. Remove the thresher latching relay K28 from the fuse
panel. Use a multi-meter to test for voltage at pin 3 of the relay base in the fuse panel. There should be 12
volts.
A. If there is voltage, continue with step 17.
B. If there is no voltage, there is an open circuit in the cab main (CM) harness between fuse F48 and the
K28 relay base wire 109 orange. Locate the open and repair.
17. Key on, thresher latching relay K28 removed. Use a multi-meter to test for voltage at pins 5 and 1 of the
K28 relay base in the fuse panel while depressing the top cap of the thresher engage switch S30. There
should be 12 volts at both pins.
A. If there is 12 volts at both pins, continue with step 18.
B. If there is 12 volts at pin 5 but not at pin 1, there is an open circuit in the cab main (CM) harness between
K28 relay base pins 1 and 5 wire 115 yellow. Locate open and repair.
C. If there is no voltage at both pins, there is an open circuit in the cab main (CM) harness between
connector X001 pin 14 and K28 relay base pin 5 wire 118 yellow. Locate the open and repair.
18. Key off, thresher latching relay K28 removed. Use a multi-meter to test for continuity between the K28 relay
base pin 2 and chassis ground. There should be continuity.
A. If there is continuity, the thresher latching relay K28 is defective. Replace relay.
B. If there is no continuity, there is an open circuit in the cab main (CM) harness between K28 relay base
pin 2 and cab ground #3 wire 120 black. Locate open and repair.
19. The electrical portion of the thresher engage system is functioning properly. Inspect the following areas of
the combine:
-- loose main drive belt is slipping at start-up, so that the minimum rotor or left returns speeds are not met.
-- Physical blockage of thresher drive components, causing excessive heat-build-up in gearbox clutch at
start-up and/or minimum rotor or left returns speeds are not met.
-- Low control pressure [< 24 bar (350 psi)] at 1500 engine RPM, resulting in excessive clutch slippage,
causing excessive heat-build-up in gearbox clutch at start-up and/or minimum rotor or left returns speeds
are not met. Refer to Section 35 – Hydraulics in this manual for more information.
55-11
Symptom: Thresher disengages during operation.
Solution:
During operation, there are limited conditions that may result in the thresher system being disengaged.
-- If the rear ladder is lowered for more than 4 seconds while the thresher system is engaged, the thresher
system will be disengaged, and the alarm message
“A0021 Rear Ladder Down” will be displayed.
-- If the gearbox clutch temperature is greater than 130 degrees C (266 degrees F) for more than 0.1
seconds during operation, the gearbox clutch will be disengaged, and the alarm message
“A0013 Gearbox Clutch Temperature HIGH” will be displayed.
If either of these alarms is displayed when the threshing system disengages, the cause of the alarm must be
corrected in order for the threshing system to be re-engaged.
The remaining possibilities include excessive resistance on the gearbox clutch solenoid L22 circuit or the
thresher input voltage circuit through the thresher engage switch S30, or intermittent loss of voltage from the
thresher input voltage circuit through the thresher engage switch S30.
1. Key off. Unplug connector X035 at the low pressure manifold on the engine gearbox. Use a multi-meter to
check the resistance between connector X035 pins 7 and 8. The proper resistance range is 7.2 to 11.2
ohms.
A. If out of specification, replace the solenoid. Continue with step 4.
B. If the coil is within specification, continue with Step 2.
2. Disconnect inline connector X011. Use a multimeter to check the resistance of the gearbox clutch solenoid
circuit between connector X011 pins N & O. The resistance should be the same as, or slightly higher than
the resistance of the solenoid as measured in step 1.
A. If the resistance is significantly higher than the previously measured resistance, there is excessive
resistance in the harness or connections between connector X035 and connector X011 wires 878 white
and 877 blue. Locate the source of the resistance and repair. Continue with step 4.
B. If the resistance is the same as previously measured, continue with step 3.
3. Disconnect connector X016 on the bottom of CCM2 module. Use a multimeter to check the resistance of
the gearbox clutch solenoid circuit between connector X016 pins J2-30 & J2-40.
A. If the resistance is significantly higher than the previously measured resistance, there is excessive
resistance in the harness or connections between connector X011 and connector X016 wires 878 white
and 877 blue. Locate the source of the resistance and repair. Continue with step 4.
4. Key on. Use a multi-meter to measure the voltage at the battery cable connection to the fuse panel, and
record the voltage. Engage the thresher engage switch S30, and use the multi-meter to carefully
back-probe connector X015 pin J1-7. Measure the voltage; the voltage should be within 1/2 volt of the
voltage measured at the fuse panel.
A. Voltage is within 1/2 volt of fuse panel voltage. Continue with step 9.
B. Voltage is more than 1/2 volt below fuse panel voltage. Continue with step 5.
5. Key off. Disconnect connector X001 from the right console. Use a multi-meter to check the resistance
between the cab main (CM) harness end of connector X001 pin 13 and connector X015 pin J1-7. The
resistance should be less than 1 ohm.
A. The resistance is less than 1 ohm. Continue with step 6.
B. The resistance is greater than 1 ohm. There is excessive resistance in the cab main (CM) harness
between connector X001 pin 13 and connector X015 pin J1-7 wire 147 yellow and wire 111 yellow.
Locate the source of resistance and repair.
55-12
6. Key off. Disconnect connector X001 from the right console. Engage the thresher engage switch S30. Use
a multi-meter to check the resistance between the right console end of connector X001 pins 13 and 14.
The resistance should be less than 1 ohm.
A. The resistance is less than 1 ohm. Continue with step 7.
B. The resistance is greater than 1 ohm. There is excessive resistance in the right console (RC) harness
between connector X001 pins 13 and 14 in one of the following wires or components:
Wire 147 yellow, connector X001 pin 13 to RC harness splice

Wire 118 yellow, RC harness splice to connector X001 pin 14
Thresher engage switch S30 assembly
Locate the source of resistance and repair.
7. Key on. Remove the thresher latching relay K28 from the fuse panel. Use a multi-meter to measure the
voltage at the K28 relay base pin 3. The voltage should be within 1/2 volt of the voltage recorded at the fuse
panel in step 4.
A. Voltage is within 1/2 volt of fuse panel voltage. Continue with step 8.
B. Voltage is more than 1/2 volt below fuse panel voltage. There is excessive resistance in the fuse panel
wiring through the cab power relay K26 to fuse F48 to the K28 relay base pin 3. Locate the source of the
resistance and repair.
8. Install a jumper wire in the K28 relay base between pin 3 and pin 5. Unbolt the top half of the right console
to gain access to the thresher engage switch S30 connector X055. Turn the key switch to the “On” position,
and engage the thresher engage switch S30. Unplug connector X055, and use a multi-meter to measure
the voltage at right console (RC) harness end of connector X055 pin 6. The voltage should be within 1/2
volt of the voltage recorded at the fuse panel in step 4.
A. Voltage is within 1/2 volt of fuse panel voltage. The thresher latching relay K28 is defective. Replace
the relay.
B. Voltage is more than 1/2 volt below fuse panel voltage. There is excessive resistance in the cab main
(CM) harness between the K28 relay base pin 5 and connector X001 pin 14. Locate the source of the
resistance and repair.
9. Excessive resistance has been eliminated as a source of concern; intermittent supply voltage is suspected.
Key on. Engage the thresher engage switch S30, and use a multi-meter to carefully back-probe connector
X015 pin J1-7 to monitor the voltage. Carefully check the following areas while monitoring the voltage supply
at CCM2:
-- flex the cab main harness between the fuse panel, CCM2, and connector X001. If the voltage drops to
zero at any time, there is a intermittent connection in the harness wiring at that point that must be repaired.
-- carefully wiggle the thresher latching relay K28 in its base in the fuse panel. If the voltage drops to zero
at any time, there is an intermittent connection in the fuse panel in the area of the thresher latching relay
K28.
-- Wiggle the thresher engage switch S30 firmly; if the voltage drops to zero at any time, there is a fault in
the switch. Replace the switch.
-- Unbolt the top half of the right console. Flex the right console (RC) harness between the thresher engage
switch S30 and connector X001. If the voltage drops to zero at any time, there is an intermittent
connection in the harness wiring at that point that must be repaired.
55-13
THRESHER TROUBLESHOOTING
50020070
1
8
2
7 10004669
6
40025230
10020076
4
1. GEARBOX CLUTCH SOLENOID L22
5
2. CONNECTOR X035
40020077
3. CONNECTOR X011
4. CONNECTOR X016
5. CONNECTOR X015
10004693 6. CONNECTOR X055
7. THRESHER, LATCHING RELAY K28
20031004 8. FUSE F48
55-14
55-15
55-16
55-17
Rotor Speed but the engine is not throttled up to high idle
Rotor speed is adjusted from the cab by the operator immediately. The alarm will reset after the rotor rpm
using a switch on the right console, and the rotor increases above 200 rpm for more than 3 seconds.
RPM may be monitored using the Infoview monitor.
The rotor speed is adjusted using electrical control of If this alarm occurs while harvesting, the typical
a hydraulic valve assembly that controls a hydraulic causes would be a slipping or damaged rotor drive
piston in the rotor drive variable sheave. belt, or some other problem with the physical rotor
drive components.
Rotor Speed Adjust

When the operator moves the rotor speed switch S17 Rotor Speed Errors
on the right console, a 12 volt signal is sent to the right The combine electronic system monitors the rotor
hand module (RHM). To increase rotor speed, a 12v speed sensor B01 and the outputs to the rotor
signal is sent to connector X030 pin 11 wire 349 increase and decrease solenoids L29/L30. In the
yellow; to decrease rotor speed, a 12v signal is sent event of any problems with these circuits, the
to connector X030 pin 4 wire 348 yellow. appropriate fault code will be displayed to indicate
the specific fault with these components and the
When the RHM receives a rotor speed increase or circuits containing them.
decrease signal, it broadcasts a message over CAN
which is picked up by CCM2. CCM2 will then activate The following fault codes relate to the rotor speed
the appropriate output to change the rotor speed. sensor B01:
Power is sent to the rotor increase solenoid L29 to
increase rotor speed, while the rotor decreases E0146-03 Rotor RPM sensor Shorted
solenoid L30 is powered to decrease rotor speed. to High Source
These solenoids are simply turned ‘on’ or ‘off’, so do
not need to be grounded back through CCM2 like a E0146-04 Rotor RPM sensor Shorted
PWM solenoid. Both solenoids are grounded at the to Low Source
main frame ground #2, located behind the left rear
E0146-05 Rotor RPM sensor Line Disconnected
corner of the cab on the main frame.
The following fault code relates to the rotor increase
The actual rotor rpm is measured at the front of the
solenoid L29:
left rotor using the rotor rpm sensor B01.
E0191-11 Rotor Increase Unidentified
Failure Code
Rotor Speed Alarms
A0037 Rotor RPM Low – this alarm occurs if the The following fault code related to the rotor decrease
threshing system is engaged, no manual changes solenoid L30:
are being made, and the rotor RPM is less than 200
rpm for more than 1 second. A typical cause of this E0192-11 Rotor Decrease Unidentified
alarm would be if the threshing system is engaged, Failure Code
55-18
ROTOR SPEED SWITCH S17

ROTOR SPEED SENSOR B01
ROTOR INCREASE SOLENOID L29
ROTOR DECREASE SOLENOID L30
50031005
55-19
Rotor Speed Troubleshooting

Symptom: Rotor speed will not increase or decrease.
Solution:
Select “CSW Thresher Speed Incr” or “CSW Thresher Speed Decr”, and cycle the rotor speed switch S17
in both directions to check voltage range. The voltage should be 1.5 when the switch is in the “middle”
position, and 5 volts when in the “Increase” or “Decrease” positions.
C. If the voltage reading indicates 5 volts for “CSW Thresher Speed Incr” but 1.5 volts for “CSW Thresher
Speed Decr”, there is an open circuit in the right console (RC) harness between the rotor speed switch
D. If the voltage reading indicates 5 volts for “CSW Thresher Speed Decr” but 1.5 volts for “CSW Thresher
Speed Incr”, there is an open circuit in the right console (RC) harness between the rotor speed switch

4. Toggle the rotor speed switch S17 in both directions, and observe the fuse F48.
harness between the rotor speed switch connector X046 pin 1 and connector X030 pin 4 wire 348
harness between the rotor speed switch connector X046 pin 3 and connector X030 pin 11 wire 349
5. Unbolt the top half of the right console to gain access to the rotor speed switch S17 connector X046. Turn
A. If there is 12 volts, the rotor speed switch S17 is defective. Replace the switch.
55-20
9. Verify that the RHM and CCM2 modules are on-line on the network by entering the InfoViewt monitor –
Electrical, Chapter 4 – ‘CAN Network’ in this manual for more information in troubleshooting this concern.
55-21
ROTOR TROUBLESHOOTING
4
2
50020070
10010917
10010918
1. CONNECTOR X046
2. CONNECTOR X030
3. CONNECTOR X001
4. FUSE F48
50031004
55-22
ROTOR SPEED SWITCH S17

ROTOR SPEED SENSOR B01
ROTOR INCREASE SOLENOID L29
ROTOR DECREASE SOLENOID L30
50031005
55-23
55-24
55-25
Concave Clearance Concave Clearance Errors
Concave clearance is adjusted from the cab by the The combine electronic system monitors the
operator using a switch on the right console, and the concave clearance potentiometer R06 and the
relative concave clearance may be monitored using H-bridge outputs to the concave clearance motor
the Infoview monitor. The concave clearance is M04. In the event of any problems with these circuits,
adjusted using an electrical actuator working a the appropriate fault code will be displayed to
mechanical linkage to raise and lower the center indicate the specific fault with these components and
plate that carries the inner ends of the concaves. the circuits containing them.
The following fault codes relate to the concave

Concave Clearance Adjust clearance potentiometer R06:
When the operator moves the concave clearance
switch S16 on the right console, a 12 volt signal is E0034-03 Concave Position sensor Shorted
sent to the right hand module (RHM). To increase To Low Source
concave clearance, a 12v signal is sent to connector
E0034-05 Concave Position sensor Line
X030 pin 3 wire 347 yellow; to decrease concave
Disconnected
clearance, a 12v signal is sent to connector X030 pin
8 wire 346 yellow. The following fault code relates to the output to the
concave / covers relay K16:
When the RHM receives a concave clearance
increase or decrease signal, it broadcasts a E0069-11 Covers / Concave Cl Sel Unidentified
message over CAN which is picked up by CCM1. Failure Code
CCM1 will then activate the appropriate output to
change the concave clearance. Power is sent to The following fault codes relate to the concave
activate the concave/covers relay K16, so that the clearance motor M04:
appropriate output signal is directed to the concave
clearance motor M04. E0044-06 Current Sense Concave
Cl Short Circuit
The concave clearance motor is powered by an
“H-bridge” circuit in CCM1; H-bridge circuits have E0045-06 Current Sense Bin Covers
two connector pins associated with them to control Short Circuit
both sides of the circuit, and function by connecting
one pin to ground when the opposite pin is connected E0078-11 Concave Clearance motor
to power. To reverse direction of the output, the Unidentified Failure Code
power and ground connections are switched. This
type of output control allows the module to operate E0079-11 Grainbin Covers motor
motors and actuators in both directions. The Unidentified Failure Code
H-bridge circuit holds both sides of the circuit to
ground when the circuit is not active to “lock” the NOTE: The concave clearance is controlled using an
motor and prevent it from rotating. H-bridge-controlled circuit. The concave clearance
motor (M04) circuit is paired with the grainbin covers
The relative concave clearance is measured at the motor (M12) circuit, and the module switches
rear of the linkage using the concave clearance between these two circuits using the Concave /
potentiometer R06. Covers relay K-16. Because these circuits are
connected and driven from the same module
outputs, the troubleshooting procedure must consid-
Concave Clearance Alarms er both circuits at the same time. Refer to the ‘CCM1
A0076 Concave Shearbolt Broken – If the relative Fault Codes’ chapter in this manual for more
concave clearance exceeds a certain value, this information.
alarm will be displayed, indicating that the shear bolt
in the concave clearance linkage has failed.
55-26
55-27
Concave Clearance Troubleshooting

Symptom: Concave clearance will not increase or decrease.
Solution:
Select “CSW Concave Clear Decr” or “CSW Concave Clear Incr”, and cycle the concave clearance switch
S16 in both directions to check voltage range. The voltage should be 1.5 when the switch is in the “middle”
position, and 5 volts when in the “Increase” or “Decrease” positions.
C. If the voltage reading indicates 5 volts for “CSW Concave Clear Incr” but 1.5 volts for “CSW Concave
Clear Decr”, there is an open circuit in the right console (RC) harness between the concave clearance
switch S16 pin 1 and the RHM connector X030 pin 8 wire 346 yellow. Locate the open and repair.
D. If the voltage reading indicates 5 volts for “CSW Concave Clear Decr” but 1.5 volts for “CSW Concave
Clear Incr”, there is an open circuit in the right console (RC) harness between the concave clearance
switch S16 pin 3 and the RHM connector X030 pin 3 wire 347 yellow. Locate the open and repair.

4. Toggle the concave clearance switch S16 in both directions, and observe the fuse F48.
harness between the concave clearance switch connector X044 pin 1 and connector X030 pin 8 wire
346 yellow. Locate the short and repair.
harness between the concave clearance switch connector X044 pin 3 and connector X030 pin 3 wire
347 yellow. Locate the short and repair.
55-28
5. Unbolt the top half of the right console to gain access to the concave clearance switch S16 connector X044.
Turn the key switch to the “On” position. Unplug connector X044, and use a multi-meter to measure the
voltage at right console (RC) harness end of connector X044 pin 2. There should be 12 volts.
A. If there is 12 volts, the concave clearance switch S16 is defective. Replace the switch.
Electrical, Chapter 4 - ‘CAN Network’ in this manual for more information in troubleshooting this concern.
55-29
CONCAVE TROUBLESHOOTING
4
2
50020070
10010917
10010918
1. CONNECTOR X044
2. CONNECTOR X030
3. CONNECTOR X001
4. FUSE F48
50031004
55-30
55-31
55-32
Chapter 13 - Cleaning Systems
CONTENTS

Self-leveling Cleaning Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cleaning Fan Motor M-05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cleaning Fan Motor (Hydraulic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning System Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lateral Inclination Sensor B02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fan Speed Switch S15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cleaning Fan Rpm Sensor B16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Left Returns Rpm Sensor B06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Clean Grain Elevator Rpm Sensor B08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Right Returns Rpm Sensor B39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Loss Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remote Sieve Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Calibration Of The Upper Sieve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Calibration Of The Lower Sieve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cleaning Fan Motor M05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Loss Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Left Rotor Loss Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Right Rotor Loss Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Sieves Loss Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Remote Sieve Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Upper Remote Sieve Adjust Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lower Remote Sieve Adjust Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Upper Sieve Rear Adjust Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Lower Sieve Rear Adjust Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
55-1

SELF-LEVELING CLEANING SHOE
The function of the self-leveling cleaning shoe is
quite simple. The lateral inclination sensor, 1,
monitors the tilt of the combine and sends the
information to pin J2-33 of CCM1. CCM1 uses this
information to determine how far the cleaning shoe
must be tilted to be level.
1
10004686
1
CCM1 uses two pairs of pins to send current to the
shoe leveling actuator. This allows CCM1 to reverse
the polarity and change the direction of the actuator.
The first pair of pins, J-39 and J-40, send current
through to a wire splice and through connector X023
pin 2 to pin D of the actuator (M-03). The second pair
of pins, J3-19 and J3-20, send current through a wire
splice to Pin E of the shoe leveling actuator (M-03).
The Shoe Leveling Actuator M-03 at the front right of

cleaning shoe (behind the transmission) is also used
to monitor the angle in which the cleaning shoe is
tilted. Voltage is applied to pin A of the actuator. The 1
10004665
ground path travels from pin B. As the actuator
moves through its travel, the resistance through the 2
actuator changes. A signal is sent from pin C of the
actuator to pin J3-32 of CCM1. CCM1 receives the
signal and uses the changes in resistance to monitor
the position of the actuator.
CCM1’s software detects when the self-leveling

cleaning shoe makes contact with the frame (by
detecting that the actuator motor is stalled) and
establishes the limit of travel. These limits are NOT
stored in non-volatile memory so they are
established at least once (each direction) every time
that the threshing is engaged.
55-2
Calibration
To calibrate the self levelling shoe, proceed as
follows:
1. Check first if the item “Self levelling shoe” is set
to “installed”, refer to headed: “13. Threshing” of
this paragraph.
2. Select the “Self Levelling Shoe” calibration
window.
Message: “Verify combine is level”.
Message: “Engage threshing”.
Message: “Set engine at high idle”.
Message: “Then press enter”.
CAUTION
Lift the feeder to its maximum height, place the
header safety latch over the cylinder rod and
stop the engine before starting the self levelling
shoe calibration procedure.
3. Place a levelling-instrument on the front axle to

check if the combine is level.
3
4. Engage the threshing mechanism and run the
engine at high idle.
DANGER
The self levelling calibration is an automatic
process. No person should be in the moving area
of the self levelling while calibrating.
5. Press the “enter” key to continue or “esc” key to

exit the calibration window.
Message: “Calibration initiated”.
Message: “Shoe is moving CW”.
Message “Shoe is moving CCW”.
6. The self levelling shoe moves first clockwise and
subsequently counter-clockwise.
55-3
7. Press “Enter” or “Esc” to close the calibration
window.
5
Remark: If an error occurs while calibrating the
self-levelling shoe, the calibration procedure will be
aborted and an error code will appear on the screen.
Error Possible Cause Remedy

23 Threshing not engaged Engage threshing
30 Lateral inclination sensor giving wrong signal Signal must be minimum 0.25V, maximum 5V
31 Shoe position sensor giving wrong signal Signal must be minimum 0.25V, maximum 5V
32 Option not installed Select “Self-levelling shoe” installed
33 Self-levelling shoe actuator error Check with diagnostics if actuator is still
moving
34 Combine not level within limits Put combine more level
54 Engine at low idle Throttle engine to high idle
Alarms
Alarm
Code Description Priority Check Condition Activation Resetting
A0077 Leveling Shoe Med Threshing En- Shoe actuator run- Shoe position stable
Not level gaged ning in one direction
for 15 seconds
Low Shoe position sensor Shoe position sensor

faulty or lateral in- OK and lateral in-
clination sensor faulty clination sensor OK
Fault Codes E0032-05 Shoe position sensor Line

The self-leveling cleaning shoe operation is disconnected
completely monitored by fault codes. If the
self-leveling shoe does not operate correctly, check E0043-06 Current Sense lev Shoe
the fault history for any of the following fault codes, Short Circuit
and correct. Recalibrate the cleaning system if
E0075-11 Leveling Shoe Motor Unidentified
necessary.
Failure Code
This is the (feedback) sensor in the linear actuator.
E0032-03 Shoe position sensor Shorted

to high source
55-4
CLEANING FAN MOTOR M-05

The cleaning fan motor, 1, is used to move the 1
variable drive sheave for the cleaning fan drive in
order to vary the fan speed.
30998030
6
A switch on the right hand console, 1, may be
activated by the operator to manually adjust the 1
cleaning fan RPM. In addition, the Automatic Crop
Settings (ACS) system will automatically adjust the
fan speed to a predefined RPM setting when
activated, using feedback from the cleaning fan RPM
sensor B16.
When the operator activates the switch in cab, the

RHM (right hand module) sends a message via CAN
to CCM1. CCM1 activates the appropriate output in
order to rotate the fan speed motor in the desired
direction. An RPM sensor on the cleaning fan shaft 20030010
provides feedback to the operator about the actual
fan RPM. 7
The fan speed motor is powered by an H-bridge

circuit within the CCM. When the circuit is not active,
the CCM connects both motor leads to ground to
“lock” the motor in position, preventing inadvertent
motion that would result in an undesired speed
change. When the CCM activates the output, one of
the motor leads is connected to power, while the
other is connected to ground. When the opposite
rotation of the motor is desired, the CCM reverses
the connections.
The fan speed shares an output circuit on CCM1 with

the feeder reverser actuator; a relay is used to switch
between the two motors.
Fault Codes
E0062-11 Fan Sp/Reverser Select
E0041-06 Current Sense Fan Motor

Short Circuit
E0076-11 Fan Speed Motor Unidentified

Failure Code
55-5
CLEANING FAN MOTOR (HYDRAULIC)

The hydraulic cleaning fan motor, 1, replaces the belt
drive and electric speed adjusting motor used in
pre-model year 2006 combines. The hydraulic
system is provided in all 2006 models and may be
installed in some earlier models.
10051783
8
A hydraulic pump, 1, mounted on and driven by the
hydrostatic propulsion drive pump, 2, drives the 1
cleaning fan motor, 3. A proportional valve, 4, driven
by a pulse width--modulated (PWM) signal from the 4 2
system electronics modulates oil flow to the motor to
regulate the motor speed.
3
66060051
9
The operator can manually control the speed of the
fan via the cleaning fan speed rocker switch, 1, on the 1
right--hand console. In Automatic Crop Settings
(ACS) mode, the operator can enter a predeter-
mined speed and the ACS will maintain the fan speed
at this setting.
20030010
10
55-6
When the operator activates the cleaning fan speed
switch in the cab, the right--hand module (RHM)
sends a message via the CAN bus to controller
CCM1, which sends a PWM signal to solenoid L--44,
1, on the cleaning fan control valve, 2. The solenoid
2
valve works together with a proportional valve to
regulate the flow of oil to the cleaning fan motor in
accordance with the speed setting. An RPM sensor
on the cleaning fan shaft sends speed information to
CCM1. CCM1 relays the information to RHM, which 1
provides the operator with a visual indication of the
speed on the InfoView TM monitor.
66060560
In Automatic Crop Settings (ACS) mode, the speed
sensor provides feedback to the system, which in 11
turn delivers the correct amount of PWM signal to the
solenoid valve to maintain a constant speed.
Fault Code
E0054--11 Cleaning Fan Valve Unidentified
Failure Code
55-7
CLEANING SYSTEM SENSORS

The cleaning system sensors monitor the shaft
speeds of the mechanical components of the
cleaning system. The sensors report this information
to CCM1. CCM1 activates an audible alarm when a
sensor reports that a cleaning system component
speed has dropped below 80%. This number is
relative to the engine speed. This means that if the
engine rpm is lowered and the cleaning system
components slow to 80% of their original speed, the
audible alarm will not be activated.
Lateral Inclination Sensor B02
The lateral inclination sensor, 1, is mounted under
the cab near the right front cab mount. The lateral
inclination sensor provides information to CCM1
regarding the lateral positioning of the combine
chassis relative to level.
Fault Codes
E0033--03 Lateral Inclination sens Shorted to
high source
1
E0033--05 Lateral Inclination sens Line discon-
10004686
nected
12
Fan Speed Switch S15
The fan speed switch, 1, is located on the right hand 1
console, and is used by the operator to adjust the
cleaning fan speed.
Fault Codes
E0662--04 CSW Fan Speed Incr Shorted to low
source
E0662--07 CSW Fan Speed Incr Mechanical

out of range
E0663--04 CSW Fan Speed Decr Shorted to 20030010

low source
13
E0663--07 CSW Fan Speed Decr Mechanical
out of range
55-8
Cleaning Fan RPM Sensor B16

The cleaning fan RPM sensor, 1, monitors the RPM
of the cleaning fan and reports the information to 1
CCM1.
30998030
14
The hydraulic cleaning fan RPM sensor, 1, monitors
the speed of the cleaning fan and reports the
information back to CCM1.
10051858
15
Alarms
Alarm Description Priority Activation Resetting

Code
A0041 Fan RPM Low High 1 sec < 130 RPM 3 sec > 130 RPM
Med 1 sec < 80% of threshold RPM 3 sec > 80% of threshold RPM
Fault Code
E0013-03 Cleaning Fan RPM sensor Shorted
to high source
E0013-04 Cleaning Fan RPM sensor Shorted

to low source
E0013-05 Cleaning Fan RPM sensor Line

disconnected
55-9
Left Returns RPM Sensor B06
The left returns sensor, 1, provides RPM information
to warn in case of blockage. The left returns sensor
also provides information to the operator display
regarding returns volume; one fixed paddle and one
hinged paddle are mounted on the end of the returns
auger. The sensor monitors the time difference
between the two paddles, as well as ‘counting’ RPM. 1
As returns volume increases, the hinged paddle is
deflected more, resulting in a longer time between
the fixed paddle and hinged paddle, and a shorter
time between the hinged paddle and the fixed
paddle. CCM1 processes this time delay, and 10004638
converts it into a representation of the volume of
16
returns flowing through the system – this is displayed
to operator on Infoview monitor.
Alarms
Alarm
Code Description Priority Activation Resetting
A0043 Returns Left High 1 sec < 195 RPM 3 sec > 195 RPM
RPM Low
Fault Codes
to high source

to low source
E0015-05 Left Returns RPM sensor Line

Disconnected
55-10
Clean Grain Elevator RPM Sensor B08
The clean grain elevator sensor, 1, monitors the RPM 1
of the clean grain cross auger and elevator to guard
against drive failure or blockage.
10004651
17
Alarms
Alarm
A0040 Grain Elevator High 1 sec < 100 RPM 3 sec > 100 RPM
RPM Low
Fault Codes
E0016-03 Clean Grain Elevator
RPM Shorted to high source

RPM Shorted to low source

RPM Line disconnected
55-11
Right Returns RPM Sensor B39
The right returns RPM sensor, 1, monitors the RPM
of the right returns auger to guard against drive
failure or blockage.
10004668
18
Alarms
Alarm
A0044 Returns Right High 1 sec < 195 RPM 3 sec > 195 RPM
RPM Low
Fault Codes
E0018-03 Right Returns RPM sensor Shorted
to high source
E0018-04 Right Returns RPM sensor Shorted

to low source
E0018-05 Right Returns RPM sensor Line

disconnected
Loss Sensors
Several loss sensors are used on the combine to
monitor the performance of the separating and
cleaning systems. Two rotor loss sensors are
mounted on either side of the rotors to monitor the
amount of grain being separated from the straw at
the rear of the rotor, prior to the straw being
discharged from the combine.
55-12
Rotor Loss Sensors
The rotor loss sensors, 1, are located on either side
of the rotor.
40025223
19
Sieves Loss Sensor
A single, full-width sensor, 1, is positioned behind the
chaffer sieve to monitor the volume of grain that is
discharged off the rear of the cleaning shoe.
1
10010864
20
55-13
REMOTE SIEVE ADJUST

The combine may be equipped with optional remote
adjust sieves, which uses linear actuators to adjust
the chaffer and clean grain sieve clearance, either
remotely from the cab using switches,1 and 2, on the
right hand console,
21
or using remote mounted switches, 3 and 4, at the
rear of the cleaning shoe. The sieve clearance may
also be set automatically using the “Automatic Crop
Settings” feature in the combine.
3
Sensors in the linear actuators provide a signal back
to CCM3 on the relative opening of the sieve, so that
information may be displayed to the operator on the
InfoView monitor. 4
The remote sieve adjust is powered from an H-bridge
circuit off of CCM3, and this circuit is switched by a
relay, since both sieve actuators are powered from 40024710
the same set of module outputs.
22
Configurations Settings
Select the “cleaning” sub-menu, and adjust the
following parameter:
• Remote upper sieve
If press “enter” when this item is selected, a pop-up
screen 1 appears, showing the two possibilities
“Installed” or “Not installed”.
Using the “up” or “down” navigation keys to select

and press “enter” to confirm your choice.
23
55-14
Alarms
Alarm Description Priority Activation Resetting

Code
A0120 Upper Sieve Not Med Actual upper sieve position is Actual upper sieve position
In Position not within 1 mm of position set is within 1 mm of position
point for 4 seconds set point
A0124 Lower Sieve Not Med Actual lower sieve position is Actual lower sieve position
In Position not within 1 mm of position set is within 1 mm of position
point for 4 seconds set point
A0125 Upper Sieve Cal- Low Upper sieve has never been Calibrate upper sieve
ibration Required calibrated
A0126 Lower Sieve Cal- Low Lower sieve has never been Calibrate lower sieve
ibration Required calibrated
Fault Codes E0334-11 Lower Sieve motor

E0261--03 Lower Sieve Decr – Unidentified Failure Code
Rear Shorted to high source
E0335-11 Upper Sieve motor
E0261--04 Lower Sieve Decr – Unidentified Failure Code
Rear Shorted to low source
E0672--04 CSW Upper Sieve Decr
E0262--03 Upper Sieve Decr – Shorted to low source
E0672--07 CSW Upper Sieve Decr
E0262--04 Upper Sieve Decr – Mechanical out of range
E0673--04 CSW Upper Sieve Incr
E0263--03 Lower Sieve Incr – Shorted to low source
E0673--07 CSW Upper Sieve Incr
E0263--04 Lower Sieve Incr – Mechanical out of range
E0674--04 CSW Lower Sieve Decr
E0282--03 Upper Sieve Incr – Shorted to low source
E0674--07 CSW Lower Sieve Decr
E0282--04 Upper Sieve Incr – Mechanical out of range
E0675--04 CSW Lower Sieve Incr
E0300-06 Current Sense Lower Sieve Shorted to low source
Short Circuit
E0675--07 CSW Lower Sieve Incr
E0301-06 Current Sense Upper Sieve Mechanical out of range
Short Circuit
E0325-11 Upper / Lower Sieve

Sel Unidentified Failure Code
55-15
Calibration of the Upper sieve
To calibrate the upper sieve, proceed as follows:
1. Check first if the item “Remote upper sieve” is set

to “installed”, in the Configuration screen,
“cleaning” sub-menu.
2. Select the “Upper Sieve” calibration window.
Message: “Close sieve completely then open
again to 6 mm (1/4″)”.
Message: “Then press enter”.
3. Close the upper sieve completely using the
upper sieve rocker switch.
Remark: Check if the upper sieve is clean before
closing.
4. Open the upper sieve until the physical distance

measure 6 mm (1/4″).
5. Press “Enter” to continue or “esc” to exit the
calibration window.
24
6. The calibration is done.
7. Press “Enter” or “esc” to close the calibration
window.
25
Remark: If an error occurs while calibrating the
upper sieve, the calibration procedure will be aborted
and an error code will appear on the screen.

40 Upper sieve position sensor giving wrong Signal must be minimum 0.25V, maximum 5V
signal
43 Upper sieve opening not 6 mm (1/4″) within Open sieve to 6 mm (1/4″)
limits
55-16
Calibration of the Lower sieve
To calibrate the lower sieve,
1. Check first if the item “Remote lower sieve” is set

to “installed”, in the Configuration screen,
“cleaning” sub-menu.
2. Select the “Lower Sieve” calibration window.
Message: “Close sieve completely, then open
again to 6 mm (1/4″).
Message: “Then press ENTER”.
3. Close the lower sieve completely using the lower
sieve rocker switch.
Remark: Check if the lower sieve is clean before
closing.
4. Open the lower sieve until the physical distance

measure 6 mm (1/4″).
5. Press “Enter” to continue or “esc” to exit the
calibration window.
26
6. The calibration is done.
7. Press “Enter” or “esc” to close the calibration
window.
27
Remark: If an error occurs while calibrating the lower
sieve, the calibration procedure will be aborted and
an error code will appear on the screen.

41 Lower sieve position sensor giving wrong Signal must be minimum 0.25V, maximum 5V
signal
44 Lower sieve opening not 6 mm (1/4″) within Open sieve to 6 mm (1/4″)
limits
55-17

55-18
B-16 = CLEANING FAN RPM M-03 = SHOE LEVELING ACTUATOR

B-21 = SIEVES LOSS S-13 = UPPER SIEVE
F-22 = SHOE LEVELING MOTOR FUSE S-14 = LOWER SIEVE CLEANING
L-44 = FAN DRIVE SOLENOID S-15 = FAN SPEED FRAME--19
55-19

55-20

55-21

H-01 = AUDIO ALARM
55-22
TROUBLESHOOTING
CLEANING FAN MOTOR M05
Symptom: Fan speed will not increase or decrease.
Solution:
1. Enter the InfoViewt monitor - Dealer Diagnostics screen.
Select “Fan speed switch” and cycle the fan speed switch S15 in both directions to check voltage range. The
voltage should be 0 when the switch is in the “middle” position, and 12 volts when in the “Increase” or
“Decrease” positions.
C. If the voltage reading indicates 12 volts for “CSW Fan Speed Fan Increase” but 0 volts for “CSW Fan
Speed Decrease”, there is an open circuit in the right console (RC) harness between the fan speed switch
D. If the voltage reading indicates 12 volts for “CSW Fan Speed Decrease” but 0 volts for “CSW Fan Speed
Increase”, there is an open circuit in the right console (RC) harness between the fan speed switch S15
pin 3 and the RHM connector X030 pin 10 wire 345 yellow. Locate the open and repair.

4. Toggle the fan speed switch S15 in both directions, and observe the fuse F48.
harness between the fan speed switch connector X045 pin 1 and connector X030 pin 9 wire 344
harness between the fan speed switch connector X045 pin 3 and connector X030 pin 10 wire 345
5. Unbolt the top half of the right console to gain access to the fan speed switch S15 connector X045. Turn
A. If there is 12 volts, the fan speed switch S15 is defective. Replace the switch.
55-23
6. Key on. Use a multi-meter to measure the voltage at splice block B, W02, pin A. There should be 12 volts.
B. If there is 12 volts, there is an open circuit in the right console (RC) harness between splice block B, W02,
pin A and connector X045 pin 2 wire 372 orange or 374 orange. Locate the open and repair.
7. Key on. Use a multi-meter to measure the voltage at splice block B, W02, pin M. There should be 12 volts.
B. If there is 12 volts, there is an open circuit internally in the splice block due to loose wire connections, or
a corroded or damaged splice bar. Repair or replace the splice block as required to repair the open.
Scroll through the screen as necessary to locate the RHM and CCM1 icons. If either of the icons are
‘grayed out’, the indicated module is off-line and is not capable of transmitting on the network. Refer to
Section 55 Electrical, Chapter 4 - ‘CAN Network’ in this manual for more information in troubleshooting
this concern.
55-24
LOSS SENSORS
There are no fault codes to indicate a problem with
the loss sensors. To troubleshoot a problem with the
loss sensors, check for continuity between CCM1
and each sensor.
IMPORTANT: Disconnect the batteries while

troubleshooting the Rotor Loss Sensors to avoid
damaging the electrical system.
Left Rotor Loss Sensor
1. Check the input side of the left rotor loss sensor
by unplugging connector X016 from CCM2 and
jumping wire MF-457-BL of the harness to
ground. Unplug connector X191 from the left
rotor sensor and check for continuity between pin
1 and ground. If continuity exists, proceed to step
2. If continuity does not exist, check wire
MF-457-Blue for damage.
2. Unplug connector X191 from the left rotor loss
sensor and jump wire MF-410 Yellow to ground.
Unplug connector X016 from CCM2 and check 40025223
for continuity between wire MF-410 Yellow and
ground. If continuity exists proceed to Step 3. If 28
continuity does not exist, check wire MF-410
Yellow for damage.
3. The left rotor loss sensor is defective and
requires replacement.
Right Rotor Loss Sensor

1. Check the input side of the right rotor loss sensor
by unplugging connector X017 from CCM2 and
jumping wire MF-458-BL of the harness to
ground. Unplug connector X188 from the right
rotor sensor and check for continuity between pin
1 and ground. If continuity exists, proceed to step
2. If continuity does not exist, check wire
MF-458-Blue for damage.
2. Unplug connector X188 from the right rotor loss
sensor and jump wire MF-402 Yellow to ground.
Unplug connector X016 from CCM2 and check 40025224
for continuity between wire MF-402 Yellow and
ground. If continuity exists proceed to Step 3. If 29
continuity does not exist, check wire MF-402
Yellow for damage.
3. The right rotor loss sensor is defective and
requires replacement.
55-25
Sieves Loss Sensor
Symptom: Sieves Loss Sensor is not functioning properly.
Solution:
Use a multimeter to test the Sieves Loss Sensor circuit.
Make sure the key switch is in the “Run” position while testing the sieve loss sensor.
1. Unplug connector X232 and test for continuity to ground on pin 1.

A. If continuity exists, go to step 6.
B. If continuity to ground does not exist, go to the next step.
2. Unplug connector X072 and test wire SW-494-BL for continuity to ground on pin C.
A. If continuity exists, wire LR-494-BL is broken or damaged. Replace as necessary.
B. If continuity does not exist, go to the next step.
3. Unplug connector X024 and test wire MF-461-BL for continuity to ground on pin 11.
A. If continuity exists, wire MF-461-BL is broken
or damaged. Replace as necessary.
B. If continuity does not exist, go to the next step.
4. Unplug connector X008 and test wire FF-401-BL for continuity to ground on pin 7.
A. If continuity exists, wire FF-401-BL is broken or damaged. Replace as necessary.
B. If continuity does not exist, check wire FF-501-BL for damage.
5. Unplug connector X020 and test pin J3-18 of CCM1 for continuity to ground.
A. If continuity exists, wire FF-501-BL is broken or damaged. Replace as necessary.
B. If continuity does not exist, CCM1 is damaged and requires repair or replacement.
6. Unplug connector X232 and test pin 2 for voltage.
A. If voltage exists, the sieve loss sensor is defective and requires replacement.
B. If voltage does not exist, go to the next step.
A. If voltage exists, wire LR-431-YE is broken or damaged and requires replacement.
A. If voltage exists, wire SW-431-YE is broken or damaged and requires replacement.
9. Unplug connector X019 and test pin J2-25 for voltage.
A. If voltage exists, wire MF-431-YE is broken or damaged and requires replacement.
B. If voltage does not exist, CCM1 is damaged and requires repair or replacement.
55-26
REMOTE SIEVE ADJUST

When activated, the remote sieve switches cause
power to be sent from the CCM3, and activate the
circuit by connecting the circuit to ground - when the
CCM3 sees a particular remote switch circuit shorted
to ground, it then activates the appropriate output).
As an example, if one of the remote switch circuits
was shorted to ground, CCM3 would think the switch
was being depressed, and would try to adjust the
sieve - ultimately fully opening or closing it,
depending on which wire was grounded.
30
55-27
Upper Remote Sieve Adjust Switch
Symptom: Upper sieve will not raise or lower.
Solution:
Select “Upper sieve switch” and cycle the upper sieve switch S13 in both directions to check voltage range.
The voltage should be 0 when the switch is in the “middle” position, and 12 volts when in the “Raise” or “Lower”
positions.

C. If the voltage reading indicates 12 volts for “upper sieve raise” but 0 volts for “upper sieve lower”, there
is an open circuit in the right console (RC) harness between the upper sieve switch S13 pin 1 and the
RHM connector X030 pin 7 wire 340 yellow. Locate the open and repair.
D. If the voltage reading indicates 12 volts for “upper sieve lower” but 0 volts for “upper sieve raise”, there
is an open circuit in the right console (RC) harness between the upper sieve switch S13 pin 3 and the

4. Toggle the upper sieve switch S13 in both directions, and observe the fuse F48.
B. If the fuse immediately fails in the ‘lower’ direction, there is a short to ground in the right console (RC)
harness between the upper sieve switch connector X043 pin 1 and connector X030 pin 7 wire 340
C. If the fuse immediately fails in the ‘raise’ direction, there is a short to ground in the right console (RC)
harness between the upper sieve switch connector X043 pin 3 and connector X030 pin 2 wire 341
55-28
5. Unbolt the top half of the right console to gain access to the upper sieve switch S13 connector X043. Turn
A. If there is 12 volts, the upper sieve switch S13 is defective. Replace the switch.
B. If there is 12 volts, there is an open circuit in the right console (RC) harness between splice block B,
B. If there is voltage, there is an open circuit in the right console (RC) harness between splice block B, W02,
Scroll through the screen as necessary to locate the RHM and CCM3 icons. If either of the icons are ‘grayed out’,
the indicated module is off-line and is not capable of transmitting on the network. Refer to Section 55 Electrical,
Chapter 4 - ‘CAN Network’ in this manual for more information in troubleshooting this concern.
55-29
Lower Remote Sieve Adjust Switch
Symptom: Lower sieve will not raise or lower.
Solution:
Select “lower sieve switch” and cycle the lower sieve switch S14 in both directions to check voltage range. The
voltage should be 0 when the switch is in the “middle” position, and 12 volts when in the “Raise” or “Lower” posi-
tions.

C. If the voltage reading indicates 12 volts for “lower sieve raise” but 0 volts for “lower sieve lower”, there
is an open circuit in the right console (RC) harness between the lower sieve switch S14 pin 1 and the
D. If the voltage reading indicates 12 volts for “lower sieve lower” but 0 volts for “lower sieve raise”, there
is an open circuit in the right console (RC) harness between the lower sieve switch S14 pin 3 and the

4. Toggle the lower sieve switch S14 in both directions, and observe the fuse F48.
B. If the fuse immediately fails in the ‘lower’ direction, there is a short to ground in the right console (RC)
harness between the lower sieve switch connector X042 pin 1 and connector X030 pin 1 wire 342
C. If the fuse immediately fails in the ‘raise’ direction, there is a short to ground in the right console (RC)
harness between the lower sieve switch connector X042 pin 3 and connector X030 pin 6 wire 343
55-30
5. Unbolt the top half of the right console to gain access to the lower sieve switch S14 connector X042. Turn
A. If there is 12 volts, the lower sieve switch S14 is defective. Replace the switch.
B. If there is 12 volts, there is an open circuit in the right console (RC) harness between splice block B,
7. Key on. Use a multi-meter to measure the voltage at splice block B, W02, pin M. There should be 12 volts.
B. If there is voltage, there is an open circuit in the right console (RC) harness between splice block B, W02,
Scroll through the screen as necessary to locate the RHM and CCM3 icons. If either of the icons are ‘grayed out’,
the indicated module is off-line and is not capable of transmitting on the network. Refer to Section 55 Electrical,
Chapter 4 - ‘CAN Network’ in this manual for more information in troubleshooting this concern.
55-31
Upper Sieve Rear Adjust Switch
The Upper Sieve Rear Adjust Switch, 1, is a

two-position momentary rocker switch. When the
1
switch is activated in either direction, the correspond-
ing ground path is completed. CCM3 establishes a
ground path is completed, and activates the upper
sieve actuator in the proper direction. If the rocker
switch is pushed in the opposite position, CCM3
reverses the current flow to send the upper actuator
in the opposite direction.
Resolve any issues with Fault codes before

40024710
troubleshooting the upper sieve rear adjust circuit.
31
Refer to the chart below to troubleshoot the Upper
Sieve Rear Adjust Switch Circuit.
Symptom Probable Causes Troubleshooting
Upper Sieve Actuator Raises Short to ground on circuit 540 1. Unplug connectors X025 and X013. Test
Without Switch Activation for continuity to ground on pin 7 on wire
EX-540YE-0.8. If continuity exists, wire
EX-540-YE-0.8 is damaged and re-
quires repair. If continuity does not exist,
proceed to the next step.
2. With connector X025 still unplugged,
unplug connector X225 and test for
continuity to ground on wire
SW-540-YE-0.8. If continuity exists,
wire SW-540-YE-0.8 is damaged and
requires repair. If no continuity exists,
3. With the upper sieve rear adjust switch
in the middle (off) position, test the pins
for continuity. If continuity exists be-
tween any of the pins in the off position,
the switch is defective and requires
replacement.
4. If it is determined that the switch or wire
harness is not defective, CCM3 is
defective and requires repair or replace-
ment.
55-32
Upper Sieve Actuator Lowers Short to ground on circuit 539 1. Unplug connectors X025 and X013. Test
3. With the lower sieve rear adjust switch in
the middle (off) position, test the pins for
continuity. If continuity exists between
any of the pins in the off position, the
switch is defective and requires replace-
ment.
ment.
Upper Sieve Actuator Will Not Open circuit 550 1. Check for loose or corroded connectors
Raise or Lower on circuit 539. If no loose or corroded
connectors are found, proceed to the
next step.
2. Unplug connector X025 and test for
continuity to ground on circuit
EX-550-Bk-0.8. If continuity does not
exist, circuit EX-550-Bk-0.8 is damaged
and requires repair. If continuity exists,
3. With connector X025 still disconnected,
unplug connector X225 and jump pin 2
to ground. Test pin 19 of connector X025
for continuity to ground. If continuity
does not exist, Circuit SW-550 is
damaged and requires repair. If continu-
ity exists, the upper sieve rear adjust
ment.
55-33
Upper Sieve Actuator Will Not Open circuit 540 1. Unplug connector X225 and press the
Raise upper sieve rear adjust switch into the
“raise” position. Continuity should exist
between pins 2 and 3. If continuity does
not exist, the switch is defective and
requires replacement. If continuity ex-
ists between terminals 2 and 3 when the
switch is in the “raise” position, proceed
to the next step.
2. Disconnect connector X025 and turn to
the key to the “RUN” position. Using a
voltmeter, check for voltage at pin 7 of
connector X025 of circuit EX-540YE-0.8.
If voltage exist, circuit SW-540-YE is
damaged and requires replacement. If
voltage does not exist, unplug connector
X013 and check voltage at pin J2-17 of
CCM3. If voltage exists, circuit SW-540 is
voltage does not exist at pin J2-17,
CCM3 is defective and requires replace-
ment.
Upper Sieve Actuator Will Not Open circuit 539 1. Unplug connector X225 and press the
Lower upper sieve rear adjust switch into the
“lower” position. Continuity should exist
to the next step.
2. Disconnect connector X025 and turn to
the key to the “RUN” position. Using a
connector X025 of circuit EX-540YE-0.8.
If voltage exist, circuit SW-540-YE is
voltage does not exist at pin J2-17,
CCM3 is defective and requires replace-
ment.
55-34
Lower Sieve Rear Adjust Switch
The Lower Sieve Rear Adjust Switch (S-46), 2, is a

two-position momentary rocker switch. When the
switch is activated in either direction, the correspond-
ing ground path is completed. CCM3 establishes a
ground path is completed, and activates the lower
sieve actuator in the proper direction. If the rocker 2
switch is pushed in the opposite position, CCM3
reverses the current flow to send the lower actuator
in the opposite direction.
Resolve any issues with alarm codes before

40024710
troubleshooting the lower sieve rear adjust circuit.
32
Refer to the chart below to troubleshoot the Lower
Sieve Rear Adjust Switch Circuit.
Lower Sieve Actuator Raises Short to ground on circuit 542 1. Unplug connectors X025 and X013. Test
SW-542-YE-0.8. If continuity exists, wire
SW-542-YE-0.8 is damaged and requires
repair. If no continuity exists, proceed to
the next step.
ment.
ment.
55-35
Lower Sieve Actuator Lowers Short to ground on circuit 541 1. Unplug connectors X025 and X013. Test
ment.
ment.
Lower Sieve Actuator Will Not Open circuit 551 1. Check for loose or corroded connectors
Raise or Lower on circuit 551. If no loose or corroded
connectors are found, proceed to the
next step.
2. Unplug connector X025 and test for
continuity to ground on circuit
EX-551-Bk-0.8. If continuity does not
exist, circuit EX-551-Bk-0.8 is dam-
aged and requires repair. If continuity
exists, proceed to the next step.
3. With connector X025 still disconnected,
unplug connector X226 and jump pin 2
to ground. Test pin 13 of connector X025
for continuity to ground. If continuity
does not exist, Circuit SW-551 is
damaged and requires repair. If continu-
ity exists, the lower sieve rear adjust
ment.
55-36
Lower Sieve Actuator Will Not Open circuit 542 1. Unplug connector X226 and press the
Raise lower sieve rear adjust switch into the
“raise” position. Continuity should exist
to the next step.
2. Disconnect connector X025 and turn to the
key to the “RUN” position. Using a
connector X025 of circuit EX-542YE-0.8. If
voltage exist, circuit SW-542-YE is
voltage does not exist at pin J2-35, CCM3
is defective and requires replacement.
Lower Sieve Actuator Will Not Open circuit 541 1. Unplug connector X226 and press the
Lower lower sieve rear adjust switch into the
“lower” position. Continuity should exist
to the next step.
2. Disconnect connector X025 and turn to the
key to the “RUN” position. Using a
connector X025 of circuit EX-542YE-0.8. If
voltage exist, circuit SW-542-YE is
voltage does not exist at pin J2-35, CCM3
is defective and requires replacement.
55-37
55-38
Chapter 14 - Clean Grain Systems
CONTENTS

Unload Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Grain Bin Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Unload Tube Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Grain Bin Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
55-1
This section explains the following clean Grain sys-
tem components:
• Unload system engage

• Grain bin sensors
• Grain Tank covers
• Unload Tube Swing
Unload Engage
The Unload engage is triggered from a switch, 1, in
the Multi-Function Handle (MFH); press once to en-
gage the unloading system, press again to disen-
gage unloading. The MFH switch sends a signal to
the Right-hand Control Module (RHM). The RHM 1
transmits messages via CAN to CCM2, CCM2 sends
a PWM signal to a solenoid on the engine gearbox
valve to engage the clutch in the engine gearbox.
The Unload engage will not engage if:
• The Road/Field switch is in “Road” mode or the 20030010

Emergency stop button on the MFH is de-
pressed. 1
• The Unload tube is in, or is moved into the
“Home” Position.
UNLOAD ENGAGE – ALARMS

A0022 Unload Engaged – will occur any time
the unloading system is engaged.
UNLOAD ENGAGE – FAULT CODES

E0177-03 Isense Unload Cross Auger Shorted to
high source
E0184-11 Unload Cross Auger valve Unidentified

Failure Code
55-2
UNLOAD ENGAGE – TROUBLESHOOTING B. If the voltage reading is within the proper lim-
The unload system will not engage. its, continue the troubleshooting at step 3.
NOTE: Visually inspect the wiring harness and con-
Cause: No signal from the unload engage switch on nectors. Verify that the connector was fully installed.
MFH. Inspect the terminals and wires at the connector for
pushed back or corroded terminals or damaged
wires. Flex the harnesses involved to reveal intermit-
Possible Failure Modes: tent breaks or shorts in the wiring concerned.
1. Switch failed.
2. The voltage reading on the Infoview monitor
does not change. Disconnect connector X028
3. RHM module failure. from the RHM module. Use a multimeter to check
resistance between the harness end of connec-
Solution: tor X028 pin 4 and pin 1, with the black (com-
mon) probe of the multimeter on pin 1. Depress
1. Enter the Infoview monitor - Diagnose Info the unload auger engage switch; the resistance
screen. should change from infinite to approximately 1.6
Select “MFH” sub menu. – 1.8 M ohms resistance.
Select “HSW Unload Auger Engage” and monitor A. If there is no change in resistance, the switch
the display while cycling the Unload Engage or wiring in the MFH handle has failed. Re-
switch. The “switch” screen should show “on” place the MFH.
when the switch is depressed. If the “Voltage” B. If the resistance reading is correct, continue
screen is selected, there should be 5.1 volts with with Step 3.
the switch open, and 1.8 volts when the switch is
depressed. 3. Use the electronic service tool (EST) to reload
the software in the RHM module, and retest the
A. If the voltage does not change, continue with system. If the problem still exists, the RHM has
Step 2. failed. Replace the RHM.
55-3
Grain Bin Sensors
There are two grain bin sensors that work together to
monitor the amount of grain in the grain bin. The two
sensors are wired in series. The system monitors
change in resistance controlled by the two grain bin
sensors. 2
• Grain Bin Becoming Full – The combine is
equipped with a lower (3/4), 1, and upper (bin
full), 2, grain tank level sensor. These sensors 1
monitor the level of material in the grain bin.
When the thresher is engaged and the material
in the grain bin reaches the lower sensor, the ro- 40025217
tating beacons will flash*. The flashing beacons
inform a grain truck operator to prepare for un-
2
loading the grain bin.
*If the work lights are activated, the rotating beacons
will only flash for approximately 10 seconds. The ro-
tating beacons flash again for another 10 seconds
when the upper sensor detects material. If the work
lights are not activated, the beacons will remain illu-
minated until the grain bin is emptied.
GRAIN BIN SENSORS – ALARMS

A0030 Grainbin FULL
GRAIN BIN SENSORS – FAULT CODES

E0159-03 Grain Bin Full sensor Shorted to
high source
E0159-05 Grain Bin Full sensor Line

Disconnected
UNLOAD TUBE SWING

Activated by two position switches, 1, and 2, on multi-
function handle (MFH). RHM sends signal via CAN
to CCM2 to activate the extend or retract the unload 2
tube. Unload tube swing is disabled by road mode
switch on console. There are two swing modes – one 1
manual (first switch position), and one automatic
(second switch position) – see Operator’s manual
pg. 2-13 for details.
Unload swing open is disabled when in ‘Road’ mode.
20030010
UNLOAD TUBE SWING - ALARMS
A0029 Unloading Tube Open – will occur if 3
‘Road’ mode is selected while unload
tube is out of the cradle.
A0051 Road Mode selected – will occur if

attempt to swing unload tube out while
’Road’ mode is selected.
55-4
UNLOAD TUBE SWING - FAULT CODES 2. The voltage reading on the Infoview monitor
E0193-11 Unload Tube In valve Unidentified does not change. Disconnect connector X028
Failure Code from the RHM module. Use a multimeter to check
resistance between the harness end of connec-
E0194-11 Unload Tube Out valve Unidentified tor X028 pin 5 and pin 1, with the black (com-
Failure Code mon) probe of the multimeter on pin 1. Depress
the unload tube out switch; the resistance should
change from infinite to approximately 1.6 – 1.8 M
UNLOAD TUBE SWING CONTROL ohms resistance.
TROUBLESHOOTING
A. If there is no change in resistance, the switch
Unload tube will not swing in or out.
or wiring in the MFH handle has failed. Re-
Cause: No signal from unload swing in or swing out place the MFH.
switches on MFH. B. If the resistance reading is correct, continue
with Step 3.
3. Enter the Infoview monitor - Diagnose Info
1. Switch failed. screen.
2. Open circuit on switch wiring in MFH. Select “MFH” sub menu.
3. RHM module failure. Select “HSW Unload Tube Out Lock” and moni-
tor the display while cycling the unload tube out
switch to the second position. The “switch”
Solution:
screen should show “on” when the switch is fully
1. Enter the Infoview monitor - Diagnose Info depressed. If the “Voltage” screen is selected,
screen. there should be 5.1 volts with the switch open,
Select “MFH” sub menu. and 1.8 volts when the switch is depressed.
Select “HSW Unload Tube Out” and monitor the A. If the voltage does not change, continue with
display while cycling the unload tube out switch. Step 4.
The “switch” screen should show “on” when the B. If the voltage reading is within the proper lim-
switch is depressed. If the “Voltage” screen is se- its, continue the troubleshooting at step 5.
lected, there should be 5.1 volts with the switch
open, and 1.8 volts when the switch is de- NOTE: Visually inspect the wiring harness and con-
pressed. nectors. Verify that the connector was fully installed.
Inspect the terminals and wires at the connector for
A. If the voltage does not change, continue with pushed back or corroded terminals or damaged
Step 2. wires. Flex the harnesses involved to reveal intermit-
B. If the voltage reading is within the proper lim- tent breaks or shorts in the wiring concerned.
its, continue the troubleshooting at step 3.
4. The voltage reading on the Infoview monitor
NOTE: Visually inspect the wiring harness and con- does not change. Disconnect connector X028
nectors. Verify that the connector was fully installed. from the RHM module. Use a multimeter to check
Inspect the terminals and wires at the connector for resistance between the harness end of connec-
pushed back or corroded terminals or damaged tor X028 pin 11 and pin 1, with the black (com-
wires. Flex the harnesses involved to reveal intermit- mon) probe of the multimeter on pin 1. Fully de-
tent breaks or shorts in the wiring concerned. press the unload tube out switch; the resistance
should change from infinite to approximately 1.6
– 1.8 M ohms resistance.
A. If there is no change in resistance, the switch
or wiring in the MFH handle has failed. Re-
place the MFH.
B. If the resistance reading is correct, continue
with Step 5.
55-5
5. Enter the Infoview monitor - Diagnose Info 7. Enter the Infoview monitor - Diagnose Info
screen. screen.
Select “MFH” sub menu. Select “MFH” sub menu.
Select “HSW Unload Tube In” and monitor the Select “HSW Unload Tube In Lock” and monitor
display while cycling the unload tube in switch. the display while cycling the unload tube in switch
The “switch” screen should show “on” when the to the second position. The “switch” screen
switch is depressed. If the “Voltage” screen is se- should show “on” when the switch is fully de-
lected, there should be 5.1 volts with the switch pressed. If the “Voltage” screen is selected, there
open, and 1.8 volts when the switch is de- should be 5.1 volts with the switch open, and 1.8
pressed. volts when the switch is depressed.
A. If the voltage does not change, continue with A. If the voltage does not change, continue with
Step 6. Step 8.
B. If the voltage reading is within the proper lim- B. If the voltage reading is within the proper lim-
its, continue the troubleshooting at step 7. its, continue the troubleshooting at step 9.
NOTE: Visually inspect the wiring harness and con- NOTE: Visually inspect the wiring harness and con-
nectors. Verify that the connector was fully installed. nectors. Verify that the connector was fully installed.
Inspect the terminals and wires at the connector for Inspect the terminals and wires at the connector for
pushed back or corroded terminals or damaged pushed back or corroded terminals or damaged
wires. Flex the harnesses involved to reveal intermit- wires. Flex the harnesses involved to reveal intermit-
tent breaks or shorts in the wiring concerned. tent breaks or shorts in the wiring concerned.
6. The voltage reading on the Infoview monitor 8. The voltage reading on the Infoview monitor
does not change. Disconnect connector X028 does not change. Disconnect connector X028
from the RHM module. Use a multimeter to check from the RHM module. Use a multimeter to check
resistance between the harness end of connec- resistance between the harness end of connec-
tor X028 pin 10 and pin 1, with the black (com- tor X028 pin 9 and pin 1, with the black (com-
mon) probe of the multimeter on pin 1. Depress mon) probe of the multimeter on pin 1. Fully de-
the unload tube in switch; the resistance should press the unload tube in switch; the resistance
change from infinite to approximately 1.6 – 1.8 M should change from infinite to approximately 1.6
ohms resistance. – 1.8 M ohms resistance.
A. If there is no change in resistance, the switch A. If there is no change in resistance, the switch
or wiring in the MFH handle has failed. Re- or wiring in the MFH handle has failed. Re-
place the MFH. place the MFH.
B. If the resistance reading is correct, continue B. If the resistance reading is correct, continue
with Step 7. with Step 7.
9. Use the electronic service tool (EST) to reload
the software in the RHM module, and retest the
system. If the problem still exists, the RHM has
failed. Replace the RHM.
55-6
GRAIN BIN COVERS

The grain bin covers are activated by a switch, 1. This
is a two position switch – it will either be in the ‘open’
or ‘closed’ position – the operator does not have to
hold it. The switch is located on the upper left console
in the headliner.
4
The switch sends a signal to CCM2 module, which is
relayed via CAN to CCM1. CCM1 then activates the
output to the covers motor M12 to open or close the
grain bin covers. A linear actuator, 2, is used to move
linkage that opens and closes the grain bin covers,
as well as fold the bubble-up auger up or down. The
covers closed sensor B47 on the bubble-up auger is
used to determine if the covers are open or not.
For Grain Tank Covers control on CX/CR combines

the following will stop or prevent the covers from
2
opening or closing:
10004684
• Emergency switch actuation
5
• Grain Tank Covers switch error
• Threshing engaged
• If the actuator current is greater than 18amps for

0.1seconds (i.e. actuator stalled)
Additionally, if Road Mode is engaged it will stop or

prevent the covers from opening (generates alarm
A0051). You can close covers in road mode.
55-7
GRAIN BIN COVERS - ALARMS GRAIN BIN COVERS - FAULT CODES

A0028 Grain tank Covers Open – will occur E0001-03 Bin Covers Open sensor Shorted to
if ‘Road’ mode is selected or ground high source
speed exceeds 15 kph (10 mph) and
covers are open. E0001-04 Bin Covers Open sensor Shorted to low
source
A0051 Road mode selected – will occur if
‘Road” mode is selected, and attempt to E0001-05 Bin Covers Open sensor Line
open covers. Disconnected
A0079 Grain tank Covers Closed – will occur if E0045-06 Current Sense Bin Covers Short Circuit
covers are closed and threshing is
engaged. E0069-11 Covers / Concave Cl Sel
E0079-11 Grainbin Covers motor Unidentified

Failure Code
E0137-04 Open Covers switch Shorted to low

source (disabled)
55-8
Chapter 15 - Crop Residue
CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Straw Chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chopper RPM Sensor B10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Alarm Code Chopper RPM Sensor B10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Codes for Chopper RPM Sensor B10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chaff Spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chaff Spreader Valve Solenoid L28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Code for Chaff Spreader Valve Solenoid L28 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Positive Straw Discharge (PSD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Straw Chopper Spreader Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Spreader Plate Switch S23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault Codes for Spreader Plate Switch S23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Spreader Plate Motor M11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fault Codes for Spreader Plate Motor M11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Spreader Plate Switch S23 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Spreader Plate Motor M11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
55-1
INTRODUCTION
The Crop Residue System in located at the rear end
of the combine. This system chops and/or disperses
the residue of the crops processed by the combine.
The electrical portion of the Crop Residue System

controls and monitors the various components of this
system.
55-2
STRAW CHOPPER
Chopper RPM Sensor B10
The Chopper RPM Sensor B10 is located at the right
rear of the combine.
40011023
2
The Chopper RPM Sensor B10, 1, is a proximity
sensor that sends a signal to CCM2 every time the
sensor plate, 2, passes over the face of the switch.
CCM2 monitors the pulsed signals and determines if
the rotor shaft is rotating.
NOTE: In order for CCM2 to recognize and report

chopper RPM, it must be configured as “Installed”.
Refer to the Configuration and Calibration Section of
the Operators Manual for more information.
2 1
40011026
55-3
Alarm Code Chopper RPM Sensor B10
Alarm Description Priority Check Condition Activation Resetting
Code
A0042 Chopper RPM LOW High Threshing and no 1 sec< 100 RPM 3 sec> 100 RPM
manual RPM -- OR -- -- OR --
changes 1 sec < 80% of 3 sec > 80% of
threshold RPM threshold RPM
Fault Codes for Chopper RPM Sensor B10

E0143-03 Chopper RPM Sensor Shorted to High Source
E0143-04 Chopper RPM Sensor Shorted to Low Source
E0143-05 Chopper RPM Sensor Line Disconnected
NOTE: Refer to the CCM2 Fault Codes section of the repair manual for troubleshooting.
CHAFF SPREADER
1
Chaff Spreader Valve Solenoid L28
The Chaff Spreader Valve Solenoid L28, 1, is located
at the left rear of the combine.
The Chaff Spreader is activated by CCM1 module

when Threshing is engaged.
NOTE: Chaff Spreader must be configured as

”Installed”. Refer to the Configuration and Calibration 2
Section of the Operators Manual for more
information. 10020028
When the Chaff Spreader Valve Solenoid L28 is 4

activated, low-pressure oil is directed to the
adjustable flow control valve, 2. Oil that can flow
through the flow control valve travels through a quick
coupler to the two chaff spreader motors that are
connected in series.
Fault Code for Chaff Spreader Valve Solenoid L28

E0053-11 Chaff Spreader Valve Unidentified Failure Code
NOTE: Refer to the CCM1 Fault Codes section of the repair manual for troubleshooting.
55-4
POSITIVE STRAW DISCHARGE (PSD)

In combines equipped with the positive straw
discharge (PSD) system, the PSD works in
2
conjunction with the chaff spreader system to provide
a more positive delivery of straw to the spreaders. An
additional hydraulic motor is place in series with the
spreader motors, thus operating simultaneously with
them. Also, a different valve block, 1, is used, since
additional outputs must be provided for the PSD
motor.
Electrically, the system works the same as in

combines equipped with chaff spreader but not the
1
66060557
PSD. Chaff Spreader Valve Solenoid L28, 2, controls
the flow of oil to the spreader motors and the PSD 5
motor as described above. Alarm and error codes
valid for the L28 apply here as well.
55-5
STRAW CHOPPER SPREADER PLATE
20030010
6
Spreader Plate Switch S23 When the Spreader Plate Switch S23 is toggled, a
The Spreader Plate Switch S23, 1, is located on the signal is sent to the RHM. The RHM relays the signal
RHC. to CCM3. CCM3 applies current to the Spreader
Plate Motor M11 energizing it to extend or retract to
The Spreader Plate Switch S23 controls the move the Spreader Plates.
Spreader Plate Motor M11 to adjust the direction of
the divider plates. The adjustment of the divider NOTE: Spreader Plate Switch must be configured as
plates allows the operator to choose the direction of “Installed”. Refer to the Configuration and Calibration
the residue exiting the rear of the combine. Section of the Operators Manual for more
information.
55-6
1 Right Hand Discharge

2 Neutral
3 Left Hand Discharge 1

connections clean and tight. Use a multimeter 2
manual.
3
7
Fault Codes for Spreader Plate Switch S23
E0648-04 CSW Spreader Plates Right Shorted to Low Source

E0648-07 CSW Spreader Plates Right Mechanical Out of Range
E0655-04 CSW Spreader Plates Left Shorted to Low Source
E0655-07 CSW Spreader Plates Left Mechanical Out of Range
Spreader Plate Motor M11

The Spreader Plate Motor M11, 1, is located on the
rear of the combine on the top of the spreader plate.
The Spreader Plate Motor M11 is controlled by

Spreader Plate Switch S23 on the RHC. When the
1
Spreader Plate Switch S23 is cycled, either for left
hand discharge or right hand discharge, a signal is
sent to the RHM. From the RHM a signal is sent to
CCM3 which energizes the motor causing it to move
the plunger in (left) or out (right) in turn moving the
Spreader Plate Fins. The position of the motor and
the Spreader Plate Fins are monitored by an integral 50032239
potentiometer on the motor.
8
The potentiometer sends a signal to CCM3 which
relays it to be displayed on Infoview while the
Spreader Plate Switch S23 is activated.
Fault Codes for Spreader Plate Motor M11
E0297-06 Current Sense Spreader Pl Short Circuit
E0332-11 Spreader Plates Motor Unidentified Failure Code
NOTE: Refer to the CCM3 Fault Codes Section of the repair manual for troubleshooting.
55-7

55-8
B-10 = CHOPPER RPM

L-28 = CHAFF SPREADER
M-11 = SPREADER PLATE MOTOR TRASH
S-23 = SPREADER PLATE FRAME--23
55-9

H-01 = AUDIO ALARM
55-10
F-49 = CAB FUSE

S-05 = SEAT SWITCH
FRAME--27
55-11
SPREADER PLATE SWITCH S23 TROUBLESHOOTING
CAUTION
WARNING
driven equipment.
Step Test Point Good Reading Possible Cause

of Bad Reading
1 Diagnostic Menu; RHC sub-menu; ON is displayed when switch Blown fuse F48, open or
CSW Spreader Plates Right; Switch. is cycled to ON position. shorted circuit, Failed switch.
Cycle switch per the icon for right- Proceed to next test point.
hand discharge.
2 Diagnostic Menu; RHC sub-menu; Approximately 1.3 volts with Blown fuse F48, open or
CSW Spreader Plates Right; Voltage. switch in neutral, Approxi- shorted circuit, Failed switch.
mately 4.9 volts with switch
Cycle switch per the icon for right- depressed for right-hand dis-
hand discharge. charge. Proceed to next test
point.
3 Diagnostic Menu; RHC sub-menu; ON is displayed when switch Blown fuse F48, open or
CSW Spreader Plates Left; Switch. is cycled to ON position. shorted circuit, Failed switch.
Cycle switch per the icon for left-hand
discharge.
4 Diagnostic Menu; RHC sub-menu; Approximately 1.3 volts with Blown fuse F48, open or
CSW Spreader Plates Left; Voltage. switch in neutral, Approxi- shorted circuit, Failed switch.
mately 4.9 volts with switch
Cycle switch per the icon for left-hand depressed for left-hand dis-
discharge. charge. Proceed to next test
point.
5 Disconnect connector X037 and re- Less than 1 ohm. Switch failure.
move Spreader Plate Switch S23 from
RHC. Test continuity between pin 2
and 3 while depressing switch for
right-hand spreading. Proceed to next test point.
6 Test continuity between pin 2 and 1 Less than 1 ohm. Switch failure.
while depressing switch for left-hand
spreading. Proceed to next test point.
7 Test continuity of circuit 324 (YE) Less than 1 ohm. Open circuit in 324 (YE) or
between connector X037 pin 3 and short to ground.
connector X029 pin 18. Proceed to next test point.
8 Test continuity of circuit 325 (YE) Less than 1 ohm. Open circuit in 325 (YE) or
connector X029 pin 14. Proceed to next test point.
55-12

of Bad Reading
9 Test continuity of circuit 357 (OR) Less than 1 ohm. Open circuit in 357 (OR) or
connector X054 pin B. Proceed to next test point.
10 Spreader Plate Switch S23 Back Less than 1 ohm. Open circuit in 398 (PU) or
lighting. Test continuity of circuit 398 short to ground.
(PU) between connector X037 pin 7 Proceed to next test point.
and connector X198 pin L.
11 Spreader Plate Switch S23 Back Less than 1 ohm. Open circuit in 386 (BK)
lighting. Test continuity of circuit 386
(BK) between connector X037 pin 9 Good switch and circuitry.
and Cab ground #3.
55-13
SPREADER PLATE MOTOR M11 TROUBLESHOOTING

manual.
CAUTION
WARNING
driven equipment.

of Bad Reading
1 Diagnostic menu, Residue Sub-Menu, Curved arrow rotating to the Fuse F27 blown, open or
Spreader Plates Motor; Enter, H right will display on Infoview. shorted circuit, Failed switch.
Bridge. Spreader Plate Switch S23 (See Spreader Plate Switch
activated for right hand discharge. Proceed to next test point. S23 troubleshooting)
2 Diagnostic menu, Residue Sub-Menu, Curved arrow rotating to the Fuse F27 blown, open or
Spreader Plates Motor; Enter, H left will display on Infoview. shorted circuit, Failed switch.
Bridge. Spreader Plate Switch S23 (See Spreader Plate Switch
activated for left hand discharge. Proceed to next test point. S23 troubleshooting)
3 Diagnostic menu, Residue Sub-Menu, OK displayed on Infoview. Fuse F27 blown, open or
Spreader Plates Motor; Enter, STATUS shorted circuit, Failed switch.
Proceed to next test point. (See Spreader Plate Switch
S23 troubleshooting)
4 Diagnostic menu, Residue Sub-Menu, Bar graph should display Fuse F27 blown, open or
Spreader Plates Motor; Enter, Current. approximately 14.1 amps. shorted circuit, Failed switch.
Spreader Plate Switch S23 activated (See Spreader Plate Switch
for left hand discharge. Proceed to next test point. S23 troubleshooting)
5 Diagnostic menu, Residue Sub-Menu, Bar graph should display Fuse F27 blown, open or
Spreader Plates Motor; Enter, Current. approximately 14.1 amps. shorted circuit, Failed switch.
Spreader Plate Switch S23 activated (See Spreader Plate Switch
for right hand discharge. Proceed to next test point. S23 troubleshooting)
6 Diagnostic menu, Residue Sub-Menu, Approximately 5 volts. Fuse F27 blown, open or
Spreader Plates Motor; Enter, Voltage. shorted circuit, Failed switch.
Spreader Plate Switch S23 activated Proceed to next test point. (See Spreader Plate Switch
for right hand discharge. S23 troubleshooting)
55-14

of Bad Reading
7 Diagnostic menu, Residue Sub-Menu, Approximately 5 volts. Fuse F27 blown, open or
Spreader Plates Motor; Enter, Voltage. shorted circuit, Failed switch.
Spreader Plate Switch S23 activated Proceed to next test point. (See Spreader Plate Switch
for left hand discharge. S23 troubleshooting)
8 Disconnect connector X224. Test Approximately 3.6 ohms Failed motor.
continuity between pin D and pin E.
This will test Spreader Plate Motor
M11.
9 Test continuity between pin A and pin B. Approximately 10 ohms Failed potentiometer.
This will test position potentiometer. Proceed to next test point.

10 Test continuity between pin A and pin C. >10 ohms Failed potentiometer.

11 Test continuity between pin B and pin C. Approximately 10 ohms Failed potentiometer.

12 Test continuity between connector Less than 1 ohm. Open circuit or short to
X224 pin A and connector X071 pin 1. ground in circuit 473 (PK).
This circuit is 473 (PK). Proceed to next test point.
X071 pin 1 and connector X025 pin 1. ground in circuit 473 (PK).
This circuit is 473 (PK). Proceed to next test point.
X025 pin 1 and connector X013 pin ground in circuit 473 (PK).
J2-31. This circuit is 473 (PK). Proceed to next test point.
X224 pin B and connector X071 pin 2. ground in circuit 471 (BL).
This circuit is 471 (BL). Proceed to next test point.
X071 pin 2 and connector X025 pin 2. ground in circuit 471 (BL) and
This circuit is 471 (BL) and 439 (BL) Proceed to next test point. 439 (BL)
X224 pin C and connector X071 pin 10. ground in circuit 477 (YE)
This circuit is 477 (YE). Proceed to next test point.
X071 pin 10 and connector X025 pin 5. ground in circuit 477 (YE)
This circuit is 477 (YE). Proceed to next test point.
X025 pin 5 and connector X013 pin ground in circuit 477 (YE)
J2-33. This circuit is 477 (YE).
55-15
55-16
Chapter 16 - Precision Farming
CONTENTS

55 000 Precision Farming Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Moisture Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Grain Yield Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Grain Yield Sensor Offset Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GPS/DGPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Precision Farming Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Precision Farming Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Precision Farming Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
55-1
The CR Series combine may be equipped with
several different precision farming packages to allow
the operator to monitor and/or record different
harvesting parameters for analysis.
The basic precision farming component is the

moisture sensor, which is mounted in the clean grain
elevator. This component measures the moisture
level of the grain being harvested, and displays this
information on the Infoview monitor.
40024715
1
The next precision farming component that may be
added is the grain yield sensor, which mounts in the
top of the clean grain elevator, and provides
information to the operator on instantaneous or
average yield of the crop being harvested. In
addition, the operator may view reports with average
and total values for the field that was harvested.
10004680
2
The optional CCM3 module, 1, must be installed for
both the moisture sensor and grain yield sensor.
Addition of a data logger unit and GPS antenna and

receiver allows the moisture and yield information to
be ‘mapped’ to specific locations in the field, and
further allows the operator to create maps following
the harvest showing detailed moisture and yield
information at specific locations throughout the field. 1
Precision Farming Accuracy

The following items all affect precision farming 10004693
accuracy, and must be adjusted or calibrated
accurately in order for the precision farming system 3
to provide accurate information.
• Grain Yield sensor calibration

• Moisture sensor calibration
• Tire Radius calibration (ground speed)
• Maximum Stubble Height calibration
• GPS configuration
• Header width & Header Usage settings
• Row Distance & Rows in Use settings
55-2
Moisture Sensor
The moisture sensor is mounted in a bypass housing
that is located on the clean grain elevator housing.
The moisture sensor provides a measurement of
both grain moisture and temperature.
40024715
4
A portion of the grain being transported up the clean
grain elevator falls into the opening, 1, of the bypass 1
housing, and fills up the cavity around the moisture 2 3
sensor, 2, so that it remains completely surrounded
by grain all the time. When the cavity is completely
full, as monitored by an optical sensor, 3, CCM3 turns
on a small transfer auger, 4, which augers the grain
out of the cavity and back into the return side of the
clean grain elevator. This ensures a constant flow of
harvested grain past the moisture sensor. By
positioning the moisture sensor in the bypass
housing, the potential for plugging or build-up
4
occurring in weedy or muddy crop conditions is 19995412
reduced.
5
CCM3 will run the transfer auger for 30 seconds after
the threshing system is disengaged in order to clean
all material from the bypass housing.
The optical sensor may be adjusted for sensitivity;

refer to Section 80 Grain Storage, Chapter 1 Clean
Grain Transport for more information.
55-3
Grain Yield Sensor
A mass-flow type sensor is used to monitor the flow
of grain into the grain bin, representing the volume of
grain harvested. The sensor is mounted at the top of
the clean grain elevator. Grain flowing out of the
elevator is concentrated and guided to the sensor
plate. The sensor plate is connected via a lever beam
over a rotation point to a load cell and counter weight.
The counter weight keeps the sensor unit in balance
when driving uphill or downhill to maintain accuracy.
The design of the sensor results in a near-linear

relationship with crop flow, so that the sensor 10004680
typically only requires a single calibration to ensure
proper accuracy. In addition, if the sensor detects 6
“zero flow” for at least 5 seconds (would typically
occur during headland turns), the system will reset
the “zero flow” value. This compensates for
temperature changes, build-up, and wear and tear of
the sensing plate to insure maximum accuracy.
There are several critical adjustments that affect the

accuracy and performance of the sensor, as follows:
Grain elevator upper shaft adjustment; controls

paddle tip clearance to top of elevator housing. This
clearance is increasingly critical in light or small seed
crops. Refer to Section 80 Grain Storage Chapter 1
Clean Grain Transport for more information.
Grain yield sensor plate adjustment; controls

positioning of the sensor plate to the elevator
housing. This adjustment is critical to the overall
accuracy of the grain yield sensor. Refer to Section
80 Grain Storage Chapter 1 Clean Grain Transport
for more information.
Grain yield sensor offset adjustment; may be

required if alarm “A0052 Yield Sensor Out of Range”
occurs frequently, and sensor plate is clean and
adjusted properly.
Grain Yield Sensor Offset Adjustment
If the alarm message “A0052 Yield Sensor Out of
Range” occurs frequently while harvesting high
capacity crops, and the sensor plate is clean (no
residue build-up) and adjusted properly, the grain
yield sensor offset may need to be adjusted.
Navigate to the “Diagnose Info - Precision Farming”
screen, and select “Grain Yield sensor”.
20031022
55-4
The voltage level for the Grain Yield sensor should be
between 0.5 to 1.2 volts. If the voltage is above the
range, it needs to be adjusted.
20031023
8
Remove the cover, 1, in the grain tank to expose the
grain yield sensor.
9
Remove the four bolts, 1, and slide the shield, 2, off
of the grain yield sensor.
2
10
55-5
Remove the protective cover, 1, from the connector
on the yield sensor control box to expose the
connector pins. 1
50031024
11
Use a small screwdriver or other metal object to
carefully short between the offset control pin, 1, and
the ground pin, 2. Move the screwdriver as required
to provide short pulses between these two pins. By
giving short pulses shorter than one second, the
offset will move in one direction. Halting the pulses
longer than one second, and then restarting the
pulses will change the direction of the offset
movement. Provide pulses to the pins as required
while monitoring the offset voltage value on the
Infoview monitor until the offset is within 0.5 to 1.2
volts.
To memorize the new offset position, apply nine

pulses (offset will move in one direction), pause for
a period longer than 2 seconds, and then apply an
additional nine pulses (offset should return to desired
value).
20031025
12
55-6
Install the protective cap over the connector. Slide
the shield, 1, onto the grain yield sensor, using 2
caution to install the wire harness grommet, 2, in the 1
slot. Secure the shield using the four bolts, 3. Install
the cover in the grain tank.
3
13
55-7
GPS/DGPS Receiver settings, resulting in loss of differential

The Global Positioning System (GPS) consists of 24 correction signal. In some cases, it may be
satellites in earth orbit that travel in predictable and necessary to change from one differential method to
constant 12 hour orbits. Signals sent from the another to compensate for loss of correction signal.
satellite to a GPS antenna and receiver may be used The following table indicates the adverse affects of
to define the distance from the satellite to the some obstacles with the different methods of
receiver. At least 3 satellites are required to calculate differential correction.
position using triangulation, but at least 4 satellites
are recommended to provide a reliable GPS position. Satellite Beacon
Obstacle Affected? Affected?
By itself, GPS only provides position accuracy to Hilly terrain No No
approximately 90 meters (300 feet), which is not Tree canopy Yes No
accurate enough for site-specific farming purposes. Lightning No Yes
Therefore, a correction signal (location signal from
Power lines No Yes
another source) is necessary to provide ‘sub-meter’
Radar / Microwave Yes No
accuracy. This correction signal is typically provided
by Coast Guard beacons, a base station, or from a
satellite provider, and is required to obtain Configurations
“Differential” GPS, or DGPS. There is a “Precision Farming” configuration screen,
with the following user settings available:
There are several possible sources of GPS errors.
Use the Operator’s manual supplied with the GPS Crop - may change the crop type being harvested.
antenna and receiver to make the necessary
settings, as follows: Crop delay - is the time needed (in seconds) to
transport the crop from the cutter bar through the
Multipath errors; caused by second-hand, bounced combine to the grain yield sensor. This adjustment is
signals. Set the “PV” filter (position velocity) to “ON” necessary for use with GPS, to synchronize the grain
to provide the most accurate data. yield sensor data with a specific location in the field
as determined by GPS. In general, this value should
Atmospheric effects on signal, causing ‘signal be left at the factory default setting.
noise’. Monitor the SNR (Signal-to-Noise Ratio); a
low value indicates significant loss of precision due Calibrations
to atmospheric interference. It is possible to adjust There are several different calibration procedures
the “AMU Mask” value to allow the receiver to ignore required to ensure accurate information is provided
satellites that are transmitting noisy or inaccurate by the precision farming sensors.
signals. In general, a setting of 8 or higher provides
the best accuracy. In addition, the “Elevation Mask” Grain yield sensor - must be calibrated in order to
may be adjusted to either include or ignore satellites provide accurate yield data. This calibration is
that are low on the horizon. Satellites low on the generally only required to be done once per season,
horizon will not provide as accurate a signal as those and does not have to be done in each crop harvested.
higher in the sky. In general, a setting of 15 degrees Refer to the CR Combine Operator’s manual for
is recommended for highest accuracy. more information.
NOTE: It may be necessary to set the Elevation Mask Moisture sensor - must be done for each crop type
or AMU Mask at less than desirable settings in order that is harvested, unlike the grain flow sensor, in
to ensure that at least 4 satellites are visible by the order to ensure accurate moisture readings during
receiver. There is a trade off between having a harvest. Refer to the CR Combine Operator’s
slightly flawed signal, and having no signal at all. manual for more information.
55-8
Precision Farming Alarms
Alarm Module Description
A0052 Yield Sensor Out of Range CCM3 Yield sensor out of range (> 5.2 volts). Clean and
adjust sensor plate. Adjust sensor offset.
A0054 Moisture bypass auger not activating CCM3 Will occur if auger is not activated within 2 minutes
after threshing and feeder engaged, and combine
moving forward. Relay is open, fuse is blown; or
motor is not functioning.
A0055 Moisture bypass not cycling CCM3 Will occur if CCM3 is activating motor and bypass
unit full sensor does not change within 30 seconds.
Mud buildup on sensor, sensor too sensitive,
housing plugged, or motor damaged.
A1000 PLD (fpga) DLU Module can’t be programmed. Reset the module
(power off & on), and try a different data card.
Replace module if necessary.
A1001 eeprom DLU Reset DLU module (power off & on). Replace
module if necessary.
A1002 Log error DLU Will occur due to corrupt files on data card. Format
data card.
A1003 Message set error DLU Use Service Info/Network screen to check function-
ing of CCM modules.
A1004 Object file error DLU Corrupt ‘objects.def’ file on data card; erase file.
A1005 Marker error DLU Corrupt ‘markers.def’ file on data card; erase file.
A1006 Datacard space DLU Data card is 95% full. Remove files from data card.
Precision Farming Fault Codes

E0142-03 Groundspeed RPM sensor Shorted to high source
E0142-04 Groundspeed RPM sensor Shorted to low source
E0142-05 Groundspeed sensor Line Disconnected
E0277-03 Bypass Unit Full sensor Shorted to high source

E0277-05 Bypass Unit Full sensor Line Disconnected
E0283-03 Moisture Temp sensor Shorted to high source

E0283-05 Moisture Temp sensor Line Disconnected
E0284-03 Moisture Sensor - Shorted to high source

E0284-05 Moisture Sensor - Line Disconnected
E0285-03 Moisture Sensor + Shorted to high source

E0285-05 Moisture Sensor + Line Disconnected
E0288-03 Grain Yield Sensor Shorted to high source

E0288-05 Grain Yield Sensor Line Disconnected
E0310-11 Bypass Unit Engage output Unidentified Failure Code
E0512-05 Feeder Angle sensor Line Disconnected
55-9
Precision Farming Troubleshooting
Component Concern Solution
Grain Yield sensor Alarm message “A0052 Yield sen- Adjust sensor offset via diagnostic
sor out of range” connector. Refer to “Grain Yield
Sensor Offset Adjustment” proce-
dure listed above.
Flow read out at zero when Engage threshing and feeder, and
threshing is engaged. run engine at high idle. Wait until
flow read out is zero (unit is
self-calibrating).
Errors consistently out of range in Check and adjust grain yield sensor
both directions. plate. Refer to Section 80 Grain
Storage Chapter 1 Clean Grain
Transport for more information.
Errors consistently out of range in Recalibrate the grain yield sensor.

one direction
Moisture sensor Moisture read out not varying Optical switch not sensitive
enough. Adjust switch sensitivity.
Refer to Section 80 Grain Storage
Chapter 1 Clean Grain Transport
for more information.
In line fuse failed. Replace fuse.
Fuse F47 failed. Replace fuse.
Moisture read out is vibrating. Optical switch set too sensitive.

Adjust switch sensitivity. Refer to
Section 80 Grain Storage Chapter
1 Clean Grain Transport for more
information.
Acre Counting Acre counting is not accurate. Recalibrate maximum stubble

height. Refer to the CR Combine
Operator’s manual for more infor-
mation.
DGPS GPS icon flashing (no differential Set the receiver up for differential
signal). correction.
55-10
Chapter 17 - Electrical Connectors
CONTENTS

Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
X001 Cab Main/Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
X002 Cab Main/Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
X003 Cab Main/Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
X006 Cab Main/HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
X007 Front Frame/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
X008 Main Frame/Front Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
X009 Main Frame/Grain Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
X010 Main Frame/Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
X011 Main Frame/Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
X012 CCM-3 J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
X013 CCM-3 J2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
X014 CCM-3 J3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
X015 CCM-2 J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
X016 CCM-2 J2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
X017 CCM-2 J3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
X018 CCM-1 J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
X019 CCM-1 J2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
X020 CCM-1 J3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
X021 Front Frame/Feeder Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
X022 Main Frame/Valve Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
X023 Front Frame/Lower Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
X024 Main Frame/Straw Walker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
X025 Straw Walker/Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
X026 RHM J6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
X027 RHM J7A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
X028 RHM J7B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
55-1

X029 RHM J8A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
X030 RHM J8B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
X031 Front Frame/Cab Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
X032 Header/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
X033 Cab Main/Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
X034 Expansion/Main Frame A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
X035 Gearbox Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
X036 Cab Roof/Outer Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
X037 Spreader Plate S23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
X038 Alternate Settings S21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
X039 Feeder Reverser S07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
X040 Reel Speed Mode S08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
X041 Neutral Lock S22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
X042 Lower Sieves S14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
X043 Upper Sieves S13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
X044 Concave Clearance S16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
X045 Fan Speed S15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
X046 Rotor Speed S17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
X047 Feeder Speed S18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
X048 Gear Select S24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
X049 On the Road S12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
X050 Dual Range S11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
X051 Rear Wheel Assist 210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
X052 Park Brake S09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
X053 Splice Block A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
X054 Splice Block B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
X055 Thresher Engage S30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
X056 Feeder Engage S31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
X057 Ground Speed R04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
X058 Audio Alarm H01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
X059 Neutral Switch S22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
X060 Throttle S36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
X061 Header Height S04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
X062 Header Width Adjust S06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
X063 Vertical Knives S51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
55-2

X064 Main Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
X065 Diagnostics and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
X066 Cold Start Indicator E36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
X067 Acc. Socket J06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
X068 Key Switch S02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
X069 Lighter R08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
X070 Lighter Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
X071 Straw Hood/Straw Walker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
X072 Lower Frame Rear/Straw Walker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
X073 Seat Switch S05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
X074 Seat Pump M26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
X075 Accessory Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
X076 Accessory Outlet J08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
X077 Ground, 3, CM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
X079 Reverser Disengage B09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
X080 Feeder Reverser M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
X081 Lat Float Pot R02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
X083 ASP Door Position B-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
X084 LH Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
X085 RH Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
X087 Ground Speed RPM B17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
X088 Shoe Motor M03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
X089 Cleaning Fan RPM B16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
X090 Cleaning Fan Motor M05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
X091 Hydrostat Motor Temp B46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
X092 Foot and Inch L05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
X093 Trans Shift Position B37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
X094 Transmission Shift Motor M02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
X095 Ground, 2, FF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
X097 Gearbox Temperature B32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
X098 Control Pressure B35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
X099 Clutch Temperature B45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
X100 Ground Speed Hydrostat L23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
55-3

X101 Charge Pressure S37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
X102 Ground, 1, GB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
X103 Reservoir Temperature B18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
X104 Reservoir Level S33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
X105 Unload Tube Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
X106 Left Rear Work Light E27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
X107 3/4 Full Bin Sensor S28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
X108 Grain Tank Light E30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
X109 Full Bin Sensor S29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
X110 Right Rear Work Light E28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
X111 Left Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
X112 Left Outer Work Light E15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
X113 Left Beacon Light E31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
X114 Left Middle Work Light E19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
X115 Left Inner Work Light E17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
X116 Wiper Motor M25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
X117 Right Inner Work Light E18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
X118 Right Middle Work Light E20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
X119 Right Beacon Light 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
X120 Right Outer Work Light E16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
X121 Right Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
X122 Right Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
X123 Left Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
X124 Ground, 4, CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
X124 Ground, 4, CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
X124 Ground, 4, CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
X125 Grain Tank Extensions Switch S42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
X126 Mirror Adjust Switch S27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
X127 Mirror Heat Switch S19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
X128 HVAC Control Panel A09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
X129 Dome Light E34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
X130 Beacon Light Switch S41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
X131 Rear Work Light Switch S44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
X132 Front Work Lights Switch S43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
X133 Splice Block C, Backlighting, CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
55-4

X134 Washer Switch S38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
X135 Wiper Switch S20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
X136 Front Left Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
X137 Door Switch S40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
X138 Right Console Light E35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
X139 Front Right Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
X141 Transceiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
X142 G.P.S. Unit A11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
X145 Ground, 3, AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
X146 Ambient Temp Sensor B25 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
X147 Cold Box Door M15 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
X148 Outlet Temp Sensor B27 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
X149 Cab Temperature Sensor B26 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . 81
X150 Evaporator Probe B28 (ATC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
X151 Water Valve M16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
X152 Main Blower M17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
X155 Ground, Main Blower M17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X156 High Speed, Main Blower M17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X157 Medium Speed, Main Blower M17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X158 Low Speed, Main Blower M17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X159 Data Logger A10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X160 Left Front Hazard Light E03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
X161 Left Front Service Socket J02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
X162 Left Header Light E21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
X163 Left Lower Work Light E23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X164 Left Road Light E13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X165 Right Front Hazard Light E04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X166 Right Front Service Socket J01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
X167 Right Header Light E22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
X168 Right Lower Work Light E24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
X169 Right Road Light E14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
55-5

X170 Lateral Inclination Sensor B02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
X171 Wiper Washer Motor M24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
X172 Horn H02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
X172 Horn H02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
X174 Feeder Angle R03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
X175 Ground, 2, MF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
X177 Rotor RPM B01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
X178 Mirror Select Switch S-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X181 Left Returns RPM B06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X182 Clean Grain RPM B08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X183 Fuel Pump M23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X184 Fuel Level R01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
X186 Right Returns RPM B39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
X188 RH Rotor Loss B20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
X189 Concave Position R06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
X190 Concave Motor M04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
X191 LH Rotor Loss B19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
X192 ECU Connector A (7.5L Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
X193 ECU Connector B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
X194 Service Socket J05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
X195 Covers Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
X196 Throttle Motor M13 (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
X197 Iveco Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
X198 Splice Block F, Backlighting, RC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
X199 Start Relay Coil K36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X200 Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X201 Engine Oil Pressure B30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X202 Air Filter B07 (SN #HAJ100072 and Below) . . . . . . . . . . . . . . . . . . . . . . . . 96
X202 Air Filter S61 (SN #HAJ100073 and Above) . . . . . . . . . . . . . . . . . . . . . . . . 97
X203 Fuel Injection Pump (Electronic 7.5L Only) . . . . . . . . . . . . . . . . . . . . . . . . . 97
X204 Starter Motor M01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
X205 Starter Solenoid M01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
X206 Rotary Screen Brush M27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
55-6

X207 Flywheel RPM B43 (Electronic 7.5L Only) . . . . . . . . . . . . . . . . . . . . . . . . . 98
X208 Ground, 5, EN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
X209 Engine Oil Temperature B03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
X210 Ambient Temperature/Boost Pressure B41 (Electronic 7.5L Only) . . . . . 99
X211 Grid Heater Relay K37/K39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
X212 Fuel Temperature B40 (Electronic 7.5L Only) . . . . . . . . . . . . . . . . . . . . . . . 99
X213 Alternator G01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
X213 Alternator G01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
X213 Alternator G01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
X214 Coolant Temperature B31/B42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
X215 A/C Clutch L07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
X216 A/C High Pressure S47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
X217 A/C Low Pressure S48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
X218 Flip-Up Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
X219 Expansion B/Main Frame B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
X220 Front Ground, 2, EX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
X221 Moisture Sensor B12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
X222 Sample Motor M28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
X223 Yield Sensor R05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
X224 Spreader Plate Motor M11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
X225 Upper Sieve Adjust S35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
X226 Lower Sieve Adjust S46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
X227 Upper Sieve Motor M06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
X228 Lower Sieve Motor M07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
X231 Ground, 1, SW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
X232 Sieves Loss B21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
X233 RWA Solenoid L26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
X234 Sieve Light E37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
X235 Chaff Spreader Solenoid L28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
X236 Left Service Socket J04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
X237 Sieve Light Switch S54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
X238 Gearbox Filter Bypass S34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
X239 Returns Filter Bypass S32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
X240 Swath Plate Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
X243 Left Tail Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
55-7

X244 Unload Cradle B38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
X246 Right Tail Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
X247 Rear Beacon Light E-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
X248 Back Up Alarm H-08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
X248 Back Up Alarm H-08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
X251 Rear Ladder B22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
X252 Right Service Socket J03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
X253 Chopper RPM B10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
X255 Flasher Module A05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
X256 Road Lights Switch S26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
X257 Turn Indicator E09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
X258 High Beam/Trailer E10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
X259 Hazard Switch S25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
X260 ASP Top Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
X261 ASP Bottom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
X262 LH Bottom ASP Sensor B49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
X263 RH Bottom ASP Sensor B48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
X264 RH Top ASP Sensor B50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
X265 LH Top ASP Sensor B51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
X266 Feeder Reverse L21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
X267 Lateral Float CW L18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
X268 Reel AFT L15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
X269 Reel Down L13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
X270 Feeder Forward L20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
X271 Lateral Float CCW L19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
X272 Reel Fore L16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
X273 Reel Up L14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
X274 Reel Drive L17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
X275 Rotor Increase L29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
X276 Unload Tube In L03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
X277 Unload Tube Out L04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
X278 Rotor Decrease L30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
X279 HDR Height Pressure B29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
X280 Accumulator L06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
X281 HHC Module A07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
55-8

X282 Feeder Decrease L12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
X283 Feeder Increase L11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
X284 Feeder RPM B14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
X285 Trailer Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
X286 24 Volt Start Relay K38 (Iveco Cursor Only) . . . . . . . . . . . . . . . . . . . . . . . 118
X287 German Third Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
X288 Covers Position B-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
X289 Covers Actuator M-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
X290 Fuel Solenoid L02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
X291 Can Node (7.5L Mech. Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
X292 Stone Door Open L31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
X293 Dual Range Solenoid L27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
X294 LH Brake Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
X295 RH Brake Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
X296 Dome Light Power E-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
X314 FM Radio “B” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
X315 FM Radio “C” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
X316 Center Work LT E38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
X321 GPS Antenna A-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
X322 Unload Tube Work LT E29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
X323 Unload Tube Marker LT E39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
X326 HID Distance LT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
X327 Brake Fluid Level S49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
X329 Brake Limiting Valve L-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
X330 Air Filter Resistor R15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
X331 Flip Up Low Beam Relay K-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
X332 Flip Up High Beam Relay K-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
X333 LH Flip Up Road LT E-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
X334 RH Flip Up Road LT E-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
X335 LH Road LT E-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
X336 RH Road LT E-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
X339 Left Light Switch S-63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
X340 Engine Light Switch S-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
X341 Right Light Switch S-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
X342 LH Shield LTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
55-9

X343 RH Shield LTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
X344 Right Shield Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
X345 Left Front Light E-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
X346 Left Rear LIght E-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
X347 Right Front Light E-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
X348 Right Rear Light E-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
X349 Engine Light E-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
X350 RH Position Light E-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
X351 LH Position Light E-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
X352 RH Flashing Light E-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
X353 LH Flashing Light E-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
X354 RH Front Austria Light E-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
X355 LH Front Austria Light E-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
X356 RH Front Turn/Position Light E-04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
X357 LH Front Turn/Position Light E-03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
X358 RH Marker Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
X359 LH Marker Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
X360 RH Rear Marker Light E-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
X361 LH Rear Marker Light E-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
X362 RH License Plate LIght E-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
X363 LH License Plate LIght E-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
X367 Spreader RPM B55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
X368 Park Brake Pressure B53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
X382 Chopper RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
X389 Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
X421 Marker Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
X472 Washer Motor M-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
55-10
ELECTRICAL CONNECTORS
CONNECTOR X001
CAB MAIN/CONSOLE
WIRE
1 1212 (YE) X012-CCM-3 J1-17, NOT USED

2 051 (RD) MODULE MEMORY AMP_206838--1
FUSE #48, RH CONSOLE POWER
3 108 (OR) FROM RELAY K-26
X001
4 -
5 - CONSOLE
6 127 (YE) CAN HI
7 128 (GN) CAN LO
8 129 (YE) CAN HI
9 130 (GN) CAN LO
10 135 (RD) DAM-CONN X065 PIN F
11 136 (BK) DAM-CONN X065 PIN G
12 122 (BK) GROUND
13 147 (YE) THRESHER ENGAGE SWITCH S30
K-28, THRESHER LATCHING RELAY
14 118 (YE) TO S-30, THRESHER ENGAGE
SWITCH
15 112 (YE) K-19, FEEDER DISENGAGE RELAY AMP_206837--1
16
X015-CCM-2 J1-17, NEUTRAL
17 113 (YE) SWITCH S22 X001
POWER TO K-23, NEUTRAL START
18 093 (WH) RELAY CAB MAIN
19 -
20 -
1
21 -
22 -
23 -
24 -
10010921
1
TO RH CONSOLE (RC) HARNESS
55-11
CONNECTOR X002
CAB MAIN/ROOF
WIRE

4 059 (PU) RH CAB WORK LIGHTS FUSE #7 AMP_206838--1
DISTANCE WORK LIGHTS RELAY, X002
5 061 (PU) K-21
FUSE #35, BATTERY POWER TO CAB MAIN
6 048 (RD) RADIO MEMORY
POWER FROM RELAY K-22 TO LH,
8 079 (OR) S-19, S-27, AND S-38
X015-CCM-2 J1-3, OPEN COVERS AMP_206837--1
14 272 (OR) RELAY K-6
X002
18 232 (PU) X015-CCM-2 J1-11, BACKLIGHTING 1
19 965 (RD) MODULE, K-20
20 076 (PU) F-52 TO DOME LIGHT E-34
21 579 (PU) RELAY, K-29
23 - -
24 - -
10010915
2
55-12
CONNECTOR X003
CAB MAIN/ ROOF
WIRE
1 131 (YE) CAN HI

2 132 (GN) CAN LOW
3 900 (WH) A/C CLUTCH RELAY, K-10
4 137 (YE) CAN HI
5 902 (WH) SEPARATOR BLOWER RELAY, K-9
6 138 (GN) CAN LOW
AMP_206151
7 904 (WH) MAIN BLOWER RELAY HIGH, K-11
MAIN BLOWER RELAY MEDIUM, X003
8 905 (WH) K-12 CAB MAIN
9 906 (WH) MAIN BLOWER RELAY LOW, K-13
10 907 (BL) HVAC FREEZE SWITCH, S-53
11 908 (YE) HVAC FREEZE SWITCH, S-53
HVAC AMBIENT TEMP SENSOR,
12 909 (BL) B-25
HVAC AMBIENT TEMP SENSOR,
13 910 (YE) B-25
14 911 (BL) HVAC OUTLET TEMP SENSOR, B-27
15 912 (YE) HVAC OUTLET TEMP SENSOR, B-27
16 913 (BL) HVAC CAB TEMP SENSOR, B-26
17 914 (YE) HVAC CAB TEMP SENSOR, B-26
X005 -- PIN 27 A/C LOW PRES
AMP_206150--1
X005 -- PIN 28 A/C PRESSURE
19 916 (BL) SWITCH GROUND
X003
X005 -- PIN 29 A/C HIGH PRES
20 917 (YE) SWITCH S47 ROOF
21 918 (BK) COLD BOX DOOR MOTOR, M-15
22 919 (YE) COLD BOX DOOR MOTOR, M-15
23 920 (OR) COLD BOX DOOR MOTOR, M-15 1
24 978 (PU) ROAD LIGHTS RELAY, K-27
25 922 (BK) WATER VALVE MOTOR, M-16
26 923 (YE) WATER VALVE MOTOR, M-16
27 924 (OR) WATER VALVE MOTOR, M-16
28 934 (BL) SOLAR SENSOR, B-36
29 939 (YE) SOLAR SENSOR, B-36
30 981 (PU) ROAD LIGHTS RELAY, K-27
31 967 (YE) TIME DELAY RELAY, K-20
10010915
3
55-13
CONNECTOR X004
MAIN FRAME/CAB MAIN
WIRE
1 032 (OR) CCM-1, FUSE 43

2 033 (OR) CCM-1, FUSE 43
3 1159 (WH) NOT USED
4 035 (OR) SAMPLE MOTOR, FUSE 47
5 036 (OR) CCM-3, FUSE 47
6 037 (OR) CCM-2, FUSE 36
DEUTSCH_HDP26--24--31S_PLUG
FUSE F34, UNDERSHIELD
7 1214 (RD) LIGHTING X004
8 039 (OR) CCM-2, FUSE 37 MAIN FRAME
LOWER WORK LIGHTS RELAY,
9 065 (PU) K-30
10 067 (PU) REAR WORK LIGHTS RELAY, K-31
11 068 (RD) SERVICE SOCKETS FUSE, F-15
12 578 (PU) BEACON LIGHT RELAY, K-29
13 875 (BL) NOT USED
15 077 (PU) UNLOAD TUBE LIGHT RELAY, K-32
16 078 (PU) BRAKE LIGHTS RELAY, K-33
17 827 (YE) DAM CONNECTOR X065
DEUTSCH_HDP24--24--31P_RECEPTACLE
18 193 (WH) ROAD LIGHT SWITCH
19 856 (WH) FUEL PUMP RELAY, K-07 X004
20 814 (WH) COLD START
CAB MAIN
21 604 (OR) SERVICE LIGHTS FUSE, F-14
X033 PIN 13 LH FLASHING LAMP
22 243 (PU) E07
X033 PIN 14 RH FLASHING LAMP
23 244 (PU) E08
24 808 (YE) ECU POWER RELAY, K-14
25 809 (WH) ECU POWER RELAY, K-14
31 696 (WH) CONCAVE/COVERS RELAY, K-16 1
10010899
4
55-14
CONNECTOR X005
MAIN FRAME/CAB MAIN
WIRE
1 025 (RD) THROTTLE/BRUSH FUSE, F-23

2 026 (RD) FAN, REVERSER FUSE, F-24
3 030 (RD) CROSS AUGER TENT FUSE, F-26
4 031 (RD) SIEVE/SPREADER FUSE, F-27
5 013 (OR) HHC MODULE FUSE, F-45
6 092 (WH) NEUTRAL START RELAY, K-23
7 176 (PU) RH MARKER LIGHTS FUSE, F-21
8 177 (PU) LH MARKER LIGHTS FUSE, F-20
X005
9 178 (WH) A/C CLUTCH RELAY, K-10 MAIN FRAME
10 186 (PU) HIGH BEAM RELAY, K-4
11 196 (PU) X033 PIN 7, RS FLASHING LIGHTS
12 200 (PU) X033 PIN 9, LS FLASHING LIGHTS
13 237 (PU) LOW BEAM RELAY, K-5
14 278 (WH) X002 PIN 17, WASHER MOTOR M24
15 786 (WH) UPPER/LOWER SIEVE RELAY, K-18
18 -
FUSE F34, UNDERSHIELD DEUTSCH_HDP24--24--29P_RECEPTACLE
19 1215 (RD) LIGHTING
X015 - CCM-2 J1-12, GRID HEATER X005
20 839 (WH) OUTPUT
CAB MAIN
21 -
22 -
23 -
24 - 1
25 859 (OR) KEY SWITCH
26 -
X003 PIN 18, A/C LOW PRES
X003 PIN 19, A/C PRES SWITCH
28 916 (BL) GROUND
X003 PIN 20, A/C HIGH PRES
10010899
5
55-15
CONNECTOR X006
CAB MAIN/HVAC
WIRE
A 907 (BL) HVAC FREEZE SWITCH S53

B 926 (WH) SEPARATOR BLOWER RELAY, K-09
C 908 (YE) HVAC FREEZE SWITCH S53
D 928 (WH) MAIN BLOWER RELAY HIGH, K-11
E 929 (WH) MAIN BLOWER RELAY MED., K-12
F 909 (BL) HVAC AMBIENT TEMP SENSOR B25
G 946 (WH) MAIN BLOWER RELAY LOW, K-13
H 910 (YE) HVAC AMBIENT TEMP SENSOR B25
X006
J 911 (BL) HVAC OUTLET TEMP SENSOR B27 HVAC
K 912 (YE) HVAC OUTLET TEMP SENSOR B27
L 913 (BL) HVAC CAB TEMP SENSOR B26
M 914 (YE) HVAC CAB TEMP SENSOR B26
N 918 (BK) COLD BOX DOOR MOTOR M15
P 919 (YE) COLD BOX DOOR MOTOR M15
R 920 (OR) COLD BOX DOOR MOTOR M15
S 922 (BK) WATER VALVE MOTOR M16
T 923 (YE) WATER VALVE MOTOR M16
U 924 (OR) WATER VALVE MOTOR M16
V - DEUTSCH_HDP24--24--21P_RECEPTACLE
W -
X006
X -
CAB MAIN
10010899
6
1. CONNECTOR X006, A/C HARNESS TO CAB MAIN
(CM) HARNESS
55-16
CONNECTOR X007
FRONT FRAME/FEEDER
WIRE
1 719 (WH) FEEDER REVERSER ACTUATION

FEEDER REVERSER DECREASING
2 770 (GY) ACTUATION
X017 - CCM-2 J3-8, REEL SPEED
3 712 (WH) MOTOR M09
4 -
5 613 (PU) L HEADER FLASHING LIGHT E01 DEUTSCH_HDP26--24--29S_PLUG
6 618 (PU) R HEADER FLASHING LIGHT E02 X007
7 580 (WH) POWER TO ASP AMPLIFIER FRONT FRAME
8 729 (YE) CAN HI
9 730 (GN) CAN LO
10 733 (YE) REVERSER POSITION SIGNAL
11 743 (YE) ASP DOOR POSITION
REFERENCE GROUND FOR
12 749 (BL) FEEDER SENSORS
REFERENCE GROUND FOR REEL
13 750 (BL) RPM SENSOR B15
14 737 (YE) X032 PIN 7, REEL RPM SENSOR B15
15 738 (YE) L STUBBLE HEIGHT SENSOR R12
16 739 (YE) R STUBBLE HEIGHT SENSOR R13 DEUTSCH_HDP24--24--29P_RECEPTACLE
17 741 (YE) LATERAL FLOAT SENSOR R02
18 752 (PU) HEADER MARKER LIGHTS E40, E41 X007
19 711 (GY)
X017 -- CCM2 J3-6, REEL SPEED FEEDER
MOTOR M09
20 -
21 776 (BK) GROUND
POWER TO LAT FLOAT SENSOR
22 757 (PK) R02 1
23 -
24 -
25 767 (BK) GROUND
POWER TO STUBBLE HEIGHT
26 758 (PK) SENSORS R12, R13
27 -
REFERENCE GROUND FOR
28 748 (BL) STUBBLE HEIGHT SENSORS R12,
R13
40024707
29 -
7
1. CONNECTOR X007 - FEEDER (FE) HARNESS TO
FRONT FRAME (FF) HARNESS
55-17
CONNECTOR X008
MAIN FRAME/FRONT FRAME
CA WIRE
V NUMBER CIRCUIT REFERENCE
1 674 (YE) CAN HI

2 675 (GN) CAN LO
3 744 (YE) CAN HI
4 746 (GN) CAN LO
X019 - CCM-1 J2-26, BRAKE PAD
5 1503 (YE) WEAR SWITCHES S55, S56
6 - DEUTSCH_HDP24--24--31P_RECEPTACLE
X020 - CCM-1 J3-18, REF. GROUND
7 401 (BL) FOR SENSORS X008
8 485 (YE)
X024 - PIN 14, UNLOAD TUBE MAIN FRAME
CRADLED SENSOR B38
9 872 (GY) X011 - PIN J, NOT USED
10 873 (WH) X011 - PIN K, NOT USED
X011 - PIN P, HYDROSTAT EDC
11 879 (GY) VALVE L23
X011 - PIN Q, HYDROSTAT EDC
12 880 (WH) VALVE L23
X022 - PIN H, REF. GROUND FOR
13 555 (BL) LAT. FLOAT SOLENOIDS L18, L19
14 425 (BL) REF. GROUND FOR SENSORS
15 613 (PU) LH HEADER FLASHING LAMP, E-01
16 618 (PU) RH HEADER FLASHING LAMP, E-02 DEUTSCH_HDP26--24--31S_PLUG
X011 - PIN U, GEARBOX CLUTCH
17 682 (YE) TEMP SENSOR B45 X008
LEFT STUBBLE HEIGHT SENSOR,
18 758 (PK) R-12 FRONT FRAME
19 -
LEFT STUBBLE HEIGHT SENSOR,
20 748 (BL) R-12
21 874 (BL) X011 - PIN F, NOT USED
X011 - PIN G, REF. GROUND FOR
22 881 (BL) HYDRO EDC VALVE L23
X022 - PIN D, L STUBBLE HEIGHT
23 738 (YE) SENSOR R12
X022 - PIN E, R STUBBLE HEIGHT
24 739 (YE) SENSOR R13
X022 - PIN F, LAT. FLOAT CCW 1
25 548 (WH) SOLENOID L19
X022 - PIN G, LAT. FLOAT CW
27 435 (YE) COVERS CLOSED SENSOR B47
10020075
28 -
29 776 (BK) FLIP UP KIT, GROUND 8
30 - 1. CONNECTOR X008, MAIN FRAME (MF)
31 - HARNESS TO FRONT FRAME (FF) HARNESS
(BEHIND CAB)
55-18
CONNECTOR X009
MAIN FRAME/GRAIN TANK
WIRE
A -
B -
C -
X004 - PIN 15, UNLOAD TUBE LIGHT
D 077 (PU) E29
X016 - CCM-2 J2-22, GRAIN BIN
E 400 (YE) SENSORS S28, S29
F -
G 440 (PK)
X016 - CCM-2 J2-31, 5V REF. X009
VOLTAGE
MAIN FRAME
H 443 (BL) FOR SENSORS
J 646 (PU) GRAIN TANK LIGHT E30
GROUND, UNLOAD & GRAIN TANK
K 668 (BK) LIGHTS
L -
M -
N -
P 530 (PU) UNLOAD TUBE MARKER LIGHT E39
X009
GRAIN TANK
10010900
9
1. CONNECTOR X009, GRAIN TANK (GT) HARNESS
TO MAIN FRAME (MF) HARNESS
55-19
CONNECTOR X010
MAIN FRAME/ENGINE
WIRE
X016 -- CCM-2 J2-1, THROTTLE

1 524 (GY) MOTOR M13/ROT SCR BRUSH
MOTOR M27
X004 - PIN 27, ROT SCR BRUSH
2 821 (WH) MOTOR M27
X004 - PIN 29, THROTTLE MOTOR
3 829 (WH) M13
4 - DEUTSCH_HDP26--24--29S_PLUG
X005 - PIN 6, NEUTRAL START
5 092 (WH) RELAY K23 X010
X016 -- CCM-2 J2-33, ENG OIL PRES MAIN FRAME
6 419 (YE) SENSOR B30
7 814 (WH) X004 - PIN 20, COLD START
X016 -- CCM-2 J2-29, ENG AIR FILT
X016 -- CCM-2 J2-36, ENG RPM
9 421 (YE) SENSE G01
X016 -- CCM-2 J2-27, ENG. OIL TEMP
11 178 (WH) X005 - PIN 9, A/C CLUTCH L07
12 650 (RD) RH FT SERVICE SOCKET, J-01
X016 -- CCM-2 J2-31, 5V REF.
13 463 (PK) VOLTAGE
REF. GROUND FOR COOLANT
14 468 (BL) TEMP SENSOR, B-31
X010
X005 - PIN 27, A/C LOW PRES
15 915 (YE) SWITCH S48 ENGINE
X016 -- CCM-2 J2-13, FUEL
16 571 (WH) SHUT-OFF SOLENOID L02
17 827 (YE)
X004 - PIN 17, DAM CONNECTOR 1
X065
X016 -- CCM-2 J2-24 COOLANT
18 429 (YE) TEMP SENSOR B31
19 819 (YE) CAN HI
20 839 (WH) X005 - PIN 20, GRID HEATER
21 820 (GN) CAN LO
X005 - PIN 28, A/C PRES SWITCH
22 916 (BL) GROUND
23 859 (OR) X005 - PIN 25, KEY SWITCH
24 -
X005 - PIN 29, A/C HIGH PRES
10020076
X004 - PIN 24, ECU POWER RELAY
26 808 (YE) K14 10
27 - 1. CONNECTOR X010 - ENGINE (EN) HARNESS TO
X004 - PIN 25, ECU POWER RELAY MAIN FRAME (MF) HARNESS
28 809 (WH) K14
29 -
55-20
CONNECTOR X011
MAIN FRAME/GEARBOX
WIRE
X019 - CCM-1 J2-27, GEARBOX

A 422 (YE) TEMP SENSOR B32
X016 - CCM-2 J2-19, CONTROL
B 423 (YE) PRES SENSOR B35
X016 - CCM-2 J2-39, HYD.
C 424 (YE) RESERVOIR LEVEL S33
X016 - CCM-2 J2-31, 5V REF.
D 486 (PK) VOLTAGE DEUTSCH_HDP26--24--23S_PLUG
X019 - CCM-1 J2-24, HYD.
E 446 (YE) RESERVOIR TEMP B18 X011
F 874 (BL) X020 - CCM-1 J3-35, NOT USED MAIN FRAME
G 881 (BL) FOR HYDRO EDC VALVE L23
H 488 (BL) REF. GROUND FOR SENSORS
J 872 (GY) X020 - CCM-1 J3-21, NOT USED
K 873 (WH) X020 - CCM-1 J3-31, NOT USED
X019 - CCM-1 J2-40, FEEDER
L 875 (BL) CLUTCH L24
X019 - CCM-1 J2-30, FEEDER
M 876 (WH) CLUTCH L24
X016 - CCM-2 J2-40, THRESHER
N 877 (BL) CLUTCH L22
X016 - CCM-2 J2-30, THRESHER DEUTSCH_HDP24--24--23P_RECEPTACLE
O 878 (WH) CLUTCH L22
P 879 (GY)
X017 - CCM-2 J3-21, HYDROSTAT X011
EDC VALVE L23
GEARBOX
X017 - CCM-2 J3-31, HYDROSTAT
Q 880 (WH) EDC VALVE L23
X016 - CCM-2 J2-15, PARK BRAKE
R 572 (WH) VALVE L10
1
X016 - CCM-2 J2-4, UNLOAD AUGER
S 568 (WH) VALVE L08
X016 - CCM-2 J2-20, UNLOAD
T 601 (BL) AUGER VALVE L08
X017 - CCM-2 J3-33, THRESHER
U 682 (YE) CLUTCH TEMP B45
V 683 (BL) FOR SENSORS
X016 - CCM-2 J2-35, CHARGE PRES
W 684 (YE) SWITCH S37
X -
10020076
11
1. IN-LINE CONNECTOR X011 - GEARBOX (GB)
HARNESS TO MAIN FRAME (MF) HARNESS
55-21
CONNECTOR X012
CCM-3 J1
WIRE
1 049 (RD) FUSE F-39, KEEP ALIVE POWER

2 -
3 -
4 101 (OR) KEYSWITCH POWER
5 -
UPPER/LOWER SIEVE RELAY,
6 787 (WH) K-18
X001 - PIN 13, THRESHER
7 1061 (YE) ENGAGE SWITCH S30 DEUTSCH_DRC16--24S_PLUG
8 217 (BK) GROUND
9 - X012
10 - CCM-3 J1
11 -
12 -
13 134 (GN) CAN LO
14 133 (YE) CAN HI
15 -
16 -
17 1212 (YE) X001 - PIN 1, NOT USED
18 -
19 -
20 -
21 -
22 -
23 -
24 -
1
10004693
12
1. CONNECTOR X012 - CCM3-J1 FROM CAB MAIN
(CM) HARNESS
55-22
CONNECTOR X013
CCM-3 J2
WIRE
1 785 (GY) UPPER SIEVE MOTOR M06

2 505 (OR) FUSE 47
3 520 (BK) GROUND
4 -
5 -
6 -
7 771 (WH) LH VERTICAL KNIFE RELAY K43
8 772 (WH) RH VERTICAL KNIFE RELAY K42
9 506 (OR) FUSE 47 DEUTSCH_DRC16--40S_PLUG
10 -
11 511 (RD) FUSE 27 X013
12 690 (BK) GROUND CCM-3 J2
13 837 (WH) SAMPLE MOTOR M28
15 -
16 -
UPPER SIEVE ADJUST SW S35 -
17 540 (YE) INCR
18 691 (BK) GROUND
19 476 (YE) LOWER SIEVE MOTOR M07
20 -
21 786 (WH) UPPER/LOWER SIEVE RELAY K-18
22 475 (YE) UPPER SIEVE MOTOR M06
23 -
24 -
40020077
1
25 838 (YE) SAMPLE MOTOR M28
26 - 13
27 - 1. CONNECTOR X013 - CCM-3 J2 FROM
28 -
EXPANSION (EX) HARNESS
29 -
30 -
31 683 (PK) 5V REF. VOLTAGE
32 -
33 477 (YE) SPREADER PLATE MOTOR M11
UPPER SIEVE ADJUST SW S35 -
34 539 (YE) DEC
LOWER SIEVE ADJUST SW S46 -
35 542 (YE) INCR
36 -
37 -
38 -
LOWER SIEVE ADJUST SW S46 -
39 541 (YE) DEC
40 -
55-23
CONNECTOR X014
CCM-3 J3
WIRE
1 -
2 -
3 -
4 -
5 -
6 509 (GY) SPREADER PLATE MOTOR M11
7 512 (RD) FUSE 27
8 510 (WH) SPREADER PLATE MOTOR M11
9 536 (BK) GROUND
10 537 (BK) GROUND DEUTSCH_DRC16--40S_PLUG
11 -
12 - X014
13 - CCM-3 J3
14 -
15 -
16 521 (BK) GROUND
17 593 (YE) MOISTURE SENSOR B12
18 563 (BL) YIELD SENSOR R05
19 -
20 -
21 -
22 -
23 594 (YE) MOISTURE SENSOR B12
24 -
25 -
26 -
27 -
1
40020077
28 -
29 534 (RD) B(+) FUSE 26 14
30 535 (RD) B(+) FUSE 26 1. CONNECTOR X014 - CCM-3 J3 FROM
31 - EXPANSION (EX) HARNESS
32 552 (YE) YIELD SENSOR SIGNAL R05
33 -
34 595 (YE) MOISTURE SENSOR SIGNAL B12
35 -
36 -
37 -
38 -
39 -
40 -
55-24
CONNECTOR X015
CCM-2 J1
WIRE
1 050 (RD) FUSE F39, KEEP ALIVE POWER

X002 - PIN 12, BEACON LIGHTS
X002 - PIN 13, OPEN COVERS
X033 - PIN 10, FLASHER MODULE
5 204 (YE) A05
6 502 (WH) THROTTLE/BRUSH RELAY, K-15 DEUTSCH_DRC16--24S_PLUG
X001 - PIN 13, THRESHER ENGAGE
7 111 (YE) SWITCH S30 X015
8 216 (BK) GROUND
CCM-2 J1
9 168 (YE) SEAT SWITCH S05
10 -
SPICE BLOCK C, W-03,
11 231 (PU) BACKLIGHTING
X005 - PIN 20, GRID HEATER
12 839 (WH) OUTPUT
13 132 (GN) CAN LO
14 131 (YE) CAN HI
15 1209 (PU) X033 - PIN 2, HAZARD SWITCH S25
16 -
X001 - PIN 17, NEUTRAL SWITCH
17 113 (YE) S22
18 183 (WH) BRAKE LIGHTS RELAY, K-33
19 134 (GN) CAN LO
20 133 (YE) CAN HI 1
10004693
21 090 (OR) NEUTRAL START RELAY, K-23
22 - 15
23 - 1. CONNECTOR X015 - CCM2-J1 FROM CAB MAIN
24 182 (WH) BEACON LIGHTS RELAY, K-29 (CM) HARNESS
55-25
CONNECTOR X016
CCM-2 J2
WIRE
X010 - PIN 1, THROTTLE MOTOR

1 524 (GY) M13/ROT SCR BRUSH MOTOR M27
2 037 (OR) FUSE 36
3 514 (BK) GROUND
X011 - PIN S, UNLOAD AUGER
4 568 (WH) VALVE L08
5 1504 (WH)
6 574 (WH) X022 - PIN R, UNLOAD TUBE IN L03
X022 - PIN P, ROTOR INCREASE
7 567 (WH) L29
X022 - PIN 0, ROTOR DECREASE DEUTSCH_DRC16--40S_PLUG
8 566 (WH) L30
X016
9 039 (OR) FUSE 37
10 - CCM-2 J2
11 025 (RD) FUSE 23
12 688 (BK) GROUND
X010 - PIN 16, FUEL SHUT-OFF
X011 - PIN R, PARK BRAKE VALVE
15 572 (WH) L10
X022 - PIN Q, UNLOAD TUBE OUT
16 573 (WH) L04
17 427 (YE) FUEL LEVEL SIGNAL R01
18 689 (BK) GROUND
X011 - PIN B, CONTROL PRES 1
X011 - PIN T, UNLOAD AUGER
20 601 (BL) VALVE L08 40020077
21 525 (WH) THROTTLE/BRUSH RELAY K-15
X009 - PIN E, GRAIN BIN SENSORS 16
22 400 (YE) S28, S29 1. CONNECTOR X016 - CCM-2 J2 FROM MAIN
23 746 (GN) CAN LO FRAME (MF) HARNESS
X010 - PIN 18, COOLANT TEMP
25 410 (YE) LEFT ROTOR LOSS B19
26 402 (YE) RIGHT ROTOR LOSS B20
X010 - PIN 10, ENG OIL TEMP
28 414 (YE)
X010 - PIN 8, ENG AIR FILT SWITCH
29 420 (YE) S61
X011 - PIN 0, THRESHER CLUTCH
30 878 (WH) L22
31 459 (PK) 5V REF VOLTAGE
32 744 (YE) CAN HI
X010 - PIN 6, ENG OIL PRES
34 418 (YE) BRAKE PRESSURE SWITCH S39
X011 - PIN W, CHARGE PRES.
36 421 (YE) X010 - PIN 9, ENG RPM SENSE G01
37 416 (YE) ROTOR RPM B01
38 413 (YE) CHOPPER RPM B10
X011 - PIN C, HYD. RESERVOIR
39 424 (YE) LEVEL S33
X011 - PIN N, THRESHER CLUTCH
40 877 (BL) L22
55-26
CONNECTOR X017
CCM-2 J3
WIRE
1 560 (WH) X021 - PIN P, REEL FORWARD L16

2 556 (WH) X021 - PIN E, REEL DRIVE L17
3 558 (WH) X021 - PIN L, REEL UP L14
4 557 (WH) X021 - PIN N, REEL DOWN L13
5 559 (WH) X021 - PIN R, REEL AFT L15
X032 - PIN 26, REEL SPEED MOTOR
6 711 (GY) M09
7 028 (RD) FUSE 23
X032 - PIN 20, REEL SPEED MOTOR
8 712 (WH) M09
DEUTSCH_DRC16--40S_PLUG
9 516 (BK) GROUND
10 517 (BK) GROUND X017
11 038 (OR) FUSE 36 CCM-2 J3
12 -
X032 - PIN 7, REEL RPM SENSOR
13 737 (YE) B15
X023 - PIN 6, GROUND SPEED RPM
14 403 (YE) B17
X023 - PIN 13, FOOT AND INCH
15 575 (WH) VALVE L05
16 515 (BK) GROUND
17 -
X023 - PIN 3, TRANS SHIFT MOTOR
19 526 (GY) M02 1
20 527 (GY) M02
X011 - PIN P, HYDROSTAT EDC
21 879 (GY) VALVE L23 40020077
22 -
17
23 -
1. CONNECTOR X017 - CCM-2 J3 FROM FRONT
24 -
FRAME (FF) HARNESS
25 -
X023 - PIN 12, SHIFT POSITION
27 409 (YE) SENSOR B37 (4TH)
X023 - PIN 10, SHIFT POSITION B37
28 407 (YE) (N)
29 507 (RD) FUSE 25
30 508 (RD) FUSE 25
X011 - PIN Q, HYDROSTAT EDC
31 880 (WH) VALVE L23
32 -
X011 - PIN U, THRESHER CLUTCH
33 682 (YE) TEMP B45
34 1536 (YE) PARK BRAKE PRESSURE B53
X008 - PIN 22, REF. GROUND FOR
35 881 (BL) HYDRO EDC VALVE L23
36 405 (YE) SENSOR B37 (1ST)
37 406 (YE) SENSOR B37 (2ND)
38 408 (YE) SENSOR B37 (3RD)
39 528 (WH) M02
40 529 (WH) M02
55-27
CONNECTOR X018
CCM-1 J1
WIRE
1 052 (RD) FUSE F39, KEEP ALIVE POWER

2 198 (PU) LEFT TURN SIGNAL S26
X002 - PIN 16, FRONT WORK
5 117 (WH) ROAD LIGHTS RELAY, K-27
7 1211 (YE) FEEDER DISENGAGE RELAY, K-19
8 215 (BK) GROUND DEUTSCH_DRC16--24S_PLUG
9 194 (PU) RIGHT TURN SIGNAL S26
X018
10 -
CAB ROOF WORK LIGHTS RELAY, CCM-1 J1
11 190 (WH) K-1
12 181 (WH) UNLOAD TUBE LIGHT RELAY, K-32
13 138 (GN) CAN LO
14 137 (YE) CAN HI
X002 - PIN 15, REAR WORK LIGHTS
16 -
X001 - PIN 13, THRESHER ENGAGE
18 184 (WH) REAR WORK LIGHTS RELAY, K-31
19 130 (GN) CAN LO 1
20 129 (YE) CAN HI
21 212 (OR) LIGHT CONTROL RELAY, K-2
22 -
23 107 (BK) CCM-3/CAB POWER RELAY, K-26 10004693
24 180 (WH) SIDE WORK LIGHT RELAY, K-35 18
1. CONNECTOR X018 - CCM1-J1 FROM CAB MAIN
(CM) HARNESS
55-28
CONNECTOR X019
CCM-1 J2
WIRE
CONCAVE CLEARANCE MOTOR

1 522 (GY) M04/COVERS MOTOR M12
2 032 (OR) FUSE 43
3 513 (BK) GROUND
4 -
5 -
6 452 (WH) X024 - PIN 13, BACKUP ALARM H08
X022 - PIN N, FEEDER INCREASE
7 582 (WH) L11
X022 - PIN M, FEEDER DECREASE
8 581 (WH) L12 DEUTSCH_DRC16--40S_PLUG
9 033 (OR) FUSE 43
10 - X019
11 026 (RD) FUSE 24 CCM-1 J2
12 686 (BK) GROUND
13 -
X024 - PIN 17, CHAFF SPREADER
15 576 (WH) L28
16 569 (WH) X024 - PIN 15, RWA SOLENOID L26
X024 - PIN 16, REAR LADDER
18 687 (BK) GROUND
19 411 (YE) CONCAVE CLEARANCE R06
20 - 1
21 523 (WH) CONCAVE/COVERS RELAY K-16
22 -
23 -
40020077
X011 - PIN E, HYD. RESERVOIR
24 446 (YE) TEMP. SENSOR B18
19
25 431 (YE) X024 - PIN 5, SIEVES LOSS B21
1. CONNECTOR X019 - CCM-1 J2 FROM MAIN
X008 - PIN 5, BRAKE PAD WEAR
26 1503 (YE) SWITCHES S55, S56 FRAME (MF) HARNESS
X011 - PIN A, GEARBOX TEMP
28 450 (YE) CLEAN GRAIN RPM B08
29 -
30 876 (WH) X011 - PIN M, FEEDER CLUTCH L24
31 453 (PK) 5V REF VOLTAGE
32 -
LATERAL INCLINATION SENSOR
33 430 (YE) B02
34 447 (YE) X024 - PIN 7, RETURNS FILTER S32
35 448 (YE) X024 - PIN 8, GEARBOX FILTER S34
36 -
37 441 (YE) RIGHT RETURNS RPM B39
38 433 (YE) LEFT RETURNS RPM B06
39 432 (YE) NOT USED
40 875 (BL) X011 - PIN L, FEEDER CLUTCH L24
55-29
CONNECTOR X020
CCM-1 J3
WIRE
1 -
2 -
X023 - PIN 21, DUAL RANGE
4 -
X021 - PIN A, FEEDER JOG
5 561 (WH) FORWARD L20
CLEANING FAN MOTOR
6 713 (GY) M05/REVERSER ACTUATOR M10
7 027 (RD) FUSE 24
CLEANING FAN MOTOR DEUTSCH_DRC16--40S_PLUG
8 714 (WH) M05/REVERSER ACTUATOR M10
9 702 (BK) GROUND X020
10 703 (BK) GROUND CCM-1 J3
11 034 (OR) FUSE 44
12 768 (WH) FAN/REVERSER RELAY K-17
X023 - PIN 7, CLEANING FAN RPM 1
13 404 (YE) B16
14 489 (YE) FEEDER RPM B14
X021 - PIN C, FEEDER JOG
15 562 (WH) REVERSE L21
16 704 (BK) GROUND
X007 - PIN 17, LATERAL FLOAT POT
17 741 (YE) R02
X023 - PIN 1, SHOE LEVELING
19 705 (GY) ACTUATOR M03
20 706 (GY) ACTUATOR M03
40020077
21 872 (GY) NOT USED
22 - 20
23 - 1. CONNECTOR X020 - CCM-1 J3 FROM FRONT
24 - FRAME (FF) HARNESS
25 -
X007 - PIN 10, REVERSER
27 733 (YE) POSITION B09
X007 - PIN 11, ASP DOOR POSITION
28 743 (YE) B24
29 700 (RD) FUSE 22
30 701 (RD) FUSE 22
31 873 (WH) NOT USED
32 721 (YE) ACTUATOR M03
X023 - PIN 26, HYDROSTAT TEMP.
34 -
36 485 (YE) UNLOAD CRADLE SENSOR B38
37 -
38 435 (YE) COVERS CLOSED SENSOR B47
39 708 (WH) ACTUATOR M03
40 709 (WH) ACTUATOR M03
55-30
CONNECTOR X021
FRONT FRAME/FEEDER VALVE
WIRE
A 561 (WH) FEEDER FORWARD ACTUATION

B 590 (BK) FEEDER FORWARD GROUND
C 562 (WH) FEEDER REVERSE ACTUATION
D 591 (BK) FEEDER REVERSE GROUND
E 556 (WH) REEL DRIVE ACTUATION
F 585 (BK) REEL DRIVE GROUND
G 549 (WH) LATERAL FLOAT CW ACTUATION DEUTSCH_HDP26--24--23S_PLUG
LATERAL FLOAT CW PRINTED
H 554 (BL) CIRCUIT GROUND X021
J 548 (WH) LATERAL FLOAT CCW ACTUATION FRONT FRAME
LATERAL FLOAT CCW PRINTED
K 553 (BL) CIRCUIT GROUND
L 558 (WH) REEL UP ACTUATION
M 587 (BK) REEL UP GROUND
N 557 (WH) REEL DOWN ACTUATION
O 586 (BK) REEL DOWN GROUND
P 560 (WH) REEL FORE ACTUATION
Q 589 (BK) REEL FORE GROUND
R 559 (WH) REEL AFT ACTUATION
S 588 (BK) REEL AFT GROUND
T - DEUTSCH_HDP24--24--23P_RECEPTACLE
U -
V - X021
W - FEEDER VALVE
X -
40024707
21
1. CONNECTOR X021 - FEEDER VALVES (FV)
HARNESS TO FRONT FRAME (FF) HARNESS
55-31
CONNECTOR X022
MAIN FRAME/VALVE STACK
WIRE
A 017 (OR) POWER TO BOSCH HHC

B 501 (BK) GROUND
C 600 (BK) GROUND
X008 - PIN 23, L STUBBLE HEIGHT
D 738 (YE) SENSOR R12
X008 - PIN 24, R STUBBLE HEIGHT
E 739 (YE) SENSOR R13 DEUTSCH_HDP24--24--23P_RECEPTACLE
X008 - PIN 25, LAT. FLOAT CCW
F 548 (WH) SOLENOID L19 X022
G 549 (WH)
X008 - PIN 26, LAT. FLOAT CW MAIN FRAME
SOLENOID L18
X008 - PIN 13, REF. GROUND FOR
H 555 (BL) LAT. FLOAT SOLENOIDS L18, L19
J 740 (YE) FEEDER ANGLE SENSOR R03
BOSCH HHC, REF. GROUND
K 546 (BL) FOR SENSORS
L 547 (PK) 5V REF. VOLTAGE
X019 - CCM1 J2-8 FEEDER
M 581 (WH) DECREASE L12
X019 - CCM1 J2-7 FEEDER
N 582 (WH) INCREASE L11
X016 - CCM2 J2-8 ROTOR
O 566 (WH) DECREASE L30 DEUTSCH_HDP26--24--23S_PLUG
X016 - CCM2 J2-7 ROTOR
P 567 (WH) INCREASE L29 X022
X016 - CCM2 J2-16 UNLOAD TUBE VALVE STACK
Q 573 (WH) OUT L04
X016 - CCM2 J2-6 UNLOAD TUBE IN
R 574 (WH) L03
S 544 (YE) CAN HI
T 545 (GN) CAN LO
U -
V -
W -
X -
1
40025225
22
1. CONNECTOR X022, VALVE STACK (MS)
55-32
CONNECTOR X023
FRONT FRAME/LOWER FRAME
WIRE
X020 CCM1 J3-19, 20, SHOE

1 707 (GY) LEVELING ACTUATOR M03
X020 CCM1 J3-39, 40, SHOE
2 710 (WH) LEVELING ACTUATOR M03
X017 CCM2 J3-19, 20, TRANS SHIFT
3 715 (GY) MOTOR M02
X017 CCM2 J3-39, 40, TRANS SHIFT
4 716 (WH) MOTOR M02 DEUTSCH_HDP24--24--29P_RECEPTACLE
X023
X017 CCM2 J3-14, GROUND SPEED
6 403 (YE) RPM B17 FRONT FRAME
X020 CCM1 J3-13, CLEANING FAN
7 404 (YE) RPM B16
X017 CCM2 J3-36, SHIFT POSITION
8 405 (YE) SENSOR B37 (1ST)
9 406 (YE) SENSOR B37 (2ND)
10 407 (YE) SENSOR B37 (N)
11 408 (YE) SENSOR B37 (3RD)
12 409 (YE) SENSOR B37 (4TH)
X017 CCM2 J3-15, FOOT AND INCH
13 575 (WH) VALVE L05
X023
X019 CCM1 J2-26, BRAKE PAD
14 434 (YE) WEAR SWITCHES S55, S56 LOWER FRAME
X020 CCM1 J3-32, SHOE LEVELING
15 721 (YE) ACTUATOR M03
18 -
19 761 (GY) CLEANING FAN MOTOR M05
20 - 1
X020 CCM1 J3-3, DUAL RANGE
22 763 (WH) CLEANING FAN MOTOR M05
23 -
24 -
25 765 (BK) GROUND
X020 CCM1 J3-33, HYDROSTAT
26 773 (YE) TEMP SENSOR B46 10010898
27 -
28 -
23
29 836 (BK) GROUND
1. CONNECTOR X023, FRONT FRAME (FF)
HARNESS TO LOWER FRAME (LF) HARNESS
55-33
CONNECTOR X024
MAIN FRAME/STRAW WALKER
WIRE
1 -
2 078 (PU) BRAKE LIGHTS RELAY K-33
3 -
4 -
X019 CCM1 J2-25, SIEVES LOSS
5 431 (YE) B21
6 432 (YE) NOT USED
X019 CCM1 J2-34, RETURNS FILTER
7 447 (YE) SWITCH S32 X024
X019 CCM1 J2-35, GEARBOX
8 448 (YE) FILTER SWITCH S34 MAIN FRAME
9 243 (PU) LEFT FLASHING LAMP E07
10 244 (PU) RIGHT FLASHING LAMP E08
X020 CCM1 J3-18, REF. GROUND
11 461 (BL) FOR SENSORS
12 -
X019 CCM1 J2-6, BACKUP ALARM
13 452 (WH) H08
X020 CCM1 J3-36, UNLOAD CRADLE
14 485 (YE) B38
X019 CCM1 J2-16, REAR WHEEL
15 569 (WH) ASSIST L26
X019 CCM1 J2-17, REAR LADDER
X024
X019 CCM1 J2-15, CHAFF
17 576 (WH) SPREADER L28 STRAW WALKER
18 -
19 578 (PU) REAR BEACON LIGHT E33
20 614 (PU) LH REAR FLASHING LAMP E05
21 617 (PU) RH REAR FLASHING LAMP E06
22 -
23 - 1
24 067 (PU) REAR WORK LIGHTS RELAY K-31
25 -
26 -
27 -
28 604 (OR) FUSE 14 TO SIEVE LIGHT E37
29 625 (PU) FUSE 20 TO LEFT MARKER LIGHTS
FUSE 21 TO RIGHT MARKER
30 626 (PU) LIGHTS
10020076
B(+) FUSE 15 TO SERVICE
31 649 (RD) SOCKETS J03, J04
24
1. CONNECTOR X024 - STRAW WALKER (SW)
55-34
CONNECTOR X025
STRAW WALKER/EXPANSION
WIRE

X013 CCM3 J2-22, UPPER SIEVE
3 475 (YE) MOTOR M06
X013 CCM3 J2-19, LOWER SIEVE
4 476 (YE) MOTOR M07
X013 CCM3 J2-33, SPREADER DEUTSCH_HDP24--24--19P_RECEPTACLE
5 477 (YE) PLATE MOTOR M11
X013 CCM3 J2-34, UPPER SIEVE X025
6 539 (YE) ADJUST SW S35 - DEC
STRAW WALKER
X013 CCM3 J2-17, UPPER SIEVE
7 540 (YE) ADJUST SW S35 - INCR
X014 CCM3 J3-6, SPREADER PLATE
8 509 (GY) MOTOR M11
9 541 (YE) ADJUST SW S46 - DEC
10 510 (WH) MOTOR M11
11 542 (YE) ADJUST SW S46 - INCR
12 -
13 551 (BK) GROUND
14 785 (GY) SIEVE MOTORS M06, M07 DEUTSCH_HDP26--24--19S_PLUG
15 790 (WH) LOWER SIEVE MOTOR M07
16 - X025
17 792 (WH) UPPER SIEVE MOTOR M06 EXPANSION
18 -
19 550 (BK) GROUND
10020076
25
1. CONNECTOR X025, STRAW WALKER (SW)
HARNESS TO EXPANSION (EX) HARNESS
55-35
CONNECTOR X026
RHM J6
WIRE
1 130 (BK) GROUND FOR RHM

2 129 (RD) X018 - CCM-1-J1
3 136 (BK) GROUND
4 098 (OR) SPLICE BLOCK B
5 089 (OR) SPLICE BLOCK B
6 320 (BL) GROUND SPEED
7 323 (BL) GEAR SELECT
8 -
9 -
10 128 (BK) GROUND
AMP_O--174952--1
11 127 (RD) CONN - DAM
X026
14 -
RHM J6
15 389 (BK) GROUND SPLICE BLOCK A
16 316 (PK) GROUND SPEED
17 319 (PK) GEAR SELECT
18 388 (BK) GROUND FOR AUDIO ALARM
19 376 (WH) ACTUATION FOR AUDIO ALARM 1
20 352 (BK) GROUND FOR SPLICE BLOCK A
10010917
26
1. CONNECTOR X026, RHMJ6 FROM RIGHT
CONSOLE (RC) HARNESS
55-36
CONNECTOR X027
RHM J7A
WIRE
1 381 (YE) GROUND SPEED

2 -
3 -
6 304 (YE) SIGNAL FOR HHC FINE ADJUST
7 303 (YE) SIGNAL FOR HHC FINE ADJUST
8 355 (PU) LIGHTING FOR PARK BRAKE
9 - AMP_173853
10 -
11 391 (YE) GEAR SELECT SIGNAL
X027
12 301 (WH) ACTUATION FOR NEUTRAL LOCK RHM J7A
13 305 (WH) ACTUATION FOR NEUTRAL LOCK
14 228 (PU) LIGHTING FOR VERTICAL KNIVES
15 354 (PU) LIGHTING FOR REEL SPEED 1
16 353 (PU) LIGHTING FOR HEADER HEIGHT
17 338 (YE) THROTTLE SIGNAL
18 329 (PU) SPLICE BLOCK C LIGHTING FEED
10010917
27
1. CONNECTOR X027, RHMJ7A FROM RIGHT
55-37
CONNECTOR X028
RHM J7B
WIRE
1 PU UNLOAD CIRCUITS – COMMON

2 PK HEADER TILT RIGHT/REEL SPEED
INCREASE/HANDLE UNLOCK
3 OPEN
4 GN UNLOAD AUGER ENGAGE/HEADER
UP FAST/REEL UP
5 WH UNLOAD TUBE OUT/HEADER TILT AMP_O--173851--1
LEFT/REEL FORWARD
6 BK HEADER CIRCUITS – COMMON X028
7 RD REEL CIRCUITS, EMERGENCY STOP RHM J7B
– COMMON
8 BL HEADER DOWN SLOW/EMERGENCY
STOP
9 GY UNLOAD TUBE IN LOCK/HEADER
RESUME/REEL AFT
10 YE UNLOAD TUBE IN/HEADER UP
SLOW/REEL SPEED DECREASE
11 BN UNLOAD TUBE OUT LOCK/HEADER 1
DOWN FAST/REEL DOWN
12 OPEN
NOTE: Use the following table to determine the

correct pin combinations for each switch on the
propulsion handle. The MFH circuits contain diodes,
so the multimeter test leads must be connected to the
proper pins as indicated in the table. The active 10010917
switch reading will be approximately 1.7M ohms.
28
SWITCH NAME + PIN -- PIN
1. CONNECTOR X028, FROM MULTI-FUNCTION
HANDLE UNLOCK 2 PK 1 PU HANDLE (MFH)
UNLOAD AUGER ENGAGE 4 GN 1 PU
UNLOAD TUBE OUT 5 WH 1 PU
UNLOAD TUBE IN LOCK 9 GY 1 PU
UNLOAD TUBE IN 10 YE 1 PU
UNLOAD TUBE OUT LOCK 11 BN 1 PU
HEADER TILT RIGHT/CW 2 PK 6 BK
HEADER UP SLOW 4 GN 6 BK
HEADER TILT LEFT/CCW 5 WH 6 BK
HEADER DOWN SLOW 8 BL 6 BK
HEADER RESUME 9 GY 6 BK
HEADER UP FAST 10 YE 6 BK
HEADER DOWN FAST 11 BN 6 BK
REEL SPEED INCREASE 2 PK 7 RD
REEL UP 4 GN 7 RD
REEL FORE 5 WH 7 RD
EMERGENCY STOP 8 BL 7 RD
REEL AFT 9 GY 7 RD
REEL SPEED DECREASE 10 YE 7 RD
REEL DOWN 11 BN 7 RD
55-38
CONNECTOR X029
RHM J8A
WIRE
1 335 (YE) PARK BRAKE SIGNAL

2 332 (YE) REEL SPEED SIGNAL
3 330 (YE) HEADER HEIGHT SIGNAL
5 326 (YE) FEEDER DIRECTION SIGNAL
6 337 (YE) DUAL RANGE SIGNAL
7 230 (YE) VERTICAL KNIVES SIGNAL
8 -
9 334 (YE) PARK BRAKE SIGNAL AMP_173853
10 333 (YE) REEL SPEED SIGNAL
11 331 (YE) HEADER HEIGHT SIGNAL
X029
12 328 (YE) ALTERNATE SETTING SIGNAL RHM J8A
14 325 (YE) SPREADER PLATE SIGNAL
15 229 (YE) VERTICAL KNIVES SIGNAL
16 339 (YE) ON THE ROAD SIGNAL
17 336 (YE) REAR WHEEL ASSIST SIGNAL
10010917
1
29
1. CONNECTOR X029, RHMJ8A FROM RIGHT
55-39
CONNECTOR X030
RHM J8B
WIRE
1 342 (YE) LOWER SIEVE SIGNAL

2 341 (YE) UPPER SIEVE SIGNAL
3 347 (YE) CONCAVE CLEARANCE SIGNAL
4 348 (YE) ROTOR/DRUM SPEED SIGNAL
5 350 (YE) FEEDER SPEED SIGNAL
6 343 (YE) LOWER SIEVE SIGNAL
7 340 (YE) UPPER SIEVE SIGNAL AMP_O--173851--1
9 344 (YE) FAN SPEED SIGNAL X030
10 345 (YE) FAN SPEED SIGNAL RHM J8B
1
10010917
30
1. CONNECTOR X030, RHMJ8B FROM RIGHT
55-40
CONNECTOR X031
FRONT FRAME/CAB MAIN
WIRE
1 034 (OR) CCM-1B FUSE, F-44

2 038 (OR) CCM-2A FUSE, F-36
3 027 (RD) FAN/REVERSER FUSE, F-24
4 028 (RD) THROTTLE/BRUSH FUSE, F-23
5 -
6 -
7 580 (OR) ASP POWER FUSE, F-46
8 714 (WH) FAN/REVERSER RELAY, K-17 X031
9 768 (WH) FAN/REVERSER RELAY, K-17 FRONT FRAME
10 719 (WH) FAN/REVERSER RELAY, K-17
11 -
12 763 (WH) FAN/REVERSER RELAY, K-17
13 -
14 029 (RD) TRANSMISSION SHIFT FUSE, F-25
15 -
16 024 (RD) SHOE LEVELING MOTOR FUSE, F-22
17 -
18 -
19 -
X031
CAB MAIN
10010899
31
1. CONNECTOR X031, FRONT FRAME (FF)
55-41
CONNECTOR X032
HEADER/FEEDER
WIRE
X281 HHC PIN 15, LEFT STUBBLE

1 738 (YE) HEIGHT R12
X281 HHC PIN 16, LEFT STUBBLE
2 739 (YE) HEIGHT R13
3 -
4 -
LEFT STUBBLE HEIGHT R12 - 5V DEUTSCH_HDP24--24--31P_RECEPTACLE
5 848 (PK) REF.
LEFT STUBBLE HEIGHT R12 - REF. X032
6 847 (BL) GROUND
HEADER
7 737 (YE) X017 CCM2 J3-13, REEL RPM B15
8 -
9 -
10 -
11 -
12 -
13 750 (BL) REEL RPM B15 - REF. GROUND
14 -
15 -
16 -
17 -
18 -
19 - X032
X017 CCM2 J3-8, REEL SPEED
20 712 (WH) MOTOR M09 FEEDER
GROUND FOR FLIP-UP HEAD LIGHT
21 776 (BK) KIT
22 613 (PU) LH HEADER FLASHING LAMP E01
RIGHT STUBBLE HEIGHT R13 - 5V
23 849 (PK) REF.
24 752 (PU) HEADER MARKER LIGHTS E40, E41
RIGHT STUBBLE HEIGHT R13 - REF.
25 846 (BL) GROUND
X017 CCM2 J3-6, REEL SPEED
26 711 (GY) MOTOR M09
27 -
28 618 (PU) RH HEADER FLASHING LAMP E02
1
29 -
30 775 (BK) GROUND, FRONT FRAME 2
31 - 10020040
32
1. CONNECTOR X032, FEEDER (FE) HARNESS TO
HEADER (HH) HARNESS
55-42
CONNECTOR X033
CAB MAIN/STEERING COLUMN
WIRE
1 054 (RD) HAZARD LIGHTS FUSE, F-56

X015 - CCM-2 J1-15, HAZARD
2 1209 (PU) SWITCH S25
3 -
4 043 (PU) HIGH BEAM INDICATOR E-10
5 -
6 201 (PU) RH TURN SIGNAL
AMP_206037--1
7 196 (PU) RH FLASHING LIGHTS
X033
8 197 (PU) LH TURN SIGNAL
9 200 (PU) LH FLASHING LIGHTS CAB MAIN
X015 - CCM-2 J1-5, ISO/NASO
10 204 (PU) SELECT
11 -
12 219 (BK) GROUND
13 243 (PU) LH NASO FLASHING LAMP E07
14 244 (PU) RH NASO FLASHING LAMP E08
15 -
16 -
AMP_206036--1
X033
STEERING COLUMN
10010914
33
1. CONNECTOR X033, STEERING COLUMN (SC)
55-43
CONNECTOR X034
EXPANSION/MAIN FRAME A
WIRE
1 030 (RD) FUSE F26

2 031 (RD) FUSE F27
3 035 (OR) FUSE F47
4 036 (OR) FUSE F47 DEUTSCH_DT06--6S_PLUG
5 -
X034
6 -
EXPANSION A
DEUTSCH_DT04--6P_RECEPTACLE
X034
MAIN FRAME A
40025228
34
HARNESS TO EXPANSION (EX) HARNESS
55-44
CONNECTOR X035
GEARBOX VALVE
WIRE
1 876 (WH) FEEDER CLUTCH ACTUATION

2 875 (BL) FEEDER CLUTCH GROUND
PARK BRAKE DISENGAGE
3 572 (WH) ACTUATION
4 605 (BK) PARK BRAKE DISENGAGE GROUND
UNLOAD TUBE CLUTCH
5 568 (WH) ACTUATION DEUTSCH_DT06--8S_PLUG
6 601 (BL) UNLOAD TUBE CLUTCH GROUND
7 878 (WH) GEARBOX CLUTCH ACTUATION X035
8 877 (BL) GEARBOX CLUTCH GROUND GEARBOX VALVE
10004669
35
1. GB W/H, CONNECTOR X035 - GEARBOX VALVE
55-45
CONNECTOR X036
CAB ROOF/OUTER ROOF
WIRE

1 058 (PU) LIGHTS
2 059 (PU) LIGHTS
5 072 (PU) RH SIDE WORK LIGHT E26 DEUTSCH_HDP24--24--31P_RECEPTACLE
X036
GROUND THROUGH WORK LIGHT CAB ROOF
12 295 (BK) HEAT
13 665 (BK) E32
14 280 (BK) GROUND, WIPER MOTOR M25
15 275 (WH) WIPER MOTOR M25 - PARK
16 276 (WH) WIPER MOTOR M25 - ON X036
WIPER MOTOR M25 -
17 277 (WH) INTERMITTENT OUTER ROOF
20 963 (WH) RH GERMAN MIRROR M30 - DOWN
22 958 (WH) LH MIRROR M21 - DOWN 1
27 -
28 -
30 -
31 - 10010916
36
55-46
CONNECTOR X037
SPREADER PLATE S23
WIRE

2 357 (OR) SPREADER PLATE IGNITION B+
4 - EATON_25--13936
5 -
6 - X037
SPREADER PLATE
8 -
9 386 (BK) SPREADER PLATE GROUND
10 -
CONNECTOR X038
ALTERNATE SETTINGS S21
WIRE
1 -
2 359 (OR) ALTERNATE SETTING IGNITION B+
3 328 (YE) ALTERNATE SETTING SIGNAL
4 - EATON_25--13936
5 -
6 - X038
ALTERNATE SETTINGS
8 -
9 377 (BK) ALTERNATE SETTING GROUND
10 -
CONNECTOR X039
FEEDER REVERSER S07
WIRE
1 326 (YE) FEEDER REVERSER SIGNAL

2 358 (OR) FEEDER REVERSER B+
3 -
4 - EATON_25--13936
5 -
6 - X039
FEEDER REVERSER
8 -
FEEDER REVERSER CHASSIS
9 387 (BK) GROUND
10 -
55-47
CONNECTOR X040
REEL SPEED MODE S08
WIRE
1 333 (YE) REEL SPEED MODE SIGNAL

2 362 (OR) REEL SPEED MODE IGNITION B+
3 332 (YE) REEL SPEED MODE SIGNAL
4 - EATON_25--13936
5 -
6 - X040
REED SPEED MODE
8 -
9 380 (BK) REEL SPEED MODE GROUND
10 354 (PU) REEL SPEED MODE “ON” LIGHT
CONNECTOR X041
NEUTRAL LOCK S22
WIRE
301, 305
1 (WH) NEUTRAL LOCK SOLENOID FEED
NEUTRAL LOCK SOLENOID

2 317 (BK) GROUND
AMP_926474--1
X041
NEUTRAL LOCK
CONNECTOR X042
LOWER SIEVES S14
WIRE
1 342 (YE) LOWER SIEVES SIGNAL

2 371 (OR) LOWER SIEVES IGNITION B+
3 343 (YE) LOWER SIEVES SIGNAL
4 - EATON_25--13936
5 -
6 - X042
7 -
LOWER SIEVES
8 -
9 -
10 -
55-48
CONNECTOR X043
UPPER SIEVES S13
WIRE
1 340 (YE) UPPER SIEVES SIGNAL

2 370 (OR) UPPER SIEVES IGNITION B+
3 341 (YE) UPPER SIEVES SIGNAL
4 - EATON_25--13936
5 -
6 - X043
7 -
UPPER SIEVES
8 -
9 -
10 -
CONNECTOR X044
CONCAVE CLEARANCE S16
WIRE

CONCAVE CLEARANCE IGNITION
2 373 (OR) B+
EATON_25--13936
4 -
5 -
X044
6 -
7 - CONCAVE CLEARANCE
8 -
9 -
10 -
CONNECTOR X045
FAN SPEED S15
WIRE
1 344 (YE) FAN SPEED SIGNAL

2 372 (OR) FAN SPEED IGNITION B+
3 345 (YE) FAN SPEED SIGNAL
4 - EATON_25--13936
5 -
6 - X045
7 -
FAN SPEED
8 -
9 -
10 -
55-49
CONNECTOR X046
ROTOR SPEED S17
WIRE

2 374 (OR) ROTOR/DRUM SPEED IGNITION B+
4 - EATON_25--13936
5 -
6 - X046
7 -
ROTOR/DRUM SPEED
8 -
9 -
10 -
CONNECTOR X047
FEEDER SPEED S18
WIRE

2 375 (OR) FEEDER SPEED IGNITION B+
3 351 (YE) FEED SPEED SIGNAL
4 - EATON_25--13936
5 -
6 - X047
7 -
FEEDER SPEED
8 -
9 -
10 -
CONNECTOR X048
GEAR SELECT S24
WIRE
GEAR SELECT REFERENCE

A 319 (PK) VOLTAGE PAC_12064758
B 323 (BL) GEAR SELECT GROUND
C 391 (YE) GEAR SELECT SIGNAL X048
GEAR SELECT
55-50
CONNECTOR X049
ON THE ROAD S12
WIRE
1 -
ON THE ROAD SWITCH B+
2 368 (OR) IGNITION
3 339 (YE) ON THE ROAD SWITCH SIGNAL EATON_25--13936
4 -
5 - X049
6 - ON THE ROAD
8 -
9 392 (BK) ON THE ROAD SWITCH GROUND
10 -
CONNECTOR X050
DUAL RANGE S11
WIRE
1 -
2 367 (OR) DUAL RANGE B+ IGNITION
3 337 (YE) DUAL RANGE SIGNAL
4 - EATON_25--13936
5 -
6 - X050
DUAL RANGE
8 -
9 385 (BK) DUAL RANGE GROUND
10 -
CONNECTOR X051
REAR WHEEL ASSIST S10
WIRE
1 -
2 366 (OR) REAR WHEEL ASSIST B+ IGNITION
3 336 (YE) REAR WHEEL ASSIST SIGNAL
4 - EATON_25--13936
5 -
6 - X051
REAR WHEEL ASSIST
8 -
9 384 (BK) REAR WHEEL ASSIST GROUND
10 -
55-51
CONNECTOR X052
PARK BRAKE S09
WIRE

2 365 (OR) PARK BRAKE B+ IGNITION
4 - EATON_25--13936
5 -
6 - X052
PARK BRAKE
8 -
9 393 (BK) PARK BRAKE GROUND
10 355 (PU) PARK BRAKE “ON” LIGHT
CONNECTOR X053
SPLICE BLOCK A
WIRE
A 122 (BK) CHASSIS GROUND

GROUND FOR NEUTRAL LOCK
B 317 (BK) SOLENOID L01
C 352 (BK) GROUND FOR RPM
D 356 (BK) GROUND FOR RHM
E 364 (BK) GROUND FOR RHM
GROUND FOR HEADER HEIGHT
F 383 (BK) MODE
PAC_15305291
G 384 (BK) GROUND FOR DUAL RANGE
H 385 (BK) GROUND FOR DUAL RANGE
X053
J 389 (BK) GROUND FOR RHM
GROUND FOR ON THE ROAD
SPLICE BLOCK A
K 392 (BK) SWITCH
L 393 (BK) GROUND FOR PARK BRAKE
GROUND FOR REEL SPEED MODE,
VERTICAL KNIVES, FEEDER
M 399 (BK) REVERSER, ALTERNATE SETTING,
AND SPREADER PLATES
55-52
CONNECTOR X054
SPLICE BLOCK B
WIRE
B+ FOR LOWER SIEVE, UPPER

SERVE, CONCAVE CLEARANCE
A 321 (OR) FAN SPEED, ROTOR DRUM SPEED,
AND FEEDER REVERSER, REEL
SPEED MODE
B+ FOR FEEDER REVERSER, REEL
SPEED MODE, VERTICAL KNIVES,
B 327 (OR) ALTERNATE SETTING AND
SPREADER PLATE
C 365 (OR) B+ FOR PARK BRAKE PAC_15305291
D 366 (OR) B+ FOR REAR WHEEL ASSIST
E 367 (OR) B+ FOR DUAL RANGE
X054
F 368 (OR) B+ FOR ON THE ROAD SWITCH SPLICE BLOCK B
G 360 (OR) B+ FOR HHC FINE ADJUST
H 361 (OR) B+ FOR HEADER HEIGHT MODE
J 098 (OR) B+ FOR RHM
K 369 (OR) B+ FOR ENGINE THROTTLE
L 089 (OR) B+ FOR RHM
M 287 (OR) B+ FOR THRESHER ENGAGE
CONNECTOR X055
THRESHER ENGAGE S30
WIRE
1 -
2 858 (YE) THRESHER ENGAGE SIGNAL
3 110 (OR) THRESHER ENGAGE B+ IGNITION AMP_344266--1
4 -
5 302 (YE) THRESHER ENGAGE SIGNAL X055
6 857 (YE) THRESHER ENGAGE SIGNAL THRESHER ENGAGE
CONNECTOR X056
FEEDER ENGAGE S31
WIRE
1 -
2 860 (YE) FEEDER ENGAGE SIGNAL
3 861 (YE) FEEDER ENGAGE SIGNAL AMP_344266--1
4 -
5 112 (YE) FEEDER ENGAGE SIGNAL X056
6 859 (YE) FEEDER ENGAGE SIGNAL FEEDER ENGAGE
55-53
CONNECTOR X057
GROUND SPEED R04
WIRE
5V REF. VOLTAGE, X026 PIN 16,

A 316 (PK) RHM
B 320 (BL) GROUND, X026 PIN 6, RHM
C 381 (YE) X027 PIN 1, RHM
DEUTSCH_DT06--3S_PLUG
X057
GROUND SPEED
CONNECTOR X058
AUDIO ALARM H01
WIRE
1 376 (WH) X026 PIN 19, RHM

2 388 (BK) X026 PIN 18, RHM
AMP_280543--0
X058
AUDIO ALARM
CONNECTOR X059
NEUTRAL SWITCH S22
WIRE
1 300 (OR) NEUTRAL SWITCH B+ IGNITION

2 113 (YE) NEUTRAL SWITCH SIGNAL
3 093 (WH) NEUTRAL SWITCH ACTUATION AMP_360010--1
X059
NEUTRAL SWITCH
CONNECTOR X060
THROTTLE S36
WIRE

2 369 (OR) THROTTLE B+ IGNITION
4 - EATON_25--13936
5 -
6 - X060
THROTTLE
8 -
9 390 (BK) THROTTLE GROUND
10 338 (PU) THROTTLE LIGHTING
55-54
CONNECTOR X061
HEADER HEIGHT S04
WIRE
1 331 (YE) HEADER HEIGHT MODE SIGNAL

HEADER HEIGHT MODE B+
2 361 (OR) IGNITION
3 330 (YE) HEADER HEIGHT MODE SIGNAL
EATON_25--13936
4 -
5 -
X061
6 -
7 395 (PU) BACKLIGHTING HEADER HEIGHT
8 -
9 379 (BK) HEADER HEIGHT MODE GROUND
10 353 (PU) HEADER HEIGHT MODE LIGHTING
CONNECTOR X062
HEADER WIDTH ADJUST S06
WIRE
1 303 (YE) HDR WIDTH ADJUST SIGNAL

2 360 (OR) HDR WIDTH ADJUST B+ IGNITION
3 304 (YE) HDR WIDTH ADJUST SIGNAL
4 - EATON_25--13936
5 -
6 - X062
HEADER WIDTH ADJUST
8 -
9 378 (BK) GROUND
10 -
CONNECTOR X063
VERTICAL KNIVES S51
WIRE
1 230 (YE) VERTICAL KNIVES SWITCH SIGNAL

2 248 (OR) SWITCHED B+
3 229 (YE) VERTICAL KNIVES SWITCH SIGNAL
4 - EATON_25--13936
5 -
6 - X063
7 292 (PU) CCM ILLUMINATION CONTEST
VERTICAL KNIVES
8 -
9 226 (BK) GROUND
VERTICAL KNIVES SWITCH
10 228 (PU) INDICATOR CONTROL
55-55
CONNECTOR X064
MAIN DISPLAY MODULE
WIRE
A 143 (YE) CAN HI

B -
C 097 (OR) KEYSWITCH POWER
D 057 (RD) FUSE F39, KEEP ALIVE POWER
E 144 (GN) CAN LO
F 145 (BK) GROUND
PAC_12064762
X064
MAIN DISPLAY MODULE
CONNECTOR X065
DIAGNOSTICS AND MAINTENANCE
WIRE
A 146 (BK) GROUND

B 142 (RD) FUSE F39, KEEP ALIVE POWER
C 271 (YE) CAN HI
D 270 (GN) CAN LO
ISO-K, ECU CONNECTOR X193
E 827 (YE) PIN 13
DEUTSCH_HD10--9--1939PE
F 135 (RD) RS-232 RX
G 136 (BK) RS-232 TX X065
H - DIAGNOSTICS AND MAINTENANCE
J -
CONNECTOR X066
COLD START INDICATOR E36
WIRE
1 -
2 1102 (OR) ACCESSORY SOCKET FUSE, F-10
3 1159 (WH) CONNECTOR X004, PIN 3
4 - EATON_25--13936
5 -
6 - X066
7 814 (WH) COLD START SIGNAL
COLD START INDICATOR
8 -
9 294 (BK) GROUND
10 -
55-56
CONNECTOR X067
ACC. SOCKET J06
WIRE
1 151 (BK) GROUND

2 084 (OR) ACCESSORY OUTLET FUSE, F-8
AMP_926522
X067
ACC. SOCKET
CONNECTOR X068
KEY SWITCH S02
WIRE
1 053 (RD) KEY SWITCH FUSE, F-38

2 091 (OR) NEUTRAL START RELAY, K-23
3 -
4 123 (OR) ACCESSORY POWER
5 859 (OR) POWER TO ECU
6 096 (OR) POWER, IGNITION PAC_02984017
X068
KEY SW
CONNECTOR X069
LIGHTER R08
WIRE
1 152 (BK) GROUND

2 085 (OR) CIGAR LIGHTER FUSE, F-5
AMP_926522
X069
LIGHTER
CONNECTOR X070
LIGHTER BACKLIGHT
WIRE

AMP_154719
X070
LIGHTER BACKLIGHT
55-57
CONNECTOR X071
STRAW HOOD/STRAW WALKER
WIRE

3 481 (BL) REF. GROUND FOR SENSOR B22
4 -
5 -
6 -
7 -
8 - X071
9 - STRAW WALKER
X013 CCM3 J2-33, SPREADER
10 477 (YE) PLATE MOTOR M11
X019 CCM1 J2-17, REAR LADDER
12 -
13 678 (RD) RH SERVICE SOCKET J03
X019 CCM1 J2-6, BACKUP ALARM
14 452 (WH) H08
15 510 (WH) MOTOR M11
16 509 (GY) MOTOR M11
17 243 (PU) LEFT FLASHING LAMP E07 DEUTSCH_HDP26--24--31S_PLUG
18 412 (PU) LH TAIL LIGHT E11
X071
19 619 (PU) LH REAR FLASHING LAMP E05
20 629 (PU) LH BRAKE LIGHT E11 STRAW HOOD
21 421 (PU) RH TAIL LIGHT E12
22 578 (PU) REAR BEACON LIGHT E33
23 244 (PU) RIGHT FLASHING LAMP E08
1
24 622 (PU) RH REAR FLASHING LAMP E06
25 630 (PU) RH BRAKE LIGHT E12
26 478 (BK) GROUND
27 628 (BK) GROUND
28 067 (PU) REAR WORK LIGHTS E27, E28
29 672 (BK) GROUND
30 444 (BL) REF. GROUND FOR SENSOR B38
X020 CCM1 J3-36, UNLOAD CRADLE
31 485 (YE) B38
50026220
37
HARNESS TO STRAW HOOD (SH) HARNESS
55-58
CONNECTOR X072
LOWER FRAME REAR/STRAW WALKER
WIRE
X019 CCM1 J2-16, REAR WHEEL

A 569 (WH) ASSIST L26
B 602 (BK) GROUND
C 494 (BL) REF. GROUND FOR SENSORS
D 431 (YE) X019 CCM1 J2-25, SIEVE LOSS B21
5V REF. VOLTAGE, UPPER SIEVE
E 793 (PK) MOTOR DEUTSCH_HDP26--18--14S_PLUG
REF. GROUND FOR UPPER SIEVE
F 795 (BL) MOTOR M06 X072
X013 CCM3 J2-22, UPPER SIEVE LOWER FRAME REAR
G 475 (YE) MOTOR M06
H 792 (WH) UPPER SIEVE MOTOR M06
J 791 (GY) UPPER SIEVE MOTOR M06
5V REF. VOLTAGE LOWER SIEVE
K 794 (PK) MOTOR
REF. GROUND FOR LOWER SIEVE
L 796 (BL) MOTOR M07
M 476 (YE) MOTOR M07
N 790 (WH) LOWER SIEVE MOTOR M07
P 789 (GY) LOWER SIEVE MOTOR M07
X072
STRAW WALKER
40020080
38
HARNESS TO LOWER FRAME REAR (LR)
HARNESS
CONNECTOR X073
SEAT SWITCH S05
WIRE
A 046 (OR) CAB FUSE, F-49

B 168 (YE) X015-CCM-2 J1-9
PAC_12052641
X073
SEAT SWITCH
55-59
CONNECTOR X074
SEAT PUMP M26
WIRE
A 080 (OR) MAIN BLOWER FUSE, F-18

B 164 (BK) GROUND
PAC_12015792
X074
SEAT PUMP
CONNECTOR X075
ACCESSORY BACKLIGHT
WIRE
3 247 (PU) ACCESSORY LIGHTING

AMP_154719
X075
ACCESSORY BACKLIGHT
CONNECTOR X076
ACCESSORY OUTLET J08
WIRE
1 153 (BK) GROUND

2 086 (OR) ACCESSORY OUTLET FUSE, F-8
AMP_926522
X076
ACCESSORY OUTLET
CONNECTOR X077
GROUND, 3, CM
WIRE
116 (BK) CCM-1, 2, AND 3

156 (BK) LOW BEAM RELAY, K-5
160 (BK) BEACON LIGHTS RELAY, K-29
161 (BK) SIDE WORK LIGHT RELAY, K-35
945 (BK) A/C CLUTCH RELAY, K-10
152 (BK) CIGAR LIGHTER, R-08 X077
151 (BK) ACCESSORY SOCKET, J-06 GROUND
153 (BK) ACCESSORY OUTLET, J-08
164 (BK) SEAT PUMP MOTOR, M-26
294 (BK) COLD START INDICATOR, E-36
788 (BK) UPPER/LOWER SIEVE RELAY, K-18
55-60
CONNECTOR X079
REVERSER DISENGAGE B09
WIRE
REF. GROUND FOR REVERSER

1 777 (BL) DISENGAGE B09
X020 CCM1 J3-27, REVERSER
2 733 (YE) DISENGAGE B09
X079
REVERSER DISENGAGE
CONNECTOR X080
FEEDER REVERSER M10
WIRE
A 719 (WH) FEEDER REVERSER M10

B 770 (GY) FEEDER REVERSER M10
PAC_15300027
X080
FEEDER REVERSER
CONNECTOR X081
LAT FLOAT POT R02
WIRE
5V REF. VOLTAGE, LATERAL FLOAT

A 757 (PK) POT R02
REF. GROUND, LATERAL FLOAT
B 745 (BL) POT R02
X020 CCM1 J3-17, LATERAL FLOAT PAC_12065287
C 741 (YE) POT R02
X081
LAT FLOAT POT
55-61
CONNECTOR X082
ASP AMPLIFIER KN2
WIRE
1 720 (BK) GROUND

2 731 (WH) STONE DOOR OPEN L31
3 -
4 580 (WH) FUSE F46
5 -
6 729 (YE) CAN HI DEUTSCH_DT06--8S_PLUG
7 730 (GN) CAN LO
X082
8 732 (BK) STONE DOOR OPEN L31
ASP AMPLIFIER KN2
1
10020074
39
1. CONNECTOR X082 -- ASP AMPLIFIER KN2
CONNECTOR X083
ASP DOOR POSITION B-24
WIRE
1 754 (BL) REFERENCE GROUND B TO CCM1

J3-18
2 743 (YE) SIGNAL TO CCM1 J3-28
X083
ASP DOOR POSITION B-24
CONNECTOR X084
LH BRAKE PADS
WIRE
1 607 (YE) X019-CCM-1 J2-26

2 -
3 843 (YE) X019-CCM-1 J2-26
AMP_794412--1
X084
LH BRAKE PADS
55-62
CONNECTOR X085
RH BRAKE PADS
WIRE
1 835 (YE) X019-CCM-1 J2-26

2 -
3 844 (YE) X019-CCM-1 J2-26
AMP_794412--1
X085
RH BRAKE PADS
CONNECTOR X086
ASP AMPLIFIER KN2
WIRE
1 990 (YE) LH ASP TOP SENSOR B51

2 988 (YE) RH ASP TOP SENSOR B50
3 986 (YE) LH ASP BOTTOM SENSOR B49
4 984 (YE) RH ASP BOTTOM SENSOR B48
REF. GROUND, RH ASP BOTTOM
5 985 (BL) SENSOR B48
REF. GROUND, LH ASP BOTTOM
REF. GROUND, RH ASP TOP X086
7 989 (BL) SENSOR B50 ASP AMPLIFIER KN2
REF. GROUND, LH ASP TOP
10020074
40
1. CONNECTOR X086 -- ASP AMPLIFIER KN1
55-63
CONNECTOR X087
GROUND SPEED RPM B17
WIRE
REF. GROUND, GROUND SPEED

1 717 (BL) RPM B17
X017 CCM2 J3-14, GROUND SPEED
2 403 (YE) RPM B17
X087
GROUND RPM
CONNECTOR X088
SHOE MOTOR M03
WIRE
5V REF. VOLTAGE, SHOE LEVELING

A 727 (PK) ACTUATOR M03
REF. GROUND, SHOE LEVELING
B 724 (BL) ACTUATOR M03
X020 CCM1 J3-32, SHOE LEVELING
C 721 (YE) ACTUATOR M03
D 710 (WH) SHOE LEVELING ACTUATOR M03
E 707 (GY) SHOE LEVELING ACTUATOR M03
PAC_12084891
X088
SHOE MOTOR
CONNECTOR X089
CLEANING FAN RPM B16
WIRE
REF. GROUND, CLEANING FAN RPM

1 718 (BL) B16
X020 CCM1 J3-13, CLEANING FAN
2 404 (YE) RPM B16
X089
CLEANING FAN RPM
CONNECTOR X090
CLEANING FAN MOTOR M05
WIRE
CLEANING FAN ADJUST MOTOR

A 763 (WH) M05
CLEANING FAN ADJUST MOTOR
B 761 (GY) M05
PAC_15300027
X090
CLEANING FAN MOTOR
55-64
CONNECTOR X091
HYDROSTAT MOTOR TEMP B46
WIRE
REF. GROUND, HYDROSTAT

A 774 (BL) MOTOR TEMP B46
X020 CCM1 J3-33, HYDROSTAT
B 773 (YE) MOTOR TEMP B46
PAC_12162193
X091
HYDROSTAT TEMP
CONNECTOR X092
FOOT AND INCH L05
WIRE
X017 CCM2 J3-15, FOOT AND INCH

A 575 (WH) VALVE L05
B 606 (BK) GROUND
PAC_12015792
X092
FOOT AND INCH
CONNECTOR X093
TRANS SHIFT POSITION B37
WIRE
X017 CCM2 J3-28, TRANS SHIFT

1 407 (YE) POSITION B37 - NEUTRAL
2 405 (YE) POSITION B37 - 1ST GEAR
X017 CCM2 J3-37, TRANS SHIFT DEUTSCH_DT06--6S_PLUG
3 406 (YE) POSITION B37 - 2ND GEAR
X017 CCM2 J3-38, TRANS SHIFT X093
4 408 (YE) POSITION B37 - 3RD GEAR TRANS SHIFT POSITION
5 409 (YE) POSITION B37 - 4TH GEAR
REF. GROUND, TRANS SHIFT
6 426 (BL) POSITION B37
CONNECTOR X094
TRANSMISSION SHIFT MOTOR M02
WIRE
A 716 (WH) TRANSMISSION SHIFT MOTOR M02

B 715 (GY) TRANSMISSION SHIFT MOTOR M02
PAC_15300027
X094
TRANSMISSION SHIFT MOTOR
55-65
CONNECTOR X095
GROUND, 2, FF
WIRE
585 (BK) REEL DRIVE SOLENOID L17

767 (BK) HEADER LIGHTING, ASP MODULE
X020 CCM1 J3-9, 10 -- SHOE
LEVELING MOTOR M03, X020 CCM1
778 (BK) J3-16 -- CLEANING FAN MOTOR
M05, FEEDER REVERSER MOTOR X095
M10
GROUND
X017 CCM2 J3-9, 10 -- TRANS SHIFT
538 (BK) MOTOR M02, X017 CCM2 J3-16 --
REEL SPEED MOTOR M09
592 (BK) REEL UP/DOWN, FORE/AFT L13-16
FOOT AND INCH L05, DUAL RANGE
765 (BK) L27
836 (BK) BRAKE PAD WEAR SENSORS
CONNECTOR X097
GEARBOX TEMPERATURE B32
WIRE
REF. GROUND, GEARBOX

A 466 (BL) TEMPERATURE B32
B 422 (YE) TEMPERATURE B32
PAC_12162193
X097
GEARBOX TEMPERATURE
CONNECTOR X098
CONTROL PRESSURE B35
WIRE
REF. GROUND, LOW CONTROL

A 434 (BL) PRESSURE B35
5V REF. VOLTAGE, LOW CONTROL
B 486 (PK) PRESSURE B35
X016 CCM2 J2-19, LOW CONTROL PAC_12065287
C 423 (YE) PRESSURE B35
X098
CONTROL PRESSURE
CONNECTOR X099
CLUTCH TEMPERATURE B45
WIRE
REF. GROUND, GEARBOX CLUTCH

A 685 (BL) TEMP B45
B 682 (YE) CLUTCH TEMP B45
PAC_12052641
X099
CLUTCH TEMPERATURE
55-66
CONNECTOR X100
GROUND SPEED HYDROSTAT L23
WIRE
A 879 (GY) GROUND SPEED HYDROSTAT L23

B 886 (BL) GROUND SPEED HYDROSTAT L23
C 887 (BL) GROUND SPEED HYDROSTAT L23
D 880 (WH) GROUND SPEED HYDROSTAT L23
PAC_12015797
X100
GROUND SPEED HYDROSTAT
CONNECTOR X101
CHARGE PRESSURE S37
WIRE
X016 CCM2 J2-35, CHARGE

684 (YE) PRESSURE
X101
CHARGE PRESSURE
CONNECTOR X102
GROUND, 1, GB
WIRE
487 (BK) HYD. RESERVOIR LEVEL S33

605 (BK) PARK BRAKE DISENGAGE L10
X102
GROUND
CONNECTOR X103
RESERVOIR TEMPERATURE B18
WIRE
REF. GROUND, HYD OIL

A 480 (BL) RESERVOIR TEMP B18
X019 CCM1 J2-24, HYD OIL
B 446 (YE) RESERVOIR TEMP B18
PAC_12162193
X103
RESERVOIR TEMPERATURE
55-67
CONNECTOR X104
RESERVOIR LEVEL S33
WIRE
A 487 (BK) GROUND

X016 CCM2 J2-39, RESERVOIR
B 424 (YE) LEVEL S33
PAC_12015792
X104
RESERVOIR LEVEL
CONNECTOR X105
UNLOAD TUBE LIGHT
WIRE
1 077 (PU) WORK LIGHT POWER

2 669 (BK) WORK LIGHT GROUND
3 530 (PU) MARKER LIGHT POWER
4 531 (BK) MARKER LIGHT GROUND
X105
UNLOAD TUBE LIGHT
CONNECTOR X106
LEFT REAR WORK LIGHT E27
WIRE
A 652 (PU) LEFT REAR WORK LIGHT POWER

B 661 (BK) GROUND
PAC_12124819
X106
LEFT REAR WORK LIGHT
CONNECTOR X107
3/4 FULL BIN SENSOR S28
WIRE
5V REF. VOLTAGE, 3/4 FULL

A 440 (PK) SENSOR S28
B 445 (YE) FULL BIN SENSOR S29
X016 CCM2 J2-22, BIN SENSOR
C 400 (YE) SIGNAL PAC_12015793
X107
3/4 FULL BIN SENSOR
55-68
CONNECTOR X108
GRAIN TANK LIGHT E30
WIRE
1 646 (PU) GRAIN TANK LIGHT POWER

2 681 (BK) GROUND
X108
GRAIN TANK LIGHT
CONNECTOR X109
FULL BIN SENSOR S29
WIRE
A 443 (BL) REF. GROUND, FULL BIN SENSOR

B 445 (YE) 3/4 FULL BIN SENSOR S28
C -
PAC_12015793
X109
FULL BIN SENSOR
CONNECTOR X110
RIGHT REAR WORK LIGHT E28
WIRE
A 653 (PU) RIGHT REAR WORK LIGHT POWER

B 662 (BK) GROUND
PAC_12124819
X110
RIGHT REAR WORK LIGHT
CONNECTOR X111
LEFT MIRROR
WIRE
1 959 (WH) LEFT MIRROR IN/OUT ACTUATION

3 935 (OR) HEATED MIRROR SWITCH OUTPUT
LEFT MIRROR UP/DOWN DEUTSCH_DT06--6S_PLUG
5 076 (PU) RELAY K-34 X111
6 671 (BK) GROUND LEFT MIRROR
55-69
CONNECTOR X112
LEFT OUTER WORK LIGHT E15
WIRE
A 251 (PU) LEFT OUTER WORK LIGHT POWER

B 259 (BK) GROUND
PAC_12059183
X112
LEFT OUTER WORK LIGHT
CONNECTOR X113
LEFT BEACON LIGHT E31
WIRE
1 663 (PU) LEFT BEACON LIGHT POWER

2 666 (BK) GROUND
X113
LEFT BEACON LIGHT
CONNECTOR X114
LEFT MIDDLE WORK LIGHT E19
WIRE
A 252 (PU) LEFT MIDDLE WORK LIGHT POWER

B 260 (BK) GROUND
PAC_12059183
X114
LEFT MIDDLE WORK LIGHT
CONNECTOR X115
LEFT INNER WORK LIGHT E17
WIRE
A 255 (PU) LEFT INNER WORK LIGHT POWER

B 261 (BK) GROUND
PAC_12059183
X114
LEFT INNER WORK LIGHT
55-70
CONNECTOR X116
WIPER MOTOR M25
WIRE
1 280 (BK) GROUND

2 -
3 275 (WH) WIPER LOW SPEED
4 277 (WH) WIPER HIGH SPEED FRAM_FFH05102BKT
5 276 (WH) WIPER PARK POSITION
X116
WIPER MOTOR
CONNECTOR X117
RIGHT INNER WORK LIGHT E18
WIRE
A 256 (PU) RIGHT INNER WORK LIGHT POWER

B 265 (BK) GROUND
PAC_12059183
X117
RIGHT INNER WORK LIGHT
CONNECTOR X118
RIGHT MIDDLE WORK LIGHT E20
WIRE
RIGHT MIDDLE WORK LIGHT

A 253 (PU) POWER
B 263 (BK) GROUND
PAC_12059183
X118
RIGHT MIDDLE WORK LIGHT
CONNECTOR X119
RIGHT BEACON LIGHT E32
WIRE
1 664 (PU) RIGHT BEACON LIGHT POWER

2 667 (BK) GROUND
X119
RIGHT BEACON LIGHT
55-71
CONNECTOR X120
RIGHT OUTER WORK LIGHT E16
WIRE
RIGHT OUTER WORK LIGHT

A 254 (PU) POWER
B 264 (BK) GROUND
PAC_12059183
X120
RIGHT OUTER WORK LIGHT
CONNECTOR X121
RIGHT MIRROR
WIRE
1 962 (WH) RIGHT MIRROR IN/OUT ACTUATION

3 932 (OR) HEATED MIRROR SWITCH OUTPUT
RIGHT MIRROR UP/DOWN DEUTSCH_DT06--6S_PLUG
5 072 (PU) RELAY K-35 X121
6 670 (BK) GROUND RIGHT MIRROR
CONNECTOR X122
RIGHT REAR SPEAKER
WIRE
A 979 (BL) RIGHT REAR SPEAKER (-)

B 974 (WH) RIGHT REAR SPEAKER (+)
PAC_12052832
X122
RIGHT REAR SPEAKER
CONNECTOR X123
LEFT REAR SPEAKER
WIRE
A 982 (BL) LEFT REAR SPEAKER (-)

B 975 (WH) LEFT REAR SPEAKER (+)
PAC_12052832
X122
LEFT REAR SPEAKER
55-72
CONNECTOR X124
GROUND, 4, CR
WIRE
RS MID, OUTER WORK LIGHTS E16,

266 (BK) E20
295 (BK) MIRRORS
854 (BK) DATA LOGGER A10
855 (BK) DATA LOGGER A10
947 (BK)
SWITCH BACKLIGHTING, MIRROR X124
ADJUST S27
GROUND
CONNECTOR X124
GROUND, 4, CR
WIRE
280 (BK) WIPER MOTOR M25

281 (BK) TRANSCEIVER, X141 PIN 1
282 (BK) GPS MODULE A11
299 (BK) SWITCH BACKLIGHTING
X124
GROUND
CONNECTOR X124
GROUND, 4, CR
WIRE
HEADER, CENTER WORK LIGHTS

246 (BK) E21, E22, E38
LS MID, OUTER WORK LIGHTS E15,
262 (BK) E19
269 (BK) CONSOLE LIGHT E35, RADIO A04
665 (BK) BEACON LIGHTS E31, E32 X124
925 (BK) FRONT WORK LIGHTS SWITCH S43
GROUND
CONNECTOR X125
GRAIN TANK EXTENSIONS SWITCH S42
WIRE
1 -
2 124 (OR) SWITCHED B+
TANK EXTENSIONS SWITCH
3 167 (YE) SIGNAL
4 - EATON_25--13936
5 -
6 - X125
7 284 (PU) BACKLIGHTING GRAIN TANK EXTENSIONS SWITCH
8 -
9 298 (BK) GROUND
10 -
55-73
CONNECTOR X126
MIRROR ADJUST SWITCH S27
WIRE
A 949 (BK) GROUND

B 959 (WH) LEFT MIRROR IN/OUT ACTUATION
C 961 (GY) ACTUATION PAC_12046688
LEFT MIRROR UP/DOWN
D 958 (WH) ACTUATION X126
RIGHT MIRROR UP/DOWN MIRROR ADJUST SWITCH
E 957 (WH) ACTUATION
F 954 (GY) ACTUATION
G 960 (WH) RIGHT MIRROR IN/OUT ACTUATION
H 274 (OR) SWITCHED B+
CONNECTOR X127
MIRROR HEAT SWITCH S19
WIRE
1 -
4 -
EATON_25--13936
5 -
6 -
X127
8 - MIRROR HEAT SWITCH
9 950 (BK) GROUND
10 -
55-74
CONNECTOR X128
HVAC CONTROL PANEL A09
WIRE
C1 972 (PU) BACKLIGHTING

C2 901 (OR) SWITCHED B+
C3 900 (WH) A/C CLUTCH RELAY K10
C4 902 (WH) SEPARATOR BLOWER RELAY K09
C5 -
C6 -
C7 904 (WH) MAIN BLOWER RELAY HIGH K11
C8 905 (WH) MAIN BLOWER RELAY MED K12
C9 906 (WH) MAIN BLOWER RELAY LOW K13
EVAPORATOR TEMPERATURE
SENSOR B28 GROUND (ATC),
C10 907 (BL) FREEZE SWITCH GROUND S53
(MTC) PAC_12110207
EVAPORATOR TEMPERATURE
C11 908 (YE) SENSOR B28 SIGNAL (ATC),
FREEZE SWITCH SIGNAL S53 (MTC) X128
AMBIENT TEMPERATURE SENSOR HVAC CONTROL PANEL
C12 909 (BL) B25 GROUND
AMBIENT TEMPERATURE SENSOR
C13 910 (YE) B25 SIGNAL
OUTLET TEMPERATURE SENSOR
C14 911 (BL) B27 GROUND
OUTLET TEMPERATURE SENSOR
C15 912 (YE) B27 SIGNAL
CAB TEMPERATURE SENSOR B26
C16 913 (BL) GROUND
D1 914 (YE) SIGNAL
A/C LOW PRESSURE SWITCH S48
D2 915 (YE) SIGNAL
D3 916 (BL) A/C PRESSURE SENSOR GROUND
A/C HIGH PRESSURE SWITCH S47
D4 917 (YE) SIGNAL
D5 918 (BK) RECIRC DOOR M15 GROUND
D6 919 (YE) RECIRC DOOR M15 SIGNAL
D7 920 (OR) RECIRC DOOR M15 B+
D8 -
D9 922 (BK) WATER VALVE M16 GROUND
D10 923 (YE) WATER VALVE M16 SIGNAL
D11 924 (OR) WATER VALVE M16 B+
D12 -
D13 -
D14 921 (BK) GROUND
D15 -
D16 -
55-75
CONNECTOR X129
DOME LIGHT E34
WIRE
1 971 (BK) GROUND

2 865 (YE) DOME LIGHT CONTROL (TIME
2 967 (YE) DELAY K20, LH DOOR SW S40)
AMP_926522
X129
DOME LIGHT
CONNECTOR X130
BEACON LIGHT SWITCH S41
WIRE
1 -
BEACON LIGHT SWITCH IGNITION
2 172 (OR) B+
3 166 (YE) BEACON LIGHT SWITCH SIGNAL
4 - EATON_25--13936
5 -
6 - X130
7 283 (PU) BACKLIGHTING BEACON LIGHT SWITCH
8 -
9 297 (BK) BEACON LIGHT SWITCH GROUND
10 -
CONNECTOR X131
REAR WORK LIGHT SWITCH S44
WIRE
1 -
REAR WORK LIGHT SWITCH
2 239 (OR) IGNITION FEED
3 170 (YE) SIGNAL EATON_25--13936
4 -
5 - X130
6 - REAR WORK LIGHT SWITCH
8 -
9 223 (BK) GROUND
10 -
55-76
CONNECTOR X132
FRONT WORK LIGHTS SWITCH S43
WIRE
1 -
3 171 (YE) X018 CCM1 J1-3
4 -
EATON_25--13936
5 245 (BK) INNER WORK LIGHTS E17, E18
6 925 (BK) WORK LTS GROUND
X132
8 - FRONT WORK LIGHTS SWITCH
9 224 (BK) GROUND
10 -
CONNECTOR X133
SPLICE BLOCK C, BACKLIGHTING, CR
WIRE
A 175 (PU) CONSOLE LIGHT E35

B 232 (PU) X015 CCM2 J1-11
C 233 (PU) REAR WORK LIGHT SWITCH S44
D 235 (PU) WORK LIGHT SWITCH S43
E 273 (PU) WIPER SWITCH S20
F 283 (PU) BEACON LIGHT SWITCH S41
G 284 (PU) TANK EXTENSIONS SWITCH S42
H 285 (PU) MIRROR HEAT SWITCH S19 PAC_15305291
J 286 (PU) WASHER SWITCH S38
K - X133
L -
SPLICE BLOCK C
M 972 (PU) HVAC MODULE A09
CONNECTOR X134
WASHER SWITCH S38
WIRE
1 -
2 279 (OR) WASHER SWITCH IGNITION B(+)
3 278 (WH) WASHER SWITCH ACTUATION
4 -
EATON_25--13936
5 -
6 -
X134
8 - WASHER SWITCH
9 951 (BK) GROUND
10 -
55-77
CONNECTOR X135
WIPER SWITCH S20
WIRE
1 276 (WH) WIPER SWITCH ACTUATION, ON

2 272 (OR) WIPER SWITCH IGNITION B(+)
3 275 (WH) WIPER SWITCH ACTUATION, PARK
4 -
EATON_25--13936
5 -
WIPER SWITCH ACTUATION,
6 277 (WH) INTERMITTENT X135
7 273 (PU) BACKLIGHTING WIPER SWITCH
8 -
9 296 (BK) GROUND
10 -
CONNECTOR X136
FRONT LEFT SPEAKER
WIRE
A 983 (BL) FRONT LEFT SPEAKER (-)

B 977 (WH) FRONT LEFT SPEAKER (+)
PAC_12052832
X136
FRONT LEFT SPEAKER
CONNECTOR X137
DOOR SWITCH S40
WIRE
1 865 (YE) DOOR SWITCH SIGNAL
AMP_154719
X137
DOOR SWITCH
CONNECTOR X138
RIGHT CONSOLE LIGHT E35
WIRE

269, 973
2 (BK) GROUND
AMP_926522
X138
RIGHT CONSOLE LIGHT
55-78
CONNECTOR X139
FRONT RIGHT SPEAKER
WIRE
A 980 (BL) FRONT RIGHT SPEAKER (-)

B 976 (WH) FRONT RIGHT SPEAKER (+)
PAC_12052832
X139
FRONT RIGHT SPEAKER
CONNECTOR X141
TRANSCEIVER
WIRE
1 281 (BK) GROUND

2 083 (OR) IGNITION B+
AMP_926522
X141
TRANSCEIVER
CONNECTOR X142
G.P.S. UNIT A11
WIRE
1 903 (OR) B+ IGNITION

2 999 (YE) CAN HI
3 282 (BK) GROUND DEUTSCH_DT06--4S_PLUG
4 996 (GN) CAN LO
X142
G.P.S. UNIT
CONNECTOR X143
SEPARATOR BLOWER M18
WIRE
1 926 (WH) SEPARATOR BLOWER ACTUATION

X143
SEPARATOR BLOWER
CONNECTOR X144
SEPARATOR BLOWER M18
WIRE
1 933 (BK) SEPARATOR BLOWER GROUND

X144
SEPARATOR BLOWER
55-79
CONNECTOR X145
GROUND, 3, AC
WIRE
933 (BK) SEPARATOR BLOWER M18

948 (BK) MAIN BLOWER M17 X145
GROUND
CONNECTOR X146
AMBIENT TEMP SENSOR B25
(ATC ONLY)
WIRE
1 909 (BL) AMBIENT TEMP SENSOR GROUND

2 910 (YE) AMBIENT TEMP SENSOR SIGNAL
X146
AMBIENT TEMP SENSOR
(ATC ONLY)
CONNECTOR X147
COLD BOX DOOR M15 (ATC ONLY)
WIRE
A 920 (OR) B+
B -
C 918 (BK) GROUND
D 919 (YE) COLD BOX DOOR SIGNAL
E -
F - PAC_12052848
X147
COLD BOX DOOR
(ATC ONLY)
CONNECTOR X148
OUTLET TEMP SENSOR B27 (ATC ONLY)
WIRE
1 911 (BL) OUTLET TEMP SENSOR GROUND

2 912 (YE) OUTLET TEMP SENSOR SIGNAL
X148
OUTLET TEMP SENSOR
(ATC ONLY)
55-80
CONNECTOR X149
(ATC ONLY)
WIRE
CAB TEMPERATURE SENSOR

1 913 (BL) GROUND
2 914 (YE) SIGNAL DEUTSCH_DT06--2S_PLUG
X149
(ATC ONLY)
CONNECTOR X150
EVAPORATOR PROBE B28 (ATC ONLY)
WIRE
1 907 (BL) EVAPORATOR PROBE GROUND

2 908 (YE) EVAPORATOR PROBE SIGNAL
X150
AMBIENT TEMP SENSOR
(ATC ONLY)
CONNECTOR X151
WATER VALVE M16
WIRE
A 924 (OR) SWITCHED (B+)

B -
C 922 (BK) GROUND
D 923 (YE) WATER VALVE SIGNAL
E -
F - PAC_12052848
X151
WATER VALVE
55-81
CONNECTOR X152
MAIN BLOWER M17
WIRE
1 928 (WH) MAIN BLOWER FEED, HIGH (K11)

2 929 (WH) MAIN BLOWER FEED, MED (K12)
3 946 (WH) MAIN BLOWER FEED, LOW (K13)
4 948 (BK) GROUND
DEUTSCH_DTP06--4S_PLUG
DEUTSCH_DTP04--4P_RECEPTACLE
X152
MAIN BLOWER
CONNECTOR X153
FREEZE SWITCH S53 (MANUAL A/C ONLY)
WIRE
1 907 (BL) FREEZE SWITCH GROUND
AMP_172076
X153
FREEZE SWITCH
(MANUAL A/C ONLY)
CONNECTOR X154
FREEZE SWITCH S53 (MANUAL A/C ONLY)
WIRE
1 908 (YE) FREEZE SWITCH SIGNAL

AMP_172076
X154
FREEZE SWITCH
(MANUAL A/C ONLY)
55-82
CONNECTOR X155
GROUND, MAIN BLOWER M17
WIRE
1 948 (BK) GROUND

AMP_154509
X155
GROUND
CONNECTOR X156
HIGH SPEED, MAIN BLOWER M17
WIRE
1 946 (RD) HIGH SPEED SIGNAL
AMP_172076
X156
HIGH SPEED
CONNECTOR X157
MEDIUM SPEED, MAIN BLOWER M17
WIRE
1 929 (OR) MEDIUM SPEED SIGNAL
AMP_172076
X157
MEDIUM SPEED
CONNECTOR X158
LOW SPEED, MAIN BLOWER M17
WIRE
1 928 (YE) LOW SPEED SIGNAL
AMP_172076
X158
LOW SPEED
CONNECTOR X159
DATA LOGGER A10
WIRE
1 831 (RD) DATA LOGGER B+

2 807 (YE) CAN HI
3 -
4 -
5 805 (OR) B+ IGNITION
6 854 (BK) GROUND
7 806 (GN) CAN LO
DATA LOGGER
55-83
CONNECTOR X160
LEFT FRONT HAZARD LIGHT E03
WIRE
A 624 (PU) MARKER LIGHT

B 615 (PU) HAZARD LIGHT
C 620 (BK) GROUND
X160
LEFT FRONT HAZARD LIGHT
CONNECTOR X161
LEFT FRONT SERVICE SOCKET J02
WIRE
A 647 (RD) UNSWITCHED (B+)

B 656 (BK) GROUND
PAC_2973781
X161
LEFT FRONT SERVICE SOCKET
CONNECTOR X162
LEFT HEADER LIGHT E21
WIRE
A 257 (PU) HEADER WORK LIGHTS RELAY K22

B 267 (BK) GROUND
PAC_12124819
X162
LEFT HEADER LIGHT
55-84
CONNECTOR X163
LEFT LOWER WORK LIGHT E23
WIRE
A 644 (PU) LOWER WORK LIGHTS RELAY K30

B 654 (BK) GROUND
PAC_12124819
X163
LEFT LOWER WORK LIGHT
CONNECTOR X164
LEFT ROAD LIGHT E13
WIRE
A 642 (BK) GROUND

B 638 (PU) LOW BEAM RELAY K05
C 640 (PU) HIGH BEAM RELAY K04
PAC_08917857
X164
LEFT ROAD LIGHT
CONNECTOR X165
RIGHT FRONT HAZARD LIGHT E04
WIRE
A 627 (PU) MARKER LIGHT

B 616 (PU) HAZARD LIGHT
C 621 (BK) GROUND
X165
RIGHT FRONT HAZARD LIGHT
55-85
CONNECTOR X166
RIGHT FRONT SERVICE SOCKET J01
WIRE
A 651 (RD) UNSWITCHED (B+)

B 660 (BK) GROUND
PAC_2973781
X166
RIGHT FRONT SERVICE SOCKET
CONNECTOR X167
RIGHT HEADER LIGHT E22
WIRE
A 258 (PU) HEADER WORK LIGHT RELAY K22

B 268 (BK) GROUND
PAC_12124819
X167
RIGHT HEADER LIGHT
CONNECTOR X168
RIGHT LOWER WORK LIGHT E24
WIRE
A 645 (PU) LOWER WORK LIGHT RELAY K30

B 655 (BK) GROUND
PAC_12124819
X168
RIGHT LOWER WORK LIGHT
CONNECTOR X169
RIGHT ROAD LIGHT E14
WIRE
A 643 (BK) GROUND

B 639 (PU) LOW BEAM RELAY K05
C 641 (PU) HIGH BEAM RELAY K04
PAC_08917857
X169
RIGHT ROAD LIGHT
55-86
CONNECTOR X170
LATERAL INCLINATION SENSOR B02
WIRE
A 451 (PK) 5V REF. VOLTAGE

B 462 (BL) REF. GROUND
C 430 (YE) X019 CCM-1 J2-33
X170
LATERAL INCLINATION SENSOR
CONNECTOR X171
WIPER WASHER MOTOR M24
WIRE
1 449 (BK) GROUND

2 278 (WH) WASHER SWITCH S38
AMP_926522
X171
WIPER WASHER MOTOR
CONNECTOR X172
HORN H02
WIRE
1 193 (WH) ROAD LIGHTS SWITCH S26
CONNECTOR X172
HORN H02
WIRE
AMP_154719
1 631 (BK) GROUND
X172
HORN
CONNECTOR X173
BRAKE PRESSURE S39
WIRE
1 497 (BK) GROUND
CONNECTOR X173
BRAKE PRESSURE S39
WIRE
AMP_154719
1 418 (YE) X016 CCM-2 J2-34
X173
BRAKE PRESSURE
55-87
CONNECTOR X174
FEEDER ANGLE R03
WIRE
1 756 (BL) REF. GROUND, X281 PIN 4

2 740 (YE) HHC MODULE A07, X281 PIN 14
3 751 (PK) 5V REF. VOLTAGE, X281 PIN 5
AMP_282191--1
X174
FEEDER ANGLE
CONNECTOR X175
GROUND, 2, MF
WIRE
BRAKE PRES SWITCH S39,

246 (BK) WASHER MOTOR M24
GRAIN TANK, UNLOAD TUBE
668 (BK) LIGHTING
676 (BK) LS ROAD/HAZARD LIGHTING
RS ROAD/HAZARD LIGHTING,
677 (BK) HORN H02
MAIN VALVE STACK, HHC MODULE
483 (BK) A07, FUEL PUMP M23
X019 CCM1 J2-12, 18, MODULE
GROUND; X019 CCM1 J2-3,
583 (BK) CONCAVE CLEARANCE M04, X175
BIN COVERS M12
FRONT GROUND
X016 CCM 2 J2-12, 18, MODULE
GROUND; X016 CCM2 J2-3,
584 (BK) THROTTLE M13, ROT SCR
BRUSH M27
2014 (BK) LS UNDERSHIELD LIGHTING
2015 (BK) RS UNDERSHIELD LIGHTING
CONNECTOR X177
ROTOR RPM B01
WIRE
1 495 (BL) REF. GROUND

2 416 (YE) X016 CCM-2 J2-37
X177
DRUM RPM
55-88
CONNECTOR X178
MIRROR SELECT SWITCH S-57
WIRE
1 963 (WH) TO GERMAN MIRROR UP/DOWN

MOTOR M-30
2 957 (WH) FROM MIRROR ADJUST SWITCH
S--27
3 2009 (PU) TO RH MIRROR UP/DOWN MOTOR EATON_25--13936
M-19
4 964 (WH) TO GERMAN MIRROR IN/OUT X178
MOTOR M-31
MIRROR SELECT SWITCH
5 960 (WH) FROM MIRROR ADJUST SWITCH
S-27
6 962 (WH) TO RH MIRROR IN/OUT MOTOR M-20
7 --
8 --
9 --
10 --
CONNECTOR X181
LEFT RETURNS RPM B06
WIRE

2 433 (YE) X019 CCM-1 J2-38
X181
LEFT RETURNS RPM
CONNECTOR X182
CLEAN GRAIN RPM B08
WIRE

2 450 (YE) X019 CCM1 J2-28
X182
CLEAN GRAIN RPM
CONNECTOR X183
FUEL PUMP M23
WIRE
A 856 (WH) FUEL PUMP RELAY K07

B 845 (BK) GROUND
PAC_15300027
X183
FUEL PUMP
55-89
CONNECTOR X184
FUEL LEVEL R01
WIRE

2 427 (YE) X016 CCM2 J2-17
X184
FUEL LEVEL
CONNECTOR X186
RIGHT RETURNS RPM B39
WIRE

2 441 (YE) X019 CCM1 J2-37
X186
RIGHT RETURNS RPM
CONNECTOR X188
RH ROTOR LOSS B20
WIRE

2 402 (YE) X016 CCM2 J2-26
X188
RH ROTOR LOSS
CONNECTOR X189
CONCAVE POSITION R06
WIRE

C 411 (YE) X019 CCM1 J2-19
PAC_12065287
X189
CONCAVE POSITION
55-90
CONNECTOR X190
CONCAVE MOTOR M04
WIRE
A 695 (WH) CONCAVE MOTOR INCREASE

B 694 (GY) CONCAVE MOTOR DECREASE
PAC_15300027
X190
CONCAVE MOTOR
CONNECTOR X191
LH ROTOR LOSS B19
WIRE

2 410 (YE) X016 CCM2 J2-25
X191
LH ROTOR LOSS
55-91
CONNECTOR X192
ECU CONNECTOR A (7.5L ONLY)
WIRE
1 826 (YE) FLYWHEEL RPM B43

2 893 (YE) FUEL INJECTOR PUMP L09
3 -
4 -
5 892 (BL) COOLANT TEMP B42
6 882 (BL) FUEL TEMPERATURE B40
7 -
8 -
GRID HEATER RELAY K37, COLD
9 813 (WH) START INDICATOR E36
10 890 (YE) AIR TEMP/BOOST PRESS B41
11 883 (YE) FUEL TEMPERATURE B40
12 889 (YE) AIR TEMP/BOOST PRESS B41 BOSCH 1928401982
13 823 (BL) FLYWHEEL RPM B43
14 884 (BL) FUEL INJECTION PUMP L09 X192
15 -
ECU CONNECTOR A
16 -
17 885 (BL) AIR TEMP/BOOST PRESS B41
18 -
19 -
20 -
21 -
22 891 (YE) COOLANT TEMP B42
23 888 (YE) AIR TEMP/BOOST PRESS B41
24 -
25 898 (WH) FUEL INJECTION PUMP L09
26 897 (WH) FUEL INJECTION PUMP L09 1
27 870 (GY) FUEL INJECTION PUMP L09
28 871 (GY) FUEL INJECTION PUMP L09
29 -
30 -
31 -
32 -
33 896 (BL) FUEL INJECTION PUMP L09
34 894 (YE) FUEL INJECTION PUMP L09 50014698
35 895 (YE) FUEL INJECTION PUMP L09 41
1. CONNECTOR X192 -- ECU CONNECTOR A
55-92
CONNECTOR X193
ECU CONNECTOR B
WIRE
1 815 (BK) GROUND

2 816 (BK) GROUND
ECU POWER RELAY K14 - MAIN
3 810 (WH) POWER
ECU POWER RELAY K14 - MAIN
4 811 (WH) POWER
5 -
6 -
7 -
8 -
9 -
GRIDHEATER RELAY K39 -
10 822 (BK) GROUND (IVECO ONLY)
BOSCH 1928401982
11 820 (GN) CAN LO
12 819 (YE) CAN HI
13 827 (YE) DAM CONNECTOR X065 PIN E X193
14 - ECU CONNECTOR B
KEY SWITCH S02, IGN
15 859 (OR) (SWITCHED B+)
16 -
17 -
18 -
19 -
20 -
21 -
22 -
23 -
24 -
25 -
26 -
ECU POWER RELAY K14 -
27 808 (YE) CONTROL
28 - 1
29 - 50014698
30 - 42
31 -
32 -
33 -
34 -
35 -
10010906
43
1. CONNECTOR X193 -- ECU CONNECTOR B (7.5L)
2. CONNECTOR X193 -- ECU CONNECTOR B
(IVECO)
55-93
CONNECTOR X194
SERVICE SOCKET J05
WIRE
A 659 (BK) GROUND

B 650 (RD) B+
PAC_2973781
X194
SERVICE SOCKET
CONNECTOR X195
COVERS CLOSED
WIRE
X020 CCM1 J3-38, COVERS

1 435 (YE) CLOSED B47
REF. GROUND, COVERS CLOSED
2 454 (BL) B47 DEUTSCH_DT04--4P_RECEPTACLE
3 693 (GY) COVERS MOTOR M12
4 696 (WH) COVERS MOTOR M12
X195
COVERS CLOSED
CONNECTOR X196
THROTTLE MOTOR (MECHANICAL) M13
WIRE
A 829 (WH) THROTTLE/BRUSH RELAY K15

B 828 (GY) X016 CCM2 J2-1
PAC_15300027
X196
THROTTLE MOTOR
55-94
CONNECTOR X197
IVECO ENGINE
WIRE
REF. GROUND, FUEL FILTER

1 852 (BL) SWITCH S62
2 -
3 -
4 853 (BL) REF. GROUND, ENG. OIL PRES. B52
X016 CCM-2 J2-31, 5V REF.
5 490 (PK) VOLTAGE
X016 CCM-2 J2-33, ENG. OIL PRES.
6 419 (YE) B52 AMP_174661--2
7 -
8 - X197
X016 CCM-2 J2-27, ENG. OIL TEMP. IVECO ENGINE
9 504 (YE) B03
10 850 (BL) REF. GROUND, ENG. OIL TEMP. B03
11 -
X016 CCM-2 J2-24, FUEL FILTER
1
10010908
44
1. CONNECTOR X197 -- EN TO IVECO W/H
CONNECTOR X198
SPLICE BLOCK F, BACKLIGHTING, RC
WIRE
A 288 (PU) HHC FINE ADJUST S06

B 289 (PU) REAR WHEEL ASSIST S10
C 290 (PU) DUAL RANGE S11
D 291 (PU) ON THE ROAD SWITCH S12
E 292 (PU) VERTICAL KNIVES S51
F 293 (PU) FEEDER REVERSER S07
G 249 (PU) ALTERNATE SETTINGS S21
H 329 (PU) X027 PIN 18, RHM PAC_15305291
J 396 (PU) REEL SPEED MODE S08
K 397 (PU) PARK BRAKE S09 X198
L 398 (PU) SPREADER PLATE S23 SPLICE BLOCK F
M -
55-95
CONNECTOR X199
START RELAY COIL K36
WIRE
1 092 (WH) NEUTRAL START RELAY K23

2 800 (BK) GROUND
AMP_926522
X199
START RELAY COIL
CONNECTOR X200
START RELAY
WIRE
50A 804 (OR) STARTER RELAY ACTUATION

51 801 (RD) STARTER RELAY B+
SPRING_SPADE
X200
START RELAY
CONNECTOR X201
ENGINE OIL PRESSURE B30
WIRE
A 853 (BL) REF GROUND

B 490 (PK) 5V REF. VOLTAGE
C 419 (YE) X016 CCM2 J2-33
PAC_12065287
X201
ENGINE OIL PRESSURE
CONNECTOR X202
AIR FILTER B07
(SN HAJ100072 AND BELOW)
WIRE
A 851 (BL) REF. GROUND

C 420 (YE) X016 CCM2 J2-29
PAC_12065287
X202
AIR FILTER
55-96
CONNECTOR X202
AIR FILTER S61
(SN HAJ100073 AND ABOVE)
WIRE

X016 CCM2 J2-29; AIR FILTER
2 864 (YE) RESISTOR R15
AMP_282189--1
X202
AIR FILTER
CONNECTOR X203
FUEL INJECTION PUMP L09
(ELECTRONIC 7.5L ONLY)
WIRE
1 896 (BL) X192 PIN 33

2 -
3 893 (YE) X192 PIN 3
4 884 (BL) X192 PIN 14
5 894 (YE) X192 PIN 34
6 895 (YE) X192 PIN 35 SCHL_9800617
7 899 (WH) X192 PIN 25, 26
8 812 (GY) X192 PIN 27, 28 X203
FUEL INJECTION PUMP
CONNECTOR X204
STARTER MOTOR M01
WIRE
801 (RD) START RELAY K36

802 (RD) ALTERNATOR B+
X204
STARTER MOTOR
CONNECTOR X205
STARTER SOLENOID M01
WIRE
804 (OR) START RELAY K36

FUEL SOLENOID L02
837 (WH) (7.5L MECH ONLY)
X205
STARTER SOLENOID
55-97
CONNECTOR X206
ROTARY SCREEN BRUSH M27
WIRE
A 821 (WH) THROTTLE/BRUSH RELAY K15

B 524 (GY) X016 CCM2 J2-1
PAC_15300027
X206
ROTARY SCREEN BRUSH
CONNECTOR X207
FLYWHEEL RPM B43
WIRE
1 824 (BL) REF. GROUND, X192, PIN 1

2 826 (YE) X192 PIN 13
AMP_282191--1
X207
FLYWHEEL RPM
CONNECTOR X208
GROUND, 5, EN
WIRE
659 (BK) ENGINE SERVICE SOCKET J05

800 (BK) START RELAY K36
815 (BK) ECU, X193, PIN 1
816 (BK) ECU, X193, PIN 2
822 (BK) GRID HEATER RELAY K37 X208
838 (BK) FUEL SOLENOID L02
ENGINE GROUND
803 (BK) ALTERNATOR G01
637 (BK) A/C CLUTCH L07
CONNECTOR X209
ENGINE OIL TEMPERATURE B03
WIRE
1 504 (YE) X016 CCM2 J2-27
AMP_154719
X209
ENGINE OIL TEMPERATURE
55-98
CONNECTOR X210
AMBIENT TEMPERATURE/
BOOST PRESSURE B41
WIRE
1 885 (BL) REF. GROUND, X192 PIN 17

2 890 (YE) X192 PIN 10, AMBIENT TEMP.
3 888 (PK) REF. VOLTAGE, X192 PIN 23
4 889 (YE) X192 PIN 12, BOOST PRES. BOSCH 1928403112
X210
AMBIENT TEMPERATURE/BOOST
PRESSURE
CONNECTOR X211
GRID HEATER RELAY K37/K39
WIRE
X015 CCM2 J1-12 (7.5L MECH.)

A 818 (WH) X192 PIN 9, ECU (7.5L ELEC.)
ECU POWER RELAY K14 (IVECO)
GROUND (7.5L);
B 822 (BK) X193 PIN 10, ECU (IVECO)
BOSCH 1928403112
X211
GRID HEATER RELAY
CONNECTOR X212
FUEL TEMPERATURE B40
WIRE
1 -
3 883 (YE) X192, PIN 11 BOSCH_0--281--002--135
X212
FUEL TEMPERATURE
55-99
CONNECTOR X213
ALTERNATOR G01
WIRE
803, 673
(BK) GROUND
CONNECTOR X213
X213
ALTERNATOR G01
CAV
WIRE
CIRCUIT REFERENCE
ALTERNATOR
NUMBER
802 (RD) B+
CONNECTOR X213
ALTERNATOR G01
WIRE
X016 CCM2 J2-36 (ENG. RPM,

421 (YE) 7.5L MECH. ONLY)
CONNECTOR X214
COOLANT TEMPERATURE B31/B42
WIRE
X192 PIN 5, ECU (ELEC.);

1 891 (YE) X016 CCM2 J2-24 (7.5L MECH.)
BOSCH 1928404655
X214
COOLANT TEMPERATURE
CONNECTOR X215
A/C CLUTCH L07
WIRE
A 178 (WH) A/C CLUTCH RELAY K10

B 673 (BK) GROUND
PAC_12015791
X215
A/C CLUTCH
55-100
CONNECTOR X216
A/C HIGH PRESSURE S47
WIRE
1 917 (YE) X128 PIN D-4, HVAC MODULE A09

GROUND, X128 PIN D-3, HVAC
2 925 (BL) MODULE A09
PAC_12065863
X216
A/C HIGH PRESSURE
CONNECTOR X217
A/C LOW PRESSURE S48
WIRE
1 915 (YE) X128 PIN D-2, HVAC MODULE A09

GROUND, X128 PIN D-3, HVAC
2 927 (BL) MODULE A09
PAC_12015792
X217
A/C LOW PRESSURE
CONNECTOR X218
FLIP-UP KIT
WIRE
1 637 (PU) RH MARKER LIGHTS FUSE F21

GROUND (THROUGH X032 HEADER
2 776 (BK) CONNECTOR)
X218
FLIP-UP KIT
55-101
CONNECTOR X219
EXPANSION B/MAIN FRAME B
WIRE
1 786 (WH) UPPER/LOWER SIEVE RELAY B+

UPPER/LOWER SIEVE RELAY N/O
2 790 (WH) OUTPUT
UPPER/LOWER SIEVE RELAY N/C DEUTSCH_DT04--6P_RECEPTACLE
3 792 (WH) OUTPUT
4 -
X219
5 -
6 -
EXPANSION B
X219
MAIN FRAME B
CONNECTOR X220
FRONT GROUND, 2, EX
WIRE
X013 CCM3 J2-3, SIEVE

520 (BK) ACTUATORS M06, M07
X014 CCM3 J3-16, SPREADER
521 (BK) PLATE MOTOR M11
MOISTURE SENSOR B12, SAMPLE
543 (BK) MOTOR M28, REAR SIEVE ADJ X220
SW’S S35, S46
536 (BK) X014 CCM3 J3-9
FRONT GROUND
537 (BK) X014 CCM3 J3-10
X013 CCM3 J2-12, MODULE
690 (BK) GROUND
X013 CCM3 J2-18, MODULE
691 (BK) GROUND
CONNECTOR X221
MOISTURE SENSOR B12
WIRE
1 699 (OR) SWITCHED B+, FUSE F47

2 565 (BK) GROUND
3 593 (YE) X014 CCM3 J3-17
4 594 (YE) X014 CCM3 J3-23
5 595 (YE) X014 CCM3 J3-34
6 - X221
MOISTURE SENSOR
55-102
CONNECTOR X222
SAMPLE MOTOR M28
WIRE
1 682 (OR) SWITCHED B+, FUSE 47

2 564 (BK) GROUND
3 838 (YE) X013 CCM3 J2-25 DEUTSCH_DT06--4S_PLUG
4 837 (WH) X013 CCM3 J2-13
X222
SAMPLE MOTOR
CONNECTOR X223
YIELD SENSOR R05
WIRE
A 698 (OR) SWITCHED B+, FUSE 47

B 563 (BL) REF. GROUND, X014 CCM3 J3-18
C 552 (YE) X014 CCM3 J3-32
X223
YIELD SENSOR
CONNECTOR X224
SPREADER PLATE MOTOR M11
WIRE

C 477 (YE) X013 CCM3 J2-33
D 510 (WH) X014 CCM3 J3-8
E 509 (GY) X014 CCM3 J3-6
PAC_12084891
X224
SPREADER PLATE MOTOR
CONNECTOR X225
UPPER SIEVE ADJUST S35
WIRE
1 540 (YE) X013 CCM3 J2-34; DECR

2 550 (BK) GROUND
3 539 (YE) X013 CCM3 J2-17; INCR
DEUTSCH_DTM04--3P_RECEPTACLE
X225
UPPER SIEVE ADJUST
55-103
CONNECTOR X226
LOWER SIEVE ADJUST S46
WIRE
1 542 (YE) X013 CCM3 J2-39; DECR

2 551 (BK) GROUND
3 541 (YE) X013 CCM3 J2-35; INCR
DEUTSCH_DTM04--3P_RECEPTACLE
X226
LOWER SIEVE ADJUST
CONNECTOR X227
UPPER SIEVE MOTOR M06
WIRE

C 475 (YE) X013 CCM3 J2-2
D 792 (WH) UPPER/LOWER SIEVE RELAY K18
E 791 (GY) X013 CCM3 J2-1
PAC_12146045
X227
UPPER SIEVE MOTOR
CONNECTOR X228
LOWER SIEVE MOTOR M07
WIRE

C 476 (YE) X013 CCM3 J2-19
D 790 (WH) UPPER/LOWER SIEVE RELAY K18
E 789 (GY) X013 CCM3 J2-1
PAC_12146045
X228
LOWER SIEVE MOTOR
CONNECTOR X231
GROUND, 1, SW
WIRE
REAR BEACON LIGHT E33, BACKUP

478 (BK) ALARM H08
CHAFF SPDR L28, FILTER SW’S,
479 (BK) SIEVE LT E37
REAR MARKER, TAIL, HAZARD
628 (BK) LIGHTS X231
657 (BK) LH SERVICE SOCKET J04 FRONT GROUND
672 (BK) REAR WORK LIGHTS E27, E28
55-104
CONNECTOR X232
SIEVES LOSS B21
WIRE

2 431 (YE) X019 CCM1 J2-25
X232
SIEVES LOSS
CONNECTOR X233
RWA SOLENOID L26
WIRE
A 569 (WH) X019 CCM1 J2-16

B 602 (BK) GROUND
PAC_12015792
X233
RWA SOLENOID
CONNECTOR X234
SIEVE LIGHT E37
WIRE
A 610 (PU) SIEVE LIGHT SWITCH S54

B 611 (BK) GROUND
PAC_12124819
X234
SIEVE LIGHT
CONNECTOR X235
CHAFF SPREADER SOLENOID L28
WIRE
A 576 (WH) X019 CCM1 J2-15

B 577 (BK) GROUND
X235
CHAFF SPREADER SOLENOID
55-105
CONNECTOR X236
LEFT SERVICE SOCKET J04
WIRE
A 657 (BK) GROUND

B 648 (RD) B+
PAC_2973781
X236
LEFT SERVICE SOCKET
CONNECTOR X237
SIEVE LIGHT SWITCH S54
WIRE
1 -
2 604 (OR) B+
3 610 (PU) SIEVE LIGHT E37
4 -
EATON_25--13936
5 -
6 -
X237
7 -
8 - SIEVE LIGHT SWITCH
9 -
10 -
CONNECTOR X238
GEARBOX FILTER BYPASS S34
WIRE
A 484 (BK) GROUND

B 448 (YE) X019 CCM1 J2-35
PAC_12015792
X238
GEARBOX FILTER BYPASS
CONNECTOR X239
RETURNS FILTER BYPASS S32
WIRE
A 603 (BK) GROUND

B 447 (YE) X019 CCM1 J2-34
PAC_12015792
X239
RETURNS FILTER BYPASS
55-106
CONNECTOR X240
SWATH PLATE POSITION
WIRE
1 482 (BL) GROUND

2 415 (YE) SWATH PLATE POSITION SIGNAL
X240
SWATH PLATE POSITION
CONNECTOR X243
LEFT TAIL LIGHT
WIRE
1 629 (PU) BRAKE LIGHTS RELAY K33

2 412 (PU) LH MARKER LIGHTS
3 619 (PU) LH HAZARD LIGHTS
4 634 (BK) GROUND
5 243 (PU) LH NASO FLASHING LAMP E07
LEFT TAIL LIGHT
CONNECTOR X244
UNLOAD CRADLE B38
WIRE

2 485 (YE) X020 CCM1 J3-36
X244
UNLOAD CRADLE
CONNECTOR X246
RIGHT TAIL LIGHT
WIRE
1 630 (PU) BRAKE LIGHTS RELAY K33

2 421 (PU) RH MARKER LIGHTS
3 622 (PU) RH HAZARD LIGHTS
4 635 (BK) GROUND
5 244 (PU) RH NASO FLASHING LAMP E08
RIGHT TAIL LIGHT
55-107
CONNECTOR X247
REAR BEACON LIGHT E-33
WIRE
1 578 (PU) POWER FROM BEACON LIGHT

RELAY K-29
2 623 (BK) TO REAR FRAME GROUND 1
X247
BEACON LT
CONNECTOR X248
BACK UP ALARM H-08
WIRE
452 (WH) SIGNAL FROM CCM-1 J2-6
CONNECTOR X248
BACK UP ALARM H-08 SPRING_SPADE
WIRE
CAV NUMBER CIRCUIT REFERENCE X248
455 (BK) TO REAR FRAME GROUND 1 BACK-UP ALARM
CONNECTOR X251
REAR LADDER B22
WIRE

2 570 (YE) X019 CCM1 J2-17
X251
REAR LADDER
CONNECTOR X252
RIGHT SERVICE SOCKET J03
WIRE
A 658 (BK) GROUND

B 678 (RD) B+
PAC_2973781
X252
RIGHT SERVICE SOCKET
55-108
CONNECTOR X253
CHOPPER RPM B10
WIRE

2 413 (YE) X016 CCM2 J2-38
X253
CHOPPER RPM
CONNECTOR X255
FLASHER MODULE A05
WIRE
1 102 (RD) B(+)

2 179 (PU) HAZARD SWITCH S25
3 199 (PU) LH FLASHING LIGHTS
5 208 (PU) INDICATOR LIGHT E10
6 141 (BK) GROUND
7 201 (PU) ROAD LIGHT SW. S26; RIGHT TURN
8 197 (PU) ROAD LIGHT SW. S26; LEFT TURN
9 204 (PU) ISO/NASO SELECTION
10 243 (PU) LH NASO FLASHING LIGHT E07 X255
11 244 (PU) RH NASO FLASHING LIGHT E08 FLASHER MODULE
12 -
CONNECTOR X256
ROAD LIGHTS SWITCH S26
WIRE
LIGHT CONTROL RELAY, K02,

1 173 (OR) MARKER LIGHTS
2 203 (PU) RIGHT TURN
3 202 (PU) LEFT TURN
4 218 (YE) HIGH BEAM RELAY K04
5 213 (OR) FUSE, F-51
6 055 (OR) KEY SWITCH S02, IGNITION AMP_1--480706--O
7 169 (YE) LOW BEAM RELAY, K05
8 214 (RD) FUSE, F51 X256
9 193 (WH) HORN, H02
ROAD LIGHTS SWITCH
55-109
CONNECTOR X257
TURN INDICATOR E09
WIRE
1 -
2 -
3 -
4 -
EATON_25--13936
5 -
6 -
X257
7 140 (PU) LH FLASHING LIGHTS
8 - TURN INDICATOR
9 209 (BK) GROUND
CONNECTOR X258
HIGH BEAM/TRAILER E10
WIRE
1 -
2 -
3 -
4 -
EATON_25--13936
5 -
6 -
X258
7 208 (PU) FLASHER MODULE A05, X255 PIN 5
8 - HIGH BEAM/TRAILER
9 221 (BK) GROUND
10 043 (PU) ROAD LIGHTS SW. S26; HIGH BEAM
CONNECTOR X259
HAZARD SWITCH S25
WIRE
1 -
2 040 (RD) FUSE F56
X015 CCM2 J1-15; FLASHER
3 207 (PU) MODULE A05, X255 PIN 2
4 - EATON_25--13936
5 -
6 - X259
7 - HAZARD SWITCH
8 -
9 220 (BK) GROUND
10 -
55-110
CONNECTOR X260
ASP TOP SENSORS
WIRE
1 988 (YE) RH TOP ASP SENSOR B50

2 989 (BL) RH TOP ASP SENSOR B50
3 990 (YE) LH TOP ASP SENSOR B51 DEUTSCH_DT06--4S_PLUG
4 991 (BL) LH TOP ASP SENSOR B51
X260
ASP TOP SENSORS
CONNECTOR X261
ASP BOTTOM SENSORS
WIRE
1 984 (YE) RH BOTTOM ASP SENSOR B48

2 985 (BL) RH BOTTOM ASP SENSOR B48
3 986 (YE) LH BOTTOM ASP SENSOR B49
4 987 (BL) LH BOTTOM ASP SENSOR B49
X261
ASP BOTTOM SENSORS
CONNECTOR X262
LH BOTTOM ASP SENSOR B49
WIRE
1 986 (YE) X086 PIN 3

2 987 (BL) X086 PIN 6
3 -
AMP_282191--1
X262
LH BOTTOM ASP SENSOR
CONNECTOR X263
RH BOTTOM ASP SENSOR B48
WIRE
1 984 (YE) X086 PIN 4

2 985 (BL) X086 PIN 5
3 -
AMP_282191--1
X263
RH BOTTOM ASP SENSOR
55-111
CONNECTOR X264
RH TOP ASP SENSOR B50
WIRE
1 988 (YE) X086 PIN 2

2 989 (BL) X086 PIN 7
3 -
AMP_282191--1
X264
RH TOP ASP SENSOR
CONNECTOR X265
LH TOP ASP SENSOR B51
WIRE
1 990 (YE) X086 PIN 1

2 991 (BL) X086 PIN 8
3 -
AMP_282191--1
X265
LH TOP ASP SENSOR
CONNECTOR X266
FEEDER REVERSE L21
WIRE
1 562 (WH) X020 CCM1 J3-15

2 591 (BK) GROUND
AMP_282189--1
X266
FEEDER REVERSE
CONNECTOR X267
LATERAL FLOAT CW L18
WIRE
1 549 (WH) X281 PIN 8, HHC MODULE A07

AMP_282189--1
X267
LATERAL FLOAT CW
55-112
CONNECTOR X268
REEL AFT L15
WIRE
1 559 (WH) X017 CCM2 J3-5

2 588 (BK) GROUND
AMP_282189--1
X268
REEL AFT
CONNECTOR X269
REEL DOWN L13
WIRE
1 557 (WH) X017 CCM2 J3-4

2 586 (BK) GROUND
AMP_282189--1
X269
REEL DOWN
CONNECTOR X270
FEEDER FORWARD L20
WIRE
1 561 (WH) X020 CCM1 J3-5

2 590 (BK) GROUND
AMP_282189--1
X270
FEEDER FORWARD
CONNECTOR X271
LATERAL FLOAT CCW L19
WIRE

AMP_282189--1
X271
LATERAL FLOAT CCW
55-113
CONNECTOR X272
REEL FORE L16
WIRE
1 560 (WH) X017 CCM2 J3-1

2 589 (BK) GROUND
AMP_282189--1
X272
REEL FORE
CONNECTOR X273
REEL UP L14
WIRE
1 558 (WH) X017 CCM2 J3-3

2 587 (BK) GROUND
AMP_282189--1
X273
REEL UP
CONNECTOR X274
REEL DRIVE L17
WIRE
1 556 (WH) X017 CCM2 J3-2

2 585 (BK) GROUND
AMP_282189--1
X274
REEL DRIVE
CONNECTOR X275
ROTOR INCREASE L29
WIRE
1 566 (WH) X016 CCM2 J2-7

2 596 (BK) GROUND
AMP_282189--1
X275
DRUM DECREASE
55-114
CONNECTOR X276
UNLOAD TUBE IN L03
WIRE
1 574 (WH) X016 CCM2 J2-6

2 599 (BK) GROUND
AMP_282189--1
X276
UNLOAD TUBE IN
CONNECTOR X277
UNLOAD TUBE OUT L04
WIRE
1 573 (WH) X016 CCM2 J2-16

2 598 (BK) GROUND
AMP_282189--1
X277
UNLOAD TUBE OUT
CONNECTOR X278
ROTOR DECREASE L30
WIRE
1 567 (WH) X016 CCM2 J2-8

2 597 (BK) GROUND
AMP_282189--1
X278
ROTOR INCREASE
CONNECTOR X279
HDR HEIGHT PRESSURE B29
WIRE

2 722 (YE) X281 PIN 9, HHC MODULE A07
AMP_282189--1
X279
HDR HEIGHT
55-115
CONNECTOR X280
ACCUMULATOR L06
WIRE

2 760 (BK) GROUND
AMP_282189--1
X280
ACCUMULATOR
CONNECTOR X281
HHC MODULE A07
WIRE
1 759 (WH) ACCUMULATOR SOLENOID L06

2 013 (OR) SWITCHED (B+)
3 438 (BK) GROUND
6 545 (BK) CAN LO
7 548 (WH) LATERAL FLOAT CCW L19
8 549 (WH) LATERAL FLOAT CW L18
HDR HEIGHT PRESSURE
9 722 (YE) SENSOR B29 BOSCH 1928404201
10 -
11 -
12 544 (RD) CAN HI
LATERAL FLOAT SOLENOID
13 555 (BL) GROUND
14 740 (YE) FEEDER ANGLE R03
X281
15 738 (YE) LEFT STUBBLE HEIGHT R12 HHC MODULE
16 739 (YE) RIGHT STUBBLE HEIGHT R13
CONNECTOR X282
FEEDER DECREASE L12
WIRE
1 581 (WH) X019 CCM1 J2-8

2 608 (BK) GROUND
AMP_282189--1
X282
FEEDER DECREASE
55-116
CONNECTOR X283
FEEDER INCREASE L11
WIRE
1 582 (WH) X019 CCM1 J2-7

2 609 (BK) GROUND
AMP_282189--1
X283
FEEDER INCREASE
CONNECTOR X284
FEEDER RPM B14
WIRE

2 489 (YE) X020 CCM1 J3-14
X284
FEEDER RPM
CONNECTOR X285
TRAILER HITCH
WIRE
1 997 (PU) BRAKE LAMPS

2 992 (PU) LEFT TURN/HAZARD LAMPS
3 993 (PU) RIGHT TURN/HAZARD LAMPS
4 994 (PU) LEFT TAIL LAMPS
5 995 (PU) RIGHT TAIL LAMPS
6 998 (BK) GROUND
X285
TRAILER HITCH
55-117
CONNECTOR X286
24 VOLT START RELAY K38
(IVECO CURSOR ONLY)
WIRE
START RELAY K36

50A 804 (OR) (SN HAJ101500 AND BELOW)
START RELAY K36
50A 092 (WH) (SN HAJ101501 AND ABOVE)
24V STARTER MOTOR M29 - RING_TERMINAL
50 834 (WH) SOLENOID
X286
30 802 (RD) ALTERNATOR G01
START RELAY K36 24 VOLT START RELAY
51 801 (RD) (SN HAJ101500 AND BELOW)
50 50A
30A 51
31
31A
30
10035345
45
CONNECTOR X287
GERMAN THIRD MIRROR
WIRE
1 964 (OR) MIRROR SELECT SWITCH S57

2 966 (GY) MIRROR ADJUST SWITCH S27
4 963 (WH) MIRROR SELECT SWITCH S57 DEUTSCH_DT04--6P_RECEPTACLE
5 -
GERMAN THIRD MIRROR
CONNECTOR X288
COVERS POSITION B-47
WIRE
1 454 (BL) REFERENCE GROUND TO CCM1

J2-14
2 435 (YE) SIGNAL TO CCM1 J3-38
X288
COVERS POSITION
55-118
CONNECTOR X289
COVERS ACTUATOR M-12
WIRE
A 696 (WH) POWER FROM CCM1 J2-21

THROUGH CONCAVE/COVERS
RELAY K-16
B 693 (GY) POWER FROM CCM1 J2-1
PAC_15300027
X289
COVERS ACTUATOR
CONNECTOR X290
FUEL SOLENOID L02
WIRE
A 571 (WH) X016 CCM2 J2-13

B 837 (WH) STARTER SOLENOID M01
C 838 (BK) ENGINE GROUND
X290
FUEL SOLENOID
CONNECTOR X291
CAN NODE (7.5L MECH. ONLY)
WIRE
A 819 (YE) CAN HI

B 820 (GN) CAN LO
C -
X291
CAN NODE
CONNECTOR X292
STONE DOOR OPEN L31
WIRE
1 731 (WH) X082 PIN 2, ASD MODULE A08

2 732 (BK) X082 PIN 8, ASD MODULE A08
AMP_282189--1
X292
STONE DOOR OPEN
55-119
CONNECTOR X293
DUAL RANGE SOLENOID L27
WIRE
X020 CCM1 J3-3, DUAL RANGE

2 764 (BK) DUAL RANGE SOLENOID GROUND PAC_12010793
X293
DUAL RANGE SOLENOID
CONNECTOR X294
LH BRAKE GROUND
WIRE
1 866 (BK) LH BRAKE GROUND

X294
LH BRAKE GROUND
CONNECTOR X295
RH BRAKE GROUND
WIRE
1 867 (BK) RH BRAKE GROUND

X295
RH BRAKE GROUND
CONNECTOR X296
DOME LIGHT POWER E-34
WIRE
965 (RD) POWER FROM FUSE F-52

AMP_154719
X296
DOME LIGHT POWER
CONNECTOR X314
FM RADIO “B”
WIRE
1 -
2 -
3 -
4 830 RD KEEP ALIVE POWER, B+, FUSE F35
5 -
6 -
7 081 OR RADIO POWER, B+, FUSE F11 AMP_962189--1
8 973 BK RADIO GROUND TO CAB ROOF #4
X314
FM RADIO “B”
55-120
CONNECTOR X315
FM RADIO “C”
WIRE
1 974 WH REAR RIGHT SPEAKER, SUPPLY

2 979 BL REAR RIGHT SPEAKER, GROUND
3 976 WH FRONT RIGHT SPEAKER, SUPPLY
4 980 BL FRONT RIGHT SPEAKER, GROUND
5 977 WH FRONT LEFT SPEAKER, SUPPLY
6 983 BL FRONT LEFT SPEAKER, GROUND
7 975 WH REAR LEFT SPEAKER, SUPPLY AMP_962191--1
8 982 BL REAR LEFT SPEAKER, GROUND
X315
FM RADIO “C”
CONNECTOR X316
CENTER WORK LT E38
WIRE
1 210 (PU) HEADER WORK LIGHT RELAY K22

2 234 (BK) GROUND
X316
CENTER WORK LT
CONNECTOR X321
GPS ANTENNA A-11
WIRE
1 1238 (OR) POWER FROM FUSE F-45

2 1240 (YE) CAN HIGH
3 1239 (BK/ TO BATTERY CLEAN GROUND 6 DEUTSCH_DT04--4P_RECEPTACLE
WH)
4 1241 (GN) CAN LOW
X321
GPS ANTENNA
CONNECTOR X322
UNLOAD TUBE WORK LT E29
WIRE
A 077 (PU) UNLOAD TUBE LIGHT RELAY K32

B 669 (BK) GROUND
PAC_12124819
X322
UNLOAD TUBE WORK LT
55-121
CONNECTOR X323
UNLOAD TUBE MARKER LT E39
WIRE
1 530 (PU) MARKER LIGHTS, FUSE F20

2 531 (BK) GROUND
AMP_282080--1
X323
UNLOAD TUBE MARKER LT
CONNECTOR X326
HID DISTANCE LT
WIRE
A 210 (WH) POWER FROM ROAD LIGHTS

RELAY K-27
PAC_12059181
B 234 (BK) TO WORK LIGHT SWITCH S-43 TO
CAB ROOF GROUND 4
X326
HID DISTANCE LT
CONNECTOR X327
BRAKE FLUID LEVEL S49
WIRE
1502 (BK)
122 (BK) GROUND
AMP_154719
1501 (YE) X019 CCM1 J2-26
X327
BRAKE FLUID LEVEL
CONNECTOR X329
BRAKE LIMITING VALVE L-32
WIRE
A 1504 (WH) POWER FROM CCM2 J2-7

B 1505 (BK) TO FRONT FRAME GROUND 2
PAC_12015792
X329
BRAKE LIMITING VALVE
CONNECTOR X330
AIR FILTER RESISTOR R15
WIRE

AIR FILTER SWITCH S61; X016
B 860 (YE) CCM2 J2-29
X330
AIR FILTER RESISTOR
55-122
CONNECTOR X331
FLIP UP LOW BEAM RELAY K-40
WIRE
1 1509 (PU) POWER FROM ROAD LIGHT

SWITCH S-26 THROUGH FUSE F-21
2 1510 (BK) TO FRONT FRAME GROUND 2
THROUGH HEADER CONNECTOR
X032
3 1518 (PU) POWER FROM LOW BEAM RELAY PAC_12065685
K-05 THROUGH ROAD LIGHT
CONNECTORS X164 & X169
4 1515 (PU) OUTPUT TO ROAD LIGHTS E-13 & X331
E14
FLIP UP LOW BEAM RELAY
5 1512 (PU) OUTPUT TO FLIP UP ROAD LIGHTS
E-47 & E-48
CONNECTOR X332
FLIP UP HIGH BEAM RELAY K-41
WIRE

THROUGH HEADER CONNECTOR
X032
3 1527 (PU) POWER FROM HIGH BEAM RELAY PAC_12065685
K-04 THROUGH ROAD LIGHT
4 1524 (PU) OUTPUT TO ROAD LIGHTS E-13 & X332
E14
FLIP UP HIGH BEAM RELAY
5 1521 (PU) OUTPUT TO FLIP UP ROAD LIGHTS
E-47 & E-48
CONNECTOR X333
LH FLIP UP ROAD LT E-47
WIRE
1 1513 (PU) POWER FROM FLIP UP LOW BEAM

RELAY K-40
2 1523 (PU) POWER FROM FLIP UP HIGH BEAM DEUTSCH_DT06--4S_PLUG
RELAY K-41
THROUGH ROAD LIGHT X333
CONNECTORS X164 &X169
LH FLIP UP ROAD LT
CONNECTOR X334
RH FLIP UP ROAD LT E-48
WIRE
1 1514 (PU) POWER FROM FLIP UP LOW BEAM

RELAY K-40
2 1522 (PU) POWER FROM FLIP UP HIGH BEAM DEUTSCH_DT06--4S_PLUG
RELAY K-41
LH FLIP UP ROAD LT
55-123
CONNECTOR X335
LH ROAD LT E-13
WIRE
A 1525 (PU) POWER FROM FLIP UP HIGH BEAM

RELAY K-41
B 1516 (PU) POWER FROM FLIP UP LOW BEAM
RELAY K-40 PAC_02965810
C 1532 (BK) TO FRONT FRAME GROUND 2
LH ROAD LT
CONNECTOR X336
RH ROAD LT E-14
WIRE
A 1526 (PU) POWER FROM FLIP UP HIGH BEAM

RELAY K-41
B 1517 (PU) POWER FROM FLIP UP LOW BEAM
RELAY K-40 PAC_02965810
RH ROAD LT
CONNECTOR X339
LEFT LIGHT SWITCH S-63
WIRE
1 -
2 1214 (RD) POWER FROM FUSE F-34
3 2004 (PU) POWER TO LEFT UNDER SHIELD
LIGHTS E-42 & E-43
EATON_25--13936
4 -
5 -
X339
6 -
7 -
LEFT LIGHT SWITCH
8 -
9 -
10 -
CONNECTOR X340
ENGINE LIGHT SWITCH S-64
WIRE
1 -
3 2009 (PU) POWER TO ENGINE LIGHT E-46
4 - EATON_25--13936
5 -
6 - X340
7 -
ENGINE LIGHT SWITCH
8 -
9 -
10 -
55-124
CONNECTOR X341
RIGHT LIGHT SWITCH S-65
WIRE
1 -
3 2010 (PU) POWER TO RIGHT UNDER SHIELD
LIGHTS E-44 & E-45 EATON_25--13936
4 -
5 -
X341
6 -
7 -
RIGHT LIGHT SWITCH
8 -
9 -
10 -
CONNECTOR X342
LH SHIELD LTS
WIRE
A 1214 (RD) FUSE F34

B 2014 (BK) GROUND
PAC_12015792
X342
LH SHIELD LTS
CONNECTOR X343
RH SHIELD LTS
WIRE
A 1215 (RD) FUSE F34

B 2015 (BK) GROUND
PAC_12015792
X343
RH SHIELD LTS
CONNECTOR X344
RIGHT SHIELD LIGHTS
WIRE
A 2009 (PU) POWER TO ENGINE LIGHT E-46

B 2013 (BK) GROUND FOR ENGINE LIGHT E-46 PAC_12010973
THROUGH X343 TO FRONT FRAME
GROUND 2
PAC_12015792
X344
RIGHT SHIELD LIGHTS
55-125
CONNECTOR X345
LEFT FRONT LIGHT E-42
WIRE
A 2005 (PU) POWER FROM UNDER SHIELD

LIGHT SWITCH S-63
PAC_12124819
X345
LEFT FRONT LIGHT
CONNECTOR X346
LEFT REAR LIGHT E-43
WIRE

LIGHT SWITCH S-63
PAC_12124819
X346
LEFT REAR LIGHT
CONNECTOR X347
RIGHT FRONT LIGHT E-44
WIRE

LIGHT SWITCH S-63
PAC_12124819
X347
RIGHT FRONT LIGHT
CONNECTOR X348
RIGHT REAR LIGHT E-45
WIRE

LIGHT SWITCH S-63
PAC_12124819
X348
RIGHT REAR LIGHT
55-126
CONNECTOR X349
ENGINE LIGHT E-46
WIRE
A 2009 (PU) POWER FROM ENGINE LIGHT

SWITCH S-64
PAC_12124819
X349
ENGINE LIGHT
CONNECTOR X350
RH POSITION LIGHT E-49
WIRE
1 1553 (WH) POWER FROM FUSE F-21

X350
RH POSITION LIGHT
CONNECTOR X351
LH POSITION LIGHT E-50
WIRE
1 1563 (WH) POWER FROM FUSE F-20

X351
LH POSITION LIGHT
CONNECTOR X352
RH FLASHING LIGHT E-51
WIRE
1 1551 (YE) POWER FROM FLASHER MODULE

A-05
X352
RH FLASHING LIGHT
55-127
CONNECTOR X353
LH FLASHING LIGHT E-52
WIRE
1 1561 (YE) POWER FROM FLASHER MODULE

A-05
X353
LH FLASHING LIGHT
CONNECTOR X354
RH FRONT AUSTRIA LIGHT E-53
WIRE
A 1555 (WH) POWER FROM FUSE F-21

AMP_282080--1
X354
RH FRONT AUSTRIA LIGHT
CONNECTOR X355
LH FRONT AUSTRIA LIGHT E-54
WIRE

AMP_282080--1
X355
LH FRONT AUSTRIA LIGHT
CONNECTOR X356
RH FRONT TURN/POSITION LIGHT E-04
WIRE

B 1558 (YE) POWER FROM FLASHER MODULE
A-05
X356
RH FRONT TURN/POSITION LIGHT
55-128
CONNECTOR X357
LH FRONT TURN/POSITION LIGHT E-03
WIRE

B 1548 (YE) POWER FROM FLASHER MODULE
A-05
X357
LH FRONT TURN/POSITION LIGHT
CONNECTOR X358
RH MARKER LIGHT
WIRE
1 1573 (PU) POWER FROM FUSE F-21

X358
RH MARKER LIGHT
CONNECTOR X359
LH MARKER LIGHT
WIRE

X359
LH MARKER LIGHT
CONNECTOR X360
RH REAR MARKER LIGHT E-55
WIRE
1 (WH) POWER FROM FUSE F-21

2 (BK) TO REAR FRAME GROUND 1
AMP_282080--1
X360
RH REAR MARKER LIGHT
55-129
CONNECTOR X361
LH REAR MARKER LIGHT E-56
WIRE
1 (WH) POWER FROM FUSE F-20

2 (BK) TO REAR FRAME GROUND 1
AMP_282080--1
X361
LH REAR MARKER LIGHT
CONNECTOR X362
RH LICENSE PLATE LIGHT E-57
WIRE

AMP_282080--1
X362
RH LICENSE PLATE LIGHT
CONNECTOR X363
LH LICENSE PLATE LIGHT E-58
WIRE

AMP_282080--1
X363
LH LICENSE PLATE LIGHT
CONNECTOR X367
SPREADER RPM B55
WIRE
A 1254 (OR) FUSE F45

B 414 (YE) X016 CCM2 J2-28
C 492 (BL) REF. GROUND
X367
SPREADER RPM
CONNECTOR X368
PARK BRAKE PRESSURE B53
WIRE
A 1538 (BL) REF. GROUND

C 1536 (YE) X017 CCM2 J3-34 PAC_12065287
X368
PARK BRAKE PRESSURE
55-130
CONNECTOR X382
CHOPPER RPM
WIRE
1 632 (BL) CCM-2 REFERENCE GROUND B

2 413 (YE) TO CCM-2 J2-38
X382
CHOPPER RPM
CONNECTOR X389
ENGINE HARNESS
WIRE
A 092 (WH) 12/24V RELAY
PAC_12010996
X389
ENGINE HARNESS
CONNECTOR X421
MARKER LIGHT
WIRE

X421
MARKER LIGHT
CONNECTOR X472
WASHER MOTOR M-24
WIRE

2 278 (WH) POWER FROM WASHER SWITCH
S-38
AMP_926522
X472
WASHER MOTOR
55-131
55-132
CONTENTS

E0000 Stone Trap Closed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E0001 Bin Covers Open Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
E0003 Unload Tube Cradled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
E0004 Fdr Reverser Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
E0006 Return Filter Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
E0007 Gearbox Filter Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
E0008 Left Turn Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
E0009 Front Work Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
E0010 Rear Work Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
E0011 Road Lights Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
E0012 Right Turn Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
E0013 Cleaning Fan RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
E0014 Feeder RPM sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
E0015 Left Returns RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
E0016 Clean Grain Elevator RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
E0018 Right Returns RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
E0023 Hydrostat Motor Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
E0024 Hydraulic Reservoir Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
E0025 Gearbox Temp Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
E0026 Rear Ladder Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
E0029 Lateral Float Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
E0032 Shoe Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
E0033 Lateral Inclination Sens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
E0034 Concave Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
E0038 CCM1 8V Ref Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
E0040 CCM1 Key Switch Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
E0041 Current Sense Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
55-1

E0042 Current Sense Reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
E0043 Current Sense Lev Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
E0044 Current Sense Concave CL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
E0045 Current Sense Bin Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
E0047 V Supply Feeder Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
E0050 Isense Feeder Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
E0052 Feeder Clutch Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
E0053 Chaff Spreader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
E0059 Dual Range Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
E0061 Feeder Jog Forward Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
E0062 Fan Sp / Reverser Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
E0065 Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
E0066 Rear Wheel Assist Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
E0067 Feeder Jog Reverse Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
E0068 Unload Tube Light Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
E0069 Covers / Concave Cl Sel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
E0070 Front Work Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
E0071 Rear Work Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
E0072 Side Work Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
E0073 Field Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
E0075 Leveling Shoe Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
E0076 Fan Speed Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
E0077 Reverser Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
E0078 Concave Clearance Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
E0079 Grain Bin Covers Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
E0080 HHC Module Bad Intelligent Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
E0082 Feeder Speed Incr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
E0083 Feeder Speed Decr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
E0084 Voting Conflicts Found . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
E0085 Voting Differences Found . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
55-2
FAULT CODE – E0000-03 Stone Trap Closed Sensor

Shorted To High Source
Cause:
The stone trap closed sensor (B24) circuit is shorted to a higher than normal voltage source.
Possible failure modes:
1. Sensor supply wiring shorted to 12 volts.
2. Controller internal failure (internal regulator failure).
Solution:
1. Enter the InfoviewR monitor - “Diagnose Info” screen.

Select “Stone Trap Closed sensor” and check voltage range.
The proper voltage for sensor when blocked by ferrous metal - 5.6 to 7.3 volts.
The proper voltage for sensor when not blocked by ferrous metal - 0.5 to 5.6 volts.
The proper voltage sensor when disconnected - 7.3 to 9.0 volts.
A. If the voltage reading is high out of range (9.0 to 10.0 volts), continue with Step 2.
B. If the voltage reading is within the proper limits, the shorted wire may not be powered up at this time.
Continue the troubleshooting at step 4.
2. The voltage reading is high. Disconnect the stone trap closed sensor connector X083.
A. If the voltage drops to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor.
B. If the voltage remains high, continue with Step 3.
3. The voltage reading is high. Disconnect the feeder (FE) harness and front frame (FF) harness at connector
X007.
A. If the voltage drops to 7.3 to 9.0 volts, the short is in the feeder (FE) harness between connector X007
and connector X083 wire 743 yellow. Locate the short and repair.
B. If the voltage remains high, the short circuit is in the front frame (FF) harness between connector X007
and connector X020 pin J3-28 wire 743 yellow. Locate the short and repair.
4. Turn the key to ON position. Observing the LED on the harness end side of the sensor, place ferrous metal
in front of sensor then remove. The sensor is functioning if LED changes state. Adjust the sensor clearance
to 3 mm (1/8″). Erase the fault code and continue operation.
55-3
FAULT CODE – E0000-04 Stone Trap Closed Sensor

Shorted To Low Source
Cause:
The stone trap closed sensor (B24) circuit is shorted to ground.
1. Sensor supply wiring shorted to ground.
Solution:
1. Enter the Infoview monitor - “Diagnose Info” screen.

The proper voltage sensor blocked by ferrous metal - 5.6 to 7.3 volts.
The proper voltage sensor unblocked by ferrous metal - 0.5 to 5.6 volts.
A. If the voltage reading is low (0 to 0.5 volts), continue with Step 2.
2. The voltage reading is low. Disconnect the stone trap closed sensor connector X083.
A. If the voltage increases to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor.
B. If the voltage remains low, continue with Step 3.
3. The voltage reading is low. Disconnect the feeder (FE) harness from the front frame (FF) harness at
connector X007.
A. If the voltage increases to 7.3 to 9.0 volts, the short is in the feeder (FE) harness between connector
X007 and connector X083 wire 743 yellow. Locate the short and repair.
B. If the voltage remains low, the short circuit is in the front frame (FF) harness between connector X007
55-4
FAULT CODE – E0000-05 Stone Trap Closed Sensor Line Disconnected

Cause:
The stone trap closed sensor (B24) circuit has an open.
1. Sensor supply wiring has an open.
Solution:

A. If the voltage reading is high (7.3 to 9.0 volts), continue with Step 2.
the terminals and wires at the connector for pushed back or corroded terminals or damaged wires.
2. The voltage reading is 7.3 to 9.0 volts. Disconnect the stone trap closed sensor connector X083. Use a
jumper wire to short pin B on the harness end of connector X083 to ground.
A. If the Infoview monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is not in the supply
side of the circuit. Continue with step 4.
B. If the Infoview monitor still displays 7.3 to 9.0 volts, continue with Step 3.
3. The voltage reading is 7.3 to 9.0 volts. Disconnect the feeder (FE) harness from the front frame (FF) harness
at connector X007. Use a jumper wire to short pin 11 on connector X007 to ground.
A. If the Infoview monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the feeder (FE)
harness between connector X007 and the connector X083 pin B, wire 743 yellow. Locate the open
and repair.
B. If the Infoview monitor still displays 7.3 to 9.0 volts, the open circuit is in the front frame (FF) harness
between connector X007 and connector X020 pin J3-28 wire 743 yellow. Locate the open and repair.
4. Disconnect the stone trap closed sensor connector X083. Use a multimeter to check for continuity between
the harness end of connector X083 pin A and chassis ground.
A. If there is continuity, the ground path for the sensor is complete, and the fault is in the sensor itself.
Replace the sensor.
B. If there is no continuity, continue with Step 5.
5. Disconnect the feeder (FE) harness from the front frame (FF) harness at connector X007. Use a multimeter to
check for continuity between the front frame (FF) harness end of connector X007 pin 12 and chassis ground.
A. If there is continuity, the open circuit is in the feeder (FE) harness between connector X007 and the
connector X083 pin A, wire 754 blue or 749 blue. Locate the open and repair.
B. If there is no continuity, the open circuit is in the front frame (FF) harness between connector X007 and
connector X020 pin J3-18 wire 749 blue or 501 blue. Locate the open and repair.
55-5
1 2
40024707
50031009
50020085
1
1. STONE TRAP CLOSED SENSOR B24 3. CONNECTOR X007
2. CONNECTOR X083 4. CONNECTOR X020
55-6
55-7
55-8
FAULT CODE – E0001-03 Bin Covers Open Sensor Shorted To High Source
Cause:
The bin covers open sensor (B47) circuit is shorted to a higher than normal voltage source.
Solution:
Select “Clean Grain” sub menu.

Select “Bin Covers Open Sensor” and check voltage range.
The proper voltage for covers open - 5.6 to 7.3 volts.

The proper voltage for covers closed - 0.5 to 5.6 volts.
A. If the voltage reading is high out of range, continue with Step 2.
Continue the troubleshooting at Step 5.
2. The voltage reading is high. Disconnect the covers closed proximity sensor connector X288 in the grain bin.
3. The voltage reading is high. Disconnect the connector X195 behind the grain bin.
A. If the voltage drops to 7.3 to 9.0 volts, the short is in the jumper (JP) harness between connector X195
4. The voltage reading is high. Disconnect the main frame (MF) harness from the front frame (FF) harness at
connector X008.
A. If the voltage drops to 7.3 to 9.0 volts, the short is in the main frame (MF) harness between connector
and connector X020 J3-38 on CCM1 wire 435 yellow. Locate the short and repair.
5. Operate the grain bin doors in both directions and monitor the voltage readings.
A. If high voltage reading is viewed, continue with Step 2 while operating grain bin doors.
B. If a high voltage reading cannot be generated, erase the fault code and continue operation.
55-9
FAULT CODE – E0001-04 Bin Covers Open Sensor Shorted To low Source
Cause:
The bin covers open sensor (B47) circuit is shorted to ground.
Solution:


B. If the voltage reading is within the proper limits, continue the troubleshooting at Step 5.
2. The voltage reading is low. Disconnect the covers closed proximity sensor connector X288 in the grain bin.
3. The voltage reading is low. Disconnect the connector X195.
A. If the voltage increases to 7.3 to 9.0 volts, the short to ground is in the jumper (JP) harness between
connector X195 and connector X288 wire 435 yellow. Locate the short and repair.
4. The voltage reading is low. Disconnect the connector X008.
A. If the voltage increases to 7.3 to 9.0 volts, the short to ground is in the main frame (MF) harness between
B. If the voltage remains low, the short to ground is in the front frame (FF) harness between connector
X008 and connector X020 J3-38 on CCM1 wire 435 yellow. Locate the short and repair.
5. If a 0 to 0.5 voltage reading is not shown, erase the fault code and continue operation.
55-10
FAULT CODE – E0001-05 Bin Covers Open Sensor Line Disconnected

Cause:
The bin covers open sensor (B47) has an open circuit.
1. Sensor supply wiring is open.
Solution:


If there is an open in the supply, the voltage will read 7.3 to 9.0 volts.
A. If the voltage reading is high indicating an open, continue with Step 2.
2. The voltage reading is 7.3 to 9.0 volts. Disconnect the covers closed proximity sensor connector X288 in
the grain bin. Install a jumper wire between pins 1 and 2 on connector X288.
A. If the voltage drops to 0 to 0.5 volts, the open is in the sensor, or sensor wiring. Replace the sensor.
B. If the voltage remains at 7.3 to 9.0 volts, continue with Step 3.
3. The voltage reading is 7.3 to 9.0 volts. Check for continuity between pin 1 on connector X288 and chassis
ground.
A. If no continuity is found, continue with Step 4.
B. If continuity is found, continue with Step 5.
4. Disconnect connector X195. Check for continuity between pin 2 on connector X195 and chassis ground.
A. If continuity is found, the open is in the jumper (JP) harness between connector X195 and X288 wire
454 blue. Locate open and repair.
B. If no continuity is found, the open is in the main frame (MF) harness between connector X195 and
connector X019 pin J2-14 CCM1, wires 454, or 460 blue. Locate open and repair.
5. The voltage reading is 7.3 to 9.0 volts. Disconnect the connector X195. Install a jumper wire between pins
1 and 2 on connector X195.
A. If the voltage drops to 0 to 0.5 volts, the open is in the jumper (JP) harness between connector X195
and X288 on wire 435 yellow. Locate and repair the open.
B. If the voltage remains at 7.3 to 9.0 volts, continue with Step 6.
6. The voltage reading is 7.3 to 9.0 volts. Disconnect the connector X008. Install a jumper wire between pin
27 on connector X008 and chassis ground.
A. If the voltage drops to 0 to 0.5 volts, the open is in the main frame (MF) harness between connector
X008 and X195 wire 435 yellow. Locate and repair the open.
B. If the voltage remains at 7.3 to 9.0 volts, the open is in the front frame (FF) harness between connector
X008 and connector X020 J3-38 wire 435 yellow. Locate and repair the open.
7. Visually inspect harness and connectors for damage, bent or dislocated pins, corroded terminals or broken
wires. If no damage is found, erase fault code and continue operation.
55-11
10004683
4
5
10020075
50020082
2
1. BIN COVERS SENSOR B47 4. CONNECTOR X019
3. CONNECTOR X008
55-12
55-13
55-14
FAULT CODE – E0003-03 Unload Tube Cradled Shorted To High Source

Cause:
The unload tube cradled sensor (B38) circuit is shorted to a higher than normal voltage source.
Solution:

Select “Unload Tube Cradled sensor” and check voltage range.
2. The voltage reading is high. Disconnect the unload tube cradled sensor connector X244.
3. The voltage reading is high. Disconnect the straw hood (SH) harness and straw hood front (SW) harness
at connector X071.
A. If the voltage drops to 7.3 to 9.0 volts, the short is in the straw hood (SH) harness between connector
4. The voltage reading is high. Disconnect the straw hood front (SW) harness and main frame (MF) harness
at connector X024.
A. If the voltage drops to 7.3 to 9.0 volts, the short is in the straw hood front (SW) harness between
5. The voltage reading is high. Disconnect the main frame (MF) harness and front frame (FF) harness at
connector X008.
A. If the voltage drops to 7.3 to 9.0 volts, the short is in the main frame (MF) harness between connector
55-15
FAULT CODE – E0003-04 Unload Tube Cradled Shorted To Low Source

Cause:
The unload tube cradled sensor (B38) circuit is shorted to ground.
Solution:

2. The voltage reading is low. Disconnect the unload tube cradled sensor connector X244.
A. If the voltage increases to 7.3 to 9.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor
3. The voltage reading is low. Disconnect the straw hood (SH) harness from the straw hood front (SW) harness
at connector X071.
A. If the voltage increases to 7.3 to 9.0 volts, the short is in the straw hood (SH) harness between
4. The voltage reading is low. Disconnect the straw hood front (SW) harness from the main frame (MF) harness
at connector X024.
A. If the voltage increases to 7.3 to 9.0 volts, the short is in the straw hood front (SW) harness between
5. The voltage reading is low. Disconnect the main frame (MF) harness from the front frame (FF) harness at
connector X008.
A. If the voltage increases to 7.3 to 9.0 volts, the short is in the main frame (MF) harness between
55-16
FAULT CODE – E0003-05 Unload Tube Cradled Line Disconnected

Cause:
The unload tube cradled sensor (B38) circuit has an open.
Solution:

2. The voltage reading is 7.3 to 9.0 volts. Disconnect the unload tube cradled sensor connector X244. Use a
jumper wire to short pin B on the harness end of connector X244 to ground.
3. The voltage reading is 7.3 to 9.0 volts. Disconnect the straw hood (SH) harness from the straw hood front
(SW) harness at connector X071. Use a jumper wire to short pin 31 on connector X071 to ground.
A. If the Infoview monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the straw hood
(SH) harness between connector X071 and the connector X244 pin B, wire 485 yellow. Locate the
open and repair.
4. The voltage reading is 7.3 to 9.0 volts. Disconnect the straw hood front (SW) harness from the main frame
(MF) harness at connector X024. Use a jumper wire to short pin 14 on connector X024 to ground.
front (SW) harness between connector X071 and the connector X024 wire 485 yellow. Locate the
open and repair.
5. The voltage reading is 7.3 to 9.0 volts. Disconnect the main frame (MF) harness from the front frame (FF)
harness at connector X008. Use a jumper wire to short pin 8 on connector X008 to ground.
A. If the Infoview monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the main frame
(MF) harness between connector X008 and the connector X024 wire 485 yellow. Locate the open and
repair.
55-17
6. Disconnect the unload tube cradled sensor connector X244. Use a multimeter to check for continuity
between the harness end of connector X244 pin A and chassis ground.
Replace the sensor.
7. Disconnect the straw hood (SH) harness from the straw hood front (SW) harness at connector X071. Use
a multimeter to check for continuity between the straw hood front (SW) harness end of connector X071 pin
30 and chassis ground.
A. If there is continuity, the open circuit is in the straw hood (SH) harness between connector X071 and
the connector X244 pin A, wire 444 blue. Locate the open and repair.
8. Disconnect the straw hood front (SW) harness from the main frame (MF) harness at connector X024. Use
a multimeter to check for continuity between the main frame (MF) harness end of connector X024 pin 11
and chassis ground.
A. If there is continuity, the open circuit is in the straw hood front (SW) harness between connector X071
and the connector X024 wire 444 blue or 461 blue. Locate the open and repair.
9. Disconnect the main frame (MF) harness from the front frame (FF) harness at connector X008. Use a
multimeter to check for continuity between the front frame (FF) harness end of connector X008 pin 7 and
chassis ground.
A. If there is continuity, the open circuit is in the main frame (MF) harness between connector X008 and
the connector X024 wire 461 blue or 401 blue. Locate the open and repair.
B. If there is no continuity, the open circuit is in the front frame (FF) harness between connector X008 and
connector X020 pin J3-18 wire 401 blue or 501 blue. Locate the open and repair.
55-18
40024709
5 2
50026220
4 3
10020075 10020076
50020084
3
1. UNLOAD TUBE CRADLED SENSOR B38 4. CONNECTOR X008
3. CONNECTOR X024
55-19
55-20
55-21
FAULT CODE – E0004-03 Fdr Reverser Disengaged

Cause:
The feeder reverser disengaged sensor (B09) circuit is shorted to a higher than normal voltage source.
Solution:

Select “Fdr Reverser Disengaged” and check voltage range.
The proper voltage with feeder reverser disengaged - 5.6 to 7.3 volts.
The proper voltage with feeder reverser engaged - 0.5 to 5.6 volts.
2. The voltage reading is high. Disconnect the feeder reverser disengaged proximity sensor connector X079.
3. The voltage reading is high. Disconnect the feeder (FE) harness from the front frame (FF) harness at
connector X007.
A. If the voltage drops to 7.3 to 9.0 volts, the short is in the feeder (FE) harness between connector X007
4. Operate the feeder reverser function and monitor the voltage readings.
A. If high voltage reading is now viewed, go back to Step 2.
55-22
FAULT CODE – E0004-04 Fdr Reverser Disengaged

Cause:
The feeder reverser disengaged sensor (B09) circuit is shorted to ground.
Solution:

The proper voltage with feeder reverser engaged- 0.5 to 5.6 volts.
2. The voltage reading is low. Disconnect the feeder reverser disengaged proximity sensor connector X079.
3. The voltage reading is low. Disconnect the feeder (FE) harness from the lower frame (LF) harness at
connector X007.
4. Operate the feeder reverser function and monitor the voltage readings.
A. If low voltage reading (0 to 0.5 volts) is now viewed, go back to Step 2.
B. If a low voltage reading cannot be generated, erase the fault code and continue operation.
55-23
FAULT CODE – E0004-05 Fdr Reverser Disengaged Line Disconnected

Cause:
The feeder reverser disengaged sensor (B09) has an open circuit.
Solution:

The proper voltage with feeder reverser engaged- 0.5 to 5.6 volts.
If there is an open in the supply, the voltage will read 7.3 to 9.0 volts.
2. The voltage reading is 7.3 to 9.0 volts. Disconnect the feeder reverser disengaged sensor connector X079.
Install a jumper wire between pins 1 and 2 on connector X079.
B. If the voltage remains 7.3 to 9.0 volts, continue with Step 3.
3. The voltage reading is 7.3 to 9.0 volts. Remove the jumper wire from connector X079. Check for continuity
between pin 1 on connector X079 and chassis ground.
4. Use a multimeter to check for continuity between pin 12 on connector X007 and chassis ground.
A. If no continuity is found, there is an open in the front frame (FF) harness between connectors X007
and connector X020 J3-18 wire 479 or 501 blue. Locate and repair the open circuit.
B. If continuity is found, the open is in the feeder (FE) harness between connector X007 and X079 wire
749 or 777 blue. Locate open and repair.
5. The voltage reading is 7.3 to 9.0 volts. Disconnect the connector X007. Install a jumper wire between pin
A. If the voltage drops to 0 to 0.5 volts, the open is in the feeder (FE) harness between connector X007
and X079 wire 733 yellow. Locate and repair the open.
55-24
40024707
20021064
50020085
4
1. FEEDER REVERSER DISENGAGE SENSOR B09
2. CONNECTOR X007
3. CONNECTOR X020
55-25
55-26
55-27
FAULT CODE – E0006-03 Return Filter Bypass Shorted To High Source

Cause:
The return filter bypass pressure switch (S32) circuit is shorted to a higher than normal voltage source.
Solution:
Select “Hydraulics” sub menu.

Select “Return Filter Bypass” and check voltage range.
The normal operating range for the return filter bypass is 1.8 to 10.0 volts.
A. If the voltage reading is 10.0 volts or greater, continue with Step 2.
2. The voltage reading is above 10.0 volts. Disconnect the return filter bypass pressure switch connector X239.
A. If the voltage drops below 10 volts, the short is in the sensor, or sensor wiring. Replace the sensor.
B. If the voltage is above 10.0 volts, continue with Step 3.
3. The voltage reading is above 10.0 volts. Disconnect the straw hood front (SW) harness from the main frame
(MF) harness at connector X024.
A. If the voltage drops back within range, the short is in the straw hood front (SW) harness between
connector X024 and connector X239 wire 447 yellow. Locate the short circuit and repair.
B. If the voltage remains above 10.0 volts, the short is in the main frame (MF) harness between connector
X024 and connector X019 pin J2-34 wire 447 yellow. Locate the short and repair.
4. Erase fault code and continue operation.
55-28
3
1
40020080
2
10020076
50020086
5
1. RETURN FILTER BYPASS SWITCH S32
2. CONNECTOR X024
3. CONNECTOR X019
55-29
55-30
FAULT CODE – E0007-03 Gearbox Filter Bypass Shorted To High Source

Cause:
The gearbox filter bypass switch (S34) circuit is shorted to a higher than normal voltage source.
Solution:

Select “Gearbox Filter Bypass” and check voltage range.
The normal operating range for the gearbox filter bypass is 1.8 to 10.0 volts.
2. The voltage reading is above 10.0 volts. Disconnect the gearbox filter bypass pressure switch connector
X238.
A. If the voltage drops below 10.0 volts, the short is in the sensor, or sensor wiring. Replace the sensor.
B. If the voltage is above 10.0 volts, continue with Step 3.
3. The voltage reading is above 10 volts. Disconnect the straw hood front (SW) harness from the main frame
(MF) harness at connector X024.
A. If the voltage drops below 10.0 volts, the short is in the straw hood front (SW) harness between
connector X024 and connector X238 wire 448 yellow. Locate the short circuit and repair.
B. If the voltage remains above 10.0 volts, the short is in the main frame (MF) harness between connector
4. Erase fault code and continue operation.
55-31
3
1
40020080
2
10020076
50020086
6
1. GEARBOX FILTER BYPASS SWITCH S34 3. CONNECTOR X019
2. CONNECTOR X024
55-32
55-33
FAULT CODE – E0008-04 Left Turn Signal Shorted To Low Source

Cause:
The left turn signal switch (S26) circuit is shorted to ground.
1. Switch or CCM1 supply wiring shorted to ground.
Solution:
Select “Electrical” sub menu.

Select “Left Turn signal” and check voltage range.
The normal operating range for the left turn signal switch - ON is 4.0 to 5.0 volts.
The normal operating range for the left turn signal switch - OFF is 0.25 to 4.0 volts.
NOTE: Check fuse 38. If a short to ground occurred on this circuit the fuse will have blown.
A. If the voltage reading is 0 to 0.25 volts in either switch position, continue with Step 2.
B. If the voltage reading is 0.25 to 4.0 volts with the switch OFF and 0 to 0.25 with the switch ON, continue
with Step 3.
2. The voltage reading remains near zero. The short to ground is somewhere between the switch and CCM1.
Disconnect the cab main (CM) harness from the steering column (SC) harness at connector X033.
A. If the voltage increases to 0.25 to 4.0 volts, the short is in the electronic flasher, or steering column (SC)
harness wire 197 purple. Replace the electronic flasher before attempting to repair the steering column
(SC) harness. Erase fault code and operate system.
B. If the voltage remains low, the short is somewhere in the cab main (CM) harness between connector
X033, connector X018 and the road light switch connector X256 wires 197,198 or 202 purple. Locate
3. The voltage reading is 0.25 to 4.0 volts with the switch OFF and 0 to 0.25 with the switch ON. The short to
ground is between the fuse and switch.
A. The short is in the cab main (CM) harness wire 055 orange. Visually inspect the cab main (CM) harness
for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair.
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1. ROAD LIGHT SWITCH S26 4. CONNECTOR X256
2. FLASHER MODULE A05 5. CONNECTOR X018
3. CONNECTOR X033
55-35
55-36
FAULT CODE – E0009-04 Front Work Lights Switch

Cause:
The front work lights switch (S43) circuit is shorted to ground.
Solution:

Select “Front Work Lights switch” and check voltage range.
The normal operating range for the front work lights switch - ON is 4.0 to 5.0 volts.
The normal operating range for the front work lights switch - OFF is 0.25 to 4.0 volts.
with Step 3.
2. The voltage reading remains near zero. The short to ground is between the switch and CCM1. Disconnect
the cab main (CM) harness from the cab roof (CR) harness at connector X002.
A. If the voltage increases to 0.25 to 4.0 volts, the short is in the cab roof (CR) harness between connector
X002 and the switch wire 171 yellow. Locate and repair the short.
B. If the voltage remains low, the short is in the cab main (CM) harness between connector X002 and
connector X018 J1-3, wire 171 yellow. Locate the short and repair.
ground is between the fuse and switch. Disconnect the cab main (CM) harness from the cab roof (CR)
harness at connector X002.
A. Operate the switch again and observe the voltage reading. If the voltage reading is 0.25 to 4.0 volts with
the switch OFF and 0 to 0.25 with the switch ON, the short is in the cab roof (CR) harness between
connector X002 and the switch wire 240 or 045 orange. Locate and repair the short.
B. If the voltage reading remains between 0.25 to 4.0 volts, the short is in the cab main (CM) harness
between connector X002 and fuse 49 wire 045 orange. Locate the short and repair.
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1. FRONT WORK LIGHTS SWITCH S43 3. CONNECTOR X018
2. CONNECTOR X002 4. FUSE F49
55-38
55-39
55-40
FAULT CODE – E0010-04 Rear Work Lights Switch Shorted To Low Source
Cause:
The rear work lights switch (S44) circuit is shorted to ground.
Solution:

Select “Rear Work Lights switch” and check voltage range.
The normal operating range for the rear work lights switch - ON is 4.0 to 5.0 volts.
The normal operating range for the rear work lights switch - OFF is 0.25 to 4.0 volts.
with Step 3.
2. The voltage reading is 0 to 0.25 volts. The short to ground is between the switch and CCM1. Disconnect the
cab main (CM) harness from the cab roof (CR) harness at connector X002.
A. If the voltage increases to 0.25 to 4.0 volts, the short is in the cab roof (CR) harness between connector
X002 and the switch wire 170 yellow. Locate and repair the short.
B. If the voltage remains low, the short is in the cab main (CM) harness between connector X002 and
connector X018 J1-15 wire 170 yellow. Locate the short and repair.
ground is between the fuse and switch. Disconnect the cab main (CM) harness from the cab roof (CR)
A. Operate the switch again and observe the voltage reading. If the voltage reading is 0.25 to 4.0 volts with
the switch OFF and 0 to 0.25 with the switch ON, the short is in the cab roof (CR) harness between
connector X002 and the switch wire 239 or 045 orange. Locate and repair the short.
B. If the voltage reading remains between 0.25 to 4.0 volts, the short is in the cab main (CM) harness
between connector X002 and fuse 49 wire 045 orange. Locate and repair the short.
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1. REAR WORK LIGHTS SWITCH S44 3. CONNECTOR X018
2. CONNECTOR X002 4. FUSE F49
55-42
55-43
55-44
FAULT CODE – E0011-04 Road Lights Signal Shorted To Low Source

Cause:
The road light switch (S26) circuit is shorted to ground.
Solution:
The input to CCM1 for the road light signal is supplied by the “Park” lights output (Pin1) of the road light switch
(S26).

Select “Road Lights Signal” and check voltage range.
The normal operating range for the road lights signal switch - ON is 4.0 to 5.0 volts.
The normal operating range for the road lights signal switch - OFF is 0.25 to 4.0 volts.
If a short to ground is present, the voltage indicated will be less than 0.25V.
2. Check fuse F51. If a short to ground occurred, the fuse will have failed.
A. If fuse F51 has failed, go to Step 3.
B. If the fuse is okay, go to Step 8.
3. Replace fuse F51.
A. If fuse F51 immediately fails, the short to ground is in the cab main (CM) harness wire 213 red to road
light switch S26 pin 5 (lights) or wire 214 red to road light switch S26 pin 8 (horn). Locate the short and
repair.
B. If fuse F51 is okay, go to Step 4.
4. Turn the Road Light switch S26 to the “Park” lights position and inspect fuse F51.
A. If fuse F51 immediately fails, the short to ground is in the cab main (CM) harness in one of the following
wires:
wire 173 orange, road light switch S26 pin 1 to light control relay K02 pin 5
wire 114 orange, light control relay K02 pin 5 to pin 1
wire 212 orange, light control relay K02 pin 1 to CCM1 connector X018 pin J1-21
5. Turn the Road Light switch S26 to the “Road” lights, “Low Beam” position and inspect fuse F51.
A. If fuse F51 immediately fails, the short to ground is in the cab main (CM) harness wire 169 yellow, from
the road light switch S26 pin 7 to the Low Beam relay K05 pin 1. Locate the short and repair.
6. Turn the Road Light switch S26 to the “Road” lights, “High Beam” position and inspect fuse F51.
A. If fuse F51 immediately fails, the short to ground is in the cab main (CM) harness in one of the following
wires:
wire 218 yellow, road light switch S26 pin 4 to CM harness splice
wire 191 yellow, CM splice to High Beam relay K04 pin 1.
wire 043 purple, CM splice to High Beam indicator lamp E10
55-45
7. Blow the horn by depressing the road light switch S26, and inspect fuse F51.
A. If fuse F51 immediately fails, the short to ground is in the cab main (CM) harness wire 193 white, from
the road light switch S26 pin 9 to horn H02. Locate the short and repair.
8. If fuse F51 is okay, and testing does not reveal any short to ground in the circuit, the fault is either intermittent
or is no longer valid. Erase the error code and continue operation.
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1. ROAD LIGHT SWITCH S26 3. FUSE F51
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FAULT CODE – E0012-04 Right Turn Signal Shorted To Low Source

Cause:
The right turn signal switch (S26) circuit is shorted to ground.
Solution:

Select “Right Turn signal” and check voltage range.
The normal operating range for the right turn signal switch - ON is 4.0 to 5.0 volts.
The normal operating range for the right turn signal switch - OFF is 0.25 to 4.0 volts.
with Step 3.
the cab main (CM) harness from the steering column (SC) harness at connector X033.
A. If the voltage increases to 0.25 to 4.0 volts, the short is in the electronic flasher, or steering column (SC)
harness wire 201 purple. Replace the electronic flasher before attempting to repair the steering column
(SC) harness. Erase fault code and operate system.
B. If the voltage remains low, the short is in the cab main (CM) harness between connector X033,
connector X018 and the road light switch connector X256 in wires 201,194 or 203 purple. Locate the
short and repair.
ground is between the fuse and switch.
A. The short is in the cab main (CM) harness wire 055 orange. Visually inspect the cab main (CM) harness
for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and repair.
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1. ROAD LIGHT SWITCH S26 4. CONNECTOR X256
2. FLASHER MODULE A05 5. CONNECTOR X018
3. CONNECTOR X033
55-50
55-51
FAULT CODE – E0013-03 Cleaning Fan RPM Sensor

Cause:
The cleaning fan RPM sensor (B16) circuit is shorted to a higher than normal voltage source.
Solution:
Select “Cleaning” sub menu.

Select “Cleaning Fan RPM sensor” and check voltage range.
2. The voltage reading is high. Disconnect the cleaning fan RPM sensor connector X089.
3. The voltage reading is high. Disconnect the front frame (FF) harness from the lower frame (LF) harness at
connector X023.
A. If the voltage drops to 7.3 to 9.0 volts, the short is in the lower frame (LF) harness between connector
4. Operate the cleaning fan and monitor the voltage readings.
A. If high voltage reading is viewed, continue with Step 2 while operating grain bin doors.
55-52
FAULT CODE – E0013-04 Cleaning Fan RPM Sensor

Cause:
The cleaning fan RPM sensor (B16) circuit is shorted to ground.
Solution:

A. If the voltage reading is 0 to 0.5 volts, continue with Step 2.
2. The voltage reading is low. Disconnect the cleaning fan RPM sensor connector X089.
3. The voltage reading is low. Disconnect the lower frame (LF) harness from the front frame harness (FF) at
connector X023.
A. If the voltage increases to 7.3 to 9.0 volts, the short is in the lower frame (LF) harness between
and connector X020 J3-13 wire 404 yellow. Locate the short and repair.
55-53
FAULT CODE – E0013-05 Cleaning Fan RPM Sensor Line Disconnected

Cause:
The cleaning fan RPM sensor (B16) circuit is disconnected.
1. Sensor supply or ground wiring is disconnected.
Solution:

If there is an open in the supply/ground wiring, the voltage will read 7.3 to 9.0 volts.
2. The voltage reading is 7.3 to 9.0 volts. Disconnect the cleaning fan RPM sensor connector X089. Install a
jumper wire between pins A and B on connector X089.
B. If the voltage remains out of range, continue with Step 3.
3. The voltage reading is 7.3 to 9.0 volts. Remove the jumper wire from connector X089. Use a multimeter to
check for continuity between pin A on connector X089 and chassis ground.
4. Use a multimeter to check for continuity between connector X023 pin 16 and chassis ground.
and connector X020 J3-18 wire 723 or 501 blue. Locate and repair the open circuit.
B. If continuity is found, the open is in the lower frame (LF) harness between connector X023 and
connector X089 wire 723 or 718 blue. Locate the open and repair.
A. If the voltage drops to 0 to 0.5 volts, the open is in the lower frame (LF ) harness between connector
X023 and connector X089 wire 404 yellow. Locate and repair the open.
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1. CLEANING FAN RPM SENSOR B16 3. CONNECTOR X020
2. CONNECTOR X023
55-55
55-56
55-57
FAULT CODE – E0014-03 Feeder RPM sensor Shorted To High Source

Cause:
The feeder RPM sensor (B14) circuit is shorted to a higher than normal voltage source.
Solution:

Select “Feeder RPM sensor” and check voltage range.
2. The voltage reading is high. Disconnect the feeder RPM sensor connector X284.
55-58
FAULT CODE – E0014-04 Feeder RPM sensor Shorted To Low Source

Cause:
The feeder RPM sensor (B14) circuit is shorted to ground.
Solution:

2. The voltage reading is low. Disconnect the feeder RPM sensor connector X284.
B. If the voltage remains low, the short is in the front frame (FF) harness between connector X284 and
connector X020 pin J3-14 wire 489 yellow. Locate the short and repair.
55-59
FAULT CODE – E0014-05 Feeder RPM Sensor Line Disconnected

Cause:
The feeder RPM sensor (B14) circuit has an open.
Solution:

2. The voltage reading is 7.3 to 9.0 volts. Disconnect the feeder RPM sensor connector X284. Use a jumper
wire to short pin B on the harness end of connector X284 to ground.
3. The voltage reading is 7.3 to 9.0 volts. Disconnect the feeder RPM sensor connector X284. Use a multimeter
to check for continuity between the harness end of connector X284 pin A and chassis ground.
Replace the sensor.
B. If there is no continuity to ground, there is an open circuit in the front frame (FF) harness between
connector X284 and connector X020 pin J3-18 wire 437 blue or 501 blue. Locate the open and repair.
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1. FEEDER RPM SENSOR B14 3. CONNECTOR X020
2. CONNECTOR X284
55-61
55-62
55-63
FAULT CODE – E0015-03 Left Returns RPM Sensor

Cause:
The left returns RPM sensor (B06) circuit is shorted to a higher than normal voltage source.
Solution:

Select “Left Returns RPM sensor” and check voltage range.
2. The voltage reading is high. Disconnect the left hand returns RPM sensor connector X181.
B. If the voltage remains high, the short is in the main frame (MF) harness between connector X181 and
3. Operate the left hand returns auger and monitor the voltage readings.
A. If high voltage reading is viewed, continue with Step 2.
55-64
FAULT CODE – E0015-04 Left Returns RPM Sensor

Cause:
The left returns RPM sensor (B06) circuit is shorted to ground.
Solution:

2. The voltage reading is low. Disconnect the left returns RPM sensor connector X181.
B. If the voltage remains low, the short is in the main frame (MF) harness between connector X181 and
55-65
FAULT CODE – E0015-05 Left Returns RPM Sensor Line Disconnected

Cause:
The left returns RPM sensor (B06) circuit is open.
Solution:

The proper voltage for sensor unblocked by ferrous metal is 0.5 to 5.6 volts.
The proper voltage for sensor blocked by ferrous metal is 5.6 to 7.3 volts.
The proper voltage with sensor disconnected is 7.3 to 9.0 volts.
B. If the voltage reading is within the proper limits, the open is not present at this time. Continue the
troubleshooting at step 5.
NOTE: Visually inspect the wiring harness and connectors. Verify that the connector was fully installed. In-
spect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires. Flex
the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned.
2. The voltage reading is 7.3 to 9.0 volts. Disconnect the left returns RPM sensor connector X181. Use a
jumper wire to short the harness end of connector X181 pin 2 to chassis ground.
B. If the Infoview monitor still displays 7.3 to 9.0 volts, the open circuit is in the main frame (MF) harness
between connector X181 pin 2 and connector X019 pin J2-38 wire 433 yellow. Locate the open and
repair.
3. Disconnect the left returns RPM sensor connector X181. Use a multimeter to check for continuity between
the harness end of connector X181 pin 1 and chassis ground.
Replace the sensor.
B. If there is no continuity to ground, the ground path for the sensor is open. Continue with step 4.
multimeter to check for continuity between the harness end of connector X008 pin 7 and chassis ground.
A. If there is continuity, the open circuit is in the main frame (MF) harness between connector X181 pin
1 and connector X008 pin 7 wire 500 blue or 401 blue. Locate the open and repair.
B. If there is no continuity to ground, the open circuit is in the front frame (FF) harness between connector
X008 pin 7 and connector X020 pin J3-18 wire 401 blue or 501 blue. Locate the open and repair.
5. Erase the error code and, continue operation.
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FAULT CODE – E0016-03 Clean Grain Elevator RPM

Cause:
The clean grain elevator RPM sensor (B08) circuit is shorted to a higher than normal voltage source.
Solution:

Select “Clean Grain Elevator RPM” and check voltage range.
2. The voltage reading is high. Disconnect the clean grain elevator RPM sensor connector X182.
B. If the voltage remains high, the short circuit is in the main frame (MF) harness between connector X182
3. Operate the clean grain elevator and monitor the voltage readings.
55-70
FAULT CODE – E0016-04 Clean Grain Elevator RPM

Cause:
The clean grain elevator RPM sensor (B08) circuit is shorted to ground.
Solution:

2. The voltage reading is low. Disconnect the clean grain RPM sensor connector X182.
B. If the voltage remains low, the short circuit is in the main frame (MF) harness between connector X182
55-71
FAULT CODE – E0016-05 Clean Grain Elevator RPM Line Disconnected

Cause:
The clean grain elevator RPM sensor (B08) circuit is open.
Solution:

2. The voltage reading is 7.3 to 9.0 volts. Disconnect the clean grain elevator RPM sensor connector X182.
Use a jumper wire to short the harness end of connector X182 pin 2 to chassis ground.
repair.
3. Disconnect the clean grain elevator RPM sensor connector X182. Use a multimeter to check for continuity
between the harness end of connector X182 pin 1 and chassis ground.
Replace the sensor.
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1. CLEAN GRAIN RPM SENSOR B08 3. CONNECTOR X019
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55-75
FAULT CODE – E0018-03 Right Returns RPM Sensor

Cause:
The right returns RPM sensor (B39) circuit is shorted to a higher than normal voltage source.
Solution:

Select “Right Returns RPM sensor” and check voltage range.
2. The voltage reading is high. Disconnect the right hand returns RPM sensor connector X186.
3. Operate the right returns auger and monitor the voltage readings.
55-76
FAULT CODE – E0018-04 Right Returns RPM Sensor

Cause:
The right returns RPM sensor (B39) circuit is shorted to ground.
Solution:

A. If the voltage reading is low out of range, continue with Step 2.
2. The voltage reading is low. Disconnect the right returns RPM sensor connector X186.
B. If the voltage remains low, the short is in the main frame (MF) harness between connector X186 and
55-77
FAULT CODE – E0018-05 Right Returns RPM Sensor Line Disconnected

Cause:
The right returns RPM sensor (B39) circuit is open.
Solution:

2. The voltage reading is 7.3 to 9.0 volts. Disconnect the right returns RPM sensor connector X186. Use a
jumper wire to short the harness end of connector X186 pin 2 to chassis ground.
repair.
3. Disconnect the right returns RPM sensor connector X186. Use a multimeter to check for continuity between
the harness end of connector X186 pin 1 and chassis ground.
Replace the sensor.
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1. RIGHT RETURNS RPM SENSOR B39 3. CONNECTOR X019
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55-80
55-81
FAULT CODE – E0023-03 Hydrostat Motor Temp Shorted To High Source

Cause:
The hydrostat motor temperature (B46) is shorted to high source.
Solution:
Select “Driveline” sub menu.

Select “Hydrostat Motor Temp” and check voltage range.
The normal operating voltage range is - 0.5 to 4.9 volts.

A. If the voltage reading is above 5.2 volts, continue with Step 2.
2. The voltage reading is high. Disconnect the hydrostatic motor temperature sensor connector X091.
3. The voltage reading is high. Disconnect the lower frame (LF) harness from the front frame (FF) harness at
connector X023.
55-82
FAULT CODE – E0023-04 Hydrostatic Motor Temp Shorted To Low Source

Cause:
The hydrostat motor temperature (B46) is shorted to ground.
Solution:


A. If the voltage reading is (0 to 0.5 volts), continue with Step 2.
2. The voltage reading is low. Disconnect the hydrostatic motor temperature sensor connector X091.
3. The voltage reading is low. Disconnect the front frame (FF) harness from the lower frame (LF) harness at
connector X023.
55-83
FAULT CODE – E0023-05 Hydrostatic Motor Temp Line Disconnected

Cause:
The hydrostatic motor temperature (B46) is disconnected.
Solution:


If there is an open in the supply/ground wiring the voltage will read 4.9 to 5.2 volts.
A. If the voltage reading is 4.9 to 5.2 volts, continue with Step 2.
2. The voltage reading is 4.9 to 5.2 volts. Disconnect the hydrostatic motor temperature sensor connector
X091. Install a jumper wire between pins A and B on connector X091.
B. If the voltage remains out of range, continue with Step 3.
3. The voltage reading is 4.9 to 5.2 volts. Remove the jumper wire from connector X091. Use a multimeter to
check for continuity between pin A on connector X091 and chassis ground.
4. Use a multimeter to check for continuity between pin 16 on connector X023 and chassis ground.
and connector X020 J3-18 wire 723, or 501 blue. Locate and repair the open circuit.
B. If continuity is found, the open is in the lower frame (LF) harness between connector X023 and X091
wire 723 or 774 blue. Locate the open and repair.
A. If the voltage drops to 0 to 0.5 volts, the open is in the lower frame (LF) harness between connector
X023 and X091 wire 773 yellow. Locate and repair the open.
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1. HYDROSTATIC MOTOR TEMPERATURE SENSOR B46
2. CONNECTOR X023
3. CONNECTOR X020
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FAULT CODE – E0024-03 Hydraulic Reservoir Temp

Cause:
The hydraulic reservoir temperature (B18) is shorted to high source.
Solution:

Select “Hydraulic Reservoir Temp” and check voltage range.
The proper voltage range is - 0.5 to 4.9 volts.

2. The voltage reading is high. Disconnect the hydraulic reservoir temperature sensor connector X103.
3. The voltage reading is high. Disconnect the gearbox (GB) harness from the main frame (MF) harness at
connector X011.
A. If the voltage drops to 4.9 to 5.2 volts, the short is in the gearbox (GB) harness between connector X011
55-88
FAULT CODE – E0024-04 Hydraulic Reservoir Temp

Cause:
The hydraulic reservoir temperature (B18) is shorted to ground.
Solution:


A. If the voltage reading is (0 to 0.5 volts), continue with Step 2.
2. The voltage reading is low. Disconnect the hydraulic reservoir temperature sensor connector X103.
3. The voltage reading is low. Disconnect the gearbox (GB) harness from the main frame (MF) harness at
connector X011.
A. If the voltage increases to 4.9 to 5.2 volts, the short is in the gearbox (GB) harness between connector
55-89
FAULT CODE – E0024-05 Hydraulic Reservoir Temp Line Disconnected

Cause:
The hydraulic oil reservoir temperature sensor (B18) circuit is open.
Solution:

The normal operating range for the sensor is 0.5 to 4.9 volts.
If there is an open in the supply or ground wiring, the voltage will be 4.9 to 5.2 volts.
2. The voltage reading is 4.9 to 5.2 volts. Disconnect the hydraulic oil reservoir temperature sensor connector
X103. Use a jumper wire to short the harness end of connector X103 pin B to chassis ground.
3. The voltage reading is 4.9 to 5.2 volts. Disconnect the gearbox (GB) harness from the main frame (MF)
harness at connector X011. Use a jumper wire to short connector X011 pin E to chassis ground.
A. If the Infoview monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the gearbox (GB)
harness between connector X011 pin E and connector X103 pin B wire 446 yellow. Locate the open
and repair.
between connector X011 pin E and connector X019 pin J2-24 wire 446 yellow. Locate the open and
repair.
4. Disconnect the hydraulic oil reservoir temperature sensor connector X103. Use a multimeter to check for
continuity between the harness end of connector X103 pin A and chassis ground.
Replace the sensor.
55-90
5. Disconnect the gearbox (GB) harness from the main frame (MF) harness at connector X011. Use a
multimeter to check for continuity between the harness end of connector X011 pin H and chassis ground.
A. If there is continuity, the open circuit is in the gearbox (GB) harness between connector X011 pin H
and connector X103 pin A wire 480 blue or 488 blue. Locate the open and repair.
B. If there is no continuity to ground, continue with step 6.
H and connector X008 pin 7 wire 488 blue or 401 blue. Locate the open and repair.
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1. HYDRAULIC OIL RESERVOIR TEMPERATURE B18 4. CONNECTOR X019
3. CONNECTOR X008
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55-94
FAULT CODE – E0025-03 Gearbox Temp Sensor Shorted To High Source

Cause:
The gearbox temperature (B32) is shorted to 12 volts.
Solution:

Select “Gearbox Temp sensor” and check voltage range.

2. The voltage reading is high. Disconnect the gearbox temperature sensor connector X097.
3. The voltage reading is high. Disconnect the gearbox (GB) harness from the main frame (MF) harness at
connector X011.
A. If the voltage drops to 4.9 to 5.2 volts, the short is in the gearbox (GB) harness between connector X011
55-95
FAULT CODE – E0025-04 Gearbox Temp Sensor Shorted To Low Source

Cause:
The gearbox temperature (B32) is shorted to ground.
Solution:


2. The voltage reading is low. Disconnect the gearbox temperature sensor connector X097.
3. The voltage reading is low. Disconnect the gearbox (GB) harness from the main frame (MF) harness at
connector X011.
55-96
FAULT CODE – E0025-05 Gearbox Temp Sensor Line Disconnected

Cause:
The gearbox temperature sensor (B32) circuit is open.
Solution:

The normal operating range for the sensor is 0.5 to 4.9 volts.
If there is an open in the supply or ground wiring, the voltage will be 4.9 to 5.2 volts.
2. The voltage reading is 4.9 to 5.2 volts. Disconnect the gearbox temperature sensor connector X097. Use
a jumper wire to short the harness end of connector X097 pin B to chassis ground.
3. The voltage reading is 4.9 to 5.2 volts. Disconnect the gearbox (GB) harness from the main frame (MF)
harness at connector X011. Use a jumper wire to short connector X011 pin A to chassis ground.
A. If the Infoview monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the gearbox (GB)
harness between connector X011 pin A and connector X097 pin B wire 422 yellow. Locate the open
and repair.
between connector X011 pin A and connector X019 pin J2-27 wire 422 yellow. Locate the open and
repair.
4. Disconnect the gearbox temperature sensor connector X097. Use a multimeter to check for continuity
Replace the sensor.
5. Disconnect the gearbox (GB) harness from the main frame (MF) harness at connector X011. Use a
multimeter to check for continuity between the harness end of connector X011 pin H and chassis ground.
A. If there is continuity, the open circuit is in the gearbox (GB) harness between connector X011 pin H
55-97
H and connector X008 pin 7 wire 488 blue or 401 blue. Locate the open and repair.
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3. CONNECTOR X008
55-99
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55-101
FAULT CODE – E0026-03 Rear Ladder Sensor Shorted To High Source

Cause:
The rear ladder sensor (B22) circuit is shorted to a higher than normal voltage source.
Solution:
Select “Engine” sub menu.

Select “Rear Ladder sensor” and check voltage range.
The proper voltage for sensor when rear ladder is up is 0.5 to 3.9 volts.
The proper voltage for sensor when rear ladder is down is 3.9 to 4.9 volts.
A. If the voltage reading is high out of range (>5.2 volts), continue with Step 2.
spect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires.
2. The voltage reading is high. Disconnect the rear ladder sensor connector X251.
A. If the voltage drops to 4.9 to 5.2 volts, the short is in the sensor or sensor wiring. Replace the sensor.
3. The voltage reading is high. Disconnect the straw hood (SH) harness from the straw hood front (SW) harness
at connector X071.
A. If the voltage drops to 4.9 to 5.2 volts, the short is in the straw hood (SH) harness between connector
X071 pin 11 and connector X251 pin 2 wire 570 yellow. Locate the short and repair.
4. The voltage reading is high. Disconnect the straw hood front (SW) harness from the main frame (MF) harness
at connector X024.
A. If the voltage drops to 4.9 to 5.2 volts, the short is in the straw hood front (SW) harness between
pin 16 and connector X019 pin J2-17 wire 570 yellow. Locate the short and repair.
5. Turn the key to ON position. Observing the LED on the harness end side of the sensor, raise and lower the
ladder. The sensor is functioning if LED changes state. Erase the error code and, continue operation.
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FAULT CODE – E0026-04 Rear Ladder Sensor Shorted To Low Source

Cause:
The rear ladder sensor (B22) circuit is shorted to ground.
Solution:

spect the terminals and wires at the connector for pushed back or corroded terminals or damaged wires.
2. The voltage reading is low. Disconnect the rear ladder sensor connector X251.
A. If the voltage increases to 4.9 to 5.2 volts, the short to ground is in the sensor or sensor wiring. Replace
the sensor.
3. The voltage reading is low. Disconnect the straw hood (SH) harness from the straw hood front (SW) harness
at connector X071.
A. If the voltage increases to 4.9 to 5.2 volts, the short to ground is in the straw hood (SH) harness between
4. The voltage reading is low. Disconnect the straw hood front (SW) harness from the main frame (MF) harness
at connector X024.
A. If the voltage increases to 4.9 to 5.2 volts, the short is in the straw hood front (SW) harness between
B. If the voltage remains low, the short to ground is in the main frame (MF) harness between connector
X024 pin 16 and connector X019 pin J2-17 wire 570 yellow. Locate the short and repair.
55-103
FAULT CODE – E0026-05 Rear Ladder Sensor Line Disconnected

Cause:
The rear ladder sensor (B22) circuit is open.
Solution:

The proper voltage with sensor disconnected is 4.9 to 5.2 v
olts.
2. The voltage reading is 4.9 to 5.2 volts. Disconnect the rear ladder sensor connector X251. Use a jumper
wire to short the harness end of connector X251 pin 2 to chassis ground.
3. The voltage reading is 4.9 to 5.2 volts. Disconnect the straw hood (SH) harness from the straw hood front
(SW) harness at connector X071. Use a jumper wire to short connector X071 pin 11 to chassis ground.
(SH) harness between connector X071 pin 11 and connector X251 pin 2 wire 570 yellow. Locate the
open and repair.
4. The voltage reading is 4.9 to 5.2 volts. Disconnect the straw hood front (SW) harness from the main frame
(MF) harness at connector X024. Use a jumper wire to short connector X024 pin 16 to chassis ground.
front (SW) harness between connector X024 pin 16 and connector X071 pin 11 wire 570 yellow.
repair.
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5. Disconnect the rear ladder sensor connector X251. Use a multimeter to check for continuity between the
harness end of connector X251 pin 1 and chassis ground.
Replace the sensor.
6. Disconnect the straw hood (SH) harness from the straw hood front (SW) harness at connector X071. Use
a multimeter to check for continuity between the harness end of connector X071 pin 3 and chassis ground.
A. If there is continuity, the open circuit is in the straw hood (SH) harness between connector X071 pin
3 and connector X251 pin 1 wire 481 blue. Locate the open and repair.
7. Disconnect the straw hood front (SW) harness from the main frame (MF) harness at connector X024. Use
a multimeter to check for continuity between the harness end of connector X024 pin 11 and chassis ground.
A. If there is continuity, the open circuit is in the straw hood front (SW) harness between connector X024
pin 11 and connector X071 pin 3 wire 481 blue or 461 blue. Locate the open and repair.
B. If there in no continuity to ground, continue with step 8.
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1. REAR LADDER SENSOR B22 4. CONNECTOR X008
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FAULT CODE – E0029-03 Lateral Float Sensor Shorted To High Source

Cause:
The lateral float sensor (R02) circuit is shorted to high voltage, or the sensor ground is open.
1. Sensor supply or signal wiring is shorted to high voltage (12V).
2. Sensor ground wiring is open.
3. Module internal failure (internal regulator failure).
Solution:
Select “Header” sub menu.

Select “Lateral Float sensor” and check voltage range. Tilt the feeder cradle side to side several times while
monitoring the voltage; the voltage should stay within range, and should change smoothly with feeder cradle
movement.
The proper voltage range for a properly adjusted sensor is 0.2 to 4.7 volts.
A. If the voltage reading is high (>4.7 volts) out of range, continue with Step 2.
B. If the voltage reading is within the proper limits, the circuit may not be shorted at this time. Continue the
2. Key off. Disconnect connector X081, and use a multimeter to test for continuity to ground on connector
X081 pin B. There should be low resistance (<1 ohm) to ground.
A. If continuity is found (<1 ohm), continue with step 6.
B. If no continuity is found, or there is high resistance (>1 ohm) to ground, continue with step 3.
3. Key off. Disconnect connector X007. Use a multimeter to test for continuity between connector X007 pin
12 and chassis ground. There should be low resistance (<1 ohm) to ground.
A. If no continuity is found, or there is high resistance (>1 ohm) to ground, continue with step 4.
B. If continuity is found, there is an open circuit in feeder (FE) harness between connector X081 pin B
and connector X007 pin 12 wire 745 blue or 749 blue. Locate the open and repair.
4. Key off. Carefully remove connector X020 to the bottom of CCM1. Use a multimeter to test for continuity
between connector X007 pin 12 and connector X020 pin J3-18.
A. If continuity is found, continue with step 5.
B. If no continuity is found, there is an open circuit in front frame (FF) harness between connector X007
pin 12 and connector X020 pin J3-18 wire 749 blue or 501 blue. Locate the open and repair.
5. Key off. Use a multimeter to test for continuity between connector X020 pin J3-18 on CCM1 and chassis
ground. There should be low resistance (<1 ohm) to ground.
A. If no continuity is found, or there is high resistance (>1 ohm) to ground, the CCM1 module is not
supplying a ground path for the sensor due to an internal failure. Replace the CCM1 module.
B. If continuity is found, the ground path for the sensor tests okay. Reconnect all connectors and retest
for continuity to ground at step 2.
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6. Disconnect connector X081, and use a multimeter to test for voltage on connector X081 pin C. There
should not be any voltage present.
A. If no voltage is found, continue with step 8.
B. If high (>4.7V) voltage is found, continue with step 7.
7. Disconnect connector X007, and use a multimeter to test for voltage on the front frame (FF) harness end
of connector X007 pin 17. There should not be any voltage present.
A. If high (>4.7V) voltage is found, there is a short to high voltage in the front frame (FF) harness between
connector X007 pin 17 and connector X020 pin J3-17 wire 741 yellow. Locate the short and repair.
B. If no voltage is found, there is a short to high voltage in the feeder (FE) harness between connector
X081 pin C and connector X007 pin 17 wire 741 yellow. Locate the short and repair.
8. Disconnect connector X081, and use a multimeter to test for voltage on connector X081 pin A. There
should be 5 volts present.
A. If 5 volts is found, continue with step 11.
B. If high (>5V) voltage is found, continue with step 9.
NOTE: This supply circuit is also used to supply power to the shoe leveling sensor in the shoe leveling actua-
tor M03, so a short to 12 volts anywhere on the supply circuit will activate this error code.
9. Disconnect connector X007, and use a multimeter to test for voltage on connector X007 pin 22. There
A. If 5 volts is found, there is a short to high voltage in the feeder (FE) harness between connector X081
pin A and connector X007 pin 22 wire 757 pink. Locate the short and repair.
B. If high (>5V) voltage is found, continue with step 10.
of connector X023 pin 17.
A. If 5 volts is found, there is a short to high voltage in the lower frame (LF) harness between connector
X088 pin A on the shoe leveling actuator M03 and connector X023 pin 17 wire 727 pink. Locate the
short and repair.
B. If high (>5V) voltage is found, there is a short to high voltage in the front frame (FF) harness between
connector X023 pin 17, connector X007 pin 22 and connector X020 pin J3-26 on one of the
following wires:
wire 757 pink, connector X007 pin 22 to FF harness splice
wire 727 pink, connector X023 pin 17 to FE harness splice
wire 726 pink, FE harness splice to connector X020 pin J3-26
11. Operate the machine while monitoring Infoview monitor. If no high out of range readings are indicated, erase
the fault code and continue operation. If the fault code immediately resets, determine which 12 volt circuit
(such as the shoe leveling actuator) was activated to cause the short.
55-110
FAULT CODE – E0029-05 Lateral Float Sensor Line Disconnected

Cause:
The lateral float sensor (R02) circuit is open or shorted to ground.
1. Sensor signal wiring is open or shorted to ground.
2. Loss of power to the sensor.
Solution:

Select “Lateral Float sensor” and check voltage range. Tilt the feeder cradle side to side several times while
monitoring the voltage; the voltage should stay within range, and should change smoothly with feeder cradle
movement.
The proper voltage range for a properly adjusted sensor is 0.2 to 4.7 volts.
A. If the voltage reading is low (<0.2 volts) out of range, continue with Step 2.
B. If the voltage reading is within the proper limits, the circuit may not be open or shorted to ground at this
time. Continue the troubleshooting at step 8.
B. If no voltage is found, continue with step 3.
A. If 5 volts is found, there is an open circuit in the feeder (FE) harness between connector X081 pin A
and connector X007 pin 22 wire 757 pink. Locate the open and repair.
B. If no voltage is found, there is an open circuit in the front frame (FF) harness between connector X007
pin 22 and connector X020 pin J3-26 wire 757 pink or 726 pink. Locate the open and repair.
4. Disconnect connector X081. Use a multimeter to check for continuity between connector X081 pin C and
ground.
B. If no continuity is found, continue with step 6.
5. Disconnect connector X007. Use a multimeter to check for continuity between connector X007 pin 17 and
ground.
A. If no continuity is found, there is a short to ground in the feeder (FE) harness between connector X081
pin C and connector X007 pin 17 wire 741 yellow. Locate the short and repair.
B. If continuity is found, there is a short to ground in the front frame (FF) harness between connector X007
55-111
6. Disconnect connector X081 and connector X007. Use a multimeter to check for continuity between
connector X081 pin C and connector X007 pin 17.
B. If no continuity is found, there is an open circuit in the feeder (FE) harness between connector X081
pin C and connector X007 pin 17 wire 741 yellow. Locate the open and repair.
7. Carefully disconnect connector X020 to the bottom of CCM1 module. Use a multimeter to check for
continuity between connector X007 pin 17 and connector X020 pin J3-17.
A. If continuity is found, the open is in the sensor. Replace the sensor.
B. If no continuity is found, there is an open circuit in the front frame (FF) harness between connector
X007 pin 17 and connector X020 pin J3-17 wire 741 yellow. Locate the open and repair.
8. Operate the machine while monitoring Infoview monitor. If no low out of range readings are indicated, erase
the fault code and continue operation.
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1. LATERAL FLOAT POTENTIOMETER R02 3. CONNECTOR X020
2. CONNECTOR X007
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55-115
FAULT CODE – E0032-03 Shoe Position Sensor Shorted To High Source

Cause:
The shoe leveling actuator (M03) position sensor circuit is shorted to high voltage, or the sensor ground is
open.
Solution:

Select “Shoe Position sensor” and check voltage range.
The proper voltage range is 0.3 to 5.2 volts.

3. Key off. Disconnect connector X023. Use a multimeter to test for continuity between connector X023 pin
16 and chassis ground. There should be low resistance (<1 ohm) to ground.
A. If no continuity is found, or there is high resistance (>1 ohm) to ground, continue with step 4.
B. If continuity is found, there is an open circuit in lower frame (LF) harness between connector X088 pin
B and connector X023 pin 16 wire 724 blue or 723 blue. Locate the open and repair.
between connector X023 pin 16 and connector X020 pin J3-18.
B. If no continuity is found, there is an open circuit in front frame (FF) harness between connector X023
55-116
of connector X023 pin 15. There should not be any voltage present.
A. If high (>5.2V) voltage is found, there is a short to high voltage in the front frame (FF) harness between
B. If no voltage is found, there is a short to high voltage in the lower frame (LF) harness between connector
NOTE: This supply circuit is also used to supply power to the lateral float sensor, so a short to 12 volts any-
where on the supply circuit will activate this error code.
A. If 5 volts is found, there is a short to high voltage in the lower frame (LF) harness between connector
X088 pin A and connector X023 pin 17 wire 727 pink. Locate the short and repair.
of connector X007 pin 22.
A. If 5 volts is found, there is a short to high voltage in the feeder (FE) harness between connector X081
pin A on the lateral float sensor R02 and connector X007 pin 22 wire 757 pink. Locate the short and
repair.
B. If high (>5V) voltage is found, there is a short to high voltage in the front frame (FF) harness between
connector X023 pin 17, connector X007 pin 22 and connector X020 pin J3-26 on one of the
following wires:
wire 726 pink, FF harness splice to connector X020 pin J3-26
(such as the shoe leveling actuator) was activated to cause the short.
55-117
FAULT CODE – E0032-05 Shoe Position Sensor Line Disconnected

Cause:
The shoe leveling actuator (M03) position sensor circuit is open or shorted to ground.
Solution:

Select “Shoe Position sensor” and check voltage range.

B. If no voltage is found, continue with step 3.
A. If 5 volts is found, there is an open circuit in the lower frame (LF) harness between connector X088
pin A and connector X023 pin 17 wire 727 pink. Locate the open and repair.
B. If no voltage is found, there is an open circuit in the front frame (FF) harness between connector X023
ground.
ground.
A. If no continuity is found, there is a short to ground in the lower frame (LF) harness between connector
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6. Disconnect connector X088 and connector X023. Use a multimeter to check for continuity between
connector X088 pin C and connector X023 pin 15.
B. If no continuity is found, there is an open circuit in the lower frame (LF) harness between connector
X088 pin C and connector X023 pin 15 wire 721 yellow. Locate the open and repair.
continuity between connector X023 pin 15 and connector X020 pin J3-32.
B. If no continuity is found, there is an open circuit in the front frame (FF) harness between connector
X023 pin 15 and connector X020 pin J3-32 wire 721 yellow. Locate the open and repair.
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1. SHOE LEVELING ACTUATOR M03
2. CONNECTOR X023
3. CONNECTOR X020
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FAULT CODE – E0033-03 Lateral Inclination Sens Shorted To High Source

Cause:
The lateral inclination sensor (B02) circuit is shorted to a higher than normal voltage source.
Solution:

Select “Lateral Inclination sens” and check voltage range.
The proper voltage range for the lateral inclination sensor is 0.3 to 5.2 volts.
2. The voltage reading is high. Disconnect the lateral inclination sensor connector X170.
A. If the voltage drops back to 0.3 to 5.2 volts, the short is in the sensor, or sensor wiring. Replace the
sensor.
B. If the voltage remains high, then the short circuit is in the main frame (MF) harness between connector
X170 and connector X019 J2-33 wire 430 yellow. Locate the short and repair.
55-123
FAULT CODE – E0033-05 Lateral Inclination Sens Line Disconnected

Cause:
The lateral inclination sensor (B02) circuit is open or shorted to ground.
Solution:

Select “Lateral Inclination sens” and check voltage range.

2. Key on. Disconnect connector X170, and use a multimeter to test for voltage on connector X170 pin A.
There should be 5 volts present.
B. If no voltage is found, there is an open circuit in the main frame (MF) harness between connector X170
pin A and connector X019 pin J2-31 wire 451 pink or 453 pink. Locate the open and repair.
3. Key off. Disconnect connector X170. Use a multimeter to check for continuity between connector X170 pin
C and ground.
A. If no continuity is found, continue with step 4.
B. If continuity is found, there is a short to ground in the main frame (MF) harness between connector
X170 pin C and connector X019 pin J2-33 wire 430 yellow. Locate the short and repair.
4. Key off. Carefully disconnect connector X019 to the bottom of the CCM1 module. Use a multimeter to check
for continuity between connector X170 pin C and connector X019 pin J2-33.
B. If no continuity is found, there is an open circuit in the main frame (MF) harness between connector
X170 pin C and connector X019 pin J2-33 wire 430 yellow. Locate the open and repair.
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1. LATERAL INCLINATION SENSOR B02 2. CONNECTOR X019
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FAULT CODE – E0034-03 Concave Position Sensor

Cause:
The concave position sensor (R06) circuit is shorted to high voltage, or the sensor ground is open.
Solution:

Select “Concave Position sensor” and check voltage range.

between connector X189 pin B and connector X019 pin J2-14.
X189 pin B and connector X019 pin J2-14 wire 456 blue or 460 blue. Locate the open and repair.
B. If high (>5.2V) voltage is found, there is a short to high voltage in the main frame (MF) harness between
connector X189 pin C and connector X019 pin J2-19 wire 411 yellow. Locate the short and repair.
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NOTE: This supply circuit is also used to supply power to the lateral inclination sensor B02, so a short to 12
volts anywhere on the supply circuit will activate this error code.
B. If high (>5.2V) voltage is found, there is a short to high voltage in the main frame (MF) harness between
connector X189 pin A, connector X170 pin A and connector X019 pin J2-31 on one of the following
wires:
wire 498 pink, connector X189 pin A to MF harness splice
wire 451 pink, connector X170 pin A to MF harness splice
wire 453 pink, MF harness splice to connector X019 pin J2-31
(such as the concave clearance motor) was activated to cause the short.
55-129
FAULT CODE – E0034-05 Concave Position Sensor Line Disconnected

Cause:
The concave position sensor (R06) circuit is open or shorted to ground.
Solution:

Select “Concave Position sensor” and check voltage range.

B. If no voltage is found, there is an open circuit in the main frame (MF) harness between connector X189
pin A and connector X019 pin J2-31 wire 498 pink or 453 pink. Locate the open and repair.
ground.
pin C and connector X019 pin J2-19 wire 411 yellow. Locate the short and repair.
continuity between connector X189 pin C and connector X019 pin J2-19.
X189 pin C and connector X019 pin J2-19 wire 411 yellow. Locate the open and repair.
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1. CONCAVE POSITION SENSOR R06 2. CONNECTOR X019
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FAULT CODE – E0037-03 CCM1 5V Ref Voltage 3 Shorted To High Source

Cause:
The circuit is shorted to a higher than normal voltage source.
1. Circuit wiring shorted to 12 volts.
Solution:
Select “Supply” sub menu.

Select “CCM1 5V Ref Voltage 3” and check voltage range.

2. The voltage reading is high. Disconnect the concave position sensor connector X189.
A. If the voltage drops back to the normal range, the short is in the concave position sensor, or sensor
wiring. Replace the concave position sensor.
3. The voltage reading is high. Disconnect the lateral inclination sensor connector X170.
A. If the voltage drops back to the normal range, the short is in the lateral inclination sensor, or sensor
wiring. Replace the sensor.
B. If the voltage remains high, then the short circuit is in the main frame (MF) harness between connector
X170, connector X189, and connector X019 J2-31 wires 498, 451 or 453 pink. Locate the short and
repair.
55-134
FAULT CODE – E0037-04 CCM1 5V Ref Voltage 3 Shorted To Low Source

Cause:
The circuit is shorted to ground.
1. Circuit wiring shorted to ground.
Solution:


A. If the voltage reading is low (less than 4.5 volts), continue with Step 2.
2. The voltage reading is low. Disconnect the concave position sensor connector X189.
A. If the voltage increases to 4.5 to 5.5 volts, the short is in the concave position sensor, or sensor wiring.
Replace the concave position sensor.
3. The voltage reading is low. Disconnect the lateral inclination sensor connector X170.
A. If the voltage increases to 4.5 to 5.5 volts, the short is in the lateral inclination sensor, or sensor wiring.
Replace the sensor.
B. If the voltage remains low, then the short circuit is in the main frame (MF) harness between connector
X170, connector X189, and connector X019 J2-31 wires 498, 451 or 453 pink. Locate the short and
repair.
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1. CONCAVE POSITION SENSOR R06 3. CONNECTOR X019
2. LATERAL INCLINATION SENSOR B02
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FAULT CODE – E0038-03 CCM1 8V Ref Voltage Shorted To High Source

Cause:
The CCM1 8V Ref Voltage circuit is shorted to a higher than normal source.
1. 12V short on 8V regulated power circuit.
Solution:
The 8V regulated power supply is provided from the key switch power to the module, and is used to provide
power to all the speed and position sensor circuits. In some cases, a 12V short on one of the sensor signal
wires could result in backfeeding that upsets the 8V regulator, and may cause the short to high source fault.
1. Enter Infoview monitor - “Diagnose Info” screen.

Select “CCM1 8V Ref Voltage” and check voltage range.
The proper voltage is 7.5 to 8.5 volts.

A. If the reading is high out of range, continue with step 2.
B. If the reading is within the proper range, reload the software in CCM1. Erase the fault code and continue
operation. If the fault code persists, replace the module.
2. Turn off the key switch, and disconnect the battery key to remove all power from the module. Carefully remove
connector X019 and connector X020 to the bottom of CCM1 module. Reconnect the battery key and enter
the Infoview monitor - “Diagnose Info” screen.
Select “CCM1” sub menu.


A. If the voltage reading is normal, there is a short to high source on one of the sensor wires. Continue with
step 3.
B. If the voltage reading is still high out of range, then CCM1 has an internal failure. Replace the controller.
3. Turn off the key switch, and disconnect the battery key to remove all power from the module. Carefully
reconnect connector X019 and connector X020 to the bottom of CCM1 module. Reconnect the battery key
and enter the Infoview monitor - Service Info screen. Use the “Active Errors” screen to check for any errors
for sensor circuits short to high source on CCM1 module.
A. If there are any sensor circuits on CCM1 that are shorted to high source, correct those circuits, and
continue with step 1 of this troubleshooting to verify this concern is resolved.
B. If there are no sensor circuits errors on CCM1, reload the software in CCM1. Erase the fault code and
continue operation. If the fault code persists, replace the module.
55-140
FAULT CODE – E0038-04 CCM1 8V Ref Voltage Shorted To Low Source

Cause:
The CCM1 8V Ref Voltage circuit is shorted to ground.
Solution:

A. If the voltage reading is low out of range, then CCM1 has an internal failure. Replace the controller.
B. If the voltage reading is within proper limits, the failure may not be present at this time. Continue
diagnosis with step 2.
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FAULT CODE – E0039-03 CCM1 5V Ref Voltage 1 Shorted To High Source

Cause:
Solution:

Select “CCM1 5V Ref Voltage1” and check voltage range.

2. The voltage reading is high. Disconnect the lower frame (LF) harness from the front frame (FF) harness at
connector X023.
A. If the voltage drops back to the normal range, the short is in the lower frame (LF) harness between
connector X023 and the shoe leveling actuator (M03) wire 727 pink. Locate the short and repair.
3. The voltage reading is high. Disconnect the feeder (FE) harness from the front frame (FF) harness at
connector X007.
A. If the voltage drops back to the normal range, the short is in the feeder (FE) harness between connector
X007 and the lateral float potentiometer (R02) wire 757 pink. Locate the short and repair.
B. If the voltage remains high, the short circuit is in the front frame (FF) harness between connector X023,
connector X007 and connector X020 J3-26 wires 726, 727 or 757 pink. Locate the short and repair.
55-142
FAULT CODE – E0039-04 CCM1 5V Ref Voltage 1 Shorted To Low Source

Cause:
The circuit is shorted to ground.
Solution:

Select “CCM1 5V Ref Voltage1” and check voltage range.

A. If the voltage reading is low (less than 4.5 volts), continue with Step 2.
2. The voltage reading is low. Disconnect the lower frame (LF) harness from the front frame (FF) harness at
connector X023.
connector X023 and the shoe leveling actuator (M03) wire 727 pink. Locate the short and repair.
3. The voltage reading is low. Disconnect the feeder (FE) harness from the front frame (FF) harness at
connector X007.
X007 and the lateral float potentiometer (R02) wire 757 pink. Locate the short and repair.
B. If the voltage remains low, the short circuit is in the front frame (FF) harness between connector X023,
connector X007 and connector X020 J3-26 wires 726, 727 or 757 pink. Locate the short and repair.
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1. LATERAL FLOAT POTENTIOMETER R02 4. CONNECTOR X007
2. SHOE LEVELING ACTUATOR M03 5. CONNECTOR X020
3. CONNECTOR X023
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FAULT CODE – E0040-03 CCM1 Key Switch Voltage

Cause:
The circuit is shorted to a higher than normal source.

1. Circuit wiring shorted to high voltage source.
2. Faulty alternator/regulator.
Solution:
Key switch voltage is used to initialize (wake-up) the module, and also supplies power to the 5V and 8V regulators
for the regulated voltage circuits. The module will shutdown if the voltage is less than 9 volts, but there is no
shutdown for excessive voltage.
1. Start the combine engine. Enter the Infoview monitor - “Diagnose Info” screen.
Select “CCM1 Key switch Voltage”. Increase the engine RPM to high idle (maximum) and check voltage
range.
The acceptable voltage range for the module is 10 to 18 volts.
A. If the voltage reading is greater than 18 volts, continue with Step 2.
B. If the voltage reading is between 10 and 18 volts, go to Step 5.
2. Shut off the combine engine, and then turn the key switch on again. Enter the Infoview monitor - “Diagnose
Info” screen.
Select “CCM1 Key switch Voltage” and check voltage range.
A. If the voltage reading is between 10 and 18 volts, the alternator and/or regulator has failed, and is
producing excessive voltage. Refer to “Charging Systems” in Chapter 5 - Engine Systems in this section for
additional alternator testing information.
B. If the voltage reading is greater than 18 volts, continue with Step 3.
3. Turn the key switch off to power down the system. Check the voltage at fuse F38 using a multi-meter.
A. If the voltage reading is greater than 18 volts, then the batteries have been mistakenly connected in series
(7.5L units), or there is a fault in the wiring of the 24V starting system (Iveco units). Refer to “Starting Systems”
in Chapter 5 - Engine Systems in this section for additional information.
B. If the voltage reading is between 10 and 18 volts, continue with Step 4.
55-148
4. Remove the buddy seat and storage bin to gain access to connector X018 on CCM1. Turn the key on. Check
the voltage at connector X018 pin J1-4.
A. If the voltage reading is greater than 18 volts, then a high voltage source has been connected to one of
the following wires in the cab main (CM) harness.
wire 053 red, fuse F38 to key switch S02 pin 1
wire 125 red, fuse F38 to ECU Power relay K14 pin 1
wire 859 orange, key switch S02 pin 5 to ECU connector X193 pin 15
wire 096 orange, key switch S02 pin 6 to CM harness splice
wire 055 orange, CM harness splice to Road Light switch S26 pin 6
wire 095 orange, CM harness splice to CCM1 Power relay K24 pin 1
wire 103 orange, CCM1 power relay K24 pin 1 to CCM2 Power relay K25 pin 1
wire 104 orange, CCM2 Power relay K25 pin 1 to Cab Power relay K26 pin 1
wire 222 orange, Cab Power relay pin 1 to Time Delay module K20 pin 30
wire 970 white, Time Delay relay K20 pin 30 to Fuel Pump relay K07 pin 1
wire 101 orange, CM harness splice to CCM3 connector X012 pin J1-4
wire 097 orange, CM harness splice to Infoview monitor connector X064 pin C
Locate the source of high voltage and repair.
B. If the voltage reading is 10 to 18 volts, and the diagnostic screen is still indicating voltage in excess of 18
volts, there is an internal fault in CCM1. Reload the software for CCM1. If that does not correct the concern,
replace the module.
55-149
FAULT CODE – E0040-04 CCM1 Key Switch Voltage

Cause:
Low battery voltage to CCM1, or the circuit is shorted to ground.

1. Loose or corroded connections, or damaged wires.
2. Batteries are discharged, and/or alternator/regulator failure.
3. CCM1 supply wiring from key switch shorted to ground.
NOTE: Check fuse F38. If a short to ground occurred on this circuit the fuse will have blown.
4. Controller internal “failure (internal regulator failure).
Solution:
1. Key switch in “Off” position. Check fuse F38.

A. If fuse F38 is okay, continue with Step 6.
B. If the fuse is blown, go to Step 2.

B. If the fuse immediately fails again, a short to ground exists in wire 053 red between the fuse and the key
switch S02 in the cab main (CM) harness, or in wire 125 red between the fuse and the ECU power relay K14
pin 1. Visually inspect the cab main (CM) harness for damage, bent or dislocated pins, corroded terminals
or broken wires. Locate short and repair.
3. If the fuse does not fail when it is replaced, turn the key switch to the “Acc” position.
B. If the fuse immediately fails, there is a short to ground in one of the following wires:
wire 123 orange, key switch to the Wiper relay K06 pin 1
wire 241 orange, Wiper relay K06 pin 1 to Accessory 1 relay K08 pin 1
wire 126 orange, Accessory 1 relay K08 pin 1 to Accessory 2 relay K03 pin 1
All three wires are in the cab main (CM) harness. Visually inspect the cab main (CM) harness for damage,
bent or dislocated pins, corroded terminals or broken wires. Locate short and repair.
55-150
4. If the fuse does not fail with the key switch in the “Acc” position, turn the key switch to the “On” position.
wire 859 orange, key switch to ECU connector X193 pin 15
wire 096 orange, key switch to cab main (CM) harness splice
wire 055 orange, CM harness splice to Road Light Switch S26
wire 095 orange, CM harness splice to CCM power relays K24, K25, K26 and Time delay module K20
wires 099, 100 & 101 orange to pins J1-4 on CCM’s 1, 2 & 3
wire 097 orange, CM harness splice to Infoview monitor connector X064 pin C
All wires except wire 859 orange to ECU are in the cab main (CM) harness. Visually inspect the cab main
(CM) harness for damage, bent or dislocated pins, corroded terminals or broken wires. Locate short and
repair.
5. If the fuse does not fail with the key switch in the “On” position, turn the key switch briefly to the “Start” position.
wire 091 orange, key switch to Neutral start relay K23 pin 3
wire 090 orange, neutral start relay K23 pin 3 to CCM2, connector X015, pin 21
wire 092 white, neutral start relay K23 pin 5 to start relay K36 pin 86
Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires.
Locate short and repair.
6. Key switch in “Off” position. Check the voltage at fuse F38 using a multi-meter.
A. If the voltage reading is between 10 and 18 volts, continue with Step 7.
B. If the voltage reading is less than 10 volts, there is excessive resistance between the batteries and the
cab fuse panel, due to loose or corroded connections, or the batteries have discharged excessively, and are
not capable of supplying the minimum voltage requirement for CCM1. Inspect the wiring from the batteries
to the engine compartment, and from there to the cab. Recharge or replace the batteries.
7. Key switch in “On” position. Enter the Infoview monitor - “Diagnose Info” screen.
B. If the voltage reading is less than 10 volts, there is excessive resistance between the fuse panel and
CCM1. Inspect wire 053 red to the key switch, and wires 096 and 099 orange to CCM1 connector X018 pin
J1-4 for loose or corroded connections, or damage to the wires.
Select “CCM1 Key switch Voltage”. With the engine RPM at low idle, engage road and work lights. Check
voltage range.
B. If the voltage reading is less than 10 volts, the alternator and/or regulator may have failed, and the charging
system is not producing sufficient voltage. Refer to “Charging Systems” in Chapter 7 - Electrical Systems,
Schematics and Diagnostics for additional alternator testing information.
55-151
.
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1. KEY SWITCH S02
2. CONNECTOR X018
3. FUSE F38
55-152
55-153
55-154
55-155
FAULT CODE – E0041-06 Current Sense Fan Motor Short Circuit

Cause:
The fan speed (M05) circuit indicates high current draw.
1. Circuit connection shorted.
2. Excessive mechanical load on motor.
Solution:
1. Enter the Infoview monitor - service info screens.
A. Record and erase service history.
B. Start the combine, engage the threshing mechanism and operate fan speed and feeder reverser circuits
in both directions.
C. Record in which direction(s) the fan speed increase or decrease operates. Does feeder reverser
engage?
D. Reload error history.
E. Check for the following fault codes: E0041-06, E0042-06, E0076-05 and E0077-05.
F. Use the following table to determine the location of the fault.
SYMPTOM FAULT CODES
E0041-06 E0042-06 E0076-05 E0077-05
X Go to Step 2
Fan operates in 1
direction only X Go to Step 3
Fan and reverser X X Go to Step 7

operate in 1
direction only
Fan does not X Go to Step 11
operate in either
direction X Go to Step 18
Reverser operates X Go to Step 19

in 1 direction only
X Go to Step 20
Reverser does not X Go to Step 24

operate in either
Both fan and X X Go to Step 32

reverser do not
operate in either
direction
Both fan and NO FAULT CODE Go to Step 34

reverser do not
operate in either
direction
55-156
2. The cleaning fan adjustment motor is bound up. See the appropriate service manual chapter for repair.
3. The fan operates in one direction only. Fault codes indicate a short to ground. Disconnect the fan adjustment
motor connector X090. Measure the resistance on connector X090 between pin A and pin B. The proper
resistance range for the coil is 1.0 to 5.0 ohms.
A. If out of specification, replace fan adjustment motor.
B. If the motor coil resistance is within specification, continue with Step 3.
4. Measure the resistance on connector X090 between pin A and chassis ground. Flex the lower frame and
front frame (FF) harnesses while making this check.
A. If no continuity to ground is found, erase the fault code and continue operation.
B. If there is continuity to ground, continue with Step 5.
5. Disconnect connector X023. Use the multimeter to check for continuity between connector X023 pin 22
and chassis ground.
A. If continuity is found, continue with Step 6.
B. If no continuity is found, the short to ground is in the lower frame lower frame (LF) harness between
connector X023 and connector X090 wire 763 white. Locate the short and repair.
and chassis ground.
A. If continuity is found, the short to ground is in the cab main frame harness between connector X031
and relay base K17 terminal 3 wire 763 white. Locate the short and repair.
B. If no continuity is found, the short to ground is in the lower frame (LF) harness between connector X031
and connector X023 wire 763 white. Locate the short and repair.
7. Fan and reverser operate in one direction only. Fault codes indicate a short to ground. Disconnect both the
fan adjustment motor connector X090 and reverser motor connector X080.
A. Measure the resistance on connector X090 between pin A and pin B. The proper resistance range
for the coil is 1.0 to 5.0 ohms. If out of specification, replace fan adjustment motor.
B. Measure the resistance on connector X080 between pin A and pin B. The proper resistance range
for the coil is 4.0 to 8.0 ohms. If out of specification, replace reverser motor.
C. If the motor coil resistance is within specification, continue with Step 8.
8. Check for continuity on connector X090 between pin B and chassis ground. Flex the lower frame and front
frame (FF) harnesses while making this check.
Next check for continuity on connector X080 between pin B and chassis ground. Flex the feeder frame
and front frame (FF) harnesses while making this check.
A. If no continuity to ground is found, erase fault code and continue operation.
and chassis ground.
and connector X090 wire 761 gray. Locate the short and repair.
10. Disconnect connector X007. Use the multimeter to check for continuity between connector X007 pin 2 and
chassis ground.
A. If continuity is found, the short is between connectors X080, X090 and CCM1 connector X020 J3-6
wires 713, 761 or 770 gray in front frame (FF) harness. Locate the short and repair.
B. If no continuity is found, the short to ground is in the feeder (FE) harness between connector X007 and
connector X080 wire 770 gray. Locate the short and repair.
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11. Fan does not operate in either direction. Fault code indicates an open in circuit. Disconnect the fan
adjustment motor connector X090. Measure the resistance on connector X090 between pin A and pin
B. The proper resistance range for the coil is 1.0 to 5.0 ohms.
12. Replace the fan/reverser relay K17 with a known good relay. Connect connector X090 and operate fan.
A. If the fan is now working, troubleshooting is complete.
B. If the fan still does not work, continue with Step 13.
13. Disconnect fan speed connector X090. Key switch on, engine running. Push the fan speed rocker switch
to increase fan speed. Use a multimeter to measure the voltage between connector X090 pin A and chassis
ground.
A. If 12 volts is read, continue with Step 14.
B. If 12 volts is not read, continue with Step 16.
14. Key switch on engine running. Pull the fan speed rocker switch to decrease fan speed. Use multimeter to
measure the voltage between connector X090 pin B and chassis ground.
A. If 12 volts is not read, continue with Step 15.
15. Disconnect connector X023. Key switch on, engine running. Pull the fan speed rocker switch to decrease
fan speed. Use multimeter to measure the voltage between connector X023 pin 19 and chassis ground.
A. If 12 volts is read, the open is in the lower frame (LF) harness between connector X090 and connector
X023 wire 761 gray. Locate the open and repair.
B. If 12 volts is not read, the open is in the front frame (FF) harness between connector X023 and the next
splice in wire 761 gray. Locate the open and repair.
16. Disconnect connector X023. Key switch on, engine running. Push the fan speed rocker switch to increase
fan speed. Use a multimeter to measure the voltage between connector X023 pin 22 and chassis ground.
X090 wire 763 white. Locate the open and repair.
A. If 12 volts is read, the open is in the front frame (FF) harness between connector X031 and connector
B. If 12 volts is not read, the open is in the cab main (CM) harness between connector X031 and relay
base terminal 4 on relay K17, wire 763 white. Locate the open and repair.
18. Disconnect connector X090 at the fan speed motor. Use a multimeter to check for an internal short to ground
between both pin A and B. If short to ground is found, replace motor.
19. The reverser motor actuator is bound up. See the appropriate service manual chapter for repair.
20. The reverser operates in one direction only. Fault codes indicate a short to ground. Disconnect the reverser
A. If out of specification, replace reverser motor.
55-158
21. Measure the resistance on connector X080 between pin A and chassis ground. Flex the feeder and front
chassis ground.
connector X080 wire 719 white. Locate the short and repair.
and chassis ground.
A. If continuity is found, the short to ground is in the cab main (CM) harness between connector X031 and
the relay base for relay K17 terminal 3 wire 719 white. Locate the short and repair.
B. If no continuity is found, the short to ground is in the front frame (FF) harness between connector X031
24. Reverser does not operate in either direction. Fault code indicates an open in circuit. Disconnect the reverser
25. Replace the fan/reverser relay K17 with a known good relay. Connect connector X080 and operate reverser.
A. If the reverser is now working, troubleshooting is complete.
B. If the reverser still does not work, continue with Step 26.
26. Disconnect reverser connector X080. Key switch on, engine running. Place straw elevator reverse tumbler
switch in ON position. Activate reel speed increase to REVERSE. Use a multimeter to measure the voltage
between connector X080 pin A and chassis ground.
27. Key switch on engine running. Place straw elevator reverse tumbler switch in ON position. Activate reel
speed decrease to ROCK. Use multimeter to measure the voltage between connector X080 pin B and
chassis ground.
28. Disconnect connector X007. Key switch on, engine running. Activate reel speed decrease to ROCK. Use
multimeter to measure the voltage between connector X007 pin 2 and chassis ground.
A. If 12 volts is read, the open is in the feeder (FE) harness between connector X080 and connector X007
wire 770 gray. Locate the open and repair.
29. Disconnect connector X007. Key switch on, engine running. Activate reel speed increase to REVERSE. Use
a multimeter to measure the voltage between connector X007 pin 1 and chassis ground.
wire 719 white. Locate the open and repair.
55-159
32. Both fan and reverser do not operate in either direction. Fault code indicates an open circuit. Remove the
fan/reverser relay K17 from the relay base. Operate the fan/reverser through the Infoview monitor --
”Diagnose Info” screen. Use a multimeter to measure the voltage between relay base K17 terminal 1 and
chassis ground.
A. If 12 volts is read, the open is in the front frame (FF) harness between CCM1 connector X020 J3-6
and splice with wires 713, 761 and 770 gray. Locate the open and repair.
33. Disconnect connector X031. Operate the fan/reverser through the Infoview monitor diagnostics screen. Use
A. If 12 volts is read, the open is in the cab main (CM) harness between connector X031 and relay base
K17 terminal 1. Locate the open and repair.
B. If 12 volts is not read, the open is in front frame (FF) harness between connector X031 and CCM1
connector X020 J3-8 wire 714 white. Locate the open and repair.
34. If either the fan speed or reverser do not operate in either direction, and there are no error codes indicated,
the supply power for the circuits may not be present. Remove fuse F24 and inspect.
A. Fuse has failed. Go to step 35.
B. Fuse is okay. Go to step 36.
35. If fuse has failed, replace the fuse.
A. If fuse immediately fails, a short to ground exists in the cab main (CM) or front frame (FF) harnesses
on wire 027 red from fuse F24 through connector X031 pin 3 to connector X020 pin J3-7 on CCM1
module. Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or
broken wires. Locate the short to ground and repair.
36. Test for 12V power at connector X020 pin J3-7 on the CCM1 module under the cab.
A. If there is no power, there is an open circuit in the cab main (CM) or front frame (FF) harnesses on wire
027 red from fuse F24 through connector X031 pin 3 to connector X020 pin J3-7 on CCM1 module.
Locate the open and repair. After repair, go to step 37.
B. If there is power, go to step 37.
37. Test for continuity to ground at connector X020 pin J3-16 on the CCM1 module under the cab.
A. If there is no continuity to ground, there is an open circuit in the front frame (FF) harness between
connector X020 pin J3-16 and the front frame ground #2 wire 704 black. Locate the open and repair.
After repair, go to step 38.
B. If there is continuity to ground, go to step 38.
38. Once it has been verified that power is being supplied to the module, recheck the circuit operation as
described in step 1. If the fuse fails during the testing, a short to ground on the circuit is causing the fuse to
fail. Start the troubleshooting at step 3 to locate the short to ground.
55-160
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1. FAN SPEED MOTOR M05 4. FAN/REVERSER RELAY K17
3. CONNECTOR X031
55-161
55-162
FAULT CODE – E0042-06 Current Sense Reverser Short Circuit

Cause:
The reverser (M10) circuit indicates high current draw.
Solution:
in both directions.
engage?
SYMPTOM FAULT CODES
E0041-06 E0042-06 E0076-05 E0077-05
X Go to Step 2
Fan operates in 1
Fan and reverser X X Go to Step 7

operate in 1
direction only
Fan does not X Go to Step 11
operate in either
Reverser operates X Go to Step 19

in 1 direction only
X Go to Step 20
Reverser does not X Go to Step 24

operate in either
Both fan and X X Go to Step 32

reverser do not
operate in either
direction
Both fan and NO FAULT CODE Go to Step 34

reverser do not
operate in either
direction
55-163
and chassis ground.
and chassis ground.
and chassis ground.
chassis ground.
55-164
ground.
55-165
chassis ground.
and chassis ground.
chassis ground.
55-166
chassis ground.
55-167
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2
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1. FEEDER REVERSER ACTUATOR M10 4. FAN/REVERSER RELAY K17
3. CONNECTOR X031
55-168
55-169
FAULT CODE – E0043-06 Current Sense Lev Shoe Short Circuit

Cause:
The Leveling shoe motor (M03) circuit indicates high current draw.
1. Circuit connection shorted to ground.
Solution:
B. Start the combine, and manually tilt the cleaning shoe in each direction using the controls in the Infoview
monitor “Diagnose Info” screen.
C. Record in which direction(s) the shoe leveling actuator operates.
D. Reload error history. Check for fault codes E0043-06 and E0075-05.
E. Use the following table to determine the location of the fault.
Symptom Fault Code Fault Type

E0043-06 E0075-05
Leveling shoe motor X Go to Step 2 Binding
operates in
1 direction only X Go to Step 3 Short to ground
Leveling
g shoe motor X Go to Step 2 Binding
d
does not operate in
i X Go to Step 8 Open circuit
either direction
Go to Step 13 No power supply
2. The self leveling shoe mechanism is mechanically bound up, resulting in high current draw. See the
appropriate repair manual chapter for repair and adjustment of the self leveling shoe.
3. Fault codes indicate circuit fault due to short to ground. Disconnect shoe leveling motor connector X088.
Use a multimeter to check for continuity between the actuator side of connector X088 pins D and E and a
known good ground. There should not be continuity to ground.
A. If there is continuity to ground, there is a short to ground in the motor. Replace the shoe leveling motor.
4. Disconnect the batteries using the battery key. Use the multimeter to check for continuity between connector
X088 pin E and chassis ground.
NOTE: The CCM module connects both sides of the circuit to ground when in neutral to “lock” the motor in
position. Power must be removed from the module prior to testing for short to ground condition on the motor
circuit to remove this ground path.
55-170
chassis ground.
A. If no continuity is found, the short to ground is in the lower frame (LF) harness between connector X023
pin 1 and connector X088 pin E wire 707 gray. Locate the short and repair.
B. If continuity is found, the short to ground is in the front frame (FF) harness between connector X023
pin 1 and connector X020 pins J3-19 and 20 on one of the following wires:
wire 707 gray, connector X023 pin 1 to harness splice
wire 705 gray, harness splice to connector X020 pin J3-19
6. Use a multimeter to check for continuity between connector X088 pin D and chassis ground.
B. If no continuity is found, recheck the motor for continuity to ground at step 3.
chassis ground.
pin D and X023 pin 2 wire 710 white. Locate the short and repair.
wire 710 white, connector X023 pin 2 to harness splice
wire 708 white, harness splice to connector X020 pin J3-39
8. Fault codes indicate circuit fault due to open circuit condition. Disconnect shoe leveling motor connector
X088. Measure the resistance of the motor between terminals D and E. The correct resistance is 1 to 5 ohms.
A. The resistance is infinite, indicating an open condition in the motor. Replace the shoe leveling motor.
B. The resistance is in specification. Continue with step 9.
9. Ensure that the batteries are connected using the battery key, and that fuse F22 is good. Use the multimeter
to check for continuity between connector X088 pin E and chassis ground.
position, irregardless of key switch position, as long as it receives power through fuse F22. This ground path
may be used to test for an open circuit condition.
55-171
chassis ground.
A. If continuity is found, the open circuit is in the lower frame (LF) harness between connector X023 pin
1 and connector X088 pin E wire 707 gray. Locate the open and repair.
B. If no continuity is found, the open circuit is in the front frame (FF) harness between connector X023
Locate the open circuit and repair.
B. If continuity is found, recheck the motor for continuity at step 8.
chassis ground.
D and X023 pin 2 wire 710 white. Locate the open and repair.
13. If the shoe leveling motor does not operate in either direction, and there are no fault codes indicated, the
supply power for the circuit may not be present. Remove and inspect fuse F22.
A. If fuse immediately fails, a short to ground exists on one of the following wires:
wire 024 red, from the fuse panel through connector X031 pin 16 to harness splice in front frame (FF)
harness
wire 700 red, harness splice to connector X020 pin J3-29 on CCM1 module
55-172
15. Test for 12V power at connector X020 pins J3-29 and 30 on the CCM1 module under the cab.
A. If there is no power, there is an open circuit on one of the following wires:
harness
16. Test for continuity to ground at connector X020 pins J3-9 & 10 on the CCM1 module under the cab.
A. If there is no continuity to ground, there is an open circuit on one of the following wires:
wire 702 black, from connector X020 pin J3-9 to harness splice in front frame (FF) harness
wire 778 black, harness splice to front frame ground #2
55-173
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2. CONNECTOR X023
3. CONNECTOR X020
55-174
55-175
FAULT CODE – E0044-06 Current Sense Concave CL Short Circuit

Cause:
The concave clearance motor (M04) circuit indicates high current draw.
Solution:
B. Start the combine and operate concave clearance and bin covers circuits in both directions.
C. Record in which direction(s) the concave clearance increases or decreases.
SYMPTOM FAULT CODES

E0044-06 E0045-06 E0078-05 E0079-05
X Go to Step 2
Concave operates
in 1 direction only X Go to Step 3
Concave and X X Go to Step 6

covers operate in
1 direction only
Concave does not X Go to Step 9
operate in either
Covers operates X Go to Step 15

in 1 direction only
X Go to Step 16
Covers do not X Go to Step 20
operate in either
Both concave and X X Go to Step 28

covers do not
operate in either
direction
Both concave and NO FAULT CODE Go to Step 30
covers do not
operate in either
direction
55-176
2. The concave clearance adjustment motor is bound up. See the appropriate service manual chapter for repair.
3. The concave clearance motor operates in one direction only. Fault codes indicate a short to ground.
Disconnect the concave clearance motor connector X176. Measure the resistance on connector X176
between pin A and pin B. The proper resistance range for the coil is 1.0 to 5.0 ohms.
A. If out of specification, replace concave motor.
4. Measure the resistance on connector X176 between pin A and chassis ground. Flex the main frame (MF)
harness while making this check.
and chassis ground.
A. If continuity is found, the short to ground is in the cab (CM) frame harness between connector X004
B. If no continuity is found, the short to ground is in the main frame (MF) harness between connector X004
6. Concave and covers operate in one direction only. Fault codes indicate a short to ground. Disconnect both
the concave motor connector X176 and covers motor connector X289.
for the coil is 1.0 to 5.0 ohms. If out of specification, replace concave motor.
for the coil is 1.0 to 5.0 ohms. If out of specification, replace covers motor.
7. Check for continuity on connector X176 between pin B and chassis ground. Flex the main frame (MF)
Next check for continuity on connector X289 between pin B and chassis ground. Flex the jumper (JP)
and main harnesses while making this check.
chassis ground.
A. If continuity is found, the short is in the main frame (MF) harness between connector X176, the splice,
connector X195 and connector X019 J2-1, wires 694, 693 and 522 gray. Locate the short and repair.
B. If no continuity is found, the short to ground is in the jumper (JP) harness between connector X195 and
9. Concave does not operate in either direction. Fault code indicates an open in circuit. Disconnect the concave
A. If out of specification, replace motor.
10. Replace the concave/covers relay K16 with a known good relay. Connect connector X176 and operate the
concaves.
A. If the concaves are now working troubleshooting is complete.
B. If the concaves still do not work, continue with Step 11.
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11. Disconnect concave motor connector X176. Key switch ON. Operate the concave motor using the Infoview
monitor - “Diagnose Info” screen. Use a multimeter to measure the voltage between connector X176 pin
A and chassis ground.
12. Key switch ON. Operate the concave motor using the Infoview monitor - “Diagnose Info” screen. Use a
multimeter to measure the voltage between connector X176 pin B and chassis ground.
A. If 12 volts is not read, the open is in main frame (MF) harness between connector X176 and connector
X019 J2-1 wire 694 or 522 gray. Locate the open and repair.
13. Disconnect connector X004. Key switch ON. Operate the concave motor using the Infoview monitor -
“Diagnose Info” screen. Use a multimeter to measure the voltage between connector X004 pin 30 and
chassis ground.
A. If 12 volts is read, the open is in the main frame (MF) harness between connector X004 and connector
14. Disconnect connector X176 at the concave clearance motor. Use a multimeter to check for an internal short
to ground between both pin A and B. If short to ground is found, replace motor.
15. The bin covers actuator is bound up. See the appropriate service manual chapter for repair.
16. The covers operates in one direction only. Fault codes indicate a short to ground. Disconnect the covers
A. If out of specification, replace covers motor.
17. Measure the resistance on connector X289 between pin A and chassis ground. Flex the jumper (JP) and
main frame (MF) harnesses while making this check.
chassis ground.
and chassis ground.
20. Covers do not operate in either direction. Fault code indicates an open in circuit. Disconnect the covers
55-178
21. Replace the concave/covers relay K16 with a known good relay. Connect connector X289 and operate
covers.
A. If the covers are now working, troubleshooting is complete.
B. If the covers still do not work, continue with Step 22.
22. Disconnect the covers connector X289. Key switch ON. Operate the covers motor using the Infoview
23. Key switch ON. Operate the covers motor using the Infoview monitor - “Diagnose Info” screen. Use
B. If 12 volts is read, recheck the motor for continuity at Step 20. Erase the fault codes and, continue
operation.
24. Disconnect connector X195. Key switch ON. Operate the covers motor using the Infoview monitor -
“Diagnose Info” screen. Use multimeter to measure the voltage between connector X195 pin 3 and chassis
ground.
A. If 12 volts is read, the open is in the jumper (JP) harness between connector X289 and connector
B. If 12 volts is not read, the open is in the main frame (MF) harness between connector X195 and the
next splice in wire 693 gray. Locate the open and repair.
chassis ground.
chassis ground.
27. Disconnect connector X289 at the covers motor. Use a multimeter to check for an internal short to ground
28. Both concave and covers do not operate in either direction. Fault code indicates an open circuit. Remove
the concave/covers relay K16 from the relay base. Operate the concave/covers through the Infoview monitor
-- ”Diagnose Info” screen. Use a multimeter to measure the voltage between relay base K16 terminal 3 and
chassis ground.
A. If 12 volts is read, the open is in the main frame (MF) harness between CCM1 connector X019 J2-1
and splice with wire 522 gray. Locate the open and repair.
29. Disconnect connector X004. Operate the concave/covers through the Infoview monitor - “Diagnose Info”
screen. Use a multimeter to measure the voltage between connector X004 pin 29 and chassis ground.
B. If 12 volts is not read, the open is in main frame (MF) harness between connector X004 and CCM1
55-179
30. If neither the concave or bin covers do not operate in either direction, and there are no error codes indicated,
A. If fuse immediately fails, a short to ground exists in the cab main (CM) or main frame (MF) harnesses
A. If there is no power, there is an open circuit in the cab main (CM) or main frame (MF) harnesses on wire
55-180
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1. CONCAVE CLEARANCE ACTUATOR M04 3. CONCAVE/COVERS RELAY K16
55-181
55-182
FAULT CODE – E0045-06 Current Sense Bin Covers Short Circuit

Cause:
The bin covers motor (M12) circuit indicates high current draw.
Solution:
SYMPTOM FAULT CODES

E0044-06 E0045-06 E0078-05 E0079-05
X Go to Step 2
Concave operates
in 1 direction only X Go to Step 3
Concave and X X Go to Step 6

covers operate in
1 direction only
Concave does not X Go to Step 9
operate in either
Covers operates X Go to Step 15

in 1 direction only
X Go to Step 16
Covers do not X Go to Step 20
operate in either
Both concave and X X Go to Step 28

covers do not
operate in either
direction
Both concave and NO FAULT CODE Go to Step 30
covers do not
operate in either
direction
55-183
and chassis ground.
chassis ground.
concaves.
55-184
chassis ground.
chassis ground.
and chassis ground.
55-185
covers.
operation.
ground.
chassis ground.
chassis ground.
chassis ground.
55-186
55-187
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1. GRAIN BIN COVERS MOTOR M12 4. CONCAVE / COVERS RELAY K16
3. CONNECTOR X004
55-188
55-189
FAULT CODE – E0046-03 CCM1 Battery Voltage Shorted To High Source

Cause:
1. Circuit wiring shorted to high voltage source.
Solution:
1. Start the Combine engine. Enter the Infoview monitor - “Diagnose Info” screen.

Select “CCM1 Battery voltage”. Increase the engine RPM to high idle (maximum) and check voltage range.

Info” screen.
55-190
4. Remove the buddy seat and storage bin to gain access to connector X018 on CCM1. Check the voltage
at connector X018 pin J1-1.
A. If the voltage reading is greater than 18 volts, then a high voltage source has been connected to one
of the following wires:
wire 047 red, fuse F39 to splice in the cab main (CM) harness
wire 052 red, harness splice to CCM1 connector X018, pin J1-1
wire 051 red, harness splice through connector X001, pin 2 to RHM connector X026, pin 13
wire 057 red, harness splice to Infoview monitor connector X064, pin D
wire 142 red, harness splice to DAM connector X065, pin B
Visually inspect the cab main (CM) harness for damage, bent or dislocated pins, corroded terminals or broken
wires. Locate the short and repair.
B. If the voltage reading is 10 to 18 volts, and the diagnostic screen is still indicating voltage in excess of
18 volts, there is an internal fault in CCM1. Reload the software for CCM1. If that does not correct the
concern, replace the module.
55-191
FAULT CODE – E0046-04 CCM1 Battery Voltage Shorted To Low Source

Cause:
Low battery voltage to CCM1, or the circuit is shorted to ground.

3. CCM1 supply wiring from fuse F39 shorted to ground.
Solution:

Visually inspect the cab main (CM) harness for damage, bent or dislocated pins, corroded terminals or broken
wires. Locate short and repair.
cab fuse panel, due to loose or corroded connections, or the batteries have discharged excessively, and are
4. Key switch in “On” position. Enter the Infoview monitor - “Diagnose Info” screen.
Select “CCM1 Battery Voltage” and check voltage range.
CCM1. Inspect wires 047 & 052 red to CCM1 connector X018 pin J1-1 for loose or corroded connections,
or damage to the wires.
55-192
Select “CCM1 Battery Voltage”. With the engine RPM at low idle, engage road and work lights. Check voltage
range.
system is not producing sufficient voltage. Refer to “Charging Systems” in Chapter 5 - Engine Systems in
this section for additional alternator testing information.
55-193
.
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1. FUSE F39 2. CONNECTOR X018
55-194
55-195
55-196
FAULT CODE – E0047-03 V Supply Feeder Clutch

Cause:
The feeder clutch supply voltage circuit is shorted to a higher than normal voltage source.
1. Supply wiring shorted to greater than 18.0 volts.
Solution:
1. Start the Combine engine. Engage the threshing and feeder engage switches. Enter the Infoview monitor
- “Diagnose Info” screen.
Select “V Supply Feeder Clutch” and check voltage range.
The proper feeder clutch supply voltage is 10.0 to 18.0 volts (Feeder switch engaged).
2. Shut off the combine engine, and then turn the key switch on again. Enter the Infoview monitor – “Diagnose
Info” screen.
3. Key switch in the “Off” position. Check the voltage at fuse F42 using a multi-meter.
55-197
4. Key switch in the “On” position. Engage the thresher engage switch S30 and feeder engage switch S31.
Remove the buddy seat and storage bin to gain access to connector X018 on CCM1. Check the voltage
A. If the voltage reading is greater than 18 volts, then a high voltage source has been connected to one of
the following wires:
wire 108 orange, fuse F48 through connector X001, pin 3 to RC harness splice
wire 300 orange, RC harness splice to neutral switch S22
wire 302 and 861 yellow, thresher engage switch S30 pin 5 to feeder engage switch S31 pin 6
wire 112 and 1211 yellow, feeder engage sw to CCM1 connector X018 pin J1-7
wire 147 yellow, thresher engage sw to CCM2 connector X015 pin J1-7
switch power wires from splice block B, W02 in the RH console
B. If the voltage reading is 10 to 18 volts, and the diagnostic screen is still indicating voltage in excess of 18
volts, there is an internal fault in CCM1. Reload the software for CCM1. If that does not correct the concern,
replace the module.
55-198
FAULT CODE – E0047-04 V Supply Feeder Clutch Shorted To Low Source

Cause:
Low battery voltage to CCM1 through the feeder engage switch S31, or the circuit is shorted to ground.

3. Feeder engage switch supply wiring shorted to ground.
Solution:
B. If the fuse immediately fails again, a short to ground exists in wire 010 red to Cab Power Relay K26 pin
3. Locate short and repair.
wire 108 orange, fuse F48 through connector X001, pin 3 to RC harness splice
wire 300 orange, RC harness splice to neutral switch S22
5. Engage the thresher engage switch S30, and observe the fuse F48.
wire 118 yellow, thresher engage switch S30, pins 2 & 6 to thresher latching relay K28, terminal 5
wire 115 yellow, thresher latching relay K28, terminal 5 to terminal 1
wire 861 yellow, thresher engage switch S30, pin 5 to feeder engage switch S31, pin 6
wires 147, 111, 225 & 1061 yellow, thresher engage switch S30, pin 5 to CCM1 connector X018 pin
J1-17, CCM2 connector X015 pin J1-7 and CCM3 connector X012 pin J1-7
6. Engage the feeder engage switch S31, and observe fuse F48.
B. If the fuse immediately fails, a short to ground exists in wire 112 or 1211 yellow from feeder engage switch
S31, pin 5 to CCM1 connector X018, J1-7. Locate short and repair.
55-199
cab fuse panel due to loose or corroded connections, or the batteries have discharged excessively and are
8. Key switch in “On” position. Engage thresher (S30) and feeder (S31) switches. Enter the Infoview monitor
- “Diagnose Info” screen.
Select “V Supply Feeder Clutch” and check voltage range.
The acceptable voltage range is 10 to 18 volts.
CCM1. Inspect the following for loose or corroded connections, or damage to the wires.
wire 010 red, fuse F42 to Cab Power relay K26, terminal 3
wire 007 orange, Cab Power relay K26, terminal 5 to buss strip
wire 108 orange, fuse F48 through connector X001, pin 3, to right console (RC) harness splice
wire 110 orange, RC harness splice to thresher engage switch S30, pin 3
wire 112 and 1211 yellow, feeder engage switch S31, pin 5 to CCM1 connector X018, J1-7
range.
system is not producing sufficient voltage. Refer to “Charging Systems” in Chapter 5 - Engine Systems in
this section for additional alternator testing information.
55-200
.
2
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5
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7
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1. FEEDER ENGAGE SWITCH S31
2. CONNECTOR X001
3. CONNECTOR X018
4. FUSE F42
5. CAB POWER RELAY K26
6. FUSE F48
7. THRESHER LATCHING RELAY K28
55-201
55-202
55-203
55-204
55-205
FAULT CODE – E0050-03 Isense Feeder Clutch

Cause:
The Feeder clutch solenoid (L-24) circuit has excessive current draw, or is shorted to a high voltage source.
1. Bad solenoid.
2. Return side wiring shorted to 12 volts.
Solution:
The Isense Feeder Clutch circuit is the ground path for the feeder clutch PWM solenoid. By monitoring current
flow on the return path of the feeder clutch solenoid, the module can provide precise control of the solenoid
engagement. When this error message is reported, this is an indication of excessive current draw on the cir-
cuit, or a result of a high voltage short on the return line.

Select “Feeder Clutch valve” and use the arrow keys to select the “Current” screen. Use the “+” key to in-
crease the output to 100%, and press “Enter” to power the circuit. Check the current.
The proper feeder clutch solenoid current should be approximately 1.0 to 1.5 amps. The fault code is triggered
by current flow greater than 3.3 amps.
NOTE: If the current reading is high, immediately shut off the circuit to prevent module damage by pressing
the “Enter” key.
A. If the reading is greater than 3.3 amps, continue with step 2.
B. If the reading is normal (1.0 to 1.5 amps), continue the troubleshooting at step 8.
C. If there is no current reading, the module may have failed as a result of a 12V short on the Isense circuit.
Continue with step 5.
2. The current reading is high. Turn the key switch to the OFF position and disconnect the feeder clutch solenoid
connector X035. Use a multimeter to check the resistance of the feeder clutch solenoid L24 between
connector X035 pins 1 & 2. The proper resistance range for the feeder clutch solenoid is 7.2 to 11.2 ohms.
A. If out of specification, replace the solenoid. Continue with step 7.
3. Disconnect connector X011. Use a multimeter to check the resistance of the feeder clutch solenoid circuit
between connector X011 pins L & M. The resistance should be the same as, or slightly higher than the
resistance of the solenoid as measured in step 2.
A. If the resistance is lower than the previously measured resistance, there is a short in the harness
between connector X035 and connector X011 wires 876 white and 875 blue. Locate the short and
repair. Continue with step 7.
the feeder clutch solenoid circuit between connector X019 pins J2-30 & J2-40.
between connector X011 and connector X019 wires 876 white and 875 blue. Locate the short and
repair. Continue with step 7.
55-206
5. Key on. Disconnect connector X035. Use a multimeter to check for voltage at connector X035 pin 2
(harness end). There should be no voltage on this wire.
NOTE: The high voltage source may not be present as it may not be currently powered up. If the fault code
typically appears when operating another circuit, activate that circuit while performing this check.
A. There is no voltage present on the wire. Continue with step 7.
B. There is voltage present on the wire. Continue with step 6.
6. Key on. Disconnect connector X011. Use a multimeter to check for voltage at connector X011 pin L
(module side of connector). There should be no voltage on this wire.
A. There is no voltage on the wire. The short to voltage is between connector X035 and connector X011
wire 875 blue. Locate the short and repair. Continue with step 7.
B. There is voltage on the wire. The short to voltage is between connector X011 and connector X019
wire 875 blue. Locate the short and repair. Continue with step 7.
7. The sense resistor in the module for the Isense Feeder Clutch circuit is easily damaged as a result of
excessive current draw or a short to high voltage. After locating the source of the problem and correcting,
the module must be checked for damage.
Disconnect connector X011. Use a multimeter to check resistance between connector X011 pin L and chas-
sis ground. There should be less than 1 ohm resistance.
A. There is infinite resistance. The sense resistor in the CCM1 module has failed. Replace the module.
B. The resistance is correct. The sense resistor in the CCM1 module is okay, and the circuit should function
correctly. Continue with step 8.
8. Erase fault code and continue operation. If the fault immediately reoccurs, replace CCM1 with a known good
controller.
55-207
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1. FEEDER CLUTCH SOLENOID L24 3. CONNECTOR X011
55-208
55-209
FAULT CODE – E0052-11 Feeder Clutch Valve Unidentified Failure Code

Cause:
The Feeder Clutch Valve (L-24) circuit is open, or shorted to ground.
1. Supply wiring damaged.
2. Bad solenoid.
Solution:

Select “Feeder Clutch valve” and select the “Current” screen. Engage the Feeder engage switch S31.
The proper current is approximately 1.0 to 1.5 amps.

A. If the current reading goes to maximum, and then back to zero, the circuit is shorted to ground and the
software has shut off the output to protect the module and wiring. Continue with Step 2.
B. If the reading is 0 amps, the circuit is open. Continue with step 5.
C. If the reading is within the proper range, the circuit is working properly. Continue with step 11.
2. Disconnect connector X035. Use a multimeter to check between connector X035 pin 1 (valve side) and
chassis ground.
A. If there is continuity, the feeder clutch solenoid is shorted to ground. Replace the solenoid.
3. Use a multimeter to check for continuity between connector X035 pin 1 (harness side) and chassis ground.
Flex the gearbox (GB) harness between the clutch valve and connector X011 while making this check.
A. If there is continuity to ground, continue with step 4.
B. If there is no continuity to ground, erase the fault code and continue operation.
4. Disconnect connector X011. Use a multimeter to check for continuity between connector X011 pin M and
chassis ground. Flex the main frame (MF) harness between the connector X011 and connector X019 while
making this check.
A. If there is no continuity to ground, the short to ground is in the gearbox (GB) harness between
B. If there is continuity to ground, the short to ground is in the main frame (MF) harness between
5. Disconnect connector X035. Use a multimeter to check the resistance of the feeder clutch valve coil
between connector X035 pins 1 & 2. The proper resistance range is 7.2 to 11.2 ohms.
A. If there is no continuity, replace solenoid.
B. If the coil is within specification, continue with step 6.
A. If there is no continuity to ground, continue with step 7.
B. If there is continuity to ground, continue with step 9.
55-210
7. Disconnect connector X011. Use a multimeter to check for continuity between connector X011 pin L and
making this check.
A. If there is continuity to ground, the open circuit is in the gearbox (GB) harness between connector X011
and connector X035 wire 875 blue. Locate the open and repair.
8. Disconnect connector X019 on the bottom of CCM1 module. Use a multimeter to check for continuity
between connector X019 pin 40 on the module and chassis ground.
NOTE: The sense resistor in the module for the Isense Feeder Clutch circuit is easily damaged as a result of
excessive current draw or a short to high voltage.
A. If there is infinite resistance, the sense resistor in the CCM1 module has failed. Replace the module.
B. If there is less than 1 ohm resistance, the sense resistor in the CCM1 module is okay. The open circuit
is in the main frame (MF) harness between connector X011 and connector X019 wire 875 blue. Locate
the open and repair.
9. Turn the key switch to the ON position. Use the Infoview monitor - “Diagnose Info” screen to manually power
the feeder clutch valve. Use a multimeter to check for 12 volts between connector X035 pin 1 and chassis
ground.
NOTE: The Feeder engage switch S31 must be engaged to supply power to the circuit.
A. If 12 volts is not present, continue with step 10.
B. If 12 volts is found, continue with step 11.
the Feeder clutch valve. Use a multimeter to check for 12 volts between connector X011 pin M and chassis
ground.
NOTE: The Feeder engage switch S31 must be engaged to supply power to the circuit.
A. If 12 volts is present, the open circuit is in the gearbox (GB) harness between connector X035 pin 1
and connector X011 pin M wire 876 white. Locate the open circuit and repair.
B. If 12 volts is not present there is an open circuit in the main frame (MF) harness between connector
X011 pin M and connector X019 pin J2-30 wire 876 white. Locate the open and repair.
11. Erase the fault code and continue operation.
55-211
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1. FEEDER CLUTCH SOLENOID L24 3. CONNECTOR X011
55-212
55-213
FAULT CODE – E0053-11 Chaff Spreader Valve Unidentified Failure Code

Cause:
The chaff spreader control voltage circuit open, or short to ground.
3. Bad solenoid.
Solution:
Select “Residue” sub menu.

Select “Chaff Spreader valve” and select the “Status” screen. Manually power the circuit by using the “+” key
to select 100%, and press “Enter”.
The status screen should indicate “OK” if the circuit is working properly.
A. If the status screen indicates “Error”, the circuit is open or shorted to ground. Continue with Step 2.
B. If the status screen indicates “OK”, the circuit is working properly. Continue with step 7.
2. Turn the key switch to the OFF position and disconnect the chaff spreader connector X235.
A. Use a multimeter to check the resistance of the chaff spreader coil. The proper resistance range for the
coil is 3.0 to 7.0 ohms. If out of specification, replace coil.
3. Use a multimeter to check for continuity between connector X235 pin 1 and chassis ground. Flex the straw
hood front (SW) harness while making this check.
A. If no continuity to ground is found, continue with Step 4.
the chaff spreader. Use the multimeter to check for 12 volts between connector X235 pin 1 and chassis
ground.
A. If 12 volts is not present, continue with Step 5.
B. If 12 volts is found, continue with Step 8.
5. Key switch to the ON position. Use the Infoview monitor - “Diagnose Info” screen to manually power the chaff
spreader. Use the multimeter to check for 12 volts between connector X024 pin 17 and chassis ground.
A. If 12 volts is not present, the open is in the main frame (MF) harness between connector X024 and
B. If 12 volts is read, the open is in the straw hood front (SW) harness between connector X024 and
connector X235 wire 576 white. Locate the open and repair.
and chassis ground.
A. If continuity is found, the short to ground is in the main frame (MF) harness between connector X024
and connector X019 J2-15 wire 576 white. Locate the short and repair.
B. If no continuity is found, the short to ground is in the straw hood front (SW) harness between connector
X024 and connector X235 wire 576 white. Locate the open and repair.
55-214
.
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1. CHAFF SPREADER VALVE SOLENOID L28 3. CONNECTOR X019
2. CONNECTOR X024
55-215
55-216
FAULT CODE – E0059-11 Dual Range Valve Unidentified Failure Code

Cause:
The dual range solenoid (L27) circuit open or is shorted to ground.
1. Supply wiring shorted to ground or open circuit.
Solution:

Select “Dual Range valve” and select the “Status” screen. Press the “Enter” key to manually power the circuit.
2. Turn the key switch to the OFF position and disconnect the dual range valve connector X293. Use a
multimeter to check the resistance of the dual range valve coil. The proper resistance range for the coil is
1.0 to 8.0 ohms.
A. If out of specification, replace coil.
3. Use a multimeter to check for continuity between connector X293 pin A and chassis ground. Flex the front
frame (FF) harness while making this check.
the dual range solenoid. Use the multimeter to check for 12 volts between connector X293 pin A and chassis
ground.
5. Key switch to the ON position. Use the Infoview monitor - “Diagnose Info” screen to manually power the dual
range solenoid. Use the multimeter to check for 12 volts between connector X023 pin 21 and chassis
ground.
A. If 12 volts is not present the open is in the front frame (FF) harness between connector X023 and
B. If 12 volts is read, the open is in the lower frame (LF) harness between connector X023 and connector
and chassis ground.
A. If continuity is found, the short to ground is in the front frame (FF) harness between connector X023
55-217
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1. DUAL RANGE VALVE L27
2. CONNECTOR X023
3. CONNECTOR X020
55-218
55-219
FAULT CODE – E0061-11 Feeder Jog Forward Valve

Cause:
The feeder jog forward solenoid (L20) circuit open or is shorted to ground.
Solution:

Select “Feeder Jog Forward valve” and select the “Status” screen. Press the “Enter” key to manually power
the circuit.
2. Turn the key switch to the OFF position and disconnect the feeder jog forward connector X270. Use a
multimeter to check the resistance of the feeder jog forward valve coil. The proper resistance range for the
coil is 2.0 to 6.0 ohms.
3. Use a multimeter to check for continuity between connector X270 pin 1 and chassis ground. Flex the front
frame (FF) harness while making this check.
the feeder jog forward solenoid. Use the multimeter to check for 12 volts between connector X270 pin 1 and
chassis ground.
5. Key switch to the ON position. Use the Infoview monitor - “Diagnose Info” screen to manually power the
feeder jog forward solenoid. Use the multimeter to check for 12 volts between connector X021 pin A and
chassis ground.
A. If 12 volts is not present, the open is in the front frame (FF) harness between connector X021 and
B. If there is 12 volts, the open is in the feeder valves (FV) harness between connector X021 and
6. Disconnect connector X021. Use the multimeter to check for continuity between connector X021 pin A and
chassis ground.
B. If no continuity is found, the short to ground is in the feeder valves (FV) harness between connector
X021 and connector X270 wire 561 white. Locate the short and repair.
55-220
chassis ground.
A. If there is continuity, the circuit should be functional. Continue with step 9.
8. Disconnect connector X021. Use a multimeter to check for continuity between the front frame (FF) harness
end of connector X021 pin B and chassis ground.
A. If there is continuity, there is an open circuit in the feeder valves (FV) harness between connector X270
and connector X021 wire 590 black. Locate the open and repair.
B. If there is no continuity, there is an open circuit in the front frame (FF) harness between connector X021
and front frame ground #2 wire 590 black or 592 black. Locate the open and repair.
55-221
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1. FEEDER JOG FORWARD SOLENOID L20
2. CONNECTOR X021
3. CONNECTOR X020
4. FRONT FRAME GROUND #2
55-222
55-223
FAULT CODE – E0062-11 Fan Sp / Reverser Select

Cause:
The fan speed/reverser relay (K-17) circuit is open, or shorted to ground.
2. Bad relay.
Solution:
The fan speed/reverser relay is used to switch an output circuit from CCM1 between either the cleaning fan
adjust motor M05 or the feeder reverser actuator M10. The relay is controlled by CCM1, depending on which
circuit has been activated; the relay must be energized to connect the fan speed circuit. If the control circuit to
the relay fails, the reverser circuit should function, but the fan speed circuit will not.
1. Replace the fan speed/reverser relay with a known good relay.
A. Fan speed/reverser function is restored. Troubleshooting completed.
B. If function has not been restored, continue with step 2.
2. Turn the key switch to the OFF position and remove the fan speed/reverser relay K17. Use a multimeter to
check the resistance of the fan speed/reverser relay coil. The proper resistance range for the fan
speed/reverser relay coil is 74.3 to 78.3 ohms.
A. If out of specification, replace relay.
3. Use a multimeter to check for continuity between relay socket pin 1 and chassis ground.
4. Disconnect connector X031. Use a multimeter to check for continuity between the harness end of
connector X031 pin 9 and chassis ground.
A. If there is continuity to ground, there is a short to ground in the cab main (CM) harness between
connector X031 pin 9 and the fan speed/reserver relay K17 pin 1 wire 768 white. Locate the short
and repair.
B. If no continuity to ground is found, there is a short to ground in the front frame (FF) harness between
connector X031 pin 9 and connector X020 pin J3-12 wire 768 white. Locate the short and repair.
A. If continuity to ground is found, continue with Step 6.
B. If there is no continuity to ground, there is an open circuit in the cab main (CM) harness between the
fan speed/reserver relay K17 pin 2 and cab ground #3 wire 769 black. Locate the open and repair.
the fan speed/reverser relay. Use the multimeter to check for 12 volts between relay socket pin 1 and
chassis ground.
55-224
the fan speed/reverser relay. Disconnect connector X031, and use the multimeter to check for 12 volts
between connector X031 pin 9 and chassis ground.
B. If 12 volts is found, there is an open circuit in the cab main (CM) harness between connector X031 pin
9 and the fan speed/reverser relay K17 pin 1 wire 768 white. Locate the open and repair.
8. Key switch to the ON position. Use the Infoview monitor - “Diagnose Info” screen to manually power the fan
speed/reverser relay. Use the multimeter to check for 12 volts between connector X020 J3-12 and chassis
ground.
A. If 12 volts is not present, replace the CCM1 with a known good controller.
B. If 12 volts is present, there is an open circuit in the front frame (FF) harness between connector X020
J3-12 and connector X031 pin 9 wire 768 white. Locate the open and repair.
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1. CONNECTOR X020 3. FAN/REVERSER RELAY K17
2. CONNECTOR X031
55-226
55-227
FAULT CODE – E0065-11 Backup Alarm Unidentified Failure Code

Cause:
The backup alarm (H08) circuit open or shorted to ground.
1. Circuit connection/wiring damaged between CCM1 and backup alarm.
Solution:
1. Turn the key switch to the OFF position and disconnect the backup alarm connector X248.
A. Use a multimeter to check the resistance of the backup alarm coil. The proper resistance range for the
coil is 1.0 to 8.0 ohms. If out of specification, replace coil.
2. Disconnect connector X248. Use a multimeter to check for continuity between connector X248 pin 1 (white
wire) and chassis ground. Flex the harness while making this check.
3. Disconnect connector X248. Turn the key switch to the ON position. Use the Infoview monitor - “Diagnose
Info” screen to manually power the backup alarm. Use the multimeter to check for 12 volts between
4. Disconnect connector X071. Key switch to the ON position. Use the Infoview monitor - “Diagnose Info”
screen to manually power the backup alarm. Use the multimeter to check for 12 volts between connector
X071 pin 14 and chassis ground.
B. If there is 12 volts, the open is in the straw hood (SH) harness between connector X071 and connector
screen to manually power the backup alarm. Use the multimeter to check for 12 volts between connector
B. If there is 12 volts, the open is in the straw hood front (SW) harness between connector X024 and
and chassis ground.
B. If no continuity is found, the short to ground is in the straw hood (SH) harness between connector X071
and chassis ground.
55-228
8. Use a multimeter to check for continuity between connector X248 pin 1 (black wire) and chassis ground.
Flex the harness while making this check.
A. If no continuity to ground is found, continue with step 9.
B. If there is continuity to ground, the circuit is functional. Continue with step 10.
9. Disconnect connector X071. Use a multimeter to check for continuity between the straw hood front (SW)
A. If there is continuity to ground, there is an open circuit in the straw hood (SH) harness between
connector X248 and connector X071 wire 455 black or 478 black. Locate the open and repair.
B. If there is no continuity to ground, there is an open circuit in the straw hood front (SW) harness between
connector X071 and rear frame ground #1 wire 478 black. Locate the open and repair.
55-229
40024711
5 2
50026220
10020076
50020083
41
1. BACK UP ALARM H08 4. CONNECTOR X024
3. REAR FRAME GROUND #1
55-230
55-231
FAULT CODE – E0066-11 Rear Wheel Assist Valve

Cause:
The rear wheel assist (L26) circuit open, or is shorted to ground.
1. Circuit connection/wiring damaged between CCM1 and rear wheel assist solenoid.
Solution:

Select “Rear Wheel Assist valve” and select the “Status” screen. Press the “Enter” key to manually power the
circuit.
2. Turn the key switch to the OFF position and disconnect the rear wheel assist connector X233. Use a
multimeter to check the resistance of the rear wheel assist coil. The proper resistance range for the coil is
1.0 to 8.0 ohms.
3. Use a multimeter to check for continuity between connector X233 pin A and chassis ground. Flex the
Info” screen to manually power the rear wheel assist. Use the multimeter to check for 12 volts between
connector X233 pin A and chassis ground.
screen to manually power the rear wheel assist. Use the multimeter to check for 12 volts between connector
X072 pin A and chassis ground.
B. If there is 12 volts, the open is in the lower frame rear (LR) harness between connector X072 and
screen to manually power the rear wheel assist. Use the multimeter to check for 12 volts between connector
B. If there is 12 volts, the open is in the straw hood front (SW) harness between connector X024 and
55-232
7. Disconnect connector X072. Use the multimeter to check for continuity between connector X072 pin A and
chassis ground.
B. If no continuity is found, the short to ground is in the lower frame rear (LR) harness between connector
and chassis ground.
9. Disconnect connector X233. Use a multimeter to check for continuity between connector X233 pin B and
chassis ground.
A. If there is continuity to ground, the circuit is functioning properly. Continue with step 11.
10. Disconnect connector X072. Use a multimeter to check for continuity between the straw hood front (SW)
harness end of connector X072 pin B and chassis ground.
A. If there is continuity to ground, there is an open circuit in the lower frame rear (LR) harness between
connector X233 and connector X072 wire 602 black. Locate the open and repair.
B. If there is no continuity to ground, there is an open circuit in the straw hood front (SW) harness between
connector X072 and rear frame ground #1 wire 602 black or 479 black. Locate the open and repair.
55-233
4
2
40020080
10020076
10010896
50020092
42
1. REAR WHEEL ASSIST SOLENOID L26 4. CONNECTOR X024
3. REAR FRAME GROUND #1
55-234
55-235
FAULT CODE – E0067-11 Feeder Jog Reverse Valve

Cause:
The feeder jog reverse solenoid (L20) circuit open, or is shorted to ground.
Solution:

Select “Feeder Jog Reverse valve” and select the “Status” screen. Press the “Enter” key to manually power
the circuit.
2. Turn the key switch to the OFF position and disconnect the feeder jog reverse connector X266. Use a
multimeter to check the resistance of the feeder jog reverse valve coil. The proper resistance range for the
coil is 2.0 to 6.0 ohms.
chassis ground. Flex the front frame (FF) harness while making this check.
Info” screen to manually power the feeder jog reverse solenoid. Use the multimeter to check for 12 volts
between connector X266 pin 1 and chassis ground.
screen to manually power the feeder jog reverse solenoid. Use the multimeter to check for 12 volts between
connector X021 pin C and chassis ground.
A. If 12 volts is not present, the open is in the front frame (FF) harness between connector X021 and
connector X020 J3-15 wire 562 white. Locate the short and repair.
B. If there is 12 volts, the open is in the feeder valves (FV) harness between connector X021 and
6. Disconnect connector X021. Use the multimeter to check for continuity between connector X021 pin C and
chassis ground.
B. If no continuity is found, the short to ground is in the feeder valves (FV) harness between connector
55-236
chassis ground.
end of connector X021 pin D and chassis ground.
A. If there is continuity, there is an open circuit in the feeder valves (FV) harness between connector X266
and front frame ground #2 wire 591 black or 592 black. Locate the open and repair.
55-237
40024707
10020032
50020095
43
1. FEEDER JOG REVERSE SOLENOID L21
2. CONNECTOR X021
3. FRONT FRAME GROUND #2
3. CONNECTOR X020
55-238
55-239
FAULT CODE – E0068-11 Unload Tube Light Relay

Cause:
The unload tube light relay (K32) circuit open or shorted to ground.
1. Circuit connection/wiring damaged between CCM1 and relay.
Solution:

Select “Unload Tube Light relay” and select the “Status” screen. Press the “Enter” key to manually power the
circuit.
2. Turn the key switch to the OFF position and remove the unload tube light relay K32 from relay base in cab.
Use a multimeter to check for continuity between relay base (K 32) pin 1 and chassis ground. Flex the cab
main (CM) harness while making this check.
B. If there is continuity to ground, the short to ground is in the cab main (CM) harness between relay base
3. Use a multimeter to check for continuity between relay base (K32) pin 2 and chassis ground.
A. If there is continuity to ground, continue with Step 4.
B. If no continuity to ground is found, there is an open circuit in the cab main (CM) harness between relay
base pin 2 and cab ground #3 wire 163 black. Locate the open and repair.
the unload tube light relay K32. Use the multimeter to check for 12 volts between relay base (K 32) pin
A. If 12 volts is not present, the open is between the relay base K32 and connector X018 J1-12 wire 181
white.
55-240
.
1
2
50020070
10004693
50020087
44
1. CONNECTOR X018
2. UNLOAD TUBE LIGHT RELAY K32
55-241
55-242
FAULT CODE – E0069-11 Covers / Concave Cl Sel

Cause:
The covers/concave clearance relay (K16) circuit open or shorted to ground.
Solution:

Select “Covers / Concave Cl Sel” and select the “Status” screen. Press the “Enter” key to manually power the
circuit.
2. Turn the key switch to the OFF position and remove the covers/concave clearance relay K16 from relay
base in cab. Use a multimeter to check for continuity between relay base K16 pin 1 and chassis ground. Flex
the cab main (CM) harness while making this check.
3. Use a multimeter to check for continuity between relay base K16 pin 2 and chassis ground.
the covers/concave clearance relay K16. Use the multimeter to check for 12 volts between relay base K16
pin 1 and chassis ground.
A. If 12 volts is not present, the open is between the relay base K16 and connector X018 J1-6 wire 692
white.
55-243
.
50020070
10004693
50020087
45
1. CONNECTOR X018
2. CONCAVE / COVERS RELAY K16
55-244
55-245
FAULT CODE – E0070-11 Front Work Lights Relay

Cause:
The front work lights relay(s) (K01, K21) circuit is open, or shorted to ground.
2. Bad relay(s).
Solution:
Two relays are used to control the numerous work lights installed on the combine, but both relays are en-
gaged using a single output signal from CCM1. Since the two relays are wired in parallel, it is possible to have
a single relay fail, preventing certain lighting from coming on, without having a fault code indicated. This fault
code will only occur if there is a short to ground anywhere on the supply wiring to the relays, or if there is an
open circuit between the CCM1 module and the first relay (K01). An open circuit on one of the relay ground
paths, or in the supply wiring to the K21 relay will not cause this error to be displayed.

Select “Front Work Lights relay” and select the “Status” screen. Press the “Enter” key to manually power the
circuit.
2. Key OFF. Remove the Cab Roof Work Lights relay K01, and use a multimeter to check between relay base
A. If there is not continuity to ground, continue with step 3.
B. If there is continuity to ground, there is a short to ground in the cab main (CM) harness between
connector X018 pin J1-11 and the work lights relays on one of the following wires:
wire 190 white, connector X018 pin J1-11 to relay K01 pin 1
wire 189 white, relay K01 pin 1 to relay K21 pin 1
3. Key OFF. Remove the Cab Roof Work Lights relay K01. Use the Infoview monitor - “Diagnose Info” screen
to manually power the front work lights relays. Use a multimeter to check for 12V power between relay base
A. If 12V is not present, there is an open circuit in the cab main (CM) harness between connector X018
pin J1-11 and relay base (K01) pin 1 wire 190 white. Locate the open and repair.
B. If 12V is present, continue with step 4.
55-246
.
2
3
50020070
10004693
50020087
46
1. CONNECTOR X018
2. CAB ROOF WORK LIGHTS RELAY K01
3. DISTANCE WORK LIGHTS RELAY K21
55-247
55-248
FAULT CODE – E0071-11 Rear Work Lights Relay

Cause:
The rear work lights relay (K31) circuit is open or shorted to ground.
Solution:

Select “Rear Work Lights relay” and select the “Status” screen. Press the “Enter” key to manually power the
circuit.
2. Turn the key switch to the OFF position and remove the rear work light relay K31 from relay base in cab.
the rear work light relay K31. Use the multimeter to check for 12 volts between relay base (K 31) pin 1 and
chassis ground.
A. If 12 volts is not present, the open is in the cab main (CM) harness between the relay base K31 and
55-249
.
1 2
50020070
10004693
50020087
47
1. CONNECTOR X018
2. REAR WORK LIGHTS RELAY K31
55-250
55-251
FAULT CODE – E0072-11 Side Work Lights Relay

Cause:
The side work lights relay (K35) circuit open or shorted to ground.
Solution:

Select “Side Work Lights relay” and select the “Status” screen. Press the “Enter” key to manually power the
circuit.
2. Turn the key switch to the OFF position and remove the side work light relay K35 from relay base in cab.
the side work light relay K35. Use the multimeter to check for 12 volts between relay base (K 35) pin 1 and
chassis ground.
A. If 12 volts is not present, the open is in the cab main (CM) harness between the relay base K35 and
55-252
.
2
50020070
10004693
50020087
48
1. CONNECTOR X018
2. SIDE WORK LIGHT RELAY K35
55-253
55-254
FAULT CODE – E0073-11 Field Lights Relay Unidentified Failure Code

Context:
Three relays are used to control the numerous work lights installed on the combine, but all relays are engaged
using a single output signal from CCM1. Since the three relays are wired in parallel, it is possible to have a single
relay fail, preventing certain lighting from coming on, without having a fault code indicated. This fault code will
only occur if there is a short to ground anywhere on the supply wiring to the relays, or if there is an open circuit
between the CCM1 module and the first relay (K-27). An open circuit on one of the relay ground paths, or in the
supply wiring to K-22 or K-30 relay will not cause this error to be displayed.
Cause:
The front work lights relay(s) (K-27, K-22, or K-30) circuit is open, or shorted to ground.

2. Bad relay(s).
Solution:
1. Enter the Infoview monitort “Diagnose Info” screen.
Select the “Electrical” sort menu, and select “Field Lights Relay”. Change the drop-down list to “STATUS”,
and press the “Enter” button to change the circuit output to “ON”.
The “STATUS” screen should indicate “OK” if the circuit is working properly.
A. If the status screen indicates “ERROR”, the circuit is open or shorted to ground. Continue with Step 2.
B. If the status screen indicates “OK”, the circuit is working properly. Continue with Step 4.
2. Key OFF. Remove the Road Lights relay K-27, and use a multimeter to check for continuity between relay
base pin 1 and chassis ground.
A. If there is not continuity to ground, continue with Step 3.
B. If there is continuity to ground, there is a short to ground in the cab main (CM) harness between
connector X018 pin J1-5 and the work lights relays on one of the following wires:
-- wire 117 white, connector X018 pin J1-5 to relay K-27 pin 1.
-- wire 188 white, relay K-27 pin 1 to relay K-22 pin 1.
-- wire 187 white, relay K-22 pin 1 to relay K-30 pin 1.
3. Key OFF. Remove the Road Lights relay K-27. Use the Infoview monitor “Diagnose Info” screen controls to
manually power the field lights relays. Use a multimeter to check for 12V power between relay base pin 1
and chassis ground.
A. If 12V is not present, there is an open circuit in the cab main (CM) harness between connector X018
pin J1-5 and relay base (K-27) pin 1 wire 117 white. Locate the open and repair.
B. If 12V is present, continue with Step 4.
4. Visually inspect the harness and connectors for damage, bent or dislocated pins, corroded terminals or
broken wires.
A. Repair any damage found during visual inspection.
B. If no damage is found, erase the fault code and continue operation.
55-255
55-256
55-257
FAULT CODE – E0075-05 Leveling Shoe Motor Line Disconnected

Context:
The CCM has detected that the circuit current has been <0.7 Amps for at least 3 seconds, while the control circuit
input is active. Lack of current flow in an activated circuit is an indication of an open circuit condition. However,
it is also possible to get this error message from a direct short to ground. This is because the CCM contains built-in
over temperature circuit protection logic that will electronically disconnect the motor in order to prevent damage
to the module. When a direct short to ground is present, and the motor is energized, it is possible for the rapid
spike in current to engage the circuit protection -opening the circuit. When this occurs, the fault detection software
sees the open and may report the “Line disconnected” fault.
Cause:
The shoe leveling motor (M03) control voltage circuit open, or shorted to ground.
2. Bad motor.
Solution:
B. Start the combine, and manually tilt the cleaning shoe in each direction using the controls in the Infoview
monitor “Diagnose Info” screen.
C. Record in which direction(s) the shoe leveling actuator operates.
D. Reload error history. Check for fault codes E0043-06 and E0075-05.

E0043-06 E0075-05
Leveling shoe motor X Go to Step 2 Binding
operates in
1 direction only X Go to Step 3 Short to ground
Levelingg shoe motor X Go to Step 2 Binding

d
does not operate X Go to Step 8 Open circuit
in either direction
2. The self leveling shoe mechanism is mechanically bound up, resulting in high current draw. See the
appropriate repair manual chapter for repair and adjustment of the self leveling shoe.
3. Fault codes indicate circuit fault due to short to ground. Disconnect shoe leveling motor connector X088.
Measure between terminals D or E on connector X088 and a known good ground. There should be no
continuity to ground.
A. There is continuity to ground, indicating a short to ground in the motor. Replace the shoe leveling motor.
B. There is no continuity to ground. Continue with step 4.
55-258
X088 pin E and chassis ground.
position. Power must be removed from the module prior to testing for short to ground condition on the motor
circuit to remove this ground path.
chassis ground.
pin 1 and connector X088 pin E wire 707 gray. Locate the short and repair.
B. If no continuity is found, recheck the motor for continuity to ground at step 3.
chassis ground.
pin D and X023 pin 2 wire 710 white. Locate the short and repair.
Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Lo-
cate the short to ground and repair.
8. Fault codes indicate circuit fault due to open circuit condition. Disconnect shoe leveling motor connector
X088. Measure the resistance of the motor between terminals D and E. The correct resistance is 1 to 5 ohms.
A. The resistance is infinite, indicating an open condition in the motor. Replace the shoe leveling motor.
B. The resistance is in specification. Continue with step 9.
to check for continuity between connector X088 pin E and chassis ground.
position, irregardless of key switch position, as long as it receives power through fuse F22. This ground path
may be used to test for an open circuit condition.
55-259
chassis ground.
1 and connector X088 pin E wire 707 white. Locate the open and repair.
B. If continuity is found, recheck the motor for continuity at step 8.
chassis ground.
D and X023 pin 2. Locate the open and repair.
Visually inspect the harnesses for damage, bent or dislocated pins, corroded terminals or broken wires. Lo-
cate the open circuit and repair.
13. If the shoe leveling motor does not operate in either direction, and there are no error codes indicated, the
supply power for the circuit may not be present. Remove and inspect fuse F22.
harness
55-260
harness
55-261
1
10004665
10010898
50020089
49
2. CONNECTOR X023
3. CONNECTOR X020
55-262
55-263
FAULT CODE – E0076-05 Fan Speed Motor Line Disconnected

Context:
Cause:
Solution:
in both directions.
engage?
SYMPTOM FAULT CODES

E0041-06 E0042-06 E0076-05 E0077-05
X Go to Step 2
Fan operates in 1 direction
only X Go to Step 3
Fan and reverser operate in X X Go to Step 7

1 direction only
Fan does not operate in X Go to Step 11
either direction
X Go to Step 18
Reverser operates in 1 X Go to Step 19
direction only
X Go to Step 20
Reverser does not operate X Go to Step 24
in either direction
X Go to Step 31
Both fan and reverser do not X X Go to Step 32
operate in either direction
Both fan and reverser do not NO FAULT CODE Go to Step 34
55-264
and chassis ground.
and chassis ground.
and chassis ground.
chassis ground.
55-265
ground.
55-266
chassis ground.
and chassis ground.
chassis ground.
55-267
chassis ground.
55-268
30998030 50020070
10010899
10010898
50020089
50
1. FAN SPEED MOTOR M05 4. FAN/REVERSER RELAY K17
3. CONNECTOR X031
55-269
55-270
FAULT CODE – E0077-05 Reverser Motor Line Disconnected

Context:
Cause:
Solution:
in both directions.
engage?
SYMPTOM FAULT CODES

E0041-06 E0042-06 E0076-05 E0077-05
X Go to Step 2
Fan operates in 1 direction
only X Go to Step 3
Fan and reverser operate in X X Go to Step 7

1 direction only
Fan does not operate in X Go to Step 11
either direction
X Go to Step 18
Reverser operates in 1 X Go to Step 19
direction only
X Go to Step 20
Reverser does not operate X Go to Step 24
in either direction
X Go to Step 31
Both fan and reverser do not X X Go to Step 32
Both fan and reverser do not NO FAULT CODE Go to Step 34
55-271
and chassis ground.
and chassis ground.
and chassis ground.
chassis ground.
55-272
ground.
55-273
chassis ground.
and chassis ground.
chassis ground.
55-274
chassis ground.
55-275
20021064
3 4
50020070
2
10010899
40024707
50020085
51
1. FEEDER REVERSER ACTUATOR M10 4. FAN/REVERSER RELAY K17
3. CONNECTOR X031
55-276
55-277
FAULT CODE – E0078-05 Concave Clearance Motor Line Disconnected

Context:
Cause:

Solution:
SYMPTOM FAULT CODES

E0044-06 E0045-06 E0078-05 E0079-05
X Go to Step 2
Concave operates in 1
Concave and covers operate X X Go to Step 6

in 1 direction only
Concave does not operate in X Go to Step 9
either direction
X Go to Step 14
Covers operates in 1 X Go to Step 15
direction only
X Go to Step 16
Covers do not operate in X Go to Step 20
either direction
X Go to Step 27
Both concave and covers do X X Go to Step 28
not operate in either direction
Both concave and covers do NO FAULT CODE Go to Step 30
55-278
and chassis ground.
chassis ground.
concaves.
55-279
chassis ground.
chassis ground.
and chassis ground.
55-280
covers.
operation.
ground.
chassis ground.
chassis ground.
chassis ground.
55-281
55-282
40025229
50020070
10010899
50020091
52
1. CONCAVE CLEARANCE ACTUATOR M04 3. CONCAVE/COVERS RELAY K16
55-283
55-284
FAULT CODE – E0079-05 Grain Bin Covers Motor Line Disconnected

Context:
Cause:

Solution:
SYMPTOM FAULT CODES

E0044-06 E0045-06 E0078-05 E0079-05
X Go to Step 2
Concave operates in 1
Concave and covers operate X X Go to Step 6

in 1 direction only
Concave does not operate in X Go to Step 9
either direction
X Go to Step 14
Covers operates in 1 X Go to Step 15
direction only
X Go to Step 16
Covers do not operate in X Go to Step 20
either direction
X Go to Step 27
Both concave and covers do X X Go to Step 28
Both concave and covers do NO FAULT CODE Go to Step 30
55-285
and chassis ground.
chassis ground.
concaves.
55-286
chassis ground.
chassis ground.
and chassis ground.
55-287
covers.
operation.
ground.
chassis ground.
chassis ground.
chassis ground.
55-288
55-289
10004684
4
50020070
10010899
50020082
53
1. GRAIN BIN COVERS MOTOR M12 4. CONCAVE / COVERS RELAY K16
3. CONNECTOR X004
55-290
55-291
FAULT CODE – E0080-12 HHC Module Bad Intelligent Device

Cause:
The HHC module (A07) software is incompatible with the current CCM1 module software.
1. Incorrect software loaded in either HHC module or CCM1 module.
Solution:
The HHC module communicates with the CCM1 module to report error messages and other operational
information. In some cases, due to design changes, there may be some incompatibility between certain versions
of the software installed in either module.
If this error message appears, contact the New Holland service department to obtain information on software
version compatibilities.
55-292
FAULT CODE – E0082-11 Feeder Speed Incr Unidentified Failure Code

Cause:
The feeder increase solenoid (L11) circuit is open or shorted to ground.
Solution:

Select “Feeder Speed Incr” and select the “Status” screen. Press the “Enter” key to manually power the circuit.
2. Turn the key switch to the OFF position and disconnect the feeder increase solenoid connector X283. Use
a multimeter to check the resistance of the feeder increase solenoid coil. The proper resistance range for
the coil is 2.0 to 6.0 ohms.
A. If the coil is out of specification, replace the coil.
3. Use a multimeter to check for continuity between the harness end of connector X283 pin 1 and chassis
ground. Flex the main valves harness while making this check.
the feeder increase solenoid. Use a multimeter to check for 12 volts between connector X283 pin 1 and
chassis ground.
screen to manually power the feeder increase solenoid. Use a multimeter to check for 12 volts between
connector X022 pin N and chassis ground.
A. If 12 volts is not present, there is an open circuit in the main frame (MF) harness between connector
X022 pin N and connector X019 pin J2-7 wire 582 white. Locate the open and repair.
B. If there is 12 volts, there is an open circuit in the main valves (MV) harness between connector X022
pin N and connector X283 pin 1 wire 582 white. Locate the open and repair.
6. Disconnect connector X022. Use a multimeter to check for continuity between connector X022 pin N and
chassis ground.
A. If there is continuity, there is a short to ground in the main frame (MF) harness between connector X022
pin N and connector X019 pin J2-7 wire 582 white. Locate the short and repair.
B. If there is no continuity, there is a short to ground in the main valves (MV) harness between connector
X022 pin N and connector X283 pin 1 wire 582 white. Locate the short and repair.
55-293
chassis ground.
A. If there is continuity, there is an open circuit in the main valves (MV) harness between connector X283
and connector X022 wire 609 black or 501 black. Locate the open and repair.
B. If there is no continuity, there is an open circuit in the main frame (MF) harness between connector
X022 and front frame ground #2 wire 501 black or 483 black. Locate the open and repair.
55-294
1
40025225
10020031
50031010
54
1. FEEDER SPEED INCREASE SOLENOID L11 3. FRONT FRAME GROUND #2
55-295
55-296
55-297
FAULT CODE – E0083-11 Feeder Speed Decr Unidentified Failure Code

Cause:
The feeder decrease solenoid (L12) circuit is open or shorted to ground.

Solution:

Select “Feeder Speed Decr” and select the “Status” screen. Press the “Enter” key to manually power the cir-
cuit.
2. Turn the key switch to the OFF position and disconnect the feeder decrease solenoid connector X282. Use
a multimeter to check the resistance of the feeder decrease solenoid coil. The proper resistance range for
the coil is 2.0 to 6.0 ohms.
A. If the coil is out of specification, replace the coil.
3. Use a multimeter to check for continuity between the harness end of connector X282 pin 1 and chassis
ground. Flex the main valves harness while making this check.
the feeder decrease solenoid. Use a multimeter to check for 12 volts between connector X282 pin 1 and
chassis ground.
screen to manually power the feeder decrease solenoid. Use a multimeter to check for 12 volts between
connector X022 pin M and chassis ground.
A. If 12 volts is not present, there is an open circuit in the main frame (MF) harness between connector
X022 pin M and connector X019 pin J2-8 wire 581 white. Locate the open and repair.
B. If there is 12 volts, there is an open circuit in the main valves (MV) harness between connector X022
pin M and connector X282 pin 1 wire 581 white. Locate the open and repair.
55-298
6. Disconnect connector X022. Use a multimeter to check for continuity between connector X022 pin M and
chassis ground.
A. If there is continuity, there is a short to ground in the main frame (MF) harness between connector X022
pin M and connector X019 pin J2-8 wire 581 white. Locate the short and repair.
B. If there is no continuity, there is a short to ground in the main valves (MV) harness between connector
X022 pin M and connector X282 pin 1 wire 581 white. Locate the short and repair.
chassis ground.
A. If there is continuity, there is an open circuit in the main valves (MV) harness between connector X282
and connector X022 wire 608 black or 501 black. Locate the open and repair.
B. If there is no continuity, there is an open circuit in the main frame (MF) harness between connector
X022 and front frame ground #2 wire 501 black or 483 black. Locate the open and repair.
55-299
1
40025225
10020031
50031010
55
1. FEEDER SPEED INCREASE SOLENOID L12 3. FRONT FRAME GROUND #2
55-300
55-301
55-302
FAULT CODE – E0084-14 Voting Conflicts Found Special Instructions

Cause:
A data location has data which is different in all of the voting modules.

1. Vehicle configuration and calibration information corrupted.
Solution:
When installing a new or replacement CCM module into the vehicle, the other modules will supply current
configuration information to this module based on true democratic voting rules. If all reporting modules have
different configuration data, there is no majority consensus as to what the values should be. As a result,
configuration information will not be written to the new or replacement module, and the configuration data will
remain unchanged (and therefore different) in all modules.
If this error message appears, review machine configurations to make sure that they are correct. Re-write
configuration data using the electronic service tool (EST).
FAULT CODE – E0085-14 Voting Differences Found Special Instructions

Cause:
A data location has data which is different in one of the voting modules.

1. One of the voting modules has corrupted configuration and calibration data.
Solution:
When installing a new or replacement CCM module into the vehicle, the other modules will supply current
configuration information to this module based on true democratic voting rules. If one reporting module has
different configuration data, this will be reported, however, there is majority consensus as to what the value
should be. The majority data is copied to all modules on the network so that the configuration data will be the
same in all modules.
This error message appears as a notification message, however, no further action is required, as the problem
is automatically corrected.
55-303
55-304
CONTENTS

E0128 Trans Shift Gear N sens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E0129 Trans Shift Gear 3 sens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
E0133 Hydraulic Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
E0134 Brake Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
E0135 Charge Pressure Switch Valid Below Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
E0136 Beacon Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
E0137 Open Covers Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
E0138 Hazards Switch Shorted to Low Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
E0140 Operator Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
E0141 Header Reel RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
E0142 Groundspeed RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
E0143 Chopper RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
E0145 Engine RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
E0146 Thresher RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
E0148 Header Type Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
E0151 Thresher Clutch Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
E0152 Coolant Temp / Fuel Filt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
E0153 Engine Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
E0154 Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
E0159 Grain Bin Full Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
E0161 Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
E0162 Control Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
E0163 Engine Air Filter Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
E0164 V Supply Ground Spd Hydro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
E0166 CCM2 8V Ref Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
E0169 Current Sense Reel Speed Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
55-1

E0171 Curr Sense Transm Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
E0172 Curr Sense Rot Scr Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
E0173 Curr Sense Eng Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
E0174 CCM2 Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
E0175 V Supply Thresher Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
E0177 Isense Unload Cross Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
E0178 Isense Thresher Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
E0179 LoP Isense Grnd Spd Hydro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
E0180 Thresher Clutch Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
E0181 Parking Brake Disengage Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
E0182 Fuel Shutoff Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
E0183 Brake Limiting Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
E0184 Unload Cross Auger Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
E0185 Header Reel Fore Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
E0186 Header Reel Drive Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
E0187 Header Reel Up Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
E0188 Header Reel Down Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
E0189 Header Reel Back Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
E0191 Thresher Speed Increase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
E0192 Thresher Speed Decrease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
E0193 Unload Tube In Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
E0194 Unload Tube Out Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
E0195 Foot-an-Inch Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
E0196 Grid Heater Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
E0197 Rot Scr Brush / Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
E0198 Backlighting Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
E0199 Brake Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
E0200 Beacon Lights Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
E0201 Flasher System Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
E0202 Ground Speed Hydrostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
E0203 Transmission Shift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
E0204 Header Reel Speed Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
E0206 Rotary Screen Brush Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
E0207 Engine Throttle Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
E0208 ECU Module Data Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
55-2
FAULT CODE – E0128-03 Trans Shift Gear N sens

Shorted to High Source
Cause:
The transmission shift position N sensor (B-37) circuit is shorted to 12 volts.

Solution:
1. Enter the Infoview® monitor - “Diagnose info” screen.
Select “Trans shift gear N sens” and check voltage range.
The proper voltage when in shift position N - 5.6 to 7.3 volts
The proper voltage when not in shift position N - 0.5 to 5.6 volts
A. If the voltage reading is high out of range continue with Step 2.
Continue troubleshooting at Step 4.
2. The voltage reading on the Infoview monitor is high. Disconnect the transmission shift position sensor
connector X093 at the transmission.
A. If the voltage drops to 7.3 to 9.0 volts the short is in the sensor, or sensor wiring. Replace the sensor.
To temporarily bypass that sensor see Step 5.
B. If the voltage remains high on Infoview monitor continue with Step 3.
3. The voltage reading on the Infoview monitor is high. Disconnect the lower frame harness from the front frame
A. If the voltage drops to 7.3 to 9.0 volts the short is in the lower frame harness between connector X023
pin 10 and connector X093 pin 1 wire 407 yellow. Locate the short and repair.
B. If the voltage remains high on Infoview monitor the short circuit is somewhere between connector X023
pin 10 and connector X017 pin J3-28 on CCM2 in the front frame harness wire 407 yellow. Locate
4. Operate the transmission shift gear lever and monitor the Infoview monitor voltage readings.
A. If high voltage reading is now viewed continue with Step 2.
B. If a high voltage reading cannot be generated erase the fault code and continue operation.
5. To bypass a bad sensor create a short circuit between the bad sensor wire and common ground (pin 6) in
connector X093. The system will generate a fault code for “shorted to low source” and the operator can
continue without that gear.
55-3
FAULT CODE – E0128-04 Trans Shift Gear N sens

Shorted to Low Source
Cause:
The transmission shift position N sensor (B-37) circuit is shorted to ground.

Solution:
1. Enter the Infoview monitor - “Diagnose info” screen.
A. If the voltage reading is low 0 to 0.5 volts continue with Step 2.
B. If the voltage reading is within the proper limits. Continue the troubleshooting at Step 4.
2. The voltage reading on the Infoview monitor is low. Disconnect the transmission shift position sensor
A. If the voltage increases to 7.3 to 9.0 volts the short is in the sensor, or sensor wiring. Replace the sensor.
B. If the voltage remains low on Infoview monitor continue with Step 3.
3. The voltage reading on the Infoview monitor is low. Disconnect the lower frame harness from the front frame
A. If the voltage increases to 7.3 to 9.0 volts the short is in the lower frame harness between connector
X023 pin 10 and connector X093 pin 1 wire 407 yellow.
B. If the voltage remains low on Infoview monitor the short circuit is somewhere between connector X023
pin 10 and connector X017 pin J3-28 on CCM2 in the front frame harness wire 407 yellow.
A. If low voltage reading is now viewed continue with Step 2.
B. If a low voltage reading cannot be generated erase the fault code and continue operation.
55-4
FAULT CODE – E0128-05 Trans Shift Gear N sens Line Disconnected

Cause:
The transmission shift position N sensor (B-37) circuit is open.

1. Sensor supply or ground wiring is open.
Solution:
A. If the voltage reading is 7.3 to 9.0 volts continue with Step 2.
2. The voltage reading on the Infoview monitor is 7.3 to 9.0 volts. Disconnect the transmission shift position sensor
connector X093 at the transmission. Use a jumper wire to short connector X093 pin 1 to chassis ground.
side of the circuit. Continue with Step 4.
B. If the Infoview monitor still displays 7.3 to 9.0 volts continue with Step 3.
3. The voltage reading on the Infoview monitor is 7.3 to 9.0 volts. Disconnect the lower frame harness from the
front frame harness at connector X023. Use a jumper wire to short connector X023 pin 10 to ground.
A. If the Infoview monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the lower frame
(LF) harness between connector X023 pin 10 and connector X093 pin 1 wire 407 yellow. Locate the
open and repair.
B. If the Infoview monitor still displays 7.3 to 9.0 volts, the open is in the front frame (FF) harness between
connector X023 pin 10 and CCM2 connector X017 pin J3-28 wire 407 yellow. Locate the open and repair.
4. Disconnect the transmission shift position sensor connector X093. Use a multimeter to check for continuity
Replace the sensor.
B. If there is no continuity to ground, the ground path for the sensor is open. Continue with Step 5.
5. Disconnect the lower frame harness from the front frame harness at connector X023. Use a multimeter to
check for continuity between the harness end of connector X023 pin 5 and chassis ground.
A. If there is continuity, the open circuit is in the lower frame (LF) harness between connector X023 pin
B. If there is no continuity to ground, the open is in the front frame (FF) harness between connector X023
pin 5 and CCM2 connector X017 pin J3-18 wire 042 blue or 766 blue. Locate the open and repair.
6. Shift the transmission through all gears and monitor the voltage readings.
A. If a 7.3 to 9.0 voltage reading is now viewed, continue with Step 2.
B. If 7.3 to 9.0 voltage reading cannot be generated, erase the fault code and continue operation.
55-5
2
1
10004664
10010898
50020096
1
1. Transmission Shift Position Sensor B37
2. Connector X023
3. Connector X017
55-6
55-7
55-8
FAULT CODE – E0129-03 Trans Shift Gear 3 sens

Cause:
The transmission shift position 3 sensor (B-37) circuit is shorted to 12 volts.

Solution:
Select “Trans shift gear 3 sens” and check voltage range.
The proper voltage when in shift position 3 - 5.6 to 7.3 volts
The proper voltage when not in shift position 3 - 0.5 to 5.6 volts
B. If the voltage reading is within the proper limits, since the shorted wire may not be powered up at this
time. Continue the troubleshooting at Step 4.
pin 11 and connector X093 pin 4 wire 408 yellow.
55-9

Cause:
The transmission shift position 3 sensor (B-37) circuit is shorted to ground.

Solution:
The proper voltage when in shift position 3- 5.6 to 7.3 volts
The proper voltage when not in shift position 3- 0.5 to 5.6 volts
55-10
FAULT CODE – E0129-05 Trans Shift Gear 3 sens Line Disconnected

Cause:
The transmission shift position 3 sensor (B-37) circuit is open.

Solution:
front frame harness at connector X023. Use a jumper wire to short connector X023 pin 11 to chassis ground.
open and repair.
Replace the sensor.
A. If a 7.3 to 9.0 voltage reading is now viewed continue with Step 2.
B. If 7.3 to 9.0 voltage reading cannot be generated erase the fault code and continue operation.
55-11
2 1
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2. Connector X023
3. Connector X017
55-12
55-13
55-14

Cause:

Solution:
connector X093 pin 3 at the transmission.
55-15

Cause:

Solution:
The proper voltage when in shift position 2 - 5.6 to 7.3 volts
The proper voltage when not in shift position 2 - 0.5 to 5.6 volts
55-16
FAULT CODE – E0130-05 - Trans Shift Gear 2 sens Line Disconnected

Cause:

Solution:
2. The voltage reading on the Infoview monitor is 7.3 to 9.0 volts. Disconnect the transmission shift position
sensor connector X093 at the transmission. Use a jumper wire to short connector X093 pin 3 to ground.
open and repair.
B. If the Infoview monitor still displays 7.3 to 9.0 volts the open is in the front frame (FF) harness between
Replace the sensor.
55-17
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2. Connector X023
3. Connector X017
55-18
55-19
55-20

Cause:

Solution:
Select “Transmission shift position 1″ and check voltage range.
To temporarily bypass that speed see Step 5.
55-21

Cause:

Solution:
55-22

Cause:

Solution:
2. The voltage reading on the Infoview monitor is 7.3 to 9.0 volts. Disconnect the transmission shift position
sensor connector X093 at the transmission. Use a jumper wire to short connector X093 pin 2 to chassis
ground.
open and repair.
Replace the sensor.
55-23
2 1
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10010898
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4
2. Connector X023
3. Connector X017
55-24
55-25
55-26
FAULT CODE – E0132-03 Trans Shift Gear 4 sens Shorted to High Source
Cause:

Solution:
To temporarily bypass that speed see Step 5.
55-27

Cause:

Solution:
55-28

Cause:
The transmission shift position 4 sensor (B37) circuit is open.

Solution:
open and repair.
connector X023 pin 12 and CCM2 connector X017 pin J3-27, wire 409 yellow. Locate the open and repair.
Replace the sensor.
55-29
2 1
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2. Connector X023
3. Connector X017
55-30
55-31
55-32
FAULT CODE – E0133-03 Hydraulic Reservoir Level

Cause:
The hydraulic reservoir level switch (S-33) circuit is shorted to 12 volts.

1. Switch supply wiring shorted to 12 volts.
Solution:
Select “Hydraulic reservoir level” and check voltage range.
The proper voltage range for the hydraulic reservoir level switch is - 1.8 volts or less, oil level okay.
The proper voltage for the hydraulic reservoir level switch when oil level is low is approximately 8.3 volts.
A. If the voltage reading is high out of range (>10 volts), continue with Step 2.
2. The voltage reading on the Infoview monitor is high. Disconnect the hydraulic reservoir level switch
connector X104 at the reservoir.
A. If the voltage drops back into the proper range the short is in the switch, or switch wiring. Replace the
switch.
3. The voltage reading on the Infoview monitor is high. Disconnect the gearbox harness from the main frame
A. If the voltage drops back into the proper range the short is in the gearbox harness between connector
X011 pin C and connector X104 pin B wire 424 yellow. Locate and repair.
pin C and connector X016 pin J2-39 on CCM2 in the main frame harness wire 424 yellow. Locate and
repair.
4. Operate the machine while monitoring Infoview display. If no high out of range readings are indicated, erase
55-33
10020076
1
50014693
50020097
6
1. Hydraulic Reservoir Level Switch S33
2. Connector X011
3. Connector X016
55-34
55-35
FAULT CODE – E0134-03 Brake Pressure Switch

Cause:
The brake pressure switch (S-39) circuit is shorted to 12 volts.

Solution:
Select “Brake pressure switch” and check voltage range.
The proper voltage for the brake pressure switch is approximately 8.3 volts - brakes off.
The proper voltage range for the brake pressure switch is 1.8 volts or less - brakes on.
B. If the voltage is within range, the short may not be present at this time. Continue with Step 3.
2. The voltage reading on the Infoview monitor is high. Disconnect the brake pressure switch connector X173.
A. If the voltage drops back into the proper range the short is in the switch, or switch wiring. Replace the
switch.
and connector X016 pin J2-34 on CCM2 in the main frame harness wire 418 yellow. Locate the short
and repair.
55-36
10010876
50020098
7
1. Brake Pressure Switch S39
2. Connector X016
55-37
55-38
FAULT CODE – E0135-01 Charge Pressure Switch Valid Below Normal

Context:
When the hydrostatic charge pressure drops below 5 bar (73 psi) for more than 1 second after the engine has
been running for at least 4 seconds, the alarm message “A0081 Hydrostatic Charge Pressure LOW” will be
displayed to the operator. The engine will be shutdown after the alarm has been active for 2 seconds to prevent
damage to the hydrostatic systems. When the alarm message is displayed, a permanent record is created in the
error history. The EST must be used to erase this fault code.
Cause:
CCM2 has detected that the charge pressure switch circuit voltage has dropped to < 1.8 volts with the engine
running for > 1 second, indicating a low pressure condition. The “A0081 Hydrostatic Charge Pressure LOW”
alarm has occurred at least once on the vehicle.

1. The charge pressure has dropped below acceptable limits during operation and the switch has closed -this
is normal operation of the circuit and indicates a mechanical failure.
2. The charge pressure switch S-37 circuit is shorted to ground while the engine is running.
3. Charge pressure switch S-37 failure.
IMPORTANT: Do not run the engine without first verifying there are no mechanical faults in the system and you
are now only troubleshooting an electrical fault. Serious and costly damage to the hydraulic components of the
system will occur.
Solution:
1. Verify the fault is present. Enter the Infoview monitor “Diagnose info” screen, “Driveline” submenu. Select
“Charge Pressure switch” and observe the voltage. Install a pressure gauge to monitor hydrostatic charge
pressure.
A. With the engine off, the voltage reading should be < 1.8 volts. If the voltage is > 1.8 volts, another fault
code will be present. Repair the E0135-03 or E0135-05 fault first.
B. With the engine running, the voltage reading should be between 1.8-10.0 volts. If the voltage remains
< 1.8 volts (the engine will shut down) and the charge pressure is above 5 bar (73 psi), continue
troubleshooting with Step 2.
2. Verify charge pressure switch S-37 is functioning. Disconnect the charge pressure switch circuit 684 yellow
at X101. With the key off, use an ohmmeter to measure the continuity between the switch side of X101 and
ground. Start the engine and repeat the continuity check.
A. If continuity is indicated with the engine off, and open with the engine running, then the switch is
functioning properly. The fault will be in the wiring. Continue troubleshooting with Step 3.
B. If continuity is indicated while the engine is running and the pump is known to be working properly
mechanically, then the switch is faulty. Replace the charge pressure switch S-37. Continue
3. Verify circuit 684 yellow is not shorted to ground. Disconnect the charge pressure switch circuit 684 yellow
at X101 and disconnect gearbox harness connector X011. Use an ohmmeter to check for continuity
between circuit 684 yellow and ground.
A. If continuity to ground is found, locate and repair the short to ground in the gearbox harness. Continue
B. If no continuity to ground is found, locate and repair the short to ground in the main frame harness
between connector X011 and connector X016. Continue troubleshooting with Step 4.
4. Visually inspect the harness and connectors for damage, bent or dislocated pins, broken or pinched wires.
55-39
FAULT CODE – E0135-03 Charge Pressure Switch

Cause:
The charge pressure switch (S-37) circuit is shorted to 12 volts.

Solution:
Select “Charge pressure switch” and check voltage range.
The proper voltage range for the charge pressure switch (engine not running) is 0 to 1.8 volts.
The proper voltage range for the charge pressure switch (engine running) is - 1.8 to 10.0 volts.
2. The voltage reading on the Infoview monitor is high. Disconnect the charge pressure switch connector
X101.
A. If the voltage drops back into the proper range the short is in the switch. Replace the switch.
A. If the voltage drops back into the proper range the short is in the gearbox harness between connector
X011 pin W and connector X101 wire 684 yellow. Locate and repair.
pin W and connector X016 pin J2-35 on CCM2 in the main frame harness wire 684 yellow. Locate
and repair.
55-40
FAULT CODE – E0135-05 Charge Pressure Switch Line Disconnected

Cause:
The charge pressure switch (S-37) circuit is open.

Solution:
The charge pressure switch is normally closed when there is no pressure (engine not running), and open when
there is pressure (engine running). The check for an open circuit only occurs when the electrical system is initially
powered up before the engine is started.

Select “Charge pressure switch” and check voltage range.
The proper voltage range for the charge pressure switch when the engine is not running is 1.8 volts or less.
A. If the voltage reading is high (1.8 to 10 volts), continue with Step 2.
B. If the voltage reading is within the proper limits, the wire may not be open at this time. Continue the
troubleshooting at Step 4.
2. The voltage reading on the Infoview monitor is high. Disconnect the charge pressure switch connector X101
ring terminal and ground the terminal to the chassis.
A. If the voltage drops back into the proper range (0 to 1.8 volts), the switch has failed open. Replace the
switch.
B. If the voltage remains high on Infoview monitor, continue with Step 3.
harness at connector X011 and provide a ground to pin W.
A. If the voltage drops back into the proper range (0 to 1,8 volts), the open is in the gearbox (GB) harness
between the switch connector X101 and connector X011 pin W wire 684 yellow. Locate open and
repair.
B. If the voltage remains high on Infoview monitor, the open circuit is in the main frame (MF) harness
between connector X011 pin W and connector X016 pin J2-35 wire 684 yellow. Locate open and
repair.
55-41
10020076
10010872
50020097
8
1. Charge Pressure Switch S37
2. Connector X011
3. Connector X016
55-42
55-43
FAULT CODE – E0136-04 Beacon Lights Switch Shorted to Low Source

Cause:
The beacon light switch (S-41) circuit is shorted to ground.

1. Switch supply wiring shorted to ground.
Solution:
Select “Beacon Lights switch” and check voltage range. Cycle the beacon light switch between the On and
Off positions.
The normal operating range for the beacon light in the “Off” position is 0.25 to 3.5 volts.
The normal operating range for the beacon light in the “On” position is 3.5 to 5.0 volts.
NOTE: The beacon light switch actually supplies 12 volts (battery voltage) to the module when in the On position,
however, the Diagnostic screen bar graph only displays to 5 volts.
A. If the voltage reading is low (0 to 0.25 volts) continue with Step 2.

B. If the voltage reading is within the proper limits continue the troubleshooting at Step 5.
2. Check fuse F49.

A. If fuse has failed, continue with Step 3.
B. If fuse is okay, continue with Step 4.
A. If fuse immediately fails, there is a short to ground on one of the following wires in the cab main (CM)
or cab roof (CR) harnesses:
wire 046 orange, fuse F49 through connector X073 to seat switch S05
wire 045 orange, fuse F49 through connector X002 pin 1 [pin A, below SN HAJ100074] to cab roof
harness splice
wire 901 orange, harness splice to HVAC module connector X128 pin C2
wire 240 orange, harness splice to rear work light switch connector X131 pin 2
wire 172 orange, harness splice to beacon light switch connector X130 pin 2
wire 124 orange, harness splice to tank extensions switch connector X125 pin 2
4. Place the beacon light switch in the ON position.
A. If fuse immediately fails, there is a short to ground in the cab main (CM) or cab roof (CR) harnesses
between the beacon lights switch connector X130 pin 3 through connector X002 pin 12 [pin M, below
SN HAJ100074] to connector X015 pin J1-2 wire 166 yellow. Locate the short and repair.
5. Operate the machine while monitoring Infoview display. If no low out of range readings are indicated, erase
55-44
10010915
4 3
10004693 50020070
50020099
9
1. Beacon Light Switch S41
2. Connector X002
3. Fuse F49
4. Connector X015
55-45
55-46
55-47
FAULT CODE – E0137-04 Open Covers Switch Shorted to Low Source

Cause:
The tank extensions switch (S42) circuit is shorted to ground.

Solution:
Select “Open Covers switch” and check voltage range. Cycle the tank extensions switch between the On and
Off positions.
The normal operating range for the tank extensions switch in the “Off” position is 0.25 to 3.5 volts.
The normal operating range for the tank extensions switch in the “On” position is 3.5 to 5.0 volts.
NOTE: The tank extensions switch actually supplies 12 volts (battery voltage) to the module when in the On
position, however, the Diagnostic screen bar graph only displays to 5 volts.
A. If the voltage reading is low (0 to 0.25 volts) out of range, continue with Step 2.
2. Check fuse F49.

harness splice
4. Place the tank extensions switch in the ON position.
A. If fuse immediately fails, there is a short to ground in the cab main (CM) or cab roof (CR) harnesses
between the tank extensions switch connector X125 pin 3 through connector X002 pin 13 [pin N,
below SN HAJ100074] to connector X015 pin J1-3 wire 167 yellow. Locate the short and repair.
55-48
10010915
4 3
10004693 50020070
50020099
10
1. Tank Extensions Switch S42
2. Connector X002
3. Fuse F49
4. Connector X015
55-49
55-50
55-51
FAULT CODE -- E0138-04 Hazards Switch Shorted to Low Source
Cause:
The hazard warning lights switch (S25) circuit is shorted to ground.

Solution:
1. Enter the Infoview monitor - “Diagnose info” screen. Select the “LIGHTS” sub menu, and select “HAZARDS
SWITCH” to check the voltage range. Cycle the hazard warning lights switch between the On and Off
position.
The normal operating range for the hazards switch -- ON is 4.0 -- 5.0 volts.
The normal operating range for the hazards switch -- OFF is 0.25 -- 4.0 volts.
A. If the voltage reading is 0 -- 0.25 volts in either switch position, continue with Step 2.
B. If the voltage reading is 0.25 -- 4.0 volts with the switch OFF and 0 -- 0.25 volts with the switch ON,
continue with Step 3.
NOTE: Check fuse 56. If a short to ground occurred on this circuit, the fuse will have blown.
the cab main (CM) harness from the steering column (SC) harness at connector X033.
A. If the voltage increases to 0.25 -- 4.0 volts, the short is in the electronic flasher, or steering column (SC)
harness wire 1209 or 179 purple. Replace the electronic flasher before attempting to repair the steering
column (SC) harness. Erase fault code and operate system.
B. If the voltage remains low, the short is in the cab main (CM) harness between connector X033, CCM2
connector X015 and the road light switch connector X256 in wires 207,1209 or 179 purple. Locate the
short and repair.
3. The voltage reading is 0.25 -- 4.0 volts with the switch OFF and 0 -- 0.25 volts with the switch ON. The short
to ground is between the fuse and switch.
A. The short is in the cab main (CM) or steering column (SC) harness wires 054, 040 or 102 red. Visually
inspect the cab main (CM) harness for damage, bent or dislocated pins, corroded terminals or broken
wires. Locate short and repair.
55-52
55-53
FAULT CODE – E0140-04 Operator Seat Switch Shorted to Low Source

Cause:
The seat switch (S-05) circuit is shorted to ground.

Solution:
Select “Operator seat switch” and check voltage range. Sit on and raise out of the operator’s seat to cycle
the seat switch.
The normal operating range for the seat switch when off the seat is 0.25 to 3.5 volts.
The normal operating range for the seat switch when sitting on the seat is 3.5 to 5.0 volts.
NOTE: The seat switch actually supplies 12 volts (battery voltage) to the module when in the On position,
however, the Diagnostic screen bar graph only displays to 5 volts.
A. If the voltage reading is low (0 to 0.25 volts) out of range continue with Step 2.
2. No operator in seat. Check fuse F49.

3. No operator in seat. Replace fuse F49.
harness splice
4. Sit in the seat to close the seat switch.
A. If fuse immediately fails, there is a short to ground in the cab main (CM) or jumper harnesses between
the seat switch connector X317 pin B through connector X037 pin B to connector X015 pin J1-9
wire 168 yellow. Locate the short and repair.
55-54
10010921
3 4
10004693 50020070
50026204
11
1. Seat Switch S05
2. Connector X073
3. Connector X015
4. Fuse F49
55-55
55-56
FAULT CODE – E0141-03 Header Reel RPM Sensor

Cause:
The header reel RPM sensor (B15) circuit is shorted to a higher than normal voltage source.

Solution:
Select “Header Reel RPM sensor” and check voltage range.
The proper voltage for sensor when blocked by ferrous metal - 5.6 to 7.3 volts
The proper voltage for sensor when not blocked by ferrous metal - 0.5 to 5.6 volts
A. If the voltage reading is high out of range 9.0 volts or more continue with Step 2.
2. The voltage reading on the Infoview monitor is high. Disconnect the reel RPM sensor connector X309.
3. The voltage reading on the Infoview monitor is high. Disconnect the feeder harness at connector X032.
A. If the voltage drops to 7.3 to 9.0 volts the short is in the header harness between connector X032 pin
7 and connector X309 pin B wire 737 yellow.
4. The voltage reading on the Infoview monitor is high. Disconnect the feeder harness and front frame harness
at connector X007.
A. If the voltage drops to 7.3 to 9.0 volts the short is in the feeder (FE) harness between connector X007
Pin 14 and connector X032 pin 7 wire 737 yellow.
B. If the voltage remains high on Infoview monitor the short circuit is in the front frame harness between
connector X007 pin 14 and connector X017 pin J3-13 wire 737 yellow.
in front of sensor then remove. The sensor is functioning if LED changes state.
55-57
FAULT CODE – E0141-04 Header Reel RPM Sensor

Cause:
The Header reel RPM sensor (B15) circuit is shorted to ground.

Solution:
The proper voltage sensor blocked by ferrous metal - 5.6 to 7.3 volts
The proper voltage sensor unblocked by ferrous metal - 0.5 to 5.6 volts
2. The voltage reading on the Infoview monitor is low. Disconnect the reel RPM sensor connector X309.
3. The voltage reading on the Infoview monitor is low. Disconnect the feeder harness at connector X032.
A. If the voltage increases to 7.3 to 9.0 volts the short is in the header harness between connector X032
pin 7 and connector X309 pin B wire 737 yellow.
4. The voltage reading on the Infoview monitor is low. Disconnect the feeder harness from the front frame
A. If the voltage increases to 7.3 to 9.0 volts, the short is in the feeder(FE) harness between connector
B. If the voltage remains low, the short circuit is in the front frame harness between connector X007 pin
14 and connector X017 pin J3-13 wire 737 yellow.
55-58
FAULT CODE – E0141-05 Header Reel RPM Sensor Line Disconnected

Cause:
The header reel RPM sensor (B15) circuit is open.

Solution:
The proper voltage sensor disconnected 7.3 to 9.0 volts.
A. If the voltage reading is high 7.3 to 9.0 volts, continue with Step 2.
2. The voltage reading on the Infoview monitor is 7.3 to 9.0 volts. Disconnect the reel RPM sensor connector
X309. Use a jumper wire to short pin B on the harness end of connector X309 to ground.
3. The voltage reading on the Infoview monitor is 7.3 to 9.0 volts. Disconnect the feeder harness at connector
X032. Use a jumper wire to short pin 7 on connector X032 to ground.
A. If the Infoview monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the header harness
between connector X032 and connector X309 wire 737 yellow. Locate the open and repair.
B. If the Infoview monitor still displays 7.3 to 9.0 continue with Step 4.
4. The voltage reading on the Infoview monitor is 7.3 to 9.0 volts. Disconnect the feeder harness from the front
frame harness at connector X007. Use a jumper wire to short pin 14 of connector X007 to ground.
A. If the Infoview monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the feeder (FE)
harness between connector X007 pin 14 and connector X032 pin 7 wire 737 yellow.
repair.
5. Disconnect the header reel RPM sensor connector X309. Use a multimeter to check for continuity between
the harness end of connector X309 pin A and chassis ground.
Replace the sensor.
55-59
6. Disconnect the header harness from the feeder harness at connector X032. Use a multimeter to check for
continuity between the harness end of connector X032 pin 7 and chassis ground.
A. If there is continuity, the open circuit is in the header (HE) harness between connector X032 pin 7 and
connector X309 pin A wire 750 blue. Locate the open and repair.
B. If there is no continuity to ground, continue with Step 7.
7. Disconnect the feeder harness from the front frame harness at connector X007. Use a multimeter to check
for continuity between the harness end of connector X007 pin 14 and chassis ground.
A. If there is continuity, the open circuit is in the feeder (FE) harness between connector X007 pin 14 and
connector X032 pin 7 wire 750 blue. Locate the open and repair.
8. Operate header reel and monitor the Infoview monitor voltage readings.
55-60
2
10020040
40024707
50026205
12
1. Reel RPM Sensor B15 (On Header)
2. Connector X032
3. Connector X007
4. Connector X017
55-61
55-62
55-63
FAULT CODE – E0142-03 Groundspeed RPM Sensor

Cause:
The ground speed RPM sensor (B17) circuit is shorted to a higher than normal voltage source.

Solution:
Select “Groundspeed RPM sensor” and check voltage range.
A. If the voltage reading is high out of range 9.0 to 10.0 volts continue with Step 2.
2. The voltage reading on the Infoview monitor is high. Disconnect the ground speed RPM sensor connector
X087.
3. The voltage reading on the Infoview monitor is high. Disconnect the lower frame harness and front frame
X023 pin 6 and connector X087 pin B wire 403 yellow.
B. If the voltage remains high on Infoview monitor the short circuit is in the front frame (FF) harness
between connector X023 pin 6 and connector X017 pin J3-14 wire 403 yellow.
55-64
FAULT CODE – E0142-04 Groundspeed RPM Sensor

Cause:
The ground speed RPM sensor (B17) circuit is shorted to ground.

Solution:
2. The voltage reading on the Infoview monitor is low. Disconnect the ground speed RPM sensor connector
X087.
A. If the voltage increases to 7.3 to 9.0 volts, the short is in the sensor or sensor wiring. Replace the sensor.
B. If the voltage remains low on Infoview display, continue with Step 3.
connector X023 pin 6 and connector X087 pin B wire 403 yellow.
B. If the voltage remains low, the short circuit is in the front frame harness between connector X023 pin
6 and connector X017 pin J3-14 wire 403 yellow.
55-65
FAULT CODE – E0142-05 Groundspeed RPM Sensor Line Disconnected

Cause:
The ground speed RPM sensor (B17) circuit is open.

Solution:
A. If the voltage reading is high 7.3 to 9.0 volts continue with Step 2.
2. The voltage reading on the Infoview monitor is 7.3 to 9.0 volts. Disconnect the ground speed RPM sensor
connector X087. Use a jumper wire to short pin B on the harness end of connector X087 to ground.
front frame harness at connector X023. Use a jumper wire to short pin 6 on connector X023 to ground.
(LF) harness between connector X023 pin 6 and connector X087 pin B wire 403 yellow. Locate the
open and repair.
B. If the Infoview monitor still displays 7.3 to 9.0 volts, the open circuit is in the front frame (FF) harness between
connector X023 pin 6 and connector X017 pin J3-14 wire 403 yellow. Locate the open and repair.
4. Disconnect the ground speed RPM sensor connector X087. Use a multimeter to check for continuity
Replace the sensor.
5 and connector X087 pin A wire 717 blue or 042 blue. Locate the open and repair.
55-66
10004641
10010898
50020096
13
1. Ground Speed Sensor B17
2. Connector X023
3. Connector X017
55-67
55-68
55-69
FAULT CODE – E0143-03 Chopper RPM Sensor

NOTE: This troubleshooting chart is for CR combines with serial numbers < HAJ10073. The troubleshooting
chart for CR combines with serial numbers HAJ10073 and above is listed after this chart.
Cause:
The chopper RPM sensor (B- 10) circuit is shorted to a higher than normal voltage source.

Solution:
1. Enter the Infoview monitor “Diagnose info” screen.
Select “Chopper RPM sensor” and observe the voltage range.
The proper voltage for sensor when blocked by ferrous metal – 5.6 to 7.3 volts.
The proper voltage for sensor when not blocked by ferrous metal – 0.5 to 5.6 volts.
The proper voltage for sensor when disconnected – 7.3 to 9.0 volts.
2. The voltage reading on the Infoview monitor is high. Disconnect the chopper RPM sensor connector X253.
3. The voltage reading on the Infoview monitor is high. Disconnect the strawhood harness from the straw walker
A. If the voltage drops to 7.3 to 9.0 volts, the short is in the strawhood harness between connector X071
4. The voltage reading on the Infoview monitor is high. Disconnect the straw walker harness from the main
frame harness at connector X024.
A. If the voltage drops to 7.3 to 9.0 volts, the short is in the straw walker harness between connector X024
B. If the voltage remains high on Infoview monitor, the short circuit is in the main frame harness between
connector X024 pin 3 and connector X016 pin J2--38 wire 413 yellow.
55-70
FAULT CODE – E0143-04 Chopper RPM Sensor Shorted to Low Source

Cause:
The chopper RPM sensor (B- 10) circuit is shorted to ground.

Solution:
Select “Chopper RPM sensor” and observe the voltage range.
The proper voltage sensor blocked by ferrous metal – 5.6 to 7.3 volts.
The proper voltage sensor unblocked by ferrous metal – 0.5 to 5.6 volts.
The proper voltage sensor disconnected – 7.3 to 9.0 volts.

2. The voltage reading on the Infoview monitor is low. Disconnect the chopper RPM sensor connector X253.
B. If the voltage remains low on Infoview monitor, continue with Step 3.
3. The voltage reading on the Infoview monitor is low. Disconnect the strawhood harness from the straw walker
A. If the voltage increases to 7.3 to 9.0 volts, the short is in the strawhood harness between connector
B. If the voltage remains low on Infoview display, continue with Step 4.
4. The voltage reading on the Infoview monitor is low. Disconnect the straw walker harness from the main frame
A. If the voltage increases to 7.3 to 9.0 volts, the short is in the straw walker harness between connector
B. If the voltage remains low on Infoview monitor, the short to ground is in the main frame harness between
connector X024 pin 3 and connector X016 pin J2--38 wire 413 yellow.
55-71
FAULT CODE – E0143-05 Chopper RPM Sensor Line Disconnected

Cause:
The chopper RPM sensor (B- 10) circuit is open.

Solution:
Select “Chopper RPM sensor” and check voltage range.
The proper voltage sensor blocked by ferrous metal – 5.6 to 7.3 volts.
The proper voltage sensor unblocked by ferrous metal – 0.5 to 5.6 volts.
The proper voltage sensor disconnected – 7.3 to 9.0 volts.
2. The voltage reading on the Infoview monitor is 7.3 to 9.0 volts. Disconnect the chopper RPM sensor
connector X253. Use a jumper wire to short the harness end of connector X253 pin 2 to chassis ground.
3. The voltage reading on the Infoview monitor is 7.3 to 9.0 volts. Disconnect the straw hood harness from the
straw walker harness at connector X071. Use a jumper wire to short connector X071 pin 6 to chassis
ground.
(SH) harness between connector X071 pin 6 and connector X253 pin 2 wire 413 yellow. Locate the
open and repair.
4. The voltage reading on the Infoview monitor is 7.3 to 9.0 volts. Disconnect the straw walker harness from
the main frame harness at connector X024. Use a jumper wire to short connector X024 pin 3 to chassis
ground.
A. If the Infoview monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the straw walker
(SW) harness between connector X024 pin 3 and connector X071 pin 6 wire 413 yellow. Locate the
open and repair.
between connector X024 pin 3 and connector X016 pin J2--38 wire 413 yellow. Locate the open and
repair.
55-72
5. Disconnect the chopper RPM sensor connector X253. Use a multimeter to check for continuity between the
Replace the sensor.
6. Disconnect the straw hood harness from the straw walker harness at connector X071. Use a multimeter to
A. If there is continuity, the open circuit is in the straw hood (SH) harness between connector X071 pin
4 and connector X253 pin 1 wire 632 blue. Locate the open and repair.
7. Disconnect the straw walker harness from the main frame harness at connector X024. Use a multimeter
to check for continuity between the harness end of connector X024 pin 12 and chassis ground.
A. If there is continuity, the open circuit is in the straw walker (SW) harness between connector X024 pin
8. Disconnect the main frame harness from the front frame harness at connector X008. Use a multimeter to
X008 pin 14 and connector X017 pin J3--18 wire 425 blue or 766 blue. Locate the open and repair.
55-73

B-11 = SWATH PLATE POSITION
55-74
FAULT CODE – E0143-03 Chopper RPM Sensor Shorted to High Source

NOTE: This troubleshooting chart is for CR combines with serial numbers HAJ10073 and above. The
troubleshooting chart for CR combines with serial numbers < HAJ10073 is listed before this chart.
Cause:
The chopper RPM sensor (B-10) circuit is shorted to a higher than normal voltage source.

Solution:
2. The voltage reading on the Infoview monitor is high. Disconnect the chopper RPM sensor connector X253.
3. The voltage reading on the Infoview monitor is high. Disconnect the chopper harness from the main frame
A. If the voltage drops to 7.3 to 9.0 volts, the short is in the chopper (CH) harness between connector X382
pin 2 and connector X253 pin 2 wire 413 yellow. Locate the short and repair.
B. If the voltage remains high on Infoview monitor, the short circuit is in the main frame (MF) harness
55-75
FAULT CODE – E0143-04 Chopper RPM Sensor Shorted to Low Source

Cause:
The chopper RPM sensor (B-10) circuit is shorted to ground.

Solution:
2. The voltage reading on the Infoview monitor is low. Disconnect the chopper RPM sensor connector X253.
B. If the voltage remains low on Infoview display continue with Step 3.
3. The voltage reading on the Infoview monitor is low. Disconnect the chopper harness from the main frame
A. If the voltage increases to 7.3 to 9.0 volts, the short is in the chopper (CH) harness between connector
B. If the voltage remains low on Infoview monitor, the short to ground is in the main frame (MF) harness
55-76
FAULT CODE – E0143-05 Chopper RPM Sensor Line Disconnected

Cause:
The chopper RPM sensor (B-10) circuit is open.

Solution:
A. If the voltage reading is high 7.3 to 9.0 volts continue with Step 2.
2. The voltage reading on the Infoview monitor is 7.3 to 9.0 volts. Disconnect the chopper RPM sensor
connector X253. Use a jumper wire to short the harness end of connector X253 pin 2 to chassis ground.
3. The voltage reading on the Infoview monitor is 7.3 to 9.0 volts. Disconnect the chopper harness from the main
frame harness at connector X382. Use a jumper wire to short connector X382 pin 2 to chassis ground.
A. If the Infoview monitor drops to 0 to 0.5 volts indicating a ground, the open circuit is in the chopper (CH)
harness between connector X382 pin 2 and connector X253 pin 2 wire 413 yellow. Locate the open
and repair.
between connector X382 pin 2 and connector X016 pin J2-38 wire 413 yellow. Locate the open and repair.
55-77
4. Disconnect the chopper RPM sensor connector X253. Use a multimeter to check for continuity between the
Replace the sensor.
5. Disconnect the chopper harness from the main frame harness at connector X382. Use a multimeter to check
A. If there is continuity, the open circuit is in the chopper (CH) harness between connector X382 pin 1
and connector X253 pin 1 wire 632 blue. Locate the open and repair.
55-78
40024712
5
4
10020075
50026206
14
1. Straw Chopper RPM Sensor B10
2. Connector X382
3. Connector X008
4. Connector X016
5. Connector X017
55-79
55-80
55-81
FAULT CODE – E0145-03 Engine RPM Sensor Shorted to High Source

Cause:
The Alternator RPM Sensor (G-01) circuit is shorted to a higher than normal voltage source. (NH7.5L
Mechanical Engines Only)

Solution:
1. Enter Infoview monitor - “Diagnose info” screen.
Select “Engine RPM sensor” and check voltage range.
The proper voltage for the Engine RPM sensor circuit is 4.6 volts (no metal) to 6.6 volts (metal).
The proper voltage with the sensor wire disconnected is 7.3 to 9.0 volts.
A. If the voltage reading is high, out of range (>9.0 volts), continue with Step 2.
B. If the voltage reading is within proper limits. The shorted wire may not be powered up at this time.
Continue with Step 4.
2. The voltage reading on the Infoview monitor is high. Disconnect the alternator RPM sensor Terminal R at
the sensor.
A. If the voltage decreases to 7.3 to 9.0 volts, the short is in alternator. Repair the alternator.
B. If voltage remains high on the Infoview monitor, continue with Step 3.
3. The voltage reading on the Infoview monitor is high. Disconnect Connector X010.
A. If the voltage decreases to 7.3 to 9.0 volts, the short is in the engine (EN) harness between the alternator
and Connector X010 pin 9 on wire 421 yellow.
B. If the voltage remains high on the Infoview monitor, the short is in the mainframe (MF) harness between
Connector X010 pin 9 and Connector X017 pin J2-36 wire 421 yellow.
55-82
FAULT CODE – E0145-04 Engine RPM Sensor Shorted to Low Source

Cause:
The Alternator RPM Sensor (G-01) circuit is shorted to ground. (NH7.5L Mechanical Engines Only)

Solution:
B. If the voltage reading is within proper limits, continue troubleshooting with Step 4.
2. The voltage reading on the Infoview monitor is low. Disconnect the alternator RPM sensor Terminal R at the
sensor.
A. If the voltage increases to 7.3 to 9.0 volts, the short is in the alternator. Repair the alternator.
B. If voltage remains low on the Infoview monitor, continue with Step 3.
3. The voltage reading on the Infoview monitor is low. Disconnect Connector X010.
A. If the voltage increases to 7.3 to 9.0 volts, the short is in the engine (EN) harness between the alternator
and Connector X010 pin 9 on wire 421 yellow.
B. If the voltage remains low on the Infoview monitor, the short is in the main frame (MF) harness between
55-83
FAULT CODE – E0145-05 Engine RPM Sensor Line Disconnected

Cause:
The Alternator RPM Sensor (G-01) circuit is open. (NH7.5L Mechanical Engines Only)

1. Sensor wiring open.
Solution:
B. If the voltage reading is within proper limits, continue troubleshooting with Step 5.
2. The voltage reading on the Infoview monitor is high. Disconnect the alternator RPM sensor Terminal R at
the sensor and connect to a known good ground.
A. If the voltage decreases to 0.5 volts or less, the open is in the alternator or alternator ground wire.
B. If voltage remains high on the Infoview monitor, continue with Step 3.
3. The voltage reading on the Infoview monitor is high. Disconnect Connector X010 and use a jumper wire to
short Connector X010 pin 9 to chassis ground.
A. If the voltage decreases to 0.5 volts or less, the open is in the engine (EN) harness between the
alternator and Connector X010 pin 9 on wire 421 yellow.
B. If the voltage remains high on the Infoview monitor, the open is in the main frame (MF) harness between
4. Remove the ground wire from the alternator. Use a multimeter to check for continuity to chassis ground on
the ground wire.
A. If there is continuity to ground, the open is in the alternator. Repair the alternator.
B. If there is no continuity, there is an open circuit in the alternator ground wire 803 black to the engine
ground #5 or to the chassis ground #1. Locate the open and repair.
55-84
10020076 10004675
50026207
15
1. Alternator G01, Engine RPM Terminal
2. Connector X010
3. Connector X016
4. Engine Ground #5
5. Chassis Ground #1
55-85
55-86
FAULT CODE – E0146-03 Thresher RPM Sensor

Cause:
The Rotor RPM sensor (B-01) circuit is shorted to a higher than normal voltage source.

Solution:
Select “Thresher RPM sensor” and check voltage range.
2. The voltage reading on the Infoview monitor is high. Disconnect the rotor RPM sensor connector X177.
B. If the voltage remains high on Infoview monitor, the short circuit is in the main frame harness between
connector X177 pin 2 and connector X016 pin J2-37 wire 416 yellow. Locate short and repair.
55-87
FAULT CODE – E0146-04 Thresher RPM Sensor

Cause:
The Rotor RPM sensor (B-01) circuit is shorted to ground.

Solution:
2. The voltage reading on the Infoview monitor is low. Disconnect the rotor RPM sensor connector X177.
B. If the voltage remains low on Infoview monitor, the short to ground is in the main frame harness between
connector X177 pin 2 and connector X016 pin J2-37 wire 416 yellow. Locate and repair the short to
ground.
55-88
FAULT CODE – E0146-05 Thresher RPM Sensor Line Disconnected

Cause:
The Rotor RPM sensor (B-01) circuit is open.

Solution:
The proper voltage sensor blocked by ferrous metal is 5.6 to 7.3 volts
The proper voltage sensor unblocked by ferrous metal is 0.5 to 5.6 volts
The proper voltage sensor disconnected is 7.3 to 9.0 volts.
2. The voltage reading on the Infoview monitor is 7.3 to 9.0 volts. Disconnect the rotor RPM sensor connector
X177. Use a jumper wire to short the harness end of connector X177 pin 2 to chassis ground.
B. If the Infoview monitor still displays 7.3 to 9.0 volts, the open circuit is main frame (MF) harness between
connector X177 and connector X016 pin J2-37 wire 416 yellow. Locate the open and repair.
3. The voltage reading on the Infoview monitor is 7.3 to 9.0 volts. Disconnect the rotor RPM sensor connector
X177. Use a multimeter to check for continuity between connector X177 pin 1 and chassis ground.
A. If there is continuity to ground, the sensor has failed. Replace the sensor.
B. If there is no continuity, the open circuit is in the main frame (MF) harness between connector X177
55-89
40025213
50020098
16
1. Rotor RPM Sensor B01
2. Connector X016
55-90
55-91
55-92
FAULT CODE – E0148-02 Header Type Module Data Incorrect

Context:
Headers used on the CR combines may be equipped with a header type module, which is used to identify the
header type to the combine. This allows the operator to store configuration information in memory that may be
recalled when the header is attached.
This fault code will occur if the controller sees the header type “change” due to a significant voltage change on
the signal wire while the thresher is running. This is typically the result of an intermittent open circuit on the 5 volt
supply wire or on the signal wire, but may also be caused by the signal wire resistance changing due to bad
connections.
Cause:
The header type module (R--20) circuit is intermittently open, or circuit resistance is changing due to bad
connections.

1. Sensor supply or signal wiring open.
2. Sensor signal wiring has bad connections.
Solution:
1. Enter the Infoview monitor “Diagnose Info” screen. Select the “Header” sort menu, and select “Header Type
Input Select” to check the voltage range.
The normal operating range for the header type module circuit is 0.3 -- 4.72 volts.
Flex the front frame, feeder and header harnesses along their lengths while monitoring the voltage. The
voltage should not vary at any time.
The normal voltage readings for the different header types are as follows:
Header Type Sensor Voltage

Corn header 3.72 -- 4.72 volts
Grain header 2.93 -- 3.72 volts
Draper header 2.02 -- 2.93 volts
Pick up header 1.22 -- 2.02 volts
Programmable header 0.3 -- 1.22 volts
No header installed 0 -- 0.3 volts
A. If the voltage reading fluctuates significantly while flexing the harnesses, continue with Step 2.
B. If the voltage reading is within the proper limits, and does not vary while flexing the harnesses, the fault
condition is not currently present. Continue the troubleshooting at Step 6.
2. Disconnect the header type module connector X435. Locate the wire 1223 pink in the connector using the
following table:
Header Type Connector X435 5 volts Power Wire

Corn header Pin A
Grain header Pin A
Draper header Pin A
Pick up header Pin F
Programmable header Pin F
55-93
Use a multimeter to check the voltage between connector X435 wire 1223 pink and chassis ground. There
should be 5 volts. Flex the front frame, feeder and header harnesses along their lengths while monitoring
the voltage. The voltage should not vary at any time.
A. If the voltage drops significantly while flexing the wire harnesses, there is an intermittent open circuit on
the 5 volts supply wire. Repair the open circuit in the harness that was being flexed when the voltage
fluctuated. Check the wire 1223 pink connection to the terminals at each connector on the problem
harness. If necessary, install a jumper wire to bypass the area of failure, and replace the failed wire
harness as soon as possible.
B. If the voltage is 5 volts, and does not vary while flexing the harnesses, continue with Step 3.
3. Carefully disconnect connector X017 from the bottom of CCM2 module. Connect a jumper wire between
connector X017 pin J3--24 wire 1116 yellow and chassis ground.
Disconnect the header type module connector X435. Locate the wire 1116 yellow in the connector using the
following table:
Header Type Connector X435 Signal Wire

Corn header Pin B
Grain header Pin E
Draper header Pin B
Pick up header Pin E
Programmable header Pin B
Use a multimeter to check the resistance between connector X435 wire 1116 yellow and chassis ground. Flex
the header (HE) harness while making this check. There should be 0 to 0.1 ohms resistance.
A. If the resistance is correct, the header type module has failed internally. Replace the header type module.
B. If there is high resistance (> 0.1 ohms), continue with Step 4.
4. Disconnect the header (HH) harness to feeder (FE) harness connector X032. Use a multimeter to check the
resistance between the feeder (FE) harness end of connector X032 pin 27 and chassis ground. Flex the
feeder (FE) harness while making this check. There should be 0 to 0.1 ohms resistance.
A. If the resistance is correct, there is an open circuit in the header (HH) harness between connector X032
and connector X435 wire 1116 yellow. Locate the open and repair.
B. If there is high resistance (> 0.1 ohms), continue with Step 5.
5. Disconnect the feeder (FE) harness to front frame (FF) harness connector X007. Use a multimeter to check
the resistance between the front frame (FF) harness end of connector X007 pin 27 and chassis ground. Flex
the front frame (FF) harness while making this check. There should be 0 to 0.1 ohms resistance.
A. If the resistance is correct, there is an open circuit in the feeder (FE) harness between connector X032
and connector X007 wire 1116 yellow. Locate the open and repair.
B. If there is high resistance (> 0.1 ohms), there is an open circuit in the front frame (FF) harness between
connector X007 and connector X017 pin J3--24 wire 1116 yellow. Locate the open and repair.
broken wires.
A. If no damage is found, erase the fault code and continue operation.
55-94
FAULT CODE – E0148-03 Header Type Module Shorted to High Source

Context:
Headers used on the CR combine may be equipped with a header type module, which is used to identify the
header type to the combine. This allows the operator to store configuration information in memory that may be
recalled when the header is attached.
Cause:
The header type module (R-20) circuit is shorted to a higher than normal voltage source.

1. Sensor supply or signal wiring shorted to 12 volts.
Solution:
1. Enter the Infoview monitor “Diagnose Info” screen. Select the “Header” sort menu, and select “Header Type
Input Select” to check the voltage range.
The normal operating range for the header type module circuit is 0.3 - 4.72 volts.
The normal voltage readings for the different header types are as follows:
Header Type Sensor Voltage

Corn header 3.72 - 4.72 volts
Grain header 2.93 - 3.72 volts
Draper header 2.02 - 2.93 volts
Pick up header 1.22 - 2.02 volts
Programmable header 0.3 - 1.22 volts
No header installed 0 - 0.3 volts
2. Disconnect the header type module connector X435. Locate the wire 1223 pink in the connector using the
following table:
Header Type Connector X435 5 volts Power Wire

Corn header Pin A
Grain header Pin A
Draper header Pin A
Pick up header Pin F
Programmable header Pin F
55-95
Use a multimeter to check the voltage between connector X435 wire 1223 pink and chassis ground.
A. If there is greater than 5 volts on the pink wire, there is a short to high voltage on the 5 volts supply wire.
The fault code
E0167-03 - CCM2 J3 5V Reference should be displayed in the Infoview monitor “Active Errors” screen.
Correct that fault code condition, and then return to Step 1 to determine if this fault condition has been
corrected.
B. If the voltage is 5 volts, continue with Step 3.
3. Disconnect the header type module connector X435. Locate the wire 750 blue in the connector using the
following table:
Header Type Connector X435 Ground Wire

Corn header Pin F
Grain header Pin F
Draper header Pin E
Pick up header Pin A
Programmable header Pin A
Use a multimeter to check for continuity between connector X435 wire 750 blue and chassis ground.
There should be continuity to ground.
A. If there is no continuity to ground, continue with Step 4.
4. Disconnect the header (HH) harness to feeder (FE) harness connector X032. Use a multimeter to check
for continuity between the feeder (FE) harness end of connector X032 pin 13 and chassis ground. There
should be continuity to ground.
A. If there is continuity to ground, there is an open circuit in the header (HH) harness between connector
X032 and connector X435 wire 750 blue. Locate the open and repair.
for continuity between the front frame (FF) harness end of connector X007 pin 13 and chassis ground. There
should be continuity to ground.
A. If there is continuity to ground, there is an open circuit in the feeder (FE) harness between connector
X032 and connector X007 wire 750 blue. Locate the open and repair.
connector X007 and connector X017 pin J3-18 wire 750 blue or 766 blue. Locate the open and repair.
6. Disconnect the header type module connector X435. Locate the wire 1116 yellow in the connector using
the following table:
Header Type Connector X435 Signal Wire

Corn header Pin B
Grain header Pin E
Draper header Pin B
Pick up header Pin E
Programmable header Pin B
55-96
Use a multimeter to check for voltage between connector X435 wire 1116 yellow and chassis ground.
There should not be any voltage.
A. If there is no voltage, the module has failed internally. Replace the header type module.
B. If there is voltage (> 4.72 volts), continue with Step 7.
7. Disconnect the header (HH) harness to feeder (FE) harness connector X032. Use a multimeter to check
for voltage between the feeder (FE) harness end of connector X032 pin 27 and chassis ground. There
should not be any voltage.
A. If there is no voltage, there is a short circuit in the header (HH) harness between connector X032 and
connector X435 wire 1116 yellow. Locate the short and repair.
B. If there is voltage (> 4.72 volts), continue with Step 5.
for voltage between the front frame (FF) harness end of connector X007 pin 27 and chassis ground. There
should not be any voltage.
A. If there is no voltage, there is a short circuit in the feeder (FE) harness between connector X032 and
connector X007 wire 1116 yellow. Locate the short and repair.
B. If there is voltage (> 4.72 volts), there is a short circuit in the front frame (FF) harness between connector
broken wires.
55-97
B-15 = REEL RPM

55-98
F-49 = CAB FUSE

S-05 = SEAT SWITCH
FRAME--27
55-99
FAULT CODE – E0151-03 Thresher Clutch Temp Shorted to High Source

Cause:
The thresher clutch temperature sensor (B-45) circuit is shorted to 12 volts.

Solution:
Select “Thresher Clutch Temp” and check voltage range.
2. The voltage reading on the Infoview monitor is high. Disconnect the thresher clutch temperature sensor
connector X099.
A. If the voltage drops to 4.9 to 5.2 volts, the short is in the gearbox harness between connector X011
pin U and connector X099 pin B wire 682 yellow.
4. The voltage reading on the Infoview monitor is high. Disconnect the main frame harness from the front frame
A. If the voltage drops to 4.9 to 5.2 volts the short is in the main frame harness between connector X008
pin17 and connector X011 pin U wire 682 yellow.
B. If the voltage remains high on Infoview monitor the short circuit is in the front frame harness between
55-100
FAULT CODE – E0151-04 Thresher Clutch Temp Shorted to Low Source

Cause:
The thresher clutch temperature sensor (B-45) circuit is shorted to ground.

Solution:
A. If the voltage reading is low out of range (0 to 0.5 volts), continue with Step 2.
2. The voltage reading on the Infoview monitor is low (0 to 0.5 volts). Disconnect the thresher clutch temperature
sensor connector X099.
3. The voltage reading on the Infoview monitor is low (0 to 0.5 volts). Disconnect the gearbox harness from the
main frame harness at connector X011.
A. If the voltage increases to 4.9 to 5.2 volts, the short to ground is in the gearbox (GB) harness between
connector X011 pin U and connector X099 pin B wire 682 yellow. Locate the short to ground and
repair.
4. The voltage reading on the Infoview monitor is low (0 to 0.5 volts). Disconnect the main frame harness from
the front frame harness at connector X008.
A. If the voltage increases to 4.9 to 5.2 volts, the short to ground is in the main frame (MF) harness between
connector X011 pin U and connector X008 pin 17 wire 682 yellow. Locate the short to ground and
repair.
B. If the voltage remains low, the short to ground is in the front frame (FF) harness between connector
X008 pin 17 and connector X017 pin J3-33 wire 682 yellow. Locate the short to ground and repair.
55-101
FAULT CODE – E0151-05 Thresher Clutch Temp Line Disconnected

Cause:
The thresher clutch temperature sensor (B45) circuit is open.

Solution:
2. The voltage reading on the Infoview monitor is high (4.9 to 5.2 volts). Disconnect the thresher clutch temperature
sensor connector X099 and use a jumper wire to short connector X099 pin B to chassis ground.
A. If voltage drops to less than 0.5 volts, the open circuit is not in the supply side of the circuit. Continue
with Step 5.
3. The voltage reading on the Infoview monitor is high (4.9 to 5.2 volts). Disconnect the gearbox harness from the
main frame harness at connector X011. Use a jumper wire to short connector X011 pin U to chassis ground.
A. If voltage drops to 0 to 0.5 volts, the open circuit is in the gearbox (GB) harness between connector
X011 pin U and thresher clutch temperature sensor connector X099 pin B wire 682 yellow. Locate the
open and repair.
B. If voltage remains high, continue with Step 4.
4. The voltage reading on the Infoview monitor is high (4.9 to 5.2 volts). Disconnect the main frame harness
from the front frame harness at connector X008. Use a jumper wire to short connector X008 pin 17 to
chassis ground.
A. If voltage drops to 0 to 0.5 volts, the open circuit is in the main frame harness between connector X008
pin 17 and connector X011 pin U wire 682 yellow. Locate the open and repair.
B. If voltage remains high, the open circuit is in the front frame harness between connector X008 pin 17
and connector X017 pin J3-33 wire 682 yellow. Locate the open and repair.
5. Disconnect the thresher clutch temperature sensor connector X099. Use a multimeter to check for continuity
Replace the sensor.
55-102
6. Disconnect the gearbox harness from the main frame harness at connector X011. Use a multimeter to check
for continuity between the harness end of connector X011 pin V and chassis ground.
A. If there is continuity, the open circuit is in the gearbox (GB) harness between connector X011 pin V
pin V and connector X016 pin J2-14 wire 683 blue or 465 blue. Locate the open and repair.
55-103
10020076
5 4
1
10010872
10020075
50020097
17
1. Gearbox Clutch Temp Sensor B45
2. Connector X011
3. Connector X008
4. Connector X016
5. Connector X017
55-104
55-105
55-106
FAULT CODE – E0152-00 Coolant Temp / Fuel Filt Valid Above Normal
Context:
When the engine coolant temperature exceeds 106°C (223°F) [electronic engines] or 110°C (230°F) [mechanical
engines] for more than 2 seconds, the alarm message “A0000 Engine Coolant Temperature HIGH” will be
displayed to the operator, and the engine will be shutdown within 2 seconds to prevent engine damage from
occurring. When the alarm message is displayed, a permanent record is created in the error history.
Cause:
The “A0000 Engine Coolant Temperature HIGH” alarm has occurred at least once on the vehicle.

1. The engine cooling system has been overheated during vehicle operation.
Solution:
1. This error message appears as a permanent record that an engine coolant overheat condition has occurred
on the combine, and cannot be erased using the combine display controls. The EST must be used to erase
this fault code.
A. If this fault code appears, remove and inspect the engine oil for indication of internal damage.
NOTE: This fault code is reported by the ECU (which monitors the coolant temperature using the coolant temp
sensor B--44) via CAN to the CCM2 module. This fault condition is recorded in both the ECU and the CCM2
module.
55-107
FAULT CODE – E0152-02 Coolant Temp / Fuel Filt Data Incorrect

Cause:
The ECU coolant temperature sensor reports an error (Electronic engines only).

The engine ECU has detected a coolant temperature fault and has notified CCM2. This is proper operation of
the system and indicates a cooling fault exists.
Solution:
Troubleshoot the engine ECU or refer to fault code E0399 for further details.
55-108
FAULT CODE – E0152-03 Coolant Temp / Fuel Filt

Cause:
The coolant temperature sensor (B-31) circuit is shorted to 12 volts. (NH7.5L Mechanical Engines Only)

Solution:
Select “Coolant Temp / Fuel Filt” and check voltage range.
2. The voltage reading on the Infoview monitor is high. Disconnect the coolant temperature sensor connector
X310.
3. The voltage reading on the Infoview monitor is high. Disconnect the engine harness from the main frame
A. If the voltage drops to 0.5 to 4.9 volts, the short is in the engine (EN) harness between connector X010
pin 18 and connector X310 pin B wire 429 yellow.
B. If the voltage remains high on Infoview monitor the short circuit is in the main frame harness between
55-109
FAULT CODE – E0152-04 Coolant Temp / Fuel Filt

Cause:
The coolant temperature sensor (B-31) circuit is shorted to ground. (NH7.5L Mechanical Engines Only)

Solution:
2. The voltage reading on the Infoview monitor is low (0 volts). Disconnect the coolant temperature sensor
connector X310.
3. The voltage reading on the Infoview monitor is low. Disconnect the engine harness from the main frame
A. If the voltage increases to 0.5 to 4.9 volts, the short is in the engine (EN) harness between connector
X010 pin 18 and connector 310 pin B wire 429 yellow. Locate the short to ground and repair.
B. If the voltage remains low, the short is in the main frame (MF) harness between connector X010 pin
18 and connector X016 pin J2-24 wire 429 yellow. Locate the short and repair.
55-110
FAULT CODE – E0152-05 Coolant Temp / Fuel Filt Line Disconnected

Cause:
The coolant temperature sensor (B-31) circuit is open. (NH7.5L Mechanical Engines Only)

Solution:
2. The voltage reading on the Infoview monitor is high (4.9 to 5.2 volts). Disconnect the coolant temperature
sensor connector X310. Use a jumper wire to short connector X310 pin B to chassis ground.
with Step 4.
3. The voltage reading on the Infoview monitor is high (4.9 to 5.2 volts). Disconnect the engine harness from the
main frame harness at connector X010. Use a jumper wire to short connector X010 pin 18 to chassis ground.
A. If voltage drops to less than 0.5 volts, the open is in the engine (EN) harness between connector X010
pin 18 and coolant temperature sensor connector X310 pin B wire 429 yellow. Locate the open and repair.
B. If voltage remains high, the open is in the main frame (MF) harness between connector X010 pin 18
4. Disconnect the coolant temperature sensor connector X310. Use a multimeter to check for continuity
Replace the sensor.
5. Disconnect the engine harness from the main frame harness at connector X010. Use a multimeter to check
A. If there is continuity, the open circuit is in the engine (EN) harness between connector X010 pin 14
55-111
2 1
10020076 10010869
50026207
18
1. Coolant Temp (Mechanical) B31
2. Connector X010
3. Connector X016
55-112
55-113
55-114
FAULT CODE – E0153-00 Engine Oil Temperature Valid Above Normal

Context:
When the engine oil temperature exceeds 130°C (266°F) [Iveco] or 126°C (260°F) [NH 7.5L] for more than 3
seconds, the alarm message “A0001 Engine Oil Temperature HIGH” will be displayed to the operator, and the
engine will be shutdown within 2 seconds to prevent engine damage from occurring. When the alarm message
is displayed, a permanent record is created in the error history. The EST must be used to erase this fault code.
Cause:
The “A0001 Engine Oil Temperature HIGH” alarm has occurred at least once on the vehicle.

1. The oil temperature sensor B-03 [IVECO] or engine oil temperature switch S-58 [NH 7.5L] reports that the
oil temperature is above acceptable limits -this is normal operation of the circuit and indicates the engine oil
has been overheated during vehicle operation.
2. Oil temperature sensor B-03 or engine oil temperature switch S-58 failure.
Solution:
1. This fault code appears as a permanent record that the engine oil has exceeded 130°C for IVECO (126°C
for NH 7.5L). If this fault code appears, remove and inspect the engine oil for indication of internal damage.
A. Locate and repair the mechanical fault in the oil cooling system.
B. If no oil cooling system fault can be found, replace the oil temperature sensor B-03 [IVECO] or engine
oil temperature switch S-58 [NH 7.5L]. Continue troubleshooting with Step 2.
55-115
FAULT CODE – E0153-03 Engine Oil Temperature

Cause:
The engine oil temperature sensor (B-03) [Iveco] or engine oil temperature switch (S-58) [NH7.5L] circuit
is shorted to 12 volts.

Solution:
Select “Engine Oil Temperature” and check voltage range.
2. The voltage reading on the Infoview monitor is high. Disconnect the engine oil temperature sensor
Connector X311 (Iveco) or Connector X209 (NH7.5L).
B. If the voltage remains high on Infoview monitor, continue with Step 3 (Iveco) or Step 4 (NH7.5L).
3. (Iveco only) The voltage reading on the Infoview monitor is high. Disconnect the Iveco harness from the
engine harness at Connector X197.
A. If the voltage drops to 4.9 to 5.2 volts, the short is in the Iveco harness between connector X197 pin
9 and connector X311 pin B on the blue wire. Locate the short and repair.
A. If the voltage drops to 4.9 to 5.2 volts, the short is in the engine (EN) harness between connector X010
pin 10 and connector X197 pin 9 (Iveco) or connector X209 pin A (NH7.5L) wire 504 yellow. Locate
between connector X010 pin 10 and connector X016 pin J2-27 wire 504 yellow. Locate the short and
repair.
55-116
FAULT CODE – E0153-04 Engine Oil Temperature Shorted to Low Source

Cause:
The engine oil temperature sensor (B-03)[Iveco] or engine oil temperature switch (S-58)[NH 7.5L] circuit
is shorted to ground.

Solution:
2. The voltage reading on the Infoview monitor is low (0.5 volts or less). Disconnect the engine oil temperature
sensor connector X311 (Iveco) or Connector X209 (NH7.5L).
B. If the voltage remains low out of range, continue with Step 3 (Iveco) or Step 4 (NH7.5L).
3. (Iveco only) The voltage reading on the Infoview monitor is low. Disconnect the Iveco harness from the engine
harness at Connector X197.
A. If the voltage increases to 4.9 to 5.2 volts, the short is in the Iveco harness between connector X197
pin 9 and connector X311 pin B on the blue wire. Locate the short and repair.
B. If the voltage remains low out of range, continue with Step 4.
A. If the voltage increases to 4.9 to 5.2 volts, the short is in the engine (EN) harness between connector
X010 pin 10 and connector X197 pin 9 (Iveco) or connector X209 pin A (NH 7.5L) wire 504 yellow.
B. If the voltage remains low out of range, the short is in the main frame (MF) harness between connector
X010 pin 10 and connector X016 pin J2-27 wire 504 yellow. Locate the short to ground and repair.
55-117
FAULT CODE – E0153-05 Engine Oil Temperature Line Disconnected

NOTE: This troubleshooting chart is for CR920 and CR940 combines with New Holland 7.5L engines only. The
troubleshooting chart for this fault code on CR960, CR970 and CR980 combines with Iveco engines follows this
chart.
Cause:
The engine oil temperature switch (S58)[NH 7.5L] circuit is open.

Solution:
2. The voltage reading on the Infoview monitor is high (4.9 to 5.2 volts). Disconnect the engine oil temperature
sensor connector X209. Use a jumper wire to short connector X209 pin A to chassis ground.
A. If voltage drops to less than 0.5 volts, the sensor has failed open. Replace the sensor.
3. The voltage reading on the Infoview monitor is high (4.9 to 5.2 volts). Disconnect the engine harness from
the main frame harness at connector X010. Use a jumper wire to short connector X010 pin 10 to chassis
ground.
pin 10 and engine oil temperature switch connector X209 pin A wire 504 yellow. Locate the open and
repair.
55-118
FAULT CODE – E0153-05 Engine Oil Temperature Line Disconnected

NOTE: This troubleshooting chart is for CR960, CR970 and CR980 combines with Iveco engines only. The
troubleshooting chart for this fault code on CR920 and CR940 combines with New Holland 7.5L engines is listed
before this chart.
Cause:
The engine oil temperature sensor (B-03)[Iveco] circuit is open.

Solution:
2. The voltage reading on the Infoview monitor is high (4.9 to 5.2 volts). Disconnect the engine oil temperature
sensor Connector X311. Use a jumper wire to short Connector X311 pin B to chassis ground.
with Step 5.
3. The voltage reading on the Infoview monitor is high (4.9 to 5.2 volts). Disconnect the Iveco harness from the
engine harness at Connector X197. Use a jumper wire to short the engine harness end of Connector X197
pin 9 to ground.
A. If voltage drops to less than 0.5 volts, the open is in the Iveco harness between connector X197 pin
9 and connector X311 pin B on the blue wire. Locate the open and repair.
4. The voltage reading on the Infoview monitor is high (4.9 to 5.2 volts). Disconnect the engine harness from
the main frame harness at Connector X010. Use a jumper wire to short the main frame harness end of
Connector X010 pin 10 to chassis ground.
pin 10 and connector X197 pin 9 wire 504 yellow. Locate the open and repair.
55-119
5. Disconnect the engine oil temperature sensor connector X311. Use a multimeter to check for continuity
Replace the sensor.
6. Disconnect the Iveco harness from the engine harness at Connector X197. Use a multimeter to check for
continuity between the engine harness end of Connector X197 pin 10 and chassis ground.
A. If there is continuity, the open circuit is in the Iveco harness between connector X197 pin 10 and
connector X311 pin A on the brown wire. Locate the open and repair.
7. Disconnect the engine harness from the main frame harness at Connector X010. Use a multimeter to check
for continuity between the main frame harness end of Connector X010 pin 14 and chassis ground.
B. If there is continuity, the open circuit is in the main frame (MF) harness between connector X010 pin
14 and connector X016 pin J2-14 wire 468 blue or 465 blue. Locate the open and repair.
55-120
2
1
10010907 10010908
3
10010863
10020076
50026207
19
1. Engine Oil Temperature Sensor B03 (Iveco)
2. Connector X197
3. Connector X010
4. Connector X016
5. Engine Oil Temperature Switch S58 (NH7.5L)
55-121
55-122
55-123
FAULT CODE – E0154-03 Fuel Level Sensor Shorted to High Source

Cause:
The fuel level sensor (R-01) circuit is shorted to 12 volts.

Solution:
Select “Fuel Level Sensor” and check voltage range.
A. If the voltage reading is high out of range, (> 5.2 volts), continue with Step 2.
2. The voltage reading on the Infoview monitor is high. Disconnect the fuel level sensor connector X184.
55-124
FAULT CODE – E0154-04 Fuel Level Sensor Shorted to Low Source

Cause:
The fuel level sensor (R01) circuit is shorted to ground.

Solution:
Select “Fuel Level sensor” and check voltage range.
2. The voltage reading on the Infoview monitor is low less than 0.5 volts. Disconnect the fuel level sensor
connector X184.
B. If the voltage remains low, the short is in the main frame (MF) harness between connector X184 pin
1 and connector X016 pin J2-17 wire 427 yellow. Locate the short and repair.
55-125
FAULT CODE – E0154-05 Fuel level Sensor Line Disconnected

Cause:
The fuel level sensor (R-01) circuit is open.

Solution:
Select “Fuel Level sensor” and check voltage range.
2. The voltage reading on the Infoview monitor is high (4.9 to 5.2 volts). Disconnect the fuel level sensor
connector X184. Use a jumper wire to short connector X184 pin 1 to chassis ground.
with Step 3.
B. If the voltage remains high, the open circuit is in the main frame (MF) harness between connector X184
pin 1 and connector X016 pin J2-17 wire 427 yellow. Locate the open and repair.
3. Disconnect the fuel level sensor Connector X184. Use a multimeter to check for continuity between the
harness end of Connector X184 pin 2 and chassis ground.
A. If there is continuity, the sensor has failed. Replace the sensor.
check for continuity between the front frame harness end of connector X008 pin 14 and chassis ground.
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40024714
4 3
10020075
50026206
20
1. Fuel Level Sensor R01
2. Connector X008
3. Connector X016
4. Connector X017
55-127
55-128
55-129
FAULT CODE – E0159-03 Grain Bin Full Sensor Shorted to High Source
Cause:
The grain bin switch (S-28 & S-29) circuit is shorted to high voltage.

1. Switch supply or ground wiring shorted to 12 volts.
2. Open circuit on switch ground path.
Solution:
Select “Grain Bin Full sensor” and check voltage range.
The normal voltage range is 0 to 4.9 volts.
The proper voltage range with both switches neutral is approximately 2.5 volts.
The proper voltage range with the ¾ full switch depressed is approx. 3.3 volts.
The proper voltage range with both bin switches depressed is approx. 3.7 volts.
A. If the voltage reading is high out of range (> 4.9volts), continue with Step 2.
2. The voltage reading on the Infoview monitor is high. Disconnect the grain bin full switch S29 connector X109.
A. If the voltage drops to 0 to 4.9 volts, the short is in the reference ground wire for the circuit. Continue
with Step 3.
3. Disconnect the main frame harness from the grain tank harness at connector X009. Use a multimeter to
check for voltage on MF harness end of connector X009 pin H.
A. If there is no voltage present, there is a short in the grain tank (GT) harness between connector X009
pin H and connector X109 pin A wire 443 blue. Locate the short and repair.
B. If there is voltage present, there is a short in the main frame (MF) harness between connector X009
pin H and connector X016 pin J2-14 wire 443 blue or 465 blue. Locate the short and repair.
4. The voltage reading on the Infoview monitor is high. Disconnect the grain bill full switch S29 connector X109.
Use a multimeter to check for continuity between connector X109 pin A and chassis ground.
B. If no continuity is found, continue with Step 5.
55-130
5. Disconnect the grain tank harness from the main frame harness at connector X009. Use a multimeter to
check for continuity between the harness end of connector X009 pin H and chassis ground.
A. If there is continuity, the open circuit is in the grain tank (GT) harness between connector X009 pin
H and connector X109 pin A wire 443 blue. Locate the open and repair.
pin H and connector X016 pin J2-14 wire 443 blue or 465 blue. Locate the open and repair.
6. The voltage reading on the Infoview monitor is high. Disconnect the grain bin ¾ full sensor S28 connector
X107.
A. If the voltage drops to 0 to 4.9 volts, continue with Step 7.
7. The voltage reading on the Infoview monitor is high. Disconnect the grain bin 3/4 full sensor S28 connector
X107. Use a multimeter to check for voltage on connector X107 pins A and B.
A. If there is high voltage on connector X107 pin A, the regulated voltage supply is incorrect. The error
“E0165-03 CCM2 5V Ref Voltage 3 Shorted to High Source” should be listed in the “Active Errors”
screen in the Infoview monitor. Correct that error, and then check to determine if this error has been
resolved.
B. If there is high voltage on connector X107 pin B, there is a short to high voltage in the grain tank (GT)
harness between connector X109 pin B and connector X107 pin B wire 445 yellow. Locate the short
and repair.
8. The voltage reading on the Infoview monitor is high. Disconnect the grain bin 3/4 full sensor S28 connector
X107. Use a multimeter to check for voltage on connector X107 pin C.
A. If no voltage is found, continue with Step 10.
B. If high (>4.9 volts) voltage is found, continue with Step 9.
check for voltage on connector X009 pin E.
A. If no voltage is found, the short is in the grain tank (GT) harness between connector X107 pin C and
connector X009 pin E wire 400 yellow. Locate the short and repair.
B. If high (>4.9 volts) voltage is found, the short is in the main frame (MF) harness between connector
X009 pin E and connector X016 pin J2-22 wire 400 yellow. Locate the short and repair.
55-131
FAULT CODE – E0159-05 Grain Bin Full Sensor Line Disconnected

Cause:
The grain bin switch (S-28 & S-29) circuit is open, or shorted to ground.

1. Switch supply wiring is open.
2. Switch signal wiring is open, or shorted to ground.
3. Grain bin 3/4 full switch S28 shorted to ground.
Solution:
Select “Grain Bin Full sensor” and check voltage range.
The normal voltage range is 0 to 4.9 volts.
The proper voltage range with both switches neutral is approximately 2.5 volts.
The proper voltage range with the 3/4 full switch depressed is approx. 3.3 volts.
The proper voltage range with both bin switches depressed is approx. 3.7 volts.
A. If the voltage reading is low out of range (< 0.3 volts), continue with Step 2.
2. The voltage reading on Infoview monitor is low. Manually move the paddle on the grain bin 3/4 full switch
S28 while monitoring the reading on the Infoview monitor.
A. If the voltage remains low, continue with Step 3.
B. If the voltage increases to approximately 2.5 volts, there is a short to ground in the grain tank (GT)
harness between connector X107 pin B and connector X109 pin B wire 445 yellow. Locate the short
and repair.
3. The voltage reading on the Infoview monitor is low. Disconnect the grain bin 3/4 full switch S28 connector
X107. Use a multimeter to check for voltage on connector X107 pin A. There should be 5 volts present.
B. If there is 5 volts present, continue with Step 5.
4. Disconnect connector X009. Use a multimeter to check for voltage on connector X009 pin G. There should
be 5 volts present.
A. If there is 5 volts present, there is an open circuit in the grain tank (GT) harness between connector
X009 pin G and connector X107 pin A wire 440 pink. Locate the open and repair.
B. If there is no voltage, there is an open circuit in the main frame (MF) harness between connector X009
pin G and connector X016 pin J2-31 wire 440 pink or 459 pink. Locate the open and repair.
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5. The voltage reading on the Infoview monitor is low. Disconnect the grain bill 3/4 full switch S28 connector
X107. Use a multimeter to check for continuity between connector X107 pin C and chassis ground.
check for continuity between the main frame (MF) harness end of connector X009 pin E and chassis ground.
A. If there is no continuity, there is a short to ground in the grain tank (GT) harness between connector
X009 pin E and connector X107 pin C wire 400 yellow. Locate the short and repair.
B. If there is continuity to ground, there is a short to ground in the main frame (MF) harness between
connector X009 pin E and connector X016 pin J2-22 wire 400 yellow. Locate the short and repair.
check for continuity between connector X009 pin E and connector X107 pin C.
A. If there is no continuity, there is an open circuit in the grain tank (GT) harness between connector X009
pin E and connector X107 pin C wire 400 yellow. Locate the open and repair.
B. If there is continuity, continue with Step 8.
8. Key off. Carefully disconnect connector X016 from the bottom of CCM2 module. Use a jumper wire to short
connector X009 pin E to chassis ground. Use a multimeter to check for continuity between connector X016
pin J2-22 and chassis ground.
A. If there is no continuity, there is an open circuit in the main frame (MF) harness between connector
X009 pin E and connector X016 pin J2-22 wire 400 yellow. Locate the open and repair.
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1. Grain Bin Full Sensor S29
2. Grain Bin 3/4 Full Sensor S28
3. Connector X009
4. Connector X016
55-134
55-135
55-136
FAULT CODE – E0161-01 Engine Oil Pressure Valid Below Normal

Context:
When the engine oil pressure drops below 1 bar (14 psi) for more than 3 seconds after the engine has been
running for at least 10 seconds, the alarm message “A0002 Engine Oil Pressure LOW” will be displayed to the
operator, and the engine will be shutdown within 7 seconds to prevent engine damage from occurring. When the
alarm message is displayed, a permanent record is created in the error history. The EST must be used to erase
this fault code.
Cause:
The “A0002 Engine Oil Pressure LOW” alarm has occurred at least once on the vehicle.

1. The engine oil pressure sensor B-30 (NH 7.5L) or B-52 (IVECO) reports that the oil pressure is below
acceptable limits -this is normal operation of the circuit and indicates an oil pressure failure.
2. Oil pressure sensor B-30 (NH 7.5L) or B-52 (IVECO) failure.
Solution:
1. This fault code appears as a permanent record that the engine oil pressure has dropped below 1.0 bar
(14 psi) while the engine has been running for over 10 seconds. If this fault code appears, remove and inspect
the engine oil for indication of internal damage.
A. Locate and repair the mechanical fault in the oil pressure system.
B. If no oil pressure system fault can be found, replace the oil pressure sensor B-30 (NH 7.5L) or B-52
(IVECO). Continue troubleshooting with Step 2.
55-137
FAULT CODE – E0161-03 Engine Oil Pressure sens Shorted to High Source
Cause:
The engine oil pressure sensor [B-30 (NH7.5L) or B-52 (Iveco)] circuit is shorted to 12 volts.

Solution:
Select “Engine oil pressure sens” and check voltage range.
The proper voltage range for the engine oil pressure sensor (key On, engine OFF) is – 0.5 to 0.8 volts.
The proper voltage range for the engine oil pressure sensor (key On, engine Running) is – 0.8 to 4.9 volts.
B. If voltage is normal, the shorted wire may not be energized at this time. Continue with Step 9.
2. The voltage reading on the Infoview monitor is high. Disconnect the engine oil pressure sensor Connector
X201 (NH7.5L) or Connector X337 (Iveco). Use a multimeter to check for voltage on Connector X201 pin
B (NH7.5L) or Connector X337 pin B (Iveco). There should be 5 volts present.
A. If high (>5.5 volts) voltage is found, the regulated voltage supply is incorrect. The error “E0165-03 CCM2
5V Ref Voltage 3 Shorted to High Source” should be listed in the “Active Errors” screen in the Infoview
monitor. Correct that error, and then check to determine if this error has been resolved.
B. If correct voltage is found, continue with Step 3.
X201 (NH7.5L) or Connector X337 (Iveco). Use a multimeter to check for continuity between Connector
X201 pin A (NH7.5L) or Connector X337 pin A (Iveco) and chassis ground.
B. If no continuity is found, continue with Step 4. (Iveco) or Step 5 (NH7.5L).
4. Disconnect the Iveco harness from the engine harness at connector X197. Use a multimeter to check for
continuity between the engine harness end of connector X197 pin 4 and chassis ground.
A. If there is no continuity, continue with Step 5.
B. If there is continuity, there is an open circuit in the Iveco harness between connector X197 pin 4 and
connector X337 pin A on the brown wire. Locate the open and repair.
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for continuity between the harness end of Connector X010 pin 14 and chassis ground.
and connector X201 pin A (NH7.5L) or connector X197 pin 4 (Iveco) wire 853 blue or 468 blue. Locate
X201 (NH7.5L) or Connector X337 (Iveco). Use a multimeter to check for voltage on Connector X201 pin
C (NH7.5L) or connector X337 pin C (Iveco).
B. If high (>5.2 volts) voltage is found, continue with Step 7. (Iveco) or Step 8 (NH7.5L).
voltage on connector X197 pin 6.
C. If high (>5.2 volts) voltage is found, continue with Step 8.
D. If no voltage is found, the short is in the Iveco harness between connector X197 pin 6 and connector
X337 pin C on the orange wire. Locate the short and repair.
for voltage on Connector X010 pin 6.
A. If no voltage is found, the short is in the engine (EN) harness between connector X201 pin C (NH7.5L)
or connector X197 pin 6 (Iveco) and connector X010 pin 6 wire 419 yellow. Locate the short and
repair.
55-139
FAULT CODE – E0161-05 Engine Oil Pressure sens

Line Disconnected
Cause:
The engine oil pressure sensor [B-30 (NH7.5L) or B-52 (Iveco)] circuit signal wire is open or shorted to
ground.

1. Sensor signal wiring open or shorted to ground.
Solution:
Select “Engine oil pressure sens” and check voltage range.
The proper voltage range for the engine oil pressure sensor (key On, engine OFF) is 0.5 to 0.8 volts.
The proper voltage range for the engine oil pressure sensor (key On, engine Running) is 0.8 to 4.9 volts.
A. If the voltage reading is low out of range (<0.3 volts), continue with Step 2.
B. If the voltage is normal, the shorted wire may not be open or grounded at this time. Continue with
Step 12.
2. The voltage reading on the Infoview monitor is low (<0.3 volts). Disconnect the engine oil pressure sensor
connector X201 (NH7.5L) or Connector X337 (Iveco). Use a multimeter to check for voltage on connector
X201 pin B (NH7.5L) or Connector X337 pin B (Iveco). There should be 5 volts present.
A. If no voltage is found, continue with Step 3 (Iveco) or Step 4 (NH7.5L).
voltage on connector X197 pin 5. There should be 5 volts present.
B. If correct voltage is found, there is an open circuit in the Iveco harness between connector X197 pin
5 and connector X337 pin B on the orange wire. Locate the open and repair.
for voltage on connector X010 pin 13. There should be 5 volts present.
A. If voltage is found, there is an open circuit in the engine (EN) harness between connector X201 pin
B (NH7.5L) or connector X197 pin 5 (Iveco) and connector X010 pin 13 wire 490 pink or 463 pink.
B. If no voltage is found, continue with Step 5.
55-140
5. Carefully disconnect the main frame harness from the CCM2 module at connector X016. Use a multimeter
to check for voltage on the CCM2 module connector X016 pin J2-31. There should be 5 volts present.
A. If voltage is found, there is an open circuit in the main frame (MF) harness between connector X010
B. If no voltage is found, there is an internal fault with the CCM2 module. Replace the module.
6. The voltage reading on the Infoview monitor is low (<0.3 volts). Disconnect the engine oil pressure sensor
connector X201 (NH7.5L) or Connector X337 (Iveco). Use a multimeter to check for continuity between
connector X201 pin C (NH7.5L) or connector X337 pin C (Iveco). and chassis ground.
A. If continuity is found, continue with Step 7 (Iveco) or Step 8 (NH7.5L).
A. If there is continuity, continue with Step 8.
B. If there is no continuity, there is a short to ground in the Iveco harness between connector X197 pin
6 and connector X337 pin C on the orange wire. Locate the short and repair.
A. If there is no continuity, there is a short to ground in the engine (EN) harness between connector X010
pin 6 and connector X201 pin C (NH7.5L) or connector X197 pin 6 (Iveco) wire 419 yellow. Locate
9. Carefully disconnect the main frame harness from the CCM2 module at connector X016. Install a jumper
wire between the harness end of connector X016 pin J2-33 and chassis ground. Use a multimeter to check
for continuity between connector X201 pin C (NH7.5L) or connector X337 pin C (Iveco) and chassis
ground.
B. If no continuity is found, continue with Step 10 (Iveco) or Step 11 (NH7.5L).
A. If there is no continuity, continue with Step 11.
B. If there is continuity, there is an open circuit in the Iveco harness between connector X197 pin 6 and
connector X337 pin C on the orange wire. Locate the open and repair.
A. If there is continuity, there is an open circuit in the engine (EN) harness between connector X010 pin
6 and connector X201 pin C (NH7.5L) or connector X197 pin 6 (Iveco) wire 419 yellow. Locate the
open and repair.
B. If there is no continuity to ground, there is an open circuit in the main frame (MF) harness between
55-141
10010908
1
10010912
10004681
5
4
10020076
50026207
22
1. Engine Oil Pressure Sensor B30 (NH7.5L)
2. Engine Oil Pressure Sensor B52 (Iveco)
3. Connector X197 (Iveco)
4. Connector X010
5. Connector X016
55-142
55-143
55-144
FAULT CODE – E0162-01 Control Pressure Sensor Valid Below Normal

Context:
When the control oil pressure drops below 20 bar (290 psi) for more than 2 seconds after the engine has been
running for at least 3 seconds, the alarm message “A0012 Control Pressure LOW” will be displayed to the
operator. If the engine has been running for 5 seconds and the alarm occurs, the engine will be shutdown within
2 seconds to prevent damage to the hydraulic systems. When the alarm message is displayed, a permanent
record is created in the error history. The EST must be used to erase this fault code.
Cause:
The “A0012 Control Pressure LOW” alarm has occurred at least once on the vehicle.

1. The control pressure sensor B-35 reports that the control pressure is below acceptable limits -- this is normal
operation of the circuit and indicates a hydraulic pressure failure.
2. Control pressure sensor B-35 failure.
Solution:
1. This fault code appears as a permanent record that the control pressure has dropped below 20 bar (290 psi)
while the engine has been running for over 3 seconds. If this fault code appears, remove and inspect the PTO
gearbox oil for indication of internal damage.
A. Locate and repair the mechanical fault in the hydraulic system.
B. If no hydraulic system fault can be found, replace the control pressure sensor B-35. Continue
55-145
FAULT CODE – E0162-03 Control Pressure Sensor Shorted to High Source

Cause:
The control pressure sensor (B-35) circuit is shorted to 12 volts.

Solution:
Select “Control Pressure sensor” and check voltage range.
The proper voltage range for the control pressure sensor (key On, engine OFF) is – 0.5 to 2.8 volts.
The proper voltage range for the control pressure sensor (key On, engine Running) is – 2.8 to 4.9 volts.
B. If the voltage reading is normal, the shorted wire may not be energized at this time. Continue with Step
7.
2. The voltage reading on the Infoview monitor is high. Disconnect the control pressure sensor connector
X098. Use a multimeter to check for voltage on connector X098 pin B. There should be 5 volts present.
X098. Use a multimeter to check for continuity between connector X098 pin A and chassis ground.
for continuity between the harness end of connector X011 pin V and chassis ground.
A. If there is continuity, the open circuit is in the gearbox (GB) harness between connector X011 pin V
B. If there is continuity, the open circuit is in the main frame (MF) harness between connector X011 pin
V and connector X016 pin J2-14 wire 683 blue or 465 blue. Locate the open and repair.
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X098. Use a multimeter to check for voltage on connector X098 pin C.
B. If high (>5.2 volts) voltage is found, continue with Step 6.
for voltage on connector X011 pin B.
A. If no voltage is found, the short is in the gearbox (GB) harness between connector X098 pin C and
connector X011 pin B wire 423 yellow. Locate the short and repair.
X011 pin B and connector X016 pin J2-19 wire 423 yellow. Locate the short and repair.
55-147
FAULT CODE – E0162-05 Control Pressure Sensor Line Disconnected

Cause:
The control pressure sensor (B-35) circuit is open or shorted to ground.

1. Sensor signal wiring open or shorted to ground.
2. Loss of power to sensor.
Solution:
Select “Control Pressure sensor” and check voltage range.
The proper voltage range for the control pressure sensor (key On, engine OFF) is 0.5 to 2.8 volts.
The proper voltage range for the control pressure sensor (key On, engine Running) is 2.8 to 4.9 volts.
A. If the voltage reading is low out of range (<0.3 volts), continue with Step 2.
B. If the voltage reading is normal, the shorted wire may not be open or grounded at this time. Continue
with Step 9.
2. The voltage reading on the Infoview monitor is low (<0.3 volts). Disconnect the control pressure sensor
connector X098. Use a multimeter to check for voltage on connector X098 pin B. There should be 5 volts
present.
for voltage on connector X011 pin D. There should be 5 volts present.
A. If voltage is found, there is an open circuit in the gearbox (GB) harness between connector X098 pin
B and connector X011 pin D wire 486 pink. Locate the open and repair.
pin D and connector X016 pin J2-31 wire 459 pink or 486 pink. Locate the open and repair.
5. The voltage reading on the Infoview monitor is low (<0.3 volts). Disconnect the control pressure sensor
connector X098. Use a multimeter to check for continuity between connector X098 pin C and chassis
ground.
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for continuity between the harness end of connector X011 pin B and chassis ground.
A. If there is no continuity, there is a short to ground in the gearbox (GB) harness between connector X011
pin B and connector X098 pin C wire 423 yellow. Locate the short and repair.
connector X011 pin B and connector X016 pin J2-19 wire 423 yellow. Locate the short and repair.
for continuity between connector X098 pin C and chassis ground.
for continuity between the harness end of connector X011 pin B and chassis ground.
A. If there is continuity, there is an open circuit in the gearbox (GB) harness between connector X011 pin
B and connector X098 pin C wire 423 yellow. Locate the open and repair.
connector X011 pin B and connector X016 pin J2-19 wire 423 yellow. Locate the open and repair.
55-149
10020076
3 1
50020057
50020097
23
1. Control Pressure Sensor B35
2. Connector X011
3. Connector X016
55-150
55-151
55-152
FAULT CODE – E0163-03 Engine Air Filter Sensor

Cause:
The engine air filter switch (S-61) circuit is shorted to 12 volts.

1. Switch supply or signal wiring shorted to 12 volts.
2. Switch ground path open.
3. Engine controller internal failure (internal regulator failure).
Solution:
Select “Engine Air Filter sensor” and check voltage range.
The proper voltage range for the engine air filter switch (key On, engine OFF or Running) is 0.3 to 5.2 volts.
B. If the voltage is in the proper range, the shorted wire may not be energized at this time. Continue with
Step 6.
2. The voltage reading on the Infoview monitor is high. Disconnect the resistor plug at connector X330. Use
a multimeter to check for voltage on connector X330 pin B. There should be 5 volts present.
3. The voltage reading on the Infoview monitor is high. Disconnect the air filter pressure switch connector
X202. Use a multimeter to check for continuity between connector X202 pin 1 and chassis ground.
55-153
harness at connector X010. Use a multimeter to check for voltage on the mainframe end of connector X010
pin 8.
A. If no voltage is found, the short is in the engine (EN) harness between connector X202 pin 2 and
connector X010 pin 8 wire 864 yellow or 420 yellow, or between connector X202 pin 2 and connector
X330 pin A wire 860 yellow. Locate the short and repair.
55-154
FAULT CODE – E0163-05 Engine Air Filter Sensor Line Disconnected
Cause:
The engine air filter switch (S-61) circuit is open or shorted to ground.

1. Switch signal wiring open or shorted to ground.
2. Loss of power to the switch.
Solution:
Select “Engine air filter sensor” and check voltage range.
The proper voltage range for the engine air filter switch (key On, engine Off or Running) is – 0.3 to 5.2 volts.
A. If the voltage reading is low out of range continue with Step 2.
B. If the voltage is normal the shorted wire may not be grounded at this time. Continue with Step 8.
2. The voltage reading on the Infoview monitor is low (<0.3 volts). Disconnect the resistor plug at connector
X330. Use a multimeter to check for voltage on connector X330 pin B. There should be 5 volts present.
for voltage on connector X010 pin 13. There should be 5 volts present.
A. If voltage is found, there is an open circuit in the engine (EN) harness between connector X330 pin
B and connector X010 pin 13 wire 469 pink or 463 pink. Locate the open and repair.
5. The voltage reading on the Infoview monitor is low (<0.3 volts). Disconnect the engine harness from the main
frame harness at connector X010. Use a multimeter to check for continuity between the engine harness end
of connector X010 pin 8 and chassis ground.
A. If there is continuity, there is a short to ground in the engine (EN) harness between connector X010
pin 8 and connector X202 pin C wire 420 yellow. Locate the short and repair.
55-155
6. The voltage reading on the Infoview monitor is low (<0.3 volts). Use a multimeter to check for continuity
between the main frame harness end of connector X010 pin 8 and chassis ground.
A. AIf there is continuity to ground, there is a short to ground in the main frame (MF) harness between
for continuity between connector X202 pin 2 and chassis ground, and between connector X330 pin A and
chassis ground.
A. If continuity is found from both connectors, continue with Step 9.
A. If there is continuity, there is an open circuit in the engine (EN) harness between connector X010 pin
8, connector X330 pin A and connector X202 pin 2 wire 420 yellow, 860 yellow or 864 yellow. Locate
55-156
1 2
40020128
10020076
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24
1. Air Filter Switch S61
2. Air Filter Resistor R15
3. Connector X010
4. Connector X016
55-157
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55-159
FAULT CODE – E0164-03 V Supply Ground Spd Hydro

NOTE: This fault code may occur if the propulsion handle is moved very slowly out of the neutral position, such
as when ”inching” the combine forward or reverse. This is due to the software looking at both the calibrated
neutral position of the ground speed potentiometer R-04 and the power input from the neutral switch S-22; if the
handle is moved slowly, one event may occur slightly before the other. This is normal, and does not necessarily
indicate a problem with the system.
Context:
The neutral switch S-22 is mounted on the multi-function handle (MFH) assembly, and is used to supply battery
power to CCM2 connector X015 pin J1-17 when the MFH is moved out of the neutral position. This battery power
is used by the controller to power the ground speed hydrostat electronic displacement control (EDC) valve. This
provides a margin of safety by immmediately disconnecting the power supply to the EDC valve when the MFH
is moved to the neutral position.
The MFH neutral position is determined by both the neutral switch position and the calibrated neutral position
of the ground speed potentiometer R-04. If the controller determines that the MFH is in neutral based on the
ground speed potentiometer R-04 position, but there is battery voltage at connector X015 pin J1-17, then this
fault code will occur.
Cause:
The MFH is in the neutral position, and voltage is greater than 9 volts at CCM2 connector X015 pin J1-17.

1. Multifunction handle out of calibration.
2. Wire 113 YE shorted to battery voltage.
3. Ground speed potentiometer not mounted securely.
4. Ground speed potentiometer R-04 failed.
5. Neutral switch S-22 failed.
Solution:
1. Enter the Infoview monitor – “Diagnose info” screen.
Select “V Supply Ground Spd Hydro”, and check the voltage while moving the multi-function handle (MFH)
in and out of neutral.
The proper voltage with the MFH in neutral is 0 volts.
The proper voltage with the MFH out of neutral is 12 volts (battery voltage).
A. If the voltage reading is greater than 9 volts with the MFH in neutral, continue with Step 2.
B. If the voltage reading is within the proper limits, continue with Step 4.
2. Remove the top portion of the right hand console, and carefully turn it over. Remove connector X059 from
the neutral switch. Turn the key switch to the “On” position. Use a multimeter to check for voltage at
connector X059 pin 3. There should not be voltage.
A. If there is voltage, there is a short circuit in the cab main (CM) or right console (RC) harnesses between
connector X059 pin 3, connector X001 pin 17 and connector X015 pin J1-17 wire 113 yellow. Locate
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3. Key switch in the “Off” position. Use a multimeter to check for continuity between pins 1 and 3 of the neutral
switch S-22 with the MFH handle in the neutral position. There should not be continuity.
A. If there is continuity, the neutral switch has failed. Replace the neutral switch.
4. Key switch in the “On” position. Enter the Infoview monitor “Configuration info” screen.
Select the “Calibration” sub menu.
Select “Multifunctional Handle” and press the “Enter” key. Follow the on-screen instructions to calibrate the
MFH. After the calibration is complete, operate the combine normally and check for the fault code.
A. If the fault code continues to appear after the MFH has been calibrated, continue with Step 5.
B. If the fault code no longer appears after the MFH has been calibrated, continue with Step 6.
5. Remove the top portion of the right hand console, and carefully turn it over. Inspect the MFH potentiometer
mounting to ensure that it is tight, and that the potentiometer shaft is securely engaged with the MFH linkage.
A. If the potentiometer mounting is loose, tighten the potentiometer mounting screws so that the
potentiometer does not move when moving the MFH. Return to Step 4.
B. If the potentiometer mounting is secure, the potentiometer moves properly with the MFH movement,
and the fault code still occurs, the potentiometer has failed. Replace the potentiometer.
A. If the fault code reappears, return to Step 1.
55-161
FAULT CODE – E0164-04 V Supply Ground Spd Hydro

NOTE: This fault code may occur if the propulsion handle is moved very slowly out of the neutral position, such
as when ”inching” the combine forward or reverse. This is due to the software looking at both the calibrated
neutral position of the ground speed potentiometer R-04 and the power input from the neutral switch S-22; if the
handle is moved slowly, one event may occur slightly before the other. This is normal, and does not necessarily
indicate a problem with the system.
Context:
The neutral switch S-22 is mounted on the multi-function handle (MFH) assembly, and is used to supply battery
power to CCM2 connector X015 pin J1-17 when the MFH is moved out of the neutral position. This battery power
is used by the controller to power the ground speed hydrostat electronic displacement control (EDC) valve. This
provides a margin of safety by immmediately disconnecting the power supply to the EDC valve when the MFH
is moved to the neutral position.
The MFH neutral position is determined by both the neutral switch position and the calibrated neutral position
of the ground speed potentiometer R-04. If the controller determines that the MFH is out of neutral based on the
ground speed potentiometer R-04 position, and there is not battery voltage at connector X015 pin J1-17, then
this fault code will occur.
Cause:
The MFH is not in the neutral position, and voltage is less than 9 volts at CCM2 pin connector X015 J1-17.

1. Multifunction handle out of calibration.
2. Wire 113 YE shorted to ground or open (fuse F48 or F42 failed).
3. Neutral switch S-22 mounting loose.
4. Neutral switch S-22 failed.
5. Ground speed potentiometer R-04 failed.
Solution:
Select “V Supply Ground Spd Hydro”, and check the voltage while moving the multi-function handle (MFH)
in and out of neutral.
The proper voltage with the MFH in neutral is 0 volts.
The proper voltage with the MFH out of neutral is 12 volts (battery voltage).
B. If the voltage reading is less than 9 volts with the MFH out of neutral, continue with Step 5.
C. If the voltage reading is within the proper limits, continue with Step 2.
2. Key switch in the “On” position. Enter the Infoview monitor “Configuration info” screen.
Select the “Calibration” sub menu.
Select “Multifunctional Handle” and press the “Enter” key. Follow the on-screen instructions to calibrate the
MFH. After the calibration is complete, operate the combine normally and check for the fault code.
A. If the fault code continues to appear after the MFH has been calibrated, continue with Step 3.
B. If the fault code no longer appears after the MFH has been calibrated, continue with Step 11.
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3. Remove the top portion of the right hand console, and carefully turn it over. Inspect the ground speed
potentiometer R-04 mounting to ensure that it is tight, and that the potentiometer shaft is securely engaged
with the MFH linkage.
A. If the potentiometer mounting is loose, tighten the potentiometer mounting screws so that the
potentiometer does not move when moving the MFH. Return to Step 2.
B. If the potentiometer mounting is secure, and the potentiometer moves properly with the MFH
movement, the potentiometer has failed. Continue with Step 4.
4. Replace the ground speed potentiometer R-04. Calibrate the MFH handle as described in Step 2. Operate
the combine to determine if the fault reoccurs.
A. If the fault reoccurs after replacing the ground speed potentiometer R-04, continue with Step 10.
B. If the fault does not reoccur after replacing the ground speed potentiometer R-04, continue with Step
11.
5. Check the condition of fuses F-42 and F-48 in the fuse panel. If one or both of the fuses have failed, replace
them.
A. If fuse F-42 is replaced, and fails immediately after being replaced, there is short to ground in the cab
main (CM) harness between fuse F-42 and the cab power relay K-26 wire 010 red, or between the cab
power relay K-26 and the fuse panel buss strip wire 007 orange. Locate the short and repair. Return
to Step 1.
B. If fuse F-48 is replaced, and fails immediately after being replaced, there is a short to ground in the one
-- wire 109 orange, fuse F48 to thresher latching relay K28, terminal 3
-- wire 108 orange, fuse F48 to connector X001, pin 3
-- switch power wires from splice block B, W02 in the RH console
Locate the short and repair. Return to Step 1.
C. If both fuses are in good condition, continue with Step 6.
6. Remove the top portion of the right hand console, and carefully turn it over. Inspect the neutral switch
mounting to ensure it is tight, and the roller is centered in the notch with the MFH in the neutral position. When
the MFH is moved out of neutral, there should be an audible “click” as the neutral switch roller climbs out of
the notch.
A. If the neutral switch mounting is loose, properly position the switch and tighten the mounting screws.
Return to Step 1.
B. If the neutral switch is securely mounted in the proper position, continue with Step 7.
7. Remove connector X059 from the neutral switch. Turn the key switch to the “On” position. Use a multimeter
to check for voltage at connector X059 pin 1. There should be approximately 12 volts.
A. If there is no voltage, there is an open circuit in the cab main (CM) harness or right console (RC)
harnesses between fuse F48, connector X001 pin 3 and connector X059 pin 1 wires 108 or 300
orange. Locate the open and repair. Return to Step 1.
B. If there is less than 9 volts, there is excessive resistance in the cab main (CM) or right console (RC)
harnesses between fuse F48, connector X001 pin 3 and connector X059 pin 1 wires 108 or 300
orange. Locate the source of the resistance and repair. Return to Step 1.
C. If there is greater than 9 volts, continue with Step 8.
8. Use a multimeter to check for continuity between pin 1 and pin 3 of the neutral switch S-22 with the MFH out
of the neutral position. There should be continuity.
A. If there is no continuity, the neutral switch has failed internally. Replace the neutral switch. Return to Step
1.
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9. Reconnect connector X059 at the neutral switch. Remove the instructional seat and storage bin to gain
access to the CCM controllers. Turn the key switch to the “On” position. Use a multimeter to check for voltage
at CCM2 connector X015 pin J1-17 when the MFH is out of the neutral position. There should be
approximately 12 volts.
A. If there is no voltage, there is an open circuit in the right console (RC) or cab main (CM) harnesses
between connector X059, connector X001 pin 17 and connector X015 pin J1-17 wire 113 yellow.
Locate the open and repair. Return to Step 1.
B. If there is less than 9 volts, there is excessive resistance in the right console (RC) or cab main (CM)
harnesses between connector X059, connector X001 pin 17 and connector X015 pin J1-17 wire 113
yellow. Locate the source of the resistance and repair. Return to Step 1.
C. If there is greater than 9 volts, continue with Step 10.
10. Use the electronic service tool (EST) to reload the CCM2 software. After reloading the software, operate the
combine and check for the fault code.
A. If the fault still occurs, there is a failure in the CCM2 controller. Replace the CCM2 controller. Return
to Step 1.
B. If the fault no longer occurs, continue with Step 11.
11. Erase the fault code and continue normal operation.
A. If the fault code reappears, return to Step 1.
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4 3
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1. Fuse F42
2. Fuse F48
3. Connector X001
4. Neutral Switch S22
5. Connector X015
55-165
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55-168
FAULT CODE – E0165-03 CCM2 5V Ref Voltage 3

Cause:
The CCM2 5V Ref Voltage 3 circuit is shorted to a higher than normal voltage source.

Solution:
The CCM2 5V Ref Voltage 3 circuit supplies power from connector X016 pin J2-31 to four different sensors;
the air filter switch S61 and oil pressure sensor [B30 (NH 7.5L) or B52 (Iveco)] in the engine harness, the grain
bin sensors S28 & S29 in the grain tank harness, and the control pressure sensor B35 in the gearbox harness.
A short to high voltage on any of these supply wires will result in this fault code being displayed.

The proper voltage supply is 4.5 to 5.5 volts.
2. The voltage reading on the Infoview monitor is high. Disconnect the grain tank harness from the main frame
A. If the voltage decreases to 4.5 to 5.5 volts, the short is in the grain tank (GT) harness between
connector X009 pin G and connector X107 pin A wire 440 pink. Locate the short and repair.
A. If the voltage decreases to 4.5 to 5.5 volts, the short is in the gearbox (GB) harness between connector
X011 pin D and connector X098 pin B wire 486 pink. Locate the short and repair.
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A. If the voltage decreases to 4.5 to 5.5 volts, the short is in the engine (EN) harness on one of the following
wires:
wire 463 pink, connector X010 pin 13 to engine harness splice
wire 469 pink, engine harness splice to connector X330 pin B (air filter resistor R15)
wire 490 pink, engine harness splice to connector X197 pin 5 (Iveco only)
wire orange, connector X197 pin 5 to oil pressure sensor connector X337 pin B (Iveco only)
wire 490 pink, engine harness splice to oil pressure sensor connector X201 pin B (NH 7.5L only)
5. Carefully disconnect connector X016 from the bottom of the CCM2 module. Use a multimeter to check for
voltage at connector X016 pin J2-31. There should be 4.5 to 5.5 volts.
A. If the voltage is within 4.5 to 5.5 volts, the short is in the main frame harness. Carefully inspect the main
frame harness between connector X016 and the grain tank, engine and gearbox harnesses for any
signs of chaffing, pinch marks, or other damage which could result in an internal short. Repair any
damage found.
B. If the voltage is greater than 5.5 volts, there is a problem with an internal component in the CCM2
module. Replace the module.
6. Operate the machine while monitoring the Infoview monitor. If no high out of range readings are indicated,
erase the fault code and continue operation.
55-170
FAULT CODE – E0165-04 CCM2 5V Ref Voltage 3 Shorted to Low Source

Cause:
The CCM2 5V Ref Voltage 3 circuit is shorted to ground.

Solution:
The CCM2 5V Ref Voltage 3 circuit supplies power from connector X016 pin J2-31 to four different sensors;
the air filter switch S61 and oil pressure sensor [B30 (NH 7.5L) or B52 (Iveco)] in the engine harness, the grain
bin sensors S28 & S29 in the grain tank harness, and the control pressure sensor B35 in the gearbox harness.
A short to ground on any of these supply wires will result in this fault code being displayed.

A. If the voltage reading is low (<4.5 volts), continue with Step 2.
2. The voltage reading on the Infoview monitor is low. Disconnect the grain tank harness from the main frame
A. If the voltage increases to 4.5 to 5.5 volts, the short is in the grain tank (GT) harness between connector
X009 pin G and connector X107 pin A wire 440 pink. Locate the short and repair.
3. The voltage reading on the Infoview monitor is low. Disconnect the gearbox harness from the main frame
X011 pin D and connector X098 pin B wire 486 pink. Locate the short and repair.
A. If the voltage increases to 4.5 to 5.5 volts, the short is in the engine (EN) harness on one of the following
wires:
wire 463 pink, connector X010 pin 13 to engine harness splice
wire 469 pink, engine harness splice to connector X330 pin B (air filter resistor R15)
wire 490 pink, engine harness splice to connector X197 pin 5 (Iveco only)
wire orange, connector X197 pin 5 to oil pressure sensor connector X337 pin B (Iveco only)
wire 490 pink, engine harness splice to oil pressure sensor connector X201 pin B (NH 7.5L only)
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A. If the voltage is within 4.5 to 5.5 volts, the short is in the main frame harness. Carefully inspect the main
frame harness between connector X016 and the grain tank, engine and gearbox harnesses for any
signs of chaffing, pinch marks, or other damage which could result in an internal short. Repair any
damage found.
B. If the voltage is less than 4.5 volts, there is a problem with an internal component in the CCM2 module.
Replace the module.
55-172
1 5
4
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11
10010900 10020076 50020057
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26
1. Grain Bin Full Sensor S29 5. Connector X197 (Iveco) 10. Connector X011
2. Grain Bin 3/4 Full Sensor S28 6. Air Filter Switch S61 11. Connector X009
3. Engine Oil Pressure Sensor B30 7. Air Filter Resistor R15 12. Connector X016
(NH7.5L) 8. Control Pressure Sensor B35
4. Engine Oil Pressure Sensor B52 (Iveco) 9. Connector X010
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55-174
55-175
55-176
55-177
FAULT CODE – E0166-03 CCM2 8V Ref Voltage Shorted to High Source

Cause:
The CCM2 8V Ref Voltage circuit is shorted to a higher than normal source.

1. 12V short on 8V regulated power circuit.
Solution:
1. The 8V regulated power supply is provided from the key switch power to the module, and is used to provide
power to all the speed and position sensor circuits. In some cases, a 12V short on one of the sensor signal
wires could result in backfeeding that upsets the 8V regulator, and may cause the short to high source fault.
A. If the reading is high out of range, continue with Step 2.
B. If the reading is within the proper range, reload the software in CCM2. Erase the Fault code and continue
operation. If the fault code persists, replace the module.
3. Turn off the key switch, and disconnect the battery key to remove all power from the module. Carefully remove
connector X016 and connector X017 from the bottom of CCM2 module. Reconnect the battery key and
enter the Infoview monitor - “Diagnose info” screen.
A. If the voltage reading is normal, there is a short to high source on one of the sensor wires. Continue with
Step 3.
B. If the voltage reading is still high out of range then CCM2 has an internal failure. Replace the controller.
4. Turn off the key switch, and disconnect the battery key to remove all power from the module. Carefully
reconnect connector X016 and connector X017 from the bottom of CCM2 module. Reconnect the battery
key and enter the Infoview monitor -Service Info screen. Use the “Active Errors” screen to check for any errors
for sensor circuits short to high source on CCM2 module.
A. If there are any sensor circuits on CCM2 that are shorted to high source, correct those circuits, and then
continue with Step 1 of this troubleshooting to verify this concern is resolved.
B. If there are no sensor circuits errors on CCM2, reload the software in CCM2. Erase the Fault code and
continue operation. If the fault code persists, replace the module.
55-178
FAULT CODE – E0166-04 CCM2 8V Ref Voltage Shorted to Low Source

Cause:
The CCM2 8V Ref Voltage circuit is shorted to ground.

Solution:
A. If the voltage reading is low out of range then CCM2 has an internal failure. Replace the controller.
55-179
FAULT CODE – E0167-03 CCM2 5V Ref Voltage 1

Cause:
The CCM2 5V Ref Voltage 1 circuit is shorted to a higher than normal voltage source.

Solution:
The CCM2 5V Ref Voltage 1 circuit supplies power from connector X017 pin J3-26 to the park brake pressure
sensor B53 in the front frame harness. A short to high voltage on this supply wire will result in this fault code being
displayed.

2. The voltage reading on the Infoview monitor is high. Disconnect the park brake pressure sensor connector
X368.
A. If the voltage decreases to 4.5 to 5.5 volts, the short is in the sensor. Replace the sensor.
A. If the voltage is within 4.5 to 5.5 volts, the short is in the front frame (FF) harness between connector
X017 and connector X368 wire 1537 pink. Locate the short and repair.
B. If the voltage is greater than 5.5 volts, there is a problem with an internal component in the CCM2
module. Replace the module.
55-180
FAULT CODE – E0167-04 CCM2 5V Ref Voltage 1 Shorted to Low Source

Cause:
The CCM2 5V Ref Voltage 1 circuit is shorted to ground.

Solution:
The CCM2 5V Ref Voltage 1 circuit supplies power from connector X017 pin J3-26 to the park brake pressure
sensor B53 in the front frame harness. A short to ground on this supply wire will result in this fault code being
displayed.

A. If the voltage reading is low (<4.5 volts), continue with Step 2.
2. The voltage reading on the Infoview monitor is low. Disconnect the park brake pressure sensor connector
X368.
A. If the voltage increases to 4.5 to 5.5 volts, the short is in the sensor. Replace the sensor.
A. If the voltage is within 4.5 to 5.5 volts, the short is in the front frame (FF) harness between connector
X016 and connector X368 wire 1537 pink. Locate the short and repair.
B. If the voltage is less than 4.5 volts, there is a problem with an internal component in the CCM2 module.
Replace the module.
55-181
55-182
FAULT CODE – E0168-03 CCM2 Keyswitch Voltage

Cause:
The CCM2 Keyswitch Voltage circuit is shorted to a higher than normal source.

1. The keyswitch voltage circuit to the CCM2 controller is shorted to a high source.
Solution:
1. Start the combine engine. Enter the Infoview monitor - “Diagnose info” screen.
Select “CCM2 Key switch Voltage”. Increase the engine RPM to high idle (maximum) and check voltage
range.
info” screen.
producing excessive voltage. Refer to “Charging Systems” in Chapter 5 - Engine Systems in this
Section for additional alternator testing information.
A. If the voltage reading is greater than 18 volts, then the batteries have been mistakenly connected in
series (7.5L units), or there is a fault in the wiring of the 24V starting system (Iveco units). Refer to
“Starting Systems” in Chapter 5 - Engine Systems in this Section for additional information.
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4. Remove the buddy seat and storage bin to gain access to connector X015 on CCM2. Turn the key on. Check
the voltage at connector X015 pin J1-4.
wire 096 orange, key switch S02 to CM harness splice
wire 100 orange, harness splice to CCM2 connector X015, pin J1-4
wire 097 orange, harness splice to Infoview monitor connector X064, pin C
wire 055 orange, harness splice to road light switch connector X256, pin 6
wire 095 orange, harness splice to power relays K24, K25 & K26, pins 1
wire 222 orange, power relay K26 to time delay module K20, pin 30
wire 970 orange, time delay module K20, pin 30 to fuel pump relay K07, pin 1
All wires listed are located in the cab main (CM) harness. Visually inspect the cab main harness for
damage, bent or dislocated pins, corroded terminals or broken wires. Locate the high voltage short and
repair.
5. Erase the error code and continue operation.
55-184
FAULT CODE – E0168-04 CCM2 Keyswitch Voltage

Cause:
The CCM2 Keyswitch Voltage circuit is shorted to a lower than normal source.

3. The keyswitch voltage circuit to the CCM2 controller is shorted to ground.
Solution:

B. If the fuse immediately fails again, a short to ground exists in wire 053 red between the fuse and the
key switch in the cab main (CM) harness. Visually inspect the cab main harness for damage, bent or
dislocated pins, corroded terminals or broken wires. Locate short and repair.
3. If the fuse does not fail when it is replaced, turn the key switch to the “Acc” position.
wire 123 orange, key switch to the Wiper relay K06
wire 241 orange, Wiper relay K06 to Accessory 1 relay K08
wire 126 orange, Accessory 1 relay K08 to Accessory 2 relay K03
All three wires are in the cab main harness. Visually inspect the cab main harness for damage, bent
or dislocated pins, corroded terminals or broken wires. Locate short and repair.
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4. If the fuse does not fail with the key switch in the “Acc” position, turn the key switch to the “On” position.
wire 096 orange, key switch S02 to CM harness splice
wire 097 orange, harness splice to Infoview monitor connector X064, pin C
wire 055 orange, harness splice to road light switch connector X256, pin 6
wire 095 orange, harness splice to power relays K24, K25 & K26, pins 1
wire 222 orange, power relay K26 to time delay module K20, pin 30
wire 970 orange, time delay module K20, pin 30 to fuel pump relay K07, pin 1
All wires are in the cab main harness. Visually inspect the cab main harness for damage, bent or
dislocated pins, corroded terminals or broken wires. Locate short and repair.
5. If the fuse does not fail with the key switch in the “On” position, turn the key switch briefly to the “Start” position.
B. If the fuse immediately fails, there is a short to ground in wire 091 orange from the key switch to Neutral
start relay K23, or wire 090 orange from the relay to CCM2, connector X015, pin J1-21. Both wires
are in the cab main harness. Visually inspect the cab main harness for damage, bent or dislocated pins,
corroded terminals or broken wires. Locate short and repair.
cab fuse panel, due to loose or corroded connections, or the batteries have discharged excessively, and
are not capable of supplying the minimum voltage requirement for CCM2. Inspect the wiring from the
batteries to the engine compartment, and from there to the cab. Recharge or replace the batteries.
7. Key switch in “On” position. Enter the Infoview monitor - “Diagnose info” screen.
CCM2. Inspect wire 053 red to the key switch, and wires 096 and 100 orange to CCM2 connector X015
pin J1-4 for loose or corroded connections, or damage to the wires.
Select “CCM2 Key switch Voltage”. With the engine RPM at low idle, engage road and work lights. Check
voltage range.
B. If the voltage reading is less than 10 volts, the alternator and/or regulator may have failed, and the
charging system is not producing sufficient voltage. Refer to “Charging Systems” in Chapter 5 - Engine
Systems in this Section for additional alternator testing information.
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1. Fuse F38
2. Key Switch S02
3. Connector X015
55-187
55-188
FAULT CODE – E0169-06 Current Sense Reel Speed Short Circuit

Cause:
The reel speed motor (M-09) circuit indicates high current draw. (European Heads Only)

Solution:
1. Enter the Infoview monitor - “Service info” screen.
B. Start the combine, engage the thresher and feeder circuits, and operate the reel speed motor in both
directions.
C. Record in which direction(s) the reel speed increase or decrease operates.
D. Reload error history. Check for fault codes 0169-06 and 0204-05.

0169-06 0204-05
Reel Speed adjust operates in 1 di- X Go to Step 2 Binding
rection only
X Go to Step 3 Short to ground
Reel Speed adjust does not operate X Go to Step 2 Binding
in either direction
X Go to Step 10 Open circuit
2. The reel speed motor or reel mechanism is mechanically bound up, resulting in high current draw. See the
appropriate repair manual chapter for repair and adjustment of the reel speed linkage.
3. Fault codes indicate circuit fault due to short to ground. Disconnect reel speed motor connector X308.
Measure between terminals A or B on the motor connector and a known good ground. There should be no
A. There is continuity to ground, indicating a short to ground in the motor. Replace the reel speed motor.
B. There is no continuity to ground. Continue with Step 4.
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X308 pin B and chassis ground.
position. Power must be removed from the module prior to testing for short to ground condition on the motor circuit
to remove this ground path.

5. Disconnect inline connector X032. Use a multimeter to check for continuity between connector X032 pin
A. If no continuity is found the short to ground is in the harness between connector X032 pin 26 and
connector X308 pin B. Locate the short and repair.
chassis ground.
A. If no continuity is found, the short to ground is in the harness between connector X032 pin 26 and
connector X007 pin 19 wire 711 gray. Locate the short and repair.
B. If continuity is found, the short to ground is in the harness between connector X007 pin 19 and
connector X017 pin J3-6 wire 711 gray. Locate the short and repair.
7. Use a multimeter to check for continuity between connector X308 pin A and chassis ground.
B. If no continuity is found, recheck the motor for continuity to ground at Step 3.
chassis ground.
A. If no continuity is found, the short to ground is in the harness between connector X308 pin A and X032
pin 20. Locate the short and repair.
chassis ground.
A. If no continuity is found, the short to ground is between connector X007 pin 3 and connector X017
pin J3-8 wire 712 white. Locate the short and repair.
connector X007 pin 3 wire 712 white. Locate the short and repair.
10. Fault codes indicate circuit fault due to open circuit condition. Disconnect reel speed motor connector X308.
Measure the resistance of the motor between terminals A and B. The correct resistance is XX to XX ohms.
A. The resistance is infinite, indicating an open condition in the motor. Replace the reel speed motor.
B. The resistance is in specification. Continue with Step 11.
55-190
to check for continuity between connector X308 pin B and chassis ground.
position, irregardless of key switch position, as long as it receives power through fuse F23. This ground path may
be used to test for an open circuit condition.

A. If continuity is found the open circuit is in the harness between connector X032 pin 26 and connector
X308 pin B. Locate the open and repair.
chassis ground.
A. If continuity is found, the open circuit is in the harness between connector X032 pin 26 and connector
X007 pin 19 wire 711 gray. Locate the open and repair.
B. If no continuity is found, the open circuit is in the harness between connector X007 pin 19 and
connector X017 pin J3-6 wire 711 gray. Locate the open and repair.
B. If continuity is found, recheck the motor for continuity at Step 10.
chassis ground.
A. If continuity is found, the open circuit is in the harness between connector X308 pin A and X032 pin
20. Locate the open and repair.
chassis ground.
A. If continuity is found, the open circuit is between connector X007 pin 3 and connector X017 pin J3-8
connector X007 pin 3 wire 712 white. Locate the open and repair.
17. If the header reel speed motor does not operate in either direction, and there are no error codes indicated,
the supply power for the circuit may not be present. Remove fuse F23 and inspect.
A. Fuse has failed. Go to Step 18.
B. Fuse is okay. Go to Step 19.
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A. If fuse immediately fails, a short to ground exists on one of the two following wires:
wire 025 red, from the fuse panel through connector X005 pin 1 to connector X016 pin J2-11 on
CCM2 module.
wire 028 red, from the fuse panel through connector X031 pin 4 to connector X017 pin J3-7 on CCM2
module.
A. If there is no power, there is an open circuit on wire 028 red, from the fuse panel through connector
X031 pin 4 to connector X017 pin J3-7 on CCM2 module. Locate the open and repair. After repair,
go to Step 20.
B. If there is power, go to Step 20.
A. If there is no continuity to ground, there is an open circuit on wire 515 black, from connector X017 pin
J3-16 on CCM2 module to the front frame ground #2. Locate the open and repair. After repair, go to
Step 21.
described in Step 1. If the fuse fails during the testing, a short to ground on the circuit is causing the fuse to
fail. Start the troubleshooting at Step 3 to locate the short to ground.
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1. Reel Speed Motor M09 (On Header)
2. Connector X032
3. Connector X007
4. Connector X017
55-193
55-194
55-195
FAULT CODE – E0171-06 Curr Sense Transm Shift Short Circuit

Cause:
The Transmission shift motor (M-02) circuit indicates high current draw.

Solution:
B. Start the combine, and shift the transmission in both directions.
C. Record in which direction(s) the transmission shift operates.

0171-06 0203-05
Transmission shift motor operates in X Go to Step 2 Binding
1 direction only
Transmission shift motor does not X Go to Step 2 Binding
X Go to Step 8 Open circuit
2. The transmission shift mechanism is mechanically bound up, resulting in high current draw. See the
appropriate repair manual chapter for repair and adjustment of the transmission shift linkage.
3. Fault codes indicate circuit fault due to short to ground. Disconnect transmission shift motor connector
X094. Measure between terminals A or B on the motor connector and a known good ground. There should
be no continuity to ground.
A. There is continuity to ground, indicating a short to ground in the motor. Replace the transmission shift
motor.
55-196

A. If no continuity is found the short to ground is in the harness between connector X023 pin 3 and
connector X094 pin B wire 715 grey. Locate the short and repair.
connector X017 pins J3-19 and 20 on one of the following wires:
wire 715 grey, connector X023 pin 3 to harness splice
wire 526 grey, harness splice to connector X017 pin J3-19
B. If no continuity is found, recheck the motor for continuity to ground at Step 3.
chassis ground.
A. If no continuity is found, the short to ground is in the harness between connector X094 pin A and X023
pin 4 wire 716 white. Locate the short and repair.
8. Fault codes indicate circuit fault due to open circuit condition. Disconnect transmission shift motor connector
X094. Measure the resistance of the motor between terminals A and B. The correct resistance is 4.0 to
5.0 ohms.
A. The resistance is infinite, indicating an open condition in the motor. Replace the transmission shift
motor.
55-197

wire 715 grey, connector X023 pin 3 to harness splice
B. If continuity is found, recheck the motor for continuity at Step 8.
chassis ground.
A. If continuity is found, the open circuit is in the harness between connector X094 pin A and X023 pin
4. Locate the open and repair.
13. If the transmission shift motor does not operate in either direction, and there are no error codes indicated,
harness
55-198
harness
Locate the open and repair. After repair, go to Step 16.
Locate the open and repair. After repair, go to Step 17.
B. If there is continuity to ground, go to Step 17.
described in Step 1. If the fuse fails during the testing, a short to ground on the circuit is causing the fuse to
fail. Start the troubleshooting at Step 3 to locate the short to ground.
55-199
2
1
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29
1. Transmission Shift Motor - M02
2. Connector X023
3. Connector X017
55-200
55-201
FAULT CODE – E0172-06 Curr Sense Rot Scr Brush Short Circuit
NOTE: This troubleshooting chart is for CR920 combines with 7.5L mechanical governor engines only. The
troubleshooting chart for this fault code on CR940, CR960, CR970 and CR980 combines with electronic
governor engines follows this chart.
Cause:
The Rotary Screen Brush motor (M-27) circuit indicates high current draw.

1. Circuit wiring short to ground.
Solution:
This is an H-bridge-controlled circuit; the Rotary screen brush motor (M27) circuit is paired with the engine throttle
motor (M13) circuit, and the module switches between these two circuits using the Throttle/Brush relay K-15.
Because these circuits are connected and driven from the same module outputs, the troubleshooting procedure
must consider both circuits at the same time.
1. Enter the Infoview monitor - Service Info screens.

B. Enter the Infoview monitor - “Diagnose info” screens. Select “Engine” sub-menu, and scroll down to
select “Rotary Screen Brush motor”. Manually operate the motor in both directions.
C. Start the combine, and operate the engine throttle in both directions.
D. Record in which direction(s) each circuit operates.
E. Reload error history. Check for fault codes 0172-06 and 0206-05 (Rotary screen brush motor) and fault
codes 0173-06 and 0207-05 (Throttle motor).
55-202
Symptom Errors
0172-06 0173-06 0206-05 0207-05
Rotary screen brush motor oper- X Go to Step 2 Motor
ates in 1 direction only bound up
X Go to Step 3 Short to
ground
Rotary screen brush motor and X X Go to Step 6 Short to
Throttle motor (7.5L mechanical ground
engine only) operate in 1 direc-
tion only
Rotary screen brush motor does X Go to Step 10 Open
ground
Throttle motor (7.5L mechanical X Go to Step 19 Motor
engine only) operates in 1 direc- bound up
tion only
ground
Throttle motor (7.5L mechanical X Go to Step 23 Open
engine only) does not operate in
either direction X Go to Step 32 Short to
ground
Both Rotary screen brush motor X X Go to Step 33 Open
and Throttle motor (7(7.5L
5L me-
me
chanical engine only) do not op- Go to Step 38 Fuse 23
erate in either direction blown or
open
2. The rotary screen brush mechanism is mechanically bound up, resulting in high current draw. See the
appropriate repair manual chapter for repair and adjustment of the rotary screen brush linkage.
3. Fault codes indicate circuit fault due to short to ground between the rotary screen brush motor and the
Throttle/Brush relay K15. Disconnect the batteries using the battery key. Unplug the rotary screen brush
motor connector X206. Use a multimeter to check for continuity between connector X206 pin A and chassis
ground.

B. If no continuity is found, erase the fault codes and continue operation.
55-203
chassis ground.
A. If no continuity is found, the short to ground is in the harness between connector X206 pin A and
B. If continuity is found, continue with Step 5
chassis ground.
B. If continuity is found, the short to ground is in the harness between connector X004 pin 27 and the
Throttle/Brush relay K15 pin 4 on the fuse panel. Locate the short and repair.
6. Fault codes indicate circuit fault due to short to ground between the rotary screen brush motor and/or the
throttle motor and the CCM2 module. Disconnect the batteries using the battery key. Unplug the rotary screen
brush motor connector X206 and the throttle motor connector X196. Use the multimeter to check for
continuity between connector X206 pin B and chassis ground.

A. If continuity is found the short to ground is in the main frame (MF) harness between connector X010
pin 1 and connector X016 pin J2-1 wire 524 gray. Locate the short and repair.
B. If no continuity is found, the short to ground is in the engine (EN) harness between connector X010
pin 1, the rotary screen brush motor connector X206 pin B and connector X196 pin B on one of
wire 817 gray, harness splice to connector X206 pin B
8. Remove the Throttle/Brush relay K15 from the fuse panel. Use a multimeter to check for continuity between
the relay terminal 3 and chassis ground.
B. If no continuity is found, the short to ground is in the cab main (CM) harness between connector X004
pin 26 and the Throttle/Brush relay K15 pin 3 on the fuse panel.
55-204
10. Fault codes indicate circuit fault due to open circuit condition. Disconnect the rotary screen brush motor
connector X206. Measure the resistance of the motor between terminals A and B. The correct resistance
is xx to xx ohms.
A. The resistance is infinite, indicating an open condition in the motor. Replace the rotary screen brush
motor.

connector X016 pin J2-1 on wire 524 gray. Locate the open and repair.
B. If continuity is found, recheck the motor for continuity at Step 10. Erase the fault codes and continue
operation.
chassis ground.
A. If continuity is found, the open circuit is in the harness between connector X206 pin A and connector
X010 pin 2 wire 821 white. Locate the open and repair.
Throttle/Brush relay K15 terminal 4 and chassis ground.
NOTE: Continuity check is being done back through circuit through the motor. The resistance will read
significantly higher than previous tests, but should not be higher than 10 ohms above the motor resistance
measured in Step 10.
A. If no continuity is found, the open circuit is in wire 821 white from the fuse panel through connector X004
pin 27 to connector X010 pin 2. Locate the open and repair.
16. Use a multimeter to check for continuity between Throttle/Brush relay K15 terminal 3 and chassis ground.
A. If continuity is found, the relay has failed open between terminals 3 and 4. Replace the relay.
chassis ground.
A. If continuity is found, the open circuit is in the harness between the Throttle/Brush relay K15 terminal
3 on the fuse panel connector X004 pin 26 wire 525 white. Locate the open and repair.
connector X016 pin J2-21 wire 525 white. Locate the open and repair.
55-205
18. Fault codes and operating condition indicate that the motor has shorted to ground. Disconnect rotary screen
brush motor connector X206. Measure between terminals A or B on the motor connector and a known good
ground. There should be no continuity to ground.
A. There is continuity to ground, indicating a short to ground in the motor. Replace the rotary screen brush
motor.
B. There is no continuity to ground. Erase the fault codes and continue operation.
19. The throttle mechanism is mechanically bound up, resulting in high current draw. See the appropriate repair
manual chapter for repair and adjustment of the throttle linkage.
20. Fault codes indicate circuit fault due to short to ground between the throttle motor and the Throttle/Brush relay
K15. Disconnect the batteries using the battery key. Unplug the throttle motor connector X196. Use a
multimeter to check for continuity between connector X196 pin A and chassis ground.

chassis ground.
chassis ground.
23. Fault codes indicate circuit fault due to open circuit condition. Disconnect the throttle motor connector X196.
Measure the resistance of the motor between terminals A and B. The correct resistance is xx to xx ohms.
A. The resistance is infinite, indicating an open condition in the motor. Replace the throttle motor.
24. Replace the Throttle/Brush relay K15 on the fuse panel with a known good relay, and retest the throttle
circuit function.
A. If the throttle circuit now functions properly, the relay was faulty, and was not providing continuity
between terminals 3 & 5 when energized. Replace the relay.
B. If the throttle circuit still does not work, continue with Step 25.

55-206
27. Remove the Throttle/Brush relay K15 on the fuse panel, and install a jumper wire between terminals 3 & 5.
Use a multimeter to check for continuity between connector X196 pin A and chassis ground.
operation.
chassis ground.
29. Remove the jumper wire between terminals 3 & 5 for relay K15 on the fuse panel. Use a multimeter to check
for continuity between Throttle/Brush relay K15 terminal 5 and chassis ground.
A. If continuity is found, replace the relay. Erase the fault codes and continue operation.
chassis ground.
32. Fault codes and operating condition indicate that the motor has shorted to ground. Disconnect throttle motor
connector X196. Measure between terminals A or B on the motor connector and a known good ground.
There should be no continuity to ground.
A. There is continuity to ground, indicating a short to ground in the motor. Replace the throttle motor.
33. Fault codes and operating condition indicates that there is an open circuit on shared wiring between the
throttle motor and rotary screen brush motor circuits. Replace the Throttle/Brush relay K15 on the fuse
panel with a known good relay, and retest the throttle circuit function.
A. If both circuits now function properly, the relay was faulty, and was not providing continuity between the
work terminal 3 and terminals 4 & 5. Replace the relay.
B. If both circuits still do not work, continue with Step 34.
55-207
34. Ensure that the batteries are connected using the battery key, and that fuse F23 is good. Remove the
Throttle/Brush relay K15 on the fuse panel. Use a multimeter to check for continuity between

chassis ground.
36. Unplug the throttle motor connector X196. Use a multimeter to check for continuity between connector
B. If continuity is found, erase the fault codes and continue operation.
A. If continuity is found, the open circuit is in the engine (EN) harness, wire 524 gray between connector
X010 pin 1 and harness splice. Locate the open and repair.
B. If no continuity is found, the open circuit is in the main frame (MF) harness between connector X010
pin 1 and connector X016 pin J2-1 on wire 524 gray. Locate the open and repair.
38. If the throttle motor and rotary brush screen motor do not operate in either direction, and there are no error
codes indicated, the supply power for the circuit may not be present. Remove fuse F23 and inspect.
CCM2 module
module
55-208
go to Step 41.
Step 42.
described in Step 1. If the fuse fails during the testing, a short to ground on the circuit being operated at the
time of failure is causing the fuse to fail.
55-209
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1. Rotary Screen Brush Motor M27
2. Connector X010
3. Connector X004
4. Throttle/Brush Relay K15
5. Connector X016
55-210
55-211
FAULT CODE – E0172-06 Curr Sense Rot Scr Brush Short Circuit
NOTE: This troubleshooting chart is for CR940, CR960, CR970 and CR980 combines with electronic governor
engines only. The troubleshooting chart for this fault code on CR920 combines with 7.5L mechanical governor
engines is listed before this chart.
Cause:
The Rotary Screen Brush motor (M-27) circuit indicates high current draw.

1. Circuit wiring short to ground.
Solution:
C. Record in which direction the circuit operates.
Symptom Errors
0172-06 0206-05
Rotary screen brush motor oper- X Go to Step 2 Motor bound up
ates in 1 direction only
Go to Step 20 Fuse 23 blown or open
3. Fault code indicates circuit has shorted to ground. Disconnect rotary screen brush motor connector X206.
Measure between terminals A or B on the motor connector and a known good ground. There should be no
motor.
55-212
4. Replace the Throttle/Brush relay K15 with a known good relay, and retest the circuit.
A. If the circuit now works properly, then the relay had shorted out internally. Replace the relay.
B. The circuit does not work properly. Continue with Step 5.
5. Disconnect the batteries using the battery key. Unplug the rotary screen brush motor connector X206. Use
the multimeter to check for continuity between connector X206 pin B and chassis ground.

pin 1 and connector X206 pin B on wire 524 gray. Locate the short to ground and repair.
chassis ground.
the Throttle/Brush relay K15 terminal 4 and chassis ground.
A. If continuity is found, the short to ground is in wire 821 white from the fuse panel through connector
X004 pin 27 to connector X010 pin 2. Locate the short and repair.
10. Use a multimeter to check for continuity between the Throttle/Brush relay K15 terminal 3 and chassis
ground.
B. If no continuity is found, replace the relay. Erase the fault codes and continue operation.
55-213
is xx to xx ohms.
motor.

operation.
chassis ground.
A. If continuity is found, the open circuit is in the harness between connector X004 pin 27 and connector
55-214
chassis ground.
20. If the rotary brush screen motor does not operate in either direction, and there are no error codes indicated,
CCM2 module
module
go to Step 23.
Step 24.
time of failure is causing the fuse to fail. Start the troubleshooting at Step 3 to locate the short to ground.
55-215
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10010899 10020076
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31
1. Rotary Screen Brush Motor M27
2. Connector X010
3. Connector X004
5. Connector X016
55-216
55-217
FAULT CODE – E0173-06 Curr Sense Eng Throttle Short Circuit

Cause:
The Throttle actuator motor (M-13) circuit indicates a high current draw. (7.5L mechanical governor engine
only)

Solution:
This is an H-bridge-controlled circuit; the Rotary screen brush motor (M27) circuit is paired with the engine throttle
motor (M13) circuit, and the module switches between these two circuits using the Throttle/Brush relay K-15.
Because these circuits are connected and driven from the same module outputs, the troubleshooting procedure
must consider both circuits at the same time.
1. Enter the Infoview monitor - Service Info screens.

C. Start the combine, and operate the engine throttle in both directions.
D. Record in which direction(s) each circuit operates.
E. Reload error history. Check for fault codes 0172-06 and 0206-05 (Rotary screen brush motor) and fault
codes 0173-06 and 0207-05 (Throttle motor).
55-218
Symptom Errors
0172-06 0173-06 0206-05 0207-05
Rotary screen brush motor oper- X Go to Step 2 Motor
ates in 1 direction only bound up
ground
Rotary screen brush motor and X X Go to Step 6 Short to
Throttle motor (7.5L mechanical ground
engine only) operate in 1 direc-
tion only
ground
Throttle motor (7.5L mechanical X Go to Step 19 Motor
engine only) operates in 1 direc- bound up
tion only
ground
Throttle motor (7.5L mechanical X Go to Step 23 Open
engine only) does not operate in
either direction X Go to Step 32 Short to
ground
Both Rotary screen brush motor X X Go to Step 33 Open
and Throttle motor (7(7.5L
5L
mechanical engine only) do not Go to Step 38 Fuse 23
operate in either direction blown or
open
3. Fault codes indicate circuit fault due to short to ground between the rotary screen brush motor and the
Throttle/Brush relay K15. Disconnect the batteries using the battery key. Unplug the rotary screen brush
motor connector X206. Use a multimeter to check for continuity between connector X206 pin A and chassis
ground.

55-219
chassis ground.
B. If continuity is found, continue with Step 5
chassis ground.
6. Fault codes indicate circuit fault due to short to ground between the rotary screen brush motor and/or the
throttle motor and the CCM2 module. Disconnect the batteries using the battery key. Unplug the rotary screen
brush motor connector X206 and the throttle motor connector X196. Use the multimeter to check for
continuity between connector X206 pin B and chassis ground.

pin 1, the rotary screen brush motor connector X206 pin B and connector X196 pin B on one of
the relay terminal 3 and chassis ground.
55-220
is xx to xx ohms.
motor.

operation.
chassis ground.
chassis ground.
55-221
18. Fault codes and operating condition indicate that the motor has shorted to ground. Disconnect rotary screen
brush motor connector X206. Measure between terminals A or B on the motor connector and a known good
ground. There should be no continuity to ground.
motor.
19. The throttle mechanism is mechanically bound up, resulting in high current draw. See the appropriate repair
manual chapter for repair and adjustment of the throttle linkage.
20. Fault codes indicate circuit fault due to short to ground between the throttle motor and the Throttle/Brush relay
K15. Disconnect the batteries using the battery key. Unplug the throttle motor connector X196. Use a
multimeter to check for continuity between connector X196 pin A and chassis ground.

chassis ground.
chassis ground.
23. Fault codes indicate circuit fault due to open circuit condition. Disconnect the throttle motor connector X196.
Measure the resistance of the motor between terminals A and B. The correct resistance is xx to xx ohms.
A. The resistance is infinite, indicating an open condition in the motor. Replace the throttle motor.
24. Replace the Throttle/Brush relay K15 on the fuse panel with a known good relay, and retest the throttle
circuit function.
A. If the throttle circuit now functions properly, the relay was faulty, and was not providing continuity
between terminals 3 & 5 when energized. Replace the relay.
B. If the throttle circuit still does not work, continue with Step 25.

55-222
27. Remove the Throttle/Brush relay K15 on the fuse panel, and install a jumper wire between terminals 3 &
operation.
chassis ground.
29. Remove the jumper wire between terminals 3 & 5 for relay K15 on the fuse panel. Use a multimeter to check
for continuity between Throttle/Brush relay K15 terminal 5 and chassis ground.
A. If continuity is found, replace the relay. Erase the fault codes and continue operation.
chassis ground.
32. Fault codes and operating condition indicate that the motor has shorted to ground. Disconnect throttle motor
connector X196. Measure between terminals A or B on the motor connector and a known good ground.
There should be no continuity to ground.
A. There is continuity to ground, indicating a short to ground in the motor. Replace the throttle motor.
33. Fault codes and operating condition indicates that there is an open circuit on shared wiring between the
throttle motor and rotary screen brush motor circuits. Replace the Throttle/Brush relay K15 on the fuse
panel with a known good relay, and retest the throttle circuit function.
A. If both circuits now function properly, the relay was faulty, and was not providing continuity between the
work terminal 3 and terminals 4 & 5. Replace the relay.
B. If both circuits still do not work, continue with Step 34.
55-223
34. Ensure that the batteries are connected using the battery key, and that fuse F23 is good. Remove the
Throttle/Brush relay K15 on the fuse panel. Use a multimeter to check for continuity between

chassis ground.
36. Unplug the throttle motor connector X196. Use a multimeter to check for continuity between connector
B. If continuity is found, erase the fault codes and continue operation.
A. If continuity is found, the open circuit is in the engine (EN) harness, wire 524 gray between connector
X010 pin 1 and harness splice. Locate the open and repair.
B. If no continuity is found, the open circuit is in the main frame (MF) harness between connector X010
pin 1 and connector X016 pin J2-1 on wire 524 gray. Locate the open and repair.
38. If the throttle motor and rotary brush screen motor do not operate in either direction, and there are no error
codes indicated, the supply power for the circuit may not be present. Remove fuse F23 and inspect.
CCM2 module
module
55-224
go to Step 41.
Step 42.
time of failure is causing the fuse to fail.
55-225
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32
1. Engine Throttle Motor M13
2. Connector X010
3. Connector X004
5. Connector X016
55-226
55-227
FAULT CODE – E0174-03 CCM2 Battery Voltage Shorted to High Source

Cause:
The CCM2 Battery Voltage circuit is shorted to a higher than normal source.

1. Circuit wiring is shorted to a high voltage source.
Solution:
Battery voltage is used as “keep alive memory” power in the module to retain settings and configuration
information. The module will not initialize (wake-up at “key on”) if battery voltage drops below 9V, but there is no

info” screen.
55-228
4. Remove the buddy seat and storage bin to gain access to connector X015 on CCM2. Check the voltage
of the following wires in the cab main harness:
wire 047 red, fuse F39 to harness splice
wire 052 red, harness splice to CCM1 connector X018 pin J1-1
wire 051 red, harness splice through connector X001 pin 2 to RHM connector X026 pin 13
wire 057 red, harness splice to Infoview monitor connector X064 pin D
wire 142 red, harness splice to DAM connector X065 pin B
Locate the high voltage source and correct.
5. The short to high voltage is not present at this time. Erase the error code and continue operation.
55-229
FAULT CODE – E0174-04 CCM2 Battery Voltage Shorted to Low Source

Cause:
The CCM2 Battery Voltage circuit is shorted to a lower than normal source.

Solution:
Battery voltage is used as “keep alive memory” power in the module to retain settings and configuration
information. The module will not initialize (wake-up at “key on”) if battery voltage drops below 9V, but there is no
shutdown for excessive voltage. This fault code would typically be seen when battery voltage drops below 10V
(threshold for the fault) but is above 9V (shutdown threshold).

Visually inspect the cab main and cab roof harnesses for damage, bent or dislocated pins, corroded terminals
or broken wires. Locate short and repair.
55-230
4. Key switch in “On” position. Enter the Infoview monitor - “Diagnose info” screen.
CCM2. Inspect wires 047 & 050 red to CCM2 connector X015 pin J1-1 for loose or corroded
connections, or damage to the wires.
range.
55-231
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33
1. Fuse F39
2. Connector X015
55-232
55-233
55-234
FAULT CODE – E0175-03 V Supply Thresher Clutch

Cause:
The V Supply Thresher Clutch (S-30) circuit is shorted to a higher than normal voltage source.

1. V Supply Thresher Clutch wiring shorted to a high source.
Solution:
1. Start the combine engine. Engage the threshing engage switch. Enter Infoview monitor - “Diagnose info”
screen.
Select “V Supply Thresher Clutch” and check voltage range.
The proper voltage is 10.0 to 18.0 volts (Thresher switch engaged).
info” screen.
3. Key switch in the “Off” position. Check the voltage at fuse F42 using a multi-meter.
55-235
4. Key switch in the “On” position. Engage the thresher engage switch S30. Remove the buddy seat and
storage bin to gain access to connector X015 on CCM2. Check the voltage at connector X015 pin J1-7.
wire 108 orange, fuse F48 through connector X001, pin 3 to harness splice
wire 300 orange, harness splice to neutral switch S22 connector X059 pin 1
wire 110 orange, harness splice to thresher engage switch connector X055 pin 3
wire 147 yellow, thresher engage switch connector X055 pin 5 to CCM2 connector X015 pin J1-7
55-236
FAULT CODE – E0175-04 V Supply Thresher Clutch

Cause:
Low battery voltage to CCM2 through the thresher engage switch S30, or the circuit is shorted to ground.

3. Thresher engage switch supply wiring shorted to ground.
Solution:
B. If the fuse immediately fails again, a short to ground exists in wire 010 red to Cab Power Relay K26
pin 3. Locate short and repair.
B. If the fuse immediately fails, a short to ground exists in wire 007 orange from the Cab Power relay K26
to fuse panel buss strip. Locate short and repair.
wire 108 orange, fuse F48 through connector X001, pin 3 to harness splice
wire 300 orange, harness splice to neutral switch S22 connector X059 pin 1
wire 110 orange, harness splice to thresher engage switch S30 connector X055 pin 3
55-237
6. Engage the thresher engage switch S30, and observe the fuse F48.
wires 147, 111, 225 & 1061 yellow, thresher engage switch S30, pin 5 to CCM1 connector X018, J1-17,
CCM2 connector X015, J1-7 and CCM3 connector X012, J1-7
7. Engage the feeder engage switch S31, and observe fuse F48.
B. If the fuse immediately fails, a short to ground exists in wire 112 yellow from feeder engage switch S31,
pin 5 to CCM1 connector X018, J1-7. Locate short and repair.
9. Key switch in “On” position. Engage thresher engage switch S30. Enter the Infoview monitor - “Diagnose
info” screen.
Select “V Supply Thresher Clutch” and check voltage range.
The acceptable voltage range is 10 to 18 volts.
CCM2. Inspect the following wires for loose or corroded connections, or damage to the wires.
wire 010 red, fuse F42 to Cab Power relay K26, terminal 3
wire 007 orange, Cab Power relay K26, terminal 5 to fuse panel buss strip
wire 108 orange, fuse F48 through connector X001, pin 3, to right console (RC) harness splice
wire 110 orange, RC harness splice to thresher engage switch S30, pin 3
wire 147 yellow, thresher engage switch S30, pin 5 to CCM2 connector X015 pin J1-7
range.
55-238
4
10010921
10010919
2
5
10004693 50020070
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34
1. Fuse F48
2. Thresher Latching Relay K28
3. Connector X001
4. Thresher Engage Switch S30
5. Connector X015
55-239
55-240
55-241
55-242
FAULT CODE – E0177-03 Isense Unload Cross Auger

Cause:
The Unload cross auger solenoid (L-08) circuit has excessive current draw, or is shorted to a high voltage
source.

1. Bad solenoid.
Solution:
1. The Isense Unload Cross Auger circuit is the ground path for the cross auger PWM solenoid. By monitoring
current flow on the return path of the cross auger solenoid, the module can provide precise control of the
solenoid engagement. When this error message is reported, this is an indication of excessive current draw
on the circuit, or a result of a high voltage short on the return line.
Select “Unload Cross Auger valve” and use the arrow keys to select the “Current” screen. Use the “+” key
to increase the output to 100%, and press “Enter” to power the circuit. Check the current.
The proper unload cross auger solenoid current should be approximately 1.0 to 1.5 amps. The fault code
is triggered by current flow greater than 3.3 amps.
NOTE: If the current reading is high, immediately shut off the circuit by pressing the “Enter” key after verifying
the reading to prevent module damage.
A. If the reading is greater than 3.3 amps, continue with Step 3.

B. If the reading is normal (1.0 to 1.5 amps), continue the troubleshooting at Step 8.
3. The current reading on the Infoview monitor is high. Turn the key switch to the OFF position and disconnect
the unload cross auger solenoid connector X035. Use a multimeter to check the resistance of the unload
cross auger solenoid L08 between connector X035 pins 5 & 6. The proper resistance range for the unload
clutch solenoid is 7.2 to 11.2 ohms.
A. If out of specification, replace the solenoid. Continue with Step 8.
4. Disconnect inline connector X011. Use a multimeter to check the resistance of the unload cross auger
solenoid circuit between connector X011 pins S & T. The resistance should be the same as, or slightly higher
than the resistance of the solenoid as measured in Step 3.
between connector X035 and connector X011 wires 568 white and 601 black. Locate the short and
repair. Continue with Step 8.
B. If the resistance is the same as previously measured, continue with Step 5.
55-243
the unload cross auger solenoid circuit between connector X016 pins J2-4 & J2-20.
A. There is no voltage present on the wire. Continue with Step 8.

B. There is voltage present on the wire. Continue with Step 7.
7. Key on. Disconnect connector X011. Use a multimeter to check for voltage at connector X011 pin T
wire 601 black. Locate the short and repair. Continue with Step 8.
8. The sense resistor in the module for the Isense Unload Auger Clutch circuit is easily damaged as a result
of excessive current draw or a short to high voltage. After locating the source of the problem and correcting,
Disconnect connector X011. Use a multimeter to check resistance between connector X011 pin T and
chassis ground. There should be less than 1 ohm resistance.
correctly. Continue with Step 9.
controller.
55-244
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1. Unload Tube Clutch Solenoid L08
2. Connector X035
3. Connector X011
4. Connector X016
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FAULT CODE – E0178-03 Isense Thresher Clutch

Cause:
The Thresher clutch solenoid (L-22) circuit has excessive current draw, or is shorted to a high voltage source.

1. Bad solenoid.
Solution:
1. The Isense Thresher Clutch circuit is the ground path for the thresher clutch PWM solenoid. By monitoring
current flow on the return path of the thresher clutch solenoid, the module can provide precise control of the
solenoid engagement. When this error message is reported, this is an indication of excessive current draw
on the circuit, or a result of a high voltage short on the return line.
Select “Thresher Clutch valve” and use the arrow keys to select the “Current” screen. Use the “+” key to
increase the output to 100%, and press “Enter” to power the circuit. Check the current.
The proper thresher clutch solenoid current should be approximately 1.0 to 1.5 amps. The fault code is
triggered by current flow greater than 3.3 amps.
NOTE: If the current reading is high, immediately shut off the circuit by pressing the “Enter” key after verifying
the reading to prevent module damage.
A. If the reading is greater than 3.3 amps, continue with Step 3.

B. If the reading is normal (1.0 to 1.5 amps), continue the troubleshooting at Step 8.
3. The current reading on the Infoview monitor is high. Turn the key switch to the OFF position and disconnect
the thresher clutch solenoid connector X035. Use a multimeter to check the resistance of the thresher
clutch solenoid L22 between connector X035 pins 7 & 8. The proper resistance range for the thresher
clutch solenoid is 7.2 to 11.2 ohms.
A. If out of specification, replace the solenoid. Continue with Step 8.
4. Disconnect inline connector X011. Use a multimeter to check the resistance of the unload cross auger
solenoid circuit between connector X011 pins N & O. The resistance should be the same as, or slightly
higher than the resistance of the solenoid as measured in Step 3.
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the thresher clutch solenoid circuit between connector X016 pins J2-30 & J2-40.
A. There is no voltage present on the wire. Continue with Step 8.

B. There is voltage present on the wire. Continue with Step 7.
7. Key on. Disconnect connector X011. Use a multimeter to check for voltage at connector X011 pin N
8. The sense resistor in the module for the Isense Thresher Clutch circuit is easily damaged as a result of
excessive current draw or a short to high voltage. After locating the source of the problem and correcting,
Disconnect connector X011. Use a multimeter to check resistance between connector X011 pin N and
chassis ground. There should be less than 1 ohm resistance.
controller.
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1. Thresher Clutch Solenoid L22
2. Connector X035
3. Connector X011
4. Connector X016
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55-250
FAULT CODE – E0179-03 LoP Isense Grnd Spd Hydro

Context:
The LoP Isense Grnd Spd Hydro circuit is the ground path for the Ground Speed Hydrostat solenoid circuit. By
monitoring the current flow on the return path of the ground speed hydrostat solenoid, the module can provide
precise control of the solenoid engagement, and monitor the circuit for faults. When this error message is
reported, this is an indication that the ground speed hydrostat circuit is shorted to battery voltage. The short may
be on the output or return side of the circuit.
Cause:
CCM2 has detected that the LoP Isense Grnd Spd Hydro circuit is >4.7 volts while the MFH handle is in neutral.

1. The LoP Isense Grnd Spd Hydro wiring is shorted to battery voltage.
2. CCM2 internal failure.
Solution:
1. Verify the fault is present. Enter the Infoview monitor -- “Diagnose info” screen, “Driveline” sub menu. Select
“LoP Isense Grnd Spd Hydro” and observe the voltage with the MFH handle in neutral. The normal operating
range for the LoP Isense Grnd Spd Hydro circuit is 0 -- 4.4 volts. With the MFH handle in neutral, the voltage
indicated should be 0 volts.
A. If the voltage reading is >4.7 volts, continue with Step 2.
2. Key switch ON, MFH handle in neutral. Disconnect the ground speed hydrostat connector X100. Use a
multimeter to check for voltage between connector X100 pins B and C and chassis ground. There should
not be any voltage.
A. If there is voltage, then there is a short to battery voltage on the ground speed hydrostat sense circuit.
B. If there is no voltage, continue the troubleshooting at Step 3.
multimeter to check for voltage between connector X100 pin A and chassis ground. There should not be
any voltage.
A. If there is voltage, then there is a short to battery voltage on the ground speed hydrostat reverse circuit.
B. If there is no voltage, continue the troubleshooting at Step 4.
multimeter to check for voltage between connector X100 pin D and chassis ground. There should not be
any voltage.
A. If there is voltage, then there is a short to battery voltage on the ground speed hydrostat forward circuit.
B. If there is no voltage, the ground speed hydrostat circuit tests okay. Continue the troubleshooting at Step
12.
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5. Key switch ON, MFH handle in neutral. Disconnect connector X011 between the gearbox (GB) and main
frame (MF) harnesses. Use a multimeter to check for voltage between connector X011 pin G and chassis
ground. There should not be any voltage.
A. If there is no voltage, there is a short to battery voltage in the gearbox (GB) harness between connector
X011 and connector X100 wires 886 blue, 887 blue or 881 blue. Locate the short and repair. Continue
the troubleshooting at Step 7.
B. If there is voltage, continue the troubleshooting at Step 6.
6. Key switch ON, MFH handle in neutral. Disconnect connector X008 between the front frame (FF) and main
frame (MF) harnesses. Use a multimeter to check for voltage between connector X008 pin 22 and chassis
A. If there is no voltage, there is a short to battery voltage in the mainframe (MF) harness between
connector X011 and connector X008 wire 881 blue. Locate the short and repair. Continue the
B. If there is voltage, there is a short to battery voltage in the front frame (FF) harness between connector
X008 and connector X017 wire 881 blue. Locate the short and repair. Continue the troubleshooting
at Step 7.
7. The sense resistor in the CCM2 module for the “LoP Isense Grnd Spd Hydro” ground drive circuit is easily
damaged as a result of excessive current draw or a short to high voltage. After locating the source of the
problem and correcting, the module must be checked for damage.
Carefully disconnect connector X017 from the bottom of CCM2. Use a multimeter to check resistance
between connector X017 pin J3-35 and chassis ground. There should be 47 ohms resistance.
A. If there is infinite resistance, the sense resistor in the CCM2 module has failed. Replace the module,
and continue with Step 12.
B. If the resistance is correct, the sense resistor in the CCM2 module is okay, and the circuit should function
frame (MF) harnesses. Use a multimeter to check for voltage between connector X011 pin P and chassis
X011 and connector X100 wire 879 gray. Locate the short and repair. Continue the troubleshooting at
Step 12.
connector X011 and connector X008 wire 879 gray. Locate the short and repair. Continue the
X008 and connector X017 wire 879 gray. Locate the short and repair. Continue the troubleshooting
at Step 12.
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frame (MF) harnesses. Use a multimeter to check for voltage between connector X011 pin Q and chassis
X011 and connector X100 wire 880 white. Locate the short and repair. Continue the troubleshooting
at Step 12.
connector X011 and connector X008 wire 880 white. Locate the short and repair. Continue the
X008 and connector X017 wire 880 white. Locate the short and repair. Continue the troubleshooting
at Step 12.
Repair any damage found during visual inspection. If no damage is found, erase the fault code and continue
operation.
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FAULT CODE – E0179-04 LoP Isense Grnd Spd Hydro

NOTE: It is possible that this fault could occur at the same time as E0202-11 -- Ground Speed Hydrostat
Unidentified Failure Code. This would indicate that the short to ground has occurred on the output side of the
ground drive hydrostat circuit, and the combine should not move in the direction that generated the fault.
Context:
monitoring the current flow on the return path of the ground speed hydrostat solenoid, the module can provide
precise control of the solenoid engagement, and monitor the circuit for faults. When this error message is
reported, this is an indication that the ground speed hydrostat circuit is shorted to ground.
Cause:
CCM2 has detected that the LoP Isense Grnd Spd Hydro circuit current is <5 mA while the MFH handle is not
in neutral, and the combine is moving.

1. The LoP Isense Grnd Spd Hydro wiring is shorted to ground.
2. CCM2 internal failure.
Solution:
1. Verify the fault is present. Enter the Infoview monitor -- “Diagnose info” screen, “Driveline” sub menu. Select
“LoP Isense Grnd Spd Hydro” and observe the voltage with the MFH handle in neutral. The normal operating
range for the LoP Isense Grnd Spd Hydro circuit is 0 -- 4.4 volts. With the MFH handle out of neutral and the
combine moving, the voltage indicated should be greater than 0.2 volts.
A. If the voltage reading is less than 0.2 volts, there is a short to ground in the sense circuit. Continue the
B. If the voltage reading is within the proper limits, the shorted wire may be intermittent at this time.
2. Stop the combine and turn off the ignition switch. Disconnect the ground speed hydrostat solenoid connector
X100. Use a multimeter to check for continuity between the valve end of connector X100 pin B or C and
chassis ground. There should not be continuity to ground.
A. If there is continuity to ground, there is a short to ground in the ground speed hydrostat solenoid L-23.
Replace the solenoid, and continue troubleshooting at Step 12.
3. Carefully disconnect connector X017 under the cab from the bottom of CCM2. Use a multimeter to check
for continuity between the harness end of connector X100 pin B and chassis ground, and then between pin
C and chassis ground. There should not be continuity to ground.
B. If there is no continuity to ground, the shorted wire may be on the output side of the ground drive
hydrostat circuit. Continue the troubleshooting at Step 6.
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4. Disconnect connector X011 between the gearbox (GB) and main frame (MF) harnesses. Use a multimeter
to check for continuity between the main frame (MF) harness end of connector X011 pin G and chassis
ground. There should not be continuity to ground.
A. If there is no continuity to ground, there is a short to ground in the gearbox (GB) harness between
connector X011 and connector X100 wires 886 blue, 887 blue or 881 blue. Locate the short and repair.
5. Disconnect connector X008 between the front frame (FF) and main frame (MF) harnesses. Use a multimeter
to check for continuity between the front frame (FF) harness end of connector X008 pin 22 and chassis
A. If there is no continuity, there is a short to ground in the mainframe (MF) harness between connector
X011 and connector X008 wire 881 blue. Locate the short and repair. Continue the troubleshooting at
Step 12.
B. If there is continuity, there is a short to ground in the front frame (FF) harness between connector X008
and connector X017 wire 881 blue. Locate the short and repair. Continue the troubleshooting at Step
12.
6. Use a multimeter to check for continuity between the harness end of connector X100 pin D and chassis
7. Disconnect connector X011. Use a multimeter to check for continuity between the main frame (MF) harness
end of connector X011 pin Q and chassis ground. There should not be continuity to ground.
connector X011 and connector X100 wire 880 white. Locate the short and repair. Continue with Step
12.
end of connector X008 pin 12 and chassis ground. There should not be continuity to ground.
A. If there is no continuity to ground, there is a short to ground in the main frame (MF) harness between
connector X011 and connector X008 wire 880 white. Locate the short and repair. Continue at Step
12.
B. If there is continuity to ground, there is a short to ground in the front frame (FF) harness between
connector X008 and connector X017 pin J3-31 wire 880 white. Locate the short and repair. Continue
at Step 12.
9. Use a multimeter to check for continuity between the harness end of connector X100 pin A and chassis
B. If there is no continuity to ground, the shorted wire may be intermittent. Continue the troubleshooting
at Step 12.
end of connector X011 pin P and chassis ground. There should not be continuity to ground.
connector X011 and connector X100 wire 879 grey. Locate the short and repair. Continue with Step
12.
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end of connector X008 pin 11 and chassis ground. There should not be continuity to ground.
A. If there is no continuity to ground, there is a short to ground in the main frame (MF) harness between
connector X011 and connector X008 wire 879 grey. Locate the short and repair. Continue with Step
12.
B. If there is continuity to ground, there is a short to ground in the front frame (FF) harness between
connector X008 and connector X017 pin J3-21 wire 879 grey. Locate the short and repair. Continue
with Step 12.
Reinstall all connectors and wiring disconnected during troubleshooting. Repair any damage found during
visual inspection. If no damage is found, erase the fault code and continue operation.
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FAULT CODE – E0179-05 LoP Isense Grnd Spd Hydro Line Disconnected
Context:
monitoring the current flow on the return path of the ground speed hydrostat solenoid, the CCM2 module can
provide precise control of the solenoid engagement, and monitor the circuit for faults. When this error message
is reported, this is an indication that the ground speed hydrostat circuit is open. The open circuit could be on the
output or return side of the circuit.
Cause:
CCM2 has detected that the LoP Isense Grnd Spd Hydro circuit current is <5 mA while the MFH handle is not
in neutral, and the combine is not moving.

1. Failed solenoid.
2. Circuit output or return side wiring is open.
3. Controller internal failure.
Solution:
1. Enter the Infoview monitor -- “Diagnose info” screen. Select the “Driveline” sort menu, and select “LoP Isense
Grnd Spd Hydro” to check the voltage range. Move the MFH handle to the full forward position, the full
rearward position, and back to the neutral position while monitoring the voltage. With the MFH handle in
neutral, the voltage indicated should be 0 volts. With the MFH handle in the full forward position, the voltage
indicated should be approximately 4.4 volts. With the MFH handle in the full rearward position, the voltage
indicated should be approximately 2.5 volts. The fault code is generated if the current flow is less than 5 mA
(0.2 volts indicated on bar graph) at any time when the MFH handle is out of neutral.
A. If one or both of the readings are less than 0.2 volts, continue with Step 2.
B. If the readings are normal, continue the troubleshooting at Step 13.
2. Turn the key switch to the OFF position. Disconnect the ground speed hydrostat solenoid connector X100.
Use a multimeter to check the resistance of the ground speed solenoid L-23 between connector X100 pins
A and B (rev) and connector X100 pins C and D (fwd). The proper resistance range for the ground speed
solenoid is 16k -- 20k ohms.
A. If out of specification, replace the solenoid. Continue at Step 13.
B. If the solenoid is within specification, continue with Step 3.
3. Use a multimeter to check for continuity between the gearbox (GB) harness end of connector X100 pin B
and chassis ground, and between pin C and chassis ground. There should be approximately 47 ohms
resistance measured between each pin and chassis ground.
A. If there is continuity to ground on connector X100 pin B, but not pin C, there is an open circuit in the
gearbox (GB) harness between connector X100 pin C and the harness splice wire 887 blue. Locate
the open and repair. Continue with Step 13.
B. If there is continuity to ground on connector X100 pin C, but not pin B, there is an open circuit in the
gearbox (GB) harness between connector X100 pin B and the harness splice wire 886 blue. Locate
the open and repair. Continue with Step 13.
C. If there is no continuity on either pin, continue with Step 4.
D. If there is continuity on both pins, continue with Step 7.
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end of connector X011 pin G and chassis ground. There should be approximately 47 ohms resistance to
chassis ground.
A. If there is continuity, there is an open circuit in the gearbox (GB) harness between the harness splice
with wires 886 blue and 887 blue, and connector X011 pin 7 wire 881 blue. Locate the open and repair.
5. Disconnect connector X008 behind the caUse a multimeter to check for continuity between the front frame
harness end of connector X008 pin 22 and chassis ground. There should be approximately 47 ohms
resistance to chassis ground.
A. If there is continuity, there is an open circuit in the main frame (MF) harness between connector X011
pin 7 and connector X008 pin 22 wire 881 blue. Locate the open and repair. Continue with Step 13.
continuity between connector X017 pin J3-35 on the module and chassis ground. There should be
approximately 47 ohms resistance to chassis ground.
A. If there is continuity, there is an open circuit in the front frame (FF) harness between connector X008
pin 22 and connector X017 pin J3-35 wire 881 blue. Locate the open and repair. Continue with Step
13.
B. If there is no continuity, the sense resistor in the CCM2 module has failed. Replace the module.
7. Carefully disconnect connector X017 under the cab from the bottom of CCM2. Connect a jumper wire
between connector X017 pin J3-31 and chassis ground. Use a multimeter to check from continuity between
gearbox (GB) harness end of connector X100 pin D and chassis ground. There should be continuity to
ground.
to check for continuity between connector X011 pin Q and chassis ground. There should be continuity.
A. If there is continuity, there is an open circuit in the gearbox (GB) harness between connector X011 and
connector X100 wire 880 white. Locate the open and repair. Continue the troubleshooting at Step 13.
B. If there is no continuity, continue the troubleshooting at Step 9.
to check for continuity between connector X008 pin 12 and chassis ground. There should be continuity.
A. If there is continuity, there is an open circuit in the mainframe (MF) harness between connector X011
and connector X008 wire 880 white. Locate the open and repair. Continue the troubleshooting at Step
13.
and connector X017 wire 880 white. Locate the open and repair. Continue the troubleshooting at Step
13.
10. Remove the jumper wire from connector X017 pin J3-31, and connect the jumper wire between connector
X017 pin J3-21 and chassis ground. Use a multimeter to check from continuity between gearbox (GB)
harness end of connector X100 pin A and chassis ground. There should be continuity to ground.
A. If there is continuity to ground, the open wire may be intermittent. Continue with Step 13.
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to check for continuity between connector X011 pin P and chassis ground. There should be continuity.
A. If there is continuity, there is an open circuit in the gearbox (GB) harness between connector X011 and
connector X100 wire 879 gray. Locate the open and repair. Continue the troubleshooting at Step 13.
B. If there is no continuity, continue the troubleshooting at Step 12.
to check for continuity between connector X008 pin 11 and chassis ground. There should be continuity.
A. If there is continuity, there is an open circuit in the mainframe (MF) harness between connector X011
and connector X008 wire 879 gray. Locate the open and repair. Continue the troubleshooting at Step
13.
and connector X017 wire 879 gray. Locate the open and repair. Continue the troubleshooting at Step
13.
Repair any damage found during visual inspection.
A. If no damage is found, operate the machine while monitoring the Infoview monitor -- “Diagnose info”
screen, “LoP Isense Grnd Spd Hydro” voltage. If no low (<0.2 volts) out of range readings are indicated,
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1. Ground Speed Hydrostat L23
2. Connector X011
3. Connector X008
4. Connector X017
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FAULT CODE – E0180-11 Thresher Clutch Valve Unidentified Failure Code

Cause:
The Thresher Clutch Valve (L-22) circuit is open, or shorted to ground.

2. Bad solenoid.
Solution:
Select “Thresher Clutch valve” and select the “Current” screen. Engage the thresher engage switch S30.
B. If the reading is 0 amps, the circuit is open. Continue with Step 5.
C. If the reading is within the proper range, the circuit is working properly. Continue with Step 11.
chassis ground.
A. If there is continuity, the thresher clutch solenoid is shorted to ground. Replace the solenoid.
4. Disconnect connector X011. Use a multimeter to check for continuity between connector X011 pin O and
making this check.
5. Disconnect connector X035. Use a multimeter to check the resistance of the thresher clutch valve coil
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making this check.
NOTE: The sense resistor in the module for the Isense Thresher Clutch circuit is easily damaged as a result of
excessive current draw or a short to high voltage.
B. There is less than 1 ohm resistance, indicating the sense resistor in the CCM2 module is okay. The open
circuit is in the main frame (MF) harness between connector X011 and connector X016 wire 877 black.
9. Turn the key switch to the ON position. Use the Infoview monitor - “Diagnose info” screen to manually power
the thresher clutch valve. Use a multimeter to check for 12 volts between connector X035 pin 7 and chassis
ground.
NOTE: The thresher engage switch S30 must be engaged to supply power to the circuit.

the thresher clutch valve. Use a multimeter to check for 12 volts between connector X011 pin O and chassis
ground.
NOTE: The thresher engage switch S30 must be engaged to supply power to the circuit.
and connector X011 pin O wire 878 white. Locate the open circuit and repair.
X011 pin O and connector X016 pin J2-30 wire 878 white. Locate the open and repair.
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1. Thresher Clutch Solenoid L22
2. Connector X035
3. Connector X011
4. Connector X016
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FAULT CODE – E0181-11 Parking Brake Disengage Valve

Cause:
The parking brake disengage valve (L-10) circuit is open, or shorted to ground.

2. Bad solenoid.
Solution:
Select “Parking Brake Disengage valve” and select the “Status” screen. Press the “Enter” key to manually
power the circuit.
chassis ground.
A. If there is continuity, the park brake disengage solenoid is shorted to ground. Replace the solenoid.
4. Disconnect connector X011. Use a multimeter to check for continuity between connector X011 pin R and
making this check.
5. Disconnect connector X035. Use a multimeter to check the resistance of the park brake disengage valve
coil between connector X035 pins 7 & 8. The proper resistance range is 7.2 to 11.2 ohms.
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Flex the gearbox (GB) harness between the clutch valve and engine ground 5 while making this check.
A. If there is no continuity to ground, there is an open circuit in the gearbox (GB) harness between
connector X035 pin 4 and the engine ground 5. Locate the open and repair.
the park brake disengage valve. Use a multimeter to check for 12 volts between connector X035 pin 3 and
chassis ground.
the park brake disengage valve. Use a multimeter to check for 12 volts between connector X011 pin R and
chassis ground.
and connector X011 pin R wire 572 white. Locate the open circuit and repair.
X011 pin R and connector X016 pin J2-15 wire 572 white. Locate the open and repair.
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1. Park Brake Disengage Solenoid L10
2. Connector X035
3. Connector X011
4. Connector X016
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FAULT CODE – E0182-11 - Fuel Shutoff Output

NOTE: This troubleshooting chart is for CR920 combines with 7.5L mechanical governor engines only.
Cause:
The fuel solenoid (L-02) circuit open, or shorted to ground.

2. Bad solenoid.
Solution:
Select “Fuel Shutoff Output” and select the “Status” screen. Press the “Enter” key to manually power the
circuit.
2. Disconnect connector X290. Use a multimeter to check between connector X290 pin A (valve side) and
chassis ground.
A. If there is continuity, the fuel solenoid is shorted to ground. Replace the solenoid.
3. Use a multimeter to check for continuity between connector X290 pin A (harness side) and chassis ground.
Flex the engine (EN) harness between the fuel solenoid and connector X010 while making this check.
making this check.
A. If there is no continuity to ground, the short to ground is in the engine (EN) harness between connector
5. Disconnect connector X290. Use a multimeter to check the resistance of the fuel solenoid coil between
connector X290 pins A & B. The proper resistance range is XX to XX ohms.
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6. Use a multimeter to check for continuity between connector X290 pin B (harness side) and chassis ground.
Flex the engine (EN) harness between the fuel solenoid and engine ground 5 while making this check.
A. If there is no continuity to ground, there is an open circuit in the engine (EN) harness between
connector X290 pin B and the engine ground 5 wire 838 black. Locate the open and repair.
the fuel solenoid. Use a multimeter to check for 12 volts between connector X290 pin A and chassis ground.
the fuel solenoid. Use a multimeter to check for 12 volts between connector X010 pin 16 and chassis
ground.
A. If 12 volts is present, the open circuit is in the engine (EN) harness between connector X290 pin A and
connector X010 pin 16 wire 571 white. Locate the open circuit and repair.
X010 pin 16 and connector X016 pin J2-13 wire 571 white. Locate the open and repair.
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1. Fuel Solenoid L02
2. Connector X010
3. Connector X016
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FAULT CODE – E0183-11 Brake Limiting Valve Unidentified Failure Code

Cause:
The brake limiting valve (L-32) circuit is open, or shorted to ground.

2. Bad solenoid.
Solution:
1. Enter the Infoview monitor “Diagnose Info” screen. Select the “CCM2” sort menu, and select “Brake
Limitation valve”. Change the drop-down list to “Status”, and press the “Enter” button to change the circuit
output to “ON”.
The “Status” screen should indicate “OK” if the circuit is working properly.
A. If the status screen indicates “ERROR”, the circuit is open or shorted to ground. Continue with Step 2.
2. Disconnect connector X329. Use a multimeter to check the resistance of the brake limiting valve coil (L32).
The proper resistance range is 3 - 5 ohms.
A. If there is zero resistance, the brake limiting solenoid is shorted internally. Replace the solenoid.
B. If there is infinite resistance, the brake limiting solenoid is open. Replace the solenoid.
C. If the resistance is correct, continue with Step 3.
Flex the main frame (MF) harness while making this check.
A. If there is continuity to ground, the short to ground is in the main frame (MF) harness between connector
X329 and connector X016 pin J2-5 wire 1504 white. Locate the short and repair.
Flex the main frame (MF) harness while making this check.
A. If there is no continuity to ground, there is an open circuit in the main frame (MF) harness between
connector X329 pin B and the front frame ground #2 wire 1505 black. Locate the open and repair.
5. Turn the key switch to the ON position. Use the Infoview monitor “Diagnose Info” screen controls to manually
power the brake limiting valve. Use a multimeter to check for 12 volts between connector X329 pin A and
chassis ground.
A. If 12 volts is not present there is an open circuit in the main frame (MF) harness between connector
X329 pin A and connector X016 pin J2-5 wire 1504 white. Locate the open and repair.
broken wires.
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FAULT CODE – E0184-11 Unload Cross Auger Valve

Cause:
The unload cross auger valve (L-08) circuit open, or shorted to ground.

2. Bad solenoid.
Solution:
Select “Unload cross auger valve” and select the “Current” screen. Manually power the circuit by using the
“+” key to select 100%, and press “Enter”.
B. If the reading is 0 amps, the circuit is open. Continue with Step 5.
C. If the reading is within the proper range, the circuit is working properly. Continue with Step 11.
chassis ground.
A. If there is continuity, the Unload cross auger valve solenoid is shorted to ground. Replace the solenoid.
4. Disconnect connector X011. Use a multimeter to check for continuity between connector X011 pin S and
making this check.
5. Disconnect connector X035. Use a multimeter to check the resistance of the unload cross auger valve coil
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7. Disconnect connector X011. Use a multimeter to check for continuity between connector X011 pin T and
making this check.
NOTE: The sense resistor in the module for the Isense Unload Cross Auger circuit is easily damaged as a result
of excessive current draw or a short to high voltage.
B. There is less than 1 ohm resistance, indicating the sense resistor in the CCM2 module is okay. The open
circuit is in the main frame (MF) harness between connector X011 and connector X016 wire 601 black.
the unload cross auger valve. Use a multimeter to check for 12 volts between connector X035 pin 5 and
chassis ground.
the unload cross auger valve. Use a multimeter to check for 12 volts between connector X011 pin S and
chassis ground.
and connector X011 pin S wire 568 white. Locate the open circuit and repair.
X011 pin S and connector X016 pin J2-4 wire 568 white. Locate the open and repair.
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1. Unload Tube Clutch Solenoid L08
2. Connector X035
3. Connector X011
4. Connector X016
55-278
55-279
FAULT CODE – E0185-11 Header Reel Fore Valve

Cause:
The header reel fore valve (L-16) circuit open, or shorted to ground.

2. Bad solenoid.
Solution:
Select “Header Reel Fore valve” and select the “Status” screen. Press the “Enter” key to manually power the
circuit.
2. Disconnect connector X272. Use a multimeter to check the resistance of the header reel fore valve coil
(L16). The proper resistance range is 3 to 5 ohms.
A. If there is zero resistance, the header reel fore solenoid is shorted internally. Replace the solenoid.
B. If there is infinite resistance, the header reel fore solenoid is open. Replace the solenoid.
Flex the feeder valves (FV) harness while making this check.
4. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin P and
chassis ground. Flex the front frame (FF) harness between the connector X021 and connector X017 while
making this check.
A. If there is no continuity to ground, the short to ground is in the feeder valves (FV) harness between
B. If there is continuity to ground, the short to ground is in the front frame (FF) harness between connector
55-280
6. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin Q
(harness side) and chassis ground. Flex the front frame (FF) harness between connector X021 and the
front frame ground 2 while making this check.
A. If there is continuity to ground, there is an open circuit in the feeder valves (FV) harness between
connector X021 pin Q and the front frame ground 2 wire 589 or 592 black. Locate the open and repair.
the header reel fore valve. Use a multimeter to check for 12 volts between connector X272 pin 1 and chassis
ground.
the header reel fore valve. Use a multimeter to check for 12 volts between connector X021 pin P and chassis
ground.
A. If 12 volts is present, the open circuit is in the feeder valves (FV) harness between connector X272
pin 1 and connector X021 pin P wire 560 white. Locate the open circuit and repair.
B. If 12 volts is not present there is an open circuit in the front frame (FF) harness between connector X021
pin P and connector X017 pin J3-1 wire 560 white. Locate the open and repair.
55-281
40024707
10020032
50026211
42
1. Reel Fore Solenoid L16 (Front, Third From Top)
2. Connector X021
3. Connector X017
4. Front Frame Ground 2
55-282
55-283
FAULT CODE – E0186-11 Header Reel Drive Valve

Cause:
The header reel drive valve (L-17) circuit open, or shorted to ground.

2. Bad solenoid.
Solution:
Select “Header Reel Drive valve” and select the “Status” screen. Press the “Enter” key to manually power
the circuit.
2. Disconnect connector X274. Use a multimeter to check the resistance of the header reel drive valve coil
A. If there is zero resistance, the header reel drive solenoid is shorted internally. Replace the solenoid.
B. If there is infinite resistance, the header reel drive solenoid is open. Replace the solenoid.
4. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin E and
making this check.
55-284
6. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin F
connector X021 pin F and the front frame ground 2 wire 585 black. Locate the open and repair.
the header reel drive valve. Use a multimeter to check for 12 volts between connector X274 pin 1 and
chassis ground.
the header reel fore valve. Use a multimeter to check for 12 volts between connector X021 pin E and chassis
ground.
pin 1 and connector X021 pin E wire 556 white. Locate the open circuit and repair.
pin E and connector X017 pin J3-2 wire 556 white. Locate the open and repair.
55-285
40024707
10020032
50026211
43
1. Reel Drive Solenoid L17 (Front, Fifth From Top)
2. Connector X021
3. Connector X017
55-286
55-287
FAULT CODE – E0187-11 Header Reel Up Valve

Cause:
The header reel up valve (L-14) circuit open, or shorted to ground.

2. Bad solenoid.
Solution:
Select “Header Reel Up valve” and select the “Status” screen. Press the “Enter” key to manually power the
circuit.
2. Disconnect connector X273. Use a multimeter to check the resistance of the header reel up valve coil
A. If there is zero resistance, the header reel up solenoid is shorted internally. Replace the solenoid.
B. If there is infinite resistance, the header reel up solenoid is open. Replace the solenoid.
4. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin L and
making this check.
55-288
6. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin M
connector X021 pin M and the front frame ground 2 wire 587 black. Locate the open and repair.
the header reel up valve. Use a multimeter to check for 12 volts between connector X273 pin 1 and chassis
ground.
the header reel up valve. Use a multimeter to check for 12 volts between connector X021 pin L and chassis
ground.
pin 1 and connector X021 pin L wire 558 white. Locate the open circuit and repair.
pin L and connector X017 pin J3-3 wire 558 white. Locate the open and repair.
55-289
40024707
10020032
50026211
44
1. Reel Up Solenoid L14 (Front, Fourth From Top)
2. Connector X021
3. Connector X017
55-290
55-291
FAULT CODE – E0188-11 Header Reel Down Valve

Cause:
The header reel down valve (L-13) circuit is open, or shorted to ground.

2. Bad solenoid.
Solution:
Select “Header Reel Down valve” and select the “Status” screen. Press the “Enter” key to manually power
the circuit.
2. Disconnect connector X269. Use a multimeter to check the resistance of the header reel down valve coil
A. If there is zero resistance, the header reel down solenoid is shorted internally. Replace the solenoid.
B. If there is infinite resistance, the header reel down solenoid is open. Replace the solenoid.
making this check.
55-292
6. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin O
connector X021 pin O and the front frame ground 2 wire 586 black. Locate the open and repair.
the header reel down valve. Use a multimeter to check for 12 volts between connector X269 pin 1 and
chassis ground.
the header reel down valve. Use a multimeter to check for 12 volts between connector X021 pin N and
chassis ground.
pin 1 and connector X021 pin N wire 557 white. Locate the open circuit and repair.
pin N and connector X017 pin J3-4 wire 557 white. Locate the open and repair.
55-293
40024707
10020032
50026211
45
1. Reel Down Solenoid L13 (Back, Fourth From Top)
2. Connector X021
3. Connector X017
55-294
55-295
FAULT CODE – E0189-11 Header Reel Back Valve

Cause:
The header reel back valve (L-15) circuit is open, or shorted to ground.

2. Bad solenoid.
Solution:
Select “Header Reel Back valve” and select the “Status” screen. Press the “Enter” key to manually power
the circuit.
2. Disconnect connector X268. Use a multimeter to check the resistance of the header reel back valve coil
A. If there is zero resistance, the header reel back solenoid is shorted internally. Replace the solenoid.
B. If there is infinite resistance, the header reel back solenoid is open. Replace the solenoid.
making this check.
55-296
6. Disconnect connector X021. Use a multimeter to check for continuity between connector X021 pin S
connector X021 pin S and the front frame ground 2 wire 588 black. Locate the open and repair.
the header reel back valve. Use a multimeter to check for 12 volts between connector X268 pin 1 and
chassis ground.
the header reel back valve. Use a multimeter to check for 12 volts between connector X021 pin R and
chassis ground.
pin 1 and connector X021 pin R wire 559 white. Locate the open circuit and repair.
pin R and connector X017 pin J3-5 wire 559 white. Locate the open and repair.
55-297
40024707
10020032
50026211
46
1. Reel Back Solenoid L15 (Back, Third From Top)
2. Connector X021
3. Connector X017
55-298
55-299
FAULT CODE – E0191-11 Thresher Speed Increase

Cause:
The rotor increase valve (L-29) circuit is open, or shorted to ground.

2. Bad solenoid.
Solution:
Select “Thresher Speed Increase” and select the “Status” screen. Press the “Enter” key to manually power
the circuit.
2. Disconnect connector X275. Use a multimeter to check the resistance of the drum increase valve coil
A. If there is zero resistance, the drum increase solenoid is shorted internally. Replace the solenoid.
B. If there is infinite resistance, the drum increase solenoid is open. Replace the solenoid.
Flex the main valves (MV) harness while making this check.
4. Disconnect connector X022. Use a multimeter to check for continuity between connector X022 pin P and
making this check.
A. If there is no continuity to ground, the short to ground is in the main valves (MV) harness between
55-300
6. Disconnect connector X022. Use a multimeter to check for continuity between connector X022 pin C
(harness side) and chassis ground. Flex the main frame (MF) harness between connector X022 and the
A. If there is continuity to ground, there is an open circuit in the main valves (MV) harness between
connector X275 and connector X022 wire 597 or 600 black. Locate the open and repair.
connector X022 pin C and the front frame ground 2 wire 600 black. Locate the open and repair.
the thresher increase valve. Use a multimeter to check for 12 volts between connector X275 pin 1 and
chassis ground.
the thresher increase valve. Use a multimeter to check for 12 volts between connector X022 pin P and
chassis ground.
A. If 12 volts is present, the open circuit is in the main valves (MV) harness between connector X275 pin
1 and connector X022 pin P wire 567 white. Locate the open circuit and repair.
X022 pin P and connector X016 pin J2-7 wire 567 white. Locate the open and repair.
55-301
40025225
1
10020035
50026212
47
1. Rotor Increase Solenoid L29 (Back Of Stack)
2. Connector X022
3. Connector X016
55-302
55-303
FAULT CODE – E0192-11 Thresher Speed Decrease

Cause:
The rotor decrease valve (L-30) circuit is open, or shorted to ground.

2. Bad solenoid.
Solution:
Select “Thresher Speed Decrease” and select the “Status” screen. Press the “Enter” key to manually power
the circuit.
2. Disconnect connector X278. Use a multimeter to check the resistance of the drum decrease valve coil
A. If there is zero resistance, the drum decrease solenoid is shorted internally. Replace the solenoid.
B. If there is infinite resistance, the drum decrease solenoid is open. Replace the solenoid.
4. Disconnect connector X022. Use a multimeter to check for continuity between connector X022 pin O and
making this check.
55-304
the thresher decrease valve. Use a multimeter to check for 12 volts between connector X278 pin 1 and
chassis ground.
the thresher decrease valve. Use a multimeter to check for 12 volts between connector X022 pin O and
chassis ground.
1 and connector X022 pin O wire 566 white. Locate the open circuit and repair.
X022 pin O and connector X016 pin J2-8 wire 566 white. Locate the open and repair.
55-305
1
40025225
10020036
50026212
48
1. Rotor Decrease Solenoid L30 (Front Of Stack)
2. Connector X022
3. Connector X016
55-306
55-307
FAULT CODE – E0193-11 Unload Tube In Valve Unidentified Failure Code

Cause:
The unload tube in valve (L-03) circuit is open, or shorted to ground.

2. Bad solenoid.
Solution:
Select “Unload Tube In valve” and select the “Status” screen. Press the “Enter” key to manually power the
circuit.
2. Disconnect connector X276. Use a multimeter to check the resistance of the unload tube in valve coil
A. If there is zero resistance, the unload tube in solenoid is shorted internally. Replace the solenoid.
B. If there is infinite resistance, the unload tube in solenoid is open. Replace the solenoid.
making this check.
55-308
the unload tube in valve. Use a multimeter to check for 12 volts between connector X276 pin 1 and chassis
ground.
the unload tube in valve. Use a multimeter to check for 12 volts between connector X022 pin R and chassis
ground.
1 and connector X022 pin R wire 574 white. Locate the open circuit and repair.
X022 pin R and connector X016 pin J2-6 wire 574 white. Locate the open and repair.
55-309
40025225
10020035
50026212
49
1. Unload Tube In Solenoid L03 (Back Of Stack)
2. Connector X022
3. Connector X016
55-310
55-311
FAULT CODE – E0194-11 Unload Tube Out Valve

Cause:
The unload tube out valve (L-04) circuit is open, or shorted to ground.

2. Bad solenoid.
Solution:
Select “Unload Tube Out valve” and select the “Status” screen. Press the “Enter” key to manually power the
circuit.
2. Disconnect connector X277. Use a multimeter to check the resistance of the unload tube out valve coil
A. If there is zero resistance, the unload tube out solenoid is shorted internally. Replace the solenoid.
B. If there is infinite resistance, the unload tube out solenoid is open. Replace the solenoid.
4. Disconnect connector X022. Use a multimeter to check for continuity between connector X022 pin Q and
making this check.
55-312
the unload tube out valve. Use a multimeter to check for 12 volts between connector X277 pin 1 and chassis
ground.
the unload tube out valve. Use a multimeter to check for 12 volts between connector X022 pin Q and chassis
ground.
1 and connector X022 pin Q wire 573 white. Locate the open circuit and repair.
X022 pin Q and connector X016 pin J2-16 wire 573 white. Locate the open and repair.
55-313
40025225
10020036
50026212
50
1. Unload Tube Out Solenoid L04 (Front Of Stack)
2. Connector X022
3. Connector X016
55-314
55-315
FAULT CODE – E0195-11 Foot-an-Inch Valve

Cause:
The foot-and-inch valve (L-05) circuit is open, or shorted to ground.

2. Bad solenoid.
Solution:
Select “Foot-an-Inch valve” and select the “Status” screen. Press the “Enter” key to manually power the
circuit.
2. Disconnect connector X092. Use a multimeter to check the resistance of the foot and inch valve coil (L05).
The proper resistance range is 8 to 12 ohms.
A. If there is zero resistance, the foot and inch solenoid is shorted internally. Replace the solenoid.
B. If there is infinite resistance, the foot and inch solenoid is open. Replace the solenoid.
Flex the lower frame (LF) harness while making this check.
making this check.
A. If there is no continuity to ground, the short to ground is in the lower frame (LF) harness between
Flex the lower frame (LF) harness while making this check.
55-316
6. Disconnect connector X023. Use a multimeter to check for continuity between connector X023 pin 25
A. If there is continuity to ground, there is an open circuit in the lower frame (LF) harness between
connector X023 pin 25 and the front frame ground 2 wire 765 black. Locate the open and repair.
the foot and inch valve. Use a multimeter to check for 12 volts between connector X092 pin A and chassis
ground.
the foot and inch valve. Use a multimeter to check for 12 volts between connector X023 pin 13 and chassis
ground.
A. If 12 volts is present, the open circuit is in the lower frame (LF) harness between connector X092 pin
A and connector X023 pin 13 wire 575 white. Locate the open circuit and repair.
pin 13 and connector X017 pin J3-15 wire 575 white. Locate the open and repair.
55-317
2
10013278
10010898
50020096
51
1. Foot and Inch Solenoid L05
2. Connector X023
3. Connector X017
55-318
55-319
FAULT CODE – E0196-11 Grid Heater Output

NOTE: This troubleshooting chart is for CR920 combines with 7.5L mechanical governor engines only. The
troubleshooting chart for this fault code on CR960, CR970 and CR980 combines with Iveco engines follows this
chart. This fault is not active on CR combines with 7.5L electronic engines.
Cause:
The grid heater output circuit is open, or shorted to ground.

2. Bad relay and/or indicator light.
Solution:
Select “Grid Heater output” and select the “Status” screen. Press the “Enter” key to manually power the
circuit.
2. Key off. Disconnect the grid heater relay connector X211. Use a multimeter to check the resistance of the
grid heater relay coil. The proper resistance is 2 to 6 ohms.
A. If out of specification, replace the relay.
B. If there is no continuity to ground, there is an open circuit in the engine (EN) harness in wire 822 black
between the grid heater relay K37 and engine ground 5. Locate the open and repair.
4. Disconnect connector X004 on the side of the cab to isolate the cold start indicator E36 from the circuit.
Use a multimeter to check for continuity between connector X211 pin 1 and chassis ground.
B. If no continuity to ground is found, continue with Step 8.
chassis ground.
55-320
6. Disconnect connector X005 on the side of the cab. Use a multimeter to check for continuity between
A. If there is no continuity to ground, a short to ground is located in the main frame (MF) harness between
B. If there is continuity to ground, a short to ground is located in the cab main (CM) harness between
A. If there is no continuity to ground, a short to ground is located in wires 814 white, 839 white or 818 white
in the engine (EN) harness between connector X010 and connector X211. Locate the short and repair.
B. If there is continuity to ground, a short to ground is located in the main frame (MF) harness between
connector X010 and connector X004 wire 814 white. Locate short and repair.
8. Remove the ignition switch panel in the cab, and unplug connector X066 from the cold start indicator
E36. Use a multimeter to check for continuity between connector X066 pin 7 and chassis ground.
NOTE: Connector X004 on the side of the cab should still be disconnected.
A. If there is continuity to ground, a short to ground in located in the cab main (CM) harness between
A. If there is no continuity to ground, there is an open circuit in the cab main (CM) harness between
connector X066 and cab ground 3 wire 294 black. Locate open and repair.
10. Reconnect all harness connectors, except for connector X066 to the cold start indicator E36 and
connector X211 to the grid heater relay K37. Turn the key switch to the ON position. Use the Infoview
monitor - “Diagnose info” screen to manually power the grid heater circuit. Use the multimeter to check for
12 volts between connector X211 pin 1 and chassis ground.
A. If 12 volts is not present continue with Step 11.
B. If 12 volts is found continue with Step 14.
the grid heater circuit. Disconnect connector X010. Use the multimeter to check for 12 volts between
B. If 12 volts is present, there is an open circuit in the engine (EN) harness between connector X010 pin
20 and the harness splice wire 839 white. Locate open and repair.
12. Key switch to the ON position. Use the Infoview monitor - “Diagnose info” screen to manually power the grid
heater circuit. Disconnect connector X005. Use the multimeter to check for 12 volts between connector
B. If 12 volts is present, there is an open circuit in the main frame (MF) harness between connector X010
pin 20 and connector X005 pin 20 wire 839 white. Locate open and repair
heater circuit. Use the multimeter to check for 12 volts between connector X015 pin J1-12 and chassis
ground.
A. If 12 volts is present, the open is between connector X005 pin 20 and connector X015 pin J1-12 wire
839 white.
B. If 12 volts is not present, replace the CCM2 controller.
55-321
FAULT CODE – E0196-11 Grid Heater Output

NOTE: This troubleshooting chart is for CR960, CR970 and CR980 combines below serial number HAJ100801
only. The troubleshooting chart for this fault code on CR920 combines with 7.5L mechanical governor engines
is listed before this chart. The troubleshooting chart for this fault code on CR960, CR970 and CR980 combines
serial number HAJ100801 and above follows this chart. This fault is not active on CR combines with 7.5L
electronic engines.
Cause:

2. Bad cold start indicator.
Solution:
circuit.
2. Remove the ignition switch panel in the cab, and unplug connector X066 from the cold start indicator
E36. Use a multimeter to check for continuity between connector X066 pin 9 and chassis ground.
4. Disconnect connector X004. Use a multimeter to check for continuity between the main frame harness end
of connector X004 pin 20 and chassis ground.
A. If there is no continuity to ground, a short to ground is located in the cab main (CM) harness between
5. Disconnect connector X010. Use a multimeter to check for continuity between connector X010 pin 7 (main
frame (MF) harness side) and chassis ground.
A. If there is continuity to ground, a short to ground is located in the main frame (MF) harness between
55-322
6. Use a multimeter to check for continuity between connector X010 pin 7 (engine (EN) harness side) and
chassis ground.
A. If there is continuity to ground, a short to ground is located in the engine (EN) harness between
connector X010 pins 7 and 20 wire 814 white. Locate short and repair.
7. Disconnect connector X005 on the side of the cab. Use a multimeter to check for continuity between
A. If there is no continuity to ground, a short to ground is located in the main frame (MF) harness between
B. If there is continuity to ground, a short to ground is located in the cab main (CM) harness between
the grid heater circuit. Use the multimeter to check for 12 volts between connector X066 pin 7 and chassis
ground.
the grid heater circuit. Disconnect connector X004. Use the multimeter to check for 12 volts between the
main frame harness end of connector X004 pin 20 and chassis ground.
B. If 12 volts is present, there is an open circuit in the cab main (CM) harness between connector X004
pin 20 and connector X066 pin 7 wire 814 white. Locate open and repair.
10. Disconnect connector X010. Use a multimeter to check for continuity between connector X010 pin 7 & pin
20 (engine (EN) harness side).
A. If there is no continuity, there is an open circuit in the engine (EN) harness between connector X010
pins 7 and 20 wire 814 white. Locate open and repair.
the grid heater circuit. Disconnect connector X010. Use the multimeter to check for 12 volts between the
main frame harness end of connector X010 pin 20 and chassis ground.
pin 7 and connector X004 pin 20 wire 814 white. Locate open and repair.
heater circuit. Disconnect connector X005. Use the multimeter to check for 12 volts between the cab main
pin 20 and connector X005 pin 20 wire 839 white. Locate open and repair
heater circuit. Use the multimeter to check for 12 volts between connector X015 pin J1-12 and chassis
ground.
A. If 12 volts is present, the open is between connector X005 pin 20 and connector X015 pin J1-12 wire
839 white.
B. If 12 volts is not present, replace the CCM2 controller.
55-323
20013706 50031013
10020076
3
5
10004693 10010899
50031012
52
1. Grid Heater Relay K37 (CR920)
2. Connector X010
3. Connector X005
4. Connector X004
5. Connector X015
6. Cold Start Indicator E36
55-324
55-325
FAULT CODE – E0196-11 Grid Heater Output Unidentified Failure Code

NOTE: This troubleshooting chart is for CR960, CR970 and CR980 combines serial number HAJ100801 and
above. The troubleshooting charts for this fault code on CR960, CR970 and CR980 below serial number
HAJ100801 and for CR920 combines with 7.5L mechanical engines are listed before this chart. This fault is not
active on CR combines with 7.5L electronic engines.
Cause:

2. Bad cold start indicator E-36.
Solution:
circuit.
2. Remove the ignition switch panel in the cab, and unplug connector X066 from the cold start indicator E36.
Use a multimeter to check for continuity between connector X066 pin 9 and chassis ground.
3. Turn the key switch to the ON position. Use the InfoviewM monitor – “Diagnose info” screen to manually power
the grid heater circuit. Use the multimeter to check for 12 volts between connector X066 pin 7 and chassis
ground.
B. If 12 volts is present, the circuit is functioning properly. Replace the cold start indicator E36.
4. Key OFF. Use a multimeter to check for continuity between connector X066 pin 7 and chassis ground. There
should not be continuity.
A. If there is continuity to ground, there is a short to ground in the cab main harness between connector
X066 and connector X015 pin J1-12 wire 839 white. Locate the short and repair.
B. If there is no continuity to ground, there is an open circuit in the cab main (CM) harness between
connector X066 and connector X015 pin J1-12 wire 839 white. Locate the open and repair.
55-326
55-327
FAULT CODE – E0197-11 Rot Scr Brush / Throttle

NOTE: This troubleshooting chart is for CR920 combines with 7.5L mechanical governor engines only.
Cause:
The Throttle/Brush Relay (K-15) circuit is open, or shorted to ground. (7.5L mechanical governor units only)

2. Bad relay.
Solution:
Select “Rot Scr Brush / Throttle” and select the “Status” screen. Press the “Enter” key to manually power the
circuit.
2. Turn the key switch to the OFF position and remove the Throttle/Brush Relay K15. Use a multimeter to check
the resistance of the throttle/brush relay coil. The proper resistance range for the throttle/brush relay coil is
74.3 to 78.3 ohms.
A. If out of specification replace relay.
B. If the coil is within specification continue with Step 3.
A. If no continuity to ground is found continue with Step 4.
B. If there is continuity to ground, there is a short to ground on wire 502 white in the cab main (CM) harness
between the fuse panel and connector X015 pin J1-6. Locate the short and repair.
A. If continuity to ground is found continue with Step 5.
B. If there is no continuity to ground, there is an open circuit on wire 148 black in the cab main (CM) harness
between the fuse panel and cab ground 3. Locate the open and repair.
55-328
the throttle/brush relay. Use the multimeter to check for 12 volts between relay socket pin 1 and chassis
ground.
6. Key switch to the ON position. Use the Infoview monitor - “Diagnose info” screen to manually power the
throttle/brush relay. Use the multimeter to check for 12 volts between connector X015 J1-6 and chassis
ground.
B. If 12 volts is present, the open is between connector X015 J1-6 and relay socket pin 1 wire 502 white.
55-329
10004693 50020070
50026204
53
1. Connector X015
55-330
55-331
FAULT CODE – E0198-11 Backlighting Lamps

Cause:
The Backlighting Lamps circuit is open, or shorted to ground.

Solution:
The backlighting circuit is used to power the backlights in the HVAC module and all cab roof switches. Power
is sent from CCM2 to the splice block C, W03, in the cab roof. From there, power is distributed to all switches
for backlighting. The backlighting circuits in each cab roof switch are grounded to the cab roof ground 4.
A short to ground between the module and any one of the switch backlights fed by this circuit will cause this error,
while an open circuit must be between the CCM2 module and the splice block C, W03, in order to generate this
error. An open circuit between the splice block and one of the switches will result in that backlight not functioning,
while the overall circuit will still perform properly.

Select “Backlighting Lamps” and select the “Status” screen. Press the “Enter” key to manually power the
circuit.
backlighting lamps circuit. Use the multimeter to check for 12 volts between connector X015 J1-11 and
chassis ground.
B. If 12 volts is present, continue with Step 3.
3. Key off. Remove the HVAC controller from its DIN slot to provide access to the cab roof harness. Remove
the cap/buss strip from the cab roof harness splice block C connector X133. Use the multimeter to check
for continuity between connector X133 pin B and chassis ground. There should be no continuity, or very
high continuity to ground, depending on the type of multimeter used.
A. If there is continuity to ground, there is a short to ground in the cab main (CM) harness or cab roof (CR)
harness between connector X015 pin J1-11 through connector X002 pin 18 [pin U, below SN
HAJ100074] to connector X133 pin B on one of the following wires:
wire 231 purple, connector X015 pin J1-11 to cab main harness splice
wire 247 purple, cab main harness splice to connector X075 on accessory socket J08
wire 206 purple, cab main harness splice to connector X070 on cigar lighter R08
wire 232 purple, cab main harness splice to connector X002, pin 18 [pin U, below SN HAJ100074]
wire 232 purple, connector X002 pin 18 [pin U, below SN HAJ100074] to connector X133 pin B
55-332
backlighting lamps circuit. Use the multimeter to check for 12 volts between connector X133 pin B and
chassis ground.
A. If 12 volts is not present, there is an open circuit in the cab main (CM) harness or cab roof (CR) harness
between connector X015 pin J1-11 through connector X002 pin 18 [pin U, below SN HAJ100074]
to connector X133 pin B on wires 231 purple or 232 purple. Locate open and repair.
B. If 12 volts is present, continue with Step 5.
5. Key off. Use the multimeter to check for continuity between connector X133 pin A and chassis ground.
There should be no continuity, or very high continuity to ground, depending on the type of multimeter used.
A. If there is continuity to ground, there is a short to ground in the cab roof (CR) harness between
connector X133 pin A to connector X138 pin 1 wire 175 purple to the console light E35.
6. Key off. Use the multimeter to check for continuity between connector X133 pin C and chassis ground.
connector X133 pin C to connector X131 pin 7 wire 233 purple to the rear work lights switch S44.
7. Key off. Use the multimeter to check for continuity between connector X133 pin D and chassis ground.
connector X133 pin D to connector X132 pin 7 wire 235 purple to the work lights switch S43.
8. Key off. Use the multimeter to check for continuity between connector X133 pin E and chassis ground.
connector X133 pin E to connector X135 pin 7 wire 273 purple to the wiper switch S20.
9. Key off. Use the multimeter to check for continuity between connector X133 pin F and chassis ground. There
should be no continuity, or very high continuity to ground, depending on the type of multimeter used.
connector X133 pin F to connector X130 pin 7 wire 283 purple to the beacon light switch S41.
10. Key off. Use the multimeter to check for continuity between connector X133 pin G and chassis ground.
connector X133 pin G to connector X125 pin 7 wire 284 purple to the tank extensions switch S42.
11. Key off. Use the multimeter to check for continuity between connector X133 pin H and chassis ground.
connector X133 pin H to connector X127 pin 7 wire 285 purple to the mirror heat switch S19.
55-333
12. Key off. Use the multimeter to check for continuity between connector X133 pin J and chassis ground. There
should be no continuity, or very high continuity to ground, depending on the type of multimeter used.
connector X133 pin J to connector X134 pin 7 wire 286 purple to the washer switch S38.
13. Key off. Use the multimeter to check for continuity between connector X133 pin M and chassis ground.
connector X133 pin M to connector X128 pin C1 wire 972 purple to the HVAC control module A09.
14. Remove the tank extensions switch S42 from the cab roof head liner, and unplug connector X125. Use
the multimeter to check for continuity between connector X125 pin 9 and chassis ground.
A. If there is no continuity to ground, remove the cab headliner and check the condition of the cab roof
ground 4. If all switch backlighting ground wires were disconnected from this ground point, this could
also generate this fault code.
55-334
3 4 5 6 7 8 9 10 11
ZDA2687A
14
12
13
10004693
50026213
54
1. Connector X015 6. Splice Block C, W03 11. Front Work Lights Switch S43
2. Console Light E35 7. Wiper Switch S20 12. Cigar Lighter R08
3. Mirror Heat Switch S19 8. Washer Switch S38 13. Accessory Outlet J08
4. Covers Open Switch S42 9. Beacon Light Switch S41 14. Cab Roof Ground #4
5. Climate Control Module A09 10. Rear Work Lights Switch S44
55-335
55-336
55-337
55-338
55-339
55-340
55-341
55-342
55-343
FAULT CODE – E0199-11 Brake Lights Relay

Cause:
The Brake lights Relay (K-33) circuit is open, or shorted to ground.

2. Bad relay.
Solution:
Select “Brake Lights relay” and select the “Status” screen. Press the “Enter” key to manually power the circuit.
B. If the reading is within the proper range, the circuit is working properly. Continue with Step 7.
2. Turn the key switch to the OFF position and remove the Brake Lights Relay K33. Use a multimeter to check
the resistance of the relay coil. The proper resistance range for the relay coil is 74.3 to 78.3 ohms.
A. If out of specification replace relay.
B. If the coil is within specification continue with Step 3.
A. If no continuity to ground is found continue with Step 4.
B. If there is continuity to ground, there is a short to ground on wire 183 white in the cab main (CM) harness
between the fuse panel and connector X015 pin J1-18. Locate the short and repair.
A. If continuity to ground is found continue with Step 5.
B. If there is no continuity to ground, there is an open circuit on wire 159 black in the cab main (CM) harness
between the fuse panel and cab ground 3. Locate the open and repair.
the brake lights relay. Use the multimeter to check for 12 volts between relay socket pin 1 and chassis
ground.
6. Key switch to the ON position. Use the Infoview monitor - “Diagnose info” screen to manually power the brake
lights relay. Use the multimeter to check for 12 volts between connector X015 J1-18 and chassis ground.
B. If 12 volts is present, the open is between connector X015 J1-18 and relay socket pin 1 wire 183 white.
55-344
10004693 50020070
50026204
55
1. Connector X015
2. Brake Lights Relay K33
55-345
55-346
FAULT CODE – E0200-11 Beacon Lights Relay

Cause:
The Beacon lights relay (K-29) circuit is open, or shorted to ground.

2. Bad relay.
Solution:
Select “Beacon Lights relay” and select the “Status” screen. Press the “Enter” key to manually power the
circuit.
The

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SECTION 14 - LIVE PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION 25 - FRONT MECHANICAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SECTION 29 - HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SECTION 33 - BRAKES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

SECTION 35 - HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

SECTION 41 - STEERING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

SECTION 50 - CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

SECTION 55 - ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

SECTION 60 - PRODUCT FEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

SECTION 72 - DISCHARGE BEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

SECTION 74 - CLEANING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

SECTION 80 - GRAIN STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

SECTION 90 - PLATFORM, CAB, BODYWORK, DECALS . . . . . . . . . . . . . . . 98

© 2006 CNH America LLC 87600570 10/06

Chapter 1 - General Information

Section Description Page

Chapter 1 - General Information (Continued)

Section Description Page

Chapter 1 -- 7.5L Engine Block

Section Description Page

Chapter 1 -- 7.5L Engine Block (Continued)

Section Description Page

Chapter 2 - 7.5L Cooling

Section Description Page

Chapter 3 - 7.5L Complete Engine, Remove and Replace

Section Description Page

Chapter 4 - 7.5L Fuel System

Section Description Page

Chapter 4 - 7.5L Fuel System (Continued)

Section Description Page

Chapter 5 - 7.8L, 10.3L Description of Operation

Section Description Page

Chapter 6 - 7.8L, 10.3L Complete Engine, Remove and Replace

Section Description Page

Chapter 7 - 7.8L, 10.3L Engine Block

Model Engine Size

Section Description Page

Chapter 7 - 7.8L, 10.3L Engine Block (Continued)

Section Description Page

Chapter 8 - Common Engine Compartment Components

Section Description Page

Chapter 1 - Engine Gearbox, Clutch Pack Removal/Installation

Section Description Page

SECTION 14 - LIVE PTO

Chapter 2 - Engine Gearbox, Clutch Pack Rebuild

Section Description Page

Chapter 3 - Engine Gearbox Removal/Installation

Section Description Page

SECTION 14 - LIVE PTO

Chapter 4 - Engine Gearbox Rebuild

Section Description Page

Section Description Page

Chapter 1 - Planetary Final Drive

Section Description Page

Chapter 1 - Planetary Final Drive (Continued)

Section Description Page

Chapter 2 - 11/111 Final Drives

Section Description Page